MCE 2323 Lab Report

Table of content:

Content No. of Page

Safety rules 3
Personal Protective Equipment 4
Introduction, Objectives and Apparatus 5
Procedure 6
Experimental setups and Photos 7
Analysis, Discussion and Conclusion 8
Guide Questions 9
References 10

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Safety Rules:

• Put a protective clothing: lab coat, overall, safety shoes.

• Never enter the laboratory without permission.

• Wear goggle and gloves for necessary protection.

• Tie back long hair and dangling sleeves/ clothes.

• Take off loose and long jewelry.

• Familiarize yourself the location of fire safety devices, first- aid box and

emergency exit.

• Always follow instruction from your teacher; if in doubt about something

you should ask your teacher.

• Switch of the machine before adjusting and cleaning.

• Press the Emergency/ Estop button in case of accidents and inform lab in

charge immediately.

• Report any spillage or breakage immediately to your lab in charge.

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Personal protective Equipment (PPE)

• PPE is defined as all equipment which is intended to be worn or held to

protect against risk to health and safety.

• Eye Protection: Serves as a guard against the hazards of impact, splashes

from chemical or molten metal, liquid droplets (chemical mist or sprays),
dust, gasses and welding arcs.

• Foot Protection: Shoes made with a protective reinforcement at the front to

protect your ankles, toes and feet from injury. The reinforcement helps to
protect the toes from falling objects or any kind of compression.

• Hand Protection: Gloves provide protection against a range of hazards

including cuts and abrasions, extremes of temperature (cold or hot).

• Protective clothing: Designed to protect the body from injury or infection.

The hazards addressed by protective equipment include physical, electrical,
heat.

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EXPERIMENT 5: Sheet metal forming rolling and riveting

Introduction:
Sheet metal is a process of being modified pieces of sheet metal without removing any
material. It is not a specific material, the material used should have a specific characteristic
such as toughness, rigidity, and ductile. Also, it gives the ability to stretch the sheet. In the
manufacturing industry, four main methods are used to fabricate a metallic product such as
casting, cutting, joining, and metal forming. It’s difficult to use casting to produce complex
shapes. Also, in the metal cutting process because a lot of materials are wasted. In this
case, we can use the rolling process which is a metal shaping process in which stock of the
material is passed between pairs of rollers to reduce and maintain the thickness. As we
know it is focused on the cross-section of the ingot. The riveting process can be used to
join parts together when lightweight and high strength are vital to the application. They can
fasten wood, metal, and plastic.

Objective:

• To learn sheet metal forming by rolling machine and finish the job by joining process
(riveting).

Apparatus:
The apparatus consists of the following:

§ Scriber
§ Steel rule
§ Try square
§ Mallet
§ Bench vice
§ Tin snip
§ Punch rolling machine
§ Rivet gun and rivet
§ Drilling machine

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Procedure:

1. The size of the given sheet is checked with steel rule.

2. Mark the measurement and make the development surface sketch diagram.
3. The layout of the drawing is marked on the given sheet.
4. The sheet which needs to be rolled is placed on the rolling machine.
5. Adjusted the tightening of rods on rolling machine.
6. Turn the rolling machine to get the desired cylindrical shape.
7. The base sheet is sheared to the required shape using shearing machine or tin snip.
8. Apply the required force using mallet placing on vice to achieve the required shape
at corners for support the base plate.
9. Also bend the clamps to place the cylindrical shape on the base sheet.
10. Rivet the points so as to hold the work piece on position to get the desired shape.
11. Also complete the joining process (riveting) of the sheet metal formed on last
exercise (lab2) to achieve the desired shape.

Figure 1: Rolling machine

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Experiment setups:
First, we take the dimenmsions of the given sheet metal using the ruler (210mmX145mm).
Second, we drew lines using the scriber to know where we will cut and the lines were
apparent on the sheet. Third, we used the shearing machine to cut the sheet metal to the
desired shape. After cutting the sheet metal, we placed the sheet metal on the rolling machine
then we turned the machine to get the required shape which is cylindrical shape. Then, we
applied force by using mallet to the cylindrical shape to get the desired shape. The sheet
metal that sheared by the shearing machine has been used as a base. We draw lines by using
the scriber in each corner on the base sheet. After that we used the bending machine to bend
the corners of the base sheet and the clamps to place the cylindrical shape on the base sheet.
At the end, we used the drill to make holes on the cylindrical shape, base sheet and the
clamps. Then, we riveted all the holes (Joining process) to hold the cylindrical shape to get
the desired shape.

Photos of the experiment:

Figure 2: Sheet metal Figure 3: Adjusting the dimensions Figure 4: Cutting the sheet metal

Figure 5: The sheet metal after the cutting Figure 6: Rolling machine Figure 7: Bending machine

Figure 8: The sheet metal after the Figure 9: The base and the clamps Figure 10: Final shape
rolling and riveting machine

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Analysis and Discussion:

In this experiment, we analyzed that sheet metal can be used in a large number of
manufacturing processes. Which include welding, bending, drawing, shearing, punching
and more. As the sheet metal can be bended and cut into various shapes and dimensions.
We observed that in Rolling operation there are three rolling pins and when the metal
sheet passes through them the thickness reduces and turns it into cylindrical shape easily
by rolling the handle. Lastly, we used rivets to enclose the cylindrical shape by applying
force with the help of a drill, we got a hole where we placed the rivets and we used a
rivets gun to remove the access piece of the rivet.

Conclusion:

In conclusion, we achieved the goal of the lab which is learning new manufacturing
process which is rolling operation but in riveting we became capable in doing rivets
because we done it in the previous experiment. Moreover, when handling with these
machines we should be careful and wear protective gear because the equipment could be
dangerous if not handled safely. Lastly, the experiment was easy and interesting as the
instruction given clear and helpful in achieving our task.

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Guide Questions:

1. Differentiate rolling and drawing?

• Drawing is a metalworking process that uses tensile forces to stretch metal, glass,
or plastic. As the metal is pulled, it stretches thinner, into a required shape and
thickness. Drawing is classified in two types: sheet metal drawing and wire, bar,
and tube drawing.

• Rolling is a metal forming process in which metal stock is passed through one or
more pairs of rolls to reduce the thickness and to make the thickness uniform.
The concept is similar to the rolling of dough.

• Drawing is different from rolling in that the pressure of drawing it not

transmitted through the turning action of the mill, but instead depends on force
directed locally at the area of compression.

2. Mention any 2 types of rivets?

• Solid/round head rivets: Solid rivets are one of the oldest and most reliable
types of fasteners, having been found in archaeological findings dating back to
the Bronze Age.

• Oscar rivets: Oscar rivets are similar to blind rivets in appearance and
installation but have splits (typically three) along the hollow shaft.

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References:

• Drawing (manufacturing). (2020, July 02). Retrieved October 17, 2020, from
[Link]

• Metal Rolling and Drawing - Ganoksin Jewelry Making Community. (n.d.). Retrieved
October 17, 2020, from [Link]

• Rolling (metalworking). (2020, October 05). Retrieved October 17, 2020, from
[Link]

• Rivet. (2020, August 29). Retrieved October 17, 2020, from

[Link]

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