Structure
4.1 4.2
4.3
4.4
4.5
HEMS
SEAMS Sheet Metal Operations Development Procedure Experiment No. 1 Experiment No. 2
4.6
4.7
4.8
4.9
4.1 INTRODUCTION
Sheet metal work is generally regarded as the working of metal from 16 gauges down to 30 gauges, with hand tools and simple machines into various forms by cutting, forming into shape and joining.
. -
It is also known as uncoated sheet since it carries no artificial coating on its surfaces. However, it is probably the cheapest of all types of sheets used in sheet metal work. Being uncoated, it is prone to corrosion. Consequently, its use is confined mostly to the manufacture of such items which are to be painted before shipment, e.g. block iron is used in tanks, pans, trunks, stove pipes, etc.
Galvanized Iron
Zinc coated iron is called 'Galvanized iron'. This soft steel sheet is popularly known as GI sheet. The zinc coating resist rust, improves the appearance of the metal and permits it to be soldered with greater ease; but welding is not so easy as zinc gives toxic fumes and residues. Because of zinc it can with stand contact with water and exposure to weather, e.g. articles like cabinets, trunks, buckers, pans, etc. are made of galvanized iron sheets
Copper Sheets
These sheets are relatively costlier but having specific advantages in being good corrosion resistant and good in appearance. They are reddish in colour and their cold rolled variety, which is vastly used in sheet metal work, is highly ductile and malleable and therefore can be easily worked. Some representative examples of automobiles, various applications in chemical plants, domestic heating appliance, etc.
.4luminum Sheets
On account of it's inherit weakness it is not used in its pure form. The useful variety of aluminium alloy. Which is rolled into sheet form, carries additions of suitable amount of silicon, manganese copper and iron. It is whitish in colour and light in weight. It offers very high resistance to corrosion and abrasion. Its coinmon applications are aeroplane bodies, kitchen ware, etc.
Tin Plates
The nomenclature tin plates are used for those iron sheets which are coated with pure tin. As a result, these sheets which are coated with pure tin. As a result, these sheets provide a bright silvery appearance. They offer good resistance to corrosion and rusting and are mainly used for making packed food containers, cans, etc.
Stainless Steel
It is highly corrosion resistant alloy steel, which exhibits a bright surface without any coating. Though it is a little tougher than galvanized iron, in sheet form it can be shaped and span. It is widely used for making kitchen ware, food handling equipment, etc.
Brass
It is basically an alloy of copper and zinc and is available in many shades and colours. In sheet and strip forms it is used in many cold working processes, such as deep drawing, pressing, stamping, spinning, etc. Earlier it used to be the principal metal for making kitchen ware and utensils. But, now it is largely replaced by stainless steel and aluminum.
I
Lead
It is a very soft, weak, low melting point, malleable and heavy metal and possesses high resistance to acid corrosion. Due to low mechanical strength it is normally used in foil form to provide lining for containers and other articles made from some stronger material. It finds its application in sheet form in radiation shielding and an inner lining for acid tanks.
Zinc
It is bluish white metal and is quite ductile. In sheet form it is widely used for roofing work. But, in many other forms, it has its applications in coating, die casting, etc.
Thickness Gauge This is also called slip gauge and is used to measure the clearance between the parts during assembly. Sheet Metal Gauge This is used to measure the thickness of sheets.
Straight Edge This is a flat graduated bar of steel with one longitudinal edge beveled. This bar comes in variety of lengths ranging from 1 to 3 meters. It is useful for scribing long straight lines. Steel Square It is a T-shaped piece of hardened steel with marks graduated on the edges for measuring. The narrow arm of the square is called tongue and the wider part is known as the body. It is used for marking in the perpendicular direction to any base line.
Trammel Points
The trammel points consist pf a bar with two movable heads. It is used to draw large circles or arcs that are beyond the limits of the divider. Punches
A Punch is used in sheet metal work for marking out work, locating centers, etc. in a more permanent manner. Two types of punches are generally used :
Prink Punch
It is used to make small marks on layout lines in order to mark the prick punch marks longer.
Center Punch
It is used on1y to make the prick punch marks larger at the centers of holes that are to be drilled. Solid and hollow punches are very similar the other two puncher the inner and outer faces of the punch meeting at an angle of 400.These are used for making small holes from 2.5 mm to 10 mm.
A hand level punch is sometimes used for making holes with a punch and die incorporated in the tool when a large number of holes are to be punched.
Hammers
They are used for forming shapes by hallo\;ling, raising, stretching or throwing off. These are many types of hammers but the most commonly used hammers are :
Riveting Hammer
Uscd for riveting.
Setting Hammer
Useful for setting down the edge, when making a double seam.
Raising Hammer
Used for forming of a flat sheet of metal into a curved or hallow shape such as a square, bowl, tray, etc.
'
Mallet
These are soft hammers and made of saw hide, hard rubber, copper brass, lead or mostly of wood, used to strike a soft and light blow on the metal.
Rivet~ng Hammers
Snips of Shears
A snip, also called a hand shear is used like a pair of scissors to cut thin, soft metal. It should be used only to cut 20 gauge or thinner metal. There are several types of snips available for making straight or circular cuts, the most common being straight snip have straight blade for straight line cutting while curved or bent snips have curved blades for making circular cuts. Both these snips are very light and can be easily handled by one hand. These are also double cutting shear, squaring shear, ring shear and circular shear used for particular requirements as the name indicates. The heavier classes are known as bench shears and block shears where one handle may be held in vice bench plate while the other handle is moved up and down to do the cutting.
Cut Only 20 Gauge of Thinner Metal
A Hand Shears
Bent Shears
Straight Shears
Stakes
Stakes are the sheet metal workers evils used for bending, seaming or forming, using a hammer or mallet. They actually work as supporting tools as well as forming tools. They also help in bending operation. They are made in different shape and sizes to suit the requirements of the work.
i I
i
Used to form comer and edges. Hatchet Stake Used to make straight, sharp bends and for folding and bending edges.
Blowhorn
stake
stake
Figure 4.8
Pliers
Hand Groover
This is used for groove and flattern a seam. It is available in many shapes.
Rivet Set
This is hardened steel tool with hollow in one end. It is used to shape the end of a rivet into round, smooth head.
Soldering Iron
They are used for soldering work and consis1 of a forged piece of copper joined to an iron with a wooden handle. These are also called soldering coppers. They are made in various shapes and sizes.
Half moan
Blck lron
Funnel stake
Convex
Horse head
4.4 HEMS
A Hem is an edge or border made by folding. It stiffens the sheet of metal and does away with the sharp edge. Three common types of hems are :
Single Hem
It is made by folding the edges of the sheet metal over the make it smooth and stiff.
Double Hem
It is mad- by folding the edges over twice to make it stiff and smooth.
Wired Edge
4.5 SEAMS
A Seam is a joint made by fastening two edges together. Most common types of seams are :
Lap Seam
It is the simplest type of seam and can be prepared as lap joint by means of soldering.
Grooved Seam
It is made by hooking two single hems together and then locking them by a groover.
Single Seam
It is used to join a bottom to vertical bodies of various shapes.
Double Seam
It is similar to single seam with the difference that its formed edge is bent upward against the body.
Dovetail Seam
It is similar to dovetail joint in carpentry and is used to join flat plate to a cylindrical piece.
Step 1
4.6.2 Cleaning
Many a times the blank surfaces need proper cleaning before being processed. This requirement is more prominent in case of non-ferrous metal sheets, like those of copper, brass and silver. For cleaning the surfaces of these blanks pickling process is used. It involves immersing the blank in a pickle both, consisting of one part of dil. &So4 and twenty parts water. This bath is heated and the blanks immersed in the hot bath. After allowing sufficient time for pickling the blanks are thoroughly washed in a stream of water and then allowed to dry. Cold pickling is also sometimes used in such cases where cleaning operation is not required very frequently, but in such cases either the pickling personal is to be increased or a smaller acid to water ratio of the pickle has to be used so as to ensure an effective cleaning of the surface.
Shearing Down
Cutting Off
Parting
Blanking
Punching or Piercing
Notching
Slitting
/ / , / / I f / / /
// /
Llne of Cut
Figure 4.11
4.6.7 Nibbling
It is a process of continuous cutting along a contour, which may be a straight line or an irregular profile. The machines used in this operation are known as Nibblers, which are portable type shearing machines. These machines can be either electrically operated or pneumatically operated.
F /
Compression side
I '
Angle of bend
Single Bend
Double Bend
%rai@
fib
Edge Hem
Beading
Curling or wring
e&nor Lockseam
4.6.12 Bending
Sheet metal is required to be bent at several angles and curvatures to shape it into the required form. The bending operation involves stretching of metal on the outer surface and compressing it on the inner surface along a neutral line, which remains unchanged in . length. Sheet metal can be bent by hammering over a base by hand or by means of bending or rolling machines.
4.6.13 Drawing
Thin walled hallow shapes are produced in sheet metal through the drawing operation. The operation is carried out with the help of a die and a punch on a suitable press. If the drawn length of the component is less than its width or diameter it is called box drawing or shallow drawing. When the drawn length is more than the width the operation is known as deep drawing.
4.6.14 Soldering
It is a very common method of joining sheet metal parts. It involves spreading of a low melting point alloy, i.e. solder in molten condition between the surfaces or edges to be joined and allowing it to solidify these detailed study of soldering process and also of welding and brozing processes is important in sheet metal work.
Workshop Laboratory
4.7
DEVELOPMENT PROCEDURE
In sheet metal work the usual requirement is to lay the full size pattern on metal sheet that when the latter is cut according to the laid pattern and then folded or bent it will give the required object. This laying out of complete surface on the metal sheet is known as the development of the surface of the object or pattern layout for doing this job successfully the shape of the object should be carefully examined and then it should be divided into simple geometrical solids or portions of these solids. Then only it would be easy to develop the whole surface of the object for this, the surfaces of the simple solids, obtained as a result of the above division, can be developed separately and sheet cut accordingly. All these pieces when joined together will give the required object three common methods of laying out a pattern are :
lines
For fabricating wires to carry electricity. For manufacturing body parts of various electronic devices likes refrigerator, washing machines, etc. Used in communication industry
Apparatus
Metal sheet, mallet, shear, scribber, flattner, development on sheet.
Theory
The material of the sheet used in making box is glavanised iron (GI). The detailed theory is given in pages preceding this job.
Procedure
(a) (b) (c) (d) (e)
(f)
(g)
Make, i.e. draw the development of the given job on the sheet with all allowances marked on it. After the approval of development, trace it on metal sheet using scribber with allowances. Cut the sheet using shear. Mark the six notches as shown in development attached on adjacent page using shear. Bent the allowances at 90" on proper side using stake and mallet. Bent the sheet at marked places to get four sides of the box. prepare the seam to lock the sides Prepare single hem on top sides. Bent the bottom sides at 90' outwards. Cut out metal sheet for base of the box using development, shear and scribber. Bent the outer allowances at 90" and then further by 60". Place the four sided hollow box on the base and prepare double seam using the allowances provided for it. We get the required box.
(h) (i)
(j)
(k)
(1)
Result
(a) (b) (c) (d) (e) The box of sheet metal has been prepared having given dimensions. Precautions and Sources of Errors. Take the proper allowances, low value of allowances may lead to poor locks of metal while high value of allowances leads to metal wastage. Any bleeding caused by cut from metal should be immediately treated. Precaution should be taken while hammering to avoid dent formation on the metal surface.
Apparatus
Metal sheet, Mallet, shear, scriber, flattner, development on sheet, stakes, rivets, punch, iron hammer, scale, etc.
Theory
The material of the sheet used in making box is galvanized iron. The detailed theory is given in pages preceding first job.
Procedure
(a) (b)
(c)
Cut the metal sheet according to development of the cylindrical portion with appropriate allowances. Mark the lines (required ones) .on sheet using scriber. Bent the 5 mm and 10 mm allowance on same sides. Bent of 5 mm of 10 mm one on reverse and then roll the sheet. Lock the seam tightly. Bent the 5 mm allowance provided on top and bottom of cylinder outwards using iron bars. Cut the base of cylinder from sheet as per its development. Make the seam (double) using this base, one outward bend of cylinder, iron bar. Completely bend the other outward allowance. Now cut at metal strip of dimension 110 x 25 rnrn which includes 5mm allowance on both sides along 25 mm breadth. Bend the allowances inward using stakes, mallet, iron bar. Punch a hole in cylinder and strip using nut, punch and iron hammer. River the two using rivets and riveting set which has a hole for adjusting a flat for pressing. Roll the handle to required position and rivet the other end of strip. This gives the complete beaker, harnmerlfile down any pointed metal sites present on tha oeaker.
(d) (e)
(f)
Cj)
(k) (1)
'
(m) (n)
71