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Prototyping with Sheet Metal

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Today you will make a name plate. Some possible dimensions are shown below – you decide. You will be provided with a 6 inch long piece of sheet metal that is 1 inch wide.

Fabricating a Name Plate

3 in

1 in

(all pieces)

2 in

1 in

2

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Tools and Supplies

rivet gun lettering punches

hammer

6 inch pieceof sheet metal

2 rivets

Hand punch (makes holes in

sheet metal)

rulerpen

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Sheet Metal Brake (bending) and Shear (cutting)

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Safety Checklist

1. Sheet metal edges are sharp and will cut you (like a knife). Avoid the sharp edges and corners.

2. Wear safety glasses.3. Only one person at a time should use a shearing / bending machine (don’t let

one person hold the workpiece and another pull down the handle). Do not remove the safety bar attachment in front of the shearing edge.

4. Keep hands clear of the hand punch when making holes.5. No “horse play” in the lab.6. Keep work area clean.7. Report any unsafe working conditions and/or practices to the instructor.8. Take all common sense precautions. If you have an accident, report it

immediately to the instructor.

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Lay Out Your Workpiece

1. The location for shearing (cutting) the metal.

2. The location for bending the metal.

3. A line to mark the bottom of your letters and the center of your name plate.

Use your ruler and pen to make marks on your workpiece for . . .

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Class Structure – The Aim is for ALL to Finish

It will take the longest amount of time to punch your name into the metal. Each group should take turns punching their names. Each group should use only one punch kit (do not share punch kits between groups since the letters will get mixed up).

When the shearing / bending machine becomes available, go over and do your shearing and bending. You can do the shearing / bending first, or you can punch your name first.

There is one hand punch for making holes for every two teams.

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Punch Your Name into PlateStart with the center letter and move to the edges (for centering)

DO NOT punch on the countertops or on your tables – it will damage them. Use the vise anvil.

Two firm strokes of the hammer on the punch creates a visible impression.

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Straighten Your Name PlateThe plate will become bent when imprinting your name. Straighten it in the vise when finished.

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Shear your Strip Slowly pull down handle until the shear contacts the metal. Then provide a stronger force to the shear handle to complete the cut.

shearing edge in contact with workpiece

guard (do not remove)

workpiece under shearing edge

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Bend Your StripMove control handle until your piece is bent to the desired angle.

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Punch Rivet Hole #1

Position your name plate and the stand together and tighten up in the vise. Then, punch the first hole (through both pieces). You will need to open the hand punch all the way back open so you can remove the punch.

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Install Rivet #1

insert rivet all the way into gun

insert rivet all the way into gun

you don’t want this part to show

you don’t want this part to show

Insert until head is flush with workpieceInsert until head is

flush with workpiece

Open and close handles repeatedly to draw the mandrel into the rivet. The mandrel will snap off when the two

pieces are joined tightly.

Open and close handles repeatedly to draw the mandrel into the rivet. The mandrel will snap off when the two

pieces are joined tightly.

blind rivet (pop rivet)

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Punch Hole #2 and Install Rivet #2You can hold the nameplate and stand by hand to punch the second hole. Then install the second rivet as before.

Congratulations!!!Congratulations!!!

see next slides for applications

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Things Made of Sheet Metal: Servo Bracket

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Things Made of Sheet Metal: Double Servo Bracket

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Things Made of Sheet Metal: Lead Screw With Servo

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Things Made of Sheet Metal: A Large Duct

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Things Made of Sheet Metal: Airplanes

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Things Made of Sheet Metal: Brackets

simple bracket more complex part

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Things Made of Sheet Metal: Various Parts

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More Types and Sizes of Rivets