Operations of Sheet Metal Forming - Engineering Workshop Lab - Second/2004

A H M 531 Operations on sheet metal forming By: Ahmed Essam Mansour
Table of Contents:
Title Page
Introduction 2
Objectives 2
Discussion 3
Operations of sheet metal forming 3

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The CivilWelding
Engineering Center 5
MIG & MAG Welding 5
Fusion welding 6
Electric arc welding 9
Blacksmithing 12
Conclusion 13
Reference 13
Appendix: Figures 14
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The Civil Engineering Center 1
Introduction (Background):
Sheet Metals are that pieces of metal that its thickness is not more than
0.25 inches (When the thickness is more than that we call it metal plates).
Dealing with these metal sheets is the axis of our four weeks working in
the workshop;
Folding them, shearing them drilling them and rolling them.
Welding was the other part of our working project. Welding s useful and
clever operation to join the sheet we formed together.
Objectives:
• Learning about the main operations in sheet metal forming.
• Learning about the tools of these operations.
• Learning about the different welding types and there apparatus
and uses.
• Getting the skill of good welding.
• Being able to test the welded metal using tensile or folding
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applications.
The Civil Engineering Center

Apparatus and Procedures:
This report contains too many operations and so I attached each

operation with its tools and procedures during this report.

Discussion:
Operations of sheet metal forming:

Scribing (Marking):
It is an operation to mark parts of sheet metal to be cut.

The tools we use in scribing:
A) Steel Ruler.
B) Right Angle.
C) Scriber.
D) Center Punch.
E) Hammer.
Notes on scribing:
• When we scribble the dimensions on the sheet metal, we mark them

in the shape of V. That is to avoid confusion between the marks and
the scribble that are originally on the sheet.
•
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To know the tools more and their uses see (figure 1).

Shearing:
It is an operation to get rid of unneeded parts in the sheet metal by

cutting them.
Types of shearing tools:
1. Hand shears:
• Used for tin plates and thin metal sheets ; not more that 0.9mm
in thickness.
• Can be used to cut straight and curved surface.
2. Bench shears:
• Works on a levering system.
• Can be used to cut up 9mm thick sheet besides that it cuts
Rods by using it rod cropping hole. See Figure 2.
3. Treadle Shears (Guillotine Shears):

• Are used for breaking large sheets into strips and
rectangular blanks.
• They cannot be used for cutting curved sheets.
• The sheet is fixed on the table using a leg handle and then
we knock the blade hardly for several times on the sheet

till it is cut.
4. Table electric shears:

• Used only fir thick sheets and are operated automatically.
Drilling:
It is an operation to make holes in metal sheets.

The diameter of the hole depends on the twist drill used in the
operation.
In our work we used the Bench Drilling Machine.
It is Preferable that the rotating speeds of the drilling machine is

small, otherwise we should be careful and wear the suitable safety
clothing.
Small speed of the drilling machine helps in:

1. keeping the drill bits well.
2. Avoiding the spreading of the drilled parts so that the safety is
satisfied.
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Rolling: The Civil Engineering Center
This operation is used to make curved shapes of the metal sheets, using
a machine called lathe.
Bending Rollers are found in 2 types, Manual and Electrical.
Folding:
It is an operation to fold metal sheets in specified angles.
The machines used in this operation are of two types:
1. Hand Operated Machine for small works.

2. Power Operated Machines for large works.
In both machines there are protractors to determine the wanted angle

the sheet is supposed to be folded to.
Assembling:
This is done by welding.

Welding is an operation in which two pieces of metal or more are

connected or joined by means of heating or electric current or pressure.
Welding Types:
1- MIG & MAG Welding:
• MIG Welding;
MIG Stand for Metal Inner Gas Welding,
The Argon is used in this type of welding.
• MAG Welding;
MAG Stands for Metal Arc Gas Welding,
The CO2 is used in this type of welding.
MIG & MAG Apparatus:

• Gas cylinders.
• Pressure Gauge.
• Hose.
• Rod filler roller.
•
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Heater just in the case of MAG.(Just on the CO2 cylinder)
Thewelded
Types of metals Civilin that
Engineering
way: Center
In case of MAG we can weld the following;
• Mild steel.
• Carbon steel.
• Stylist steel.
In case of MIG we can weld the following;

• Aluminum
See (Figure 10)
2- Fusion Welding:
In fusion welding there is a rule, which is the metal sheets being joined
together should have the same composition and strength.
In fusion welding metals are melted and then put together and the get
cool together.

Oxy-Acetylene welding:
It contains 2 types of gases;

O² it helps in burning.
C²H² it is the gas which burns.
The Acetylene burns in atmosphere of pure Oxygen to produce a flame

that can reach 3250 C which is above of melting point of most metals.
Apparatus for the Oxy-Acetylene welding:
Two Cylinders:
One for the Oxygen and one for the acetylene. (Table 1) shows the
main differences between the two cylinders.
Oxygen Cylinder Acetylene Cylinder
It is black colored It is maroon colored
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It is Taller than the acetylene diameter is bigger than the
cylinder
Oxygen cylinder one.
It Can Stand more gas pressure. It can stand less gas pressure
It contains oxygen only It contains Fibers and acetone

liquid besides the acetylene gas.*
No safety screws are there in this It contains safety screws that melts
cylinder. at 260 F.*
Right hand valve Left Hand valve
*As I said before the Acetylene is the gas which burns in this
operation, so satisfying the safety was considered while designing
its cylinder.

The safety in the cylinder is represented in two methods
• Containing the Acetone and the fibers to keep the gas in

cool condition.
• Containing safety screws that melts if the acetylene burns
inside the cylinder at 260F, and so holes are created in the
cylinder and the gas flows out of it and so explosion is
avoided
Pressure Gauge:
Each cylinder contains two pressure gages;

one of them is called Inlet Pressure Gauge to control the
pressure of the gas inside the cylinder.
The other one is called Outlet Pressure Gauge to control the
external pressure and it is changed according to the thickness of
the metal.
Hoses:
The oxygen hose is blue/green colored.

The Acetylene hose it red/brown colored
Torch: A H M 531
The ofCivil
It consists Engineering Center
three parts:
1-Handle
2-Valves; Used to control the kind of the flame wanted in the
operation.
3-Welding Nozzle.
To view the Oxy-Acetylene welding apparatus view (figure 3)

Flame Types:
I will discuss flame types using (table 2).
Flame Type The ratio of Temperature Use

Oxygen :
Acetylene
To join metals of the

following types:
Stainless steel
Neutral Flame 1:1 5850F Steel
Cast iron
Copper
Aluminum
It is used to hard facing the

metal surface.
Carbonizing 1:3 more We weld the upper surface
5550F
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Flame acetylene of the sheet so that carbon
will be fixed above it, and
The Civil Engineering Center then it is against erosion.
Oxidizing Flame 3:1 more oxygen 6000F To join brass.
How can we distinguish the flame types from vision?
It is easy when knowing that when the Oxygen is less then the blue
color in the flame is bigger.
So, Neutral flame has medium blue color.
Carbonizing flame has big blue color.
Oxidizing Flame has the less blue color.
See (figure 11)
See (figure 4), it is about fusion welding.
Spot Welding:

It depends on the principle that says; when high electrical current flows
throw high resistance, intense heating takes place.
In this welding type the joint type between the metal pieces is overlap,
which means the metal pieces are placed above each other.
The machine used in that consists of two electrodes represents the 2
edges of an electrical circle (1400Æ2000 Amber). When welding, the
metal pieces are placed between the electrodes and pressured by them,
the circle is completed and heat is presented and the sheets are joined.
Spot Welding characteristics:
1. It is very speed the max. Welding time is 5 seconds.

2. Metal deformations are rarely happened in spot welding.
Be careful of over pressing the metals more than the needed time,
because this will produce spreading sparks.
See (figure 5).
3- Electric Arc Welding:
Definition:
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It is the operation of joining two metal together using welding machine,
so the melting between the two pieces and the rod filler is satisfied and
we get a strong welding joint that has a great strength to take pressures
and weights.
Note that the source of heat here is the electrical discharge between the
filler rod and the work piece.
The following points should be considered while using Electric arc

welding:
1. When welding the metals, it is a must that the metals are identical
and similar according to the elements included in each of them.
Also the rod filler should be similar to them too.
If there was any different in these conditions the welding
operation will fail, the main reason in that is that the compression
and tension of different metal are happened in different rates.
2. Avoid welding the metal in high electrical current; we should use

the medium current. Because the high electrical current cause a
burning process to the elements in the metal, and this burning
process will cause the carbon rate to rise in the joint and this
effect negatively on its strength .
Some marks on the metal may tell that this metal is welded under
high current, and these marks are represented by dark black lines
in alignment to the welding line and also under cut represents
high current welding.

Some tests are used to test the strength of the welding joints,
such as:
1. Tensile test
2. Folding test
the test is always taken in the middle of the piece because it

beginning is cool and its end is hot.
These two tests are explained in (figure 6).
3. Avoid welding using low electrical current, because this type of

welding is poor for enough penetration. And so any load may
cause the breaking of the welded piece.
The Electrical Arc Welding Machine:

It consists of the following;
1. Electrical source.
2. Power main switch.
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3. Power Handle; to increase or decrease the current according to

the used rod filler.
4. Calibrator indicates the rod filler thickness and the suitable
electrical current.
5. Two poles (+), (-).
The (-) pole is attached to the working table.
The (+) pole has a well isolated holder at its end, and two jaws for
grabbing the rod filler.
See (Figure 7).
How the welding process is done using the Electrical Arc Welding
Machine:
¾ When we set the machine on, the electrons start moving to the
negative pole which is connected to the working table.
And the Protons move toward the positive pole.
¾ When the (+) pole, which is represented by the filler rod, gets
closer to the (-) pole, a strong and fast attraction is resulted
between them and the first spark is resulted.
¾ A space of 5mm should be kept between the (+) pole and the (-)
pole, and that is for ionizing the air between them and so it
becomes a good electric connector.
¾ A high voltage will be resulted and then the melting process of
the rod filler and the metal will start and so the welding is done.
Notes:

The ionizing distance is 35mm.

When the distance between the rod filler and the metal is increased then
the voltage will be decreased.
Four points will be noticed if the distance between the rod filler and the
metal is more than 5mm:
¾ Increase in flame volume which effect negatively on the metal

being welded.
¾ Splashing: Spreading process of the rod filler which makes tiny
circular masses on the metal piece.
¾ Arc wavering so that the welding won’t be good.
¾ Noisy sound will be resulted.
Little about the rod filler:
Many types of rod fillers can be found in the workshop. It varies in its
diameters from 2mmÆ6mm.
About the types it can’t be counted because for every metal type there is
rod filler special for it which has the same element and characteristic.
And has a specified serial number.
The rod filler consists of:

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1. Structure of electrode. (The metal part)
2. The Flux
The flux has three benefits in the welding operation:
¾ It helps in forming the flame and conserves it; as this material is

flammable.
¾ It pure and protect the melting pool from the slag and the external
effects.
¾ It protects the worker for electrical shocks; because this material
is isolating for electricity.
Safety Procedure in electric arc welding:
1. Helmets should be used in the welding process; it contains

black glass with little infiltration for the welding ray which is
classified as ultra violet.
2. Warn the group members before starting.
3. Never grab the hot pieces with your hand you must use the
tongue.
4. Be careful while moving the flux away of the metal.
5. Never through the rest of the rod fillers on the ground.
You should put them in the drawer in the table.
6. Never joke and mess with the groups members.
7. Wear the working overall.

8. To restrict with the instruction and points that are placed in

the workshop.
Blacksmithing:
Metal forming is done in different methods:
1. Folding:
We use for that purpose The Folding Machine, no
mentionable resistance occur while folding process.
But when the thickness of the metal is increased so that it
is difficult to fold it, these pieces should be heated till they
are red using electrical furnace or oxygen and acetylene.
After heating them it is easy to fold them.
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2. Casting:

This type is the most popular type for the following:
1- We can form large volumes, with irregular angles which
are difficult to for using machinery tools.
2- It saves money time and power.
3-The product looks exactly like the model.
3. Stresses:
We use for that electrical stressors or hydro electrical ones,
in the help of metal models that can stand the stresses and
exactly look like the product we want to make.
When the metal sheets are thick then it needs heating
process before stressing.
Joint Types:
• Butt joint.
• Tee joint.
• Corner Joint.
• Edge joint.
• Overlap joint.
These joint types are drawn in (figure 9).

Conclusion:
It was good experience to know and practice sheets forming and

welding, but I have the following notes:
• Most of the helmets we used while welding were broken and made
the student lose one of his hands in the work to hold it on his face.
And also some of them had holes that let the ray into our eyes.
• Special room for welding operations should be made in the
workshop, because student who are not working and the staff
who just pass by can’t control them selves of not looking because
the ray will pass into there eyes and will cause damage to them.
• All the equipments we learned about, we could see them and use
them which is a good point in my opinion.
• A H M 531
The classes of explaining should be far from the working space
because high noises and lights really distract students.
I hope my note we be under consideration.
I learned new thing which I am happy for, and I dealt with tools which
might be important in my career.
References:
• The workshop Manual.

• The instructors notes.


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A H M 531 Operations on sheet metal forming By: Ahmed Essam Mansour

Operations of sheet metal forming 3

MIG & MAG Welding 5

Electric arc welding 9

The Civil Engineering Center

This report contains too many operations and so I attached each

Visit www.AHM531.com for more lab reports and lecture notes!