Sheet Metal Shop

SHEET METALWORKING
SHEET METAL SHOP

It deals with working on thin sheets (0.4 to 6
mm thick) using hand tools and simple machines. It
includes
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 Sheets:
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.
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
Gauge 8. Chisel Iron
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
Swing Blade Protractor
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
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.
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.
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.
Hand Lever Punch
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
9. Hammers: used for forming
shapes.
Types:
1. Riveting hammer: used for Riveting Hammer
riveting
2. Setting hammer: used for
setting down the edge while Setting Hammer
making a double seam

3. Raising hammer: used for
forming of a flat sheet of metal
into a curved or hollow shape Raising Hammer
like spoon.
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
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
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 Single Hem
to reinforce an edge, hide
burrs and rough edges,
and improve appearance.
Types: Double Hem
1. Single Hem
2. Double 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.
DOUBLE SEAM
SHEET METAL WORKING MACHINE
Various machines commonly used are:
1. Shearing machine: used to cut or shear metal sheets.

Sheet Metal Shop

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SHEET METALWORKING

SHEET METAL SHOP

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

8. Chisel: used for

making a double seam

11. Stakes: sheet metal worker’s

14. Rivet Set: a hardened steel tool Groover

B. Parting: cutting a strip

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