For Corrections Group3-Technical-Report

FAST Aviation Academy Incorporated
Bacolod City
Course : Aircraft Maintenance Technology (AMT-2)
Subject : Technical Report Writing S.Y. : 2023-2024
Report : Project Completion Report Code : 2024-AMT2B-G3
Title : Fundamental Drills In Sheet Metal
Part : 1 Content : The Project Page : 1 of 5
Subpart : 1.2 BACKGROUND OF THE PROJECT
Author : Klaryn Vee Gedoria
The structural integrity of an aircraft is of paramount importance to ensure its safe operation. It
is imperative to employ the highest quality repair methods for metal structures to mitigate
immediate or future risks. Sheet metal workers play a vital role in this process, utilizing
techniques such as welding, soldering, and riveting to fabricate and assemble metal
components according to technical specifications. Their expertise in sheet metal
characteristics, manufacturing methods, and interpretation of technical drawings is
indispensable for achieving accurate installations and measurements.
The report's purpose is to teach students and other trainees how to utilize specific instruments
needed to create the metal plate, such as cutting, bending, punching, and drilling metal into
particular shapes and forms. The report is intended to provide a consistent grasp of the subject
SHEET METAL, as well as possibilities for planning and hands-on practice.
Bacolod City
Subpart : 1.2 BACKGROUND OF THE PROJECT
Figure 1.0
Bacolod City
Part : 1 Content : Introduction Page : 2 of 5
Subpart : 1.2 OBJECTIVES OF THE PROJECT
Author : Allana Joia De La Cruz
The report aims to provide students and on-the-job trainees on how to fabricate metals into
customized shapes and forms while using some specialized tools that will be needed in the
process of making a metal plate. A hands-on experience in creating a metal plate by each
student will enhance their creativity and experience.
This study will specify the handling of the tools and measurements of the metal plate that will
be used to avoid confusion. Students must know the common cutting processes including
sawing, shaping (or planning) broaching, drilling, grinding, turning, and milling. Making a
metal plate using galvanized steel has a huge advantage because it is coated by zinc and is
applied to steel or iron to offer protection and prevent rusting.
Bacolod City
Report : Project Completion Report Code : 2024-AMT2A-G3
Subpart : 1.3 PROJECT PERIOD
Author : Joshua Klein Chua
March 21, 2023 Preparation of the materials 10:30 am- 11:30 am
March 22, 2023 Lay Out of The Materials 10:30 am- 11:30 am
March 23-24, 2023 Cutting the Sheet Metal into a Square Shape 10:30 am- 11:30 am
and Filing
March 27-28, 2023 Punch and Drilling 10:30 am- 11:30 am
March 29-April 2, 2023 Riveting Aviation Rivets to the Sheet 10:30 am- 11:30 am
Metal and Finishing
Bacolod City
Course : Aircraft Maintenance Technology (AMT-2A)
Subpart : 1.4 PROJECT OUTCOMES
Author : Adrian Von Lacson
By the end of this activity on sheet metal works, students should have acquired a
comprehensive understanding of the fabrication process, including the utilization of
specialized tools. The hands-on experience of creating a metal plate is expected to enhance
their creativity and practical skills. Additionally, they should be proficient in handling tools,
measuring metal plates accurately, and executing common cutting processes such as sawing,
shaping, broaching, drilling, grinding, turning, and milling.
The use of galvanized steel should be well understood for its advantages in providing
protection and preventing rusting. Overall, the target outcome is to equip the students with the
knowledge and practical skills necessary for effective and efficient sheet metal fabrication.
Bacolod City
Subpart : 1.4 PROJECT ACTIVITY FLOW
Author : John Lester Madamesila
Bacolod City
Part : 2 Content : Understanding the project Page : 1 of 2
Subpart : 2.1 DISCUSSION OF SUBJECT MATTER
When choosing a material for a project, it is important to take into the advantages and
disadvantages of the many varieties of sheet metal that are available. Each material is
appropriate for a particular application due to its unique set of qualities. Three main metal
types are commonly utilized in sheet work; each has certain advantages and disadvantages that
limit its application. A variety of common sheet metal characteristics are present, including
strength, weight, cost, formability, weldability, and corrosion resistance.
In general, sheet metal is used to "build" an airplane by forming pieces, creating structures,
and covering the "skeleton" structures of the wing, fuselage, and empennage. Another
significant metal technique utilized in the aircraft sector is sheet metal production. Sheet metal
fabrication is the most efficient way to manufacture the parts needed for an airplane's structure
in huge quantities.
Germany's aviation designer Hugo Junkers, 1915, produced the Junkers J 1 monoplane, which
was the first fully metal aircraft in history. The fuselage was made from an aluminum alloy
that contained copper, magnesium, and manganese.
Bacolod City
Subpart : 2.2 REVIEW OF RELATED PROJECT
This paper presents a review of sheet metal forming analysis which is widely used in
automobile industries. Several different processing methods have been implemented in
industries to achieve repeatability and productivity. The sheet metal forming process involves
nonlinearity, complex material behavior, and machining technology. As of today, FEM is
applied for determining stresses and further failure criteria for the formability prediction in the
sheet metal forming process. Material optimization by a reduction in the raw material size for
sheet metal is the focus. The computer design model is developed by scanning the die in a
coordination-manning machine. FEM, Probabilistic design, numerical analysis, forming limit
stress diagram, press forming analysis, and material optimization are some of the criteria being
used for the sheet metal forming analysis.
Source:https://www.internationaljournalssrg.org ›IJME › Volume2-Issue1
In recent years, there has been continuous research and development in the sheet metal
forming processes, to satisfy the modern applications. Forming and its characterization play a
vital role due to the limiting characteristics of metals being formed and the forming process
parameters. The sandwich materials created rapid revolutions in the field of sheet metal
manufacturing process due to their unique characteristics, such as high strength to weight.
However, due to their composite nature, process many problems may arise. Hence the rate of
material forming characteristics of sandwich materials in the conceptual design is also
Bacolod City
Subpart : 2.2 REVIEW OF RELATED PROJECT
discussed.
Source:http://iaeme.com/Home/issue/IJMET?Volume=8&Issue=8
There are several manufacturing devices behind each procedure. This means that each shape
can be divided into manufacturing features, which consist of shapes of sheet metal and their
manufacturing methods. When creating rules and structures for manufacturing features, it is
possible to prepare simple guides for engineering designers so that they can design parts that
are easy to manufacture. A manufacturing guide can be a kind of database. A design engineer
may follow the guidelines of the database. It proposes different kinds of possibilities to
produce sheet metal parts. This enables the design of products which are easy to manufacture.
In addition, it allows the designer to diversify his or he knowledge of manufacturing methods.
In this study, simple sheet metal parts and their manufacturing features are studied. For
example, simple shapes such as holes can be made in several ways. Cutting a hole consists of
several attributes which determine the requirements for manufacturing. This study tries to
validate what kinds of factors are needed for engineering designers to design parts that are
simple to manufacture.
Source:: https://www.researchgate.net/
Bacolod City
Subpart : 3.1 BUDGET PLAN
Materials Quantity Price Market
Sheet Metal 1 Php 1600.00 Hardware
100 pcs Php 100.00 Hardware
Rivets
1 pair Php 166.00 Hardware
Gloves
Ear Plugs 1 Php 25.00 Hardware
Bacolod City
Subpart : 3.1 BUDGET PLAN
Materials Quantity Price Market
1 Php 127.00 Hardware
Protective Goggles
TOTAL COST Php 2018.00

Bacolod City
Subpart : 3.2 TOOLS AND EQUIPMENT
Author : Dewles Andrei Nardo
Rivet Gun
A rivet gun is a simple tool to fasten two or

more pieces of metal together. The operator
inserts the rivets into the barrel by hand or
with an automatic feeder device that moves
them into place. The rivet gun is ready to
use once a rivet is fed into the barrel.
Aviation Snips
Are handheld cutters that are design for use

with sheet metal. Also known as sheet
snips, they support straight cuts, left cuts,
and right cuts.
Rubber Mallet
Used to bend and shape sheet metal, since

they don’t leave marks.
Bacolod City
Hand Drill
Are handheld tools with rotating drill bits

used to fabricate holes in multiple
materials.
Combination Set
Used to determine flatness, measuring

angles, inspection and layout work. The set
consists of a blade (graduated rule), square
head, protractor head, and center head
File
are used to square ends, file rounded

corners, remove burrs and slivers from
metal, straighten uneven edges, smooth
rough edges, and file holes and slots.
Prick Punch
Used this punch to transfer dimensions

from a paper pattern directly on to the
metal and use them as reference marks for
cutting
Bacolod City
Cleco Pliers
Are a type of sheet metal pliers for

attaching and removing cleco fasteners.
Cleco Fasteners
Allow you to hold two pieces of sheet

metal together in proper alignment for
drilling, riveting, marking, fitting or other
operations.
Steel Rule
Primary purpose is accurate measurement,

they can also be used as guide for laying
out lines, and if rigid enough, for cutting
Bench Vice
Used when you use a saw to cut metal, it

will grip the material effectively when you
cut the object
Bacolod City
Subpart : 2.1 MATERIALS
Sheet Metal
Sheet metal is metal that is formed into thin, flat pieces. Sheet metal is generally produced in
sheets less than 6 mm. It is one of the fundamental forms used in metalworking and can be
cut and bent into a variety of different shapes.
Rivets
A rivet is a permanently installed fastener used to secure two sheets of material such as metal
or plastic. Unlike other fasteners, a rivet is not tightened down to secure it.
Bacolod City
Subpart : 2.1 DETAILED PROCEDURE
1. Preparation. The first stage when doing the sheet metal is to prepare the materials that
are needed such as the steel rule, combination square, shear snips, and cleco clamps
(materials).
2. Lay Out. Laying out metal is the process of measuring and marking material for
cutting, drilling, or welding. Accuracy is essential in layout work. Using erroneous
measurements results in a part being fabricated that does not fit the overall job. Some
of the more common layout tools that students will use in performing layout duties are
as follows: scriber, flat steel square, combination square, prick punch, and dividers.
3. Lines are scribed on sheet metal with a SCRATCH AWL, coupled with STEEL RULE
or a STRAIGHTEDGE. To obtain the best results in scribing, hold the scale or
straightedge firmly in place, and set the point of the scriber as close to the edge of the
scale as possible by tilting the scriber outward. Then exert pressure on the point and
draw the line, tilting the tool slightly in the direction of movement. For short lines, use
the steel rule as a guide. For longer lines, use a circumference rule or a straightedge.
When students have to draw a line between two points, prick-punch each point. Start
from one prick punch mark and scribe toward the center.
4. Measuring. FLAT STEEL SQUARE is a desirable tool for constructing perpendicular

or parallel lines. In the method of layout, known as parallel line development, the flat
steel square is used to construct lines that are parallel to each other as well as
perpendicular to the baseline. The COMBINATION SQUARE can be used also to
draw a similar set of lines. An edge of the metal upon which you are working is used as
the baseline.
Bacolod City
One edge of the head of the combination square is 90 degrees and the other edge is 45
degrees. Combination squares are delicate instruments and are of little value if you
handle them roughly. Store the squares properly when students have finished using the
tool. Keep the tools clean and in tip-top shape, and students will be able to construct
90-degree angles, 45-degree angles, and parallel lines without error.
5. Cutting. After the students measured the metal the next thing the students will do is to
cut the metal plate using snips. Be mindful and make sure that students leave a metal
before the line so that when the students file the metal plate it will not change the
measurements.
6. Leveling. When the students finish cutting the metal it is necessary to be hammered
using a rubber mallet or a ball pein hammer, because as expected after cutting the sheet
metal it will bend while the students are cutting. So, for the plate to be leveled students
have to hammer the metal using a rubber mallet.
7. Filing. It is important to secure the work with a vise or other clamp to keep it from
moving around while students are filing. Student’s should avoid the back-and-forth
motion with the file, as this will damage the file and likely the workpiece as well.
Instead, only apply pressure on the forward stroke and lift the file away from the
workpiece on the return stroke.
8. MakingPatterns.Once the metal is ready, get a marker or a punch and ball pein hammer
to mark the parts that are required by the instructors or seniors.
Bacolod City
9. Punch. When locating a point and marking it with the PRICK PUNCH, be sure to use a
light tap with a small ball pein hammer, ensuring it is on the precise spot intended to be
marked. The smaller the mark students make (so long as it is visible), the more
accurate the mark becomes.
10. Drilling. Different metals place different demands on a metal drill. So that workpieces
or components made of metal can be drilled precisely and safely, a suitable drill bit
must be selected. When drilling metal, enormous forces act in the direction of drilling
and rotation. To drill metal workpieces safely, metal must therefore always be firmly
clamped. For this purpose, vices, clamping ratchets, and screw clamps are suitable for
secure fixing on a workbench. Students should ensure that workpieces are secured both
vertically and horizontally—drill stands and special machine vices are ideal for this, to
safely and precisely maintain a working angle of 90°, which ensures that the hole is not
torn out or drilled at an angle into a piece of metal. Also, avoid applying too much
pressure
11. Riveting. A rivet gun, a bucking bar, and a rivet set are the materials you need to use
when riveting a sheet metal. Firmly press your rivet into the pre-drilled hole, with the
nub completely clearing the hole. Pull on the gun's trigger to pull the mandrel through.
This will lock your rivet in place. The mandrel can be thrown away after you're done.
12. Finishing. After you rivet check for any errors or faults especially if there is damage or
scratches in the metal. Don’t forget to clean your area when you are finished.
Bacolod City

Subject : Project Completion Report S. Y : 2023-2024
Report : Project Completion Report Code : 2024-AMT-2A-G3
Part : 4 Content : The Project page : 1 of 5
Subpart : 4.1 ACTUAL PROJECT
Sheet metal is metal formed into thin, flat pieces, usually by an industrial process. Thicknesses can
vary significantly; extremely thin sheets are considered foil or leaf, and pieces thicker than 6 mm are
considered plates, such as plate steel, a class of structural steel. The sheet metal is cut into 5 by 5
perfect square pairs, and holes are made in an X-L pattern. Two sheet metal plates are then tapped to
place aviation rivets, with each hole following a specific pattern.
Figure 2.0
Figure 3.0
Bacolod City

Subjec : Project Completion Report S. Y : 2023-2024
t
Part : 4 Content : The Project page : 2 of 5
Subpart : 4.2 TARGET OUTCOME VS. ACTUAL PROJECT
In the making of the sheet metal, the student's target outcome in this project is a perfectly made 5x5
layout of a sheet metal plate. First, in the layout, cut it in the exact size given that it needs to be
followed by making a pattern. Second, punching the patterns of the metal plate using the rubber
mallet for the rivets that will be done next. Third, after punching the metal plate by the given pattern,
students are expected to drill each of the punched edges of the metal plate so the students can proceed
in riveting the metal plate. Riveting the given pattern is the last step in making this project but it is not
that easy for the students to do this because in riveting, students need to avoid putting the "smiley
face" on the button of the rivets.
In the actual project, students faced some struggles in making the sheet metal. Students were unable
to obtain the perfect size that is needed while cutting the metal plate, resulting in an excess and a
short amount of metal plate. Students didn't achieve the exact size we were expecting because when
cutting the metal, it is not aligned which is normal but it causes shortness in the size of the sheet
metal. When it comes to its pattern, it is not that hard and also for drilling. One of the problems is in
riveting because students need to be very careful in riveting. After all, the "smiley face" on the button
of the rivets needs to be avoided.
The difference between the target outcome and the actual project is the targeted outcome, students are
just targeting or want the project to be done perfectly and it is the process of making the project but in
the actual project, it is the finished product of the project we are making.
Bacolod City

Part : 4 Content : The project page : 3 of 5
Subpart : 4.3 FINDINGS
Students studying sheet metal production may run across several difficulties, such as Accuracy and
Precision: It can be challenging to obtain accurate measurements and cuts, particularly when dealing
with complex designs or close tolerances. Material Properties: Due to the distinctive qualities of each
material, it might be difficult to understand how various metals behave throughout the forming
process. Complex Techniques: It takes work and experience to become proficient in complex shaping
techniques such as compound bending and deep drawing. Tooling and Equipment: Students may find
it more difficult to hone their skills via practice if they do not have access to specific tools and
equipment. Safety concerns: Handling metal can be dangerous because of hot surfaces, sharp edges,
and large machinery.
Therefore, it's important to follow the right safety procedures. Design Interpretation: A thorough
grasp of fabrication methods and geometric concepts is necessary to convert design drawings into
actual sheet metal components. Time Management: It can be difficult for students to juggle the
demands of their coursework, practical exercises, and project deadlines, particularly when they are
learning new abilities. Feedback and Improvement: Receiving helpful criticism from peers or teachers
and applying it to one's work to keep improving can be a struggle for some students.
Bacolod City

Subpart : 4.4 RECOMMENDATIONS
While working on cutting sheet metal, the unity of each group will be appreciated to finish the work.
This report will guide future students to understand why proper usage of PPE is important, such as
protective goggles, earplugs, and gloves, during the practical of the students on the subject of sheet
metal.
When cutting and filing the metal, the correct handling of tools is also important, as it can result in
misalignment of the metal edges. Also, students must not forget to use the steel rule or the
combination set every time they are checking the edges or measurements of the metal to avoid getting
the wrong size. Students must also be aware that every time they drill a hole in the metal, the use of a
prick punch will be the first thing they should do to avoid slipping the drill bits. Observing time
management is also a top priority while doing the work, and above all, you need to be critical and
alert to what you are doing.
Bacolod City

Subpart : 4.5 CONCLUSION
One of the best options for obtaining quality components for various commercial and industrial
applications is sheet metal fabrication. Metals must undergo bending, welding, punching, drilling, and
shaping into specific forms. Modern technology, specialist tools, and experience are necessary for the
highly skilled process of sheet metal fabrication to produce high-quality products with precise
tolerances. Regardless of thickness, however, all these materials are essential in today's sheet metal
industry. Whether a mild steel plate is needed for manufacturing components, stainless steel parts for
medical equipment, or titanium and aluminum plates for aerospace projects, they can all be cut, bent,
welded, and shaped into customized forms through sheet metal fabrication. Utilizing sheet metal
fabrication to produce components offers several advantages. Not only is the process exceptionally
accurate in producing parts with tight tolerances, but it is also cost-effective and environmentally
friendly with fewer waste materials.
Sheet metal is also strong and durable, with parts often able to withstand greater pressure and heat
than those made with plastic. Additionally, being more malleable, sheet metal can be bent into a wide
variety of shapes while retaining its strength and structural integrity with the right equipment. One of
the most prominent advantages of using sheet metal is its replaceability. If multiple parts are used to
construct a unit, each piece can be replaced individually without the need to create an entirely new
part. This approach helps students or On-The-Job Trainees save money on repairs while allowing for
convenient upgrades and customizations.

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FAST Aviation Academy Incorporated

March 27-28, 2023 Punch and Drilling 10:30 am- 11:30 am

Source:https://www.internationaljournalssrg.org ›IJME › Volume2-Issue1

100 pcs Php 100.00 Hardware

1 pair Php 166.00 Hardware

TOTAL COST Php 2018.00

A rivet gun is a simple tool to fasten two or

Are handheld cutters that are design for use

Used to bend and shape sheet metal, since

Are handheld tools with rotating drill bits

Used to determine flatness, measuring

are used to square ends, file rounded

Used this punch to transfer dimensions

Are a type of sheet metal pliers for

Allow you to hold two pieces of sheet

Primary purpose is accurate measurement,

Used when you use a saw to cut metal, it

FAST Aviation Academy Incorporated

4. Measuring. FLAT STEEL SQUARE is a desirable tool for constructing perpendicular

Course : Aircraft Maintenance Technology (AMT-2A)

Course : Aircraft Maintenance Technology (AMT-2A)

Course : Aircraft Maintenance Technology (AMT-2A)

Course : Aircraft Maintenance Technology (AMT-2A)

Course : Aircraft Maintenance Technology (AMT-2A)

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