Workshop Practice Manual-8

Department of Mechanical Engineering Galgotias University Greater Noida, UP

Contents
Sheet Metal Joints Sheet Metal Operations

Sheet Metal Joints

Lap joint Seam joint Locked seam joint Hem joint Wired edge joint Cup or circular joint Flanged joint Angular joint Cap joint

Sheet Metal Operations

Measuring and Marking Laying out Hand cutting and shearing Hand forming Nibbling Circle cutting Piercing and blanking Edge forming and wiring Joint making Bending Drawing

Sheet Metal Operations

Measuring and Marking: The required size of the component may be smaller than the standard size is available in market. So, a standard size is to be cut. A little allowance for cutting is to be added to the required overall sizes so that the cut pieces are not under size. The procedure of marking various lines are: Marking a straight line Marking circles and arc Marking irregular curves Marking indentation marks Laying out: Laying out means the operation of scribbling the development of the surface of component on the sheet or sheet blank, together with the added allowance for overlapping, bending, hammering, etc. which when cut out of the blank and folded and joined will give the required components.

Sheet Metal Operations

Hand cutting and Shearing: The sheet metal is cut by chisel and hammer manually. The term shearing is stand for cutting the sheet metal by two parallel cutting edges moving in opposite directions. This can be done either manually by using hand shear or snips or by means of machine called shears. The operation is known as machine shearing or mechanical shearing. Hand forming: The term metal forming stands for shaping and/or bending of sheet metal in three dimensions in order to give it desire shape and size of the final product. For these, the metal is either is required to be starched or shrunk in all direction or may need a combination of both. Nibbling: Nibbling is a process of continuous cutting along a contour, which may be a straight line or irregular profile. The machine used in this operation is known as nibblers, which are portable size shearing machine.

Sheet Metal Operations

Circle cutting: It is the operation of cutting circular blank or curved contour with the help of a circle cutting machine. It is also a continuous cutting operation. Piercing and Blanking: Piercing is basically a hole punching operation while blanking is an operation of cutting out a blank. In both the cases blank will be produced, but in the former cases obtaining a blank is not the objective. It is hole of a desire size which is the objective and the blank produced may not be used further. However, in the latter operation the production of a blank of the desired size is the main objective which is a useful part for further processing. Edge forming and Wiring: The edges of sheet metal product are form to ensure safety of hands, while handling these products and to provide stiffness to the products in order that they will retain shape during handling i.e., will not get buckled by simple hand or finger pressure during handling.

Sheet Metal Operations

Joint making: For joining large size parts, especially when they are to be fastened to other metallic or large non-metallic bodies, screwed fasteners can be used. Sheet metal parts can also be joined by riveting, welding, brazing and adhesives. Bending: It may be done over stakes, blocks of wood or edge of a bench top. A line is marked with scriber where the metal is to be bent. In order to make right angled bend the sheet is placed on the bench so that the line is even with the edges of the bench. Now bend is made by striking metal with a mallet. In order to make curve bend, the edges of the wooden block is planed to have desired curvature the wooden block is placed even with the edges of the bench. Now strike the metal with a mallet, bent the sheet over the curved edges of the block.

Sheet Metal Operations

Drawing: The walled hollow shapes are produced in sheet metal through the drawing operation. The operation is carried out with the help of die and a punch on a suitable press. If the drawn length of the component is less than its width or diameter it is called shallow drawing. When the drawn length is more than the width, the operation is known as deep drawing.

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