Sheet Metal Tools. by:prem Mahendranathan

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1 Sheet Metal Tools by:

2 SHEET METAL TOOL KIT

3 SHEET METAL TOOLS Rivet Gun 3/32, 1/8, 5/32, 3/16",Cupped Set Mini Bucking Bar Footed Heel-Toe Bucking Bar Air Tool Oil Mechanics Tool Bag High-Speed Air Drill Countersink Unit #40, #30, #21, #3/16" Countersink Bit #40 #30 #21 Drill Bits Cleco Pliers Cleco Fasteners 3/32, 1/8, 5/32, 3/16"

4 2 Lb. "Dead Blow" Hammer Delivers a hard blow, but will not bounce

5 Needle File Set 10 assorted styles for just about any application

6 Countersinks

7 Offset Flush Rivet snap

8 90 Degree Drill Motors

9 Sealant Guns

10 PUNCHES A punch is a tool used to exert a significant amount of striking force on a very small area. All punches are made to be struck with ball peen hammers More common types include center punches, prick punches, drift punches or drifts, pin punches, alignment punches, and hole (gasket) punches.

11 Prick Punches Prick punches and center punches are primarily designed for making marks or indentations in metal. The prick punch, used to make location marks on equipment..

12 Center Punches Center punches are similar to prick punches, but they are generally thicker and more suitable for heavy duty work. Their primary purpose is to make indentations in metal deep enough to give drill bits a true start. Without the indentation made by a center punch, a drill bit is liable to "walk" across the surface of the work instead of drilling a hole.

13

14 SCRIBERS Scribes are hardened steel tools used to make shallow marks on metal. They are usually long and thin with a gripping surface on the body. Scribes are used with rules to make straight lines on metal for punch locations or to mark lines for cuts. Scribes should never be struck.

15 DRILLING MACHINE

16 PISTOL DRILL

17 ANGLE DRILL

18 CHUCK KEY

19 C-CLAMPS

20 C- CLAMPS C-clamps are light to medium duty holding devices that are far more portable than vises. However, that clamps are not as strong as vises, nor are they designed to hold work as large or heavy as that which vises can hold. C-clamps get their name from the shape of their frames. Work is held between the anvil and the swivel disc on the end of the screw. C-clamps come in a variety of sizes and shapes. Because of this, a C-clamp can usually be found to fulfill any type of holding requirement.

21 VISES Vises and clamps are used to hold pieces of material that are being worked on. Vises are usually fixed to a bench, table, or other work surface. C-clamps are light, portable, and widely used to temporarily hold objects together or secure lightweight objects for work. Bench Vises Although vises are available in a variety of types and sizes, most vises are intended for holding large or heavy objects or objects on which large forces must be exerted. As a result, most vises are too large to be considered portable, and they are generally found in relatively permanent locations, such as workshops.

22 PRECISION MEASURING INSTRUMENTS Micrometer calipers These instruments are used to measure the q thickness of sheet metal, q the out of roundness of cylindrical objects such as piston pins, and q the degree of stretch of valve stems. Furthermore when used in conjunction with other devices, micrometers can measure the fit of many engine parts. Inside micrometers Used to obtain the inside diameters and widths of slots Micrometer depth gauge Used to measure the depth of grooves or recesses in a part

23 CUTTING TOOLS Classified as q Hand operated cutting tools q Floor mounted cutting tools Metal cutting power tools q Ketts saw q Electrically operated portable circular cutting tool Head can be turned to any desired angle Advantages- the ability to cut metal up to 3/16 thick q No starting hole required. q A cut can be started anywhere on a sheet of metal q The capability of cutting an inside or outside radius

24 HAND OPPERATED CUTTING TOOLS Aviation snips q Nibblers Hacksaw q Files

25 AVIATION SNIPS This tool is a compound action shear. These shears have serrated cutting edges and leverage multiplication that allows relatively thick sheet metal to be cut without requiring excessive handle force q Color Coding Cuts to the right- Green Cuts to the left- Red Straight cut- Yellow

26 STRAIGHT CUT SNIP

27 LEFT CUT - SNIP

28 NIBBLERS Used for rough cutting small to medium size holes in skins, radio chassis, and instrument panels.

29 WOODEN FILE HANDLE - Easily installs on the "tang" of any 8" or 10" file. - Clean dried handle has a smooth comfortable finish.

30 FILES large variety of files available for use. They can be used to sharpen shears, remove burrs, or mark or shape metal. The proper use and care of files makes for a better and safer job. Files are hardened steel tools used in cutting, removing, smoothing, and/or polishing of metal.

31 FILES

32 FILE PARTS

33 File Cleaning Brush Designed to easily clean shavings from hand files.

34 HACKSAWS Hacksaws can be used to cut practically all types of metals, with the exception of tempered steel. To determine whether a metal object can be cut with a hacksaw, test it with a file. If the metal cannot be filed, it cannot be cut with a hacksaw. Good work with a hacksaw depends not only upon proper use of the saw, but also upon proper selection of the blades for the work to be done. Blade selection involves design (shape), coarseness (number of teeth per inch), and degree of toughness and hardness. The user is primarily concerned with coarseness when selecting a blade. Hand hacksaw blades are generally available with 14, 18, 24, and 32 teeth to the inch.

35 Recommendations on HACKSAW tooth selection 14 tooth For cutting stock 1 inch or over in thickness and for cutting soft materials. 18 tooth For general shop use, when the same blade is used on several jobs. 24 tooth For 1/16 to 1/4 inch in thickness, such as pipe, angles, and small drill rod. 32 tooth For cutting stock up to 1/16-inch in thickness, such as sheet metal, light tubing,. A hacksaw blade cannot be reset, sharpened, or ground. When dull or broken, it must be replaced with a new one.

36 FLOOR MOUNTED CUTTING TOOLS Squaring shears Scroll shears Throatless shears Rotary punch

37 SQUARING SHEARS Used for cutting and squaring metal Lower blade is stationary; upper blade is movable The jobs performed in squaring shear are q Cutting to a line q Squaring q Multiple cutting to a specific size

38 SCROLL SHEARS Used to cut irregular lines on the inside of a sheet without cutting through the edge Upper blade is stationary; lower blade movable Hand operated

39 THROATLESS SHEARS Used to cut 10- gage mild carbon sheet and 12-gage stainless steel. A sheet of any length can be cut Can cut any irregular shape Upper blade can be operated by a hand lever

40 ROTARY PUNCH Used to punch holes in metal parts Cutting radii in corners for making washers Machine cutting area consist of Die and punch Diameter of the punch is stamped on the front of each die holder.

41 KETTS SAW Electrically operated Head of this saw can be turned to any desired angle Commonly used to remove damaged sections of a stringer Advantages q Ability to cut metal up to 3/16 in. thick q No starting hole required q Cut can be started anywhere on a sheet of metal q Capability of cutting an inside or outside radius

42 KETTS SAW

43 RECIPROCATING SAW Easy to handle Uses standard hacksaw blade Can cut a 360 circle or a square or rectangular hole Tool is safe to use Make sure at least two teeth of the blade cutting all the time Avoid applying too much downward pressure

44 RECIPROCATING SAW Used for rough cutting.

45 DRILL PRESS Used for drilling high degree of accuracy holes. Upright drill press is commonly used Height of the drill press table can be adjusted Part to be drilled can be clamped to the table Never insert the broken drill bit in the sleeve Wear safety goggle while drilling Personal safety is very important

46 GRINDERS- Grinding wheel Machine that removes material Silicon carbide is the cutting agent for grinding hard, brittle material (Ex. Cast iron) q Also for: aluminum, brass, bronze and copper Aluminum oxide is the cutting agent for steel, and other high tensile strength Pedestal or floor type grinder is used for sharpening tools and other general grinding jobs

47 Wet Grinder Has a pump to supply water on a single grinding wheel The water reduces heat and washes away any bits of metal or abrasive removed Water can be re-used It is used to remove mushroom heads on tools The grinding wheels are removable Wheel can be changed Wear proper safety gear

48 FORMING MACHINES Hand operated q Straight line Bar folder Cornice brake Box and pan brake q Rotary Machines Slip roll former and combination machine Power driven q Power driven slip roll former q Power flanging machine

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