The Sheet Metal Worker 1942 Vocational Guidance Films

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• published: 15 Jan 2013
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more at http://quickfound.net/links/jobs.html "Vocational guidance and training film." Public domain film from the Prelinger Archive, slightly cropped to remove uneven edges, with the aspect ratio corrected, and mild video noise reduction applied. The soundtrack was also processed with volume normalization, noise reduction, clipping reduction, and/or equalization (the resulting sound, though not perfect, is far less noisy than the original). http://creativecommons.org/licenses/by-sa/3.0/ http://en.wikipedia.org/wiki/Sheet_metal Sheet metal is simply metal formed into thin and flat pieces. It is one of the fundamental forms used in metalworking, and can be cut and bent into a variety of different shapes. Countless everyday objects are constructed of the material. Thicknesses can vary significantly, although extremely thin thicknesses are considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are considered plate. Sheet metal is available in flat pieces or as a coiled strip. The coils are formed by running a continuous sheet of metal through a roll slitter. The thickness of the sheet metal is called its gauge. Commonly used steel sheet metal ranges from 30 gauge to about 8 gauge. The larger the gauge number, the thinner the metal. Gauge is measured in ferrous (iron based) metals while nonferrous metals such as aluminum or copper are designated differently; i.e. copper is measured in thickness by ounce. There are many different metals that can be made into sheet metal, such as aluminum, brass, copper, steel, tin, nickel and titanium. For decorative uses, important sheet metals include silver, gold, and platinum (platinum sheet metal is also utilized as a catalyst.) Sheet metal also has applications in car bodies, airplane wings, medical tables, roofs for buildings (Architectural) and many other things. Sheet metal of iron and other materials with high magnetic permeability, also known as laminated steel cores, has applications in transformers and electric machines. Historically, an important use of sheet metal was in plate armor worn by cavalry, and sheet metal continues to have many decorative uses, including in horse tack. Sheet metal workers are also known as "Tin Bashers",("Tin Knockers") which is derived from the hammering of panel seams when installing tin roofs... Gauge The sheet metal gauge (sometimes spelled gage) indicates the standard thickness of sheet metal for a specific material. For most materials, as the gauge number increases, the material thickness decreases. Sheet metal thickness gauges for steel are based on the weight of steel, allowing more efficient calculation of the cost of material used. The weight of steel per square foot per inch of thickness is 41.82 lb (18.96 kg), this is known as the Manufacturers' Standard Gage for Sheet Steel. For other materials, such as aluminium and brass, the thicknesses will be different... Deep drawing Drawing is a forming process in which the metal is stretched over a form. In deep drawing the depth of the part being made is more than half its diameter. Deep drawing is used for making automotive fuel tanks, kitchen sinks, 2 piece aluminum cans, etc. Deep drawing is generally done in multiple steps called draw reductions. The greater the depth the more reductions are required. Deep drawing may also be accomplished with fewer reductions by heating the workpiece, for example in sink manufacture. In many cases, material is rolled at the mill in both directions to aid in deep drawing. This has a more uniform grain structure and is referred to as "draw quality" material which limits tearing. Expanding Expanding is a process of cutting or stamping slits in alternating pattern much like the stretcher bond in Brickwork and then stretching the sheet open in accordion-like fashion. It is used in applications where air and water flow are desired as well as when a light weight is desired at cost of a solid flat surface. A similar process is used in other materials such as paper to create a low cost packing paper with better supportive properties than flat paper alone... Press brake forming This is a form of bending, used for long and thin sheet metal parts. The machine that bends the metal is called a press brake. The lower part of the press contains a V shaped groove. This is called the die. The upper part of the press contains a punch that will press the sheet metal down into the v shaped die, causing it to bend... Punching Punching is performed by placing the sheet of metal stock between a punch and a die mounted in a press. The punch and die are made of hardened steel and are the same shape. The punch just barely fits into the die. The press pushes the punch against and into the die with enough force to cut a hole in the stock....