SHEET METAL SHOP

SHEET METAL SHOP

• In sheet metal shop articles of • (*The thickness of thin
thin sheets ranging from 30 sheets and wires is
gauge to 16 gauge* thick are
produced. Hand tools and indicated in terms of
simple machines are used to gauge. Higher the gauge
cut, form and join the work the thinner is the sheet or
pieces. the wire. 10 Gauge is
•   equal to 3.416mm. For
• Hoppers, Alimirahs, cabinets,
every increase in gauge
cupboards, canisters, covers,
boxes etc. are produced in sheet number there is a
metal work. decrease of 10% in the
•   thickness).
 SHEET METAL SHOP
It deals with working of thin sheets with hand tools
and simple machines into various cutting forms by:
1. Cutting
2. Forming into shapes
3. joining

Examples: Making of canisters, boxes, funnels, pipes,

bends, cans etc.
 FEATURES
1. Less Expensive
2. Lighter in weight
3. Good surface finish
4. Requires lesser force of deformation
5. Can easily replace the use of casting or forging
 MATERIAL USED
Black Iron:
Cheapest sheet metal
Bluish black appearance
Often referred to as uncoated sheet
Corrodes rapidly
Use is limited to the articles that are to be
painted such as tanks, pans, stove pipes etc.
 MATERIAL USED
Galvenised Iron:
it is a Zn coated iron
Popularly known as GI Sheets
Zn coating :
resist rusting,
improves the appearance of metal
permit to be soldered at greater ease
Reduce weldability by producing
toxic fumes and residues
Use to make pans, buckets,
heating ducts, gutters etc.
Advantages of galvanization of steel sheets

• To retain the steel intact with its full initial

strength.
• To provide the surface a more pleasing
appearance.
• To increase the life of any suitable organic
finishing system applied over it.
• To protect the steel from corrosive attack in most
atmospheres, acting as a continuous and lasting
shield between steel and the atmosphere
 MATERIAL USED
Stainless Steel:
it is an alloy of steel with
chromium(min.10-12%), nickel and
some other materials.
Good corrosive resistance
Good weldability
Cost is very high
Tougher than GI sheets
Use in food processing, dairy
industry, chemical plants,
kitchenwares etc.
 MATERIAL USED
Copper:
Available either as cold rolled or hot
rolled sheets
Better appearance than other metals
Good corrosive resistance
Conducts heat and electricity
efficiently
Cost is very high
Use in automobile industries,
electric works, expansion joints,
gutters etc.
 MATERIAL USED
Aluminium:
Can not be used in pure form, but is
used with a very small amount of Cu,
Si, Mn and Fe.
Whitish in color
Light in weight
Highly resistance to corrosion
Use in construction of refrigerator
trays, lighting fixtures, window
panels, airplanes , many electrical
and transport items etc.
 MATERIAL USED
Tin Plates:
is a thin sheet of iron coated
with tin to prevent rusting
Very bright silvery appearance
Use in roofs, food containers,
dairy equipments, furnace
fittings, cans, pans etc.
 MATERIAL USED
Lead:
Worked by hand without
using any mechanical device
Very soft and heavy
Use in nuclear shielding,
highly corrosive acid tank
linings, roof flashing, sound-
proofing, vibration
absorbers, waterproofing
and x-ray shielding.
 SHEET METAL HAND TOOLS
1. Measuring tools 2. Straight Edge 9. Hammers
i. Steel rule
3. Steel Square 10. Snips or
ii. Folding rule
4. Scriber shears
iii.Circumference
rule 11. Pliers
5. Divider
iv. Vernier Caliper 12. Stakes
v. Micrometer 6. Trammel
13. Groovers
vi. Thickness Points
Gauge 14. Rivet Set
7. Punches
vii. Sheet Metal 15. Soldering Iron
Gauge 8. Chisel
 1. MEASURING TOOLS
i. Steel Rule: It is made of hardened
steel and used for taking linear
measurements of articles to an
accuracy from 1 to 0.5 mm.
ii. Folding Rule: This is very useful in
measuring and laying out larger
work with 0.5 mm accuracy.
iii. Steel Circumference Rule: It is
used to find out directly the
circumference of a cylinder.
iv. Swing Blade Protractor: used for
marking and measuring angle
 1. MEASURING TOOLS
v. Vernier Caliper: used for
measuring both inside and outside
dimensions upto 0.02 mm.
vi. Micrometer Caliper: used to
measure the thickness of metal
sheets accurately upto 0.01 mm.
vii. Thickness Gauge: also called slip
gauge and used to measure the
clearance between parts during
assembly
viii.Sheet Metal Gauge: used to
measure the thickness of sheets
 SHEET METAL HAND TOOLS
2. Straight Edge: is a flat
graduated steel bar with one
longitudinal edge bevelled. It
is useful for scribing long
straight lines.
3. Steel Square: made of
hardened steel. It is used for
marking in the perpendicular
direction to any base line.
 SHEET METAL HAND TOOLS
4. Scriber: also known as metal
worker’s pencil. It has one
hardened sharp pointed edge to
scratch line on sheet metal.
5. Dividers: used for drawing circles ,
arc on sheet metal and also used to
mark a desired distance between
two points.
6. Trammel Points: consist of a bar
with two movable heads. It is used
to draw large circles or arcs that are
beyond the limit of the dividers.
 SHEET METAL HAND TOOLS
7.Punch: used for marking out work,
locating centers etc.
Prick punches is used to make small
marks on layout lines.
Centre punch is used to make prick
punch markers larger at the centre
holes that are to be drilled
Hand lever punch is used for marking
holes with a punch and die
incorporated in the tool when a
large number of holes are to be
punched.
 SHEET METAL HAND TOOLS

8. Chisel: used for

cutting sheets, rivets,
bolts and chipping
operations. The flat
flat chisel
chisel and round nose
chisel are most
widely used in sheet
metal works. round nose chisel
 SHEET METAL HAND TOOLS
9. Hammers: used for forming
shapes by raising, stretching or
throwing off.
Types:
Riveting Hammer
1. Riveting hammer: used for
riveting
2. Setting hammer: used for setting Setting Hammer
down the edge while making a
double seam
3. Raising hammer: used for
forming of a flat sheet of metal into
a curved or hollow shape like spoon. Raising Hammer
 SHEET METAL HAND TOOLS
9a. Mallet: used to strike a light and
soft blow on metal.
-this is soft hammer made of
rubber, copper, brass, wood Mallet

etc.
10. Snips or shears: used to cut thin
sheets. Snips

11. Stakes: sheet metal worker’s

anvils ,i.e., supporting tool.

Stakes
 SHEET METAL HAND TOOLS
12. Pliers: used for holding,
bending and cutting work.
Plires
13. Hand Groover: used for grooves
and flatten a seam

14. Rivet Set: a hardened steel tool Groover

with hollow in one end.
-used to shape the end of rivet

Rivet Set
Snip
STAKES- sheet metal work piece holding
device
 Sheet metal shop machines
-Sheet metal cutting machine
Sheet metal rolling machine
 SHEET METAL OPERATIONS
1. Shearing
2. Bending
3. Drawing
4. Squeezing
 SHEET METAL OPERATIONS
1. Shearing: it has three
basic stages-
A. Plastic Deformation
B. Fracture
C. Shear
This procedure gives a
clean edge on the piece
of metal.
 1. SHEARING
Some basic shearing
operations are:
A. Cutting off: cutting off a
piece from a strip A

B. Parting: cutting a strip

between two pieces to
part them
B
 1. SHEARING
C. Blanking:
It is an operation of cutting a flat
shape from a sheet metal. The part
punched out is called the blank and
the remaining sheet is the scrap.

D. Punching:
It is a cutting operation by which
various shaped holes are made in
the sheet metal.
In this operation, the hole is the
required operation and the
material punched out is the scrap.
 1. SHEARING
E. Notching: removing the E
metal from the edge of
sheet metal.
F
F. Slitting: In this shearing is
conducted between rotary
blades.
G
G. Lancing: This makes a cut
part way across a strip.
H. Trimming: cutting away
excess material or flash
from a piece.
 2. BENDING
Bending is the creation of a
formed feature by angular
displacement of a sheet metal
work piece.
In this operation, the material
in the form of flat sheet or strip
is uniformly strained around a
linear axis which lies in the
neutral place and perpendicular
to the lengthwise direction of
the sheet or metal.
 3. DRAWING
It is the operation of
producing cup shaped
products from flat metal
sheet.
It is divided into two parts:
1. Deep Drawing: in this the
length of object is higher
than its width
2. Shallow Drawing: in this
the length of object is
lesser than its width
 4. SQUEEZING
In this operation, the metal is squeezed within the
cavity of the die and the punch to attain the
desired shape.
 SHEET METAL JOINTS
1.Hem:
“A hem is an edge or border
made by folding.”
Hems are commonly used to
reinforce an edge, hide Single Hem

burrs and rough edges, and

improve appearance.
Types:
1. Single Hem Double Hem

2. Double Hem
3. Wired Hem
 SHEET METAL JOINTS
2. Seams:
“A seam joins the edges
of two materials.”
Seams are commonly
used in the food
industry on canned
goods, on amusement
park cars, and in the
automotive industry.
 SHEET METAL JOINTS
Types of Seam:
A. Lap Seam: it can prepare
as lap joint by means of
LAP SEAM
soldering
B. Grooved Seam: made by
hooking two hems and
locking them by groover.
C. Single Seam: used to join
bottom to vertical bodies
of various shapes. GROOVED SEAM
 SHEET METAL JOINTS
D. Double Seam: it is like
single seam except that it
formed edge is bent
upward against the body.
E. Dovetail Seam: similar to
dove tail joint and used DOUBLE SEAM
to join flat plate to a
cylindrical piece.
F. Burred bottom Seam:
used to join bottom of
container to its body.
DOVETAIL SEAM
 SHEET METAL WORKING MACHINE
Various machines commonly used are:
1. Shearing machine: used to cut or shear metal sheets.
 SHEET METAL WORKING MACHINE
2. Bar Folder: used to bend and fold the edges of metal sheets.
 SHEET METAL WORKING MACHINE
3. Burring Machine: used to make burr of the edges of the
bottom for a can and on the end of cylinder
 SHEET METAL WORKING MACHINE
4. Turning Machine: similar to burring machine and used to produce
a rounded edge for wiring operation and for double seaming
 SHEET METAL WORKING MACHINE
5. Wiring Machine: is used to press the wire inserted into
turned sheet after the hammering.

6. Forming machine: used to form stove pipes, cans etc.

It consists of three rolls between which the curves are made.
metal.

7. Brake: is a machine used for bending and folding sheet

metal.