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

Mar 29, 2015

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Page 1: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Metal Working Processes, Tools,

and Machines(sheet and small section steel)

Eng. Bob FairchildCHAB Stove Camp

The Farm Sept 2012

Page 2: 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

• Stainless steel sheet• Plain steel rod, rebar, bar, angle• Slotted angle• Expanded metal• Hardware cloth• Steel pipe, conduit

Page 3: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

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

Page 4: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

“Processed” materials

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

Page 5: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

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

Page 6: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Measuring tools

Page 7: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Marking tools

Page 8: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

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

Page 9: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Twist drills Step drills

Page 10: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Hole saws

Bimetal Carbide

Page 11: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Hollow punches Hand punches

Page 12: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Knockout punches Foot lever punch

Page 13: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Cutting• Hammer and chisel• Hand and power snips• Hand and power nibblers• hand notchers• Hand and 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 and power saws (hack, jig, circular, chop, …)

Page 14: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Snips

Page 15: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Nibblers

Page 16: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.
Page 17: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Hand notchers

Page 18: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.
Page 19: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Lever notchers

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

Page 20: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Slotted angle shear

Page 21: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Circle cutter – electric drill powered

Page 22: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Hand lever shears

Page 23: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Shear machines

Foot shear Circle shear - manual

Page 24: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Drum deheaders

Page 25: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Grinding

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

Page 26: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Angle grinders

Page 27: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Bending

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

Page 28: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Pliers benders

Page 29: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Bending machines

Cleat bender (1/2” (12.5mm) 180° fold)

Sheet metal brake (bender)

Page 30: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Angle iron cutter, notcher, bender

Page 31: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Rolling(making cylinders and rings)

• Hand rolling• Slip roller – sheet metal• Bead roller, edger, flanger• Ring roller – bar/angle/rod

Page 32: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Manual rolling machines

Slip roll Bead roller Ring roller

Page 33: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Joining

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

Page 34: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Rivet gun

Page 35: Metal Working Processes, Tools, and Machines (sheet and small section steel) Eng. Bob Fairchild CHAB Stove Camp The Farm Sept 2012.

Spot welder