WORKSHOP PROJECT

JUNE 2013

SHEET METAL SHOP

Group 1
Sahil Garg

12107007

Mechanical

Jaskaran Singh

12107018

Mechanical

Love Garg

12107028

Mechanical

Karandeep Singh Gujral

12107032

Mechanical

Siddhant Jain

12107033

Mechanical

Group with the final project

Acknowledgment
Workshop experience has always been fun. Over 20 days of
workshop training was really a great learning experience. To prepare
a dustbin out of raw material in the Sheet Metal Shop was really an
interesting task at hand. It was the immense support of our teacher
Mr Gurmail Singh and other technicians. They paved a way for us to
reach the summit of this project. It would have been difficult
without their support to make this project. This project helped us in
thinking innovatively. We would also like to thank our fellow groups
who helped us in various ways. Last but not the least we would like to
thank the Superintendent and the Lab Foreman who provided us with
this great opportunity.

Introduction
Sheet metal is metal formed into thin and flat pieces (Sheets). It is
one the most fundamental forms of work-piece used in metal
working. It is the building material for various daily-use objects.
Sheets are manufactured of different thickness according to the
requirement for various purposes. Technically thickness of sheets is
measured in gauges Gauge varies from 30 to 8. Higher the gauge
lesser the thickness. Many different metals can be formed into
sheet metal like Aluminium, brass, copper, steel, tin, nickel, titanium
and even gold, silver and platinum.
Applications of sheet metal include bodies of car, airplanes, roofs of
buildings and many other things. Sheet metal of ferrous metals with
magnetic permeability (laminated cores) are used in transformers
and electric machines. Other uses include decorative craftworks,
utensils, buckets and much more.

Workshop Layout

Cabin
Hatch Stake

Pipe Stake
Circular
Cutting
Machine

Anvil
Leg
Vice
Nibbling
Machine

Hatch Stake

OPERATIONS

Surface
Plate

Leg
Vic
e

Table

1. Bearing Out: In this process, fold or ribs in sheet if any

are removed with the help of beating the sheet with mallet
or passing the sheet through rollers.
2. Cutting or Shearing: This operation is carried out with snip
or a hand shear. Remember to keep as smaller piece of
sheet on lower cutting blade facilitates the cutting.
a. Notching: It is removal of surplus material from corners
or edges.
b. Trimming: It is the operation of cutting away excess
metal in flange.
c. Nibbling: It is an operation of cutting any shape out of
metal sheet or punching holes at fast speed. It is done on
nibbling machine
d. Punching: It is producing circular holes on sheet metal by
punch and die.
e. Piercing: It is the process of producing hole of any
desired shape.
f. Slitting: Process of producing a recess or slot.
3. Turning Up: It is done to make sharp bends to sheets for
seaming, hemming, etc.
4. Bending: It is an operation to bring the material to any curved
shape or any angular shape.
5. Flanging: It is the operation to raise narrow edge to form
right angle.
6. Raising: In sheet metal shop, some articles to be made require
a depressed surface as a tray or as a bowl. The process of
making this depression is known as raising.
7. Blanking: Indicates the shearing of metal blank from sheets of
a metal piece which serves as initial body for subsequent
forming is called blanking.

8. Beading: It is a process of creating curved depression or

raising up the surface for stiffening the article, to protect the
hands and clothes of handler, to improve the appearance, to
provide a stop to the body of a box so as to oppose the lid. It
is mostly done on beading machine.
9. Hollowing: It is the process of beating a metal for giving it a
concave shape. The process is done on a hollow stake.
EDGE STIFFENING PROCESS

1.

HEMMING

a. Single

Hemming: If the edge is folded once it is

called single hemming. The allowance for single

hemming is 4-5 times the sheet thickness.

b. Double

Hemming: It is made by folding the edge

over twice. The allowance for it is 10 times the

thickness of sheet.

2. WIRING:

A wire is inserted at the edge of sheet metal

articles. It stiffens the edges.

SHEET METAL JOINTS

1. Lapseam:

in this one edge overlaps the other and

then these are soldered, brazed or riveted.

2. Grooved

Seam: it is made by hooking the two single

rolded edges & then locking them a groover.

3. Single

Seam: it is used to join a bottom to a

vertical body or cylindrical, square or rectangular

shaped vessel.

4. Double

Seam: this seam connects the part or

knocked up joint of the container than strong joint

is reqd. at the bottom. Double seam can be used on

rectangular, square or cylindrical shaped vessel.

5. Dove

Tail Seam: it is used to join section such as

one pipe to another or flat pipe to a pipe. Square as

well as cylindrical objects can also be joined by this
seam.

Tools and Equipments

The tools and equipments used in the sheet metal shop can be
divided into two categories:
1. Common hand tool
2. Production tools and equipments

Common Hand Tools

Scribber: It a steel wire 3 to 4 mm dia and 10 to 20 cm long
grounded to pointed shape on end or on both ends. It is used
for making and scratching lines on sheet metal surface to
layout patterns.
Steel Rule: It is a ruler made out of steel with appropriate
markings of inches and centimeters.
Dividers: Dividers are used for drawing circular arcs and for
marking desired distance between two points. Divide lines and
circles into equal parts.
Trammel Points: It consists of bar with two movable heads. It
used to draw large circle or arcs that are beyond the limit of
the dividers.
Straight Edge: these are flat graduated steel bar with a
longitudinal edge bevel. It is Avaliable in length ranging from 1
m to 3 m. It is used for drawing long lines.
Steel Square: These are L shaped piece of hardened steel
with graduation marks on edges for measuring. It used for
marking in the perpendicular direction to any base line.
Sheet Metal Gauge: It a round disc of metal having slot cuts
on the outer circumference of the disc. Each slot is numbered
and number represents gauge number.
Punches: It is used for marking and locating centers etc. in a
permanent manner. They are of two types prick punch and
center punch. Prick punch is used for making small marks while
Center Punch is used for making the prick punch mark larger at
the center of the hole

 Solid and Hollow Punches: These are used for making small
holes and hollow punch for punching some bigger holes on sheet
metal surface.
Cutting and Shearing Tools: Hand tools used for cutting metal
sheet resemble with scissor known as snip are available and are
used for cutting metal sheet along straight and curved lines
respectively. These snips are very light and are easy to handle.
The heavy classes are known as bench shear and block shear
etc. The cutting planes of these tools are made of medium and
high carbon steel.
Chisels: Chisels are used for cutting sheets, rivet bolts and
chipping operations. It is made from high carbon steel. Flat
round chisels are more commonly used. The cutting edge of the
chisel should be beveled to an angle of 40 to 45 degrees
approx.

Forming and Shaping Tools

Hammers: They are used for bending, stretching, throwing off
but are more commonly used to strike a job. Hammers are
made out of forged steel to various sizes. The size of hammer
is known from its weight. Hammers are classified according to
shape of peen such as ball peen, cross peen and straight peen.
Some hammers are named as the operation it performs that is
riveting hammer, setting hammer, raising hammer etc.
Mallet: These are soft face hammers whereas metallic hammer
is known as hard face hammers. Mallets are made from hard
wood, hard rubber, copper, brass and are used to strike light
and soft blow on metal sheet surfaces.

 Stakes: It is used as support while sheets are being bent,

seamed, formed, sheared or shaped using a hammer or a mallet.
The different shape and sizes are available for this purpose
such as hatchet stake used as support to make straight, sharp
bents and for folding and bending edges. Half Moon Stake is
used for turning the edges of the round disc. The Pipe Stake is
used as stake for circular, semicircular bending etc. Funnel
Stake is used for hammering, tapering and operations on
conical jobs.
Leg Vice: It is a holding device for hammering and holding
heavy stakes etc.
Hand Grooving Tool: It is a tool used to make a locked groove
seam or mechanical joints etc.
Rivet Set: Tool used in riveting operation. It has got two holes
with through hole and other is cup shaped hole. Through Hole is
used to pull but the punched hole and cup shaped is used to
make hand on the pulled out portion of rivet

Project
Planning
The first step was to decide what was to be made as a project that
should be feasible, useful, and could be easily made with the tools
and machines provided in the workshop and in the course of time
provided to us. Finally we came to a decision to make a DUSTBIN out
of sheet metal.
Sketch

A rough isometric sketch of the Dustbin was prepared as the first

step for our project. Its shape would be that of a frustum of a
square pyramid with open top and a closed base. The dimensions and
the shape are as descripted in the sketch below
Forming Process
Step 1 : First Step was to develop the lateral surface of the
dustbin. Firstly we developed the surface on drawing sheets,
with proper dimensions and clearances for joints and bends.
Step 2 : Next we cut out the development that was made on
the drawing sheet and marked its boundaries on a galvanised
iron sheet of 26 gauge. All other markings were done
accordingly.
Step 3 : Next the development was cut out of the metal and
bent in the form of a closed surface on the edges as marked
using stakes and mallet
Step 4 : The 3 mm clearance provided on each end was folded
at 180 degrees one opposite to other so as to form two hooks.
The these hooks were attached and a seam was formed using a
hand grooving tool
Step 5 : A base of proper dimension was cut out with 6 mm
clearance on each side(for double seam joint)
Step 6 : The Clearance at the base of the lateral surface(3
mm) was folded at 90 degrees using mallets on the stake. Then
it was kept on the base sheet and marking was done for the
double seam joint
Step 7 : The clearance on the base was folded at 180 degrees
on each side. The lateral surface was kept over it. Then the

clearance of the base was folded on respective clearance of

the surface. Then the joint formed was further folded along
the surface to form a double seam
Step 8 : A galvanised iron wire of 4 mm thickness with four
times the edge length of top surface was cut out using a heck
saw. The cut wire was first straightened out on the anvil and
was then folded to form a square to give strength to the top
boundary of the dustbin. The top clearance of the dustbin was
folded around the wire square using tongs to get a good
finishing.
Step 9 : A metal strip of 2 inch with four times the edge
length of the base and with an inch of clearance was cut out of
GI 26 gauge sheet. It was folded about 1/2 inch of its width.
Then it was folded to form a square pedestal for the dustbin
and its free ends were riveted using MS rivets.
Step 10 : The dustbin was kept on pedestal and riveted.
Step 11 : Two 6 inch strips each of width 1 inch were cut out of
GI sheet. Each sheet was folded 3mm from both sides along
the length. Both of them were bent at specific lengths (1/2
inch and 1 inch) to form the handles for the opposite sides of
the dustbin. These handles were then attached to the dustbin
by using MS rivets.
Step 12: Measurements of the PEC logo letters were taken and
were marked on the GI sheet. Thereafter, the logo letters
were cut out of the GI sheet and were riveted on one of the
surfaces of the dustbin using aluminium rivets and were then
painted accordingly.