The objective for this lab was for each individual to make a truck bed from a 1010 steel metal sheet. The individual would learn the process of bending the the metal, designing a shape based on dimensions, and shearing off parts that lack purpose in the design. This process of designing the truck bed takes time, precision, and carefulness. From this process one learns the basics of forming, and all the basic equipment required to create a truck bed.
Modern day manufacturing provides us with a vast array of metal forming processes to choose from. Sheet metalworking includes cutting and forming operations performed on relatively thin sheets of metal . Its most most commonly done as a cold working process performed on low carbon steel with thickness ranging between 0.4 mm and 6 mm . Thus sheet metalworking is associated with accuracy of dimensioning and good surface finish. Of course, there are are downsides to sheet metalworking as there would be with any other process in the world of manufacturing. Forming sheet metal at room temperatures requires significant amounts of force. Nonetheless, sheet metalworking best suits our needs in this case, as it allows to choose from an array of operations including spinning, bending, punching, shearing, and many more.
Tools, Equipment, Materials
The tools and materials required for this lab are sheet metal blank 4” x 4.25” (1010 steel), floor shears, bench shears, hand shears, rivets, markers/pencils, notchers, calipers,
hand punches, pedestal punches, benders, finger benders, hammers, hand seamers, rivet sets, anvil, welding gloves, spot welder, hand file and blank shears.
Methods and Procedures
The process begins with a 1010 steel sheet metal blank. First the sheet must have a drawn layout, which is copied from the provided pattern. After the pattern is drawn correctly on the metal sheet, the next step is shearing off pieces of the metal to create the desired shape by using the notcher. The sections of metal that could not be cut with the notcher were cut with hand held tin snips. Next, the stationary hole puncher was used to punch holes at each of the designated spots on the sheet metal totaling in eight punches. Each hole punched was approximately 0.188 inches, according to the schematic. The metal sheet is now ready to be shaped into a box. The first step in the bending process requires the outer shaded region of the metal sheet to be bent inwards at a 180˚ angle. In order the make it flatter you must safety roll the bent part. The process is repeated but instead of bending 180˚ the parts must be bent 90˚. The first section that must be bent is the welding side followed by the two adjacent sides. Before welding, a hand file was used to remove as much rust as possible from the sheet metal to ensure that a good weld is formed. Once the sides are bent and aligned as close as possible, the welding parts should be welded before bending the last side. When using...