OBJECTIVE

To expose to the techniques of shaping metal in the processes of cutting, bending, and folding,
either with the used of hand tool or by use of specific machine.

INTRODUCTION
The sheet metal shop is very important for every engineering concern. It deals with the working
of metal sheets. It requires a thorough knowledge of projective geometry particularly the
development of surfaces because the laying out of pattern and cutting of metal sheets to correct
sizes and shapes entirely depends upon the knowledge of the workman. The various operations
performed in a sheet metal shop are cutting, shearing, bending etc. In this chapter, we shall
discuss the sheet metal tools and the various processes.

EQUIPMENTS / APPARATUS

1. Snips
2. Rulers
3. Hammer
4. T-square
5. Steel rule
8. Aluminium sheets

RULERS

The rules are available in a variety of lengths and types, each of which is designed for measuring
and laying out different work.

STEEL SQUARE
It is a L-shaped piece of hardened steel with graduation marks on the edges for measuring. The
narrow arm of the square is called the tongue and the wide part is known as the body.

SNIPS
The snips are somewhat similar to a pair of scissors but are considerably heavier. There are
several types of snips available for making straight or circular cuts, but the most common are the
straight snips and the curved snips. The straight snips, have straight blades for straight line
cutting. These snips may be obtained in various sizes.
HAMMERS
The hammers, in sheet metal work, are used for forming shapes by hollowing, raising, stretching
or throwing off processes.

SHEET METAL OPERATIONS

The following are the various sheet metal operations :

1. Marking
2. Cutting
3. Notching
4. Bending
5. Riveting
6. Soldering
7. Folding edges

1. MARKING

The marking out operation consists of scratching of lines on the surface of a sheet metal. It is
also called scribing operation. Before marking operation is carried out, the paper or metal pattern
of the object is prepared. The metal pattern is desireable for repetitive work because it maintain
accuracy for a long time, whereas the paper pattern tears quickly if used repeatedly. The pattern
is now transferred to the flat sheet metal and marked as discussed below :

1. When a paper or metal pattern is transferred to the hat sheet metal, it should be held in place
by weights to prevent the pattern from slipping.
2. A sharp pointed pencil is used to mark the outline of the paper pattern, whereas a scriber is
used for metal pattern. The scriber should not be used to mark the paper pattern because it will
tear the edges of the paper.
3. When a pattern is to be traced on aluminum and stainless steel sheets, a sharp pointed pencil
should be used because the scriber will ruin the finish of the metal.
4. The best method of transferring the paper pattern to sheet metal is to mark the ends of all lines
by a prick punch through the paper. Then remove the paper from the metal and joint the all prick
points by a scriber in the proper manner.

Many simple objects can be laid out directly on the sheet metal. Usually, it is better for the
beginner to prepare a paper pattern for objects of complicated design rather than to layout
directly on the sheet metal. Since the paper pattern may be checked by folding it into the required
shape, therefore, unnecessary wastage of material is avoided. In making a layout directly on the
steel metal involves operations such as drawing straight lines or curved lines and making
indentation marks to serve as guide for drilling holes.

2. CUTTING

The sheet metals up to approximately 18 S.W.G. can be cut with hand snips. The following
procedure is adopted for straight cutting.

1. Hold the snip in one hand and the nearest part of the metal in the other hand.
Open the blades of a snip and place the upper blade on the line of cut to be followed. The blade
should be kept perpendicular to the surface of the metal.

3. Start the cut at the edge of sheet by exerting pressure on handles of snips. When the cut is
about 15 mm from the blade tips, open the blades again and push the snip forward. Repeat this
until cut is completed.

4. As the metal is sheared off, it will curl up on the left hand side of the snips and curls down on
the right hand side of the snips.

5. When cutting a large sheet of metal, it is advisable to cut along the left hand edge of the sheet
to permit the scrap or smaller section to curl away.

6. The inside curves such as circular holes are cut with curved snips. The holes are first cut
roughly with a cold chisel and hammer. It is finally trimmed to the required size by the curved
snip.

7. The outside curves are easily cut with straight snips.

3. NOTCHING
In bent sections that have folded edges, there should be some provision so that there is no
overlapping of metal where the comers come together. In order to prevent bulging at such a
place, it is necessary to slit or clip the metal or provide small openings. The openings left at the
comers of seams and edges are known as notches and the operation is called notching. The size,
locations and types of notches depend upon the shape of object. The following are the different
types of notches commonly used in sheet metal.

Square notch. The square notch is used for making a square or rectangular box. The squares on
the comers must be removed to permit the sides to be bent property.
PROCEDURE

1. Etch the project described above (using drawing)

2. Cut on etch lines and notch corners

3. Fie any burrs

4. Bend side short side and taps to 90 degree

5. Clean box

CONCLUSION

We feel know more about the materials and processes we used. The drawing says to have the taps for the rivets
on the two longer sides this would be bent with the short sides. When we was cutting sheet metal we
accidentally cut the wrong pieces on the first tab. This tab is on the short side likely we caught mistakes and
did the other tabs correctly. We was still able to make the tray.