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Class Notes - Sheet Metal

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SHEET METAL (Development & Soldering of the models)

Introduction to sheet metal work:


Sheet metal work is working with metal sheets from 16 W 30 gauge, using
hand tools and simple machines. By marking, development, cutting, forming in to
shape and joining to fabricate many domestic utility items, machine covers,
hoppers, guards, tanks, stacks, duct work, pipes, bend, boxes, etc. common
metals used in sheet metal work are black iron, galvanized iron, stainless steel,
copper, brass, zinc, aluminum, tin plate and lead.
The material, which is used in workshop, is galvanized iron. It is zinc coated
hence it is known as galvanized iron. This sheet can withstand contact with water
and exposure to atmosphere.
Development: It is method of laying out surfaces of the pattern with
suitable allowances in full size on metal sheet.
Methods of development: There are four methods of development
1) Parallel line development : This is used to develop cubes , prisms,
cylinders, and similar objects
2) Radial line development : This is used to develop pyramids, cones and
similar objects
3) Triangular development : This is used to develop transition piece, pipes
and objects of various shapes

4) Approximate Development: This is to develop sphere, ellipsoid etc.


Sheet metal operations:
1) Shearing: shearing is a cut in straight line across the strip, sheet or bar. This
procedure leaves a clean edge on the metal that is sheared or cut
2) Punching : punching is the operation of producing circular holes on sheet
metal by punch or die
3) Drawing: this is operation of producing thin walled hollow or vessel shaped

parts from sheet metal.


4) Notching: this is process of removal metal to the desired shape from the
side or edge of sheet or strip to prevent overlapping and bulging of seams,
hems and edges.
5) Flattering: It is the operation in which the sheet is made flqt by heating the

metal down where it stands up from the sheet.


Sheet metal joints: Hem sand seams
Sheet metal working incorporates a wide variety of hems and seams. A hem
is an edge made by folding. It stiffens the sheet metal and does away with
the sharp edge.

A seam is a joint made by fastening two edges together.

Gauge: gauge is only a number to know the thickness of sheet and diameter of
wire.
GAUGE number Thickness or diameter
10 G 3.25mm
12G 2.64mm
14 G 2.03mm
16 G 1.63mm
18 G 1.22mm
20 G .91mm
22 G .71mm
24 G .56mm
26 G .46mm
28 G .38mm

30 G .30mm
Tools used in sheet metal work:
 Ball peen hammer

 Snip
 Straight edge
 Stake
 Rivets
 Steel rule
 Scriber
 Mallet
 Trammel etc.

Some of these are mentioned in fitting section.


Trammel point:
It is used to draw large circles and arcs. The trammel has two removable

pointed legs and mounted on a separate holder.

Cutting tools:
Snips are used to shear or cut the metal sheets to the sheets to the
required size and shape. Snips are used to cut thin sheet metal. The following

snips metals are used in sheet metal work.


Straight snip:
It is used to cut or trim along a straight line. The blades in this snip are straight.
Bend snip:
It is used to trim or cut along inside curves. The blades in this snip are
curved back from the cutting edge, which permits the sheet to slide over the top

blades while cutting.


Prick punch:
It is sharply pointed tool. The tapered point of the punch has an angle of
I
last longer.
Center punch:
Looks like a prick punch. Its point has an angle more obtuse than that of
T
Stakes:
The stakes are the supporting tools in sheet metal work to form a shape.
And it is used when the sheet metal bending, riveting, punching etc.
Hand stake:
It is used for pressing the inner sides of straight joint in the sheet. It has a

flat surface with two straight edges, a concave and a convex edge.
Half round stake:
It is used to form a round seam joint on the inner side of the job.
Horse stake:
It has tow square holes for holding one or two stakes to carry out different
operations on the job.
Taper stake:
It is used to form a conical or tapering job.
Hammers:
Hammers are used for forming shapes by hollowing, stretching or raising.
There are many types of hammers in use in sheet metal shop. (Some other

hammer mentioned in fitting).


Mallets:
Mallets are soft hammers and are made of raw hide, hard rubber, copper,
brass, Lead, or wood. It is mostly used to strike soft metal and give light blow on

sheet metal.

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