Mat Bending

RQF LEVEL 3
MANUFACTURING
TECHNOLOGY
MODULE CODE: MATBO 301
TEACHER’S GUIDE
Module name: BENDING OPERATION
1
BENDING OPERATION
2022
Table of content
Contents
.................................................................................................................................................... 1
Table of content ......................................................................................................................... 2
Acronyms ................................................................................................................................... 7
1. RTB: Rwanda TVET Board ....................................................................................................... 7
2. TVET: Technical and Vocational Education and Training ....................................................... 7
3. RQF: Rwanda Qualification Framework ................................................................................. 7
4. AC: Alternative Current .......................................................................................................... 7
5. DC: Direct Current .................................................................................................................. 7
6. CNC: Computer Numerical Control ........................................................................................ 7
7. OSSB: Outside Setback ..................................................................................................... 7
8. ISSB: Inside Setback .......................................................................................................... 7
9. BA: Bending Allowance .......................................................................................................... 7
Learning outcome 1: Prepare for bending operation ................................................................ 2
Learning outcome 1 objectives : ................................................................................ 3
Theoretical learning Activity ............................................................................... 11

1. Hard Hats ......................................................................................................................... 12
2. Leggings, Foot Guards, and Safety Shoes ........................................................................ 13
3. Earplugs and Earmuffs ..................................................................................................... 13
4. Gloves ............................................................................................................................... 13
5. Eye Protection .................................................................................................................. 14
6. Surgical Face Masks ......................................................................................................... 14
7. Respirators ....................................................................................................................... 14
8. Face Shields ...................................................................................................................... 14
9. Proximity Sensors............................................................................................................. 15
10. Body Shields ................................................................................................................... 15
How to operate a fire extinguisher ...................................................................................... 16
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There are different types of clamps and their uses ............................................................. 28
G/C Clamps....................................................................................................................... 28
Spring Clamps................................................................................................................... 29
F Clamps ........................................................................................................................... 29
Sash Clamps ..................................................................................................................... 30
2.Vices The Vice is used to tightly hold the job while performing operations in workshops
like a filling, cutting, drilling, tapping, dyeing, etc. Types of Vices ......................................... 30
1. Bench Vice ............................................................................................................. 31
Points to be Noted While Fixing a Bench Vice ................................................................. 33
2. Pipe Vice ................................................................................................................ 33
3. Tool Makers Vice ................................................................................................... 34
4. Hand Vice ............................................................................................................... 34
This vice is used to grip screws, rivets, nails, and other similar materials that are too
small to hold in the bench vice. Sometimes it is also used to hold thin plates while
drilling. ............................................................................................................................. 34
5. Leg Vice ....................................................................................................................... 34
6. Drill vice ........................................................................................................................ 34
4. Wiping or Edge Bending ........................................................................................ 66
Wipe bending or wiping or edge bending requires a pressure pad to hold the sheet
metal parts against the die. The punch then moves up and down to bend the edge of
the sheet metal. Wipe bending is much faster than any other bending process, but
there is always a risk of scratches because the tool is moving over the surface directly.
.......................................................................................................................................... 66
Topic : Induction (Hot) Bending vs Cold Bending ................................................................ 72

Indicative content 1.3: Pre-operation activities for bending equipment .................... 75
Correct Use of CNC Bending Machinery .................................................................... 82
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Practical learning Activity ............................................................................... 83
Learning out come 1.1 : formative assessment .................................................. 84

Learning outcome 2: Carry out bending operation ................................................................. 85
Learning outcome 2 objectives : .............................................................................. 87

Topic: Basic positioning of bending machines ............................................................... 95

Mandrel Bending Tooling....................................................................................................... 102
The 5 Necessary Components for Mandrel Bending ..................................................... 103
How to Create Sheet Metal Offsets without Custom Tooling ........................................... 105
Step 1: We make sure we have the right tool. .............................................................. 106
Step 2: We set the press brake to how hard we want it to come down on the piece of
metal. ............................................................................................................................. 106
Step 3: We manually stop the press brake to create the desired angle. ...................... 106
Arc Length Formula ................................................................................................................ 107
Formulas for Arc Length..................................................................................................... 107
Denotations in the Arc Length Formula......................................................................... 108
Example Questions Using the Formula for Arc Length .................................................. 108
Practice Questions Based on Arc Length Formula ......................................................... 108
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Theoretical learning Activity ............................................................................. 111
Practical learning Activity ............................................................................. 111
Learning out come 2.1 : formative assessment ................................................ 112
Learning outcome 1 objectives : (Performance criteria in affirmative form) ........ 114

Indicative content 3.1: Finishing bent product .................................................................. 115
The Benefits ....................................................................................................................... 116
Common Heat Treatment Methods .................................................................................. 116
Annealing ....................................................................................................................... 116
Normalising .................................................................................................................... 117
Hardening....................................................................................................................... 117
Ageing ............................................................................................................................ 118
Stress Relieving .............................................................................................................. 118
Tempering ...................................................................................................................... 118
Carburisation.................................................................................................................. 119
1.EDGE-GUARD ...................................................................................................................... 120
2. GALVATRON ................................................................................................................... 120
3. HEAT STOP ..................................................................................................................... 121
4. INDUCARE DRY CLEAN ................................................................................................... 122
Indicative content 3.2 : Bending machine is properly maintained according to the
maintenance manual ......................................................................................................... 127
Indicative content 3.3 : Performed work is correctly reported as per reporting templates
............................................................................................................................................ 128
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Learning out come 3.1 : formative assessment ................................................ 130
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Acronyms
1. RTB: Rwanda TVET Board
2. TVET: Technical and Vocational Education and Training
3. RQF: Rwanda Qualification Framework
4. AC: Alternative Current
5. DC: Direct Current
6. CNC: Computer Numerical Control
7. OSSB: Outside Setback
8. ISSB: Inside Setback
9. BA: Bending Allowance

10.
11.
12.
13.
14.
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MATBO 301: BENDING OPERATION
Learning Outcome 1: Prepare for bending operation
Learning Outcome 2: Carry out bending operation
Learning Outcome 3: Perform post-operation activities
1
Learning outcome 1: Prepare for bending operation
2
Learning outcome 1. Prepare for bending operation
Indicative contents
1.1. Introduction to Bending operation
1.2. Identification of safety and security measures
1.3. Identification of material, tools and equipment
1.4. Pre-operation activities for bending equipment
Duration: 10hrs
Learning outcome 1 objectives :

By the end of the learning outcome, the trainees will be able to:
1. Apply safety and security measures at workplace
2. Select materials, tools and equipment
3. Conduct machine maintenance
Resources
Equipment Tools Materials
- PPE - Rulers - Chalks
- Bending machines - Books - Pens
- white board - Calculator - Papers
- benches - clamping tools - Pencils
- angle grinder - video tutorials - marker-pen
- anvil - brush - flip chart
- shear machine - measuring - paints
- cut-off machine - marking tools - oil and grease
- material handling - common tools - Sheet Metal
equipment (hummer, screw - Pipes
- air compressor driver, bending - Bars
pliers, spanners,
wrench, Allen key
cloths rugs, wire
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brushes, bloom,
spray gun)
Advance preparation:
 Safety equipment should be available
 Trainees should have basic skills on technical drawing
 Trainees must respect rules and regulations of the workplace
Indicative content 1.1: Introduction to Bending operation
 Definitions
Bending is a process by which metal can be deformed by
plastically deforming the material and changing its shape. The
material is stressed beyond the yield strength but below the
ultimate tensile strength. The surface area of the material does
not change much. Bending usually refers to deformation about
one axis.
Bending is a flexible process by which many different shapes can

be produced. Standard die sets are used to produce a wide
variety of shapes. The material is placed on the die, and
positioned in place with stops and/or gages. It is held in place with
hold-downs. The upper part of the press, the ram with the
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appropriately shaped punch descends and forms the v-shaped
bend.
Bending is done using Press Brakes. Press Brakes normally have

a capacity of 20 to 200 tons to accommodate stock from 1m to
4.5m (3 feet to 15 feet). Larger and smaller presses are used for
specialized applications. Programmable back gages, and multiple
die sets available currently can make for a very economical
process.
Flange length: The length of either of the two flanges, extending from the
edge of the metal to the bend line. As shown on the following figure
Bent radius: Bending radius is the smallest possible bending radius

of materials without breaking the workpiece. How much a plate can
be bent depends on several factors. The type of material and the
material thickness play an important role.
The distance from the bend axis to the inside surface of the material, between
the bend lines. Sometimes specified as the inside bend radius. The outside bend
radius is equal to the inside bend radius plus the sheet thickness.
K factor: K-Factor is a ratio that represents the location of the

neutral axis with respect to the thickness of the sheet metal part
and depends on material, thickness and bend radius.
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K-Factor (K) can be defined as follows:
Where t is the distance from inside face to the neutral sheet and T is the
sheet thickness in practice, K-Factor is used when you don’t know the
process or machine that is going to be used to bend the sheet.
Bend deduction: On the other hand, when you are trying to develop a flat
pattern you will have to make a deduction from your desired part size to
get the correct flat size. The Bend Deduction is defined as the material
you will have to remove from the total length of your flanges in order to
arrive at the flat pattern. To calculate the Ben Deduction, we can rewrite
the previous equation as:
Initial Length = Leg Length 1 + BA (bending allowance) + L

eg Length 2
Initial Length = (Flang Length 1 - OSSB) + BA + (Flang Len

gth 2 - OSSB)
Initial Length = Flang Length 1 + Flang Length 2 - (2*OSSB

- BA)
The last term of the previous equation is called the Bend Deduction
which is the difference between the Bend Allowance and twice the
outside setback.
Bend Deduction = 2*OSSB - BA
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Bend allowance: The Bend Allowance (BA) is the arc length of the
bend as measured along the neutral axis of the material.
Understanding the Bend Allowance and consequently the Bend

Deduction of a part is a crucial first step to understanding how sheet
metal parts are fabricated.
When the sheet metal is put through the process of bending the metal
around the bend is deformed and stretched. As this happens you gain a
small amount of total length in your part. The Bend Allowance is defined
as the material you will have to add to the initial length of your flat sheet
in order to arrive at the length of formed part. As it was mentioned before
the length of the neutral axis doesn’t change after the bending. So the
following equation is valid at all times:
Initial Length = Leg Length 1 + BA + Leg Length 2
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Figure 2: Bend Allowance
Outside setback: Understanding the Outside Setback of the workpiece

is an important part of designing sheet metal parts. The Outside
Setback is the distance from the apex of the outside mold lines to the
tangent point of the outside radius. When the sheet metal is bent the
inside radius pulls the edge of the material away from the apex of the
bend. Because this is a geometrical function it does not change with
a metal’s K-Factor the way Bend Allowance and Bend
Deduction do. The Outside Setback is closely related to, but should
not be confused with, the Inside Setback. The below image shows
the difference between the Outside Setback (OSSB) and the Inside
Setback (ISSB). As you can see these values are heavily dependent
on the Bend Angle.
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Bend length: bending length can also be defined as the falling length,
when a fabric falls under its own weight to a specific length, having a
specific angle
 Advantages and disadvantages of bending

Advantages
 One more advantage which is commonly known about the
hydraulic press brake is that it is preferred by the
industries as the machine is found to be adaptive and
easy to operate. There are various roles which a machine
follows like cutting, bending and spreading of the sheets
that can be easily executed by the usage of the machine.
 Other advantage is that the design of the machinery

seems to be along with a simple structure which can bend
and cut down a mass amount of materials like metals at a
particular time.
 High speed, high production efficiency and low energy consumption.

 Simple routine maintenance and low maintenance cost.
 High degree of automation, simple operation, no need to replace the
upper and lower mold, save time.
 The bending tool can complete the shape of non-right angle, right angle,
circular arc, pressing dead edge, etc.
 It’s suitable for flat molding of various materials.
 The machine body adopts high precision tempering furnace tempering
treatment, completely release the welding internal stress, ensure not easy
deformation, ensure the stability of the equipment.
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Disdvantages
 some process variants are sensitive to variations in material properties.

 Difficult to control angle. More angle variations
 Precision parts not possible
 CNC bending machine is very costly
 The relatively large number of set-ups and the geometrical changes

during bending make it difficult to address tolerances and bending errors
a priori during set-up planning, although some attempts have been made
 Bending process have high tooling and equipment costs.
 Application
There was a time when automotive companies and suppliers

had to make use of a manual process for bending brake lines
and fuel lines. There were many disadvantages of a manual
machine and it also reburied a high skill operator level. many
applications in several industries as listed here
 Agriculture industry: It is useful for Vineyard accessory, Agricultural

Spring, Tractor part
 Furniture industry: It is useful for decoration lamps, bottle holder, chair
frame
 Automotive industry: It has many applications in this industry for the
production muffler hargers with end forming units, single head or head and
collar, headrest frames, bonnet rods, tank floats, child seat hooks, etc.
 Railway industry: Applications in the railway industry include railway
clips, etc.
 Construction Industry: There a large number of applications in the
construction industry like scaffolding safety hooks, ceiling hook,
frameworks concrete.
 Appliances industry: It is useful for several appliances like barbecue
accessories, refrigerator accessory, dishwasher accessory, oven grill, iron
holder for axis, cooling coil.
 Display material: It is useful to make material like postcard support and
other display support material.
 Fastening Industry: It is useful for many types of pins and hooks.
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 Gardening industry: Applications in the gardening industry include gas
lever lawn mowers, mower lever, wire planter
Summary for the trainer relate to the indicative content
Bending is a flexible process by which many different shapes can be produced.

Standard die sets are used to produce a wide variety of shapes. The material is
placed on the die, and positioned in place with stops and/or gages. It is held in
place with hold-downs. The upper part of the press, the ram with the appropriately
shaped punch descends and forms the v-shaped bend.
Theoretical learning Activity
 Brainstorm about key terms in bending operation

 Group discussion about the meaning of bending
Points to Remember (Take home message)
Key definitions:
 Bending
 Flanged length
 K-factor
 Bend radius
 Bend deduction
 Outside setback
 Bend allowance
 Bend length
 Bend angle
 Bevel angle
 Neutral axis
 Compression and tension
 Advantages and disadvantages 11
 Applications of bending operation
Indicative content 1.2: Identification of safety and security measures
 Bending equipment safety tips

Topics: Safety equipment
1. PPE (personal protective equipment)
Personal protective equipment (PPE) refers to anything worn by an employee

that protects them from an injury or illness caused by workplace hazards.
The Occupational Safety and Health Administration (OSHA) states that

employers are responsible for the provision of any necessary PPE in accordance
with OSHA standards. This includes performing a hazard assessment,
identifying and providing appropriate PPE, training employees in the use of that
PPE, and reviewing and replacing damaged equipment as necessary.
Below is a list of essential PPE that might be required within a manufacturing

organization.
1. Hard Hats
Hard hats serve to protect industrial workers from head injuries caused by
falling, flying, or fixed objects. Protective hats must be penetration-, shock-, and
water-resistant as well as being slow-burning.
There are three industrial classes of hard hats:
 Class A: Provides impact and penetration resistance and some protection

from electrical hazards.
 Class B: As well as providing impact and penetration resistance, Class B
hard hats provide the highest level of protection against electrical
hazards, including high-voltage shock and burn protection.
 Class C: Provides some impact protection but no protection from
electrical hazards.
OSHA regulations also require employers to ensure that their employees cover
and protect long hair to prevent it from being caught in machinery.
When a hard hat sustains damage or impact — even if the damage is not visible
to the human eye — it must be replaced.
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2. Leggings, Foot Guards, and Safety Shoes
Leggings, foot guards, and safety shoes help protect workers from a range of
workplace hazards including falling, rolling, or sharp objects; wet, slippery, and
hot surfaces; and electrical hazards.
This PPE includes:
 Protective leggings: Typically made from leather or aluminized rayon,

protective leggings are fitted with safety snaps for easy removal and serve
to protect the wearer’s legs and feet.
 Metatarsal guards: These are strapped to the outside of the wearer’s shoes
to protect the instep.
 Toe guards: Typically made from steel, aluminum, or plastic, these fit
over the wearer’s toes to protect from impact.
 Shin guards: These protect the lower legs and feet.
 Safety shoes: A range of special-purpose footwear such as electrically
conductive shoes, which protect against static electricity build-up, can be
acquired by employers.
3. Earplugs and Earmuffs
Earplugs and earmuffs are used to protect workers from exposure to excessive
noise, which can lead to irreparable hearing damage and increased stress.
In a workplace where employees are consistently subjected to high

levels of noise, workers should be fitted for specially molded earplugs.
The louder and more constant the noise, the less time an employee
should be expecte
d to work without adequate hearing protection.
4. Gloves
Gloves, finger guards, and arm coverings will protect employees from the skin
damage caused by cuts, chemical and thermal burns, and punctures.
Depending on the nature of the employee’s work and their risk of exposure,
hand protection can provide different levels of thermal protection and cater to
different grip requirements. Gloves might be made of leather, canvas, or metal
mesh; fabric; chemical- and liquid-resistant materials; or insulating rubber.
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5. Eye Protection
Protective eyewear is important in certain workplaces to shield employees’ eyes

from flying particles, hot liquids, molten metal, chemical gases, and harmful
radiation. This PPE must fit closely and comfortably to the wearer’s face, be
cleanable, and not restrict vision or movement.
Protective eyewear includes safety goggles or spectacles, welding shields, and

laser safety goggles.
6. Surgical Face Masks
A surgical mask — often referred to as a face mask — is a loose-fitting,

disposable device that covers the wearer’s mouth and nose to create a physical
barrier between them and people in their immediate environment.
This PPE serves to protect the wearer from large particle droplets or splatters
that could contain germs as well as reduce the saliva and respiratory secretions
the wearer passes on to others.
7. Respirators
Respirators have long been used in a manufacturing setting to protect

employees from inhaling air contaminated with harmful dust, fumes, gases, or
sprays. This PPE must fit closely to the face and cover the nose and mouth to be
effective.
N95 filtering facepiece respirators are most commonly used and recommended
by OSHA. Once manufactured, a sample from each batch is tested for
flammability, breathing and splash resistance, particle filtration efficiency, and
bacteria filtration efficiency.
More recently, N95 respirators have become essential PPE in the fight
against COVID-19. When unavailable, more intricate alternatives such
as powered air-purifying
respirators (PAPRs), supplied-air respirators (SARs), or high-efficiency

particulate arrestance (HEPA) can be used.
8. Face Shields
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Face shields consist of a visor, a lightweight plastic or metal frame, and a
suspension system that attaches the shield to the head of the wearer. Providing
full face protection, this PPE is typically worn on top of masks or goggles to
prevent the inhalation of toxic substances or, as in the case of COVID-19, virus-
carrying aerosol droplets.
Employers looking to source PPE for their workforce must thoroughly research
and evaluate prospective suppliers to reduce the risk of purchasing counterfeit
PPE. In the wake of COVID-19, several manufacturers have retrofitted their
businesses to help meet the increasing demand for PPE.
With this in mind, it’s more important than ever before to scrutinize PPE
suppliers. Consult government resource lists to find legitimate manufacturers,
check supplier certifications, insist on checking product samples for legitimacy
and quality, and closely interrogate contracts.
9. Proximity Sensors
Proximity sensors are a new addition to the list of PPE, with their development
spurred by the COVID-19 pandemic.
This device is typically used to indicate the proximity of a user to a hazardous

object but has been updated by product developers to help manufacturing
employees adhere to the six-foot separation guidelines. This is also a means to
track exposure to COVID-19 within the workplace.
10. Body Shields
In particularly hazardous conditions, workers might be required to protect their

entire body. Body protection comes in the form of jackets, aprons, lab coats,
overalls, and full bodysuits. They are made from a range of materials including
fire-retardant wool or cotton, rubber, leather, and plastic.
Body protection of this kind must be carefully measured for each employee to
ensure a proper fit.
Safety equipment (PPE) is the protection that is used by workers to avoid

injuries, casualties, life threatening situations etc. Different types of safety
equipment are used by workers depending upon the nature of risk involved in
the work.
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2. Fire extinguisher
A fire extinguisher is an active fire protection device used to extinguish or
control small fires, often in emergency situations.
Fire extinguisher
How to operate a fire extinguisher
There are a number of different types of portable fire extinguishers, each can be
identified by the colour coding and labelling. Check that the extinguisher you
intend to use is suitable for the type of fire encountered eg a water extinguisher
must never be used on any fire involving electrical equipment.
There are four (4) basic steps for using modern portable fire extinguishers.
The acronym PASS is used to describe these four basic steps.
1. Pull (Pin)
Pull pin at the top of the extinguisher, breaking the seal. When in place,
the pin keeps the handle from being pressed and accidentally operating
the extinguisher. Immediately test the extinguisher. (Aiming away from
the operator) This is to ensure the extinguisher works and also shows the
operator how far the stream travels
2. Aim
Approach the fire standing at a safe distance. Aim the nozzle or outlet
towards the base of the fire.
3. Squeeze
Squeeze the handles together to discharge the extinguishing agent inside.
To stop discharge, release the handles.
4. Sweep
Sweep the nozzle from side to side as you approach the fire, directing the
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extinguishing agent at the base of the flames. After an A Class fire is
extinguished, probe for smouldering hot spots that could reignite the fuel.
The following images represent the steps of using fire extinguishers, is also
known as PASS
3. First aid kits

Every person at workplace is responsible for the safety of him/herself and
others. Every business needs to be conscious of potential injuries that could
occur. Having a stocked first aid kit is an essential requirement used to address
all of those potential injuries and accidents. First aid complies with the RSB
standard including the list of first aid needed and tools that will help to restock
the workplace first aid kits so that people stay in compliance.
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First aid kit contents:
A workplace first aid kit should include these items.
1. Cotton wool
2. Adhesive tape
3. Crepe bandage
4. Sterile dressing
5. Bandage
6. Thermometer
7. Scissors
8. Glove
9. Soap
10.Pain reliever
11.Antacid: Antacids help to treat heartburn (indigestion). They work by
neutralizing the stomach acid that causes heartburn
12.ORS packets
Here are some of the quick safety tips for you to follow for safe operation:
You should never forget to wear safety gloves. They protect your hands
from getting hurt by sharp equipment.
Always use safety goggles to protect your eyes from fine particles that
fly during the bending process.
Make use of work boots. They prevent any scrap, or pointed material
from hurting your feet.
Avoid running your hands over a sharp cut, even if you are wearing
gloves.
Always ensure that all the burr is filed properly.
Always keep the work surface clean. Clear all the scrap, as it can pose
a risk of injury.
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You should always handle wet metal sheets with utmost care. The wet
surfaces contain moisture, which when mixed with dirt and oil can make
the surface of the sheet slippery, thus making it hard to hold.
Safety precautions
Safety precaution while using a sheet metal bending machine
To get the desired output, and for safe operation, you are required to
follow some basic safety norms while using a sheet bending machine.
Here are some of the major ones:
1. Understand the Machine and its Operation: Have you operated the
sheet bending machine before? If not, then you should first get used to
it. You should understand the machine, and its operation, before you
actually start using it. Get familiar with the functioning of the machine.
For this, you can refer to the instruction manual. It would help you
understand the machine better, and eliminate any chances of accidents
or mishaps during its working. You can also consider taking some
training from those who are experienced in handling a sheet bending
machine.
2. Warm up Machine in Cold Weather: In cold weather, it is often

recommended to keep the machine warm. To get the best results, you
should always consider warming up the machine for a few minutes
before using it. You can do this by setting the machine in motion and
allow it to operate for a few minutes. Once, this is done, you are all set
to get the best results from the machine. When you warm up the
machine, you also eliminate the chances of it getting stressed.
3. Hold the Sheet Parallel to the Bender: Placement of the sheet is very
important. For a safe operation, you should always hold the sheet at a
proper angle. Before you start the bending process, always ensure that
the sheet is parallel to the bender. The wrong placement may cause the
sheet to hit your body, and cause injury.
4. Mind your Hands: You should be careful while operating the bender.
When you place the sheet on the bender, you should ensure that your
hands are away from getting hurt. Lack of attention can lead to severe
accidents, or even permanent injuries.
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Safety Measures While Using Hydraulic Pipe Benders:
The following are some of the important safety measures that

should be followed while using hydraulic pipe bending
equipment:
1. Check the pipe bender thoroughly. Check for any damage or defect.
Make sure to do this check every time while using the pipe.
2. Make sure that the roller shafts are properly pinned, prior to using the
pipe. Also, ensure that the bending die is properly seated, so that
there is no mishap.
3. The pipe should be cleaned regularly, so that its performance is not
lowered.
4. Always remember to keep your hands away from the die and rollers
while you are bending the pipe.
5. It is always recommended to consult a professional when it comes to
maintaining and lubricating the hydraulic unit.
6. Always use the right hydraulic oil during the maintenance.
7. You should only use hydraulic oil. Avoid using brake fluid.
8. If you find the pipe bender in a damaged state, you should not use it.
9. You should never exceed the rated capacity of the hydraulic units.
10. Use the hydraulic pipe bender only for the purpose it is meant for,
and not for any other purpose.
11. You should not change the valve settings of pressure control.
12. Always make sure that you store the hydraulic pipe in a cool and
dry place when it is not in use. This prevents moisture and formation
of moss on the pipe.
13. Read and understand the instruction manual before using the pipe
bender.
14. In order to ensure performance, make sure that all the shafts are
fitted correctly and the pip rollers are in the right holes.
15. For achieving the right degree of bend, you should ensure that the
pump and valve handle are in the correct position
16. It is always recommended to replace the hydraulic oil every year.
17. While using the high pressure hose, you should make sure that
both the ends are clean otherwise the pipe bender will not operate
properly.
18. Do not take off the nameplates and labels because they include
important safety instructions.
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Topic: Safety Measures While Using Hydraulic Pipe Benders:
The following are some of the important safety measures that should be
followed while using hydraulic pipe bending equipment:
1. Check the pipe bender thoroughly. Check for any damage or defect.
Make sure to do this check every time while using the pipe.
2. Make sure that the roller shafts are properly pinned, prior to using the
pipe. Also, ensure that the bending die is properly seated, so that
there is no mishap.
3. The pipe should be cleaned regularly, so that its performance is not
lowered.
4. Always remember to keep your hands away from the die and rollers
while you are bending the pipe.
5. It is always recommended to consult a professional when it comes to
maintaining and lubricating the hydraulic unit.
6. Always use the right hydraulic oil during the maintenance.
7. You should only use hydraulic oil. Avoid using brake fluid.
8. If you find the pipe bender in a damaged state, you should not use it.
9. You should never exceed the rated capacity of the hydraulic units.
10. Use the hydraulic pipe bender only for the purpose it is meant for, and
not for any other purpose.
11. You should not change the valve settings of pressure control.
12. Always make sure that you store the hydraulic pipe in a cool and dry
place when it is not in use. This prevents moisture and formation of
moss on the pipe.
13. Read and understand the instruction manual before using the pipe
bender.
14. In order to ensure performance, make sure that all the shafts are
fitted correctly and the pip rollers are in the right holes.
15. For achieving the right degree of bend, you should ensure that the
pump and valve handle are in the correct position
16. It is always recommended to replace the hydraulic oil every year.
17. While using the high pressure hose, you should make sure that both
the ends are clean otherwise the pipe bender will not operate
properly.
18. Do not take off the nameplates and labels because they include
important safety instructions.
19.The hydraulic pipes come in different shapes and sizes. Thus, it is
required to take the actual equipment into account while following the
aforementioned safety measures.
21
As with all manufacturing and augmenting machinery, metal bending tools must
also undergo risk assessment. Machine safety and general safety rules in
bending and stretching, specific to the equipment you will be using into
consideration.
1. Always wear appropriate and complete Personal Protective Equipment
(PPE) before approaching and operating bending equipment.
2. Before operating the tool for bending, read and understand its instruction
manual, focusing on the machine’s functioning and working principles.
3. Every new operator should be appropriately trained before using the
machine for the first time, preferably by an experienced engineer well-
versed in bending machine safety precautions.
4. File metal burrs properly, and avoid touching metal edges or cuts, even
while wearing gloves.
5. Wet metal sheets should be given extra attention to and handled with the
greatest care. The moisture, mixed with oils and dirt, can result in very
slippery surfaces, making them addled hard to grip and more dangerous
to work with.
6. The work surface should be clean and free of any scrap metal.
7. Paying attention to where your hands are during operation is also vital to
preventing accidents.
8. The machines should be inspected regularly before each operation,
especially before the initial startup.
Summary for the trainer related to the indicative content.
 Safety equipment (PPE): Is the protection that is used by workers to avoid injuries, casualties, life
threatening situations etc.
 Personal protective equipment in bending
 A fire extinguisher: Is an active fire protection device used to extinguish or control small fires, then
steps of using fire extinguishers
 First aid kits: Every person at workplace is responsible for the safety of him/herself and others. Every
business needs to be conscious of potential injuries that could occur. Having a stocked first aid kit is an
essential requirement used to address all of those potential injuries and accidents.
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 Brainstorm about key terms in bending operation
 Group discussions about safety equipment
Practical learning Activity

 Trainees select the PPE related to bending operations according to the
work to be done .
 Fire extinguisher
 PPE
 First aid kits
 Safety precautions
Indicative content 1.3: Identification of material, tools and

equipment
Basically Engineering Materials can be classified into two categories-
1. Metals
2. Non-Metals
Metals
Metals are polycrystalline bodies which are having number of differentially
oriented fine crystals. Normally major metals are in solid states at normal
temperature. However, some metals such as mercury are also in liquid
state at normal temperature. All metals are having high thermal and
electrical conductivity. All metals are having positive temperature
23
coefficient of resistance. Means resistance of metals increases with
increase in temperature.
Examples of metals – Silver, Copper, Gold, Aluminum, Iron, Zinc, Lead,

Tin etc. Metals can be further divided into two groups-
1. Ferrous Metals – All ferrous metals are having iron as common

element. All ferrous materials are having very high permeability
which makes these materials suitable for construction of core of
electrical machines. Examples: Cast Iron, Wrought Iron, Steel,
Silicon Steel, High Speed Steel, Spring Steel etc.
2. Non-Ferrous Metals - All non-ferrous metals are having very low
permeability. Example: Silver, Copper, Gold, Aluminum etc.
Non-Metals
Non-Metal materials are non-crystalline in nature. These exists in
amorphic or mesomorphic forms. These are available in both solid and
gaseous forms at normal temperature. Normally all non-metals are bad
conductor of heat and electricity. Examples: Plastics, Rubber, Leathers,
Asbestos etc. As these non-metals are having very high resistivity which
makes them suitable for insulation purpose in electrical machines.
Other classification of engineering materials:
Engineering materials can also be classified as below:
 Metals and Alloys

 Ceramic Materials
 Organic MaterialsMetals are polycrystalline bodies which are
have number of differentially oriented fine crystals. Normally
major metals are in
Metals and Alloys
solid states at normal temperature. However, some metals such as

mercury are also in liquid state at normal temperature. Pure metals
are having very a low mechanical strength, which sometimes does
not match with the mechanical strength required for certain
applications. To overcome this draw back alloys are used. Alloys
are the composition of two or more metals or metal and non-
metals together. Alloys are having good mechanical strength, low
24
temperature coefficient of resistance. Example: Steels, Brass,
Bronze, Gunmetal, Invar. Super Alloys etc.
Ceramic Materials
Ceramic materials are non-metallic solids. These are made of inorganic
compounds such as Oxides, Nitrides, Silicates and Carbides. Ceramic
materials possess exceptional Structural, Electrical, Magnetic, Chemical
and Thermal properties. These ceramic materials are now extensively
used in different engineering fields. Examples: Silica, glass, cement,
concrete, garnet, Mgo, Cds, Zno, SiC etc.
Organic Materials
All organic materials are having carbon as a common element. In organic
materials carbon is chemically combined with oxygen, hydrogen and other
non-metallic substances. Generally organic materials are having complex
chemical bonding. Example: Plastics, PVC, Synthetic Rubbers et
Material properties
Material properties are physical, chemical, or mechanical components of a

specific product that would determine its functionality and manufacturability.
This would mean that a product’s material properties would specifically define
the capabilities of the products in all aspects.
A. Physical Property of Materials
A material’s physical properties denote the physical state of materials that are
exclusive of their chemical or mechanical components. In particular, these
properties encompass texture, density, mass, melting and boiling points, and
electrical and thermal conductivity. All such physical properties are measurable
or observable.
Physical properties that are used in selecting or differentiating materials.
Density – implies the weight of a material, with higher density rates
implying heavier materials
Melting point – the minimum required temperature for a solid material to
change into liquid
Color – the reflective property of a material
Boiling point – the minimum required temperature for a liquid material to
change into gas
B. Mechanical Property of Materials
A material’s mechanical properties refer to components that react against an
applied load. An essential characteristic of all mechanical properties is their
25
ability to describe the material’s ability to resist deformation. These
mechanical properties determine the scope and limits of a material’s
functionality, as well as establish expected service life or performance. Among
industries, materials are usually classified and identified in terms of such
properties. Common mechanical properties that are considered in a wide array
of materials are:
1. Strength. It is the ability of a material to resist the externally applied forces
without breaking or yielding. The internal resistance offered by a part to an
externally applied force is called *stress.
2. Stiffness. It is the ability of a material to resist deformation under stress. The
modulus of elasticity is the measure of stiffness.
3. Elasticity. It is the property of a material to regain its original shape after
deformation when the external forces are removed. This property is desirable
for materials used in tools and machines. It may be noted that steel is more
elastic than rubber.
4. Plasticity. It is property of a material which retains the deformation
produced under load permanently. This property of the material is necessary
for forgings, in stamping images on coins and in ornamental work.
5. Ductility. It is the property of a material enabling it to be drawn into wire
with the application of a tensile force. A ductile material must be both strong
and plastic. The ductility is usually measured by the terms, percentage
elongation and percentage reduction in area. The ductile material commonly
used in engineering practice (in order of diminishing ductility) are mild steel,
copper, aluminium, nickel, zinc, tin and lead.
6. Brittleness. It is the property of a material opposite to ductility. It is the
property of breaking of a material with little permanent distortion. Brittle
materials when subjected to tensile loads, snap off without giving any sensible
elongation. Cast iron is a brittle material.
7. Malleability. It is a special case of ductility which permits materials to be

rolled or hammered into thin sheets. A malleable material should be plastic but
it is not essential to be so strong. The malleable materials commonly used in
engineering practice (in order of diminishing malleability) are lead, soft steel,
wrought iron, copper and aluminIum.
8. Toughness. It is the property of a material to resist fracture due to high
impact loads like hammer blows. The toughness of the material decreases
when it is heated. It is measured by the amount of energy that a unit volume of
26
the material has absorbed after being stressed up to the point of fracture. This
property is desirable in parts subjected to shock and impact loads.
9. Machinability. It is the property of a material which refers to a relative case
with which a material can be cut. The machinability of a material can be
measured in a number of ways such as comparing the tool life for cutting
different materials or thrust required to remove the material at some given
rate or the energy required to remove a unit volume of the material. It may be
noted that brass can be easily machined than steel.
10. Hardness. It is a very important property of the metals and has a wide
variety of meanings. It embraces many different properties such as resistance
to wear, scratching, deformation and machinability etc. It also means the
ability of a metal to cut another metal.
 Tools
Clamping tools
Clamps are hand tools designed to bind or press two or more objects
together to keep them firmly in place. This is useful when holding or
glueing materials together, for example, wood, paper, plastic, or certain
metals.
There are the following types of clamp devices found:
1. "C" Clamp
2. Vice Clamps
1. "C" Clamp
In its design, there is a frame that is shaped like the English letter 'C' and is a
screw. Clamp devices are also used to hold the tool or a job as main function
They generally feature a movable jaw affixed to an adjustable screw,

while some designs have two screws. Most types are designed to be
used temporarily, however, there are permanent models available. The
below diagram shows some of the different parts:
27
There are different types of clamps and their uses
The table below outlines some of the most common types of clamps and
their applications best suited for.
G/C Clamps
 It gets its name from its shape, which

looks like a capital G – however, it’s
also sometimes referred to as a C
clamp.
 It’s one of the most widely used and
versatile styles. It can be used to clamp
an object to a work surface or two
separate objects together.
 Different styles also have throats with
varying depths, which is the distance
from the screw to the inside edge of
the frame.
 This size of this type generally ranges
from 3″ to 14″.
 Miniature versions are also available,
which start from 1" x 1". Mini clamps
are ideal for modellers and hobbyists.
28
Spring Clamps
 Also called a pinch clamp, this tool has

two grippers, two handles and a spring
pivot which connects the parts together
in the middle.
 This type provides light clamping
pressure, with force only to be applied to
the handles when the mouth needs to be
opened.
 The jaws usually include soft plastic or
rubber pads to protect the object or
material being clamped.
 They’re commonly used in woodworking
and carpentry to hold awkward or
delicate objects; as larger clamps would
be unsuitable. It’s also a good choice for
a range of domestic tasks around the
home.
F Clamps
 The name F clamp comes from its F-

shaped design. It features a long vertical
bar and two smaller perpendicular jaws.
 Its sturdy construction means this tool is
ideal for heavy-duty woodworking.
 This style is available in a range of
different sizes.
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Sash Clamps
 This tool has a flat bar with a fixed jaw,

which can be adjusted with a screw
action. It also has a sliding gripper which
is locked in position along the bar.
 This style is mainly used for jobs
involving larger objects, such as
windows, doors or furniture, and several
are usually needed at one time.
2.Vices
The Vice is used to tightly hold the job while performing operations in
workshops like a filling, cutting, drilling, tapping, dyeing, etc.
Types of Vices
The following are types of vices used in the workshop:
1. Bench Vice
2. Pipe Vice
Tool Makers Vic
3. Tool maker vice
4. Hand vice
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5. Leg Vice
6. Drill vice
7. Pin Vice
See in the figure the different types of vices that are used in the workshop.
Different Types of Vices Used in Workshop
1. Bench Vice
This is a job holding device that is often used to hold the tasks while performing
operations such as sawing, filing, chipping, tapping, external threading, etc.
There are two steel jaws on this vice that are hardened and have grooves on
them.
See in figure parts of a bench vice.
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Bench Vice Parts
Fixed Jaw
Fixed Jaw is always fixed in the bench with the help of a nut and bolt.
A fixed jaw is made with grey cast iron.
Movable Jaw
Movable Jaw moves back and forth according to the size of the job.
Movable Jaw is also made with grey cast iron.
Jaw plates
The jaw has a plate inside, which is fixed by a screw is known as a Jaw plate.
These plates are fitted with cross-cuts, which create a grip on the job.
For making these plates carbon steel's metal is used.

Spindle
The movable Jaw has to consist of a spindle, which is made of mild steel.
The movable jaw moves back and forth only when this spindle rotates.
32
Handle
Handle is fitted with the spindle and then rotates the handle clockwise and
anticlockwise direction then the spindle moves forward and backward.
The handle is made of mild steel.

Box Nut
The nut that the spindle passes through is called the box nut as well as the guide
nut.
Box nut always fits in the fixed jaw.
It is made of cast iron or gun metal.
Points to be Noted While Fixing a Bench Vice
1. The height of the vice should be one meter from the shop floor to the top of
the vice or equal to the artisan's elbow.
2. It is advisable to fix the bench vice with bolts, nuts, and washers above
the top of the bench as it provides good support and strength.
3. It should be at the level and parallel to the vice job work bench and shop
floor. If it is not fixed to level then the material will rub more than one side on
the job.
4. Its fixed job should be slightly out of the end of the work bench.
5. The vice should be firmly fixed. If it is not held firmly, it will vibrate,
affecting the surface finish and precision.
2. Pipe Vice
This type of vice is often used for round shape work and C clamping of pipes,
especially plumbing and locksmith works.
On it, the 'V-shaped groove's jaw is cut, which allows the pipes and cylindrical
bars to be well gripped while performing cutting, threading, etc.
See in the above figure which clearly shows the v-shaped groove's jaw.
It is often fitted well at the end of the bench.
33
3. Tool Makers Vice
This type of vice is used to hold the difficult job which is in a small size while
filing and machining.
It can be swiveled to set the work at any angle.
4. Hand Vice
This vice is used to grip screws, rivets, nails, and other similar materials that are
too small to hold in the bench vice.
Sometimes it is also used to hold thin plates while drilling.
5. Leg Vice
This type of vice is used to perform heavy and rough types of work such
as bending, forging, and chiseling and it can bear heavy work.
6. Drill vice
This is a strong vice with a movable joint. It can be moved forward and
backward by rolling the handle of the movable jaw, this vice is used while
drilling on small pieces.
7. Pin Vice
This vice is used to hold a small diameter of jobs such as pins, needles, etc.
topic: Care and Maintenance of Vices

• The sliding back should not be used as an anvil. The vice should be tightened
only by its handle. Hammer should not be used to obtain more leverage.
• From time to time, the vice should be cleaned and applied to it and check its
looseness. If the jaws become loose, they should be replaced.
• When the vice is not in use, it should be kept loose.

Measuring tools
A measurement is a comparison to a standard.

Measurement is the process or the result of determining the
34
magnitude of a quantity, such as length or mass, relative to a unit
of measurement, such as a meter or a kilogram.
For example: length, width, depth, height, temperature, density etc.
Lecture 1/7
Metrology is the science of measurement.
The following are tools used in measuring

a. RULER
A ruler, sometimes called a rule or line gauge, is an instrument used

in geometry, technical drawing, printing and engineering to measure
distances and/or to rule straight lines.
b. Measuring tape
It consists of a ribbon of cloth, plastic, or metal strip with linear
measurement
markings. It is a common measuring tool. Its flexibility
allows for a measure of great length to be easily carried in pocket or
toolkit and permits one to measure around curves or corners.
A measuring tape is a flexible form of ruler.
35
c. Vernier Caliper
We can measure inside, outside and depth.
It has locknut which is very useful to keep the measurement
permanently.
Reading Vernier Caliper
36
d. Micrometer
The micrometer relies for its measuring accuracy on the accuracy of the
spindle screw thread. The spindle is rotated in a fixed nut by means of the
thimble, which opens and closes the distance between the ends of the spindle
and anvil as shown. The pitch of the spindle thread, i.e. the distance between
two consecutive thread forms, is 0.5mm. This means that, for one revolution,
the spindle and the thimble attached to it will move a longitudinal distance of
0.5mm.
On a 0–25mm micrometer, the sleeve around which the thimble rotates has a
longitudinal line graduated in mm from 0 to 25mm on one side of the line and
subdivided in 0.5mm intervals on the other side of the line. The edge of the
thimble is graduated in 50 divisions numbered 0, 5, 10, up to 45, then 0.
A reading is therefore the number of 1mm and 0.5mm divisions on the sleeve
uncovered by the thimble plus the hundredths of a millimeter indicated by the
line on the thimble coinciding with the longitudinal line on the sleeve.
Part of micrometer
37
Types of Micrometer
The names are based on their application:
A. Outside micrometer
These are typically used to measure wires, spheres, shafts
and blocks.
B. Inside micrometer
Used to measure the diameter of holes.
C. Depth micrometer
Measures depths of slots and steps
38
Reading Micrometer
39
Marking tools
Marking out is the process of transferring a design or
pattern to a work piece.
1. Divider
Divider calipers are used in the
process of marking out suitable
work pieces.
The points are sharpened so that
they act as scribers, one leg can
then be placed in the dimple
created by a center punch and the
other leg pivoted so that it scribes
a line on the work piece's surface,
thus forming an arc or circle.
2. Centre punch
It is usually used to mark the center of a hole
when drilling holes. A center punch forms a large
enough dimple to "guide" the tip of the drill bit.
3. Scriber dot
A scriber is a hand tool used in metalworking to mark lines on work piece prior
to machining. The process of using a scriber is called scribing.
Miscellaneous tools
A tool is any instrument or simple piece of equipment that you

hold in your hands and use to do a particular kind of work. For
40
example, spades, hammers, and knives are all tools. I find the best
tool for the purpose is a pair of shears.
CUTTING TOOLS
Cutting tools: cutting tools are tools used to separate metal into different parts
of metals. in those cutting tools we have;
a. Hand file
Files are cutting tools used to remove/smooth rough and sharp edges from cut
metal. They are also used to file metal to shape or size. For each type of material
there is an ideal tooth form that gives the most efficient cutting action.
Parts of a file
41
1. Point
2. Face
3. Shoulder
4. Tang
5. Length.
6. handle
The features of a file are:
 Length - measured from the point to the shoulder (does not include the
tang).
 Shape or kind - a files name is usually derived from its cross-sectional
shape, eg square, flat, triangular, half round and round (small round are
known as 'rat tails').
 Grade or cut - files are graded according to the size and spacing of cutting
teeth. There are three standard cuts in regular use:
bastard - is a course file for roughing down work to a general shape
where a good finish is not required
second cut - used on hard metals, across narrow surfaces (more teeth
in contact with the work), or for general work to close sizes requiring
a reasonable finish
smooth - produces a very fine finish.
An example of a correctly specified file is: 250mm flat second cut.
Types of files On the basis of shape

1. Flat file
Flat file
 sharpening tools
 cleaning relay contacts
 cleaning painted or rusted surfaces for earthling purposes.
2. Half round file
42
Half round file
 produce both flat and concave surfaces

 cleaning large steel conduits internally
 enlarging cable entry into cubicles etc.
3. Round file
Round file
 for opening up holes and finishing concave surfaces
 filing mounting holes for meters, lamps or switches in component case
 enlarging entries into motor connections boxes, switchboards, mounting
blocks etc.
 slotting mounting holes.
43
4. Square file
Square file
 for making square and rectangular holes

 filing mounting holes for switches in component case
 filing keyways in pulleys, etc
 filing mounting holes for coach bolts.
5. Triangular files
Triangular file
 clearing out square corners and filing acute internal angles greater than 60
degrees
 re-shaping damaged threads on bolts and screws, etc.
6. knife file
Its shape is like the edge of a knife. Its thin edge is about 10° angle. It is used for
filing small grooves and slots whose angle is less than 60°. It is generally used in
the lock industry for making keys.
Classification According to Grade

Following are the different types of file tools according to the basis of the
number of teeth:
44
1. Rough File
In this type of file, teeth are of big size and less in number. It is used for cutting
soft materials because its cutting is rough. Because of rough cutting, it cannot
be used for hard metal.
2. Bastard File
Teeth of this file are comparatively smaller than those of the rough file. It is used
initially to shed metal (through filing) in large quantity.
3. Second-cut File
This is a file of medium grade. In the filler trade, this file is mostly used to bring
the job in the proper size. As compared to the bastard file, filing done with this
file makes the surface plain.
4. Smooth File
This file makes the surface quite plain, in addition to making a job of accurate
size through filing.
5. Dead Smooth File

Its teeth are very close to each other and it rubs off the metal in very little
quantity. It is used for bringing shinning on the job after finishing has been
done.
File handles
 Clamp the work piece as close as possible to the jaws of the vice. Use
protective jaws (Aluminium) to protect the work piece.
 Start with a rough file for removing more material then take a smooth
file to reach a good surface.
 Forward stroke with pressure; Return stroke without pressure.
 Move with the file crosswise to control the area of filing.
 Clean the file from time to time (especially smooth files) with a wire
brush to prevent messy finishes and Keep files dry place.
 Never work with a file without a file grip.
 Make sure that the file grip is properly attached, that it has the right
dimension and that it is not splitted.
 Never subject the file to bending or excessive pressure.
 Store files separately from each other and from other tools.
 Check that the handle is not split and that it fits securely.
45
b. Hacksaw
A hacksaw is a type of hand tool designed specifically for cutting through
materials such as plastic, steel, and other metals. It consists of a frame and a saw
blade as shown below. It is a "U" shaped steel frame with a pistol handgrip and
a saw blade. The frame may be of fixed type to take only one length of blade, or
adjustable to take different blade lengths. It has a wing nut to adjust the tension
of the blade. Saw in a straight line along the marking line.
How to Use a Hacksaw Safely?

As with any other tool, strong focus and attention to detail are key to ensuring
safety and care when using a hacksaw:
 The cutting action is carried on the forward action only. So, the blade must
be mounted with its teeth pointing forward.
 Suitable tension should be applied on the blade to avoid breakage or
loosen.
 Change the blade if some teeth are broken.
 Avoid rapid and erratic strokes of cut.
 Avoid too much pressure.
 Work piece must be held firmly.
 When sawing through reduce pressure on hand hacksaw just before the
work piece separate
How to Change a Hacksaw Blade?
Changing a hacksaw blade is a straightforward process, regardless of whether
you are using a senior or junior model. Below is a handy step-by-step guide
detailing the process:
46
 Depending on the model of hacksaw you have, either apply the fasten-
release mechanism or turn the wing nut to loosen the current blade
 Carefully slide out the current blade
 Insert the fresh blade onto the retaining pins within the handle
 Either tighten the wing nut or reapply the fasten-release mechanism
 Conduct a test cut on a piece of scrap metal to ensure the new blade is
safe and properly secured.
c. Twist drill
A twist drill is a cutting-tool used to produce a hole in a piece of metal or other
material. are rotary cutting tools that normally have two cutting edges and two
flutes which are grooves formed in the body to provide cutting lips, to permit
the removal of chips and to allow coolant or cutting fluid to reach the cutting
action.
How to Use a Drill?

Step 1: Select a Drill Bit
Step 2: Put the Chosen Bit into the Drill
Step 3: Check All Other Settings
Step 5: Drill the Hole
Step 6: Examine the Hole
Step 7: Clean Up
47
d. Chisel
A chisel is a tool with a characteristically shaped cutting edge of blade on its end,
for carving or cutting a hard material such as wood, stone, or metal by hand,
struck with a mallet, or mechanical power. The handle and blade of Most chisels
are made of alloyed tool steels. A chisel must be harder than the piece being
worked.
Classifications of Chisel
 Hot chisel
 Cold Chisel
 Hot Chisel
Hot chisel is used for cutting hot metals in blacksmith’s workshop. There is a
hole in a chisel in which a wooden handle is fixed. Their cutting edge is made at
an angle of 30°. While using this part, it is frequently dipped into water for
making it cold so that its edges remain intact.
48
 Cold Chisel
Cold chisels are generally used in sheet metal and fitter trade workshops. With
cold chisel cutting or chipping of metal can be done when these metals are in
cold condition.
This is available in 4 sides, 6 sides or 8 sides. These are made of high carbon
steel, which contains 0.75% to 1.00% of carbon. Generally, chisel, of 150 mm
length is used. Practically, chisels measurement is known from the width of
chisels cutting edge.
Types of Chisel
Following are the different types of chisel:
1. Flat chisel
2. Cross cut chisel
3. Side cut chisel
4. Round Nose Chisel
5. Diamond point chisel
6. Cow mouth chisel
1. Flat Chisel
In these types of chisel, It is an all-metal chisel used for obtaining a flat surface
on metal by chipping. This chisel is used to cut wires, thin sheets and round rods
etc.
The edge of this chisel is in “V” shape and is flat, which is raised from the centre.
Because of this projected parts, it does not get stuck into the cut surface, while
chipping.
2. Cross Cut Chisel

It is mainly used to cut square slots and channels. Keyway on a shaft is made
with this chisel. Its cutting edge is from 3 mm to 12 mm in width
In order to ensure that this chisel does not get stuck into the grooves and slits
while using it in the grooves and slits, the part behind its edge is made
comparatively thin.
49
3. Side Cut Chisel
Where other types of chisel cannot be used easily, side cut chisels are used. The
keyway and cotter way is cleaned with this chisel.
It is almost similar to the flat chisel but the part which performs the function of
cutting is turned to one side. It is turned at an angle and then forged. Its cutting
angle is generally at and forging angle at an angle.
4. Round Nose Chisel
Its edge is round. It is used for making an oil groove in a bearing and for cutting
slits at corners. Its forging angle is at and cutting angle is of 35 ° to 40 °. In such
jobs where the drill is dislocated at the time of drilling and some substance is
left, the leftover metal is set right with this chisel.
5. Diamond Point Chisel

This is made of good quality steel. Its shape is square and it is tapered. Its edge
is pointed and of the shape of a diamond.
On the basis of its square ends, its measurement is determined. Square corners
and triangle corners are cleaned with it. We can make a groove in plain surface
with this chisel.
6. Cow Mouth Chisel

In these types of chisel, its shape is like that of the broad mouth of a cow. That
is why it is known as cow mouth chisel. Edges of the protruding parts of plain
metal and rivet heads and big round holes are made with it. Its forging angle is
at an angle.
Methods of Using Chisel

Chisel is used for cutting and chipping a thin metal sheet, plate, round rod and
such other material. In fig cutting of a metal plate has been illustrated. The
following points should be kept in mind while using a chisel:
 Accurate marking should be done on the metal to be cut.
 Always hold the chisel properly with your left hand and the hammer in
your right hand.
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 Set the chisel properly on the marked line then strike the hammer on its
head. Before striking the second blow on the chisel, it should be set again.
 While cutting with a chisel we should concentrate on its cutting edge.
 Strike the hammer blow at the centre of the head of the chisel.
Precautions of Using Chisel

 At the time of chipping, we must always use safety goggles.
 Keep your face towards the wall, while chipping.
 If someone is working in your front, you should fix chipping guard at the
rear of the vice so that chips do not hit him.
 The mushroom head chisel should never be used for chipping.
 There should not be any greasy substance on the chisel head and face of
the hammer being used for chipping.
 An extraordinarily long chisel should not be used for chipping.
 While chipping we should keep on applying grease on the edge of the
chisel.
 EQUIPMENTS
HAND HELD BENDING MACHINE

Bending machine is a machine tool used for forming metal plate, sheet metal,
strips, rods, tubes workpieces into different shapes without cutting. A bending
machine is primarily used for forming a bend on the workpiece. In the case of
bending tools, they are classified by the kind of generated bends.
Different types of bending machines:

 Metal sheet bending machine,
 Busbar bending-cutting-punching machine,
 hydraulic and mechanical Profile bending machine,
 Hydraulic hand,
 hydraulic hand/motorized pipe bending machine,
 sheet folding machine,
 sheet metal bending machine,
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 pipe bending machine.
Metal craft bender
Metalcraft is the process of creating or fashioning metal parts and objects. It
gets a bit more complicated as you get into how these parts and objects are
actually created. Hand operated tools for producing decorative scrolls from
metal strips.
Advantage of metalcraft bender

 Easy to Use
 They are extremely safe because they involve no heat, welding or fumes.
 Produces flat consistent scrolls
 No pre-heating of metal required
 Ideal entry level (low cost) scroll formers
 Ensure you have ample work space around the tool to wrap longer lengths
Disadvantages
 Expensive starter fees. Metal fabrication tools are more expensive than
plastic fabrication.
 Post fabrication process. Metal usually needs processes after its
fabrication. Deburring, finishing, and painting follows and these are
considered costlier and time consuming.
 Limited designs. If the metal is molten or viscous, metals are not ideal for
creating advances shapes and geometries.
Universal bender
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The universal bender for simple manual bending of flat, square and round
materials. The tool changer features a simple plug-in system for quick and easily
tooling for a wide variety of different bends. The modular design allows bending
of angles, radii or coils.
Advantages of universal bender
 Modular design
 Wide range of applications
 Includes various bending tools
Disadvantages of universal bender
BEND STOCK:
 Pipe & OD Tube

 Square & Rectangular Tube
 Flat Stock and Bar Stock
 Angle Iron
 Rigid Conduit
 Reinforcing Bar
 Handrail Capping
 Electro Metallic Tube
 T-Bar
BEND FORMS:
 Eye Bolts
 “S” Shapes
 “U” Shapes
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 Angles, Irregular Shapes, Offsets
 Sharp Square Bends
 Rings and Coils
 Square Tube on Section Diagonal, 180 Degrees, or Feed Along
 Angle Iron, Flange-inward, Flange-outward
 Angle Iron, Heel-inward, Heel-outward
 Notched Angle Iron
 Flat Stock, Sideways
 Flat Stock, Edgeways
 Sharp Right Angles
 Large Diameter Rings & Eyes
 Round or Square Eyes
 Ornamental Iron Work
 Scrolls, Lamb’s Tongue, Volutes
Industrial bending machine
1. Sheet metal bending machine
The sheet bending machine is mainly selected for the purpose

of creating a bend inside the metal sheets. The metal pieces
are initially fixed on the clamping device which is known to hold
them during the complete operating process. The nature of this
bending machine is found due to an unknown fact which is that
they are manufactured by using a very high-grade raw
material.
A sheet folding machine is referred to as an instrument which

is used to bend the objects at any particular angle. This profile
of bending machine is referred to as a pipe bending machine as
it is used mainly with an aim to bend the pipe objects. Mainly
this type of machine is found suitable to be used whenever it
comes to any bending objects like a pipe, tube, etc. The profile
bending machines are the ones which are used due to their
highly accurate quality and is preferred amongst most of the
users.
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Types of Sheet Bending Machines
 press brake,
 bending roller,
 shearing,
 power press metal forming.
Press braking, or brake forming: Is a metal deformation process that aligns a

piece of sheet or plate metal along an axis. This is achieved by using a machine
pressing tool (press brake) to clamp the metal piece between a punch and a die
set for prearranged bending. Press brake is a popular metal bending tool with
which metals can casted or bent to different shapes with the help of different
kinds of dies like v-dies, rotary bending dies, hemming dies, curling dies, 90
degree dies, beading dies and many more.
Figure 1:rotary bending die Figure 2:

v-die
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Figure 3:curling die Figure
4:hemming dies
Figure 5:90 degree dies

Two forms of press brake are most popular:
 Mechanical press brake that operates by electric motor
 Hydraulic press brake that uses hydraulic cylinders to empower the
bending process.
bending roller machine: Has also been called rounder and roller machine, which
is universal forming equipment for rolling metal plate into the cylinder, cone,
curved and other shapes. It gets its name because of its process of bending in
which the metal sheet stock is bent by passing it between the two rolls of
machine. the relative position change and rotational motion of the working roll
make the metal sheet produce continuous plastic deformation to obtain the
predetermined shape of the workpiece.
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It is widely used in boiler, wind mills, air conditioning channels, shipbuilding,
petroleum, chemical, metal structure and machinery manufacturing industries.
power press metal forming: Metal can be permanently bent, stretched, and
compressed into complex geometric shapes with a press.
shearing: Is defined as the mechanical cutting of large sheet of metal into

smaller pieces of predetermined sizes. A shearing operation that completes an
entire perimeter is known as blanking, with the resulting workpiece being called
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a blank. bending is defined as the creation of three dimensional shapes out of
two dimensional stock.
Figure 6: hydraulic punching machine

Blanking and punching are fabricating processes used to cut materials into forms
by the use of a die. Major variables in these processes are as follows: the punch
force, the speed of the punch, the surface condition and materials of the punch
and die, the condition of the blade edge of the punch and die, the lubricant, and
the amount of clearance. In blanking, a workpiece is removed from the primary
material strip or sheet when it is punched. The material that is removed is the
new workpiece or blank. Punching is a fabricating process that removes a scrap
slug from the workpiece each time a punch enters the punching die.
Figure 7. punching and blanking

Applications of Sheet Bending Machines
 Different metal forming jobs like curling, angled shaping, bending,
bottoming, seaming, hemming etc.
 Bending roller can be used for bending and straightening sheet metal
covers and parts of boiler tanks, pressure vessels and converters
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 shearing tool like mechanical and hydraulic shearing can be employed for
cutting sheet metal to size out of a larger stock.
 Large sheets, bars and plates of metallic and non-metallic materials can
be easily and accurately cut into different shapes with the help of shearing
machine.
 sheet bending machine, called power press is the best metal bending
equipment with which most accurate metal cutting, bending and shaping
tasks can be executed for bulk industrial processes.
2. Pipe bender
Pipe benders are commonly used in the plumbing trade for bending and shaping
a variety of pipes to make them suitable for a wide range of applications and
fitting locations. Pipe benders come in a range of sizes for specific pipe
dimensions and materials, such as copper and steel. Not all pipe and tube
benders can accommodate all pipes, so it is important to know the outer
diameter (mm or inch) of the pipe or tube you are working with is key when
buying or using a pipe bender.
Form bound bending procedures like “press bending” or “rotary draw bending”
are used to form the work piece into the shape of a die. Straight tube stock can
be formed using a bending machine to create a variety of single or multiple
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bends and to shape the piece into the desired form. These processes can be used
to form complex shapes out of different types of ductile metal tubing.
How does a pipe bender work?
To use a pipe bender, the user pulls the handles of the bender to force the pipe
around the former (shoe). The pipe is sandwiched between the former and the
roller, so is forced to take the former’s shape when pressure is exerted by the
user pushing the handles together. Pressure must be exerted to force the pipe,
but it is important that the pipe retains most of its shape to keep it in good
working condition.
The larger or thicker the pipe that needs to be bent, the larger the pipe bender
will be Longer handles mean that more force can be exerted onto the pipe. The
shoe must fit the pipe exactly, to help prevent any deformation by holding the
pipe in place. Former sizes are categorized by pipe diameter size so it easy to
match a former to your pipe.
To accurately make a bend to the correct angle, you must first measure where
on the pipe you wish to bend and how far around the former it needs to be bent.
Often the former has angle markings to help with this.
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3. Hydraulic press bending machine
Hydraulic Press - Hand/Power Operated Hydraulic Press Machine

A hydraulic press machine works on Pascal’s principle that states that pressure
remains constant all over the closed system. The system comprises of two
pistons of which one acts as a pump. This pump applies a small amount of
mechanical force on a region of small cross-sectional area. On the other hand,
the second piston has comparatively larger area that is able to produce
substantial amount of mechanical force. When a small amount of force is
applied on the smaller piston, a pressure is created that is transmitted to the
hydraulic fluid that delivers it to the large piston. They are used for varied
applications, such as- forging, clinching, molding, blanking, punching, deep
drawing, and metal forming operations.
The presses developed at our facilities boast of having a rigid structure in order
to perform accurate operations. They also consist of chevron seals and bronze
strip to ensure leak proof operation. The specially designed Power Pack Unit,
that powers the hydraulic press, comprise of- Oil Breather (Hydro line), Oil Level
Indicator (Hydro line), Suction Strainer (Hydro line), Gear pump (Bosch Rexroth),
Flexible Coupling (Jecssk Tech), Electric Motor (Crompton / Siemens), Hand
Lever operated Direction Control Valve (Bosch Rexroth), Pressure Gauge (Air
Master), Return Line Filter (Hydro line), Oil Tank (without oil), Internal & External
Pipe Line etc.
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4. Hydraulic and mechanical profile bending machine
 Types of bending
Cold bending
Cold bending is a metal processing process at room temperature (not

using any added heat). Cold bending methods often rely on sheer physical
force to help bring the metal to its final shape while hot bending methods
use careful heating to reduce the force required.
1. Air bending
Air bending means the sheet metal part is in the air when the bend is
performed. Please look into the below picture. It shows that only at two-
point is the part touching the die. When the punch is coming in contact
with the part, it is still in the air. That is why it is called air bending. In
the case of air bending V shape and U, shape parts only can be
fabricated.
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Since the air bending is done on the air, and there is minimal surface
contact between the part and die surface, it is tough to control the angle.
Often in air bending, the angle variation is up to +/- 0.5 degrees. But In
air bending, you can choose a wide variety of angles from the same too
set
The bending pressure required is less in the case of air bending. The
reason being, the punch does not necessarily need to touch the die
surface. The inner radius of the bend is not dependent on the die radius
at all. However, it is dependent on the punch radius.
The spring back is more in air bending as the bend is done on the air.
Due to the spring effect, the spring back is more in air bending. Below is
a table that shows the ideal V width, Inner radius, and angle precision of
air bending, bottoming, and coining.
Here T is the sheet metal thickness
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Angle
Bending Method V Width Inner Radius
Accuracy
+/- 0.45
Air Bending 12T-15T 2T-2.5T
degree
+/- 0.15-0.30
Bottoming 6T-12T 1T-2T
degree
+/- 0.10
Coining 4T-6T 0-.5T
degree
Advantages Of Air Bending
Wide range of bending angle selection possible

The less bending force is required
Comparatively cheaper tooling
Less maintenance
A wide variety of parts can have bends
Disadvantages Of Air Bending
Difficult to control angle. More angle variations

Precision parts not possible
2. Bottoming
Bottoming is more or less similar to air bending, but the sheet metal
parts get more contact surface than air bending. Due to this, more
precise bending is possible. The angle of the spring back is also very
less. The less bending force is required in bottoming compared to air
bending.
In bottoming U shape bend is not possible. Only V shape bend can be

created.
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Advantages Of Bottoming
More precise bend than air bending

Less spring back
Less bending force than air bending
Disadvantages Of Bottoming
No U shape bend possible

Separate tooling required for separate angles
Not suitable for precise parts
3. Coining
Coining is a bending process that gives the most precise bend. The
bending force is almost 6-30 times more than the air bending. The
finished part takes the shape of the die opening, including the radius.
The punch also goes all the way down to the die to create accurate
bends.
The bend angle tolerance is coining process is about +/- .10 degree and
the inner radius can go down all the way up to 0.5T.
Coining
Advantages Of Coining
Precise bend possible

Very fewer angle variations
Almost negligible spring back
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Disadvantages Of Coining
Higher tooling cost

More bending force
High maintenance
4. Wiping or Edge Bending
Wipe bending or wiping or edge bending requires a pressure pad to hold the
sheet metal parts against the die. The punch then moves up and down to bend
the edge of the sheet metal. Wipe bending is much faster than any other bending
process, but there is always a risk of scratches because the tool is moving over
the surface directly.
If the tool radius is very less, it can even damage the sheet instead of
bending it. Wipe bending is often used to compensate for the spring
back of the already bent part using air bending or bottoming, or coining.
Wipe bending
5. Folding
In folding, clamping beams hold the longer side of the sheet. The beam
rises and folds the sheet around a bend profile. The bend beam can move
the sheet up or down, permitting the fabricating of parts with positive and
negative bend angles. The resulting bend angle is influenced by the
folding angle of the beam, tool geometry, and material properties. Large
sheets can be handled in this process, making the operation easily
automated. There is little risk of surface damage to the sheet.
6. Rotary bending
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Rotary bending is similar to edge bending, but instead of a punch, rotary
bending has freely moving cylinders with a final formed shape cut into it.
The rotary cylinder comes in contact with the sheet metal at two-point or
edges of the cut, and when it rotates further, it creates the bend.
7. Three-point bending
Three-point bending is a newer process that uses a die with an adjustable-
height bottom tool, moved by a servo motor. The height can be set within
0.01 mm. Adjustments between the ram and the upper tool are made
using a hydraulic cushion, which accommodates deviations in sheet
thickness. Three-point bending can achieve bend angles with 0.25 deg.
precision. While three-point bending permits high flexibility and precision,
it also entails high costs and there are fewer tools readily available. It is
being used mostly in high-value niche markets.
Bending a piece of metal by placing the specimen on two supports and then ap
plying a load on it between the supported ends as shown on the following
figure .
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8. Roll Bending
The roll bending process induces a curve into bar or plate workpieces.
There should be proper pre-punching allowance.
In this method, the bottom V-die is replaced by a flat pad of urethane or

rubber. As the punch forms the part, the urethane deflects and allows
the material to form around the punch. This bending method has a
number of advantages. The urethane will wrap the material around the
punch and the end bend radius will be very close to the actual radius on
the punch. It provides a non-marring bend and is suitable for pre-painted
or sensitive materials. Using a special punch called a radius ruler with
relieved areas on the urethane U-bends greater than 180° can be
achieved in one hit, something that is not possible with conventional
press tooling. Urethane tooling should be considered a consumable item
and while they are not cheap, they are a fraction of the cost of dedicated
steel. It also has some drawbacks, this method requires tonnage similar
to bottoming and coining and does not do well on flanges that are
irregular in shape, that is where the edge of the bent flange is not
parallel to the bend and is short enough to engage the urethane pad
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9. Compression Bending
Joggling also known as joggle bending, is an offset bending process in
which two opposite bends with equal angles are formed in a single action
creating a small s-shape bend profile and an offset between the unbent
face and the result flange that is typically less than 5 material
thicknesses. Often the offset will be one material thickness, in order to
allow a lap joint where the edge of one sheet of material is laid on top of
the other.
The following image is joggle in sheet metal (at top of image) and a hand
joggling tool
10.Stretch
Stretch bending is a very intricate process that has evolved in many

ways over the years.
Stretch forming is part of metal forming where the metal is bent or

“stretched” to create perfectly shaped parts. A machine called a stretch
press usually performs this process, shaping multiple different types of
metal.
When used in manufacturing, stretch bending helps to create automotive

parts. These parts are often stronger as well as lighter than ever before,
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as a result of using very strong materials and working with higher quality
machines.
Hot bending
Hot bending generally refers to different types of induction bending. Hot

bending is highly effective at bending metals because they are fast,
precise, and make few errors.
 Induction bending
Induction Bending is a precisely controlled and efficient piping bending
technique. Local heating using high frequency induced electrical power is
applied during the induction bending process. Pipes, tubes, and even
structural shapes (channels, W & H sections) can be bent efficiently in an
induction bending machine. Induction bending is also known as hot
bending, incremental bending, or high-frequency bending. For bigger pipe
diameters, when cold bending methods are limited, Induction bending of
pipe is the most preferable option. Around the pipe to be bent, an induction
coil is placed that heats the pipe circumference in the range of 850 – 1100
degrees Celsius.
The following steps are performed for induction bending of pipe or

pipeline system:
The pre-inspected pipe or pipeline to be bent is placed in the

machine bed and clamped hydraulically.
Around the pipe, induction heating coils and cooling coils are
mounted. To ensure uniform heating, the induction coil can be
adjusted with a 3-plane movement.
By adjusting the radius arm and front clamp, the required bend
radius can be fixed. There is one pointer to display a correct
degree of turning.
Arc lengths are marked on the pipe. The pipe can be moved slowly
whilst the bending force is applied by a fixed radius arm
arrangement.
Once everything is set as required, hydraulic pressure, water level,
and switches are inspected and then the induction bending
operation is started.
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Upon reaching the required temperature range, the pipe is pushed
forward slowly at a speed of 10-40 mm/min, and the operation is
stopped when the specified bend angle and pre-determined arc
length is reached.
Just beyond the induction coil, the heated pipe material is
quenched using a water spray on the outside surface of the pipe.
In the next step, the induction bend is removed and sent for
inspection and measurement of tolerances.
The final step for the induction bends is the use of post bend heat
treatments for stress relieving, normalizing, etc.
Fig. 1 : Typical Induction Bending Process
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The major advantages of induction bending are:
Lower risk of wall thinning and deformation of the cross-section

Thin-walled pipes can easily be bent.
Less costly and available faster than traditional components.
Uniform hardness and thickness.
Smooth flow due to large radii reducing friction, wear, and pump
energy.No pipe wrinkles.
Only a straight pipe is required for induction bending.
Precise bending radius and angle.
Diverse bendings: square pipe, flat bar, I-beam, H-beam, channel
section, etc.
Topic : Induction (Hot) Bending vs Cold Bending
The main differences between Induction bending or Hot bending and Cold
Bending are listed below in a tabular format:
Induction Bending / Hot Bending Cold Bending
Heat Input is a must in induction or hot

No added heat
bending
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Fast Process as no heating &
Slow Process
cooling involved
Better control Less control
Highly efficient complex types of

Simple machines
machinery are used for hot bending.
Not suitable for large pipe

The hot bending Process is efficient for
diameters. Cold bending is limited
larger pipe diameters
to smaller diameter piping only.
Induction bending is a Costly process Cold bending is not expensive.
Normally no wrinkling on the pipe High probability of wrinkling on

surface. the pipe surface
Required force in hot bending is normally Physical Force requirement in cold

less bending is comparatively more
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Summary for the trainer related to the indicative content (key notes
using bullets such as ticks etc)
 Material are categorized into metal and non-metal

 Metal also is classified into ferrous and non- ferrous
 Tools used for holding are called clamping tool
 Tools used for separating materials into pieces are called cutting tools
 Two forms of press brake are most popular are Mechanical press brake that
operates by electric motor and Hydraulic press brake that uses hydraulic
cylinders to empower the bending process
 ……………………………
 ………………………………..
 ……………………………….
 Brainstorming about the material tools and equipment

 Group discussion cold and hot bending

 Trainer select activities related to types of bending
 Material classification
 Material properties
 Clamping tools
 Measuring tools
 Marking tools
 Miscellaneous tools
 All hand held bending machine
 All industrial bending mahine
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Indicative content 1.3: Pre-operation activities for bending equipment
Working principles
The hydraulic bending machine includes a support, a workbench and a clamping
plate. The workbench is placed on the support. The workbench includes a base
and a pressure plate. The base is connected by a hinge and a clamping plate.
The base is composed of a housing, a coil and a cover. In the recess of the seat
shell, the top of the recess is covered with a cover plate.
When in use, the wire is energized to the coil, and the energization generates a
gravitational force on the pressure plate to realize the clamping of the thin plate
between the pressure plate and the base. Because the bending machine adopts
electromagnetic force clamping, the pressing plate can be made into a variety of
workpiece requirements, and the workpiece with side walls can be processed.
The bending machine meets the needs of various workpieces by replacing the
mold of the bending machine.
Metal bending is a process, which with the help of plastic deformation, changes
the shape of sheet metals and tubes. What is plastic deformation? It is a process
in which a material undergoes certain irreversible changes because of the forces
applied to it. In certain types of bending such as tube bending and sheet
bending, a number of ways can be implemented to deform the metal. Sheet
metal is considered to be one of the most versatile metals. This post will explain
some safety tips that you need to take into account while using a sheet metal
bending machine.
1. Maintenance
The technical meaning of maintenance involves functional checks,
servicing, repairing or replacing of necessary devices,
equipment, machinery, building infrastructure, and supporting utilities in
industrial, business, and residential installations.Over time, this has come
to include multiple wordings that describe various cost-effective practices
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to keep equipment operational; these activities occur either before or after
a failure.
Lubrication
Lubrication extends the life your equipment, allowing friction-prone parts to
move smoothly with less wear. Lubricants bring other benefits depending on the
equipment, including longer service life, better temperature regulation and
stronger materials protection. The importance of lubrication maintenance is
clear: neglect will lead to failures. Small gaps can lead to bigger failures - 40%
of all bearing failures can be tied to just poor lubrication. Wear and tear due to
inadequate lubrication on parts even this small adds up, with a single bearing
failure potentially requiring full shutdown.
Before creating your plan, you need to know the current risks and strengths in
your lubrication strategy. Start with the steps or plan you currently follow for
lubrication, and highlight areas that might be forgotten or neglected. If your
existing plan meets most of your lubrication needs, you may only want to
modify it to reach more equipment. If your plan is completely missing the mark,
it may be time to start over with a new plan.
Cleaning
Cleaning is the process of removing unwanted substances, such as dirt,

infectious agents, and other impurities, from an object or environment.
Cleaning is often performed
for aesthetic, hygienic, functional, environmental, or safety purposes.
Cleaning occurs in many different contexts, and uses many different
methods. Several occupations are devoted to cleaning.
Cleaning is broadly achieved through mechanical action

and/or solvent action; many methods rely on both processes.
 Washing, usually done with water and often some kind

of soap or detergent
o Pressure washing, using a high-pressure stream of water
o Wet cleaning, methods of professional laundering that avoid the
use of chemical solvents
 Abrasive blasting, typically used to remove bulk material from a
surface, may be used to remove contaminants as well
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 Acoustic cleaning, the use of sound waves to shake particulates
loose from surfaces
o Ultrasonic cleaning, using ultrasound, usually from 20–400 kHz
o Megasonic cleaning, a gentler mechanism than ultrasonic
cleaning, used in wafer, medical implant, and industrial part
cleaning
 Carbon dioxide cleaning, a family of methods for parts cleaning and
sterilization using carbon dioxide in its various phases
 Dry cleaning of clothing and textiles, using a chemical solvent other
than water
 Flame cleaning of structural steel, with an oxyacetylene flame
 Green cleaning, using environmentally friendly methods and products
 Plasma cleaning, using energetic plasma or dielectric
barrier discharge plasma created from various gases
 Sputter cleaning, performed in a vacuum by using
physical sputtering of the surface
 Steam cleaning, in both domestic and industrial contexts
 Thermal cleaning, in industrial settings,
involving pyrolysis and oxidation
 Ultraviolet germicidal irradiation, which destroys microorganisms;
used extensively in the medical and food industries
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Topic 2. Methods of cleaning
a. Dusting: the term “dust” is already familiar, but how dust should be
removed?
If any surface is wiped with a piece of dry cloth (duster), it carries the loose
dust with it and the process is known as dusting. This should be done with a
clean soft cloth or soft brushes.
b. Removal of dirt: this is the process of removing dirt on tools and equipment.
sometimes mopping alone is not sufficient to remove dirt.
Such surfaces are then scrubbed with the help of a yard (bamboo) broom along
with plenty of water.
Eventually the dirt loosens and is carried off by water. In case of tougher stains
or dirt, detergent may be added to the water.
c. Chemical spraying: Chemicals was mostly sprayed on farms, around the
home, in gardens, parks and reserves to control pests and diseases, now it can
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also be used in workshops for the purpose of cleaning most equipment and/or
tools used there.
During chemicals spraying, care must be taken to avoid hazards because

droplets are produced that can remain suspended in air and may be carried by
wind away from the target area.
Maintenance of sheet metal bending machines and use can not only improve
work efficiency but also greatly increase the service life of industrial machinery.
The key is to avoid safety accidents, Sheet Metal Bender Machine damage, and
personal injury. More and more excellent metal plates factories realize the
importance of sheet metal bending equipment maintenance.
To ensure the sheet bending machine working principle, we have strengthened

the training of metal bending machine repair and maintenance. We have
common methods of maintenance or technical support for metal bending
machinery.
2. Lubrication
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Lubrication reduces friction and allows moving machine parts to slide smoothly
past each other. An automatic lubrication system has many advantages
compared to manual lubrication. Find out how it results in extended equipment
life, reduced wear and smaller maintenance bills. Lubrication is a crucial element
in the efficiency and life-expectancy of any rotating equipment. Most of time
bearing failures are the result of improper lubrication.
Selecting the appropriate lubrication solution can help reduce premature

bearing failures and increase machine uptime, productivity and energy
efficiency. Lubricants form a film between the metal surfaces of machine parts
to avoid metal-to-metal contact and to keep the machine running efficiently.
Manual lubrication calls for the intervention of a technician with a grease gun or
similar traditional lubrication tool. This lubrication method provides quite a few
shortcomings such as increased machine downtime, high maintenance costs and
inconsistent lubrication (too much, too less or not frequently enough).
An automatic lubrication system is one that provides your equipment with the
right amount of lubricant at the right time and in the right place – usually while
the machine is in operation. It replaces a conventional lubrication system and
results in extended equipment life, reduced wear and smaller maintenance bills.
3. Cleaning
The lower surface of Hydraulic bending machines to ensure bending accuracy

(quarterly); Keep the working table clean, remove the upper and lower molds,
wipe with a cloth, no oil pollution, and no yellow gown. the surface of the lower
die holder is clean and free of oil and foreign matter.
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Adjustment
We can adjust the bending force in two ways:
 Adjust the tensile strength of the plate in the numerical control system.
 Adjust the DA value in the system Settings
Bending machine is sheet metal processing equipment with high requirements

on strength. Different CNC systems, different adjustment methods. Users adjust
according to the specific system.
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And now we use the bending equipment is almost CNC Press Brake. Pressure
input and bending angle are controlled by CNC system. This requires that we
must have a good understanding of the calculation of bending pressure and
press brake tonnage. So, you can do a detailed calculation based on the need in
production.
Correct Use of CNC Bending Machinery
1. First, turn on the power
Switch on the control panel before starting the oil pump. So you can hear the
pump turning. At this point, the machine does not run.
2. Stroke adjustment
Pay attention to adjusting stroke! Must test before bending! When the upper die
runs down to the bottom, there must be a gap of plate thickness. Otherwise, it
will cause damage to the mold machine. Stroke adjustment is divided into:
electric quick adjustment and manual fine-tuning.
3. Bending notch selection
Generally, the width of the notch is 8 times the thickness of the plate. Such as:
bending 4mm plate, need to choose about 32mm notch.
4. Adjustment of rear retainer
Generally, there are electric quick adjustment and manual fine adjustment. The
method is the same as the plate shears.
5. Step on the foot switch to start bending
CNC bending machines and plate shears are different. The foot switch can be
released at any time. Release it and the machine stops. Step again and continue
running.
Shenchong manufactures high-quality sheet metal press brake machine. SC

machine offers high precision, need low energy consumption and requires less
hydraulic fluid than European competitors. Welcome to consult us about press
brakes and metal shears!
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 Metal bending is a process, which with the help of plastic deformation,

changes the shape of sheet metals and tubes
 The technical meaning of maintenance involves functional checks,
servicing, repairing or replacing of necessary devices,
equipment, machinery, building infrastructure, and supporting utilities
in industrial, business, and residential installations
 Brainstorming about working principles of bending machine

 Group discussion about maintenance
Trainees select the maintenance activities related to bending

operations
 Working principles of bending machines

 Lubrication
 Cleaning methods and technics
 Adjustment of bending machine
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Learning out come 1.1 : formative assessment
Mix different assessment instruments/tools for triangulation and

relevancy of assessment
Written assessment
 Assessment instruments/tools
True or false questions
Multiple choice
Essay: Question with short responses and Open ended questions
Case studies
Practical assessment
 Task to be performed with performance checklist/quality product

checklist
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Learning outcome 2: Carry out bending operation
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Learning outcome 2.
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Indicative contents
1.1. Interpretation of drawing
1.2. Setting up bending equipment
1.3. Bending the work piece
Duration: 20 hours
Learning outcome 2 objectives :

1. produce cutting list of bending works
2. select the bending machine
3. set bending machine
4. fix and shape the work piece
5. produce bend product
Resources
- PPE, - Rulers, - Chalks,
- Bending machines, - books, - Pens,
- white board, - calculator, - Papers,
- benches, - clamping tools, - Pencils,
- angle grinder, - video tutorials, - marker-pen,
- anvil, - brush, - flip chart,
- shear machine, - measuring and - paints,
- cut-off machine, marking tools and - oil and grease,
- material handling common tools - Sheet Metal,
equipment, (hummer, screw - Pipes,
- bending machine, driver, bending - Bars.
- air compressor. pliers, spanners,
wrench, Allen key
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cloths rugs, wire
brushes, bloom,
spray gun.
 Trainees should have basic skills on workplace arrangement
Indicative content 2.1: Interpretation of drawing
Technical drawings are very important, even if they aren’t used as the main
source of drafting and designing anymore. With CAD software, some might
consider technical drawings outdated and useless. That’s not the case, however.
These drawings are still very important.
Inventing starts with technical drawings. A successful, quality object can’t be
adequately built or manufactured without the assistance of one.
A technical drawing is the instruction manual for something that needs to be
built or manufactured. It is exact in offering a visual representation of what it’s
intended to be, in detail. It clearly communicates specifications of the idea. Once
the technical drawing is created, the manufacturer has a concise idea of how to
create the item in physical form.
Developing prototypes relies heavily on this form of drawing, especially when
things are mass produced. It helps streamline the manufacturing process. The
precise details of the technical drawing helps builders create objects without
errors, delays or other costly issues. This, alone is the most important duty of
the drawings.
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 Cutting list element
A cutting list, which can also be known as a material list, bill of materials,
or schedule of materials is simply a listing of all the parts that will be
required to construct a project.
Cutting lists can also include information about the joinery to be done to
the pieces noted, and what type of wood or material they are to be made
from. Without an accurate cutting list, you will lose efficiency and
accuracy and be more likely to waste timber.
Cutting list and components lists are used to help you plan for and order
materials required, they also help in working out the best use of materials
available. Components lists can be generated easily in PCB wizard through the
Bill of Materials function.
Example cutting list.
Part. No. Width Length Thickness Material

1 2 of 125mm 175mm 9mm Ply.
2 1 ..... ...... ...... .....
etc..
Part: can be a name or a number that you have allocated to a particular part of
your design.
No. (how many) I need a top and bottom, both the same size so that would be
2.
Width. Normally the shortest of the sides.
Length. The longest side.
Thickness. the last remaining dimension.
Material. What the part is to be made of, could be woods, plastics or metals.
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
 A cutting list, which can also be known as a material list, bill of
materials, or schedule of materials is simply a listing of all the parts
that will be required to construct a project.
hnical drawings are very important, even if they aren’t used as the main
source of drafting and designing anymore
 Brain storming about cutting list

 Groups discussion about elements of cutting list
Trainees select practical activities related to the abovementation

tops
 Cutting list elements such as:

1. Serial number
2. Material
3. Specification
4. Quantity
5. Dimension
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Indicative content 2.2: Setting up bending equipment
How to Use a Bending Machine?

Use bending machines to bend metal pipe and tubing. Different bending
machines exist to handle each of these two different types of metal conduit.
Hand-held machines clamp to a work surface for stability and bend thin metal
tubing. Larger, heavy-duty hydraulic machines connect to air pumps to increase
torque and bend thick metal pipe. Each machine usually comes equipped with
an angle-measure to ensure the proper degree of bend. Identify whether tubing
or pipe needs bending, and chose the appropriate bending machine for the job.
Hand Held Bending Machine

Step 1: Clamp the bending machine to a flat work surface so that it is upright
and secure.
Step 2: Rotate the upper, short handle to a position above the bender.
Step 3: Open the latch to make way for insertion of the tube. Insert the tube into
the tube groove.
Step 4: Close the latch around the tube to hold it in place. Lower the upper, short
handle until the roll dies rest against the tube and the angle-measure is aligned
at zero degrees. Close the latch firmly to clamp down tightly on the tube.
Step 5: Press the upper, short handle down until the zero on the roll-support
aligns with the desired bend degree on the angle-measure.
Step 6: Rotate the upper, short handle upward to release the newly bent tube.
Hydraulic Bending Machine

Step 1: Connect the hydraulic bending machine to an air compressor or hydraulic
pump. Pull back the brass coupling ring on the compressor or pump's hose and
slide it onto the machine's connector. Release the ring to secure the connection.
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Step 2: Set the machine's groove to receive the diameter of pipe for bending. Do
this by moving the machine's pin to the appropriate setting.
Step 3: Slide the pipe into the machine's groove so that the point of the intended
bend rests atop the zero point of the angle-measure.
Step 4: Turn on the compressor or pump.
Step 5: Unlock the machine's safety lock and allow the machine to move and
bend the pipe until the indicator on the angle-measure reaches the desired
degree of bend.
Step 6: Close the safety lock on the bender to stop the bending process. Turn off
the compressor or pump.
A bar bending machine

A bar bending machine is a type of engineering steel bar processing
equipment that is simple to operate and has good performance and reliability.
It is mainly composed of transmission parts, stands, enclosures, and electrical
appliances. It is capable of bending steel bars from 0 to 180 degrees and is widely
used in the construction of roads, bridges, tunnels, and other giant projects. The
machine comes in both automatic and manual versions
How Does It Work

The bar bending machine consists of an electric motor, a coupling, a circular
plate, a worm gear drive, and an extended shaft. An electric motor transmits
power to a gearbox, which decreases speed and increases torque. A circular
plate bends the bar using this gearbox. It can usually bend bars in the range of 6
mm to 16 mm. The auto reverse and auto forward mechanism is also powered
by an electrical system that consists of a contactor and limit switch. The bar can
be readjusted due to the spring back effect.
A bar bending machine is made up of the following parts, that are visible to its
user:
 Moving bending roller (This roller basically pushes the bar in the bending
direction. It has normally diameter less than the central roller. It rotates
around the central roller).
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 Center roller (This is the roller, around which the bar rotates. It itself remains
stationary. It is usually made of aluminum or steel with a very high strength
grade. Usually, its surface is also lubricated to aid in the bar bending process).
 Adjustable stopper.
 Pilot lamp (This light lamp indicates that power is being supplied to the
machine) Main switch.
 Angle setter (dial type or there is a circular disc with holes all around its
circumference. You can either set the angle by a dial or put a pin in the
respective hole. Note that each hole usually represents an angle. Normally
there is the only option available for the angle setter).
 Operation button On/Off
 Angle stopper (Left & Right)
 Emergency stop button
 Plug-in for foot switch or some other switching on mechanism.
 Roller set
 Foot Operated Switch (Usually it is a button which when pushed by your feet
starts the machine’s operation).
How to Operate It
 The correct rollers should be selected and set for the bars to be bent.
 Connect the electrical power cord to an appropriate outlet
 Place the bar between the center roller and the bending roller on the
machine surface.
 Make sure the bar is parallel to the front edge of the machine by adjusting
the stopper.
 The pilot lamp should be lit when the main switch is turned on.
 Make a test bend and set the angle. Adjust the angle setter slightly right
or left if the bent angle is not exactly right.
 Adjusting and presetting the angle: For example, if you wish to make a
stirrup, which have normally 4 bends at 90 and 2 bends at 135 degrees,
you can preset the angles.
 Set the angle setter to 135°, then tighten the right angle stopper to lock
the angle.
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 Position the angle setter at 90°, then tighten the left angle stopper to lock
it in place
 Set the angle setter to 135 degrees. Press the operation button to make
your first bend.
 Set the angle setter to 90 degrees and slide the rebar to the desired
length. Press the operation button to complete the second bend.
 Duplicate the same angle each time by locking in the angle stoppers.
 Activate the foot switch or operation button.
 When the bend has been completed, the moving bending roller returns
to the start position.
 If the machine has to be stopped in an emergency, press the emergency
stop button or release your foot from the foot operated switch. When the
roller returns to its original position, the machine will automatically
restart.
After the use of machine follow this maintenance schedule, which will keep your
machine in good and running condition.
 It is recommended that you grease the visible gears and pinions at least
once a month.
 You should also check the carbon brushes for wear and damage.
 Replace worn brushes with new ones if necessary.
 Before starting the operation, make sure there are no loose nuts and
bolts.
 Remove all metal dust, dirt, oil, and other residue adhering to the machine
surface after operation.
 Remove the side cover from the bender(how to make a bender) and tilt
the machine to one side to allow the metal dust to fall out.
 Ensure that you blow out any remaining dirt and dust with compressed
air before using the tool again (wear safety goggles to prevent debris from
blowing into your eyes).
 Dies positioning
The Bend Die is a tool, a mold, which allows tubes to be bent around it and
defines the results shape of the bent tubes. The choice of Bend Die depends on
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the parameters of the bent tube (OD, CLR, DOB) and on the bending machine.
These parameters have a major impact on the size and shape of the bend die.
The size of the groove will depend upon the outside diameter (OD), the center
line radius (CLR) and the maximum degree of bend (DOB).
Topic: Basic positioning of bending machines
CNC bending machines generally use a back gauge to position the work piece.
The basic principle is that during the bending process, prepared bending
program first. The work piece shape is input into the machine tool, and the
position of the work piece bending line is automatically calculated by the
machine tool. The CNC system controls the servo motor, and the two back
gauges are moved to the bending positioning position by the high-precision
screw nut pair. The operator only needs to align the positioning edge of the
work piece with the back gauge of the bending machine to complete the
positioning process. At this time, the middle line position of the bending
machine die is the bending line of the work piece. The state of the work piece
during positioning is shown in figure-1.
Figure-1 work piece position
Limitations of the bending machine positioning device
It is found in production that when using the back gauge positioning for CNC
bending machines. If the size of the positioning edge of the processed work
piece and the back gauge is too short, it is difficult to align the work piece with
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the back gauge during positioning (See Figure 2). A slight left-to-right deviation
of the work piece will cause inaccurate positioning. Which will cause problems
such as excessive work piece scrapping or uneven bending edge dimensions.
Operators need to repeatedly align to ensure the first-time forming effect. But
the effect is often Not ideal, seriously affecting production efficiency and
product quality.
Figure 2 Positioning of narrow and long work pieces
Positioning optimization of narrow and long work piece machining

Structure of positioning optimization device
Based on the consideration of the limitation of the positioning device of the

CNC bending machine. A designed positioning optimization device that can be
used for the CNC bending machine (Figure 3). The back plate is used for tight
positioning with the side of the bending machine die. The locking block is used
to cooperate to lock the entire device on the bending machine die. The front
plate is used to install the screw. The locking screw is used to fix the movable
locking block to the lower die of the bending machine. The positioning top plate
is used for work piece positioning.
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Figure 3 Positioning optimization device
 Use bending machines to bend metal pipe and tubing. Different bending
machines exist to handle each of these two different types of metal
conduit. Hand-held machines clamp to a work surface for stability and
bend thin metal tubing. Larger, heavy-duty hydraulic machines connect to
air pumps to increase torque and bend thick metal pipe
 The Bend Die is a tool, a mold, which allows tubes to be bent around it and
defines the results shape of the bent tubes.
 Brainstorming about setting of different bending machine about within

group
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Trainees select practical activities related to dies positioning,

mounting bending tools and positioning the work piece.

 Dies positioning
 Mounting bending tools
 Positioning the work piece
Indicative content 2.3: Bending the work piece
Methods of bending
Compression bending
Compression bending is slightly more complicated. The tube is clamped against
a stationary bend former and the pressure die follower sweeps the tube around
the bend former to form the bend.
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The process
The workpiece, in this case a tube pressed by a pressure bar [1] against the fixed
form block [2]. The wipe shoe [3] is pressed against and drawn along the radius
of the block so as to bend the tube along its contour by plastic deformation.
Sometimes a bending core [4] is used but it’s usually done without it, thus giving
an oval cross section in the bent area.
Rotary bending
Rotary draw bending is a cold bending method where the member is clamped
to a rotating bend die and drawn around the bend die. The tailing tangent is held
against the bend die by a pressure die, and the bend die rotates until the desired
geometry is formed. Rotary draw bending is commonly used to form small
radius bends in smaller-size round, square and rectangular HSS members.
Specific tooling is required for each member size, shape and bend radius;
therefore, this method is best suited for projects requiring many identical
bends. This bending method is primarily used in the machine and parts
industry
- steel bar bending machine
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A bar bending machine is a type of engineering steel bar processing
equipment that is simple to operate and has good performance and reliability.
It is mainly composed of transmission parts, stands, enclosures, and electrical
appliances.
It is capable of bending steel bars from 0 to 180 degrees and is widely used in
the construction of roads, bridges, tunnels, and other giant projects. The
machine comes in both automatic and manual versions
A bar bending machine is made up of the following parts, that are visible to its
user:
1. Moving bending roller (This roller basically pushes the bar in the bending
direction. It has normally diameter less than the central roller. It rotates
around the central roller)
2. Center roller (This is the roller, around which the bar rotates. It itself
remains stationary. It is usually made of aluminum or steel with a very
high strength grade. Usually, its surface is also lubricated to aid in the
bar bending process)
3. Adjustable stopper
4. Pilot lamp (This light lamp indicates that power is being supplied to the
machine)
5. Main switch
6. Angle setter (dial type or there is a circular disc with holes all around its
circumference. You can either set the angle by a dial or put a pin in the
respective hole. Note that each hole usually represents an angle.
Normally there is the only option available for the angle setter)
7. Operation button On/Off
8. Angle stopper (Left & Right)
9. Emergency stop button
10.Plug-in for foot switch or some other switching on mechanism.
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11.Roller set
12.Foot Operated Switch (Usually it is a button which when pushed by your
feet starts the machine’s operation).
Roll bending
Roll bending, sometimes spelled roll forming, is a metal forming process

in which sheet metal is progressively shaped through a series of bending
operations. The process is performed on a roll forming line in which the
sheet metal stock is fed through a series of roll stations. Each station has
a roller, referred to as a roller die, positioned on both sides of the sheet.
The shape and size of the roller die may be unique to that station, or
several identical roller dies may be used in different positions. The roller
dies may be above and below the sheet, along the sides, at an angle, etc.
As the sheet is forced through the roller dies in each roll station, it
plastically deforms and bends. Each roll station performs one stage in the
complete bending of the sheet to form the desired part. The roller dies are
lubricated to reduce friction between the die and the sheet, thus reducing
the tool wear. Also, lubricant can allow for a higher production rate, which
will also depend on the material thickness, number of roll stations, and
radius of each bend. The roll forming line can also include other sheet
metal fabrication operations before or after the roll forming, such as
punching or shearing.
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Roll Forming Line
Mandrel tube bending
Mandrel Bending Tooling
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Forming principle for tube during RDB: (a) mandrel-free bending; (b)
mandrel bending
The purpose of using a mandrel when bending tube is to prevent the tube from
flattening and to prevent wrinkles and kinks. To achieve this, the mandrel is held
in a fixed position, and the tube is pulled over it. The tube stretching process is
localized on the outer radius of the bend, and the material is work-hardened to
retain its shape and not flatten. The material stretching is done on the forward tip
of the mandrel. This force, acting on the mandrel tip, supports the inner radius of
the bend, holding it firmly into the bend die groove.
The 5 Necessary Components for Mandrel Bending
The mandrel, or mandrel assembly, consists of a mandrel body, mandrel nose

insert, a mandrel link or insert link, mandrel screw, and (if needed) a ball
subassembly. The mandrel is the part of the rotary-draw tube-bending process to
maintain the shape of the tube as it sets into the arc of the bend.
The mandrel is the tooling component that provides support to the inside of the
tube. Its primary function is to prevent the tube from buckling and necking.
Many different variations of mandrels exist. The required style and material
depend on the outside diameter (OD) and wall thickness (WT) of the tube being
bent. The simplest design style is the plug mandrel, and the most complex
design style is the ball mandrel. The ball mandrel is designed to internally
support the tube beyond tangent and depending on the number of ball segments,
throughout the entire bend.
The bend die is the primary tool forming the tube to produce the desired bend
radius. This is the form against which the tube is clamped and then drawn
around to produce the bend. The essential specifications of a bend die are the
outside diameter and the bend radius of the tube to be bent.
The wiper die keeps the tube from wrinkling during the bending process. A
wiper die is required when the tube’s resistance to compression is high.
A clamp die clamps the tubing material against the bend die as it rotates to form
the bend. There are two specifications of primary importance in a clamp die;
Length and cavity texture, which are related to each other. The shorter the
clamp, the rougher the cavity surface must be to maintain the force of the grip
on the tube. Serrations, knurling, and carbide impregnation roughen the cavity
surface which improves the clamp die’s grip upon the tube.
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A pressure die holds the tube against the bend die under constant pressure at a
tangent and follows the tube through the bend. The follower type of pressure
travels forward during the bending process, and almost all modern rotary draw
bending machines are equipped with this type of pressure.
On most bending machines, two settings control the operation of the pressure
die: direct pressure and assist pressure. To reduce drag on the point of bend,
direct pressure must be kept to the minimum necessary to hold the tube without
it separating from the bend die cavity.
Roll-bending is a process whereby we obtain cold process deformation with a

wider bend radius that theoretically can range from 5 times the cross-section to
infinity. To achieve this process, the equipment used consists of roll-bending
machines.
Roll bending machine has also been called rounder and roller machine, which is
universal forming equipment for rolling metal plate into the cylinder, cone,
curved and other shapes. According to the principle of the three-point forming
circle, the relative position change and rotational motion of the working roll
make the metal sheet produce continuous plastic deformation to obtain the
predetermined shape of the workpiece.
It is widely used in boiler, shipbuilding, petroleum, chemical, metal structure and

machinery manufacturing industries.
The following is the working principle drawing of symmetrical 3-roll bending

machine.
 Forms of bends
Offset
An offset consists of two bends:
1. The first bend should change the direction the conduit is going.
2. The second should reverse that direction change. The result is a
rather "Z" shaped piece of conduit, as shown in the pictures below.
Offset bends are important for many everyday applications such as

hinges, fasteners, chassis, and even electrical conduits. But the process
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of creating an offset can be complicated and time consuming.
Because offset bends are often too close together to be achieved with
standard press brake tooling, many sheet metal fabricators and
engineers turn to expensive offset tooling to get the precise forms
required.
But what if we told you we’ve got a trick for forming custom offset
bends?
And what if we told you that trick will save you from paying for yet
another custom offset tool?
At approved Sheet Metal, we’re happy to share our secret for creating
offset bends using the standard tooling most sheet metal shops like ours
already have. Why? Because being the BEST is about always finding
ways to help our customers succeed.
How to Create Sheet Metal Offsets without Custom Tooling
To determine whether or not you need custom offset tooling for your
part, first ask yourself: what’s more important, offset height or offset
angle?
If offset height and angle are equally important for the part, then we
recommend a custom offset tool. If, however, the offset height is more
important than the offset angle, then we can achieve the bend you
need by creating what’s called a “lazy offset.”
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A lazy offset is an easy alternative solution when a part needs a specific
height but doesn’t necessarily need a strict 90-degree offset angle.
Here’s how we do it at our precision metal fabrication shop:
Step 1: We make sure we have the right tool.
We calculate for the right V opening size by multiplying the offset tool
height x 1.414.” Then, we select the appropriate tool by checking this
chart.
Step 2: We set the press brake to how hard we want it to come down on the piece
of metal.
We adjust the press brake tonnage according to the offset height you
want to achieve. If you want a .2” offset, for example, we would use a
.25” die but not press down as hard.
Step 3: We manually stop the press brake to create the desired angle.
This step is as simple as it sounds: we run the press then manually stop
it at the desired angle to create the part that you’ve designed.
Yes—lazy offsets are that easy to make. . . when you work with the right
precision metal fabrication shop!
Here is the standard offset gaps you can use for designing your bends.
But the team at Approved Sheet Metal is always happy to calculate and
create offsets for you as well!
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Elbow
https://makepipingeasy.com/miter-elbow-or-miter-bend-design-calculations/
Curve bend
Arc is a part of a curve. An arc can be a portion of some other curved shapes like
an ellipse but mostly refers to a circle.
Arc Length Formula
Arc length formula is used to calculate the measure of the distance along the
curved line making up the arc (a segment of a circle). In simple words, the
distance that runs through the curved line of the circle making up the arc is
known as the arc length. It should be noted that the arc length is longer than the
straight line distance between its endpoints.
Formulas for Arc Length
The formula to measure the length of the arc is –
Arc Length Formula (if θ is in degrees) s = 2 π r (θ/360°)
Arc Length Formula (if θ is in radians) s=ϴ×r
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Denotations in the Arc Length Formula
 s is the arc length

 r is the radius of the circle
 θ is the central angle of the arc
Example Questions Using the Formula for Arc Length
Question 1: Calculate the length of an arc of tube , if the radius of an arc is 8 cm

and the central angle is 40°.
Solution:
Radius, r = 8 cm
Central angle, θ = 40°
Arc length = 2 π r × (θ/360°)
So, s = 2 × π × 8 × (40°/360°)
= 5.582 cm
Practice Questions Based on Arc Length Formula
1. What would be the length of the arc formed by 75° of a circle having the
diameter of 18 cm?
Offset
Offset tooling comes in two varieties: upspring (or upsweep) and horizontal. The
upspring tool is used to form two bends that are too close together for
conventional forming methods. The horizontal offset tool is designed to offset
the material by one material thickness. To determine the appropriate offset tool
for a given job, subtract the material thickness from the outside dimension of
the specified offset. The resulting number is the offset depth as measured from
the material surface.
An offset bend is a style of bend that is built independently of the 90° stub and
the Back to Back bend and is an important bend to know when running conduit.
It is common to shift the conduit a certain distance while continuing to run
parallel in the same direction as the pre-shift portion of the conduit.
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Formula for Determining the Length of
Material to Form a 90° Bend
In the following examples the following abbreviations will be used:

C = Circumference
R = Radius
D = Diameter
π = 3.142
2.1 Parts of a Circle Relevant to Pipe Bending
When bending a pipe to any radius it should be remembered that you are
constructing part of a circle.
The parts of a circle relevant to a pipe bending are:
 The circumference - the outer rim of the circle.
 The radius - a straight line from the centre of the circle to the
circumference.
 The diameter - a straight line going from one side of the
 circumference to the other passing through the centre. The diameter is
twice the length of the radius
 Every circle has 360°, as shown below.
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Example 1
Calculate the total length of pipe to be heated to bend a pipe through 90° to a
radius of 75mm.
To carry out this calculation we must find the length of the circumference and
divide it by 4:
If R = 75mm
Then D = 150mm
C=πD
Therefore: C = 3.142 X 150mm
C = 471mm
Length of pipe to be heated = 471 ÷ 4 = 117.75
Which can be written as 118mm.
Example 2
Calculate the total length of pipe to be heated to bend a pipe through 180° to a
radius of 150mm.
divide it by 2:
If R = 150
Then D = 300mm
C=πD
C = 943mm
Length of pipe to be heated = 943 ÷ 2 = 471.5
Example 3
Calculate the total length of pipe required to bend a pipe through 90° to a
radius of 50mm.
divide it by 4:
If R = 50
Then D = 100mm
C=πD
C = 314.2mm
Length of pipe required = 314 ÷ 4 =78.5
110
Arc length formula is used to calculate the measure of the distance

along the curved line making up the arc (a segment of a circle). In
simple words, the distance that runs through the curved line of the
circle making up the arc is known as the arc length. It should be noted
that the arc length is longer than the straight line distance between its
endpoints.
 Brainstorming about Formula for Determining the Length of

Material to Form a 90° Bend calculation within groups
 Group discussion about Arc length calculation

 Group discussion about form of bend
 Brainstorming on method of bending
Trainees selected practical activities related to Determining the Length of

Material to Form a 90° Bend and arc length
111
 Methods of bending
- Compression bending
- Rotary bending
- Steel bar bending
- Roll bending
- Mandrel bending
 Form of bending
- Offset
- Elbow
- Curve bend
- Twist bend
 Calculation related to arc length
Please mix different assessment instruments/tools for triangulation and

Written assessment
Multiple choice
Case studies

checklist
112
Learning outcome 3: Perform post-operation activities
Learning outcome 3. Perform post-operation activities
113
Indicative contents
1.1. Finishing bent product

1.2. Maintaining bending machine
1.3. Storing
1.4. Reporting
Duration: 10hours
Learning outcome 1 objectives : (Performance criteria in

affirmative form)
1. finish bent product
2. maintain bending machine
3. report the work
Resources
- PPE -Rulers -Chalks
-bending machines - dies - Pens
-white board -calculator- - Papers
-benches - cutting tools- - Pencils
- angle grinder clamping tools - marker-pen
- anvil - paint brush- - flip chart
-shear machine -measuring and marking -paints
tools and common tools
-cut-off machine - oil and grease
(hummer, screw driver,
pliers, spanners, -video aid
wrench, Allen key cloths -projector
114
-material handling rugs, wire brushes,
equipment bending bloom, spray gun.
machine
-air compressor.
 rules and regulation related to workplace should be respect.
Indicative content 3.1: Finishing bent product
 Finishing bent product
 Heat treatment
Heat treatment is the process of heating and cooling metals, using specific
predetermined methods to obtain desired properties. Both ferrous as well as
non-ferrous metals undergo heat treatment before putting them to use.
115
Over time, a lot of different methods have been developed. Even today,
metallurgists are constantly working to improve the outcomes and cost-
efficiency of these processes.
For that they develop new schedules or cycles to produce a variety of grades.
Each schedule refers to a different rate of heating, holding and cooling the
metal.
These methods, when followed meticulously, can produce metals of different

standards with remarkably specific physical and chemical properties.
The Benefits
There are various reasons for carrying out heat treating. Some procedures
make the metal soft, while others increase hardness. They may also affect the
electrical and heat conductivity of these materials.
Some heat treatment methods relieve stresses induced in earlier cold working
processes. Others develop desirable chemical properties to metals. Choosing
the perfect method really comes down to the type of metal and the required
properties.
Common Heat Treatment Methods
There are quite a few heat treatment techniques to choose from. Every one of
them brings along certain qualities.
The most common heat treatment methods include:
Annealing, Normalizing, Hardening, Ageing, Stress relieving, Tempering,

Carburization
Annealing
In annealing, the metal is heated beyond the upper critical temperature and
then cooled at a slow rate.
Annealing is carried out to soften the metal. It makes the metal more suitable
for cold working and forming. It also enhances the metal’s machinability,
ductility and toughness.
116
Annealing is also useful in relieving stresses in the part caused due to prior cold
working processes. The plastic deformations present are removed during
recrystallisation when the metal temperature crosses the upper critical
temperature.
Metals may undergo a plethora of annealing techniques such as

recrystallisation annealing, full annealing, partial annealing and final annealing.
Normalising
Normalising is a heat treatment process used for relieving internal stresses

caused by processes such as welding, casting, or quenching.
In this process, the metal is heated to a temperature that is 40° C above its
upper critical temperature.
This temperature is higher than the one used for hardening or annealing. After
holding it at this temperature for a designated period of time, it is cooled in air.
Normalising creates a uniform grain size and composition throughout the part.
Normalised steels are harder and stronger than annealed steel. In fact, in its
normalised form, steel is tougher than in any other condition. This is why parts
that require impact strength or need to support massive external loads will
almost always be normalised.
Hardening
The most common heat treatment process of all, hardening is used to increase
the hardness of a metal. In some cases, only the surface may be hardened.
A work piece is hardened by heating it to the specified temperature, then

cooling it rapidly by submerging it into a cooling medium. Oil, brine or water
may be used. The resulting part will have increased hardness and strength, but
the brittleness increases too simultaneously.
Case hardening is a type of hardening process in which only the outer layer of
the work piece is hardened. The process used is the same but as a thin outer
layer is subjected to the process, the resultant work piece has a hard outer
layer but a softer core.
This is common for shafts. A hard outer layer protects it from material wear.
When mounting a bearing to a shaft, it may otherwise damage the surface and
117
dislocate some particles that then accelerate the wearing process. A hardened
surface provides protection from that and the core still has the necessary
properties to handle fatigue stresses.
Induction hardening
Other types of hardening processes include induction hardening, differential

hardening and flame hardening. Flame hardening, however, may result in
a heat affected zone that is created once the part is cooled.
Ageing
Ageing or precipitation hardening is a heat treatment method mostly used to

increase the yield strength of malleable metals. The process produces
uniformly dispersed particles within a metal’s grain structure which bring about
changes in properties.
Precipitation hardening usually comes after another heat treatment process

that reaches higher temperatures. Ageing, however, only elevates the
temperature to medium levels and brings it down quickly again.
Some materials may age naturally (at room temperature) while others only age
artificially, i.e. at elevated temperatures. For naturally ageing materials, it may
be convenient to store them at lower temperatures.
Stress Relieving
Stress relieving is especially common for boiler parts, air bottles, accumulators,
etc. This method takes the metal to a temperature just below its lower critical
border. The cooling process is slow and therefore uniform.
This is done to relieve stresses that have built in up in the parts due to earlier
processes such as forming, machining, rolling or straightening.
Tempering
Tempering is the process of reducing excess hardness, and therefore

brittleness, induced during the hardening process. Internal stresses are also
118
relieved. Undergoing this process can make a metal suitable for many
applications that need such properties.
he temperatures are usually much lower than hardening temperatures. The

higher the temperature used, the softer the final work piece becomes. The rate
of cooling does not affect the metal structure during tempering and usually, the
metal cools in still air.
Carburisation
Case carburisation
In this heat treatment process, the metal is heated in the presence of another
material that releases carbon on decomposition.
The released carbon is absorbed into the surface of the metal. The carbon
content of the surface increases, making it harder than the inner core.
 Surface protection
119
Surface finishing involves cleaning surfaces which have become
unsightly, rusty or otherwise aged or worn as a result of external
factors, and restoring them as far as possible to their original
condition.
Afterwards, the best course of action is to protect the treated
surface immediately against renewed dirt, damage or ageing.
Performing the two steps in one saves you both time and money.
Find out here about surface finishing and protection products:
1.EDGE-GUARD
EDGE-GUARD is the ideal edging material for metal, wood, glass

and certain plastics.
The extruded strip is pre-coated internally with a heat-sensitive
adhesive, and is easily applied to external or internal radii as well
as straight edges.
When cool, EDGE-GUARD is bonded permanently to the edge to
be protected.
The pre-coated strip permits a clean and rapid installation.
2. GALVATRON
GALVATRON is a new scientific compound of pure powdered
zinc (96%), epoxy resins and other components.
Applied to ferritic metals and aluminium, it forms a strong
but also flexible film of metallic zinc, which provides good
resistance to corrosion, thanks to electrochemical action,
even when the covering is used or scratched.
There is an essential difference between GALVATRON and
paint. Paint and primers protect by the formation of a
‘layer’. In contrast, GALVATRON protects against corrosion
through a galvanizing function between the iron and zinc.
Stated electrochemically, as a result of the influence of
steam and oxygen, the zinc powder works like an anode and
the covered metal like a cathode. Cathodic
protection. The corrosion only influences the zinc and not the
metal base. When a layer of paint is damaged, the corrosion is
produced even below the undamaged layer.
120
When the GALVATRON covering is damaged, the non-soluble
alkaline products reproduce zinc salt. In other words, the
damaged part re-establishes itself and thus constantly protects
the surface against corrosion, which is the reverse of paints and
primers.
GALVATRON is a product that saves money and is essential in
each industry, workshop and garage for different applications.
 Stops rust, protects against corrosion.

 The microsmall zinc parts (95%) provide a galvanic
protection. The epoxy resin improves and maintains the
unique adhesion on all metals.
 Can be painted over easliy.
 Flexible, does not drip.
 Repairs warm galvanization.
3. HEAT STOP
HEAT STOP is a gel which protects surfaces and components
from heat damage during soldering, brazing and welding. It
acts like a "protective shield" and prevents e.g. a release of
seals, parts stretch significantly less, sensitive components
are protected.
HEAT STOP protects painted and finished surfaces from
discoloration due to the use of torch systems. The specially
gelled formula sticks to any surface without dripping or
running off.
121
HEAT STOP reduces the deformation of surfaces and materials
such as plastic, rubber, sealants and gaskets.
 Protects against heat damage

 Reduces danger of fire to most surrounding surfaces
 Unique gelling formula, easy to use
 Clear, leaves no residues, easy to clean
 To be used on surface which can be washed off with water
 Self-evaporation within 24-48 hours
 Non-toxic, transparent, odorless
4. INDUCARE DRY CLEAN
INDUCARE DRY CLEAN is a product that cleans, polishes and

protects in one single application, without water.
INDUCARE DRY CLEAN is very safe to use and does not scratch
treated surfaces.
122
 Superfast application: spray, spread, polish, ready.
 Saves up to 60% of your time: washing, rincing, shammying
not necessary.
 Result without streaks, deep glaze.
 No scratching, even on dirty surfaces.
 Does not become white on synthetic materials.
 Silicone-free.
 Maintaining bending machine

 Preventive maintenance
Lubrication
Cleaning
Content/Topic 1. Cleaning techniques

a. Grinding
Grinding is an abrasive machining process that uses a grinding wheel as the cutting
tool to remove some amount of material on a given workpieces in order to
123
obtainthe desired sizes and shape of the finished product
b. Filing
Filing is a machining process that uses a file as the cutting tool to remove some
amount of material on a given workpieces in order to obtain the desired sizes and
shape of the finished product
c. Brushing
Brushing is a process of removing some amount of material on a given workpieces

by using wire brush in order to obtain the desired sizes and shape of the finished
product
124
d. Polishing
Polishing is a finishing process for smoothing the workpieces’ surface using an

abrasive and a work wheel
Topic : Cleaning tools and materials

Following are some of the equipment and tools which you will come across during
the process of cleaning.
125
a. Brush: It is used for cleaning the working surface prior to welding and general
cleaning of the weldment. Most of the brushes used for cleaning tools and
equipment in workshops are wire brushes.
b. Cloth rugs - these are made of soft absorbent cloth such as flannel. Dry polishing
cloth helps to clean and shine the polished surfaces by rubbing them vigorously.
c. Mops: a tool for cleaning floors made of a bundle of cloth or yarn or a sponge
fastened to a long handle, something that looks like a cloth or yarn mop. this
process is known as mopping and is generally coarser than a duster. Mopping is
mostly done on floors.
d. Soapy water: is a mixture of powder detergent in water used for cleaning

equipment and/or workplace.
e. Compressed air: air which is compressed by air compressor then perform

cleaning process, an air compressor is a pneumatic machine used for cleaning tools
and even heavy machinery in the workshop.
126
Indicative content 3.2 : Bending machine is properly maintained
according to the maintenance manual
 Storing
Topic: Care and storage procedures of tools, equipment and materials
Regardless of the location in which you store your tools, you may want to consider
storing them in a sand/oil mixture, which can be used for years. This can be done
by using a five-gallon bucket filled with sand and a half gallon of mineral (or motor)
oil. Shovels, hoes, pitchforks, etc., can all be stored in this mixture. These buckets
may be used year after year as long as they are kept away from rain. Simply add oil
each year as needed.
In addition to buckets containing a sand/oil mixture, other methods can be used to

preserve your tools. Below are some more tips for storing your gardening
equipment:
Put clean tools in an empty plastic container, such as a trashcan. Also, consider
hanging tools up on a rack or installing brackets to hold and organize your
equipment. Hardware stores offer strong adhesives to hold tools that will not
leave residue when you decide to remove the bonding agents. Both of these
methods will keep your tools off of the ground, away from dirt and bugs, and out
from underfoot.
Gloves should always be kept in a closed container so your hand will not get eaten
by visitors when you put them on. Consider using an empty coffee can, ice cream
tub or a popcorn tin that can also hold random excess nuts and bolts that may be
lying around. Space bags that use vacuum suction to remove air can also be a nice
place to protect gloves when storing them for a longer period of time.
Special care should be taken to store larger machines such as lawn mowers and big
power tools in accordance with manufacturer directions.
Hoses should be drained before storage. Also, roll up hoses to prevent them from
getting cracked or being damaged during moves.
Put chemicals and fertilizers in a locked case away from children and pets.
Gardening tools should be kept in a cool, dry place, such as a garage or storage
unit. This will help keep your valuables away from humidity.
127
Overall, be sure to take care of your tools to ensure their longevity and efficiency.
Inspect your tools each season and take the proper steps, some of which are
mentioned above, to keep them in good condition.
 Tools
 Equipment
 Product
Indicative content 3.3 : Performed work is correctly reported as per

reporting templates
 Reporting
 Preparation of technical report
 ………………………………. (example: ask trainees to brainstorm about……….

within groups)
 ……………………………….
 ……………………………….
…………………………………… (Example: Trainees in pair perform

…………………)
128
Indicative content 3.3: Storing
 Tools
 Equipment
 Product
 ……………………………….
……………………
 ………………………………..
 ……………………………….
 ………………………………. (example: ask trainees to brainstorm about……….

within groups)
 ……………………………….
 ……………………………….
129
…………………………………… (Example: Trainees in pair perform

…………………)
Please mix different assessment instruments/tools for triangulation and

Written assessment
Multiple choice
Case studies
130
checklist
References:
 https://www.woodwardfab.com/blog/safety-measure-take-using-hydraulic-
pipe-
bender/#:~:text=Always%20remember%20to%20keep%20your,should%20o
nly%20use%20hydraulic%20oil.
 chrome-
extension://efaidnbmnnnibpcajpcglclefindmkaj/http://weldinginst.yolasite.com/reso
urces/Measuring%20&%20Marking.pdf)
 https://en.wikipedia.org/wiki/Bending_(metalworking)
 https://learnmechanical.com/parts-types-working-applications-hydraulic-press-
machine/
 https://www.chevingtonmetaltools.com/

 https://www.ricardo-barbosa.com/sheet-metal-forming-process-
advantages-and-
disadvantages/#:~:text=The%20cons%20are%20high%20labor,vary%20dep
ending%20on%20part%20size.&text=Drawing%20process%20is%20for%20
production,high%20tooling%20and%20equipment%20costs.
 https://www.iqsdirectory.com/articles/hydraulic-press/power-
press.html#:~:text=A%20power%20press%20machine%20is,required%20sh
ape%20of%20the%20components.
 https://www.machinemfg.com/3-roll-bending-machine-working-principle-
rolling-process/
 https://machinetools.bhavyamachinetools.com/features-of-a-sheet-
bending-machine/
 https://www.wonkeedonkeetools.co.uk/pipe-benders/how-does-a-pipe-
bender-work
 https://amtil.com.au/press-brake-fundamentals-the-three-types-of-
bending/#:~:text=In%20bottom%20bending%20or%20'bottoming,imprint%
20or%20thin%20the%20metal.
 https://www.rapiddirect.com/blog/how-to-bend-sheet-metal/
 https://www.china-machining.com/blog/sheet-metal-bending/
 https://www.tecnocurve.com/blog/2018/07/11/bending-and-roll-bending-
the-metal-tube/
131
 https://www.albinaco.com/bending-methods/hot-bending
 https://www.unifiedalloys.com/blog/pipe-bends
 https://www.sciencedirect.com/topics/engineering/serial-number
 https://www.sciencedirect.com/topics/engineering/working-drawing
 https://byjus.com/question-answer/what-are-physical-quantities/
 https://www.sterlingtoggle.com/products/die-positioning-system
 https://bystronic.com/usa/en-us/news/190502-rules-press-brake-tool-
selection
 https://bystronic.com/usa/en-us/news/190502-rules-press-brake-tool-
selection
 https://www.harsle.com/Bending-workpiece-process-problem-prevention-
id8332244.html
 https://www.machinemfg.com/3-roll-bending-machine-working-principle-
rolling-process/
132

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RQF LEVEL 3

MODULE CODE: MATBO 301

Learning outcome 1 objectives : ................................................................................ 3

Theoretical learning Activity ............................................................................... 11

Theoretical learning Activity ............................................................................... 74

Theoretical learning Activity ............................................................................... 83

Learning out come 1.1 : formative assessment .................................................. 84

Learning outcome 2 objectives : .............................................................................. 87

Theoretical learning Activity ............................................................................... 90

Practical learning Activity ............................................................................... 90

Theoretical learning Activity ............................................................................... 97

Practical learning Activity ............................................................................... 98

Practical learning Activity ............................................................................. 111

Learning out come 2.1 : formative assessment ................................................ 112

Learning outcome 1 objectives : (Performance criteria in affirmative form) ........ 114

Theoretical learning Activity ............................................................................. 128

Practical learning Activity ............................................................................. 128

Practical learning Activity ............................................................................. 130

Learning out come 3.1 : formative assessment ................................................ 130

1. RTB: Rwanda TVET Board

2. TVET: Technical and Vocational Education and Training

3. RQF: Rwanda Qualification Framework

4. AC: Alternative Current

5. DC: Direct Current

6. CNC: Computer Numerical Control

7. OSSB: Outside Setback

8. ISSB: Inside Setback

9. BA: Bending Allowance

Learning outcome 1 objectives :

Indicative content 1.1: Introduction to Bending operation

Bending is a flexible process by which many different shapes can

Bending is done using Press Brakes. Press Brakes normally have

Bent radius: Bending radius is the smallest possible bending radius

K factor: K-Factor is a ratio that represents the location of the

Initial Length = Leg Length 1 + BA (bending allowance) + L

Initial Length = (Flang Length 1 - OSSB) + BA + (Flang Len

Initial Length = Flang Length 1 + Flang Length 2 - (2*OSSB

Bend Deduction = 2*OSSB - BA

Understanding the Bend Allowance and consequently the Bend

Initial Length = Leg Length 1 + BA + Leg Length 2

Outside setback: Understanding the Outside Setback of the workpiece

 Advantages and disadvantages of bending

 Other advantage is that the design of the machinery

 High speed, high production efficiency and low energy consumption.

 some process variants are sensitive to variations in material properties.

 The relatively large number of set-ups and the geometrical changes

There was a time when automotive companies and suppliers

 Agriculture industry: It is useful for Vineyard accessory, Agricultural

Summary for the trainer relate to the indicative content

Bending is a flexible process by which many different shapes can be produced.

Theoretical learning Activity

 Brainstorm about key terms in bending operation

Points to Remember (Take home message)

 Bending equipment safety tips

1. PPE (personal protective equipment)

Personal protective equipment (PPE) refers to anything worn by an employee

The Occupational Safety and Health Administration (OSHA) states that

Below is a list of essential PPE that might be required within a manufacturing

There are three industrial classes of hard hats:

 Class A: Provides impact and penetration resistance and some protection

This PPE includes:

 Protective leggings: Typically made from leather or aluminized rayon,

3. Earplugs and Earmuffs