Workshop Practice-MEM 160/ Rev.

01-2022

CENTER FOR MECHANICAL ENGINEERING STUDIES, UNIVERSITI

TEKNOLOGI MARA, KAMPUS BUKIT
BESI

Program : Diploma in Mechanical Engineering

Course : Workshop Practice
Code : MEM 160

WORKSHOP PRACTICE LABORATORY SHEET (SHEET METAL FORMING)

1.0 OBJECTIVE:

1.1 To practice sheet metal forming process utilizing sheet metal forming tools and
machines
1.2 To produce a finish product (card rack) using sheet metal

2.0 THEORY:

Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental
forms used in metal working and can be cut and bent into variety of different shapes.
Thickness can vary significantly, although extremely thin thicknesses are considered foil or
leaf, and pieces thicker than 6 mm are considered plate. Sheet metal is available as flat pieces
or as coiled strip.

There are many different metals that can be made into sheet metal, such as aluminum, brass,
copper, steel, tin, nickel and titanium. Sheet metal has applications in car bodies, airplane,
wings, medical tables, roofs for buildings, electronic devices casing, and many other things.

Sheet metal forming process involves with several procedures such as layout sketching,
cutting, bending, drilling, and joining.
 Workshop Practice-MEM 160/ Rev. 01-2022

3.0 MATERIALS:

No. Figure Remarks

i. Galvanized Iron
Sheet Metal

4.0 APPARATUS/ EQUIPMENT:

i. Drill machine ii. Sheet metal iii. Sheet metal iv. Safety goggle
bending shear cutter
machine
 Workshop Practice-MEM 160/ Rev. 01-2022

5.0 HAND TOOLS:

i. Scriber ii. Steel ruler iii. L-square iv. Protractor

v Spring vi Metal snip - vii. Metal snip – viii. Metal snip -

divider straight right cut left cut

ix. Mallet x. Hammer xi. Jem Plier xii. Rivet gun

Figure

xiii. Vice xiv. Anvil xv. Blind rivets xvi. Center punch
 Workshop Practice-MEM 160/ Rev. 01-2022

6.0 PROCEDURE:

No. Figure Explanation

1. Make sure every corner of workpiece has 90° of angle. Use L
Square to produce line beside edges without square angle.

2. Cut workpiece with referring to squaring lines that had been

produced previously to obtain square workpiece.

CAUTION: Do not insert hand/fingers within cutting and

clamping area

3. Sketch layout of development drawing on workpiece with

referring to desired shape and dimension (refer to appendix
drawing). This project comprises of 3 parts (3 drawings –
front, body, and base) that need to be joined together. All
hems and seams width are 10mm. Layout sketching need to
be done using sketching tools below:

1. Scriber
2. Steel ruler
3. L-square
4. Spring divider
5. Protractor

4. Using metal snips, cut workpiece with referring to layout

sketching lines to obtain desired shape of workpiece.

CAUTION: Beware of sharp edges/cutting tools

 Workshop Practice-MEM 160/ Rev. 01-2022

4. Bend all seams and hems and walls using bending machine
with determined degree of angle.

CAUTION: Keep fingers away from clamping area

5. Ram hem to fully folded using mallet and anvil.

6. Center punch at all drill points using center punch tool and
hammer. Then, drill all joining points using 35 mm drill bit.

CAUTION: Wear eye protection and beware of moving parts

7. Join all three parts using blind rivets and rivet gun.

8.
Perform finishing process to deburr all edges using file.
 Workshop Practice-MEM 160/ Rev. 01-2022

9. Measure dimensions of finished product to verify the

compliance with the required project tolerance.

7.0 RESULT:

a) Students need to record/snap picture related to the working procedure during your
workshop session.
b) Then snap figure for the final product.
 Workshop Practice-MEM 160/ Rev. 01-2022

Appendix A: Drawing
Workshop Practice-MEM 160/ Rev. 01-2022
Workshop Practice-MEM 160/ Rev. 01-2022
 Workshop Practice-MEM 160/ Rev. 01-2022

Appendix B: Description of complete project/Welding imperfection defect

Parts produce
Indicator Excellent Good Satisfying Poor
Description 3 parts 2 parts 1 part no part
completely completely completely completely
produced (body, produced produced produced
front, and base)

Assembly
Indicator Excellent Good Satisfying Poor
Description 3 parts 3 parts 2 parts no part
completely completely completely completely
joined with good joined without joined joined
finishing and good finishing
tolerance and tolerance
compliance compliance
(body, front, and (body, front, and
base) base)
 Workshop Practice-MEM 160/ Rev. 01-2022

Appendix C: Description of complete project

Workshop Practice-MEM 160/ Rev. 01-2022