PROGRAMME : CEEM222 BACHELOR OF MECHANICAL ENGINEERING

COURSE : MEM460 ENGINEERING WORKSHOP PRACTICE

INSTRUCTOR : DR. MUHD FAIZ BIN MAT @ MUHAMMAD

LABORATORY
REPORT
LABORATORY: SHEET METAL

NO NAME STUDENT ID GROUP

NO
1 NURSAIDATUL FATIHAH BINTI 2022899488 C2
AHMAD SUHAIMI
2 MUHAMMAD FARREZ BIN MOHD 2022461562 C2
BAHARUDIN
3 MUHAMMAD SYAHMI BIN SAYUTI 2022455272 C2

4 FARIZ DANIEL BIN ABDUL RASHID 2022457698 C2

5 SYAHIR NAJWAN BIN MOHAMMAD 2022496248 C2

SUHAIMI
 1.0 TITLE
SHEET METAL

2.0 OBJECTIVE
To expose to the techniques of shaping metal in the processes of cutting, bending, and
folding,either with the used of hand tool or by use of specific machine.

3.0 INTRODUCTION
The sheet metal shop is very important for every engineering concern. It deals with the
workingof metal sheets. It requires a thorough knowledge of projective geometry
particularly thedevelopment of surfaces because the laying out of pattern and cutting of
metal sheets to correctsizes and shapes entirely depends upon the knowledge of the
workman. The various operationsperformed in a sheet metal shop are cutting, shearing,
bending etc. In this chapter, we shalldiscuss the sheet metal tools and thevarious
processes.

Sheet metalworking includes cutting and forming operations performed on relativelythin

sheet metal. Sheet metal is formed by an industrial process to produce thin and flat
piecesof metal. It can be cut, bent into many shapes and produces many other objects.
Typical sheetmetal thicknesses are between 0.4mm to 6mm. There are three major
categories of sheet-metalprocess which are cutting, bending and drawing.In this
workshop, the processes of sheet metalworking that need to be done are
cutting,punching and bending. Cutting process is to separate the sheet metal to two or
more pieces bycutting along the desired line. Punching process is to remove certain
parts on sheet metal as anexample to make holes. Bending process is to deform the
metal when force is applied and at acertain angle to form a new desired shape.
 4.0 APPARATUS

1. Scriber
A pointed tool used for making lines on
metals.

2. Metal ruler
To measure accurate measurements and also
guides for laying outlines.

3. Rubber mallet
A lightweight hammer-like with a molded
rubber is used when needed to hammer in
softer blows.
 4. Cutter
Cutters are hand tools which are used to cut
a variety of materials.

5. L Square
Used to measure lengths and calculate
angles.

6. Files
Files are used to remove or smoothen rough
and sharp edges from cut metal.

7. Bench machine
A much bigger machine compared to bench
shear. It is used to cut a bigger piece of
metal.
 8. Drilling machine
1. A powerful tool used to cut a round
hole through metal plastic and other solid
materials.

9. Bending machine
1. To bend sheet metals according to
desired angle.

10. Center punch

1. To mark the center of a point to make
it easier to drill a hole.

11. Aluminum
PROCEDURE
1. A metal ruler, L square ruler, and scriber were used to measure the length of
the sheet metal, which were 234 mm long and 40 mm wide with all four 90°
edges. It is then cut using a bench machine.

2. A divider was used to mark the 5 mm radius on the edge, which was then cut
with a cutter.

3. A scriber was used to mark the center of the two circles and an elongated hole
with a radius of 10 mm, 1.5 mm and 5mm each.

4. A center punch with rubber mallet was used.to make the circle's marked
center point more visible so that drilling is easier.

5. The sheet metal was then placed on the drilling machine's table, and the
clamp was adjusted and tightened until it reached the desired position.

6. The drilling machine was turned on and used to make a 20mm hole, which
was then lifted up until a perfect circle hole was created. Safety goggles were
worn while operating the drilling machine. This step was repeated for a 3mm
circle hole and an elongated hole with a radius of 10 mm.

7. The sample must then be bent at 92, 40, and 50 degrees using a bending
machine. Before starting the bending process, the sheet metal was ensured to
be parallel to the bender.

8. For finishing, rough and sharp edges on the product were smoothed with files.
5.0 RESULT AND DATA
 6.0 DISCUSSION

ERROR ANALYSIS AND EXPLANATION

During the process of making this product, there are few errors that were
defined. Errors such as springback and uneven texture can be seen in my products
that make it hard to get accurate measurements. When making a product or a
structure it is important, make sure the measurements are accurate when creating a
structure or a product to prevent subsequent issues.

POSSIBLE SOURCES OF ERROR

Spring backs occur when sheet metal is stressed during the manufacturing process and
then relaxes because of its elasticity. In high-strength sheet metals, this problem
typically comes from the little difference between yield and tensile strength. With spring
backs, correcting or bending too much can be helpful. Spring backs are another
possibility from positive stretching.

The second fault is wrinkles, which occur when compressive forces "push" the material
together during the sheet metal stamping process. In the worst instance, it could result
of an overlap. The improper manufacturing procedure or inappropriate parameters
could also end in wrinkles. The creased sheet metal can be straightened by stretching it
out or drawing it with pads and binders.

DEFECTS

There are a few defects in the final product after completing the sheet metal
working process. These defects can be seen on the final product that occurred
unexpectedly because of any factors during the working process.

One of the defects that was detected is surface scratch on the product. This
occurred while constructing the project without considering precautions against the
surroundings' sharp surfaces or other small, tough items that come into contact with
 the product that can scratch its surface.

Furthermore, the other defects is the chipping and fuzzing defect on the
product. This happened because the quality of the hole from drilling is low. It is not a
perfect hole because it has a smooth metal that cannot be cut or drilled perfectly. By
using files, it still cannot remove the sharp chipping or fuzzing and smooth perfectly
but it can make it better than before.

SENSITIVITY OF THE PROCEDURES APPLIED

For every design of sheet metal forming process, it is important to

acknowledge the sensitivities of the sheet metal regarding the strength and thickness
of the aluminum with respect to the parameters of the tools such as center punch and
drilling machine. This is to prevent the sheet metal from breaking.

As an example, when drilling, if the rpm of the drill is too high then it would
break the sheet metal because it exceeds the sheet metal hardiness. Other than that,
when bending there are a few conditions that need to be considered. Since we use
hand bending machines, then if we put too much force towards the sheet metal when
bending, it would break the metal. On the other hand, we also need to consider the
spring break of sheet metal.

The conclusion is, it is important for us to consider the stress and strain of the
materials so that it will not break or crumble while doing the sheet metal working
process.

POTENTIAL IMPROVEMENT OF PROJECT

There are some a few actions students can take to enhance the improvement
in the next project. Firstly, the students should improve their knowledge and skills in
the measurement, marking and cutting to make it more accurate and avoid errors in
measurement that can affect the measurement of product. Other than that, the
student also can improve themself by gaining more knowledge of handling machinery
correctly as possible as handling machinery is common when we involved in the
engineering field in the future. Other than that, the student also needs to remind
themself to always take precautions and safety when conducting projects in the
workshop seriously as it can avoid injury and accidents. The recommendation that
needed to be improved in the workshop is to make a lot of projects that involve the
processes and activities that can enhance the experience of students to prepare
themself before being involved in industry in the future as a basic knowledge of
industry practice in life.
 7.0 CONCLUSION

To conclude everything, the objectives of this workshop are are to perform the
measurement, cutting, punching and bending process correctly to produce the
product successfully. The product was done perfectly following the given drawing in
the lab sheet. The whole process took about one class of working. Although it
looked easy, there were some parts that were very difficult to do such as making a
hole. When doing the process, the correct measurement is the key to prevent any
mistakes during drilling onto the sheet metal. The final step to make the product
smoother, especially at the cutting part was to do metal sanding. This step was
important to remove any sharp or uneven area after the cutting or punching
process. Knowledge that can be gained from this workshop was to know how to use
the right tools for each process. After that, the knowledge that can be gained was to
learn how to measure sheet metal thoroughly and correctly. Lastly, it can be made
sure that all the safety rules were followed to avoid any unwanted incidents.
8.0 REFERENCES

1. Sheet metal. (2023, May 9). In Wikipedia.

https://en.wikipedia.org/wiki/Sheet_metal

2. Metrology, J., & Metrology, J. (2018, January 3). 5 Easy Ways To Strengthen Sheet
Metal - JASH Metrology. JASH Metrology.
https://www.jashmetrology.com/5-easy-ways-strengthen-sheet-metal/

3. How to Work With Sheet Metal. (2010, July 1). Popular Mechanics.
https://www.popularmechanics.com/home/how-to-plans/how-to/a5940/how-to-work-
with-sheet-metal/

4. A. (2017, July 31). Identifying and Resolving the Most Common Defects in Sheet
Metal Forming - StampingSimulation. StampingSimulation.
https://stampingsimulation.com/identifying-solving-common-defects-sheet-metal-
forming/