Keychain and safety rules - reflection

Through this hands-on project we enjoyed our creativity and practiced safety using two types of machines at the engineering lab.  The keychain was made out of aluminum. Each one of us had to cut a small piece of aluminum that was about 1/3 of an inch thick, shape it, and drill a hole for the chain to go through. This project required the use of a band saw and a drill press. Any machinery for cutting and drilling has the potential to injure the user if the user does not follow certain safety rules. These rules include the following:

When using a machine, always wear safety goggles and make sure that everyone in the room wears one as pieces may fly long distance. Additionally, wearing closed shoes in the lab is a must, whether you use a machine or not.  Loose clothing and long hair might be trapped in the machine and cause severe injury or even death. Therefore, both should be avoided in the lab and hair should be tied back. Additionally, one should never use a machine if one is alone in the lab.

When using the band saw, we need to remember that the thickness of the piece we intend to cut should be at least three teeth. The height of the base should be adjusted by switching the yellow knob in the back first then the inner black knob. We need to make sure that prior to turning the machine on, the piece should flash with the base and face the saw but not touch it. Additionally, we do not want our fingers to be near the saw, and at all times they should be away from the yellow circle under the saw. Therefore, when feeding the piece toward the saw, we need to use the gliding guide on the right side and a wood scrap (sacrificial piece) on the left side. By using guides or clamps, we prevent two things: a serious injury to our fingers, and a possible burn due to the fast accumulation of heat in the metal we cut. When turning off the machine, the piece should not touch the saw. To remove the piece from the base, use a piece of wood to drop it into a jar filled with cold water. In case of emergency turn the machine off. The benefit of the band saw include the ability to cut metal and plastic. However, the band saw can only be used to cut straight lines and cannot be used to cut thin surfaces such as sheet metals.  

Drill Press requires similar precautions above. To fasten the screw, use the chuck and make sure to tighten the screw until you feel resistance—but not more than that. When drilling make sure to peck in order to avoid the accumulation of fibers. In case of emergency turn the machine off. If the piece that we need to drill is too small such as in the case of the keychain, use the vice, clamp.

The design of my keychain reflected my major – psychology. I sketched a profile of a person’s head. Using the band saw, I realized it was not that easy to cut exactly along the little zigzag lines of the profile that I drew on the metal. Using the Drill press to mark the eye and create the hole for the chain seemed much easier than using the band saw. Next, I used the sander to smooth the edges. I was pleased with the outcome and am grateful for the instructions and help I got during the project.