SHEET METAL

WORK,
BENCH WORK
AND FITTING
TEAM
●
●
SAMARTH - 2019UME5560
TRISHAL - 2019UME5561
● UTKARSH - 2019UME5563
● AKSHAT - 2019UME5564
● SACHIN - 2019UME5565
● PIYUSH - 2019UME5570
● SAHIL - 2019UME5594
● SOUVIK - 2019UME5598
● SUDHANSHU – 2019UME5600
● ABHISHEK - 2019UME5614
 01
INTRODU
02
SHEET
METAL
CTION
What is sheet metal
work,bench work and
Tools and Equipments
WORK
Sheet Materials

03
fitting? Operations

BENCH
WORK AND
FITTING
Filling,Sawing,Chipping
Scraping,Cutting with
die and tools
 01
INTRODUC
TION
 SHEET
METAL
Sheet metalWORK
work has its own
significance in the engineering
work.Many products, which
fulfil the household needs,
decoration work and various
engineering articles are
produced from sheet metals.
Common examples of sheet
metal work are hoopers,
canisters, guards, covers, pipes,
hoods, funnels, bends, boxes etc.
Such articles are found less
expensive, lighter in weight and
in some cases sheet metal
products replace the use of
castings or forging.
BENCH WORK
AND FITTING
The bench work and fitting plays
an important role in engineering.
Although in today's industries
most of the work is done by
automatic machines which
produces the jobs with good
accuracy but still it (job) requires
some hand operations called
fitting operations.
The work carried by hand at the
bench is called bench work and
fitting is the assembling of parts
and sometimes removing the metal
for assembling. It may or may not
be carried out at bench.
02
SHEET
METAL
WORK
 SHEET
METAL
TOOLS
AND
EQUIPME
NTS
TRAMMEL POINTS
Trammels or trammel points
are the sockets or cursors that,
together with the beam, make
up a beam compass.A beam
compass is a compass with a
beam and sliding sockets or
cursors for drawing and
dividing circles larger than
those made by a regular pair of
compasses. The instrument can
be as a whole, or made on the
spot with individual sockets and
any suitable beam.
 CHISELS
A chisel is a tool with a characteristically
shaped cutting edge (such that wood
chisels have lent part of their name to a
particular grind) 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 some types of chisel are made
of metal or of wood with a sharp edge in it.
Chiselling use involves forcing the blade
into some material to cut it. The driving
force may be applied by pushing by hand,
or by using a mallet or hammer.
 SNIPS
Snips, also known as shears,
are hand tools used to cut
sheet metal.It is similar to a
pair of scissors.Most
commonly used snips are
straight snips and curved
snips.Straight snip is used
for straight cutting while
curved snip is used for
circular cuts.
 STAKES
Stakes are the sheet metal
anvils used for bending,
seaming or forming by using
a hammer or a mallet.They
work as supporting tool as
well as the forming
tools.They are made in
different sizes and shape
depending upon the job
requirement.
Soldering iron
These are used to join two
pieces of metals by means of
an alloy of tin or lead(known
as soft solder). The solder is
usually transferred to the
joint by the means of a
soldering iron
mETALS
USED IN
SHEET
METAL
WORK
1. Slack Iron Sheet

It is the cheapest among all. It has a bluish-black appearance and is uncoated sheet. Being
uncoated, it corrodes rapidly. It is prepared by rolling to the desired thickness, then annealed
by pleasing in a furnace and then set aside to cool gradually. The use of this metal is limited to
articles that are to be painted or enameled such as stovepipes, tanks, pans etc.

2. Galvanised Iron

It is soft steel coated often with molten zinc. This coating resist rust, improves appearances,
improves solderability, improves water resistance. It is popularly known as G.I. sheets.
Articles such as pans, buckets, furnaces, cabinet,are made from GI sheets.

3. Stainless Steel

It Is an alloy of steel with nickel, chromium and traces of other metals. It has good corrosive
resistance. The cost of stainless steel is very high but tougher than GI sheets. It is used in
kitchenware, food handling equipments, chemical plants etc.
4. Copper
It is a reddish coloured metal and is extremely malleable and ductile. Copper sheets have good corrosion
resistance as well as good appearances but costs are high as compared to GI and stainless steel.
Because of high thermal conductivity, it is used for the radiator of automobiles,domestic heating appliances
etc.

5. Aluminium
Aluminium cannot be used in its pure form, but is used in alloy form. Comm additions are copper, silicon,
manganese and iron. it has many qualities like high ratio of strength to weight, Corrosion resistant qualities.
ease in fabrication and whitish In colour. It is used in manufacturing of a number of products such as
refrigerator trays, household appliances, lighting fixtures, window work, construction of airplanes and in
many electrical and transportation industries.

6. Tin Plates
lt is an iron sheet coated with the tin to protect it against rust. This metal has a very bright s*very
appearance and is used principally in making food containers, cans and pans.

7. Lead
It is a very sok malleable, low melting point and possesses high resistance to acid corrosion. It is having
low mechanical strength so it is used to provide lining to the highly corrosive acid tanks. It is also used in
radiation shielding.
PROPERT
IES OF
SHEET
METAL
• The material used for the sheet metal should have high
formability. This is indicated by a low yield stress, high
tensile stress and high uniform elongation.
• Sheet metal is often anisotropic in nature. The
assessment of this variation is obtained through the
plastic strain ratio, R.

• A high R-value implies high formability.

• Stainless steel, copper alloys, aluminium alloys are
used.
 SHEET
METAL
OPERATI
ONS
Classification of Sheet-Metal Forming
Shearing Bending Drawing and Stretching

Simple Shearing Angle Bending Spinning

Slitting Air-Bend, Bottoming and Coining Shear Forming or Flow Turning

Piercing and Blanking Roll Bending Stretch Forming

Fine blanking Draw Bending, Compression Deep Drawing and Shallow

Bending and Press Bending Drawing
 Shearing
● Shearing is the mechanical cutting of
materials without the formation of chips or
the use of burning or smelting.
● Cutting blades are used for this purpose.
● There are two stages of shearing process:
1. Deformation
2. Fracture
 Simple Shearing
● In simple shearing, the cutting blades
are straight and the sheet is sheared
along a straight line.
● As the punch pushes on the work-
piece, the metal responds by flowing
plastically over the lower blade.
● When the applied stress exceeds the
shear strength of the material, an
inwardly inclined fracture takes place.
 Slitting
● Slitting is the lengthwise shearing
process used to cut coils of sheet metal
into several rolls of narrower width.
● The shearing blades are cylindrical rolls
with circumferential mating grooves.
● Since the distance between adjacent
shearing edges is fixed, the resultant
strips have accurate and constant width.
 Piercing and Blanking
● These are shearing operations where
a part is removed from a sheet
material by forcing a shaped punch
through the sheet into a shaped die.
● In blanking, the piece that is
punched out is workpiece and in
piercing the same is the scrap.
● These processes can produce any
two-dimensional shape, but one
surface has rounded edge and the
other a light burr.
 Fine blanking
● Fine blanking obtains a smooth edge
in shearing by using a pressure plate
with a V-shaped protrusion to put the
metal into localized compression
and a punch and opposing punch
descending in unison.
● In fine blanking, excellent flatness is
maintained and secondary edge
finishing can be eliminated. Also, the
work hardening that occurs during
shearing enhances wear resistance.
 Bending
● Bending is the plastic deformation
of metals about a linear axis with
little or no change in the surface
area.
● If multiple bends are made with a
single die, the process is often
called forming.
● When the axes of deformation are
not linear the processes are known
as drawing and/or stretching.
 Angle Bending
● Machines like bar folder can be used to make angle bends up to 150 ⁰ in sheets.
● Bends in heavier sheet are generally made on press brakes.
 Air-Bend, Bottoming and Coining
● Bottoming dies contact and compress the
full area within the tooling. These dies are
designed for a specific material and
material thickness.
● Air-bend dies produce the desired
geometry by simple three-point bending.
A single set of tooling can produce a
range of bend geometries, and can
accommodate a variety of materials.
● If bottoming dies continue to close
beyond the full-contact position, the
thickness of the bent material is reduced.
Due to the extensive plastic deformation,
the operation becomes one of coining.
 Roll-Bending
● Roll bending is continuous form of
the three-point bending where plates,
sheets, beams, etc, are bent to a
desired curvature using forming rolls.
● The two lower rolls are driven and the
position of the upper roll is adjusted
to control the degree of curvature.
Draw Bending, Compression Bending
and Press Bending
● In draw bending, the work piece
is clamped against a bending
form, and the entire assembly is
rotated to draw the work piece,
along a stationary pressure
tools.
● In compression bending, the
bending form remains stationary,
and the pressure tool moves
along the surface of the work
piece.
● Press Bending, utilizes a
downward descending bend die,
which pushes into the centre of
the material that is supported on
either side by wing dies.
 Drawing and Stretching
● When the starting material is sheet,
drawing refers to a family of
operations where plastic flow
occurs over a curved axis, and the
flat sheet is formed into a recessed,
three-dimensional part with a depth
more than the thickness of the
metal.
● Stretching operations restrict the
compensating movement and the
increase in surface area is
accompanied by a decrease in
material thickness.
 Spinning
● Spinning is a cold forming process
where a rotating disk of sheet
metal is progressively shaped over
a mandrel, to produce rotationally
symmetrical shapes.
● During spinning the form block
experiences only localized
compression, and the metal does
not move across it under pressure.
● Spinning is usually considered for
simple shapes that can directly
withdrawn from a one-piece form.
 Shearing Forming or Flow Turning
● Flow forming, sometimes referred to as flow
turning of tubes is a rotary point extrusion
process. There are two modes of operations,
namely the forward and backward methods.
● Flow turning is a shearing operation whereas
conventional spinning is one of bending and
drawing with the inherent problems of spring
back and wrinkling.
● Flow turning requires much higher force
compared to conventional spinning.
● In conventional spinning, the thickness remains
virtually constant while the blank diameter
changes. In flow turning, the thickness is reduced
but the blank diameter remains unchanged.
 03
BENCH
WORK AND
FITTING
 FILLING
● The widely used hand cutting tool in workshops is the file.
● It is a hardened piece of high grade steel with slanting rows of teeth. It is used to
cut, smooth, or fit metal parts.
● It is used file or cut softer metals.It consists of tang which is the pointed part,
which fitted into the handle.
● The point is the end opposite the tang. The heel is next to the handle.
● The safe edge or side of a file is that which has no teeth. It isclassified on bases
of type or cut of teeth and sectional form.
● Size of a file is specified by its length. It is the distance from the point to the
heel,without the tang. Files for fine work are usually from 100 to 200 mm and
those for heavier work from 200 to 450 mm in length.
● Teeth or cuts of files can be categorized into two groups namely single cut and
double cut. In single cut files, the teeth are cut parallel to other across the file at
an angle of about 60° to the centre line of the file. Such types of file are named as
flats and are widely used on hard metal. A double-cut file possesses two sets of
teeth, the over-cut teeth being cut at about 60°and the up cut at 75 to 80° to the
centre line.
FILLING
 SAWING
1. Purpose of sawing:-

Sawing is cutting of workpieces in a narrow

kerf by many chisel-type teeth on a saw
blade arranged one after the other for the
purpose of cutting off or of providing
workpieces with slots or recesses.Manual
sawing is used only in single-piece
production and repair work on small-section
workpieces because it is hard and time-
consuming manual work.For bigger cuts
hacksawing, circular sawing (slitting) and
band sawing machines are used.

2. Sawing tools:-

Tools for sawing are saw blades with teeth

on one or two edges which are clamped in a
hand hacksaw frame.
 STANDING POSITION AND GUIDING
OF THE SAW
Before beginning to saw make sure that the height of the vice is correct
and that the workpiece is firmly clamped!

Procedure:
● The weight of the body is resting on one leg while the other leg is
always straightened with both feet firmly on the ground.
● The saw is moved with the arms and such movement may be
slightly supported by the upper part of the body.
● When pushing the saw is pressed onto the workpiece, pulling back
is without exerting any pressure!
● Shortly before the workpiece is sawn off the pressure is to be
released so as to avoid the workpiece to be pulled away by the saw
which might damage the saw blade.
 CHIPPING
● What is chipping?
Chipping is a bench work process
which is done in order to separate or
chip material using a wedge-shaped
tool(chisel).The cutting effect of the
chisel is achieved by hammering on the
head end of the chisel.It is a time and
energy consuming process and hence
only used when no mechanical process
can be applied.
 TOOLS USED FOR CHIPPING
Main tools are chisels of various kinds. They are made of unalloyed tool steel carbon content (0.9
%). The cutting part is hammered, hardened, ground and tempered (HRC 48). The head of the chisel
is unhardened, chamfered towards the upper end and rounded.
Chisels are chosen according to the respective task as well as hardness of material of the
workpiece:
● Flat chisel:- Most common chisel for separating and chipping with straight, broad cutting
edge.
● Round chisel:- Special chisel for chiselling out big holes or separating curved forms. This
chisel has an arched cutting edge.
● Cross-cut chisel:-Chisel for chiselling out horizontal grooves or for separating webs in boring
lines. The cutting edge is across the width of the chisel, the side surfaces are hollow-ground.
● Shear tool:-Chisel for shearing sheet metal. It has a straight, broad cutting edge which is at
level with one flank and the shank of the chisel.
● Grooving chisel:-Chisel for chiselling out grooves in special workpieces (bearing shells). The
cutting edge of the chisel is across the shank, the arched back corresponds to the arched
forms.
TOOLS USED FOR CHIPPING
 SCRAPPING
Scraping means shaving or parting off thin slices or flakes of metal to make a fine, smooth
surface. This is done with a tool called scraper which has very hard cutting edges.

Most common scrapers are given below:-

● Flat Scraper:- The flat scraper is the most common and the most easily made. The cutting
edge is at end. It should be most easily made. It should be a little curved looking at the broad
side. A flat scraper is used for producing a perfectly flat surface.

● Triangular Scraper:- The triangular scraper has three cutting edges and is made from a
triangular file. It is used to scrap round or curved surfaces and to remove sharp corners.

● Half Round Scraper:- A half round scraper is trig-shaped like a half round file. In fact they
are often made from old half round files. They are used to scrape round or curved surfaces.
SCRAPPING
 a Thread
● A thread is a continuous helical ridge with a uniform
section formed on the internal (nut) or external (screw
or bolt) surface of a cylinder or a cone.
● The profile of the thread is composed of the crest (the
top of threads), root (the bottom of threads), and
flanks (joining crests and roots).
● Thread pitch is the distance measured parallel to the
thread axis, between corresponding points on adjacent
threads.
 Types of Threads
● There are many types of threads according to different classification
standards. Machine screw threads and spaced threads are in common use on
fasteners.
● Here we’ll talk about the internal thread and external thread.
– Internal threads (female): a screw thread on an inner or concave surface.
– External threads (male): a screw thread on the outside of a cone or
cylinder.
 Internal Thread Design
● A tap is a metal threading tool used to cut the
internal threads on a CNC machining part,
thrilling is the process of threading and drilling
internal threads using a specialized cutting tool
on a CNC mill. 
● In daily life, the nut is a type of typical internal
thread.
 How to Cut an Internal Thread
● For machining an internal thread, you need twist drill, 90°countersink,
internal hand or machine tap, adjustable tap wrench (for hand) or hand drill
(for machine) and safety goggles.

● Process:
1. Centering with a punch and then drill a core hole with the twist drill
2. Use the 90°countersink to countersink into the core hole and make a
chamfer
3. Put the tap into a tap wrench and turn it into the core hole to cut the
thread
 External Thread Design
● The common external thread including
screws, bolts, studs.
● The external thread is cut with a round die
which is fixed in a die stock, the round die
has three or more cutting edges which are
sperated and represent the nut thread. 
 How to Cut an external Thread
● If you have a turning lathe, turn the diameter about 0.1 times the pitch smaller than the
thread outer diameter. You need the threading tools for external threads are file, round
rod, vise for clamping, round die, die stock, flat-tip screwdriver and cutting spray. 
● Process:
1. File the edges of the round rod and chamfer it at 45°, which should be slightly
larger than the thread depth.
2. Clamp the round die into a die stock and fix it firmly, turn the round die clockwise
onto the round rod with sufficient pressure to cut the thread. Make sure to cut straight
thread. The cutting spray can be used here to improve the surface quality and extend
tool life.
HAND
TOOLS
HAND TOOLS
Fitting shop tools are classified
as below :

• Clamping Tools.
• Measuring and Marking Tools.
• Cutting Tools.
• Striking Tools.
• Drilling Tools.
• Threading Tools.
 DRILL
The tool used for making round holes
is called drill. It is a multipoint cutting
tool. It is made up of high speed steel.
 REAMER
Reamer is used to finish the drilled hole and the operation
is called reaming. So the reaming is a process of
imparting necessary smoothness, parallelism, roundness
and accuracy in size, to the previously drilled hole by
using a reamer. The commonly used reamer is shown
below :
COUNTERSUNK
Counter sunk are taper cutters used to make
the hole cone shaped from the upper end. It is
made for fitting screws and nails.
MARKIN
G
TOOLS
 METHOD OF MARKING
Marking means setting out dimensions with the help of a working drawing or directly
transferring them from a similar part. The procedure of marking is as follows :

1. The surface to be marked is coated with the paste of chalk or red lead and allowed to
dry.
2. Then the work is held in a holding device depending upon shape and size. If it is flat,
use surface plate, if it is round use V block and clamp, else use angle plate etc.
3. Lines in horizontal direction are scribed by means of a surface gauge. Lines at right
angles can be drawn by turning the work through 90 degree and then using the scriber.
If true surface is available, try square can also be used.
4. The centre on the end of a round bar can be located by using an odd leg caliper,
surface gauge etc.
5. The circles and arcs on a flat surface are marked by means of a divider.
6. After the scribing work is over, indentations on the surface are made using dot
punch and hammer.
Marking and Measuring
Tools
Laying out involves marking or scribing centre
points of circles, straight lines, central distances
between holes, angles, etc. on metal surfaces,
workpieces, or castings to guide the fitter. Marking
of layouts or profiles needs great accuracy and
care because once the job is marked out, whole
cutting or filing or drilling will be carried on the
markings. Proper tools need to be selected for
marking. Measurement of dimensions is an integral
part of laying out operations and is usually carried
out at various intermediate stages of production of
a component, assembly or machine. The common
tools and instruments used by a marker will be
discussed further.
SURFACE PLATE
It is used for testing the flatness, trueness of the
surfaces. It is made up of cast iron or graphite. Its
upper face is planed to form a very smooth surface.
It is also used in scribing work. While not in use, it
should be covered with a wooden cover.
 ANGLE PLATE
It is made up of cast iron in different sizes. It has
two planed surfaces at right angles to each
other and has various slots in each surface to
hold the work by means of bolts and clamps.
Scriber and Surface
Gauge
It consists of a cast iron base on the centre of
which a steel rod is fixed vertically. Scriber is made
up of high carbon steel and is hardened from the
front edge. It is used for locating the centres of
round bars or for marking of the lines.
 Bevel Protractor
It consists of a steel dial divided into 360 divisions.
The dial can be rotated around the centre. The
value of any angle can be marked or measured by
the straight edge. Straight edge can be slided along
the length.
UNIVERSAL MARKING
SURFACE GAUGE
Universal Marking Surface Gauge It consists of a
cast iron base, a spindle and a scriber. The spindle
can be set at any angle. Scriber can also be set at
any angle and at any height from the base
maximum upto the length of spindle. It is used for
marking purposes.
 PUNCHES
Punches are used for marking purposes. Dot punches are
used for marking dotted line and centre punch is used to
mark the centre of hole before drilling. Punches are made up
of high carbon steel or high speed steels. One end is
sharpened. Hammering is done on the second end while
working. For dot punch, angle of the punching end is 60
degree while in centre punch, angle of punching end is 90
degree.
 DIVIDERS
These are made up of steel. Dividers have
two legs having sharp feet. These are hinged
at the top. It is used for marking arcs,
dividing a line or transferring a dimension.