Metal Working Processes Tools and Machines sheet and

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Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild

Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012

“Raw” Materials • • Plain steel sheet Galvanized steel sheet – flat, corrugated, d-rib

“Raw” Materials • • Plain steel sheet Galvanized steel sheet – flat, corrugated, d-rib Stainless steel sheet Plain steel rod, rebar, angle Slotted angle Expanded metal Hardware cloth Steel pipe, conduit

Why Steel? • • • Cheap Durable Takes high temperatures Not too difficult to

Why Steel? • • • Cheap Durable Takes high temperatures Not too difficult to work Stainless - takes heat better but is harder and much more expensive and less heat conductive

“Processed” materials • • • Stovepipe Steel buckets Steel drums/barrels Stainless steel “Cornys” Pots

“Processed” materials • • • Stovepipe Steel buckets Steel drums/barrels Stainless steel “Cornys” Pots and bowls Cast iron grates

Measuring and Marking • • • Scale/ruler Tape measure (length and diameter) Square Protractor

Measuring and Marking • • • Scale/ruler Tape measure (length and diameter) Square Protractor Scribe (w or w/o blacking and bluing) Pens, pencils Dividers/compass Snap punch Center punch Sheet metal gauge

Measuring tools

Measuring tools

Marking tools

Marking tools

Making Holes • • “Church key” can opener Twist drills (lousy in sheet metal)

Making Holes • • “Church key” can opener Twist drills (lousy in sheet metal) Step drills (great in sheet metal) –small Hole saws (bimetal and carbide teeth) - large Hollow punches Hand punches Knockout punches Foot lever punches

Twist drills Step drills

Twist drills Step drills

Hole saws Bimetal Carbide

Hole saws Bimetal Carbide

Hollow punches Hand punches

Hollow punches Hand punches

Knockout punches Foot lever punch

Knockout punches Foot lever punch

 • • • • Cutting Hammer and chisel Hand power snips Hand power

• • • • Cutting Hammer and chisel Hand power snips Hand power nibblers hand notchers Hand foot lever notchers Slotted angle shear Angle shear, notcher Circle cutter Circle shear Hand lever shear Foot shear Rotary can openers Drum deheader Angle grinder Hand power saws (hack, jig, circular, chop, …)

Snips

Snips

Nibblers

Nibblers

Hand notchers

Hand notchers

Lever notchers Hand lever notcher: 6”-152 mm Foot lever notcher: 3 1/8”-80 mm

Lever notchers Hand lever notcher: 6”-152 mm Foot lever notcher: 3 1/8”-80 mm

Slotted angle shear

Slotted angle shear

Circle cutter – electric drill powered

Circle cutter – electric drill powered

Hand lever shears

Hand lever shears

Shear machines Foot shear Circle shear - manual

Shear machines Foot shear Circle shear - manual

Drum deheaders

Drum deheaders

Grinding • • Stones Files Angle grinder (electric, pneumatic) Grinding wheel (hand, foot, electric)

Grinding • • Stones Files Angle grinder (electric, pneumatic) Grinding wheel (hand, foot, electric)

Angle grinders

Angle grinders

Bending • • Pliers benders Cleat bender Sheet metal brake Angle bender

Bending • • Pliers benders Cleat bender Sheet metal brake Angle bender

Pliers benders

Pliers benders

Bending machines Cleat bender (1/2” (12. 5 mm) 180° fold) Sheet metal brake (bender)

Bending machines Cleat bender (1/2” (12. 5 mm) 180° fold) Sheet metal brake (bender)

Angle iron cutter, notcher, bender

Angle iron cutter, notcher, bender

Rolling (making cylinders and rings) • • Hand rolling Slip roller – sheet metal

Rolling (making cylinders and rings) • • Hand rolling Slip roller – sheet metal Bead roller, edger, flanger Ring roller – bar/angle/rod

Manual rolling machines Slip roll Bead roller Ring roller

Manual rolling machines Slip roll Bead roller Ring roller

Joining • • Crimping Bending (tab and slot) Riveting Screwing Bolting Spot welding Welding

Joining • • Crimping Bending (tab and slot) Riveting Screwing Bolting Spot welding Welding

Rivet gun

Rivet gun

Spot welder

Spot welder