MEM05 Metal and Engineering
Training Package
PL
E
MEM05010C
Apply fabrication, forming and shaping
techniques
(Heavy Edition)
M
Learner guide
SA
Version 1
Training and Education Support
Industry Skills Unit
Meadowbank
Product Code: 5776
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
CONTENTS
Project Manager:
Stephen Davies
Education Programs Manager
TAFE NSW
Introduction ...........................................................................................................5
Topic 1 Square and Rectangular Ducting.................................................................9
1.1 Truncated Rectagular Ducting...........................................................................22
Topic 2 Cylindrical Fabrication..............................................................................29
2.1 Theory & Calculations relating to Rolling a Cylinder.........................................29
Enquiries
2.2
2.3
2.4
2.5
2.6
Truncated Cylinder with Flanges.......................................................................53
Therory & Calculations Relating to Lobster-back Bends...................................59
Theory & Calcuations Relating to Cylindrical Square Branches &
Wrap Around Templates...................................................................................75
Inclined Branch On-Centre................................................................................85
Inclined Rectangular Branch on a Cylinder (On-Centre)...................................93
Topic 3 Concial Fabrications................................................................................ 101
3.1 Forming Main Barrel.......................................................................................118
SA
M
Tel: 02-9942 3200 Fax: 02-9942 3257
PL
Training and Education Support Industry Skills Unit, Meadowbank
Meadowbank TAFE
Level 3, Building J,
See Street,
MEADOWBANK NSW 2114
E
Enquiries about this and other publications can be made to:
© TAFE NSW (Training and Education Support, Industry Skills Unit Meadowbank) 2013
Copyright of this material is reserved to TAFE NSW Training and Education Support, Industry Skills Unit
Meadowbank. Reproduction or transmittal in whole or in part, other than for the purposes of private
study or research, and subject to the provisions of the Copyright Act, is prohibited without the written
authority of TAFE NSW Training and Education Support, Industry Skills Unit Meadowbank.
3.2
3.3
3.4
3.5
Frustum of Right Cone with Flange.................................................................122
Truncated Right Cone......................................................................................127
Forming Truncated Right Cones......................................................................138
Multi-strake Cone...........................................................................................151
Topic 4 Transitional Fabrications........................................................................ 165
4.1 Theory & Calculations.....................................................................................167
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
Rectangular to Square Hopper Transition.......................................................178
Square/Rectangular to Round Transition........................................................183
Square to Round Transition............................................................................189
Off-Centre Square to Round Transition...........................................................195
Cylinder Joining Piece.....................................................................................203
Sub Assemble of Job 4.5 & 4.6........................................................................207
Square to Round Transition (Round Corners).................................................208
Final Assembly - Transition Pieces..................................................................220
ISBN: 978 1 74236 484 1
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
Topic 1 - Square and Rectangular Ducting
Theory and calculations square/rectangular fabrications
Job Planning for Square/Rectangular Fabrications
Careful job planning is required for all types of fabrication work. Planning enables work to be carried out in
an organised way, setting out each step (the sequence) in a sensible, logical order, will assist in making the
finished product meet the required standard of quality.
There are three (3) stages to the job planning process.
E
Stage 1
Pre-planning
PL
Ducting with flanges
SA
M
Stage 2
Fabrication
Student Organiser
Topic
1
1.1
Careful pre-planning
from the start gives you
more control over the entire
fabrication process
To ensure the finished product
is made to specifications, the
fabricator will need to
progressively check each step
of the fabrication process
Stage 3
Finished product
Activity
Effective quality control is a
key to success for any
business. Without quality
control the results for the
company could be costly
•
•
•
•
•
Interpret drawings
Task sequence
Organising equipment
Make working drawings
Develop patterns and/or templates
•
•
•
•
•
•
•
•
Selection of material
Mark out
Cutting
Forming
Joining
Finishing
Installing
Final quality check
• Loss of repeat work
• High labour cost to do
recall / wattanty work
• Material losses
• No recommendation for
other work
• Company closure and
unemployment
Square/Rectangular Ducting
Truncated Rectangular Duct
• Theory/Calculations
• Job 1.1 - Truncated Rectangular Duct
• Review questions
NOTE: All employees in the workplace are responsible for quality control and safety.
Page 9 of 224
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
Pattern calculations
Correct interpretation of workshop drawings is vital if the finished fabrication is to meet its specified size,
shape and tolerance.
The material used for making ducting varies depending on its application. The most common material used
is low carbon steel as it has good workability, structural strength and a relatively smooth surface which helps
air flow. Ducting can also be made from stainless steel, aluminium, copper and plastic materials.
Development method
Parallel line development is the method used to develop square/rectangular shapes, using a series of parallel
lines. The pattern is clearly seen when the shape is folded out flat.
Pattern length
Length = Sides x 4
= 200 x 4
= 800mm
=√
Pattern length² + Pattern height ²
=√ 800²
=√
Involves three main steps:
1. Calculating required dimensions
2. Laying out and developing the pattern/template
3. Following production instructions
=√
200 mm
200 mm
800 mm
00
mm
800 mm
1000000
Example
200 mm
Truncation Angle
X =115 mm
= 115.4
30 °
= 115 mm
200 mm
True length check of truncated slope
Example
=√ 115 ² +200 ²
=√ 13225 + 40000
= 231mm
Tr
un
115 mm
=√ 53225
60 °
ca
ted
l
en
g
t h=
23
Pattern little height (h)
= Pattern height - 60° height
200 mm
th =
640000 + 360000
PL
m
m
h=485 mm
23
1
115 mm
SA
M
H=600 mm
O
AG
I
D
en
g
= 1000 mm
60°
0
ll
+ 600²
= 200 x 0.577 =1
LS
A
N
on
a
10
60° Height check
Tan Ø = opp Tan30° = X
adj
200
60°
therefore X = 200 x tan 30° m
m
00
ag
E
Marking out
Di
Diagonal length check of pattern
600 mm
Drawing Interpretation of Square/Rectangular Fabrication
= 600 - 115
= 485 mm
Pattern
Page 10 of 224
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
200 mm
Example
1m
m
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
When calculating the stretchout length of material greater than 3mm in thickness you must take into account
the amount of material loss in the bend to 90°.
Bend calculations/allowances
When calculating the stretchout length of a pattern for square/rectangular ducting you must allow for the
thickness of material.
6 mm plate
Stretchout lengths for material 3mm thick (or under) are calculated using the inside measurements of the
ducting, because the amount of material loss in the bend to 90° is small.
194 mm I/S
3 mm sheet
= (200 - 2 x 3) + (200 – 2 x 3)
= (200 – 6 ) + (200 – 6)
= 194 + 194
= 388 mm
Bend up to 90º
Calculation:
I/S Length = (O/S – 2 x t) + (O/S – 2 x t)
194 mm I/S
600 mm
NOTE
O/S = outside dimension
t = material thickness
SA
M
200 mm O/S
194 mm I/S
NOTE
I/S =
IR =
ID =
MD =
MC =
19 mm allowance
inside dimension
inside radius
inside diameter
mean diameter
mean circumference
194 mm
194 mm
Calculating distance around 90° bend
ID = IR x 2
MD = ID + t
= 9 x 2
= 18 + 6
ID = 18
MD = 24
¼ MC = MD x 3.1416 (�)
4
= 24 x 3.1416
4
= 75.3984
4
= 18.8496
Say = 19 mm
Bend up to 90°
mm
mm
194 mm I/S
600 mm
0
60
0
60
PL
200 mm O/S
E
radius
IR 9 mm
Half stretch pattern
Half stretch pattern
2 required @ 407 x 600 x 6 mm plate
2 required @ 3 mm by 388 x 600 mm sheet
407 mm
388 mm
Page 11 of 224
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
Practical method to calculate the bend allowance
Production instructions
An outside flange width of 160mm is required. To fabricate an accurate bend it is recommended that you
adopt the following procedure using a sample piece of identical material which is used for the job.
Production instructions are the markings on fabricated jobs and components. Their purpose is to identify
the component and clearly show what is to be done on (or with) the component. These instructions often
determine the way a job is done and how the sequence of operations is carried out. The sketch below shows
a typical example:
STEP (1)
Measure a distance from a pre-marked datum lines for the bend, as shown below:
50
Plate edge
50
Guillotine cut
BAP
BAP
10 mm
158 mm
58
58
50
50
50 mm
distance
each side of
the centreline
158 mm
158 mm
SA
M
STEP (2)
Now bend this to the required angle (i.e. 90°)
158 mm
Press over to 90°
Guillotine cut
E
150 mm
Press over to 90 °
PL
150 mm
ut g
e c sin
tin res
llo p
ui re
G efo
b
Oxy cut before
pressing
10 mm plate
J/N 373/4
O/N 8/3/07
Item A
Guillotine cut
Materials are cut by mechanical or thermal processes, the following are typical examples.
Mechanical cutting
1.
2.
3.
4.
Guillotines
Bench shears
Nibblers
Shears
When using mechanical cutting equipment you must comply with all safe operating procedures and OHS
requirements.
Thermal cutting
NOTE: The 58mm dimension is used as an example
STEP (3)
The sketch shows there is a 2mm reduction on each end. In turn you will have to increase your inside
measurement to 152mm to make a finished outside flange width of 160mm.
1. Oxy-fuel gas cutting is used for any shape cut on low carbon steel.
2. Plasma cutting is often used for cutting and shaping low carbon, stainless steel, aluminium and other
non ferrous alloys.
Page 12 of 224
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
The choice of cutting procedures depends on:
• Material thickness
• Type of material
• Machine cutting capacity
General rule:The Vee die (Vee block) opening should be at least 8 times the material thickness with the die angle between
80° to 88°.
On some jobs, there are sections which stay uncut until forming has been completed.
Vee
blade
This is shown by using the following initials:
60º - 88º
BAR (Burn or cut after rolling)
BAP (Burn or cut after pressing)
Radius equal to
½ material thickness
E
Forming lines and bends
PL
These lines show where bends and radii etc, will be. They also show the forming diameters/radii and/or
angles to be pressed. This information should be shown on the side on which the component is to be formed.
For example, bend/roll up, down or over and forming sequence.
Pressing
•
•
•
•
Gap press
H-frame press
Brake press
Folder
Bending techniques
SA
M
Machines used for this purpose include:
Brake press
Note: Vee-Blade angle must always be less than Vee-Block angle.
80º - 88º
Vee block
Example calculating Vee die opening:
Material: 5 mm plate
Vee width =8x5
= 40 mm Vee block
R = 1.5t
Minimum bend radius is calculated by:
The bending of metal parts in a brake press can be done by air bending or bottoming.
Inside radius = 1.5 x thickness of plate
Air bending means the material is not forced completely into the bottom die. There is some space between
the underside of the material and the bottom of the vee die.
Example: 5 mm plate
Bottoming means the material is formed between the upper and lower dies, which close completely with
only the material separating them.
8 x material
thickness
Bend radius = 1.5 x thickness
Page 13 of 224
= 1.5 x 5
= 7.5 mm minimum bend radius
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
t
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
Data sheet from manufacturers give information regarding: - material thickness, minimum bend radius, die
opening and required force (tonnes/lineal metre).
Die Blocks
The chart below is from an 80 tonne hydraulic press brake, for material up to 10mm thickness.
Vee Blocks
Are available in many different shapes and forms.
Types of Vee blocks used to form bends include:
8
0.8
1.0
1.25
6
11.4
16.4
8
8.55
12.3
21.9
10
6.84
9.85
17.5
27.4
26
29
33
4.4
5.0
5.6
35
40
45
7.82
12.2
17.6
31.3
48.9
70.4
125.0
10.7
15.4
27.4
47.8
61.6
110.0
171.0
E
6
PL
1
1.2
1.6
2
2.5
3
4
5
6
8
10
5
MIN. LEG LENGTH B (mm)
9
12
15
18
22
INSIDE RADIUS OF BEND (mm)
1.5
2.0
2.5 3.12
3.75
FEMALE DIE OPENING (mm)
12
16
20
25
30
5.70 4.28
8.21 6.16 4.93
14.6 11.0 8.76 7.01
22.8 17.1 13.7 11.0
9.12
35.5 26.7 21.4 17.1
14.3
38.5 30.8 24.7
20.5
54.7 43.8
36.5
85.5 68.4
57.0
98.5
82.1
146.0
• Knife and Vee
• Acute angle knife and Vee
• Radius knife and Vee/former
13.7
24.3
38.0
54.7
97.3
152.0
Knife & Vee
Acute angle Knife & Vee
SA
M
MAT'L THICKNESS
(mm)
TONNES FORCE REQUIRED PER LINEAR METRE TO BEND LC STEEL
THIS CHART BASED ON STEEL 440 MPa U. T.S.
Data Chart
B
The sketch below shows the minimum return bend allowance.
Inside bend radius
Radius knife & Vee
Die opening
Page 14 of 224
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
Checking pressed shapes
Assembly procedures include:
Methods include:
• Internal template
• External templates
• Check over layout
•
•
•
•
Line up one edge corner to corner, using clamps, magnetic links or jigs and fixtures
Line up the seam using light tack welds as required
Align the other seam diagonally opposite and tack weld
Check for size, squareness and twist
E
Regular checks will minimise errors, you should be especially careful when, aligning longitudinal corners
joints such as:
PL
External template
Internal template
Corner to corner
SA
M
Check over layout
Single bevel
Aligning ends of component parts
Assembly procedures for square/rectangular ducting
When assembling square or rectangular duct work ensure the fabrication is square, free of twist and joints
are in alignment, prior to tack welding.
Page 15 of 224
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
• Square ends
• Plates aligned and parallel
Corner lap
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
Progressive checking
Progressive checking should include:
Regular checking is essential to prevent errors, if a minor error occurs, spread it around the job rather than
confining it to one place.
152
152
•
•
•
•
Alignment of joints
Squaring of side plates
Checking for twist
Checking ends for squareness
1 mm
overlap
150
150
149
0.5 mm
gap
correct
150
SA
M
6mm plate corner to corner, the 152mm wide
plate laps each side by 1mm (not to scale).
E
incorrect
Square off
the side
plates with a square.
PL
correct
149
incorrect
150
6mm plate corner to corner, the149 mm wide
plate is placed so 0.5mm gap is left each side
(not to scale).
Page 16 of 224
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
Checking for twist
using a square and
a flat surface.
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
Checking ends for squareness using an Engineers square
PL
E
Measure down both
sides of the straight
edge, ensuring
distances are equal.
SA
M
This is an alternative method for checking for twist, using a straight edge.
Assembly aids for square/rectangular ducting
Tools and accessories can help you assemble a job more accurately. They include:
•
•
•
•
G-clamps
Magnets
Fixed dogs and wedges
Temporary or permanent bracing
Checking for square by measuring across the diagonals, to see if they are the same.
Page 17 of 224
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
Fixed dogs and wedges
Tack weld
Tack top only
To move
tack
To pull a stiffener into position
PL
E
Wedges
Magnets
Pivot
point
Temporary or permanent bracing
SA
M
G - Clamps
Tack weld
Cleat
Brace
90°
Gusset
Packing
Packing
Sub-assemblies
Large jobs are often fabricated as part of a sub-assembly. This is because sub-assemblies are easier to handle,
reduce overall distortion, give greater accuracy and easier to transport. Extra planning will be needed for
larger jobs. In relation to sub-assembles you need to check that:
• Workshop cranes can lift assembly or sub-assemblies
• There is sufficient clearance for lifting and turning the sub-assembly
Page 18 of 224
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
Step 3
Fabricating a Flange for Square and Rectangular Ducting
Measure out the ½ flange
width using the vertical centre
line, then use these points
to locate the four corner points.
Flanges for square and rectangular ducting are made from plate, flat bar or angle. Types of flanges include:
Marking out
Cutting
Drilling/punching
Assembly (for 4 piece flange)
Tack welding
Checking
Marking out
Mark out the out side shape
of the flange.
SA
M
Production procedures include:
•
•
•
•
•
•
Step 4
4 piece flange from
flat bar or angle
butt welded
corners
E
4 piece flange from
flat bar or angle
mitred corners
and welded
PL
1 piece flange
from plate
Step 5
From the four corners
scribe arcs equal to the
flange width.
Square and rectangular flanges are marked out and fabricated using either one or four pieces.
Step 1
Mark out a horizontal centre
line, about 100mm longer
than required for the actual
length of the flange.
Step 6
Step 2
Mark out the inside
flange shape.
From an approximate centre point,
mark out the ½ flange length,
then use these points to bisect
top and bottom to locate the
vertical centre line as shown.
Page 19 of 224
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
Step 7
Assembly
Mark out in the vertical and horizontal
centre lines to locate hole centres.
This can be done on a layout or in a jig. Make sure your work is accurate and joints are correctly aligned.
Correct
Fitting flanges to ducting
Step 8
Alignment of flanges to ducting must be within tolerance. Check that your work has:
E
Tack weld flange and locate holes
in the required places.
PL
• Correct overall length measurement
• Flanges are square to duct
• Flanges are correctly located.
Cutting
One piece flanges are manually flame cut
Profile cutting machines are used to cut large numbers
A guillotine can be used to cut outside edges if the material thickness is within the machine’s capacity
Four piece flanges can be cut with a guillotine, cropper or manually flame cut.
Drilling
SA
M
•
•
•
•
Incorrect
duct
Equal dimensions
flange
The method you use will depend on the number of flanges to be drilled. Remember small numbers of flanges
are drilled separately or in pairs and large numbers using a template or jig. Before starting, decide if you
should:
• Drill before or after assembly
• Stack drill using a template or jig.
Plate square
gooseneck
duct
Welding flanges
Fillet weld
Template used for
stack drilling
Corner weld
preparation
NOTE:
Corner weld should have
min 6 mm insertion or equal to the
material thickness or whichever is
less.
duct
For the best distortion control, you should weld the corner joint first and then the fillet joint.
Page 20 of 224
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
flange
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
Final fabrication checking
Student Notes
It is essential that you check your work for accuracy. Check your work for:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
Correct type of material
Correct thickness of material
Correct size, both internal and external, of the flange and duct
Position of holes
Diameter of holes
Squareness of flange and duct
Alignment of joint of the flange and duct
Quality of work.
Surface finish (painting or galvanising)
The job should include:
SA
M
PL
E
•
•
•
•
•
•
•
•
• Preparation of the surface
• A decision on what should be painted and at what stage it should be painted
• Protection of surfaces to avoid corrosion or mechanical damage prior to and after painting/
galvanising.
Delivery
Final delivery of the job (complete or sub-assembly) must be:
• In order of requirement
• As soon after completion as possible
• Without damage to the job or any of its surfaces.
Page 21 of 224
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
Assessment Criteria
Practical Sheet
Job 1.1: Truncated Rectangular Duct
Equipment required:
Marking out tools, hand tools, assembly aids, personal safety equipment, guillotines, press, forming
blocks, drilling or punching machine, flame cutting and welding equipment.
NOTE:After completed job has been assessed, students are required to take the assemble job apart and their job
will be used as a welding exercise at a later time.
Final assembly
Student A & B
1. Assemble Parts A to B.
2. Present your completed job for assessment.
PL
SA
M
Student B
1. Complete the associated exercises
2. Mark and cut items 3&4
3. Press items 3&4
4. Mark and cut items 6&8
5. Assemble the flange items 6&8
6. Mark and drill holes in the flange
7. Assemble items 3 to 4
8. Assemble the flange to Part B.
E
Job procedure
Student A
1. Complete the associated exercises
2. Mark and cut items 1&2
3. Press items 1&2
4. Mark and cut items 5&7
5. Assemble the flange items 5&7
6. Mark and drill holes in the flange
7. Assemble items 1 to 2
8. Assemble the flange to Part A.
1. To be dimensionally correct to within ±2mm
2. Flange is flat, i.e., free from twist and distortion
3. Holes located as specified to within ±2mm
4. Flange is square to the centre line of the truncated square duct
5. Flanges positioned as specified to within ±2mm
6. Seam alignment to be within ±2mm.
7. To be well constructed and neat in appearance
Page 22 of 224
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
Job 1.1 Truncated Rectangular Duct
214
Inside dimension
End of duct
3 mm
142
inside
dimension
Flange
face
3 mm
Duct detail
250
250
90º
PART B
60º
300
A
4
A
PART A
1
105
SA
M
105
60º
E
PL
Section A-A (without flange)
3
Pressed corner joint
Detail B
Detail A
20
20
94
5&6
Ø12 hls
94
322
47
2
94
Detail C
Detail A
FRONT VIEW
Flange detail
Detail B
7&8
Page 23 of 224
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
Corner to corner joint
Detail C
NOTES:
Material
Part A
- 350 x 500 x 3mm sheet
- 50 x 500 x 5mm flat bar
Part B
- 300 x 750 x 3mm sheet
- 50 x 750 x 5mm flat bar
- Flange clearnace approximately
1mm all round
- Use square butt joints for flanges
- All measurements are in mm
Student A will fabricate Part A
Student B will fabricate Part B
Both students to assemble
Parts A&B together
General tolerances
± 2 mm
DRAWN
A Trainer
DATE
01/07/09
SCALE
NTS
A3 RECT / DUCT FAB Issue
A
TITLE:- Rectangular duct
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
Review Questions (Theory and Practical)
Question 2 (Calculations)
Job 1.1: Truncated rectangular duct
From the rectangular truncated duct drawing, calculate the following:-
Question 1
a) What is the flange allowance for (Parts A & B)?
_____________________________________________________________________________
a) Name the three (3) stages of job planning required to make a rectangular duct.
b) What are the pattern heights (Parts A & B)?
Stage 1:- ______________________________________________________________________
Stage 2:-______________________________________________________________________
Part A = Overall height - flange allowance = _____________ = ________
Stage 3:- ______________________________________________________________________
Part B = Overall height - flange allowance = _____________ = ________
c) The pattern length (PL) for Parts A & B = (length + width) x 2
Stage 1:• _________________________________________________________________________
PL
PART A
• _________________________________________________________________________
Stage 2:-
• _________________________________________________________________________
Stage 3:-
ie. PL = 2 x (L+W)
PART B
= _______________________
= ________________________
= _______________________
= ________________________
d) The diagonal length of pattern:-
• _________________________________________________________________________
SA
M
E
b) Give two (2) examples of each stage.
Part A
Diagonal A = √ Pattern length ² + Pattern height²
=√
• _________________________________________________________________________
=√
• _________________________________________________________________________
=√
Answer =
Part B
Diagonal =
√ Pattern length²
+ Pattern height²
=√
=√
=√
Answer =
Page 24 of 224
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
Question 3
e) The 60° height check (PARTS A & B)
Slant Height = Length x Tan (90º - truncation angle)
=
Answer
=
On the patterns drawn below, fill in the missing dimensions and calculations:PART A
f) Checking truncated slope length (PARTS A & B)
√ Slant height ²
SL
=
+ Pattern length ²
SH =
Slope length (SL) =
°
H=
E
=√
PL
=√
Answer =
W=
g) Small pattern height
Small pattern height
h
SA
M
PART A
= Pattern height - Slope height
= H - SH
G
DIA
S=
AL
N
O
h=
=√
L=
L=
W=
PL =
PART B
= ____________________________________
°
SL
Small pattern height G
DIA
= ____________________________________
S=
AL
N
O
h=
PART B
= ____________________________________
H=
Answer
= ____________________________________
Answer
=
SH =
= ____________________________________
= ____________________________________
W=
L=
W=
PL =
Page 25 of 224
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
L=
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
Question 4
Question 6
Complete the parts list below for the truncated rectangular ducting job 1.1.
How many items are pressed to form Parts A & B.
8
__________________________________________________________________________________
7
Question 7
6
What type of joints are used for the rectangular truncated duct?
5
• ______________________________________________________________________________
4
• ______________________________________________________________________________
E
3
2
Question 8
1
Describe in point form how to assemble the rectangular duct.
Description
Length
No. Req’d
Mat’l
PL
Item No.
• ______________________________________________________________________________
• ______________________________________________________________________________
Question 5
• ______________________________________________________________________________
Part A & Part B
Plate edge
=
• ______________________________________________________________________________
=
=
=
=
• ______________________________________________________________________________
=
=
SA
M
On the pattern drawn below, insert the required production procedures for the rectangular truncated duct.
J/N 1.1
PART A
=
Page 26 of 224
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
Question 9
Question 10
Draw to a scale of 1:2 the flange detail for the rectangular truncated duct using the centre line below. What diameter holes are specified for the flange?
• _____________________________________________________________________________
Question 11
What tolerances are given to fabricate the rectangular truncated duct?
• Ducts ________________________________________________________________________
PL
E
• Flanges _______________________________________________________________________
Question 12
List the essential checking methods you should use on the completed rectangular truncated duct:
SA
M
• _______________________________________________________________________________
• _______________________________________________________________________________
• _______________________________________________________________________________
• _______________________________________________________________________________
• _______________________________________________________________________________
• _______________________________________________________________________________
• _______________________________________________________________________________
Page 27 of 224
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013
MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)
Student Notes
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
SA
M
PL
E
Student Drawings/Sketches
Page 28 of 224
© TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013