DEPARTMENT OF MECHANICAL ENGINEERING

LABORATORY MANUAL
FOR

Tin Smithy

Sheet metal operations with hand tools.

 Trapezoidal tray
 Funnel
 T-Joint

ME163/MEL01 WORKSHOP
(Common to all branches)

BAPATLA ENGINEERING COLLEGE

(Sponsored by Bapatla Education Society)
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(AUTONOMOUS)
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 BAPATLA-522101

ME163/MEL01 WORKSHOP
(Common to all branches)

Practical : 2 periods / week

Sectional marks : 40
University exam : 3 hrs
University exam marks : 60

LIST OF EXPERIMENTS
1. Tin Smithy

A. Trapezoidal tray
B. T- joint
C. Funnel
______________________________________________________________________________

TIN SMITHY

A. Trapezoidal tray
B. T- joint
C. Funnel
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______________________________________________________________________________
 JOB NO: 1

TRAPEZOIDAL TRAY

Aim: To prepare a Trapezoidal tray of given dimensions.

Tools Required:
Steel rule, straight snip, Try square, Scriber, Divider, Wooden Mallet, nylon mallet, stake
Sheet metal calculations:
Parallel sides of tray : 40 mm, 60 mm
Height of the tray : 20 mm
Folding dimension : 5 mm
Sheet length : 40+2(22.3)
Sheet width : 40 +2(22.3)
Material required:
90mm X 90 mm G.I .Sheet
Sequence of operations
1. Marking 2. Cutting 3.Notching 4.Folding edges 5.Bending and seam making
Procedure:
1. Marking: The dimensions of the sheet required are found by the development of the using
try square and scriber, by taking an allowance of 5 mm, does trapezoidal tray and
marking. (As shown in fig.)
2. Cutting: The sheet is cut from the given sheet using straight snip.
3. Notching: Then the unwanted material (hatched portion) is removed along the marking
lines using Straight snip
4. Folding edges: Keeping the sheet on vice bend the 5 mm edges.
5. Bending: Now the sheet is bent into the shape of trapezoidal tray.
6. Seam making: Folding the 5mm edges over the bent sides makes the joint.
Percentage of wastage:
P.O.W = (A1-A2)/A1
Where, A1= Area of the material issued.
A2= Developed Area of the tray
Precautions:
1. Sharp edges are to be avoided.
2. Care should be taken while using the mallet and snip.
Result: A Trapezoidal tray of required dimensions is prepared from the given G.I sheet.
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 JOB NO: 2

T – JOINT

Aim: To prepare a T – Joint of given dimensions.

Tools Required:
Steel rule, Straight snip, Try square, Scriber, Divider, Wooden Mallet, Nylon mallet, Stakes
Sheet metal calculations:
Sheet 1 dimensions : 70mm X (3.14 X 30) + 2(5) mm
Sheet2 dimensions : 80mm X (3.14 X 30) + 2(5) mm
Folding dimension : 5 mm on both sides
Material required:
80 mm X 120 mm, 80 X 120 mm G.I .Sheets
Sequence of operations:
1. Marking 2. Cutting 3.Notching 4.Folding edges 5.Bending and seam making
Procedure:
1. Marking: The dimensions of the sheet required are found from the development. Marking
is done with scriber and try square by taking allowance of 5 mm. (as shown in figure)
2. Cutting: the sheet is cut from the given sheet using straight snip.
3. Notching: Then the unwanted material (hatched portion) is removed along the marking
lines using straight snip.
4. Folding edges: Keeping the sheet on vice bend the 5 mm edges.
5. Bending: Now the sheet is bent into the shape of T-joint.
6. Seam making: Folding the 5mm edges over the bent sides makes the joint.
Percentage of wastage:
P.O.W = (A1-A2)/A1
Where, A1= Area of the material issued.
A2= Developed Area of the tray
Precautions:
1. Sharp edges are to be avoided.
2. Care should be taken while using the mallet and snip.
Result: A T-joint of required dimensions is prepared from the given G.I sheet.
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 JOB NO: 3

FUNNEL
Aim: To prepare a Funnel of given dimensions.
Tools Required:
Steel rule, Straight snip, Try square, Scriber, Divider, Wooden Mallet, Nylon mallet, Stakes
Sheet metal calculations:
Sheet 1 dimensions : 50mm X 70 mm
Sheet2 dimensions : 180mm X 100 mm
Folding dimension : 5 mm on both sides
Material required:
50 mm X 70 mm, 180 mm X 100mm G.I .Sheet
Sequence of operations:
1. Marking 2. Cutting 3.Notching 4.Folding edges 5.Bending and seam making
Procedure:
1. Marking: The dimensions of the sheet required are found from the development.
Marking is done with scriber and try square by taking allowance of 5 mm. (as shown in
figure)
2. Cutting: the sheet is cut from the given sheet using straight snip.
3. Notching: Then the unwanted material (hatched portion) is removed along the marking
lines using Straight snip
4. Folding edges: Keeping the sheet on vice bend the 5 mm edges.
5. Bending: Now the sheet is bent into the shape of funnel.
6. Seam making: Folding the 5mm edges over the bent sides makes the joint.
Percentage of wastage:
P.O.W = (A1-A2)/A1
Where A1= Area of the material issued.
A2= Developed Area of the tray
Precautions:
1. Sharp edges are to be avoided.
2. Care should be taken while using the mallet and snip.
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Result:
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A Funnel of required dimensions is prepared from the given G.I sheet.

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 SHEET METAL

Introduction:
Sheet metal work is generally regarded as the working of metal from 16 gauge down to 30
gauge. Tin smithy deals with making of metal boxes, pans, buckets, cans, furnaces, funnels
and ducts from flat sheet metal. In this, the development is drawn on the sheet metal and cut
and folded to form the required shape of the object. For successful working in the trade, one
should have a through knowledge of projective geometry, particularly of the development of
surfaces. Allowance should be given in the drawing stage for folding and bending. This
allowance depends upon the radius of the bend and thickness of the sheet metal.
METALS USED IN SHEET METAL WORK:
In sheet metal work, the sheet metal used is black iron, galvanized iron, stainless steel,
copper, brass, zinc, aluminum, tin plate and lead. The sheets are specified by standard gauge
numbers. Each gauge designates a definite thickness. The larger the gauge number, the lesser
the thickness.
GALVANISED IRON:
Zinc-coated iron is known as “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 it is coated with zinc, galvanized sheet iron withstands contact with water
and exposure to weather.
Hand tools:
The common hand tools used in sheet metal work are steel rule, try square, wire gauge,
scriber, ball peen hammer, Cross peen hammer, nylon mallet, snips, dividers, stakes, cutting
pliersandsoldering iron.
Here, the details of tools that are being equipped by our workshop purpose only are
presented.
Wire gauge:

The thickness of the sheet is referred in numbers known as standard wire gauge (SWG). The
gaps in the circumference of the gauge are used to check the gauge number.
Steel rule:
It is a strip of steel with graduations on its edges. It is used for measuring and setting out
dimensions.
Scriber:
A scriber is a slender steel tool, used to scribe or mark lines on sheet metal.
Snips:
Hand shears or snips are used to cut sheet metal.
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Straight snip:
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 Straight snips are having straight blades and are used for cutting ai=long straight lines and
trimming edges.
Curved snips:
Curved snips have a curved blade and are used for cutting circles and irregular shapes.
Divider:

It consists of two pointed legs. The points are hardened and tempered to prevent wear. It is
used for transferring the sizes and scribing curves or circles.
Bench vice:
It is generally used for holding and bending the work piece.
Hammers:
Light weight hammers and mallets are used in sheet metal work.
Ball Peen Hammer:
It has a cylindrical, slightly curved face and a ball head. It is a general purpose hammer used
mostly for riveting in sheet metal work.
Straight Peen Hammer:
It has a tapered peen end similar to the cross peen, but it is positioned parallel to the handle
which can be used conveniently for certain operations of folding.
Cross Peen Hammer:
Ithas a tapered peen end and is perpendicular to the handle. Because of this, it can reach
awkward corners.
Cutting pliers:
It is used for holding, cutting and bending works.
Nylon mallet:
It is used for bending and folding work. It is light in weight, covers more area and do not
damage the surface area.
Stakes:
Stakes are made of steel and forged in variety of shapes and sizes. These are used as
supporting tool and form, seam, bend or rivet sheet metal objects.
Anvil:
Anvil provides the necessary support during hammering. It is also useful for operations such
as bending. Its body is generally made of mild steel and a strip of high carbon steel about 20
mm thick is welded on top to provide hard face
Sheet metal joints:
Various types of joints are used in sheet metal work, to suit varying requirement. Some
commonly used sheet metal joints and folded ledges are shown in figure. These are self
secured joints, formed by joining together two pieces of sheet metal and using the metal it
self to form the joint.
Sheet metal Layout:
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The shapes of most articles made with sheet metal are in few geometrical forms. All these
forms are made from flat sheet; therefore the first requirement is developing the lines, which
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forms the pattern. The development or stretch out of a job is called pattern and developing
 lines which forms a pattern is layout. It may be drawn on paper first and then transferred in
the sheet or it may layout directly on sheet metal.When a pattern is made repeatedly, it is
generally made of metal and referred to as a template.
Instructions:
1. Draw the development of the object to be prepared with true dimensions only.
2. Use curved snip for trimming along inside covers.
3. Always provide folding (Hem) for top edges of the object to avoid sharp edges and to
stiffen the sheet.
4. Ground properly the exposed metal parts of electrically heated soldering iron.
5. For good soldering the metals to be joined must free from dirt, grease and oxide.
6. Do not pull or peel the cut portion by hand while cutting with snip.
7. Do not bend the sheet with hand, always use nylon mallet with proper support.
Safe practices:
1.Use hand leather gloves while handling heavy sheets.
2.Avoid pulling or felling the cut portion by hand while cutting with snip.

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 VIVA QUESTIONS
Tin smithy
1. What is the tool used for bending and folding work?
2. What is the function of stakes?
3. What is the function of soldering iron?
4. What is tool used for cutting G.I sheet?
5. How do you measure the thickness of sheet metal?
6. What is meant by G.I sheet?
7. What is the composition of solder?
8. What is the significance of SWG number?
9. Sheet metal layouts are known as _______________
10. Galvanized iron sheet is a steel sheet coated with _______________
As the gauge number increases, the sheet thickness _______________

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