1.

OBJECTIVES:
i. To get familiarized with the involved processes such as measuring, marking, laying out,
shearing, forming and finishing.
ii. To know about use of various sheet metal tools like mallet hammer, metal hammer, hand
shear, anvil, center punch, drilling machine, rivet gun and so on.
iii. To be able to perform the operations such as shearing, forming, measuring, marking,
laying out the sheet metal, drilling and finishing.
iv. To be able to make dust pain in the workshop from sheet metal by utilizing the available
resources.

2. JOB DESCRIPTION:
A dust pan is a tool with a multitude of uses in our everyday lives. A Dust Pan has to be
constructed out of sheet metal from scratch. For this purpose, we used various sheet metal
operating tools like hand shear, anvil, mallet hammer, metal hammer, center punch, drilling
machine, try square, scriber, steel ruler, vice, etc. The process of construction of dust pan
can be broken down into two parts, one is the construction of the main body/framework of
the dust pan and the other is the construction of the handle of the dust pan. These two
individual parts are then later connected together. In the verse of making the dust pan, we
should use rivet gun to make the permanent joints between different metals sheet whenever
needed. Also, high level of consciousness is required while performing sheet metal
operations since the cut edges of the thin metal sheets have very sharp edges.

3. TOOLS/EQUIPMENT USED:
Various tools falling under the category of both hand tools and machinery tools were
employed in the construction of Dust Pan in the workshop. The various tools that were used
are as described Below:

i. Vice
A vice is a handy tool in workshops for holding things in place while we work on them. It's
made of strong cast iron with tough jaws to grip things tightly. To keep it in good shape:
a. We should not hit the vice body hard with a hammer since it might break.
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b. If we need to use a hammer, we should do it
gently on the vice's anvil (a flat part made for
light hammering).
c. When tightening the vice, we should use our
hand and not too much force. Too much
tightening can be bad for both the vice and the
Figure;Vice
thing that we are working on. Just with a little bit
of carefulness, it will work well for a long time.

ii. Hand Shear

Hand shears are manual cutting tools designed for precision and versatility in various
applications, ranging from gardening and agriculture to metalworking and textile industries.
These shears consist of two sharp blades joined at a pivot point, allowing users to
efficiently cut through materials with controlled force. Typically composed of high-quality
steel or alloy, hand shears are crafted to withstand
repetitive use and maintain sharp cutting edges. The
blades may have serrated or straight edges, depending on
the intended purpose. Serrated blades are ideal for
gripping and cutting through tough materials like leather
or branches, while straight blades provide clean cuts for
tasks such as shaping metal sheets. The handles of hand
shears are ergonomically designed to ensure a
Figure;Hand shear
comfortable grip during prolonged use. Some models
feature rubberized or contoured handles to enhance control and reduce hand fatigue. The
pivot mechanism allows the blades to smoothly open and close, ensuring a precise cutting
action. In gardening, hand shears are commonly used for pruning bushes, trimming hedges,
and shaping shrubs. They provide gardeners with the ability to make precise cuts,
promoting healthy plant growth and maintaining aesthetic appeal. In metalworking, hand
shears are employed for cutting thin sheets of metal, providing a portable and cost-effective
solution for tasks that do not require the use of power tools. Maintenance is crucial for
optimal performance, and regular sharpening of the blades is necessary to ensure clean and

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efficient cuts. Some models come with adjustable blades or replaceable parts, extending the
tool's lifespan and usability.

iii. Mallet Hammer

A sheet metal mallet hammer is a specialized hand tool designed for shaping and forming
sheet metal without causing damage to the material's
surface. Comprising a head and a handle, this hammer is
distinct in its construction and application, providing a
controlled and gentle force suitable for shaping and
molding thin metal sheets. The head of a sheet metal mallet
hammer is typically made of a non-marring material such
as rubber, plastic, or rawhide. This composition prevents
scratches, dents, or other blemishes on the surface of the Figure;Mallet hammer
metal, making it an ideal tool for delicate or finished materials. The non-marring
characteristic is crucial in sheet metal work where maintaining the aesthetic integrity of the
metal is essential. The handle of the mallet is commonly made of wood or fiberglass,
providing a comfortable grip for the user. The length and weight of the handle are designed
to give the operator control over the striking force while minimizing the risk of fatigue
during extended use. Sheet metal mallet hammers find application in various industries,
including automotive repair, metal fabrication, and jewelry making. Craftsmen and
technicians use these hammers to shape and contour thin metal sheets into desired forms
without leaving unwanted marks on the surface. Whether it's forming curves, edges, or
intricate details, the sheet metal mallet hammer is a valuable tool for achieving precision in
metalworking while preserving the integrity of the material. Regular maintenance, such as
inspecting and replacing worn-out heads, ensures the longevity and continued effectiveness
of the sheet metal mallet hammer in diverse sheet metal applications.

iv. Anvil
An anvil is a robust, block-like metalworking tool with a flat
top surface and a pointed horn projecting upward.
Traditionally made from forged steel or iron, anvils serve as a
crucial tool in blacksmithing, metalworking, and other related
trades. The flat top, known as the face, provides a sturdy and
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Figure;Anvil
flat work surface for shaping and forging metal using hammers and other tools. Anvils
come in various sizes, ranging from small bench anvils to large industrial ones, each
tailored to specific applications. The pointed horn allows for intricate shaping and bending
of metal, adding versatility to the tool. A hardy hole and pritchel hole, often located on the
face or body, facilitate the use of various tools and accessories. Historically, anvils have
been essential in the development of civilizations, aiding in the creation of tools, weapons,
and other metal objects. The iconic image of a blacksmith working at an anvil symbolizes
craftsmanship and skilled labor. While modern manufacturing techniques have introduced
alternative materials and methods, the anvil remains a timeless symbol of craftsmanship
and a fundamental tool in metalworking. Whether in a traditional blacksmith's forge or a
contemporary metalworking shop, the anvil endures as a foundational instrument for
shaping and molding metal with precision and skill.

v. Center Punch
A center punch is a vital tool in metalworking and
carpentry, primarily employed to accurately mark the
center of a point on a workpiece. Its primary
application is in preparing materials for drilling, where
precision is crucial. When drilling holes, especially
with larger drill bits, a center punch is essential to
prevent the drill from wandering and ensure the hole Figure;Center punch

starts precisely where intended. The tip of a center

punch typically features an angle between 60 and 90 degrees, creating a small, concave
dimple upon striking the material. This dimple serves as a guide for the drill bit, preventing
it from slipping and enhancing the accuracy of hole placement. In instances where larger
holes are required, and the drill bit exceeds the size of the center punch indentation, a
preliminary step involves drilling a smaller pilot hole to maintain precision. Automatic
center punches have evolved to simplify the process further. Operating without the need for
a separate hammer, these tools utilize a spring-loaded mechanism triggered by pressing
down on the tool, providing a consistent and controlled force to create the center mark. This

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innovation enhances efficiency and convenience, particularly in repetitive or precision-
oriented tasks within various woodworking and metalworking applications.

vi. Scriber
A scriber is a hand tool used in metal work to mark lines on workpieces, prior to
machining. The process of using a scriber is called scribing and is just part of the process of
marking out. It is used instead of pencils or ink
lines, because the latter are hard to see, easily
erased, and imprecise due to their wide mark;
scribe lines are thin and semi-permanent. On non-
coated workpieces marking blue is commonly used
to increase the contrast of the mark lines. They are
Figure;Scriber
a rod with a tip made of cast steel that has been
hardened and tempered. The point is sharpened to
an angle of 30 or 40 degrees. Some scribers have a point at both ends. It is used by
dragging the point over the surface of the workpiece to leave a shallow scratch on its
surface.

vii. Try Square

Figure;Try square

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A try square is a fundamental measuring and marking tool used in woodworking and
metalworking. It consists of a straight metal blade, typically made of steel, and a handle set
at a right angle to the blade. The try square's primary function is to assess and mark the
perpendicularity or "squareness" of an edge or surface. Woodworkers and carpenters rely
on this tool to ensure accurate right angles
during layout and construction. To use a try
square, the user places the blade along the
material's edge, and the handle is pressed
against the adjoining surface. If the tool
aligns perfectly, it indicates a right angle.
This precision is crucial in creating joints,
assembling structures, and maintaining
overall accuracy in various woodworking Figure;Rivet gun
and metalworking projects. The try square is a simple yet indispensable tool for craftsmen
and DIY enthusiasts seeking precision and consistency in their work.

viii. Rivet Gun

A rivet gun, also recognized as a rivet hammer or pneumatic hammer, serves as a tool
designed for driving rivets into various materials. Employed primarily on the factory head
of the rivet, it operates in conjunction with a bucking bar, which supports the rivet's tail
during the process. The rivet gun's energy propels both the rivet and the workpiece against
the bucking bar. Consequently, the rivet's tail undergoes compression and work hardening,
firmly securing the workpiece between the rivet head and the flattened tail, now termed the
shop head or buck-tail. Typically powered by compressed air, rivet guns used in structural
steel applications tend to be sizable, while those employed in aircraft assembly are more
compact and can be easily held with one hand. The key distinction from an air hammer lies
in the precision of the driving force. Rivet guns
exhibit diversity in size, shape, handles, and
grips. Pneumatic variants often feature a
regulator that adjusts the incoming air volume,
with a throttle valve controlled by a trigger in
the hand grip. Squeezing the trigger opens the
throttle valve, allowing pressurized air into the
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piston. The moving piston, in turn, strikes against the rivet set, propelling the rivet into the
workpiece against the bucking bar. The bucking bar shapes the rivet's tail, and the piston
returns to its original position through a spring or valve-driven mechanism. This process
ensures a secure and durable connection in the joined materials.

ix. Pliers
Pliers are versatile hand tools designed for gripping, bending, and manipulating various
materials. Comprising two hinged metal levers, pliers typically feature jaws at one end,
providing a firm grip when pressure is applied. The jaws may come in different shapes and
sizes, tailored to specific tasks. Common types include needle-nose pliers with long,
slender jaws for precise work, and slip-joint pliers with adjustable pivot points to
accommodate various material thicknesses. The handles of pliers offer mechanical
advantage, allowing users to exert force with minimal effort. Some pliers incorporate
additional features such as wire cutters near the pivot point, enhancing their utility for
cutting and shaping wires. Pliers find application
in a multitude of trades and tasks, including
construction, electronics, automotive repair, and
crafting. Their adaptability makes them
indispensable for tasks requiring a secure grip,
precise maneuvering, or the application of force
in tight spaces. Whether used by professionals or
DIY enthusiasts, pliers are fundamental tools that facilitate a wide range of manual tasks
across diverse industries.

x. Ball peen hammer

A ball peen hammer is a specialized hand tool characterized by its distinctive design,
featuring a flat face on one end and a rounded, ball-shaped peen on the other. This hammer
variant serves various purposes, particularly in metalworking and blacksmithing. The flat
face is utilized for striking and shaping metal,
while the rounded peen is instrumental in tasks
such as riveting, rounding the edges of metal pins, and forming concave surfaces. The ball
peen hammer is known for its versatility and precision in manipulating metal. Crafted with
Figure;ball pen hammer
a durable handle, often made of wood or fiberglass, it provides a comfortable grip for the
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user. The weight and size of ball peen hammers can vary to suit different applications, from
delicate work that requires finesse to heavier tasks demanding more force. Metalworkers,
blacksmiths, and mechanics commonly employ ball peen hammers due to their ability to
deliver controlled and targeted blows. The peen's shape enables the hammer to create
specific textures and shapes on metal surfaces. This tool plays a crucial role in shaping,
forming, and finishing metalwork, making it an essential component of any toolkit in
metal-related industries and crafting.

xi. Drilling Machine

Drilling is the operation of producing circular hole in the work piece by using a rotating
cutter called drill bit. Drill bits materials are generally High-speed steel. The machine used
in drilling is called drilling machine.
Types of drilling machines:
a. Based on the construction: Portable, sensitive, radial, up-right, multi-spindle.
b. Based on Feed: Hand and power driven.
Different parts of a drilling machines:
a. Base
b. Column or Pillar
c. Arm
d. Worktable
e. Drill head
f. Feed Mechanism
g. Spindle
h. Drill jigs
i. Chuck
j. Electric Motor
k. Pulley or gears

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Types of Drilling Machine:

a. Sensitive upright Drilling machine: Light duty, can drill holes up to 15mm, can only be
hand fed and operator senses the cutting action
b. Upright Drilling machine: Medium and heavy-duty type, can Drill holes up to 50mm,
can be hand fed or power fed and table can move vertically and radially
c. Radial arm drill machines: Large and Heavy-duty type, allows operator to position the
spindle directly over the work piece rather than move the work piece to the tool. It is power
feed and there is automatic mechanism to raise and lower radial arm.
d. Gang type Drilling machine: In this type, several stations are mounted on one long table.
e. Multi spindle Drill Machine: Here, several stations are mounted on one long table, many
spindles mounted on one head and also allows many holes to be drilled simultaneously.

Nomenclature of Drill:

Types of drills:

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a. Twist drill: most common drill
b. Step drill: produces holes of two or more different diameters
c. Core drill: used to make an existing hole bigger

4. THEORY:

A dustpan is a simple yet indispensable cleaning tool

designed to efficiently collect and dispose of dust, dirt,
and debris from floors. Comprising a flat, shallow pan
with a handle, it works in conjunction with a broom to
create a cohesive and effective sweeping system.
Dustpans are essential components of household
cleaning, janitorial services, and various industries
where maintaining cleanliness is paramount. Typically
made from durable materials such as plastic, metal, or a
combination of both, dustpans are engineered for
longevity and ease of use. The pan's design
Figure 1;Dustpan
incorporates a flat, wide surface with a raised lip at the
front to facilitate the smooth collection of debris. The handle is affixed to the back,
allowing users to hold and manipulate the dustpan comfortably while maintaining an
upright posture. The symbiotic relationship between a dustpan and broom is crucial for
effective floor cleaning. After using a broom to gather dirt and debris into a manageable
pile, the dustpan comes into play. Its flat edge is placed against the floor, while the lip is
slid under the debris. With a gentle but firm press, the dustpan ensures that the collected
material is efficiently scooped up and contained within its confines. Modern dustpans often
incorporate thoughtful design features to enhance functionality. Some have rubber edges
along the lip to create a better seal with the floor, preventing debris from escaping during
the collection process. Others may have a flexible hinge that allows the pan to sit flat on the
floor, accommodating variations in surface height and facilitating more thorough cleaning.
Dustpans are not limited to household use. They are prevalent in commercial and industrial
settings, where maintaining a clean and safe working environment is crucial. In these

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contexts, dustpans may be sturdier, larger, or even equipped with wheels for increased
mobility and efficiency in larger spaces. The evolution of dustpan design has also led to the
development of dustpan and broom sets, where the two components are specifically
designed to work seamlessly together, ensuring optimal cleaning performance.
Additionally, there are variations such as handheld dustpans for smaller tasks and dustpans
with long handles for more comfortable use, especially for those who may have difficulty
bending down.

The Different processes involved while doing sheet metal works are:
i. Measuring: In sheet metal operations, measuring involves precise assessment of the
dimensions and specifications required for the metal sheet. Accurate measurements ensure
the sheet conforms to design specifications, contributing to the overall precision of the final
product.
ii. Marking: Marking involves creating guidelines or reference points on the sheet metal
surface based on the measured dimensions. This step is crucial for positioning features,
patterns, or cuts accurately, ensuring that subsequent processes align with the intended
design and specifications.
iii. Laying Out: Laying out entails arranging and positioning the marked features on the
sheet metal, ensuring proper alignment and adherence to the design blueprint. This step
serves as a preparatory stage for subsequent operations, ensuring that the sheet is ready for
shaping and forming.
iv. Shearing: Shearing involves cutting the sheet metal along the marked or laid-out lines.
This process is crucial for separating the material into the desired shapes and sizes.
Shearing can be achieved through various methods, such as mechanical shearing machines
or advanced laser cutting techniques, depending on the complexity of the design and the
thickness of the metal.
v. Forming: Forming is the process of shaping the sheet metal into three-dimensional
structures or contours. This can be achieved through bending, rolling, or stamping
operations. Forming adds depth and structure to the sheet metal, transforming it from a flat
surface into the desired component with specific shapes and features.
vi. Finishing: Finishing is the final stage of sheet metal operations, encompassing
processes like deburring, smoothing, coating, or surface treatment. This step enhances the

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 aesthetics, durability, and functionality of the sheet metal product, ensuring it meets quality
standards and is ready for its intended application. Finishing adds a professional touch,
addressing imperfections and providing a polished appearance to the final sheet metal
component.

5. PROCEDURE:
1. The metal sheet was received from the instructor with dimensions of 250 mm in length and
250 mm in breadth.
2. A piece measuring 250 mm by 200 mm was cut from the original sheet using hand shears.
3. The remaining metal sheet was further cut to create a separate piece with dimensions of 250
mm by 30 mm.
4. Both sheets were marked and cut according to the dimensions specified in the hard copy
blueprint.
5. The sheets were marked and cut to form the rough outline of the dustpan body and handle.
6. Regular quality checks were performed throughout the process to ensure precision and
accuracy.
7. The three sides of the workpiece which were labelled as 6mm were bended at 180 degrees
by clamping on the vice and were smoothed with the help of mallet hammer. The inside
folding lines were bended about 90 degrees.
8. After that, assuming the proper position, markings were done using center punch for two
holes on each corner side of pan and one on each end of handle. Then, the rough markings
were drilled with the help of lathe machine.
9. After that, riveting was done with the help of rivet gun. And the dustpan was
prepared by finalizing the rivets using ball peen hammer.

6. RESULT:
Dust Pan was constructed in the workshop by performing various sheet metal operations.
All the steps were performed in proper order to create the main body and the handle of the
dustpan as shown in the given manual. The main body and the handle were joined together
by the help of rivets. The measurements deviated substantially from the desired
measurements due to the instrumental error and human error. The isometric views of the
dust pan constructed are as shown in the pictures below.
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 7.DISCUSSION;
In the workshop, the initial phase of the dustpan preparation involved receiving a metal
sheet from the instructor, measuring 250 mm in length and 250 mm in breadth. Using hand
shears, a piece of 250 mm by 200 mm was cut from the original sheet, and an additional
sheet measuring 250 mm by 30 mm was cut from the remaining metal. Both sheets
underwent marking and cutting based on dimensions provided in the hard copy blueprint,
forming the rough outline of the dustpan body and handle. Throughout the process, regular
quality checks were conducted to ensure precision. Subsequently, the workpiece's sides
labeled as 6mm were bent at 180 degrees on a vice, with the inside folding lines bent about
90 degrees and smoothed using a mallet hammer. Further, markings were made for holes
using a center punch, and after drilling with a lathe machine, riveting was performed with a
rivet gun. The final touches were applied by using a ball peen hammer to secure the rivets,
completing the preparation of the dustpan in the workshop.

8. CONCLUSION:
In conclusion, the sheet metal operations conducted in the workshop, encompassing the
fabrication of a dustpan, demonstrated a systematic and precise approach to metalworking.
The process involved initial measurements, manual shearing, marking, and cutting of the
metal sheets based on provided blueprints. The utilization of hand shears, a lathe machine,
and a variety of tools, such as the mallet hammer, vice, and rivet gun, showcased the
versatility and efficiency of sheet metal techniques. The careful execution of bending,
drilling, and riveting procedures contributed to the creation of a well-crafted dustpan.
Throughout these operations, attention to detail and regular quality checks ensured the final
product adhered to design specifications. This hands-on experience not only enhanced
practical skills but also provided valuable insights into the intricacies of sheet metal
fabrication, laying a foundation for further proficiency in metalworking within the
workshop setting.

9. PRECAUTION AND SAFETY MEASURES:

1. Wear apron for protection and avoid soft shoes in the work shop.
2. Avoid loose clothing or accessories that could get caught in machinery.
3. Dispose of scrap metals properly and if any problem is create call the workshop teacher.

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