The Sheet-Metal

Forming Workshop
Production Technology workshop ENG006
Ibrahim Khaled Ibrahim
11/3/2016
Group 21
Sub group (B)

Supervised by : Eng.Ahmed Wafdy

 Introduction
Sheet metal forming involves a wide range of processes that manufacture
parts for a vast amount of purposes, both seen and unseen. Sheet metal
refers to metal that has a high surface area to volume ratio. Sheet metal
work stock, used for sheet metal processes, is usually formed by rolling and
comes in coils.
A distinction needs to be made between sheet metal and plate metal. Sheet
metal is 1/4 inch or less in thickness, while plate is over 1/4 inch in
thickness. Sheet and plate have different applications. Plate is generally
used for larger structural parts like boilers, turbines, bridges and ships.
Sheet metal is used in the manufacture of cars, trains, aircraft, farm
equipment, office equipment, furniture, house appliances, computers,
machine components and beverage cans to name a few. Some of the sheet
metal manufacturing processes may be applicable to plate metal as well,
even though the work piece is referenced only as sheet metal. However
plate, particularly thicker plate, will provided its own set of problems in
processing. Therefore, some of the sheet metal operations discussed may
not be applicable to plate.
Sheet metal manufacture is mostly performed on a press and parts are
formed between two die. The top die is called a punch. Sometimes sheet
metal parts are referenced to as stampings. Parts are usually economical and
easy to mass produce. Sheet metal is usually formed cold, however warm or
hot working of parts, (particularly plate), is possible. Generally for sheet
metal applications there is essentially no change, or negligible change, in
sheet thickness. For some processes like deep drawing, there is a slight and
expected change in thickness, but this may also be neglected in most cases.
Sheet metal manufacturing produces parts that typically have high strength,
good surface and accurate tolerance.

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Types of Metal Sheets: -
1. Black iron sheet: It is easy to be oxidized, able to be painted
and it's used in manufacturing all metal furniture and the
vehicles bodies.
2. Galvanized iron sheet: It's hard to be oxidized, unable to be
painted and one of the most important uses of it is making
ventilation exhausts.
3. Stainless steel sheets: It's unable to be oxidized or to be
painted and it's used in all of the addressee uses except
vehicles bodies.
4. Aluminum sheets: It's light, flexible, fast to be refrigerated,
unable to be painted and it has only few uses like the internal
body of the refrigerator.

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 Machines and tools
No. Name Uses Drawing

It's used to make

Prick Punch indentations.
1.

Straight Blade Used for straight line

Snips cutting.
2.

Scriber Used to mark out on

the work piece.
3.

To hit and fix the

Hammer work piece.
4.

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 Used for measuring
Steel Ruler dimensions on the
5. work piece.

Board Cutter cutting the sheet

Machine metal in straight lines.
6.

Bending or folding
Folding sheet metal with
7. Machine different angles.

It's used for

continuous bending
operation for
producing open
8. Rolling mill profiles or welded
tubes with long
lengths or in large
quantities.

It's used for welding

two separated metal
Spot welding
9. machine
sheets without adding
any welding
component on it.

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 Work Steps

No. Step Used tool Figure

Bring two Galvanized

metal sheets with the
1. volume of ________
(0.05*10*10) cm3

Bend 0.5 cm of the

2. both metal sheets with Folding Machine
an angle of 90 O

Treat them together to

produce a connection
point between the
3. pieces without adding ________
any welding materials
as the figure.

Weld a metal sheet

with the volume of
4. (2*10*0.05) cm3 with
the welding machine ________
the main workpiece.

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 Safety Rules

1. We should wear the safety clothes.

2. We shouldn't do noise or futility in the workshop place.
3. Students shouldn't use the machines without the operator
supervision.
4. We mustn't wear loose clothes and must wear gloves.
5. We should stop the machine and switch off the power after
using the machines.
6. Never use your hands or any part of your body to break a machine
to a stop.
7. We must keep our hands and bodies away from all the sharp
Machines.