LAB REPORT FABRICATION(BMMP) G6

BMMP 1303 LAB 1

FAKULTI TEKNOLOGI KEJURUTERAAN
MEKANIKAL DAN PEMBUATAN

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

MANUFACTURING PRACTICE

LAB REPORT 1
SHEET METAL FABRICATION

INSTRUCTOR’S NAME TS HASSAN B. ATTAN

STUDENT’S NAME MATRIX NO: GROUP
S1. MUHAMMAD HAKIMI B YUSRI B092010026 6
B092010464
S2. THANESHWARAN A/L BALU 6

ASSESSEMENT RUBRICS MARK GIVEN MARKS
ALLOCATI S1 S2 S3 S4
ASSESSMENT TASK/ITEMS
ON
1 Procedure (Indroduction & define project
objectives) 10

2 Work Process (Ability to show works 20
process by own understanding & words)
20
4 Outcome (Results – Table) 30
5 Outcome (Discussion)
20
Answer all questions
6 Outcome (Conclusion) 100

experience gained & recommendation.

TOTAL MARKS

Approved By: ………………………………………………..…..
(Instructor’s Signature & Stamp)

Date: …………………………………………….........

1.0 THEORY

The term ‘sheet metal’ is used to mean metal having thickness in the range from 0.4mm to 6 mm. When
the thickness is more than 6 mm, the metal is called a plate.

Products made from sheet metal can be found almost anywhere. Metal tables, steel cabinets, car bodies,
beverages cans and home appliances are some of the common examples. The advantages of sheet
metal are high strength, good surface finish, good dimensional accuracy and relatively low cost. Sheet
metal can be economically used in mass production, such as in the production of heating, ventilation
and air conditioning parts.

2.0 EQUIPMENTS/ EXPERIMENT APPARATUS/ CONSUMABLE MATERIALS
Equipment used:
1. Shearing machine
2. Bending machine
3. Rolling machine
4. Drilling machine
5. Drill Bit
6. Riveting tools
7. Vernier caliper
8. Hammer
9. Mallet
10. Anvil
11. Ruler
12. Scriber
Raw Materials:
Galvanized plate 0.5 – 1.5mm thickness

3.0 PROCEDURES/ METHODOLOGY
Write down the procedure of the fabrication process.

*Instruction to students during lab session
Refer Attached Drawing
1. Obtain a sample of sheet metal product from t he lecturer
2. Sketch the product with accurate and proper dimensions
3. Produce a complete drawing of the product
4. Obtain proper materials, measuring tools, cutting and hand tools
5. Measure and cut the raw material of the sheet metal provided based on drawing
6. Apply suitable tools and equipments to fabricate the product
7. Take and record measurements of the completed product

8. Submit the product and lab report.
9. Refer Attachment 1 for detail drawing.
4.0 RESULTS
Students are required to state the measurement of the finished product.
Paste the picture of finished product in this section.

Y

X
Z

Figure 1 Example picture of Finished Product

Table 1. Data obtain from actual product

Drawing Measurement X (length) Y(width) Z (height)
Measurement Data 190 75 95
189 74 85

5.0 DISCUSSION
For discussion, you should answer all questions as follows:
1. List 5 safety measures while operating machines in metal fabrication lab.

Inspecting Tools: This is needed prior to the start of the project. The tools should be tested and
reviewed for malfunctions to ensure that they are in good working order..

Handling Products: Handling raw materials, equipment, and finished goods falls under this category.
You can move large or heavy items with the right material handling equipment..

Tool Usage: It is important to maintain the right amount of security. When using hand tools or presses .
Presses and other large machinery are equipped with guards and other safety features. Generally, these
are fit by the manufacturer. Ensure that you are well versed with these features and utilize them regularly.

Protective Clothing and Equipment: Protection equipment should be worn by anyone who works with
sheet metal fabrication materials. Make sure your back and neck are properly protected when working
with or handling any product.

Precaution : A safe and injury-free metal fabrication project depends on your ability to pay attention. It is
important for sheet metal workers to take some precautions before beginning work.

2. List 3 main components of shearing machine or bending machine and briefly explain their
functions

The Bend Dies
The first component to consider is the bend die. A bend die is used to form the tube and
determines the radius of the bend. There are a number of standard die configurations, as well as
pedestal and flange mount bend dies. The application requirements will determine which style of
bend die is appropriate, but pedestal and flange mount bend dies are used in situations where
the height is larger than the width and for situations where there is not enough material left for a
post through the hole.

Mandrels
The mandrel is the component that supports the inside of the tube, which prevents collapse and
wrinkling during bending. Steel/chrome mandrels are used for bending steel, copper, aluminum,
and bronze tubing. While Aluminum/bronze mandrels are used for bending stainless, titanium,
and inconel tubing.

The Wiper Die
The wiper die supports the tube on the inside of the bend to prevent wrinkles. Steel wiper dies
are used for bending steel copper, aluminum, and bronze tubing. While aluminum/bronze wiper
dies are used for stainless, titanium, and inconel tubing.

3. Discuss any finding of difficulty based on this lab project activities.

BENDING PROCESS: The aluminium plate was hard to bend at the correct angle. We can'tsee
the plate clearly enough to get a consistent angle. Lastly , we are unable to see the labelling line
due to the machines.

6.0 CONCLUSION

Finally, we were able to follow the workshop's safety and project procedures. During this fabrication
lab session, we also learned how to use bending, cutting , shearing, and drilling machines. After
completing all of the procedures, we were able to obtain a satisfactory final product that
nearly matched the drawing on the lab board.

7.0 OTHERS