Shaping the metal


The material used in this project is low carbon mild steel.

Mild steel is the most common form of steel as its price is relatively low while it provides material properties that are acceptable for many applications. Mild steel has a low carbon content (up to 0.3%) and is therefore neither extremely brittle nor ductile. It becomes malleable when heated, and so can be forged. It is also often used where large amounts of steel need to be formed, for example as structural steel.

You used a number of tools in the shaping of the metal.

Click Image to enlargeClick Image to enlargeMarking out the metal you used the following tools; Engineering Scriber, Centre Punch, Engineers Square, Jenny Calipers, steel rule. All of these tools are located in the wooden cupboard in each of the manufacturing rooms. The metal was coated with engineering blue to allow the marking out to be seen clearly and the scriber is used to mark onto the metal. The centre punch was used to make a dent into the metal prior to drilling.

picture-043.jpg Click Image to enlargeThe engineers square was used to make a line at 90 degrees to the sides of the metal 30mm from the bottom. The jenny calipers were used to measure 6mm from the top and the sides, thsi was the location of the hole to be drilled.

Click Image to enlarge
Click image for more informationA file is a hand tool used to shape material by cutting. A file typically takes the form of a hardened steel bar, mostly covered with a series of sharp, parallel ridges or teeth. When the metal has been marked out it was put into a metalwork vice and 250mm coarse file was used to quickly remove the majority of the metal. It is essential that the file remains sharp in order to continue to cut.Click Image to enlargeClick Image to enlarge Another smaller file was used to give the metal a smooth finish. This technique is called draw filing.

When filing the metal it is important that you file most of the metal from one end first and then work back to the line which is 30 mm from the tip. See pictures. Do not try to file from one side only and then turn the metal round and file from the other side, make sure you file straight accross and you do not have high spots in the middle of the metal. If the high spot appears you need to file it off, you do not want any rounded parts to the section of the project.Click Image to enlarge

The finished porfile of the metal

2 Responses

  1. thanks for this information it helped us to fill in our plan of action in our lever booklet, thanks

  2. cool web pg

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