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(Answer Q.11 only)
11. What is the difference between Sheet Metal and Machined
parts?
Op. No. Operation Description Tools / Sign (As required) 30 20 4 E B с 900 N 29 90° 3 60 Given that: Flange Length Flat Length (FL) Material = Mild Steel Thickness (T) = 1 mm Inner Radius (R) = 1 mm Angle of bend (A) = 90° K-factor (K) = 0.4 Neutral Axis Outside Setback Outside Setback = (tan) (R+T) Bend Allowance (BA) = A (18.) (R+ (KⓇT)) Flat length (FL) = Flange Length - Outside Setback Total Development Width (TDW) = no. bends x (BA) + SFL Bend Radius (R)

01 Production planning - Total Development Width 5% each Total 30% Find the values of bend allowance and all flat lengths to determine the total development width of the material: 1 mm Plate thickness (T) - Bend radius (R) = Setback Flat length (FL-A) AND (FL-E) = Flat length (FL-B) AND (FL-D) = Flat length (FL-C) Bend allowance - Total Development Width Table 1 1 mm 3.24 16.76 22.52 53.52 2.20 140.88 02 Production planning - Development drawing Place above values onto Figure 1 dimension arrows (top of diagram) to indicate locations of Bend tangent lines Also, indicate bend tangent lines distance with respect to the plate edge (bottom of diagram) Note: dotted lines indicate bend tangent lines on the backside of the plate. 2.20 2.20 2.20 16.76 22.52 22.52 22.52 16.7€ 30 mm 22.54 41.48 20 Figure 1 43.6E

03 Production planning - bend sequence + sight line locations Refer to Figure 2 bend sequence, indicate the dimensions of sightlines on Figure 3 Mark a 'X' to indicate the position of the clamping jaw Note: dotted sightlines are marked on the backside. 4 baba Figure 2 30 mm х х х 22.54 41.48 04 Figure 3 Check-in of tools Check PPE, Hand Tools and Material are in good condition, use Table 2 below as reference. Description 1 Gloves Item 2 Deburr tool 4 Scribe 5 Engineering square 6 7 05 Divider Steel Ruler (300mm) 8 160 x 100 x 1 mm mild steel plate Table 2, PPE, Hand tools & materialist Material preparation - Shearing Set shearing machine clearance to correct material thickness. Trim material into 3 pieces as detailed in table 3 Further trim 2x 30mm wide piece to the correct Total Development Width. Note: ensure all edges are deburred Remarks Article Item 1 Specification 160 x 40 x 1mm For 1mm radius shim. Item 2 160 x 30 x 1mm For 1" trial. Item 3 160 x 30 x 1mm For 2nd trial. Table 3

06 07 Marking sight lines Refer to Figure 3, mark sightlines on both 30mm wide plates Ensure sightlines are marked on each of the sides. Production of 1 mm radius shim Secure the 40mm wide plate in between the Pan Brake jaws, use the upper dials to correct for proper clamping pressure. Set bend leaf flower dials) to 1 mm Bend the 40mm wide plate at R=0 mm to approximately 130 Bending to production drawing Secure the 30mm wide plate (together with 1mm radius shim installed) in between the Pan Brake Jaws, use the upper dials to correct clamping pressure for 2mm thickness Set bend leaf (lower dials) to 2 mm to allow room for the additional 30mm wide plate, Align sight line to the radius tool, Complete all bends with correct bend sequence. Dimension checks with use on the flat table and Vernier calliper (to 0.02mm), measure the flange lengths and record results. 08 09 10 Calculate the Total Development Width -50 --19 -30 -25 Figure 4 Given that: Material - Mild Steel Thickness (T) = 1 mm Inner Radius (R) - 1 mm Angle of bend (A) = 90° K-factor (K) = 0.4 Continued on next page

Find the values of bend allowance and all flat lengths to determine the total development width of the material: 5% each Total 55% mm mm Plate thickness (T) = Bend radius (R) = Setback = Flat length (FL-A) = Flat length (FL-B) = Flat length (FL-C) = Flat length (FL-D) = Flat length (FL-E) = Flat length (FL-F) = Bend allowance = Total Development Width = Table 4 1 1 3.24 15.76 23.52 23.52 73.52 43.52 46.76 2.20 237.6 mm 11 What is the difference between Sheet Metal and Machined parts? Total 15%