DEPARTMENT OF MECHANICAL ENGINEERING

DME 2203

WELDING AND FABRICATION TECHNOLOGY

ASSIGNMENT ONE

GROUP 2

KAZIBWE JEBRINE – 2022/A/MEK/1453/F

KANAABI ARNOLD – 2022/A/MEK/0359/F

NO2
 Fixing methods for sheet materials and structures.

As one of the most common materials used in project design, it's essential that the right fastening methods are
applied for sheet metal fabrication. Fixing methods for sheet materials and structures can vary depending on
the specific application, material type, and structural requirements.

Note; First one should be aware of sheet metal fabrication techniques since some of them can be used to
join sheet metal. There are various sheet metal fabrication techniques. Typically these processes involve
transforming different types of sheet metals into parts and components. It is also a versatile process that
can create a wide range of metal components made from

Sheet metal fabrication is a process used to create metal structures by cutting, bending, and assembling sheet
metal. It is a widely used manufacturing process in industries such as automotive, aerospace, construction, and
electronics.

To simplify it sheet metal fabrication refers to the turning of flat metal sheets into metal products and
structures.
 VITAL OPERATIONS INVOLVED

CUTTING

It means severing a piece from a strip or sheet with a cut along a single line using suitable punch and die
of press tool in press machine.

Cutting is typically the first step in fabricating sheet metal.it is divided into two groups

 Cutting with Shear

 Cutting without Shear

SHEARING

Shearing takes place in form a cut when punch strikes and enters in the sheet placed on die. The quality of
the cut surface is greatly influenced by the clearance between the two shearing edges of the punch and
dies. Its cutting sheet metal from a larger roll or flat material using a shearing machine.

BLANKING AND PUNCHING

Blanking. It is an operation in which the punch removes a portion of material called blank from the strip
of sheet metal of the necessary thickness and width using suitable punch and die of press tool in press
machine.

Punching. It is the operation of producing circular holes on a sheet metal by a punch and die. The
material punched out is removed as waste. Piercing, on the other hand, is the process of producing holes
of any desired shape in the part or sheet using suitable punch and die of press tool in press machine.

Blanking and punching are essentially the same process with opposing results. Punching creates holes in
a metal work piece, while Blanking is the final process where the final product is removed the larger
metal sheet and the remaining material is discarded as scrap.

Waterjet cutting

Waterjet Cutting uses high pressure water and Garnet Abrasives to erode materials such as glass, wood,

rubber, stone, plastic and metal.

laser cutting

Laser cutting involves the use of a high powered laser to cut various designs into materials with
advantages of higher accuracy and precision, better speed and efficiency and lower costs.

Plasma cutting. Is a process that delivers plasma highly charged particles stream via a cutting torch to
quickly cut through metal items.
FORMING.

Forming refers to the distortion of metal to create a specific shape. Common forming techniques include:
  Bending.

Is a type of forming that adds basic angles or curves to a work pieces to transform linear pieces of
material into dynamic shapes. Typical forms are U or V shaped.

 Hemming.

Hemming involves rolling the edge of sheet metal over and onto itself, essentially creating an area of two
layers.

Curling. Curling is a sheet metal forming process used to form the edges into a hollow ring.

 Rolling.

Rolling is a variation of forming, which passes sheet metal through a series of rollers that incrementally
changes the shape of the work piece through multiple steps.

 Deep drawing.

Deep drawing is a sheet metal forming process in which a sheet metal blank is radially drawn into a
forming dye by the mechanical action of a punch.

Sheet Metal Fastening/Fixing Methods.

Examples of sheet metal

 plywood,
 medium-density fiberboard (MDF),
 oriented strand board (OSB)
 mild steel sheets of any gauge

Sheet metal joining operation is crucial part of the sheet metal fabrication process. Joint reliability
depends on its type, sheet metal material, and manufacturing process

Factors affecting the selection of type of Sheet Metal Joint;

Selection of the type of sheet metal joint has an impact on product design, manufacturing cost, assembly
process, joint reliability, and performance. The following factors affect the selection of the sheet metal
joining process.

 Required Joint Type: Permanent or Temporary Joint

 Product Application
 Assembly Process
 Material Type
 Sheet Thickness

Various Types of Sheet Metal Joining Techniques

Following types of sheet metal joining techniques are available to join sheet metal parts. Each
joining method has its advantages, limitations, and applications.
1. Screw Joints
2. Rivet Joints
3. Clinching Joint.
4. Welding Joint
5. Folding/TAB Sheet Metal Joints
6. Adhesive Bonding

Screw Joint in Sheet Metal

Screw Joint is a type of temporary joint. Screws, bolts, nuts, studs, and standoff are used for
fastening sheet metal parts.
Screws and bolts are commonly used to fix sheet materials and structures together. They provide
a strong and reliable connection.

Types of screw joints

Following two types of screws are widely used to fasten sheet metal parts according to product
design and functional requirements.
Machine screw
Machine screws have an application where we require multiple assemblies and disassembly
operations. These screws require additional hardware such as clinch, riveted, or weld nuts on
sheet metal parts.

Self-tapping screw.
Self-Tapping Screws are a low-cost solution for the one-time assembly of sheet metal parts. They
require a pilot or extruded hole in one of the sheet metal parts
 Selection of the Type of Screw /Fasteners for Sheet Metal Joint
The following factors affect the selection of the type of screw to join sheet metal parts.
Sheet Metal Material
Experts recommend self-tapping fasteners for hard materials ( CRCA, SS), whereas machine
screws are the best choice for softer materials such as Aluminum.
Sheet Thickness
Self-tapping screws require larger sheet thickness to engage the recommended number of threads.
Assembly Approach
Machined screws have an application for multiple assembly and disassembly of the product,
whereas experts recommend self- tapping for one-time product assembly.
Cost Constraints
Machine screws solution is costlier than self-tapping screws.
Structural Requirements
Machine screws provide high clamping force compared to self-tapping screws.

Advantages of Screw Joints in Sheet Metal

Using screw joints to join sheet metal parts has the following advantages.
 Temporary joints.
 A blind Joint is possible.
 A wide variety of fasteners are available for various applications.
 Highly reliable compared to other sheet metal joining techniques.
 Easy to assemble.
Disadvantages of Screw Joints in Sheet Metal
 Machine screws require additional fasteners such as nut, and standoff.
 Gaskets are required to achieve a waterproof joint.

Rivet Joints.

Riveting involves using a rivet and a rivet gun to join sheet materials together. It is a type of permanent
joining operation. It requires adjacent holes in the sheet metal parts.

The riveting process

The rivet installation process involves placing the rivet inside the punched/drilled hole in the sheet metal
parts. Afterward, the rivet mandrel is pulled against the rivet head using a riveting machine. It results in
diametrical expansion of rivet pin against sheet metal part and rivet head. The above process secures the
sheet metal parts and rivets in position.

Types of Rivet

We can classify rivets into the following types according to rivet structure and the installation process.

Solid or round head rivets

Semi-tubular rivets

Oscar rivets

Blind or Pop rivets (commonly used in the sheet-metal industry)

Drive Rivets

Flush type Rivets

Advantages of Riveting in Sheet Metal Parts.

 Low operational and material costs.

 Blind joints are possible.

 Part disassembly can cause minor damage to the part.

Limitations.

Rivet joints in sheet metal have the following limitations;

 Higher stress concentration near the riveted area.

 The riveting setup is required.

Sheet Metal Clinching Joint

A clinching joint is a type of permanent sheet metal joining operation using a cold forming operation. It
creates a button type positive connection between two or three layers of sheet metal.

Clinching operation has application to join different material and sheet thickness parts.

Advantages of Clinching Joints.

 Additional fasteners are not required.

 Permanent joint.

 Low operational cost.

 Can join different materials and different thicknesses parts.

Disadvantages of Clinching Joints.

 High initial setup cost

 It cannot be used on hard materials

 Joint strength is not as strong as other joint types

Welding Joints
Welding is a process for joining two similar or dissimilar metals by fusion.
Welding is a type of permanent joining operation.
Following welding techniques are used to join sheet-metal parts.
 MIG Welding
 TIG Welding
 Arc Welding
 Gas Welding
 Spot Welding
 Seam Welding
 Brazing

Factors affecting the selection of welding process.

One should consider the following points during the selection of welding operations for an
application.
 Sheet metal material.
 Sheet Thickness.
 Final Finish Requirements.
 Airtight or waterproof joint requirements.
 Working temperature Range.

Advantages of Welded Joints in Sheet Metal

 Permanent Joint.
 Create Leak-proof joints.
 High load-carrying capacity.
 Welding of complex shapes is possible.
 Disadvantages of Welding Joints in Sheet Metal Parts
 Material properties changes near the welded area.
 Welded joints are difficult to inspect.
 Welding in thin metals can cause warping and burn through.

Folding / Tab Joints in Sheet Metal

Folding or bending tabs is an economical way of making permanent sheet metal joints. We can do this
process on sheet metal bending machines. Therefore it does not require an additional hardware setup. Tab
joints have application in joining soft steel, aluminum, copper, and brass materials.

Advantages of Folding Joint

 Additional fasteners are not required.

 Low cost and reliable permanent joint.

 Joining dissimilar materials.

Disadvantages of Forming Joint.

 Can achieve waterproof joints.

 Require a relatively long joint area to achieve the required strength.

Adhesive Bonding for Sheet Metal Parts

Adhesive bonding is a type of permanent joint used in sheet metal parts. You can disassemble parts using
chemicals. For adhesive bonding, you need to place the adhesives between the part surfaces, and
afterward, pressure is applied.

Factors affecting the selection of adhesive.

One should consider the following points during the selection of adhesives for your application.

 Part Surface Geometry

 Part Material.
 Bonding strength requirement
 Moisture or water content in the working environment

Types of Adhesive

 Cyanoacrylate Adhesives.
 Acrylic-based adhesives.
 Epoxy-based adhesive.
 Silicon-based adhesive.
 Adhesive Joint Examples.

Following are the two types of adhesives available for sheet metal joints:

Double-Sided tapes: Double-sided tapes in various thicknesses and chemical compositions are available.
We can select the adhesives as per design requirements.

Liquid Adhesives: Adhesives in a liquid state with different viscosity and chemical compositions are
available.
In summary

There are various methods for fixing sheet materials and structures depending on the application and
materials involved;

 Screws and Fasteners: Screws and fasteners are commonly used to fix sheet materials like wood,
metal, and plastic. Different types of screws are available for different materials and applications.
 Nails: Nails are used for fixing sheet materials like wood and some light-duty applications. They
are driven into the material using a hammer or nail gun.

 Adhesives: Adhesives are used to bond sheet materials together. There are various types of
adhesives available such as wood glue, epoxy, super glue, etc., each suited for specific materials
and applications.
 Welding: Welding is commonly used to fix metal sheet materials together. Different welding
processes like MIG welding, TIG welding, or spot welding can be used based on the material and
application.
 Rivets: Rivets are used to fix sheet materials together by deforming the rivet to create a strong
joint. They are commonly used in aerospace and automotive applications.
 Clips and Clamps: Clips and clamps are used to hold sheet materials together temporarily or
permanently. They are often used in applications where disassembly may be required.
 Bolts and Nuts: Bolts and nuts are used to join sheet materials together by passing a bolt through
pre-drilled holes in the materials and securing it with a nut on the other side.
 Stapling: Using staples to attach thin sheet materials, like drywall or plywood, to wood framing.

When selecting a fixing method, it's essential to consider factors such as the material being used,
the load requirements, the aesthetics of the joint, and the ease of disassembly if needed.

REFERENCES
 Introduction-to-basic-manufacturing-processes-and-workshop-technology BY Rajender
Sigh
 Workshop Processes, Practices and Materials, Bruce. J. Black
 THREADING HANDBOOK ISCAR’s Reference Guide for Threading Applications
 JSS MAHAVIDYAPEETHA FIRST YEAR B.E. WORKSHOP PRACTICE