ME/ISE 110 Lab Dr. Samuel C. Obi

SHEET METAL PROJECT (50 POINTS)

Sheet metal fabrication provides an excellent way of exploring manufacturing processes, such as measurement, layout, shearing, notching, punching, bending, hemming, spot welding, finishing and the associated safety procedures. To this end, a simple sheet metal product will be fabricated within the activity time schedule.

OBJECTIVES

1. Introduce students to basic manufacturing processes.

2. Give students an opportunity to fabricate a product and provide process documentation.

MATERIAL

Each student will be given enough 20-gage plain sheet steel to fabricate into an approved product. The student may purchase extra and/or associated material(s) as the case may be.

REQUIREMENTS, CRITERIA, AND FORMAT OF PROJECT

Students are required to review and familiarize relative laboratory tools, safety procedures and instructor demonstrations before engaging in this project. All written work must be typed. Each student must produce the following within the activity time schedule provided (see product activity schedule):

1. Process Planning Documents:

a) Process charts (8 points)

b) Operation process charts (7 points)

2. A product approved by instructor to meet the following product quality attributes:

a. All specified product dimensions to be within +/- 05” (15 points)

b. Overall finish (burrs, dents, warps, roughness etc.) (10)

c. Product functionality (functional, completeness, durability, sits flat when

assembled, strong weld etc.) 10

EXTRA CREDIT (3 Points)

You may want to paint your product for extra credit of three (3) points. The painting is not a requirement but may demand additional skill, time and material. The paint job must not show any evidence paint runs, uneven spray, wetness, pealing etc.

SUGGESTED PROCEDURES

1. Begin by studying the drawings provided by instructor

2. Do your process planning (must be typed)

3. Determine amount of material needed using the formula: total length of blank before bending = L = l1+l2+...+(Pa1/180)R1+(Pa2/180)R2 +... (Where R= radius of neutral axis= a+0.4t; a = inner radius of bend; t = thickness of sheet metal)

4. Cut rough stock

5. Trim to size

6. Do the layout

7. Process material

8. Submit for grading

ME 110 Lab Dr. Samuel C. Obi

GRADING CRITERIA FOR PROJECT ONE (50 POINTS)

STUDENT: _______________________________________

CRITERIA POSSIBLE POINTS POINTS EARNED

PROCESS PLANNING:
1. Process charts 8 ______________

(Completeness, format & clarity)

2. Operation process chart 7 ______________

(Completeness, format & clarity)

PRODUCT QUALITY:
1. Required dimensions to be

within +/- .o5” 15 ______________

(Completeness, within tolerance etc.)

2. Overall finish (burrs, dents, warps,

sharp corners, scratches, rough

finish etc.) 10 ______________

3. Product Functionality (functional,

completeness, durability, sits flat when

assembled, strong weld etc.) 10 ______________

EXTRA CREDIT:

1. Paint quality (paint runs, unevenness,

wet paint, pealing paint etc.) 3 ______________

TOTAL POINTS RECEIVED OUT OF 50 ______________

Comments: ________________________________________________________________________________________________________________________________________________________