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10.2 • Workshop Manual
Tin Smithy (' '
Aluminum in the form of sheets can be used with the addition of small quantities of metals like 10.3.3 Bench Shear
copper, silicon, manganese and iron. It is widely us~p for processing vessels and tanks, house-hold
appliances, refrigerator trays, kettles, etc. Aircraft structures are mainly made from aluminum and Sheet metal may be cut by shearing action. Figure I0.3 shows a bench shear. 1n this, the force is
its alloys. · applied through a compound lever, making it possible to cut sheet metal upto 4 mm thick. The
chopping hole can shear a mild steel rod upto IO mm ~iameter.
Stainless steel is an alloy of steel with 8-10% nickel, 18%chromium and traces of other metals.
It has got greater resistance to corrosion and can be welded. It is used for making kitchen-ware, Steady
dairy and food process!ng plants, chemical plants, etc. · (hopping
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10.3 HAND TOOLS
The common hand tools used in sheet metal work are, stP,ef rule, usually of 60 cm length, wire
gauge, dot punch, trammel, scriber, bafl~peen hammer, straight-peen hammer, cross-peen hammer,
malle~ snips and soldering iron.
Botto•
10.3.1 Trammel· blade
Sheet metal layout requires marking of arcs and circles. This may be done by using _the trammel,
Straight Bent
as shown in Fig. I0.1. The length of the beam decides the maximum size of the arc that can be
'. scribed. Fig. 10.3 Bench shear
j 10.3.4 Snips
Fig. 10.4 Snips
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I Snips are hand shears, varying in length from 200 mm to 600 mm, 200 mm and 250 mm being the
:1 . lengths commonly used. Figure I0.4 shows straight and curved snips. The straight snip is used for
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.,. } cutting along outside curves and straight lines and curved snip or bent snip is for trimming along
inside curves.
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Fig.10.1 Trammel 10.3.SHammers
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'1 10.3.2 Wire Gauge Light weight hammers and mallets are used in sheet metal work (Fig. I 0.5).
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The thickness of sheet metal is referred in numbers known as standard wire gauge (SWG). The ;i
gaps in the circumference of the gauge are used to check the gauge number as shown in Fig. I0.2. . "I{
Some of the standard wire gauge numbers with corresponding thicknesses are as follows (Table. . 1
10. l): . i
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Table IOJ
1:1 SWGNo Thickness, mm
Cross Peen Straightpeei
IO 3.20
;.\ 12 2.60
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t 14 2.30
:11 16 1.60
I',S 20 1.00 ./
22 0.70 Hallet
'If.
,, 24 0.65 Fig. 10.5 Hammers ·
it 26
10
0.45
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I Fig. 10.2 Standard wire gauge
/ 0 .4 • Wmkshop Ma""'' • ,, Tin Smithy • 10.fi-,
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.r Ball-peen hammer has a cylindrical, slightly curved face and a ball head. It is a general purpose J0.4 SHEET METAL JOINTS
hammer, used mostly for riveting in sheet metal work. Cross-peen hammer shown, has a tapered Various types of joints arc used in sheet metal work, lo suit the varying requirements. Some
peen end and'is perpendicular to the handle. Because of this, it can reach awkward corners as . commonly used sheet metal joints and folded edges are shown in Fig. 10.7. These arc self secured
shown. joints, formed by joining together two piee.::s of sheet metal and using the metal ilselfto fonn the
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Straight-peen hammer has the peen end similar to the cross-peen, but it is positioned parallel to join I. These joints arc to be used on sheets of less than 1.6 mm thickness.
the handle which can be used conveniently for certain operations of folding, Mallet is used for
bending and folding work. It is called as soft hammer. Generally, it is made of wood. It is light in
weight, covers more area and-does no_t dent the work. ·
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a-Single seam b-Double seam
10.3.6 Stakes -
Stakes are nothing but anvils, which are used as supporting tools and to form, seam, bend or rivet c-Grooved seam
DED
sheet meta.I objects. These are available in different shapes and sfaes.as shown in Fig. 1-0.6, to suit
the require111ents of the work . .They are made from wrought iron, faced with steel.
Single hem Double hem Wired edge
~ -- B- Folded edges
A-Sheet metal joints
r
Bick iron Fig.10.7
Various forms of seams and hems are associated with sheet metal works; as described below:
A se~m is a joint made by fastening two edges together. The following are the types of seams
Half mom (refer Fig. IO. 7): · ·
stake
, .. Si11gle seam It is used to join a bottom to a vertical body.
funnel sfolre f1P JDouble seam It is similar to single seam, with the main difference that its fonned edge is bent
1. _upward against the body. The layout process for this seam is similar to that used for a single seam.
\ Grooved seam It is made by hooking two folded edges together and-then off-s~tting the seam.
A hem is an edge made by folding. The following are the types of hems (refer Fig. ·10.7):
Conve,c stake
Sittgle /,em It is made by folding· the edge of the sheet metal, to make 'it smooth and stiff.
Horsehead sfulle
==, Pipe~take ·

Double hem It is a single hem, with its end bent.

Wired edge It consists t>f an edge which has been wrapped around a piece of wire. This edge is
used where more strength is needed.
10.4.J "Sheet Metal Layout
' . ' '
In sheet metal work, .it is required to lay the full size pattern on the metal sheet, so that when it is
Fig. 10.6 Stakes cut along the pattern and folded or bent, it will resullin the required object. This laying-out of the ·
~01111,lcte surface o_n the metal sheet is known as the development of the surface of the object.
.JI
 • Workshop Manual

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J0.1 Des,

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10.2 Wha
10.3 Whai
10.4 Nam,
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. 10.5 What

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Rectangular troy 10;6 What
' I 10.7 What
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I0.8 Differ,

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N• Fig. 10.21 Round tin
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10.12 What ii
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10.13 What a1
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,I 5. 20 110 - 20 5
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Flg.10.20 Flg.10.22 T-pipe joint J O.I Sheet mf
10.2 A·sheet c
10.3 · Stainless
Othe!' mel

10.4 The thick

10.5 are
10.6 In electric

10.7 Soldering1
I0.8 In solderin.
D I0.9 The worki1
Fig. 10.24 Measuring jar I0.10 Brazing is
Fig. 10.23 Waste paper basket
I0.11 The filler n

., I0.1 development
I0.6 False, I0. 7 t17