METAL WORKS

MODULE 2

NAME: ____________________________________________
YEAR & SECTION: __________________________________
INSTRUCTOR: BLAZE R. QUIBAN, LPT
 LESSON BENCH METAL AND SHEET

6 METAL WORK

Title
5
Module No. and MODULE 2: METAL WORKS

Lesson No. and LESSON 6: BENCH METAL AND SHEET METAL WORK
Title
Learning
Outcomes
A. DISTINGUISH THE BASIC PROCESSES IN BENCH METALWORKING.

Time Frame 3 Hours – Week 12

Introduction
BENCH METAL WORK

This area of metal work deals with the use of hand tools for laying out, cutting, shaping,
forming, drilling threading, assembling, and testing work at the bench.

Metals like mild steel, aluminum, copper, and others in the form of rods, squares, flat bars,
and sheet stocks of various sizes and thickness will be used.

The metal is worked cold with hand tools and machines such as drill press, grinders, buffer
and others.

Basic processes in bench metalworking

1. Measuring and laying out stocks - measuring and marking to correct sizes then transferring
the patterns to the materials being used.

Measuring and laying out tools:

a. Rules - It varies in length, width, and thickness.
b. Scriber - a pointed steel instrument that is used to scribe or scratch lines on most metal
surfaces.
c. Squares - the combination square set is a very useful measuring and layout tools.

2. Cutting metals - tools or machines are used to cut ferrous or non-ferrous metals. The most
common tools are: hacksaw, cold chisel, bench shears, and power saw.
 3. Filing metals a file is a hard steel instrument made in various sizes, shapes and cuts of teeth.
It is used for cutting, smoothing and removing small amounts of metal.
Three distinguishing features of a file:

1. Length - the distance between the heel and the point. (The tang that is made to hold the
handle is not included in the length).

2. Kind or name - the various shapes and styles that are called by such names as; flat file, mill
file, half-round file, round file, triangular file, quadrangular file.

3. Cut - refers to the character of the teeth such as; single, double, rasp, and curved, and also
to the coarseness of the teeth such as rough, coarse, bastard, second cut, smooth, and dead
smooth.

Factors in selecting the right files for the job:

1. Size of work - use a large file for large work and a small file for small work.

2. Flat or convex surface - use a flat file for flat surfaces and a half-round file or round-
shaped file for curved surfaces

3. Rough cutting - use a course double-cut file.

4. Square corners or enlarging square or rectangular openings - use a square file.

5. Filing circular openings or curved-surfaces - use a round file

6. Finishing a surface - use a single cut file in the second cut bastard, or a smooth file.

7. Hard steel-use a second-cut file.

8. Soft steel - use a bastard file.

9. Brass aluminum and lead –use a special file.

10. Draw filing - use a single-cut mill file. Generally, a mill bastard file is used for draw
filing.

11. Drilling by hand - use a hand drill.

12. Drilling with portable power drill – it is used the same way as hand drill, except that
you do not have to crank it.

13. Drilling with a drill press - the drill press automatically holds and rotates the drill bit at
the upper angle with the work.
 14. Bending metals - metals may be bent by right angles, acute angles, and obtuse angles.

Most of the ferrous and non-ferrous metals 14 inch or less in thickness can be bent cold. To
make angular curves, make a full-size layout of the part to be cut so that you can determine the
amount of metal to allow for the bends.

To make a right angle bend, add an amount equal to the thickness of the metal for each bend. If
more than one bend is to be made, decide on the order of bending to determine where to make the
allowances for bending in the layout. This is necessary because the extra amount added to the length
should always be placed above the vice jaws when making the bend.

▪ Twisting metals - twisting is used to give additional strength and to change the position of
the piece so it can be fastened at the end. Mild steel bend 4 inch or less in thickness and 1
14 inches or less in width can be bent cold. Square rods or mild steel up to 4 can be bent
without heating. To bend or twist Target stocks, heat the metal to dull red color in a forge or
in a torch.

▪ Forming a scroll - a scroll is a piece of metal which have been bent to a circular shape to
form a spiral similar to the shape that would be formed if a clock spring were spread open.
It is usually used for decorative purposes.

▪ Bending small pipe or tubing - Pipes and tubes can be formed successfully by using a jig.
If a sharp bend is necessary, fill the pipe or tube with wet sand or molten lead. This will
prevent the pipe or tube from collapsing while being formed. Place the pie or tube on the jig
and slowly draw it around the form. Remove the sand or lead after the desired shape has
been formed.

▪ Cutting threads - the cutting of threads on the metal rods (called exterior thread) and the
interior of the holes drilled in metal (called interior threads) is an important phase metal work.
Threads are used by metal worker to transmit motion to provide for adjustments and to fasten
parts together.

▪ Taps and Dies - are the tools used for cutting threads. Taps - are used for cutting threads
in the interior of the holes. Dies - are used to cut treads on the surface of the metal rods or
pipes.

SHEET METAL WORK

The most common types of sheet metal used in shops are, tin plate, mild steel coated with
tin, galvanized steel, mild steel coated with zinc, cold finished steel sheet, aluminum, pure or alloy
brass, alloyed copper, and zinc and copper. Sheet metal is available in various sizes and thickness
that is measured with a sheet metal gauge.

Laying out and developing patterns:

Before constructing a sheet metal project, it is necessary to first develop a "stretch out" or
(pattern) either on a sheet of paper or on the metal. The inexperienced sheet metal worker should
 draw the pattern on a sheet of paper first to see if any mistakes have been made. The pattern is then
transferred to the metal by scribing the lines directly on the metal. Use a pencil if a scriber mark is
objectionable. If several pieces the same kinds are to be made especially where irregular curves are
involved, a metal template is used. This template is placed on the metal and a scriber is used to trace
around the outside.

Kinds of pattern development:

1. Parallel-line development - used for making cylindrical patterns.

2. Radial line development - used for triangular or conical patterns. Ex. Funnel (in-line pyramids)

3. Triangulation - used for making curved patterns. 4. Straight-line development- used for pattern
development of squares or rectangular boxes. (prismatic shapes)

Activity
A DIAGRAM:
• Create an illustration/or Venn diagram that showcases the distinct differences of bench metal
and sheet metal according to their properties.

Score Description

5 The Venn diagram is exceptionally clear and well-organized. Categories and their intersections are accurately
(Outstanding) represented and effectively illustrate the relationships between the items. The diagram is comprehensive, with
all relevant information included and clearly labeled. The visual presentation is highly polished and enhances
understanding.

4 (Very The Venn diagram is clear and well-organized, with accurate representation of categories and intersections. Most
Good) relevant information is included, and the diagram is presented in a way that is mostly easy to understand. Minor
issues in labeling or presentation do not significantly detract from the overall effectiveness.

3 The Venn diagram is generally clear but has some issues with organization or accuracy. Categories and intersections
(Good) mostly represent the intended relationships, but there may be minor errors or omissions. The presentation is
adequate but could benefit from improved clarity or refinement.

2 The Venn diagram has noticeable issues with clarity and organization. Some categories and intersections are
(Fair) inaccurate or poorly defined, leading to partial understanding of the relationships. Relevant information may be missing
or poorly labeled, and the overall presentation is somewhat unclear.

1 The Venn diagram is unclear and poorly organized. Many categories and intersections are inaccurate, resulting in
(Poor) significant confusion about the relationships. Much of the relevant information is missing or incorrectly labeled, and the
visual presentation is unpolished.

1. What are the primary differences in the chemical composition of bench metals and steel
Analysis metals? How do these differences impact their physical properties and applications?
Abstraction Cutting sheet metal

Sheet metal 18 gauge or thinner can be cut using bench shears. Standard tinner's snip will cut up to
22 gauges. Others are designed for special purposes.

Straight snips -are for cutting straight lines and large outside curves.
Aviation snips - are used for cutting compound curves and intricate designs.
Hawk-billed snips - are used for curved cuts. It has narrow curved blades.

• Never cut with full length of the blades. If blades are completely closed, points will tear the
metal. Stop each cut about 4 inch from the end of the blades.
• Cut to the right of lay out lines when possible.
• When cutting outside curves, first rough out leaving about 1/ 8 inch beyond layout line. Finish
by carefully cutting around layout line.
• To cut inside curves, first punch or drill a hole in the waste stock to allow the blades of the
hawk-billed snips to get started. Insert the snips from the underside of the stock and rough
cut the inside opening to about 14 inch of the layout line. Then trim the hole to size.

Bending by hand

To make angular bends by hand, clamp two pieces of hardwood or angle iron in a vise, with
the sheet metal between them If the metal is too large to fit the vise, use two cclamps. The line where
the metal is to be bent should be even with the upper edge of the jig. To bend the metal down, start
by striking light blows with a mallet at one end and work along the full length of the stock. Continue
working back and forth making a gradual bend.

Bending cylindrical forms by hand

A cylindrical piece may be formed to shape by bending it around a stake, rod or pipe that is
slightly smaller or equal to the diameter of the bend.

Bending metal on a bar folder

The bar folder is a folding machine that comes in various sizes, the most common of which
has a folding length of 30 inches

• These machines will fold an edge as narrow as 1/8 to 1 inch on metal as heavy as 24 gauge.
A 3/16-inch fold is the narrowest end practicable when using 2 gauge metals.
• The bar folder is used for making single or double hems, a sharp or open lock, turning an
edge to receive the wires and turning flanges.
Forming metals on a forming machine
The forming machine or rolls, as they are most commonly called, are used for curving sheet
metals and forming cylinders of various diameters. The most common folding machines have rolls
that are 30 to 60 inches wide and 2 inches in diameter.
Application
Based on the “BASIC PROCESSES IN BENCH METALWORKING” give key points on the things
you have learned. By writing a 3-2-1.

3 CONCEPT I LEARNED
2 THINGS I FOUND VERY INTERESTING
1 THING I NEED TO LEARN MORE

Closure
References

Jones, M. R., & Patel, S. (2024). Understanding sheet metal and bench metal applications. Engineering Books Ltd.
Green, P. T. (2024). Fabrication techniques for bench metals. In L. Brown (Ed.), Advances in metalworking: Bench metals
and beyond (pp. 45-67). Metalworks Press.