1.0 INTRODUCTION

In manufacturing process study, we had asked to do a fabrication project to fulfill

our syllabus. This project is only one of the some projects that have been schedule

for us this semester. In fabrication, we need to organize a creation based on sheet

metal that supplied to us. We are needed to plan in detail and organize the project

carefully because many factors are evaluated while finishing the project.

Sheet metal that is given to us is about 4-6mm thick. The project that we have

planned must not too big because of the limitation of sheet steel given. Sheet

metal is one of the fundamental forms used in networking and can be cut and bent

into a variety of different shapes. Some of major industries in which sheet metal

play an important part are heating and air conditioning, air craft, ship building,

freight cars, refrigeration, steel furniture and etc. In our syllabus, we only use a

simple technique of fabrication, simple tool as a basic study.

In our project, we decide to create an army news day special weapon; a rocket

artilleries.

We choose to make this model because some reason;

1. It was an automotive development study, just like our course.

2. The model is quite simple and we can finish it on the time

3. The model has some mechanism that will make our model special.

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1.1 OBJECTIVE

Our objective for this project is mainly to fulfill our syllabus of BMFG 1313

Manufacturing Process.

Secondly we need to know what fabrication is, understand the theory and

application of it in engineering and also give experience in making project based

on sheet steel. The function of each tools, machines and equipment too can be

determined because in this sheet metal project. In addition, the students also need

to know the differences of tools and machines as well as their function.

We also need to do a lot of good attitude and discipline manner in this project.

Fast, efficient and careful is most important thing in this project. 3 week is very

short for us to finishing our project. But industries need a person who can handle

a problem fast and efficient. Our need in industries is all about technique and fast.

Time is important for our present carrier. This project also gives us a valuable

experience for our study.

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2.0 PROCEDURE

1. First our group are discussing, and planning the project that we want to make.

We make a short list of idea and decide what is the best based on some

factors.

2. After that, we draw technical drawing of the project and dimension it suitable

with sheet steel given. The scale of our project is very small compare to the

real one. This is due to small sheet steel given.

3. We use scribers to sketch and lining the steel with the exact scale. This

process will make cutting process easier and minimise the mistake.

4. Then, the sheet steel given is been separate to 3 major parts using cutting

machine. The 3 major parts is head part, artillery part and base part.

5. After that, we divide our group into three. 2 person doing the artillery, a

person doing base part and the other on doing head part. This technique is due

to finished our project right on time. We just take the concept at industries that

divide their worker into several workplaces for making any project.

6. Each technique and theory that has been taught to us is applied to finish this

project. Some engineering technique like drilling, cutting and bending are

used in completing our project.

7. After all the part is complete, all the part will assemble together using hinge.

8. Hinge is use to up and down the rocket launcher for our special mechanism in

this model.

9. Tires has been added using our creativity.

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10. Finally touch up process and surface finishing is applied. We alter some of the

part for the looking aspect without disturbing the mechanism and function of

the model.

11. After that, our project is finish.

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3.0 HAND TOOLS AND EQUIPMENTS.

1. Metal rulers

The meter ruler is using in the making out process. It is use for

drawing the straight line or incline line in the making out process.

Ruler instruments are manufactured in a variety of lengths and

types and to measure the dimension and layout of the work piece in

alignment with the scriber .A steel rule is a direct measuring

instrument mostly used in 300 mm length. Basically, there are

three types of rules that are called as folding rule, steel

circumference and rule tape or flexible push-pull ruler.

2. Punches

The punches are use to punch some larger holes in thin sheet metal

before doing the drilling process, it can be easy for worker drilling

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a hole onto the thin sheet metal. Usually they are in two main

parts, a punch and a die. They are closed by a draw bolt that passes

through a hole drilled in the metal sheet.

3. File

Files can be used to cutwork to prescribed dimensions and shapes

as well as to obtain a desired surface finish. Besides that, it is also

used to remove surplus metal and produce finished surface and

straighten the uneven edges. Files are classified according to

shape, cut of teeth, coarseness of teeth and size (arm file, hand file,

ward file and needle file).

4. Mallet

The mallet is use to hammer the metal sheet. When we want to

form metal sheet into various shapes by hitting it, but do not want

to mark the surface, then we use a mallet. Mallets can be

considered as soft hammers.

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5. Electric hand drill

Electric hand drill used to produce a hole for the rivet at the sheet

metal. The three main factors governing drill performances are

cutting speed, feed rate and cooling method. There are two types of

drill:

(i) Flat drill

The earliest form of drill was the flat drill which was easy and in

expensive to produce, but it had the disadvantages that it was

difficult to hold on coarse, its chip removal was poor and its

operating efficiency was very low.

(ii) Twist drill

Almost all drilling in engineering is done by using a twist drill. It is

so-called, because it has two spiral or helical flutes formed along

its length. The helical angle on the spiral depends on the type of

twist drill. The size of the twist drill is governed by the diameter

over the lands. The two basic type of twist drill are the parallel and

taper-shank types. Parallel shanks are normally only used in Sizes

below approximately 13 mm.

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6. Protractor

The protractor is use to measure angles in the project layout in

alignment with the scriber. With a simple protractor, the pointer

like measuring arm can be sets against a circular degree scale from

0º to 180º.

7. Snips

The full name of these is tin man’s snips, usually shortened to

‘tinsnpis’. Do not be misled by the name as they may be used on

any thin gauge metal. The snips is use to cut the metal sheet.

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8. Rivet set

Pop rivet gun Rivet conversion kit

Rivet set is use to riveting the edge and joints of work piece. A

hole is predrilled through both pieces, the rivet is inserted through

them both, and then the shaft of the rivet is gripped with a pop

rivet gun. Squeezing the handle on the gun pulls the rivet shaft and

deforms the rivet until the shaft "pops" off, leaving the rivet to

secure the metal. Pop rivets hold well, but are not removable.

9. Scribers

Scribers use to sketch and lining the steel sheet before cutting

process. This tool has sharp and long needle to sketch the steel.

10. Squares

Squares are use for accurate layout work in pattern drafting.

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11. Pliers

Pliers use to shaping the component that is very small to us to bend

it using hand or other machines. Pliers also can be use to remove a

little part from the main part.

4.0 DISCUSSION

Cutting

When we doing the cutting process on the metal sheet, we must to cut the metal

sheet parallel with the lines that we had to draw it as ours cutting reference lines.

If not, we will found that the lines that we had cut are not accuracy with the

drawing lines, so it will affect the outcomes of the product of the project.

Drilling

While we doing the drilling process, we need to make sure that the plate is being

held tightly and the drilling process should be done slowly as to get a smooth and

correct hole.

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5.0 CONCLUSION

Finally our project has finish right before the due date. Our syllabus of BMFG 1313

Manufacturing Process are finally fulfill successfully.

Secondly we had learned to know what fabrication is, understand the theory and

application of it in engineering and also give experience in making project based on sheet

steel. The function of each tools, machines and equipment too can be determined

because in this sheet metal project. In addition, the students also need to know the

differences of tools and machines as well as their function.

Fast, efficient and careful is most important thing in this project. Due date in 3 week is

very short for us to finishing our project. This objective also gets right in time we finish

the project. This project had gives us a valuable experience for our study.

Special thank to all member of this group, friend, technicians, lecturers and all person

that involve in this project.

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6.0 REFERENCETeknologi dan amalan bengkel kejuruteraan; Mohd Firdaus Bin Shukri , UNIVERSITI

TEKNIKAL MALAYSIA MELAKA.

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