THAKUR INSTITUTE OF AVIATION TECHNOLOGY
PRACTICAL PROCEDURE SHEET
TASK NO: TIAT/P-66/B1.1PRAC-20
Time: 06 Hrs.
MODULE: 7A
CAT: B1
TITLE: Use a range of hand tools, folding and bending machines and guillotine to shape aluminum sheet to achieve an accuracy
of ± 0.5 min X of bend angle, ± 0.030 ins/0.75mm.
Objective: Practice on cutting, bending and shaping of aluminum sheet metal.
REFERENCES: FAA 15A page no. 147
Area of Work : SHEET METAL WORK SHOP
PREPARATION FOR THE PROCEDURE:
a) Study the engineering drawing/ blue print.
b) Collect tools and tackles
c) Ensure that cutting tools are in working condition.
Safety Precautions:
1) Observe workshop safety rules.
2) Wear personal safety equipments
3) Wear hand gloves, safety shoes while handling sheet metal.
4) Ensure Emergency exits have no obstruction.
5) Ensure First aid box is available.
6) Work piece must be neat and clean free from oil and grease.
7) Ensure the safety operation of bending machine and shearing tool.
8) Bending machine must be appropriate size.
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9) Bending machine must be neat and clean before operation.
10) To bend the job, correct angular bend bar to be used.
TOOLS/EQUIPMENT: steel rule, ball peen hammer, mallet, flatter, snips, hand gloves, try square files, hand vice, bevel protractor,
vernier caliper, bending machine, guillotine.
TASK: Making a right angle bend of a sheet metal (120 x 60) mm , thickness 0.56 mm and within accuracy of ±0.5 min. x of bend
angle, ± 0.75 mm.
PROCEDURE:
a) Cut a piece of standard size of aluminum sheet of required dimensions by the guillotine or aviation snip.
b) Do file work on the edges of job sheet within the tolerance as per drawing.
c) D-burr all sharp corner and edges by using half round file.
d) Use Formula, B = 2𝜋(𝑟 + (t ÷ 2)) 𝜃 /3600 for measuring bending allowance of the job. [= 3.142, r = 6.5 mm
(inside bend radius), t = .56 mm (thickness of metal) and 𝜃 = 90 degree of bend].
e) Calculate the total length of the job.(120 mm)
f) Calculate the bending allowance. (10.64mm)
g) Calculate the flat length. (120 – 10.65) mm ÷ 2; as flats have equal length.
h) Use steel rule, try square and pencil to mark the sheet metal.
i) Ensure the marking on sheet metal job as per blue print.
j) Locate the sight line and bend tangent line or set back (r + t) to establish the distance of flat.
k) Use bending machine, flatter, hammer for bending/ folding operation of the edges of sheet metal job.
l) Now check the angular dimension and length with in the tolerance mentioned in the drawing.
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Note: thickness: 0.56 mm, Radius: 6.5 mm, Length of both flat is equal.
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Points to be noted for Evaluation:
Q. No. Questions Max. marks
1. Did the student use proper PPE while handling sheet metal? 20
2. Did the student use proper marking device to mark the sheet metal? 15
3. Did he/she cut the sheet metal by correct tool? 15
4. Has he/she found the correct bending allowance? 25
5. Has he/she found the correct flat length? 25
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FOR PRACTICAL ASSESSOR:
Points to be noted for Evaluation:
Q. No. Questions Marks Max.
obtained marks
1. Did the student use proper PPE while handling sheet metal? 20
Ans:
Safety shoes and gloves must be used while handling sheet metal.
2. Did the student use proper marking device to mark the sheet metal? 15
Ans:
When marking sheet metal, lead pencil is used so that no damage or scratch on the
sheet metal surface.
3. Did he/she cut the sheet metal by correct tool? 15
Ans:
Sheet metal is to be cut by means of aviation snip or guillotine.
4. Has he/she found the correct bending allowance? 25
Ans:
The correct bending allowance is 10.64 mm ± 0.75 mm.
5. Has he/she found the correct flat length? 25
Ans:
The correct flat length is 54.68 mm ± 0.75 mm and 54.68 mm ± 0.75 mm as both flat
have equal length.
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