Beruflich Dokumente
Kultur Dokumente
Training Package
PL
E
MEM05010C
Apply fabrication, forming and shaping
techniques
(Heavy Edition)
Learner guide
SA
Version 1
CONTENTS
Project Manager:
Stephen Davies
Education Programs Manager
TAFE NSW
Introduction ...........................................................................................................5
Topic 1 Square and Rectangular Ducting.................................................................9
1.1 Truncated Rectagular Ducting...........................................................................22
Topic 2 Cylindrical Fabrication..............................................................................29
2.1 Theory & Calculations relating to Rolling a Cylinder.........................................29
Enquiries
2.2
2.3
2.4
2.5
2.6
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PL
TAFE NSW (Training and Education Support, Industry Skills Unit Meadowbank) 2013
Copyright of this material is reserved to TAFE NSW Training and Education Support, Industry Skills Unit
Meadowbank. Reproduction or transmittal in whole or in part, other than for the purposes of private
study or research, and subject to the provisions of the Copyright Act, is prohibited without the written
authority of TAFE NSW Training and Education Support, Industry Skills Unit Meadowbank.
3.2
3.3
3.4
3.5
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
Stage 1
Pre-planning
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Stage 2
Fabrication
Student Organiser
Topic
1
1.1
Careful pre-planning
from the start gives you
more control over the entire
fabrication process
Stage 3
Finished product
Activity
Interpret drawings
Task sequence
Organising equipment
Make working drawings
Develop patterns and/or templates
Selection of material
Mark out
Cutting
Forming
Joining
Finishing
Installing
Final quality check
Square/Rectangular Ducting
Truncated Rectangular Duct
Theory/Calculations
Job 1.1 - Truncated Rectangular Duct
Review questions
NOTE: All employees in the workplace are responsible for quality control and safety.
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Pattern calculations
Correct interpretation of workshop drawings is vital if the finished fabrication is to meet its specified size,
shape and tolerance.
The material used for making ducting varies depending on its application. The most common material used
is low carbon steel as it has good workability, structural strength and a relatively smooth surface which helps
air flow. Ducting can also be made from stainless steel, aluminium, copper and plastic materials.
Development method
Parallel line development is the method used to develop square/rectangular shapes, using a series of parallel
lines. The pattern is clearly seen when the shape is folded out flat.
Pattern length
Length = Sides x 4
= 200 x 4
= 800mm
= 800
=
200 mm
200 mm
800 mm
00
mm
800 mm
1000000
Example
200 mm
Truncation Angle
X =115 mm
= 115.4
30
= 115 mm
200 mm
Example
= 115 +200
= 13225 + 40000
= 231mm
Tr
un
115 mm
= 53225
60
ca
ted
l
en
g
t h=
23
200 mm
th =
640000 + 360000
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m
m
h=485 mm
23
1
115 mm
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H=600 mm
O
AG
I
D
en
g
= 1000 mm
60
ll
+ 600
= 200 x 0.577
=1
LS
A
N
on
a
10
60 Height check
Tan = opp Tan30 = X
adj
200
60
therefore X = 200 x tan 30
m
m
00
ag
Marking out
Di
= 600 - 115
= 485 mm
Pattern
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TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
200 mm
Example
1m
When calculating the stretchout length of material greater than 3mm in thickness you must take into account
the amount of material loss in the bend to 90.
Bend calculations/allowances
When calculating the stretchout length of a pattern for square/rectangular ducting you must allow for the
thickness of material.
6 mm plate
Stretchout lengths for material 3mm thick (or under) are calculated using the inside measurements of the
ducting, because the amount of material loss in the bend to 90 is small.
194 mm I/S
3 mm sheet
= (200 - 2 x 3) + (200 2 x 3)
= (200 6 ) + (200 6)
= 194 + 194
= 388 mm
Bend up to 90
Calculation:
I/S Length = (O/S 2 x t) + (O/S 2 x t)
194 mm I/S
600 mm
NOTE
O/S = outside dimension
t = material thickness
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200 mm O/S
194 mm I/S
NOTE
I/S =
IR =
ID =
MD =
MC =
19 mm allowance
inside dimension
inside radius
inside diameter
mean diameter
mean circumference
194 mm
194 mm
Bend up to 90
mm
mm
194 mm I/S
600 mm
0
60
0
60
PL
200 mm O/S
radius
IR 9 mm
407 mm
388 mm
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Production instructions
An outside flange width of 160mm is required. To fabricate an accurate bend it is recommended that you
adopt the following procedure using a sample piece of identical material which is used for the job.
Production instructions are the markings on fabricated jobs and components. Their purpose is to identify
the component and clearly show what is to be done on (or with) the component. These instructions often
determine the way a job is done and how the sequence of operations is carried out. The sketch below shows
a typical example:
STEP (1)
Measure a distance from a pre-marked datum lines for the bend, as shown below:
50
Plate edge
50
Guillotine cut
BAP
BAP
10 mm
158 mm
58
58
50
50
50 mm
distance
each side of
the centreline
158 mm
158 mm
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STEP (2)
Now bend this to the required angle (i.e. 90)
158 mm
Press over to 90
Guillotine cut
150 mm
Press over to 90
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150 mm
ut g
e c sin
tin res
llo p
ui re
G efo
b
10 mm plate
J/N 373/4
O/N 8/3/07
Item A
Guillotine cut
Materials are cut by mechanical or thermal processes, the following are typical examples.
Mechanical cutting
1.
2.
3.
4.
Guillotines
Bench shears
Nibblers
Shears
When using mechanical cutting equipment you must comply with all safe operating procedures and OHS
requirements.
Thermal cutting
1. Oxy-fuel gas cutting is used for any shape cut on low carbon steel.
2. Plasma cutting is often used for cutting and shaping low carbon, stainless steel, aluminium and other
non ferrous alloys.
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General rule:The Vee die (Vee block) opening should be at least 8 times the material thickness with the die angle between
80 to 88.
On some jobs, there are sections which stay uncut until forming has been completed.
Vee
blade
Radius equal to
material thickness
PL
These lines show where bends and radii etc, will be. They also show the forming diameters/radii and/or
angles to be pressed. This information should be shown on the side on which the component is to be formed.
For example, bend/roll up, down or over and forming sequence.
Pressing
Gap press
H-frame press
Brake press
Folder
Bending techniques
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Brake press
80 - 88
Vee block
5 mm plate
Vee width
=8x5
= 40 mm Vee block
R = 1.5t
The bending of metal parts in a brake press can be done by air bending or bottoming.
Air bending means the material is not forced completely into the bottom die. There is some space between
the underside of the material and the bottom of the vee die.
Example: 5 mm plate
Bottoming means the material is formed between the upper and lower dies, which close completely with
only the material separating them.
8 x material
thickness
Page 13 of 224
= 1.5 x 5
= 7.5 mm minimum bend radius
TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
Data sheet from manufacturers give information regarding: - material thickness, minimum bend radius, die
opening and required force (tonnes/lineal metre).
Die Blocks
The chart below is from an 80 tonne hydraulic press brake, for material up to 10mm thickness.
Vee Blocks
0.8
1.0
1.25
6
11.4
16.4
8
8.55
12.3
21.9
10
6.84
9.85
17.5
27.4
26
29
33
4.4
5.0
5.6
35
40
45
7.82
12.2
17.6
31.3
48.9
70.4
125.0
10.7
15.4
27.4
47.8
61.6
110.0
171.0
PL
1
1.2
1.6
2
2.5
3
4
5
6
8
10
13.7
24.3
38.0
54.7
97.3
152.0
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MAT'L THICKNESS
(mm)
Data Chart
Die opening
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TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
Methods include:
Internal template
External templates
Check over layout
Line up one edge corner to corner, using clamps, magnetic links or jigs and fixtures
Line up the seam using light tack welds as required
Align the other seam diagonally opposite and tack weld
Check for size, squareness and twist
Regular checks will minimise errors, you should be especially careful when, aligning longitudinal corners
joints such as:
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External template
Internal template
Corner to corner
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Single bevel
TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
Square ends
Plates aligned and parallel
Corner lap
Progressive checking
Regular checking is essential to prevent errors, if a minor error occurs, spread it around the job rather than
confining it to one place.
152
152
Alignment of joints
Squaring of side plates
Checking for twist
Checking ends for squareness
1 mm
overlap
150
150
149
0.5 mm
gap
correct
150
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incorrect
Square off
the side
plates with a square.
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correct
149
incorrect
150
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This is an alternative method for checking for twist, using a straight edge.
G-clamps
Magnets
Fixed dogs and wedges
Temporary or permanent bracing
Checking for square by measuring across the diagonals, to see if they are the same.
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To move
tack
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Wedges
Magnets
Pivot
point
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G - Clamps
Tack weld
Cleat
Brace
90
Gusset
Packing
Packing
Sub-assemblies
Large jobs are often fabricated as part of a sub-assembly. This is because sub-assemblies are easier to handle,
reduce overall distortion, give greater accuracy and easier to transport. Extra planning will be needed for
larger jobs. In relation to sub-assembles you need to check that:
Workshop cranes can lift assembly or sub-assemblies
There is sufficient clearance for lifting and turning the sub-assembly
Page 18 of 224
TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
Step 3
Flanges for square and rectangular ducting are made from plate, flat bar or angle. Types of flanges include:
Marking out
Cutting
Drilling/punching
Assembly (for 4 piece flange)
Tack welding
Checking
Marking out
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Step 4
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1 piece flange
from plate
Step 5
From the four corners
scribe arcs equal to the
flange width.
Square and rectangular flanges are marked out and fabricated using either one or four pieces.
Step 1
Step 6
Step 2
TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
Step 7
Assembly
Mark out in the vertical and horizontal
centre lines to locate hole centres.
This can be done on a layout or in a jig. Make sure your work is accurate and joints are correctly aligned.
Correct
Step 8
Alignment of flanges to ducting must be within tolerance. Check that your work has:
PL
Cutting
Drilling
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Incorrect
duct
Equal dimensions
flange
The method you use will depend on the number of flanges to be drilled. Remember small numbers of flanges
are drilled separately or in pairs and large numbers using a template or jig. Before starting, decide if you
should:
Drill before or after assembly
Stack drill using a template or jig.
Plate square
gooseneck
duct
Welding flanges
Fillet weld
Corner weld
preparation
NOTE:
Corner weld should have
min 6 mm insertion or equal to the
material thickness or whichever is
less.
duct
For the best distortion control, you should weld the corner joint first and then the fillet joint.
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TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
flange
Student Notes
It is essential that you check your work for accuracy. Check your work for:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
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Delivery
Final delivery of the job (complete or sub-assembly) must be:
In order of requirement
As soon after completion as possible
Without damage to the job or any of its surfaces.
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Assessment Criteria
Practical Sheet
Job 1.1: Truncated Rectangular Duct
Equipment required:
Marking out tools, hand tools, assembly aids, personal safety equipment, guillotines, press, forming
blocks, drilling or punching machine, flame cutting and welding equipment.
NOTE:After completed job has been assessed, students are required to take the assemble job apart and their job
will be used as a welding exercise at a later time.
Final assembly
Student A & B
1. Assemble Parts A to B.
2. Present your completed job for assessment.
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Student B
1. Complete the associated exercises
2. Mark and cut items 3&4
3. Press items 3&4
4. Mark and cut items 6&8
5. Assemble the flange items 6&8
6. Mark and drill holes in the flange
7. Assemble items 3 to 4
8. Assemble the flange to Part B.
Job procedure
Student A
1. Complete the associated exercises
2. Mark and cut items 1&2
3. Press items 1&2
4. Mark and cut items 5&7
5. Assemble the flange items 5&7
6. Mark and drill holes in the flange
7. Assemble items 1 to 2
8. Assemble the flange to Part A.
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TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
End of duct
3 mm
142
inside
dimension
Flange
face
3 mm
Duct detail
250
250
90
PART B
60
300
PART A
1
105
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105
60
PL
Detail A
20
20
94
5&6
12 hls
94
322
47
94
Detail C
Detail A
FRONT VIEW
Flange detail
Detail B
7&8
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TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
NOTES:
Material
Part A
- 350 x 500 x 3mm sheet
- 50 x 500 x 5mm flat bar
Part B
- 300 x 750 x 3mm sheet
- 50 x 750 x 5mm flat bar
- Flange clearnace approximately
1mm all round
- Use square butt joints for flanges
- All measurements are in mm
Student A will fabricate Part A
Student B will fabricate Part B
Both students to assemble
Parts A&B together
General tolerances
2 mm
DRAWN
A Trainer
DATE
01/07/09
SCALE
NTS
A3 RECT / DUCT FAB Issue
A
TITLE:- Rectangular duct
Question 2 (Calculations)
Question 1
a) Name the three (3) stages of job planning required to make a rectangular duct.
b) What are the pattern heights (Parts A & B)?
Stage 2:-______________________________________________________________________
Stage 1: _________________________________________________________________________
PL
PART A
_________________________________________________________________________
Stage 2:-
_________________________________________________________________________
Stage 3:-
ie. PL = 2 x (L+W)
PART B
= _______________________
= ________________________
= _______________________
= ________________________
_________________________________________________________________________
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Part A
Diagonal A = Pattern length + Pattern height
=
_________________________________________________________________________
_________________________________________________________________________
Answer =
Part B
Diagonal =
Pattern length
+ Pattern height
=
=
=
Answer =
Page 24 of 224
TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
Question 3
Answer
On the patterns drawn below, fill in the missing dimensions and calculations:PART A
Slant height
SL
+ Pattern length
SH =
H=
PL
=
Answer =
W=
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PART A
G
DIA
S=
AL
N
O
h=
L=
L=
W=
PL =
PART B
= ____________________________________
SL
G
DIA
= ____________________________________
S=
AL
N
O
h=
PART B
= ____________________________________
H=
Answer
= ____________________________________
Answer
=
SH =
= ____________________________________
= ____________________________________
W=
L=
W=
PL =
Page 25 of 224
TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
L=
Question 4
Question 6
Complete the parts list below for the truncated rectangular ducting job 1.1.
__________________________________________________________________________________
Question 7
What type of joints are used for the rectangular truncated duct?
______________________________________________________________________________
______________________________________________________________________________
3
2
Question 8
Length
No. Reqd
Matl
PL
Item No.
______________________________________________________________________________
______________________________________________________________________________
Question 5
______________________________________________________________________________
Plate edge
______________________________________________________________________________
=
=
______________________________________________________________________________
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On the pattern drawn below, insert the required production procedures for the rectangular truncated duct.
J/N 1.1
PART A
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Question 9
Question 10
Draw to a scale of 1:2 the flange detail for the rectangular truncated duct using the centre line below.
Question 11
What tolerances are given to fabricate the rectangular truncated duct?
Ducts ________________________________________________________________________
PL
Flanges _______________________________________________________________________
Question 12
List the essential checking methods you should use on the completed rectangular truncated duct:
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_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
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Student Notes
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
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Student Drawings/Sketches
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