DID YOU KNOW THERE ARE SEPARATE TOOLS FOR SHEET METAL REPAIR OR CONSTRUCTION…? ARE YOU USING ANY SPECIFIC TOOLS ALREADY…? IF NOT, TRY OUT THESE CONVENTIONAL TOOLS AND ACCOMPLISH YOUR TASKS FASTER, SIMPLER, AND BETTER MANNER.
SHEET METALS – INDUSTRIAL USAGE & ADVANTAGES
Sheet metals are obtained by forming different types of metals into thin sheets. Fabrication is quite simple. Metals are passed through rough rolling stands at higher temperatures and thinned at different thicknesses then cooled and rolled into coils. Metals like Aluminum, Stainless steel, copper, and brass are often used in the sheet metal industry and are predominantly implemented in the Automobile, Aviation, and Biomedical industries for the part fabrication process.
Apart from famous plastic and casting metals, sheet metals provide you following advantages that can be used in different industrial applications.
- Strength and Durability
- Malleability
- Replaceability
- Sustainability
- Cost-effectiveness
To sustain the mechanical properties of a sheet metal fabricated product, better workmanship is necessary. To achieve a quality product, you should utilize the right set of tools in your hand. The correct set of tools will allow you to achieve the desired quality product out of sheet metals. So, Let’s dig into industrial tool types that are prominently used in sheet metal construction and repair.
CONVENTIONAL TOOL TYPES IN SHEET METAL CONSTRUCTION & REPAIR
Sheet metals are mainly used as a high-strength outer covering of a product. To form the required shape and design criteria, different types of tools are needed at different stages in fabricating or repairing a sheet metal product. Identify some of the tool types below when you start each fabricating step in the construction or repair process.
- Layout tools
- Marking tools
- Cutting tools
- Forming and Drilling tools
Each tool type is separated per the process sequence. Let’s discuss each tool type and the perfect tools for each type that can be found in the industrial market.
LAYOUT TOOLS
When you fabricate a desired design or repair a part, at first, you need to sketch/mark the layout in the sheet metal type or a part. To do that, the following specific tools can be implemented.
- Scales
- Combination square
- Dividers
SCALES
Scales are available in various lengths and units. For the construction and fabrication of sheet metals, you need to purchase a scale of at least a 12-inch-long ruler which is more common and affordable. The decimal and fractional units on either side are very useful as some of the dimensions need to be marked or measured in fractions such as fastener length, diameter, and metal thickness.
The above scale can be recommended as an engineering layout tool. The overall length is above 12 inches and both fractional and decimal units are included and angular measurement is given by a digital protector.
COMBINATION SQUARE
This tool consists of a steel ruler with three heads that can be moved to any position on the ruler and locked in place. The three heads respectively are a stock head that measures 90° and 45° angles, a protractor head that can measure any angle between the head and the blade, and a center head that uses one side of the blade as the bisector of a 90° angle. The center of a shaft can be found by using the center head. This is a perfect replacement for a general ruler and is commonly used in sheet metal constructions.
By considering the aforementioned criteria the above tool type can be recommended for use in sheet metal design constructions and repairs.
DIVIDERS
The dividers can be used to transfer measurements from a product to a layout in which construction is carried out. This tool can also be used as a marking tool in sheet metal construction and repairs. The below tool is made up of medium Carbon Steel and flat divider legs with a sharp end that provides the best measuring experience with easy handling.
MARKING TOOLS
Marking tools are used to mark the desired design on the sheet metal or the damaged product that needs to be repaired. The most common marking tool in sheet metal construction is scribes. A scribe is a pointed instrument used to mark or score metal to show where it is to be cut. A scribe should only be used when marks are removed by drilling or cutting because it makes scratches that weaken the material and could cause corrosion. Other than scribes, Punches and Fiber-tipped pens are the preferred tools for marking lines and hole locations.
The following scribes can be recommended for your repair or construction using sheet metals.
The tip of the above scribe is made up of tungsten steel. This tool can be used for marking hard materials such as hardened steel and stainless steel, ceramic, and glass. Sharp tips and easy handling design will make your marking process much faster.
The above scribe is the most common type of craft tool used for marking metals. The stainless steel stem will provide high wear resistance and the fine grip helps to grab the scribe comfortably.
Punches are also categorized as a marking tool but these can be used to drive bolts out of holes, loosen frozen or tight pins and keys, knock out rivets, and pierce holes in a material. There are a few punches like center punch, pin punch, drive punch, and transfer punch fabricated per the each of above-mentioned functions.
Installation of most sheet metal constructions or repairs is accomplished via attaching fasteners. The fastener type, no of fasteners, and diameter depend on the sheet metal design and the thickness. When repairing, the fastener map is essential, cause the distribution of fasteners in the required repair will affect the repair strength. If the fastener map is distributed unequally the whole repair won’t achieve the result you have expected. So, to plot the well-distributed fastener layout in a sheet metal you will need to mark the required layout on the sheet before starting drilling. To do so, center punches can be used as a perfect tool for marking fastener locations ideal for your repair.
The center punches shown below are recommended for use when carrying out a repair or installation via fasteners. The punch is made up of carbon steel and the rear end is attached with a spring enabling it to apply force easily and repetitively on the required marking points.
CUTTING TOOLS
Sheet metal cutting tools are categorized as powered and non-powered and tools range from small-size portable saws, nibblers, and grinders to large shop tools like square shears and band saws. The portable cutting tools become handy when dealing with small repairs and parts fabrications. Some of the prominent types of portable cutting tools are:
- Nibbler
- Cut-off wheel
- Hand-cutting tools (straight snips, files)
Nibblers are mostly used for cutting different extensive shapes out of sheet metals. They are usually powered by compressed air and utilize high-speed blanking action to cut the metal. The cutting speed of the nibbler is controlled by the thickness of the sheet metal. Nibblers satisfactorily cut through sheets of metal with a maximum thickness of 1⁄16 inch. Too much force applied to the metal during the cutting operation clogs the dies (shaped metal), causing them to fail or the motor to overheat. So, need to practice before operating these tools. Both electric and hand nibblers are available in the market. Refer to the below conventional nibbler cutting tool holder that can be implemented with any electric drill.
This nibbler cutter attachment can cut to a maximum of 2mm thickness of sheet metals such as aluminum, stainless steel, steel & copper. Included a double cutting head with a plastic handle which enables easy cutting to the desired direction and angle.
CUT-OFF WHEEL
The cut-off wheel is a thin abrasive disc driven by a high-speed pneumatic die-grinder and used to cut out damaged sheets in metal structures. Most suitable for repairing small sheet metal parts. They come up with different cutting disc sizes for each appliance. Cutting discs with grinding accessories can be separately purchased from the market and are available to fit in specific die grinders that suit your application.
The above grinding accessories are recommended for general sheet metal cutting purposes. It can be used for cutting mild/black steel, stainless steel, and other sheet metals. Includes necessary accessories like flange nuts, connecting shanks, and wrenches that can easily be mounted on grinders.
Hand-cutting tools are tool types that do not use electric or battery power for cutting. These tools are used for sharpening ends and cutting edges of light gauge sheet metals. There are conventional straight snips that are cost-effective and used for general sheet metal cutting purposes.
FORMING & DRILLING TOOLS
The most conventional forming, drilling tools are found in metal workshops and are heavy in size to form large-scale sheet metal structures. But if you need to form and drill a small sheet metal part to repair damage to a structure, the following tool types are the best choice.
The mallets or hammers are used to form sheet metals by deforming the sheet metal structures over repetitive blows onto the surface without marring or indenting the metal. The hammerhead is usually made of high carbon, heat-treated steel, while the head of the mallet, which is usually larger than that of the hammer, is made of rubber, plastic, wood, or leather.
In metal workshops drilling metals most conventional tool is a pneumatic drilling gun. It is more effective as it is powered by compressed air. But for general small-scale repair or design constructions portable drilling guns can be used. They are more cost-effective and comfortable in small-scale production processes.
The above portable drill enables a flat drill function with a good ergonomic handle design. Include a safe locking and support forward and reverse driving. The specifications mentioned in the above tool can be recommended for general-purpose sheet metal design construction and repairs.
The portable drills can be used as a rivet gun by attaching a riveting tool adapter to them. The attachment comes with a handle that makes the riveting process much easier and faster. Most probably these are cost-effective when compared to traditional revert guns and drills. These attachments are for general use for sheet metal repair and design construction.
FINAL DISCUSSION
Tools discussed above are some of the conventional tool types that can be recommended for general sheet metal design constructions and repairs. It is the technician or the operator’s responsibility to choose the correct tool type for the required fabrication process. The operation of these tools is not extensive but one needs to have a proper understanding of them before implementing them. Always follow the correct general techniques of each tool discussed. Keep in mind that the quality of a product always depends on the workmanship and the correct type of tool handling apart from the material suitability.
Keywords – sheet metal, design, repair, design construction, tools
Photos – Product photos from the given website – https://digitalzakka.com/
REFERENCES:
- https://westberg.com.au/how-is-sheet-metal-made/
- https://www.estesdm.com/5-advantages-of-sheet-metal-manufacturing/
- https://www.awprecision.co.uk/top-tools-sheet-metal-fabrication/
- https://www.flight-mechanic.com/tools-for-sheet-metal-construction-and-repair-part-four/