Workshop
M1
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Hand Tools are tools held in the hand and operated without electricity or other power.
Bench Work refers to work done at a workbench, worktable, etc., as in a factory or laboratory.
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Work Holding Tools/Devices.
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Bench Vise is a type of vise that is securely fastened to the bench with bolts.
The faces of the jaws are usually lightly serrated and hardened to ensure a firm grip on the work.
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V-Blocks are used to hold circular work when laying out or setting up for machining.
Some V-Blocks are fitted with a clamp to work securely in position.
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Toolmakers' Handvise is a small steel vise with two interchangeable blocks.
The choice of block to be used depends on the size of the article to be held by the vise.
It is used by toolmakers at the bench for small machining operations such as drilling or tapping.
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C-Clamp is an all-purpose clamp made in the shape of the letter C.
It is used to hold workpieces on machines such as drill presses, as well as to clamp parts together.
The size of the clamp is determined by the largest opening of its jaws.
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Toolmakers' Parallel Clamp consists of two flat steel jaws which may be adjusted to fit a piece of work.
Another screw in the end of one jaw is used to exert pressure on the other jaw.
This pressure lightens the opposite ends of the jaws.
It is used by toolmakers for holding small parts both at the bench and at machines.
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Vise Grip is a latching mechanism that has an exceptionally high degree of mechanical advantage.
This means that they are exceptionally strong when locked down.
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Saw is a tool consisting of a tough blade, wire, or chain with a hard toothed edge.
It is used to cut through material, very often wood.
The cut is made by placing the toothed edge against the material and moving it forcefully forth and less forcefully back or continuously forward.
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Hand Saw is used to cut pieces of wood into different shapes.
Crosscut saw is designed for cutting wood perpendicular to (across) the wood grain.
Rip saw is a wood saw that is specially designed for making a rip cut, a cut made parallel to the direction of the wood grain.
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Coping Saw is a type of hand saw used to cut intricate external shapes and interior cut-outs in woodworking or carpentry.
It is widely used to cut moldings to create coped rather than miter joints.
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Hacksaw is a type of hand tool that features a fine-toothed blade tensioned in a C-frame.
It is commonly used for cutting metals and plastics.
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Tin Snip is a common cutting tool used for cutting thin sheets of metal, plastic, fiber, and so forth.
They are used not only by tinsmiths but by all bench workers as a utility tool.
They are made in many sizes.
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Hammer is a tool or device that delivers a blow (a sudden impact) to an object.
Most hammers are hand tools used to drive nails, fit parts, forge metal, and break apart objects.
Hammers vary in shape, size, and structure, depending on their purposes.
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Ball-peen Hammer has a flat face which is used for general work while the round end is used for peening and riveting.
Straight peen Hammer has a peen that is parallel to the axis of the handle.
Cross peen Hammer has a peen that is at a right angle with the handle.
Claw Hammer is a hammer with one side of the head split and curved, used for extracting nails.
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Mallet is a kind of hammer, often made of rubber or sometimes wood, that is smaller than a maul or beetle, and usually has a relatively large head.
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Chisel is a tool made from hexagon or octagon-shaped tool steel, commonly called chisel steel.
One end is shaped for the cutting operation, and the other end is left blunt to receive the blows from a hammer.
Chisels are usually forged to the required shape, then annealed, hardened, and tempered.
Finally, a cutting edge is ground.
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File is a hand-cutting tool with many teeth, used to remove burrs, sharp edges, and surplus metal, and produces finished surfaces.
Files are made up of high-carbon steel, hardened and tempered, and are used in machine shop work when it is impractical to use machine tools.
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Single-Cut Files have a single row of parallel teeth across the face at an angle from 65 to 85 degrees.
These are used when a smooth surface is desired and when harder metals are to be finished.
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Double-Cut Files have two rows of teeth crossing each other, one row being finer than the other.
The rows crossing each other produce hundreds of sharp cutting teeth, which remove metal quickly and make for easy clearing of chips.
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Files can be identified through their cross-section, shape, and special use.
The types of files most commonly used in machine shop are the mill, flat, hand, pillar, square, round, three-square (triangular), half-round, crocket, crossing, warding, barrette, and knife.
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Proper care, selection, and use of files are important factors if good results are to be obtained during the filing operation.
In order to preserve the life of a file, the following points should be observed.
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Always use a file with a handle
Do not knock a file on a vise or hard-metallic surface to clean it
Keep a firm grip on the file at all times
Never use a file as a pry or hammer
Always store files where they will not rub against other files. Hang or store them separately to preserve their sharp cutting edges
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Depending on the task to be accomplished, different files and techniques are used.
Stroke length, stroke direction, and pressure can all be modified.
Filing Techniques
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Cross Filing – is used when metal is to be removed rapidly or the surface made flat before finishing by draw filing
Use a double-cut file and cross the stroke at regular intervals to keep the surface flat and straight.
Rough filing – use a double-cut file and cross the stroke at regular intervals to keep the surface flat and straight.
Finishing – use a single-cut file and take shorter strokes to keep the file flat on the work surface.
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Draw Filing
The operation of pushing and pulling a file sidewise across the work.
The file should be held firmly in both hands so that only a few inches of the file in the center are actually used.
The main objective in draw filing is to obtain a perfectly smooth, level surface.
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Cleaning
Always clean your tools immediately after use.
Tools can be washed using a hosepipe and/or scrubbed with a wire brush.
Make sure that there is no risk of spreading pathogens while you are washing your tools.
Spray light oil on areas prone to rust.
How To care Hand Tools
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Storage
Store tools in a dry, sheltered environment.
Place tools in racks for easy location and safety.
Place similar tools together so that people can see easily what is available.
How To care Hand Tools
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Maintenance
Keep metal blades sharp and well-oiled.
Check any nuts, bolts, rivets, screws, blades, and springs regularly for wear or damage, and replace if necessary.
Sand wooden parts back regularly and oil with a 50/50 linseed oil and turps mix.
Label damaged tools, place them out of the way and tell your supervisor or maintenance person.
How To care Hand Tools
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END Technology Driven by Innovation FEU ALABANG FEU DILIMAN FEUTECH
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COE0035L WORKSHOP THEORY AND PRACTICE Introduction to machine shop operations, layouts, tools and measuring instruments "Lay-out Tools" Technology Driven by Innovation FEU ALABANG FEU DILIMAN FEUTECH
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CHAPTER 1 OBJECTIVES
At the end of the chapter, the learner should be able to:
Identify the different lay-out tools;
Understand the lay-out tools working techniques; and
Learn lay-out tools working techniques and how to use the different lay-out tools.
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Lay-out
Is the process of placing reference marks on the blank work piece, or the transfer of measurements from a drawing to the work piece to be machined, filed or cut.
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Lay-out
This means accurately inscribing clean, sharp lines on the blank work piece to show center lines, shape or form of the finished work piece, locations of centers for holes, circle for hole sizes, angles, arcs or curves and slots.
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Lay-out
It is the first operation in work fabrication or in a sequential production works.
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Precision Layout
Is usually done by a scale measurement to a tolerance of + 0.4 mm.
This type of layout may be a simple pencil or chalk mark.
Semi-Precision Layout
It is done with tools that discriminate to a tolerance of + 0.03 mm or finer if possible.
It can be complex and involved operations making use of sophisticated tools.
TYPES OF LAYOUT
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Lay out Tools
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SCRIBERS
A sharp, pointed steel tool used to scribe lines on metal being laid out.
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CENTER PUNCH
A marking punch usually made of a hardened steel, both ends of 90 degrees used to mark the work piece prior to such machining operations such as drilling.
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DIVIDER
Is a tool with a hardened steel points used for measuring the distance between points, for transferring a measurement directly from a rule, and for scribing circles and arcs on metal.
It consists of steel legs that are fixed together or screwed to maintain the position in which it is set.
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ODDLEG CALIPER (Hermaphrodite calipers, or Oddleg jennys)
Are generally used to scribe a line a set distance from the edge of a workpiece.
The bent leg is used to run along the workpiece edge while the scriber makes its mark at a predetermined distance, this ensures a line parallel to the edge.
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TRAMMEL
Also known as Beam compass, It is a type of divider preferred for scribing large circles.
It consists of a bar and two legs.
At the end of each leg is a steel point.
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SURFACE PLATE
This have a true, smooth, plane surface from which accurate measurements may be made.
It is made of either cast iron or granite.
This are used for laying out and inspecting work piece.
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SURFACE GAUGE
A tool which consists of a steel base with a rotating clamp, which holds a steel spindle.
On the spindle is clamped a scriber.
This are usually used for scribing lines on layout work and for checking parallel lines.
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STEEL RULE
Although called a measuring tool, may also be considered a layout tool as it is indispensable in layout work for taking measurements not requiring precision.
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MACHINIST SQUARES
Is the metal workers’ equivalent of a try square.
It consists of a steel blade inserted and either welded or pinned into a heavier body at an angle of 90 degrees.
These are used for checking the squareness and perpendicularity of work.
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STEEL PROTRACTOR
Is a tool used for setting bevels, transferring or checking angles and similar work.
It consists of blade and plate.
The blade has double graduations from 0 to 180 degrees in opposite directions, thus permitting reading an angle directly and also the use of complementary angles.
The blade can be locked firmly at any angle.
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VEE BLOCKS
Are used to hold circular work when laying out or setting up for machining.
They are manufactured in pairs from cast iron or steel.
Some Vee blocks are fitted with a clamp to work securely in position.
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Combination Square Set
Is used for a number of layout operations.
The set consists of a blade(graduated rule), square head, protractor, and center head.
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The blade is designed to allow the different heads to slide along the blade and be clamped at any desired location.
The groove in the blade is concave to eliminate dirt build up and permit a free and easy slide for the heads.
By removing all the heads, the blade may be used alone as a rule.
The square head is designed with a 45° and 90° edge, which makes it possible to be used as a try square and miter square.
By extending the blade below the square, it can be used as a depth rule.
The square head can also be used as a level.
The protractor head is equipped with a revolving turret graduated in degrees from 0 to 180 or to 90 in either direction.
It is used to measure or lay out angles to an accuracy of 1°.
The center head, when inserted on the blade, is used to locate and lay out the center of cylindrical workplaces.
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END Technology Driven by Innovation FEU ALABANG FEU DILIMAN FEUTECH
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COE0035L WORKSHOP THEORY AND PRACTICE Introduction to machine shop operations, layouts, tools and measuring instruments "Measuring Instruments" Technology Driven by Innovation FEU ALABANG FEU DILIMAN FEUTECH
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Chapter 1 objectives:
Identify different measuring tools
Understand measuring tools working techniques
Learn how to use different measuring tools
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Introduction to measurement:
Measurement is the act or process of determining dimension, capacity, or amount
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Wide range of measuring tools designed for high accuracy in measuring and layout work
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Machinists and toolmakers use various tools for measuring and laying out work
Tools range from simple and inexpensive to intricate and expensive
Most tools used for linear or straight line measurement
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Ruler (rule or line gauge)
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Ruler is used in geometry, technical drawing, printing, engineering, and building
Used to measure distances and rule straight lines
Contains calibrated lines for measuring distances
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Steel rule:
Graduated in inches and fractions of an inch for the English System
Graduated in centimeters and millimeters for the Metric System
Fractional divisions indicated by division mark of different lengths
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Steel rule
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How to read a ruler in inches
Fractional measurements indicated (1/16, 3/16, 5/16, etc.)
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Narrow rule:
Made of tempered steel, about 3/64 inch thick, 3/16 inch wide, and 4 to 12 inches long
Useful for measuring in small openings and spaces
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Narrow rule
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Hook rule:
Has a hook attached to one end for measuring from inside edges or in holes
Used for measuring outside dimensions
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Hook rule
Brand: STARRETT
Model: C604R
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Flexible steel rule:
Made of tempered spring steel, about 1/64 inch wide and 6 inches long
Used for general measurement and measuring curved work
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Flexible steel rule
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Short length rule holder:
Useful for measuring in small openings where an ordinary rule can't be used
Blades are tempered steel and come in lengths of 1/4, 1/2, 3/8, and 1 inch
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Short length rule holder
Includes 20 short steel rules
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Tape rule:
Metallic tape, usually 72 inches long, used to measure bar stock and long materials
Can be retracted or rolled back into its holder
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Tape rule
Brand: STANLEY
Model: MaxSteer 7.5m/25 33-591
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Rule depth gage:
Used to measure the depth of holes and slots
Consists of a steel head with slots to receive a narrow rule
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Rule depth gage
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Caliper:
Tools used to measure a workpiece by contact rather than by scale reading
Two ways of using calipers: setting the contact tool with a steel rule or using the contact tool to approximate the size of the workpiece
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Outside caliper:
Used to measure the outside surfaces of round objects
Legs of the instrument are curved outward to accommodate the workpiece
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Outside caliper
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Inside caliper:
Used to measure the inside diameter of a hole or inside surfaces of objects like slots and keyways
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Inside caliper
Brand: FLORA
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Vernier caliper:
Gives a direct reading of the distance measured with high accuracy and precision
Calibrated scale with a fixed jaw and a sliding jaw with a pointer
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Vernier caliper
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Vernier caliper
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Parts of vernier caliper:
Internal locking jaws screw
Imperial scale
Metric scale
Depth measuring blade
External jaws
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Different parts and functions of a caliper:
Upper jaws for inside measurements
Lower jaws for outside dimensions
Depth rod for measuring hole depth
Main scale along the beam
Vernier scale for extra accuracy
Thumb screw for precise adjustment
Lock screw to secure jaws in place
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Micrometer:
Device used for precise measurement of components in mechanical engineering and machining
Provides finer results than a vernier caliper
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Micrometer caliper
Brand: Mahr Micromar 40A 0-25
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Parts of Micrometer Lock
Anvil
Spindle
Nut
Sleeve
Thimble
Ratchet
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Micrometer parts and their functions
Ratchet knob
Stops the finely threaded screw when the pressure on the object being measured is sufficient.
Frame
Horseshoe-shaped part that supports the anvil and a graduated device from which the measurement is read.
Anvil
Cylindrical part that is attached to the frame of the micrometer to support the object to be measured; the object is placed between the anvil and the spindle.
Thimble
Graduated cylindrical part that is activated by the finely threaded screw and measures the thickness with precision.
Spindle
Cylindrical end of the finely threaded screw.
Lock nut
Ring-shaped part that locks the finely threaded screw in its final position to preserve the measurement obtained.
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Protractor
Measuring instrument for measuring angles
Made of transparent plastic or glass
Most protractors measure angles in degrees (°)
Radian-scale protractors measure angles in radians
Used for a variety of mechanical and engineering-related applications
Commonly used in geometry lessons in schools
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Steel Protractor
Tool for measuring angles within one degree
Convenient to use in laying out and checking angles in some types of work
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Framing Square or Carpenter's Square
Consists of a long arm and a shorter arm, which meet at an angle of 90 degrees (a right angle)
Can also be made of aluminum or polymers, which are light and resistant to rust
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Try Square
Woodworking or metalworking tool used for marking and measuring a piece of wood
The square refers to the tool's primary use of measuring the accuracy of a right angle (90 degrees)
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Radius or Fillet Gauge
Thin flat steel tool used for inspecting, checking, or laying out work having a given radius
Made in sets of individual gauges for concave (internal) or convex (external) radii
Gauge may consist of a number of leaves, each having a different radius and held in a convenient holder for easy selection and use
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Stattess No. 178-B
Radius or Fillet Gauge
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Thickness or Feeler Gauge
Set of gauges consisting of thin strips of metal of various thickness
Used for checking and measuring bearing clearances, spark plug gaps, and other purposes where a specified clearance must be obtained
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Thickness or Feeler Gauge
FEUTECH
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Screw Pitch Gauge
Gauge for quickly determining the pitch, or number of threads per inch, on a threaded part or in a tapped hole
Pitch can be checked by simply matching the teeth in the gauge with the threaded part
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Screw Pitch Gauge
Range: 52 to 84 Storgett, 20 to
M2
M3
Sheet Metalworking Defined (Page 3)
Cutting and forming operations performed on relatively thin sheets of metal
Thickness of sheet metal ranges from 0.4 mm (1/64 in) to 6 mm (1/4 in)
Thickness of plate stock is greater than 6 mm
Operations are usually performed as cold working
Press (Page 4)
A metal forming machine tool designed to shape or cut metal by applying mechanical force or pressure
Metal is formed to the desired shape without removal of chips
Presses and press tools facilitate mass production work
Considered the fastest and most efficient way to form sheet metal into finished products
Presses Classification based on source of power (Page 5)
Manually Operated or Power Driven
Used for thin sheet metal working operations where less pressure or force is required
Operated by manual power
Examples: hand press, ball press, fly press
Power Presses
Driven by mechanical mechanism or hydraulic system
Power source can be an electric motor or engine
Presses Power and Drive Systems (Page 6)
Hydraulic presses
Use a large piston and cylinder to drive the ram
Suited to deep drawing
Slower than mechanical drives
Mechanical presses
Convert rotation of motor to linear motion of ram
High forces at the bottom of stroke
Suited to blanking and punching
Sheet and Plate Metal Products (Page 8)
Sheet and plate metal parts are used in consumer and industrial products such as:
Automobiles and trucks
Airplanes
Railway cars and locomotives
Farm and construction equipment
Small and large appliances
Office furniture
Computers and office equipment
Advantages of Sheet Metal Parts (Page 9)
High strength
Good dimensional accuracy
Good surface finish
Relatively low cost
Economical mass production operations are available for large quantities
Sheet Metalworking Terminology (Page 10)
"Punch-and-die": Tooling to perform cutting, bending, and drawing
"Stamping press": Machine tool that performs most sheet metal operations
"Stampings": Sheet metal products
Three Major Categories of Sheet Metal Processes (Page 11)
Cutting: Shearing to separate large sheets or cut part perimeters or make holes in sheets
Bending: Straining sheet around a straight axis
Drawing: Forming of sheet into convex or concave shapes
Shearing, Blanking, and Punching (Page 13)
Three principal operations in pressworking that cut sheet metal:
Shearing
Blanking
Punching
Shearing (Page 14)
Sheet metal cutting operation along a straight line between two cutting edges
Typically used to cut large sheets into smaller sections for subsequent operations
Blanking and Punching (Page 15)
Blanking: Sheet metal cutting to separate a piece from surrounding stock
Cut piece is the desired part, called a blank
Punching: Sheet metal cutting similar to blanking, but the cut piece is scrap, called a slug
Remaining stock is the desired part
Clearance in Sheet Metal Cutting (Page 16)
Distance between the punch and die
Typical values range between 4% and 8% of stock thickness
If too small, fracture lines pass each other, causing double burnishing and larger force
If too large, metal is pinched between cutting edges and excessive burr results
Bending (Page 17)
Straining sheet metal around a straight axis to take a permanent bend
Compression and tensile elongation of the metal occur in bending
Types of Sheet Metal Bending (Page 18)
V-bending: Performed with a V-shaped die
Edge bending: Performed with a wiping die
V-Bending (Page 19)
For low production
Performed on a press brake
V-dies are simple and inexpensive
Edge Bending (Page 20)
For high production
Pressure pad required
Dies are more complicated and costly
Spring back in Bending (Page 21)
Springback refers to the increase in the included angle of a bent part relative to the included angle of the forming tool after the tool is removed
When bending pressure is removed, elastic energy remains in the bent part, causing it to recover partially toward its original shape
Drawing (Page 22)
Sheet metal forming to make cup-shaped, box-shaped, or other complex-curved, hollow-shaped parts
Products include beverage cans, ammunition shells, automobile body panels
Shapes other than Cylindrical Cups (Page 23)
Square or rectangular boxes (as in sinks)
Stepped cups
Cones
Cups with spherical rather than flat bases
Irregular curved forms (as in automobile body panels)
Each shape presents its own unique technical problems in drawing
Ironing (Page 24)
Makes the wall thickness of a cylindrical cup more uniform
Examples: beverage cans and artillery shells
Embossing (Page 25)
Used to create indentations in sheet metal, such as raised or indented lettering or strengthening ribs
Guerin Process (Page 26)
Advantages:
Low tooling cost
Form block can be made of wood, plastic, or other easy-to-shape materials
Rubber pad can be used with different form blocks
Process is attractive in small quantity production
Dies for Sheet Metal Processes (Page 27)
Most pressworking operations are performed with conventional punch-and-die tooling
The term stamping die is sometimes used for high production dies
Several sheet metal parts produced on a turret press (Page 29)
Shows the variety of hole shapes possible
Sheet Metal Operations Not Performed on Presses (Page 30)
Stretch forming
Roll bending and forming
Spinning
High-energy-rate forming processes
Stretch Forming (Page 31)
Sheet metal is stretched and simultaneously bent to achieve shape change
Roll Bending (Page 32)
Large metal sheets and plates are formed into curved sections using rolls
Roll Forming (Page 33)
Continuous bending process in which opposing rolls produce long sections of formed shapes from coil or strip stock
Spinning (Page 34)
Metal forming process in which an axially symmetric part is gradually shaped over a rotating mandrel using a rounded tool or roller
High-Energy-Rate Forming (HERF) Processes
HERF processes use large amounts of energy over a very short time to form metals
HERF processes include:
Explosive forming
Electrohydraulic forming
Electromagnetic forming
Explosive Forming
Uses explosive charge to form sheet or plate metal into a die cavity
The explosive charge creates a shock wave that forces the part into the cavity
Applications: large parts, typical of aerospace industry
Steps of explosive forming:
Setup
Explosive is detonated
Shock wave forms part and plume escapes water surface
Electromagnetic Forming
Sheet metal is deformed by the mechanical force of an electromagnetic field induced in the workpart by an energized coil
Currently the most widely used HERF process
Applications: tubular parts
Steps of electromagnetic forming:
Setup in which coil is inserted into tubular workpart surrounded by die