TRADE : SHEET  METAL WORKER

SYLLABUS FOR THE FIRST YEAR

WEEK NUMBER:1-36

Weekwise Syllabus: 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36

WEEK NO. -PRACTICAL TRADE THEORY WORKSHOP CAL ENGG. DRG.
1. INDUCTION TRAINING

Familiarisation with the Institute. Importance of machinery used in the trade. Type of work done by the trainees in the Institutes-types of jobs made by the trainees in trade – Introduction to safety including fire fighting equipment and their uses, etc.

                                                                    


Importance of safety and General precautions- observed in the institute and in the section . Importance of the trade in the development of industrial economy of the country. Related instructions – subject to be taught achievement, etc be made. Recreational ,medical facility and other extra curricula activities of the institute (all necessary guidance to be provided to the new comers to become familiar with the working of training institute system including store procedure , etc) Introduction to the trade ,safety precautions.

 

 

 

 

 

2. Introduction and use of marking tools. Practice in reading , Steel Rule , Scribing of straight lines ,Bisecting of straight lines (on the sheet metal ) using marking tools.

Metals and non-metals : Metals and their characteristics. Types ,sizes and uses of sheet metals. (IS: 1137-1959 )

Standard wire gauge as per ISI. Use of reference table.

Properties & uses of C.I & W.I.

Importance of Engg.Drg. and its knowledge –free hand sketches of straight , oblique and perpendicular lines .plain figures like square, rectangle, circle,

Polygons ,triangles. Etc.

3. Practice in drawing sample geometrical shapes on metals. Practice in cutting sheet metal to these shapes. Practice in marking and cutting of sheets to various angles Mild steel and non-ferrous metals marking and laying out tools –try square, dividers , trammels ,combination set , marking block , ‘L’ square , etc. Various types of snips shears & their uses.

Fundamental Arithmetical operations- Additions, Subtraction,

Multiplication, division of whole numbers.

Identification of simple geometrical solids from the given models/ teaching aids –free hand sketches for the simple solids like cube, cone, prism, pyramid, rectangular block, etc.

4. Practice on cutting with different types of snips cutting off inside and outside curve , cutting off notches.

Description and uses of guillotine shears and circle cutting machine. Brief description of hibbling machine.

Proportion and uses of plain carbon steel and alloy steels.

Importance of good printing of letters &numbers on drawing free hand practice of lettering and numbering style as per IS: 696/1972.

5. Practice on sheet metal seamed (folded joints) Grooved seam locked grooved seam, paned down seam, knocked up seam, pitts burgh lock etc.

Sheet metal joints, types of sheet metal joints. Description of sheet metal seamed : Grooved seam , locked grooved seem, paned down seem, knocked up seam, etc. Fraction and decimals conversion-fraction to decimal and vice-versa.

Standard line convention their meaning and scope of application on Engg. Drg. As per IS : 696-1972. Standard symbols for simple Engg. Elements and materials used on Drg. a s per ISI (hand outs to be used for reference ).

6.ASSESSMENT TEST

Development on parallel line method of forming rectangular shapes using stakes .Forming cylindrical job using various stakes.

ASSESSMENT TEST

Sheet metal workers tool: Bench vice, ’C’ clamps, Pliers. Bench stacks or sheet formers, types and there uses .Uses of groover and grooving rail ,Engineering hammers.

ASSESSMENT TEST

Properties and uses of copper, Zinc, Lead, Tin and Aluminum

ASSESSMENT TEST

Free hand sketches of hand tools and measuring tools related to the trade e.g, hammer .file ,chisel, drill, hack saw , tongs, snips, soldering iron, mallets, anvil, punch horn, blow pipe , electrode holder, scale. caliper ,try square, bench vice, etc. from the supplied sketches or samples.

7. Folding / bending sheet metal to 90 degree using wooden mallet, clamps etc. making a radius using wooden blocks.

Methods applied in laying out pattern -parallel line method , radial line method, triangulation line method and geometrical construction .Bending and wiring allowances for sheet metal .

Simplification , application of fundamental arithmetical operation to shop problems . -do-

8. Preparation of soft solder sticks . Practice soft soldering on lap joints, sunklap joints and plated butt joints . Making round cylinder with lap, joints and soldering, sweating practice.

Solder, different types of solder and their composition. Use of flumes ,their affects on different metals.

(IS: 193-1966)

Practice and use of brass, bronze, solder, bearing metal, timber, rubber. -do-

9. Making a cylindrical container with knocked up bottom ,grooved joint and hemmed top. Practice of simple brazing forming ‘Cramped Seam’ or Dovetail seam.

Soldering iron, their types and classification Weight of soldering iron .Process of soft soldering .Process of hard soldering or brazing .Heating appliances.

System of units –British , metric and S.I. units for length area ,volume capacity ,weight ,time angle ,their conversion.

-do-
10.Use of solid punches/ round punches as per ISI & use of hollow punches for making holes in sheet metal with the help of grained block of wood .Making ‘Chimney’ for kerosene cooker .

Solid & hollow Punches.Difference between drill and punches holes. Description of round punches as per ISI Standard sizes of solid and hollow punches and their uses .Laying out pattern of Elbow pipe (round ) & ‘T’ pipe equal die (round).

Effect of alloying elements on the properties of G.I and steel.

Importance of putting dimension on the drawing as per IS:696 – 1972 .Method to measure the sizes of simple parts and the locations of the other operational surfaces, using simple measuring instruments and method to transfer the measurements on the drawings of the features for dimension .Free hand sketches of study the techniques employed in dimensioning on the drawing of features for size, location , hole, arcs, angles , chamfer, taper etc. from given samples or sketches.

11. Making holes in sheet metal using punch machine .Making holes in sheet metal with a twist drill , Tri-planning with use of hand and electric drilling machine. Grinding a drill bit.

Brief description of hand punch machine. Hand and power operated drilling machines. Drill bits, parts and effect of cutting angles. Angles for drilling sheet metals. Effect of speed, feed, cutting fluids, etc. on metals.

Heat and temperature thermometric scales, their conversion , temperature measuring instrument , quantity of heat ,specific heat , latent heat, heat loss and heat gain-simple problems . -do-

12. Rivetting practice using various types of rivet heads . single chain riveted joint. Double chain and zig- zag riveted joints.

ivets and riveting – riveting pitch parts ,selection of rivet heads. Types of rivet and their uses ,standard sizes of rivets and riventing tools. calculation for riveting allowance.

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PROGRESS TEST

ACHIEVEMENT: Able to:

  1. Use various hand tools .
  2. Mark off ,cut various sheet metals and make joints.
  3. Solder and Brass .
  4. Bend sheet metal with hand tools ,
  5. Make simple containers hemmed tops and bottom .
  6. Do simple riveting .
13. Making a dust pan corner riveted , handle riveted . making a fire bucket with riveted joint. Development of radial line method ‘Cone’ Selection of rivets with reference to type of joint according to thickness. Rest and motion, velocity , acceleration. Isometric and oblique drg. Their methods of representation using simple solids like cube, stepped block, cylindrical features, prisms etc. Free hand sketches for given feature.
14. Exercise using pop rivets . exercises involving practical work on aluminum sheet . Description of tools for riveting such as lazy tongs , pneumatic riveting guns rivet squeezer. Newton’s laws of motion . --do--
15. Practice in drilling holes in brick walls as applied to ducting work(use of masonry bits ).use of rawl bits and rawl plug. Technical abbreviation used in the trade. Definition of trade term , such as pattern , development , stretch out Pattern , master pattern, template etc. Moments of forces , simple problems on straight and bell cranked levers. --do--
16. Practice on hollowing and raising on non –ferrous sheet as well as ferrous sheet. Process and operations of the topics mentioned in week no. 15.

Folding , Bending, seaming, notching, turning, grooving, edge stiffening hooming , wiring , forging, etc. Dev. of spherical /hemi spherical shapes of articles.

Mass, volume, density ,weight, C.G.S., M.K.S. and F.P.S units of force weight etc. their conversions-shop problems . -do--
17. Practice on removing dents of spherical or hemi-spherical articles

using wheeling and raising machine(repairing mud guards etc. )

Sheet metal hammers , types , classifications and their uses . Mallets types materials and their uses .Brief description wheeling and raising machine --do-- --do--
18. Wiring practice on straight edge . wiring practice on curved edge . making a rectangular article with wired top. Description of hacksaw frame and hacksaw blades their specifications. Description of folder type of bar folder , wing adjustments and explanations . Power and roots –factor, power , base, exponent, Multiplication and division of power , root of number, square root and problems related to trade . --do--
19. Fitting a flange to a circular pipe by using cramped joint . Clips and connectors : their uses ,types and allowance of ‘S’ clips, Government clips, drive clips , mailing clips etc. -do- Orthographic projection std. System (Ist angle orthographic and #rd angle orthographic projection) as per IS : 696-1972 Free hand sketches of simple objects like Vee blocks, stepped block, simple brackets blocks with holes and grooves to represents the views both in Ist and IIIrd angle orthographic projection with dimension.
20. Making various types of locks and joints as applied to ducting work, joining elbows. Fastening of sheet metal. Various type of fastening devices for sheet metal. Screws, self threaded screws, etc. Development of ‘T’ pipe (square ). Effect of forces on materials – application as extending , bending . twisting , shearing , etc meaning of stress and strain. --do--
21. Forming square section segmental quarter bend pipe with suitable lock. Introduction to tube and pipes. Laying out pattern of segmental quarter bend pipe. Description and operating principles of seaming machine. -do- --do--
22. Practice on cutting cylinder obliquely. To make a ‘T’ pieces of equal diameter (round) and joint them at right angle. Laying out pattern of cylinder cut obliquely . Description of roll forming machine ,types and operating principal. Description of slip roll forming machine and its function. Percentage-changing percent to decimal and fraction ,and vice-versa. -do-
23.To make a ‘T’ piece with unequal diameter pipe. To make a 60 degree ‘T’ piece with unequal diameter pipe . Laying out pattern of 60 degree unequal dia ‘T’ pipe . Corrosion on metals, detection’s and remedies. Problems on percentages related to trade . -do-
24. Practice on pipe bending (hand process) pipe bending using hydraulic pipe bending machine Introduction to pipe /tube bending. Brief description of hydraulic pipe bending machine ,operating principles etc. Meaning of stress ,strain

Modulus of elasticity .

-do-
25.Making a ‘MUG’ with wired edge. Side and bottom locked grooved and nocked up joint Hemmed edge handle. Description of ‘Mandrel’ preparation of pickling solution .Protection –coating, cleaning and preparation of sheet metals. Meaning of tenacity, elasticity, malleability. Brittleness, hardness , ductility examples.

Ration and proportion

Ratio finding terms and ratio; proportion ,direct proportion and indirect proportions

Importance of sectioning on drawing Std. Methods (full and half section, revolved & removed section, local section) as per IS: 696-1972 std. for parts which are sectioned. Free hand sketches to represent the different sectional views in the given orthographic drawing of parts with the supports of models etc. simple hollow block &simple casting with dimensions.
26.---------------------------- REVISION      AND HALF YEARLY TEST --------------
27. Making a 60 degree off-set ’T’ piece(Round) and two way piece equal angled .angled. Laying out pattern of 60 degree off- set ‘T’ piece. Patterns development of ‘Y’ piece (Round) . Method of galvanizing , tinning, anodising, sherardising. -do- -do-
28. Cone forming in frustum, Pattern development of ‘Frustum of cone.’ Description of swaging and Deading machine, its parts, operating principles, etc. Application of ratio and proportion to shop problems .Mixed direct and indirect proportions-problems. -do-
29. (a) To make a taper chute squares to square.

(b)To make a taper chute and flat back.

Laying out pattern of taper chute square to square. Non-ferrous metals. Use of copper and alloys. -do- How to convert isometric/oblique drg. to orthographic to isometric/oblique drg. Problems for free hand sketches for trade related simple parts or exercises.
30. Forming on Elbow between round &conical. Lobster back shape bend. Laying out pattern of conical elbows. Pattern development of lobster back bend. Chemical & physical properties of aluminum. Use of aluminum and its alloys.

 

  -do-
31. ALLIED TRADE TRAINING:

Welding: simple tacking by gas welding on ferrous metal sheets.

Types of gas cylinders, differences between Oxygen and acetylene cylinders. Pressure gauges used on cylinders. General description of oxyacetylene plant and the equipments, precautions to be taken while operating gas cylinder. Algebraic symbols and fundamentals, algebraic operations. -do-
32. Practice in welding butt joints on ferrous metal . Practice in welding on non- ferrous sheet metals .Spot welding practice. Types and description of filler rods (SI:1273-1967).Fusion welding and spot welding on black iron sheet .Description of welding using filler rods. Sign and symbol used in algebra, coefficient, terms –like and unlike terms. Free hand sketches of standard rivet forms as per I.S.I Welding symbols as per I.S.I. employed on drawings-Std. forms of key & cotters.
33. Welding practice on sheet metal making pipes (three way tapered ‘Y’ piece). - do -

Description of fluxes for dissimilar metals.

Algebraic addition, subtraction, multiplication and division. Power & exponent, laws of exponent. --do –
34 . Prepare a tapered tray with welded corners. Brazing copper & brass, articles by making cylindrical pine. Silver soldering of copper pipes. Methods of brazing using blow pipes. Construction and use of blow pipes of Oxy-acetylene set. -do – Free hand sketches to study the method of surface- development of simple geometrical solids like coke, cone, prism, pyramid, rectangular block etc.
35. Make a 90 degree elbow with black iron sheet welded joint. A lobster back bend with welded joints. Types of nozzles and purposes, other types of blow pipes for other gases, butane and coal gas. Principle of carbide generator, use of coal gas for heating. Algebraic simplification- problems. Electricity and its uses. Electric current positive and negative terminals uses of fuses & switches conductor and insulators. - do -
36. Arc welding (Tacking) practice. Fusion welding stainless steel. Fusion welding on aluminum & its alloys. Fundamentals of arc welding. Advantage & disadvantage of electric arc welding. Precaution to be taken while welding other metals and alloys. Simple explanation about the use of oxy. cutter, method of over coming distortion while welding. - do - Screw thread forms as per ISI, conventional application of internal and external screw thread.

Free hand sketches of nut, bolt, screws etc.