SHEET-METAL DEVELOPMENT

In sheet- metal development work, some fabrication or repair jobs can be laid out directly on sheet metal. This development procedure, known as SCRATCHING, is used when the object to be made requires little or no duplication. When a single part is to be produced in quantity, a different development procedure is used. Instead of laying out directly on the metal, you will develop a PATTERN, or TEMPLATE, of the piece to be fabricated and then transfer the development to the metal sheet. The second development procedure is what we are primarily concerned with in this section. Special attention is given to the three primary procedures commonly used in developing sheet-metal patterns. They are parallel line, radial line, and triangular development. We will also discuss the fabrication of edges, joints, seams, and notches. PARALLEL LINE DEVELOPMENT Parallel line development is based upon the fact that a line that is parallel to another line is an equal distance horn that line at all points. Objects that have opposite lines parallel to each other or that have the same crosssectional shape throughout their length are developed by this method To gain a clear understanding of the parallel line method, we will develop, step by step, a layout of a truncated cylinder (fig. 2-50). Such apiece can be used

Figure 2-50.Truncated cylinder

as one half of a two-piece 0 degree elbow. This piece of sheet metal is developed in the following procedure: 1. First, draw a front and bottom view by orthographic projection (fig. 2-51, view A). 2. Divide half the circumference of the circle (fig. 2-51, view A) into a number of equal parts. The parts should be small enough so that when straight lines are drawn on the development or layout between division points, they will approximate the length of the arc. Project lines from these points to the front view, as shown in figure 2-51, view B. These resulting parallel lines of the front view are called ELEMENTS. 3. Lay off the baseline, called the STRETCH-OUT LINE, of the development to the right of the front view, as shown in figure 2-51, view C.

Figure 2-51.Development of a truncated cylinder

4. Divide the stretch-outline into twice the number of equal parts equal to each division of the circumference on the half circle of the orthographic view (fig. 2-51, view C). 5. Erect perpendicular lines at each point, as shown in figure 2-51, view C. 6. Using a T-square edge, project the lengths of the elements on the front view to the development (fig. 251, View D). 7. Using a curve (french or other type), join the resulting points of intersection in a smooth curve. When the development is finished, add necessary allowances for warns and joints, then cut out your patterns.

RADIAL LINE DEVELOPMENT The radial line method of pattern development is used to develop patterns of objects that have a tapering form with lines converging at a common center. The radial line method is similar in some respects to the parallel line method. Evenly spaced reference lines are necessary in both of these methods. But, in parallel line development, the reference lines are parallellike a picket fence. In radial line development, the reference lines radiate from the APEX of a conelike the spokes of a wheel. The reference lines in parallel line development project horizontally. In radial line development, the reference lines are transferred from the front view to the development with the dividers. Developing a pattern for the frustum of a right cone is a typical practice project that will help you get the feel of the radial line method. You are familiar with the shape of a cone. A right cone is one that, if set big-side-down on a flat surface, would stand straight up. In other words, a centerline drawn from the point, or vertex, to the base line would form right angles with that line. The frustum of a cone is that part that remains after the point, or top, has been removed. The procedure for developing a frustum of a right cone is given below. Check each step of the procedure against the development shown in figure 2-52. 1. Draw a cone ABC with line ED cutting the cone in such a way that line ED is parallel to the base line BC. EDCB is called a frustum. 2. With center O and radius OB, draw the half-plan beneath the base line BC. Divide the half-plan into an equal number of parts and number them as shown. 3. With vertex A as a center and with dividers, set a distance equal to AC and draw an arc for the stretchout of the bottom of the cone. 4. Set the dividers equal to the distance of the step-offs on the half-plan and step off twice as many spaces on the arcs as on the half-plan; number the step-offs 1 to 7 to 1, as shown in the illustration (fig. 2-52). 5. Draw lines connecting A with point 1 at each end of the stretch-out. This arc, from 1 to 7 to 1, is equal in length to the circumference of the bottom of the cone. 6. Now, using A for a center, set your dividers along line AC to the length of AD. Scribe an arc through both of the lines drawn from A to 1. The area enclosed between the large and small arcs and the number 1 line is the pattern for the frustum of a cone. Add allowance for seaming and edging and your stretchout is complete.

Figure 2-52.Radial line development of a frustum of a cone

TRIANGULAR DEVELOPMENT Triangulation is slower and more difficult than parallel line or radial line development, but it is more practical for many types of figures. Additionally, it is the only method by which the developments of warped surfaces may be estimated. In development by triangulation, the piece is divided into a series of triangles as in radial Line development. However, there is no one single apex for the triangles. The problem becomes one of finding the true lengths of the varying oblique lines. This is usually done by drawing a true, length diagram. An example of layout using triangulation is the development of a transition piece. The steps in the triangulation of a warped transition piece joining a large, square duct and a small, round duct are shown in figure 2-53. The steps are as follows: 1. Draw the top and front orthographic views (view A, fig. 2-53). 2. Divide the circle in the top view into a number of equal spaces and connect the division points with AD (taken from the top part of view D, fig. 2-53) from point A. This completes one fourth of the development. Since the piece is symmetrical, the remainder of the development may be constructed using the lengths from the first part. It is difficult to keep the entire development perfectly symmetrical when it is built up from small triangles. Therefore, you may check the overall symmetry by constructing perpendicular bisectors of AB, BC, CD, and DA (view E, fig. 2-53) and converging at point O. From point O, swing arcs a and b. Arc a should pass through the numbered points, and arc b should pass through the lettered points.

Figure 2-53. Triangulation of a warped transition piece join ing a large, square duct and a small, round duct

FABRICATION OF EDGES, JOINTS, SEAMS, AND NOTCHES There are numerous types of edges, joints, seams, and notches used to join sheet- metal work. We will discuss those that are most often used. Edges Edges are formed to enhance the appearance of the work, to strengthen the piece, and to eliminate the cutting hazard of the raw edge. The kind of edge that you use on any job will be determined by the purpose, by the sire, and by the strength of the edge needed. The SINGLE-HEM EDGE is shown in figure 2-54. This edge can be made in any width. In general, the heavier the metal, the wider the hem is made. The allowance for the hem is equal to its width (W in fig. 2-54). The DOUBLE-HEM EDGE (fig. 2-55) is used when added strength is needed and when a smooth edge is required inside as well as outside. The allowance for the double-hem edge is twice the width of the hem.

Figure 2-54.Single-hem edge

Figure 2-55.Double-hem edge