MECHANICAL WORKSHOP MANUAL

SHEET METAL

COURSE CODE : C207&C217

SEMESTER : 3&4
REVISION : 2021
COURSE NAME : MECHANICAL WORKSHOP III/IV

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 Workshop Practice Manual (Sem-3&4) - Sheet Metal
SAFETY PRECAUTIONS

PERSONAL SAFETY

 Wear tight clothes; beware of hanging hair, ties, clothing, scarves or

beltsgetting caught.
 Never enter the workshop without safety shoes.
 Do not use rings, watches etc. while working.
 Keep the workshop clean and tidy. The floor should be free from oil and
grease; the slippery floor is always dangerous.
 Wear goggles whenever there is danger of flying matter.
 Never attempt to measure the job in running.
 Always stand in respectful distance from moving and hanging parts.
 Practice cleanliness and orderliness in the shop.
 Do not run or play on the shop floor.
 Keep your body behind the sharp edges of cutting tools.
 Do not attempt to lift heavy articles without assistance.
 Never handle chips or shavings with bare hands; use special
hooks,brushes etc.
 Never place sharp tools on the floor or at the edges of the
workbench;keep them in proper place assigned for them.
 Be aware the cause of electrical hazards such as bare wires, poor
earthing,return connections, wet floors etc.

MACHINE SAFETY
 Never operate the machine unless you have been properly instructed.
 Never work on the machine having unguarded moving parts.
 Stop the machine immediately, if it produces any unusual sounds.
 Before starting an operation, always check whether the work and
cuttingtools are secured fast.
 Never leave a machine when it is running.
 Never mount or remove the work, replace tools, clean or lubricate the
machine, or remove the swarf, while the machine is running.
 Do not run the machine in an incorrect speed.
 Do not talk or disturb others while they are operating a machine.
JOB SAFETY
 Use right tools for right job.
 Use metal strips to hold work pieces like Brass or Aluminum, to
avoidgripping marks on the finished surface.
 Put oil lightly on finished jobs to avoid rust.
 Tools with loose fitting or broken handles shall not be used.
 To save the time and material, frequent checking has to be made.
 Do not mix the precision measuring instruments with other tools
andequipment.
 Store inflammable materials like kerosene, turpentine etc. away from
theshop.
 Be aware of the details and location of firefighting devices like fire
buckets,fire extinguishers etc. and first aid box in the workshop.

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 Workshop Practice Manual (Sem-3&4) - Sheet Metal

SHEET METAL

INTRODUCTION
Sheet metal has its own significance as a useful trade in engineering and for
our day to day requirements. It is generally the working of metals from 16
gauge down to 30 gauge, with simple tools and equipment.
In sheet metal work, the knowledge of geometry, mensuration and properties
of metal is most essential since nearly all pattern come from the development
of the surfaces of a number of geometrical models such as cylinder, prism,
cone and pyramid.
Sheet metal works include various cutting, forming and joining processes in
sheet metal. Common examples of sheet metal work are hoppers, canisters,
guards, covers, pipes, hoods, funnels, bends, boxes etc. Such articles are found
less expensive, lighter in weight and at many places they easily replace the use
of the castings or forgings.

METALS USED IN SHEET METAL WORK

The sheets used in sheet metal work are specified by standard gauge
numbers. It is a series of numbers known as standard wire gauge (SWG)
numbers. Each gauge designates a definite thickness; higher the SWG number
of a sheet, lesser will be its thickness. Lower the SWG number, higher the
thickness of sheet.
The term „sheet‟ normally used to describe metal sheets with a maximum
Thickness of 2 mm; above this, it is usual to use the term „plate‟.
Metal sheets used in sheet metal works are: Black no galvanized iron, stain
lessSteel, tin plate, aluminium, lead and copper
 SCRIBER

TRAMMEL POINTS

40° 90°

Prick Punch Centre Punch

PUNCHES

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SHEET METAL HAND TOOLS

1. MEASURING TOOLS
a. STEEL RULE
It consists of a hardened steel strip having graduations etched in it. They are
usually 150mm or 300mm long, and is used to take linear measurements to
an accuracy of 0.5mm.
b. FOLDING RULE
This is useful in measuring and laying out larger works; the accuracy of being
0.5mm. It can be folded in hinges.
c. CIRCUMFERENCE RULE
This is used to find out directly the circumference of a cylinder.
d. BEVEL PROTRACTOR
It is used for angular measurement. It consists of a semicircular steel disc
graduated in degrees from 0° to 180° and a bevel gauge pivoted centrally.
e. MICROMETER
Micrometer is a precision measuring instrument with an accuracy of 0.01mm.
Thickness of sheets can be measured by this instrument.
f. VERNIER CALIPER
Vernier caliper is a precision measuring instrument which is used for outside,
inside and depth measurements. Its accuracy is 0.02mm.
g. STANDARD WIRE GAUGE
Both the thickness of the sheet metal and diameter of wires can be checked
by means of Standard Wire Gauge.
2. MARKING TOOLS
a. SCRIBER
This is the metal worker‟s pencil with its one end sharply pointed and
hardened to scratch lines on sheet metal in laying out patterns.
 Gauge Approx.
No. thickness
(in mm)
0 7.937
1 7.142
2 6.846
4 5.895
6 4.935
10 3.175
15 1.775
20 0.996
22 0.794
24 0.629
25 0.560
26 0.498
28 0.396
30 0.315
32 0.256
35 0.177

STANDARD WIRE GAUGE

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b. DIVIDER
It consists of two pointed legs, and used for drawing circles or arcs or to
divide lines into equal parts.
c. PUNCHING TOOLS
-
SOLIND PUNCHES are used for making small holes or markings.
Different types of solid punches commonly used are:
 Prick punch - 40°
 Centre punch - 90°
- HOLLOW PUNCHES are also used to punch holes in thin sheet
metal,leather, plastic, cork etc.
- HAND LEVER PUNCH is used where a large number of holes to
bepunched.
d. TRAMMEL POINTS
It consists of a bar with two movable heads. It is used to draw large circles
or arcs that are beyond the limit of the dividers.
e. STRAIGHT EDGE
This is a flat graduated steel bar with one longitudinal edge beveled. It is
useful for scribing long straight lines.
f. STEEL SQUARE
It is a L-shaped piece of hardened steel with marks graduated on the edges
for measuring. It is used for marking perpendicular lines to any base line.
g. TRY SQUARE
Try square is used for marking in the perpendicular direction to any base
line. Main parts are stock and blade.

3. STRIKING TOOLS
i. BALL PEEN HAMMER
It is used for general purpose.
ii. SETTING HAMMER
It is used to set up seams, flaring the edge of the cylindrical job and to set
up the long channels etc.
iii. RIVETTING HAMMER
It is used to jump the rivet shanks and finish the rivet heads.
iv. CREASING HAMMER
It is used to finish the wired edges, make the corner of the sheets with the
help of creasing stake, stretch sheets etc.
 MALLET

HATCHET STAKE HORSE STAKE

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v. RAISING HAMMER
It is used for forming of a flat sheet of metal into a curved or hollow shape
such as saucer, bowl, tray or spoon.
vi. PLANISHING HAMMER
It is used to give smooth surface finish to the job. Soft nylon hammers are
also used to avoid damage to the metal sheet.
vii. MALLET
Mallets are soft hammers and are made of hard rubber, copper, brass, lead,
fiber or wood. It is used to strike a soft blow on the metal so that nicks will not
be made on the surface of the sheet. Types of mallets are; ordinary wooded
mallets, bossing mallets and end faked mallets.

4. SUPPORTING TOOLS
a. STAKES
They are the sheet metal worker‟s anvil used for bending, seaming or forming
operations, using mallet or hammer. It consists of a shank and a head or horn.
The shanks are designed to fit into a hole in the bench.
1. HATCHET STAKE
It consists of a horizontal sharp straight edge and is used for making sharp
bends, folding the edges of the sheet metal, forming boxes and pans by hand.
2. HALF MOON STAKE
It has a sharp edge in the form of an arc of a circle, beveled along one side.
It is used for circular folding and seaming.
3. FUNNEL STAKE
It is used for shaping and seaming of funnels and tapered articles. It is also
used to obtain a conical shape in sheet metals for various purposes.
4. CREASING STAKE
It has a square horn with grooved slots at one end and a tapered round horn
at the other end. These are used for wiring and heading and for conical shaped
pieces.
5. BEAK HORN STAKE (BICK IRON STAKE)
It has two horns; one is tapered and the other is rectangular shaped. It is
used as a general-purpose anvil, for riveting, forming etc.
FUNNEL STAKE CREASING STAKE

CONDUCTOR STAKE COPPER SMITH STAKE

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6. COPPER-SMITH STAKE
It has a rounded edge on one side of the head and a sharp rectangular edge
on the other.
7. CONDUCTOR STAKE
It is having two cylindrical horns of different diameter.
8. HORSE STAKE
It is double ended holder for small stakes, one of which is cranked
downwards for clearance purpose and has square/round holes at both ends.
b. FOLDING BARS
It is used for bending and folding straight sheet metal held between its bars
and clamped to the vice. The folding line coincides with the top of the folding
bars.
c. GROOVER
It is used for closing and locking of seams (joints) in sheet metal work. The
end of the tool is recessed to fit over the lock, making the grooved seam.
d. RIVET SET OR RIVET HEADER
This is a hardened steel tool with a hollow in one end. It is used to shape the
end of a rivet into a round, smooth end.

5. HOLDING TOOLS
a. BENCH VICE
It is made of cast iron or cast steel and is used to hold the work for filing,
sawing, threading and other hand operations. The size of the vice is stated by
the width of the jaws. It consists of fixed and movable jaws with jaw plates, a
lead screw with handle and a base.
b. PLIERS
It is used to hold work pieces like wires, small work sheets etc.
6. CUTTING TOOLS
a. SNIPS or HAND SHEAR
A snip, also called a hand shear is used like a scissors to cut thin, soft metals.
It should be used only to cut 20 gauge or thinner metal.
These commonly used snipes are: Straight snips and Bend snips.
b. FILES
A file is a hardened piece of high-grade steel with slanting rows of teeth. It
is used to cut, smooth, or fit metal parts.
GROOVER RIVET SET

STRAIGHT SNIPS

BEND SNIPS

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c. CHISELS
Chisels are generally used in sheet metal work for cutting sheets, rivets,
bolts and chipping operations.

7. SOLDERING IRON
Soldering iron also called soldering coppers. This is used for soldering work
pieces. It consists of a forged piece of copper joined to an iron rod with a
wooden handle.

8. SHEET METAL OPERATIONS

a. SHEARING
Shearing is a general name for most sheet metal cutting but in a specific
sense designates a cut in a straight line across a strip, sheet or bar. Shearing
action has three basic stages: plastic deformation, fracture and shear. Basic
shearing operations are:
1. CUTTING OFF
This means severing a piece from a strip with a cut along a single line.
2. PARTING
Parting signifies that scrap is removed between the two pieces to part
them.
3. BLANKING
This means cutting a whole piece from sheet metal just enough scrap is
left all around the opening.
4. PUNCHING
Punching is the operation of producing circular holes on a sheet metal by a
punch and die.
5. PIERCING
Piercing is the process of producing holes of any desired shape like square,
triangle, rectangle etc.
6. NOTCHING
Notching is a process of removing metal to the desired shape from the
edge of a sheet.
7. SLITTING
When shearing is conducted lengthwise between rotary blades, the
process is referred to as slitting.
 CUTTING-OFF

scrap work

blank
scrap
(work)

PIERCING BLANKING PUNCHING

PARTING NOTCHING SLITTING

LANCING NIBBLING TRIMMING

SHEET METAL OPERATIONS

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8. LANCING
This makes a cut part way across a strip.
9. NIBBLING
Nibbling is an operation of cutting any shape from sheet metal on a
nibblingmachine without special tools.
10. TRIMMING
Trimming is the operation of cutting away flash from a piece of excess metal
in a flange.
b. BENDING
Bending of sheet metal is the process of applying forces to localized areas,
beyond the elastic limit, such as in bending a piece of metal into a right angle.
Bending incorporates angle bending, roll bending, roll forming and seaming.
c. DRAWING
Drawing is the operation of producing thin-walled hollow or vessel shaped
parts from sheet metal. These are two types; deep drawing and box drawing.
d. SQUEEZING
It is a quick and widely used way of forming ductile metal. The squeezing
operations are sizing, coining, hobbing, ironing, riveting etc.
e. RIVETTING
It is a process of joining permanently two pieces of sheet metal with rivets.
Riveting is largely used in manufacture of steel structures, boilers, pressure
vessels, rail wagons and coaches, furnace bodies, steel bridges etc.

9. HEMS AND SEAMS

a. HEM
Hem is an edge or border made by folding. It stiffens the sheet of metal and
does away with sharp edge. Hems are three types; single hem, double hem
and wired edge.
b. SEAM
A seam is a joint made by fastening two edges together. Seams are lap seam,
grooved seam, single seam, double seam, dovetail seam and burred bottom
seam.
SINGLE HEM DOUBLE HEM WIRED HEM

SINGLE SEAM DOUBLE SEAM GROOVED SEAM

HEMS AND SEAMS

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10. SHEET METAL MACHINES

When a large number of jobs are made, particularly in heavier types of
sheets, and operations like shearing, punching, bending etc. is difficult, time
consuming and uneconomical. To cope with this problem, both hand and power
operated machines have been developed. Smaller machines are usually
referred as „bench machine‟ while the others as „floor machine‟ which are
particularly useful in mass production of identical parts.
Commonly used machines are as follows:
a. SHEARING MACHINE
Used to cut or shear metal sheets in many ways.
b. BAR FOLDER
Used for bending and folding the edges of the metal sheets to form the
joint at the seam.
c. BURRING MACHINE
Used to make burr on the edges of the bottom of a can and on the end of
a cylinder.
d. TURNING MACHINE
Similar to burring machine, but produces a rounded edge for wiring
operations, bodies of cylinders and for double seaming.
e. WIRING MACHINE
Used to perform wiring operation strengthen the edges.
f. SETTING DOWN MACHINE
After the burr has been made on a burring machine, the seams are closed or
set down on a setting down machine.
g. FORMING MACHINE
Used for various forming operations, eg. forming stove pipes, cans etc.
h. BRAKE
A brake is a machine used for bending and folding the sheet metal
 ALUMINIUM FABRICATION
INTRODUCTION

Aluminum fabrication is an important part of a great number of modern

industries, especially transportation, manufacturing and marine industries.
Aluminum fabrication takes part of the metal fabrication industry which is in
charge of building metal structures by means of bending, cutting, and
assembling. Replacing heavier metals with aluminum has proved as an
effective way to achieve considerable weight reductions. Hence aluminum
fabrication has become an ideal solution for meeting specific manufacturing
needs when it comes to product performance, flexibility, design and cost
savings.
HAND TOOLS
a) MARKING AND MEASURING TOOLS
Commonly used marking and measuring tools in aluminum fabrication work
are; steel rule, measuring tape, try square, bevel square, scriber, pencil, wing
compass, spring dividers, punches, trammels etc.
b) CUTTING TOOLS
Commonly used cutting tools are; hack saw, files (flat, square, round,
needle), flat chisel, straight snips etc.
c) STRIKING TOOLS
Commonly used striking tools are; ball peen hammer, mallet, nylon hammer
etc.
d) MISCELLANEOUS TOOLS
Other important tools used in aluminum fabrication are hand drill, screw
driver, plum bob, spirit level etc.
1. HACK SAW
Hack saw is one of the main tools used in aluminum fabrication industry for
cutting rods, angles, pipes and extrusion in to desired length. It consists of a
metal frame which may be solid or adjustable.
2. PORTABLE ELECTRIC HAND DRILL
The portable hand drill is used for easy and quick drilling operation. It
consists of an electric motor, a trigger switch and drill chuck. Holes up to 6mm

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dia can be easily drilled with an electric hand drill.
3. SCREW DRIVER
The screw drivers are used for driving the screws into the object or for
unscrewing them. These are available in various sizes and shapes.
4. PLUM BOB
It is used for checking vertical levels of articles at the time of fixing.
5. SPIRIT LEVEL
A spirit level consists of an air bubble current glass tube protected by a
wooden or metal frame. It is used for checking horizontal level of the objects.

COMMON EXTRUSIONS USED IN ALUMINIUM FABRICATION

1. FIXED GLASS FRAMES
Commonly used types are; 2x1 single side, 2x1 plane, 2x1 double side,
1½ x1plane, 2½ x1½, plane, 2 ½ x1 ½ single side, 2x2 square (plane)
glassing plate, glassing clips and beadings.
2. SIT OUT AND HAND RAILS
Commonly used are; 4” closed book, 4” open book, 3 ½ “open book, 2 ½
and 3‟ pipes, C-channels, 1 ½ flat, 1” square, 1” oval, 1” pipe, grill etc.
3. DOORS
a. FLAT DOOR
Commonly used are; door vertical, door top, door bottom, door divider,
handle, clip, door closer, lock, pivot, bolt & nut, edge beading etc.
b. SLIDING DOORS
Commonly used are; „E; channel or double channel, runner, striker etc.
c. SUPER SLIDING DOOR
They are; two rack, sliding plane, sliding lock, „U‟ bending, PVC bush and
Sleeve, lock etc.
4. CEILING
Commonly used types are; „T‟ section, „I‟ angle, four-way clip etc.

*******
 Workshop Practice Manual (Sem-3&4) – Fitting

Experiment No 1 Date

All dimensions are in mm

Scale 1:1
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 Workshop Practice Manual (Sem-3&4) – Fitting

Experiment No;1

Date.
RECTANGULAR TRAY

AIM
To make a tray as per the given dimensions

MATERIALS REQUARED

GI sheet (26swg)-size 170×150mm

TOOLS REQUIRED

Steel rule, scriber, try square, flat file, mallet, straight snips, stakes,
ball Peen hammer etc
OPERATION TO BE CARRIED OUT

Marking, cutting leveling, filing, folding and finishing

PROCEDURE
-Mark and size the given work piece as per required dimensions with the help of
Steel rule, try square, scriber, snips and file.
-Fold the edges in to required shape to form the rectangular tray using mallet bench
Vice and stakes.
-Lock the folded edges using mallet and supporting stake to form the final shape.
-Check and finish the work
 Workshop Practice Manual (Sem-3&4) – Fitting

Experiment No:2

All dimensions are in mm

Scale 1:1

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Date:
Experiment No:2
CONE
AIM
To make cone as per the given dimensions.

MATERIALS REQUIRED
GI sheet (26 SWG) – size 126x150mm

TOOLS REQUIRED
Steel rule, Scriber, Try square, Flat file, Mallet, bend snips, Straight
snips, Stakes, Ball peen hammer etc.

OPERATIONS TO BE CARRIED OUT

Measuring, marking, cutting, leveling, filing, folding, grooving, checking
and finishing.

PROCEDURE
- Prepare the development drawing of the given cone
- Mark and size the given work piece as per the drawing with the help
ofSteel rule, try square, scriber, snips and file
- Fold the edges with 5mm and 4mm respectively in 180°
- Lock folded edges and form the cone shape using mallet
,groover,funnel Stakes and bench vice
-Check and finish the work
1
 Workshop Practice Manual (Sem-3&4) – Fitting

Experiment No:3

KNOCKED UP JOINT WITH DOUBLE HEM

All dimensions are in mm

Scale 1:1
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 Workshop Practice Manual (Sem-3&4) – Fitting

KNOCKED UP JOINT WITH DOUBLE HEM

Exercise No.3
Date:

AIM
To make a knocked up joint with double hem as per the given dimensions

MATERIALS REQUARED

GI sheet (26swg)-size101×71mm

TOOLS REQUIRED

Steel rule, scriber, try square, flat file, mallet, straight snips, stakes,
ball Peen hammer etc
OPERATION TO BE CARRIED OUT

Marking, cutting leveling, filing, folding and finishing

PROCEDURE
-Mark and size the given work piece as per required dimensions with the help of
Steel rule, try square, scriber, snips and file.
-Fold the edges 4mm 5mm respectively to form a longitudinal hem using mallet bench
Vice and stakes.
-Fold other longitudinal edges through marked lines
-Lock the folded edges using mallet and supporting stake to form a locked up joint.
-Check and finish the work
 Workshop Practice Manual (Sem-3&4) – Fitting

Exercise No.4

ALUMINIUM FABRICATION-PHOTO FRAME

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Exercise No.4 Date:

ALUMINIUM FABRICATION - CORNER JOINT

AIM
To make a photo frame as per given dimension by aluminum fabrication

MATERIALS REQUIRED
aluminum 20mm s section – 410mm (length) Aluminum

L-section (size 19x19mm) –40mm (length)

Counter sunk head screw – 4 Nos (Size 3mm)
1/8inch rivet _4 Nos

TOOLS REQUIRED
Steel rule, Scriber, Try square, aluminum cutter, Flat file, Drilling
machine, Drill bit (3/32 and 1/18), Screw driver etc.

OPERATIONS TO BE CARRIED OUT

Measuring, marking, cutting, filing, drilling, screwing and finishing.

PROCEDURE
- Set aluminum cutter to 45°
- Mark and cut the given aluminum section in to required dimensions.
- Level the edges using flat file and check it by using try square.
- Cut 19mm (¾“) L angle for cleat in required dimensions.
- Drill four holes (right holes) on outside of cleat by using
drillingmachine for counter sunk screw.
- Make four holes on each rectangular section to match the cleat holes.
- Fix the cleats on the aluminum s sections using 1/8 inch rivet and
rivet gun

- Make other two corners by using 20mm fiber corners

1/8inchcountersunk set screws
- Tighten the screws and finish the work.
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