CENTRAL WORKSHOP

THAPAR UNIVERSITY
PATIALA, PUNJAB

WORKSHOP REPORT :

SHEET METAL

SHOP

Submitted By :
NAME : NITISH WADHWA
Roll No.: 10703072
Group : F3
BE Ist year

INTRODUCTION
Sheet metal is generally produced in sheets less than 6 mm. by reducing the
thickness of a long work piece by compressive forces applied through a set
of rolls. This process is known as rolling and began around 1500 AD. Sheet
metals are available as flat pieces or as strip in coils. It is characterized by its
thickness or gauge of the metal. The gauge of sheet metal ranges from 30
gauge to about 8 gauge. The higher the gauge, the thinner the metal is. There
are many different metals that can be made into sheet metal. Aluminum,
brass, copper, cold rolled steel, mild steel, tin, nickel and titanium are just a
few examples of metal that can be made into sheet metal. Sheet metal has
applications in car bodies, airplane wings, medical tables, roofs for building
and many other things.

Sheet metal is simply metal formed into thin and flat pieces. It is one of the
fundamental forms used in metalworking, and can be cut and bent into a
variety of different shapes. Countless everyday objects are constructed of the
material. Thicknesses can vary significantly, although extremely thin pieces
of sheet metal would be considered to be foil or leaf, and pieces thicker than
1/4 inch or a centimeter can be considered plate.

PROCESS STATEMENT
This is a process to convert a Galvanized Iron Sheet to a container with the
help of various operations like Shearing, Bending, Marking, Cutting etc.

JOB
We were given a plain sheet of Galvanized Iron and we were supposed to
make a container of the specific dimensions as in the diagram from that
sheet with the help of various sheet metal tools and machines.

SHEET METAL TOOLS

CRIMPERS/NOTCHES/PUNCHES TOOLS
Crimpers/Notches & Punching Tools are multi-purpose tools used for whole
punching & cutting various size notches.

DRILL BITS
Drill Bits are cutting tools used to create cylindrical holes. Bits are held in a
tool called a drill, which rotates them and provides axial force to create the
hole. Knowing your drill bits can help you choose the right drill for your job.
HAMMERS/PRY BARS
Hammers are hand tools used for pounding or striking.
Pry Bars are heavy iron levers with one end forged into a wedge.
HAND RIVETERS
Hand Riveters are used to set all popular size rivets for hand riveting
applications.
KNIVES/BLADES
Knives/Blades are tools used for cutting various types of materials.
MEASURING TOOLS
Our selections of Measuring Tools are simple to use, read and have added
features that will aid in any project.
NAILS & FASTENERS
Fasteners are used to pin, place or secure items firmly in place.
ROOFING & SOLDERING TOOLS
Our selection of roofing and soldering tools will allow you to do your own
soldering on your next roofing project and assist in your overall roof
torching needs.
SAWS/CUTTERS
Choose from our selection of Saws & Cutters to cut through various
construction materials. Your selection will depend on the type, size,
thickness and flexibility of material.
SCRIBERS/DIVIDERS
Scribers are used to measure, mark & trim lines on sheet metal in one easy
operation. The dividers are accurate and fast adjusting for different size
circles.

SEALANTS & ADHESIVES/CAULKING GUNS

Our sealants & adhesives are bonding agents for a variety of construction
materials. Use our caulking gun for simple and accurate application.
SEAMER/FOLDING TOOLS
Seamers are ideal for making clean and accurate bends. Folding Tools are
seams that are formed from two steel halves permanently joined together.
They are used for folding sheet metal edges.
SNIPS
Snips are used for notching, trimming & cutting straight lines, angles and
circles.

MARKING TOOLS
1. STEEL RULES -these are manufactured in a variety of length and types
for measuring or laying out different work. The rules could be steel foot rule,
folding rule (2m in length), tape rule.
2. SQUARE (Steel Square) - it is an l shaped piece of hardened steel. Its
one side is of 600mm while the other is of 300 mm. it is used for Checking
and marking right angles. It is also used to obtain square corners. As all
layout must start from square corners.
3. SCRIBER - It also known as the metal workers' pencil. It is
approximately 200mm long wire of steel with one end sharp and hardened to
mark lines on metallic sheet the process of laying out a job. The other end of
the scriber is generally ring shaped. Sometimes it is provided with a
replaceable wooden handle. The different types of scribers used are as
shown.
4. DIVIDERS - Dividers are available in a number of sizes and types. It is
made with straight tapered to a needle point. Its legs can be adjusted to any
position. It is used to scribe arcs and circles of metallic sheets. It is also used
to mark a desired distance and to divide a line, arc or circle into equal parts.
5. TRAMMER POINTS - These are used for drawing large circles and

arcs. It has two straight, removable legs tapered to a needle point and
mounted on separate holders which slide on wooden or steel bar and held in
position by thumb screws.

CUTTING TOOLS
SNIPS- although number of different type of snips , depending upon its a
capacity to cut , are available but mainly two basic types of snips are used
these are:
1. - STRAIGHT SNIPS - The main purpose of the snips is to cut the sheet
along the line scribed on it. The line may be a straight line or a curve. For
cutting along a straighten straight snip is used is used whose blades are
straight.
2. - BENT SNIP - the blades of the bent snip are curved back from the
cutting edge which allows the metal to slide over the top blade,
Hence used for cutting curved surfaces or circles and are suitable for 22
S.W.G sheets or lighter.
3. - COMBINATION BLADE SNIPS these are used for routine cutting of
sheets of 26 S.W.G or lighter.
4. CIRCULAR SNIPS- Whose blades are curved sideways and used for
cutting inside circles.
5. BULL DOG SNIPS - These are heavy duty snips used for cutting thicker
metals.
6. - BENCH SHAER SNIPS - These are used for slit cutting from the sheet
which may be upto 3mm wide.

PUNCHES
The following types of punches, made of tool steel, are commonly used in
sheet metal shop.
PRICK PUNCH: These punches are used for making small dent or

indentation marks for locating the centre position for dividers or trammel
points. These punches have tapered point grounded to 30 included angle
CENTER PUNCH: these are used for marking the location of points and
the centers of holes to be drilled. Its tapered point is grounded to 90 included
angle.
SOLID PUNCH: these are used to punch small holes.
HOLLOW PUNCH: these are used for cutting circular holes. The sheet
should be placed over a block of lead to avoid chipping of edges of the
punch.

HAND GROOVER: it is used to groove a seam by hand. The end of the

tool is recessed to fit over the lock for making the grooved seam.

CHISELS
FLAT HOLD CHISELS: these are generally used in sheet metal shop for
cutting sheets, rivets, bolts and for chipping operations.
ROUND NOSE CHISELS: these are used for roughing out concave surface
of corners and also for cutting grooves.

HAMMERS
The hammers are used in sheet metal shop for bending of sheets, smoothing
of sheets, riveting work, to give hollow or curved shape, for locking seam
joints etc. for these operations the following hammers are generally used:
MALLET: this is the most used hammer in any sheet metal shop. These are
made of good quality hard wood, plastic or hard fiber. These are used
whenever light force is required. The use of mallet does not spoil the surface
of sheet. It is used for smoothening the sheets. Its striking surface is flat.

BALL PEN HAMMER: It is a general purpose hammer. Its face is slightly

curved and the head is round.
SQUARE FACE HAMMER: This hammer is also called the setting
hammer and has a square, flat face. It is used for flattening the seems
without damaging the metal sheet.
RAISING HAMMER: It is used for forming a flat surface of a metal into
curved surface or hollow shape such as half moon. It is used with raising
block.
RIVETING HAMMER: Its face is square, slightly curved with beveled
edges. The peen side is double tapered and has a slightly rounded end.
RIVET SET: Rivet set is made of tool steel. There is a deep hole and a cup
shaped hole in the rivet set.
The deep hole is used to draw a rivet through sheet metal and the cup shaped
hole is used to form the finished head of the rivet. Another hole on the side
of the set is to release the burrs that are punched.
FILES: Files are used to remove burrs from the sheet metal, to square the
ends and some other operations that require removal of small amount of
metals.

PROCESS
A main feature of sheet metal is its ability to be formed and shaped by a
variety of processes. Each process does something different to the metal
giving it a different shape or size.
STRETCHING
Stretching is a process where sheet metal is clamped around its edges and
stretched over a die or form block. This process is mainly used for the
manufacture of aircraft wings, automotive door and window panels.
DRAWING

Drawing forms sheet metal into cylindrical or box shaped parts by using a
punch which presses the blank into a die cavity. Drawing process can also be
utilized to create arbitrary shapes with the help of soft punch.
DEEP DRAWING
Deep Drawing is a type of drawing process where the depth of the part is
more than half its diameter. Deep drawing is used for making automotive
fuel tanks, kitchen sinks, 2 piece aluminum cans, etc. Deep drawing is
generally done is multiple steps called draw reductions. The greater the
depth, the increased number of reductions required. Deep drawing may also
be accomplished with fewer reductions by heating the work piece, used in
sink manufacture for example.
In many cases, special material that has been rolled at the steel mill in both
directions can aid in the deep drawing process. Material that has been rolled
in both directions has a more uniform grain structure and is referred to as
"draw quality" material. Draw quality material will often improve deep
drawing (limiting tearing).
CUTTING
Cutting sheet metal can be done in various ways from hand tools called tin
snips up to very large powered shears. With the advances in technology,
sheet metal cutting has turned to computers for precise cutting.
Most modern sheet metal cutting operations are now based either on CNC
Lasers cutting or multi-tool CNC punch press.
CNC laser involves moving a lens assembly carrying a beam of laser light
over the surface of the metal. Oxygen or nitrogen or air is fed through the
same nozzle from which the laser beam exits. The metal is heated and then
burnt by the laser beam, cutting the metal sheet. The quality of the edge can
be mirror smooth, and a precision of around 0.1mm can be obtained. Cutting
speeds on thin (1.2mm) sheet can be as high as 25m a minute. Most of the
laser cutting systems use a CO2 based laser source with a wavelength of
around 10um; some more recent systems use a YAG based laser with a
wavelength of around 1um.

Punching is performed by moving the sheet of metal between the top and
bottom tools of a punch. The top tool (punch) mates with the bottom tool
(die), cutting a simple shape (e.g. a square, circle, or hexagon) from the
sheet. An area can be cut out by making several hundred small square cuts
around the perimeter. A punch is less flexible than a laser for cutting
compound shapes, but faster for repetitive shapes (for example, the grille of
an air-conditioning unit). A typical CNC punch has a choice of up to 60 tools
in a "turret" that can be rotated to bring any tool to the active punching
position. A modern CNC punch can take 600 blows per minute.
A typical component (such as the side of a computer case) can be cut to high
precision from a blank sheet in less than 30 seconds by either punch or laser.
BENDING AND FLANGING
Bending and flanging imparts stiffness to a sheet metal part or to form
various shapes, such as 3 piece aluminum cans.
ANGLE BENDING
Machines like the bar folder can be used to make angles that bends upto 150
in sheet metal under 1.5mm thick the work piece is inserted under the
folding leaf and aligned in the proper position raising the handle then
actuates a cam, causing the leaf to clamp the sheet . Further motion of the
handle bends the metal up to the desired angle. Bar folders are manually
operated and produce linear bends upto about 12 feet in length. Bends in
heavier sheet or more complex bends in thin material are generally made on
press brakes. They are mechanically or hydraulically driven presses with
long, narrow bed and short, adjustable strokes. The metal is bent between
interchangeable dies that are attached to both the bed and ram.
PUNCHING AND SHEARING
During punching or shearing, the sheet metal is cut by using a punch and
die. This process can allow many different shapes and patterns, by a
computer numerically controlled (cnc) punch machine.
SPINNING

Spinning is used to make axis-symmetric parts by applying a work piece to a

rotating mandrel with the help of rollers or rigid tools. Spinning is used to
make rocket motor casings and missile nose cones and satellite dishes for
example.
PRESS FORMING
This is a form of bending, used for long and thin sheet metal parts. The
machine that bends the metal is called a press brake. The lower part of the
press contains a V shaped groove. This is called the die. The upper part of
the press contains a blade that will press the sheet metal down into the v
shaped die, causing it to bend. There are several techniques used here, but
the most common modern method is "air bending". Here, the die has a
sharper angle than the required bend (typically 85 degrees for a 90 degree
bend) and the upper tool is precisely controlled in its stroke to push the
metal down the required amount to bend it through 90 degrees. Typically, a
general purpose machine has a bending force available of around 25 tones
per meter of length. The opening width of the lower die is typically 8 to 10
times the thickness of the metal to be bent (for example, 5mm material could
be bent in a 40mm die) the inner radius of the bend formed in the metal is
determined not by the radius of the upper tool, but by the lower die width.
Typically, the inner radius is equal to 1/6th of the V width used in the
forming process.
The press usually has some sort of backstop to position the material in the
jaws of the machine. The backstop can be computer controlled to allow the
operator to make a series of bends in a component to a high degree of
accuracy. Simple machines control only the backstop, more advanced
machines control the position and angle of the stop, its height and the
position of the two reference pegs used to locate the material. The machine
can also record the exact position and pressure required for each bending
operation to allow the operator to achieve a perfect 90 degree bend across a
variety of operations on the part.
ROLL FORMING
A continuous bending operation for producing open profiles or welded tubes
with long lengths or in large quantities.
ROLL BENDING

A continuous form of three point bending is roll bending, where plates,

sheets, and rolled shapes can be bent to a desired curvature on forming rolls.
These machines have three rolls in the form of a pyramid, with the two
lower rolls being driven and the position of the upper roll being adjustable to
control the degree of curvature.

APPENDIX

INTRODUCTION
PROCESS STATEMENT
JOB
SHEET METAL TOOLS
PROCESS

REFERENCES
1. MATERIALS AND PROCESS IN MANUFACTURING, EIGHTH
EDITION, E.PAUL DEGARMO, J.T. BLACK, RONALD A. KOHSER,
PRENTICE HALL OF INDIA PRIVATE LIMITED.
2. WWW.WIKIPEDIA.ORG