TRADE OF

Industrial Insulation
PHASE 2

Module 1

Sheet Metal and Insulation Fundamentals

UNIT: 3

Measuring, Marking &

Cutting Out
 Produced by

In cooperation with subject matter expert:

Michael Kelly

© SOLAS 2014
Module 1– Unit 3 Measuring, Marking & Cutting Out

Table of Contents
Unit Objective ...............................................................................................................2
Introduction ................................................................................................................... 3
1.0 Hand Tools....................................................................................................... 4
1.1 Marking Out Tools ........................................................................................ 4
1.2 Hammers and Mallets ..................................................................................11
1.3 Cutting Tools ................................................................................................13
1.4 Files ................................................................................................................16
1.5 Pop Riveting Guns.......................................................................................16
2.0 Workshop Machinery....................................................................................18
2.1 Safety in the Workshop ...............................................................................18
2.2 The Box and Pan Folding Machine...........................................................19
2.3 The Guillotine ..............................................................................................20
2.4 The Bending Rolls .......................................................................................21
2.5 Lubricating Machines ..................................................................................21
3.0 Measurements ................................................................................................22
3.1 SI Units of Measurement ............................................................................22
3.2 The Imperial System ....................................................................................23
3.3 The Metric System .......................................................................................23
3.4 Angle and Straight Line Bisection .............................................................23
4.0 Metals ..............................................................................................................24
4.1 Sheet Steels ....................................................................................................24
4.2 Coated and Solid Sheets ..............................................................................24
4.3 Galvanised Sheet Metal ...............................................................................25
4.4 Stainless Steel ................................................................................................25
4.5 Non-Ferrous Sheet Metals ..........................................................................26
4.6 Properties of Metal ......................................................................................27
5.0 Cutting a Sheet Metal Blank.........................................................................29
5.1 Job Planning & Preparation .......................................................................29
5.2 Drawing Symbols and Orthographic Projections ...................................29
5.3 Marking Out .................................................................................................30
5.4 Cutting ...........................................................................................................30
5.5 De-Burring ....................................................................................................30
5.6 Checking Measurements .............................................................................30
5.7 Vernier Callipers ...........................................................................................30
Summary .......................................................................................................................32

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Unit Objective
By the end of this unit each apprentice will be able to:
 Identify and name a selection of machinery.
 State the use of each tool and machine.
 Identify the hazards associated with each piece of equipment.
 Mark out and cut a sheet metal blank.
 De-burr a sheet metal blank
 Check measurements using a steel rule.

Module 1
Sheet Metal &
Insulation
Fundamentals

Unit 1 Unit 2 Unit 3 Unit 4 Unit 5

Introduction to the Manual Measuring, Notching, Folding & General Allowances for
Workshop Handling Marking & Joining Insulation & Cladding
Environment Cutting Out

Unit 6 Unit 7 Unit 8 Unit 9 Unit 10 Unit 11

Marking, Cutting, Swaging (Basic) Pipe Cladding Metal Cladding Pipe Insulation (Hot & Valve &
Punching, Rolling, Cold) Material Selection Flange Box
Seam Swagingn & Male/Female & (Basic) Fabrication Assembly
Screwing Flange Turning & Application Work & Application Fundamentals

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Introduction
One of the characteristics of the skilled worker is the way in which he selects
and uses his tools. For this reason, it is essential that you know how to select
and use both hand and machine tools correctly. If you do this you will save
time and the work will be much easier. When you have selected the correct tool
for the correct operation you have taken the first step in becoming a successful
craftsman.

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1.0 Hand Tools

Key Learning Points

 Location and identification of tools, equipment and machinery.
 Description of the application of the tools, equipment and machinery.
 Interpretation of tool, machinery and equipment manuals.

Sheet metal hand tools are used to scribe or measure lines, perform layout
operations and shape or cut metals. Some of the hand tools in the following
notes actually perform these operations while others, such as stakes and
punches, serve as aids in performing them.
It is important to keep tools in good shape. Avoid tools going rusty by giving
steel tools an occasional oiling. Tools with a sharp point should be stored
carefully.

1.1 Marking Out Tools

Scriber
This is used to mark lines on metal. It can be used in conjunction with a
straight edge and square.

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Straight Edge
The Straight Edge is used as a guide for a scriber or pencil when marking or
drawing a straight between two points. It is also used in conjunction with
square to draw lines at right angles.

Dividers
This is made with each straight leg tapered to a needle point. Dividers are
manufactured in various sizes and types and are used to space off equal
distances, to divide lines into equal parts and to scribe arcs and circles. Spring
loaded screw dividers are also available. Supplied in lengths from 150mm to
500mm. Spring dividers are also available in sizes from 75mm to 300mm.

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Steel Square
The flat Steel Square is used to layout right angles (90°) and can also be used as
a scale. It is an invaluable tool for accurate layout work in pattern drafting.
The long arm is known as the body or blade, the short arm is known as the heel
or tongue.
These squares come in various sizes.

Steel Try Square

It is used for marking and checking right angles (90°).
These squares come in various sizes from 75mm to 300mm.

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Combination Square
This is one of the most useful and convenient tools for laying out small work.
It is used as a square for measuring or laying out 90° or 45° angles.
A spirit level is mounted in the stock. Available in 300mm lengths.

Protractor
This is a device for measuring and laying out angles from the edge of the work.
This protractor consists of a head and a movable blade.
The head of the protractor has a semicircular scale graduated from zero to
180°.

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Trammel Points
These are used for scribing large arcs and circles.
They are manufactured in various types with two straight, removable legs
tapered to needle points and attached to separated heads or holders.
The heads or holders slide on wood or steel beams and are held in place by
thumb screws. Either of the points can be removed and often one point has
adjustment for fine settings. A special clamp for a pencil can be attached to one
of the points.

Steel Rule
Steel rules are manufactured in a variety of types and lengths; each of which is
designed for measuring or laying out different work. Available in lengths from
100mm to 1000mm.

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Centre Punch
Similar in design to the prick punch except that the tapered point is ground to
an angle of 90° included. They are available in various shapes and sizes and are
used for locating centres for drilling etc.

Prick Punches
Prick Punches are made of tool steel and having a tapered point ground to
approximately 30° included angle. These punches are used for making small
dents or indentations and/or establishing points for dividers and trammel
points.

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Steel Circumference Rule

This is used much like the common rule. It is invaluable for laying out patterns.
It is available in metric or imperial graduations. Its length is 24” or 600mm
depending on the type. The purpose of this rule is for finding the
circumference of cylinders and for angular measurement.

Tape Rule
It is very popular for measuring and laying out large jobs. Available in various
lengths,

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1.2 Hammers and Mallets

Stretching Hammer
This is used for stretching edges and flanges on curved work. It is normally
used in conjunction with a stake.

Planishing Hammer
The principal purpose of the Planishing Hammer is for smoothing and
finalising a surface after it has been roughed out to the required shape.

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Cross Pein Hammer

This is used by the Industrial insulator for general use in the metal shop and on
site.

Engineers Ball Pein

This is used for striking chisels, punches, rivets etc. And for general engineering
use.

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Boxwood and Rubber Mallets

These mallets can be used on mild steel, copper or aluminium to prevent
marring the metal.

1.3 Cutting Tools

Straight Snips
These snips are used for straight line cutting. They are available in many
different sizes. Available from 200mm to 350mm long.

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Combination Snips
These snips are used to cut straight and irregular lines and curves. These are the
snips used most commonly by the industrial insulator. They are available in the
same sizes and capacities as straight snips and are also available for right or left
hand use.
Spring loaded snips known as aviation snips are very good for cutting light
metal and for notching work.

Side Cutting Pliers

These pliers have flat jaws grooved to hold the work, and are sharpened to cut
light wire.

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Combination Pliers
These are used for holding, cutting and bending work. The pliers are so
constructed that the jaws can be adjusted for holding different sizes of work.

Hacksaw
The Hack Saw is used for cutting materials by hand. It consists of a renewable
hardened steel saw blade fitted into an adjustable frame, which is usually
provided with a screw adjustment for controlling the tension of the blade. It is
necessary to have both junior and senior hack saws in your tool kit.

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1.4 Files
There are many shapes and sizes of files available with various grades of cut.
Files are used to remove burrs from sheets of metal, to straighten uneven edges
and for various other operations that require a small amount of metal to be
removed. They should always be used with a handle. Common types used by
the industrial insulator are: flat, square, round, half-round.

1.5 Pop Riveting Guns

“Pop” Riveting Guns are used extensively with “pop” rivets for the assembly
of light fabrications and are particularly useful for the assembly of metal
cladding where access is restricted to one side of the work only. There are three
different types available: hand “pop” gun, lazy tongs and pneumatic (air).

Hand “Pop” Gun

Riveting in confined spaces requires the use of a hand “pop” gun. These are
unsuitable for larger dimensions of rivets, due to the reduced amount of
leverage available.

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Lazy Tongs
Lazy Tongs are used for the larger diameters of rivets, where sufficient working
space is available to permit operation of the tool.
The construction of the tool permits a moderate pressure on the handle to
provide a strong pulling force on the rivet mandrel.

Note: Always refer to and study the manufacturer’s manuals for the safe
operating procedures before using any tools or equipment.

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2.0 Workshop Machinery

Key Learning Points

 Locate and identify lubrication points on all machines and equipment.
 Identify safety hazards related to tools and equipment in the workplace.
 Work planning and communication. Safe operation and use of power
guillotine.

The flat sheet of metal with the layout on it is fabricated through a number of
different operations. These steps will vary from job to job. Some of the more
common operations are: cutting, folding / bending, edging, making seams,
forming, crimping and swaging.
A skilled sheet metal worker is a worker who correctly selects the proper hand
and the machine tools to do the job.

2.1 Safety in the Workshop

Always wear the appropriate protection at all times i.e.
 Goggles when grinding and drilling
 Safety shoes and overalls at all times; gloves when needed; also ear
protection
Good housekeeping is an important element in accident prevention. Good
housekeeping begins with planning ahead. Materials should be neatly stacked
and any spillages of oil or grease should be cleaned up immediately.
Each person should pay attention to his own work area. A neat work area
reflects a worker’s approach to his work and equipment.
The apprentice should always think safety. There are too many hazards in the
work area to list. The apprentice should cultivate a positive attitude towards
safe working habits. Planning your work properly and communicating with
others while operating machinery is vital in maintaining a safe work
environment.

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2.2 The Box and Pan Folding Machine

This type of machine, while suitable for all types of bending operations, has
special provision for folding pans, trays or boxes. No rods, wires or metal
beyond the capacity of the machine should be bent on this machine.
1. The most important points when using this machine is to set the machine
to suit the metal thickness being folded.
2. Never bend beyond the capacity of the machine. This strains the machine
and will shorten the life-span and quality of the folders.
3. Never bend round bar etc. in the machine.
4. When removing or inserting the fingers (of machine) take care not to get
your own hand or fingers squashed.

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Refer to Module 1 - unit 4 – section 3.2

Hazards:
 Beware of swinging counter-balance weights and bottom leaf (bed) of
machine.
 Use the proper manual handling techniques when using this machine or
moving metal in or out of benders. This machine can put great strain on
your back.
 Refer to module 1-unit 2-manual handling.
 Beware of crushing of fingers when using machine and especially when
changing the blades.

2.3 The Guillotine

The principle of shearing is similar to punching except that the area being
sheared is a relatively small continuous section, starting at one end of the sheet
and ending at the other. A hold-down clamping stop holds the sheet rigid while
the blade of the guillotine shears through the sheet.

An important factor in the production of a good cut edge is the clearance

between the blades as well as the sharpness of the blade edges. Some machines
have provision for altering the blade clearance to suit the thickness of sheet
being cut out, usually the clearance is set at manufacture and checked
periodically. A reasonable guide is 0.1 mm increase in clearance for every 1 mm
of sheet thickness. The shearing capacity of the guillotine should be more than
the shearing strength of the material being cut.

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Safety Issues
5. Ensure all guards are in place before starting machine.
6. Ensure prescribed personal protection is worn - Overalls, safety boots and
gloves.
7. Before using the guillotine its maximum shearing capacity must be
understood.
8. Gloves must be worn if there are sharp edges on metal.
9. Scrap behind machine to be cleared up daily and properly disposed of.

2.4 The Bending Rolls

The two types of bending rolls used in sheet metal are the plain bending and
slip bending rolls. These machines are for curving sheet metal. On the slip
bending rolls the upper roll can be released and this facilitates the removal of
the work piece. This can’t be done on plain rolls. There are power and
manually operated types available.
Hazards:
 Loose clothing e.g. cuffs may get caught up in machine. Always wear tight-
fitting overall.
 Exercise caution as fingers may also get caught in the machine.

2.5 Lubricating Machines

It is vitally important to lubricate all machines on a regular basis. A lubricant is
used for a number of different reasons:
1. To reduce friction.
2. To prevent wear.
3. To prevent adhesion.
4. To aid in distributing the load.
5. To cool moving parts.
6. To prevent corrosion.

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The range of materials used as lubricants has greatly broadened over the years
so that in addition to oils and greases many plastics and solids and even gases
are now being applied in this role. Because of the wide selection of lubricating
materials available, great care is advisable in choosing the right material and the
correct method of application. Always refer to the manufacturer’s manuals
regarding the type of lubricant to use, the correct method of application and
the frequency of application.
Note: Always refer to the equipment manuals for safe operating
procedures.

3.0 Measurements

Key Learning Points

 Metric system: units of length, mass and force.
 Angle and straight line bisection.

In science, measurement is the process of obtaining the magnitude of a

quantity, such as length or mass, relative to a unit of measurement, such as a
meter or a kilogram. The term can also be used to refer to the result obtained
after performing the process.

3.1 SI Units of Measurement

The international system of units consists of a set of units together
with a set of prefixes. The units of SI can be divided into two subsets. There
are the seven base units. Each of these base units is dimensionally independent.
From these seven base units several other units are derived. In addition to the
SI units there are also a set of non-SI units accepted for use with SI.
A prefix may be added to units to produce a multiple of the original unit. All
multiples are integer powers of ten. For example, “kilo” denotes a multiple of a
thousand and “milli” denotes a multiple of a thousandth hence there are one
thousand millimetres to the meter and one thousand meters to the kilometre.
The prefixes are never combined: a millionth of a kilogram is a milligram not a
micro kilogram.

SI Units
Length metre (m)
Mass kilogramme (kg)
Volume cubic metre (m3)
Torque Newton metre (Nm)

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Force Newton (N)

Temperature Kelvin (K)
Angle Degrees (example 90°)

3.2 The Imperial System

Imperial units or the imperial system is a system of units, first defined in the
British Weights and Measures Act of 1824, later refined (until 1959) and
reduced. By the late 20th century many countries had officially adopted the
metric system as their main system of measurement. However, the use of
imperial units does persist, with some countries, such as the United Kingdom,
Ireland, and Canada, having laws permitting and even mandating them.
12 inches = 1 foot written as 12" or 1' - 0"
24 inches = 2 feet written as 24" or 2' - 0"
36 inches = 3 feet written as 36" or 3' - 0"
42 inches = 3½ feet written as 42" or 3' - 6"
1 inch = 25.4mm
12 inches = 304.8mm
39.37 inches = 1000mm = 1 meter

3.3 The Metric System

The metric system is an international decimalised system of measurement, first
adopted by France in 1791, is the common system of measuring units used by
most of the world. It exists in several variations, with different choices of
fundamental units, though the choice of base units does not affect its day-to-
day use. Over the last two centuries, different variants have been considered
the metric system. Since the 1960s the International System of Units ("Système
International d'Unités" in French, hence "SI") has been the internationally
recognised standard metric system.
The basic unit of length is the metre (m). For small units of length the
millimetre (mm) is used. There are 1000 millimetres (mm) in a 1 metre (m). The
kilometer (km) is used to measure long distances. 1000 metres (m) = 1
kilometre (km).
10 millimetres (mm) = 1 centimetre (cm)
10 centimetres = 1 decimetre (dm) = 100 millimetres
10 decimetres = 1 meter (m) = 1000 millimetres

3.4 Angle and Straight Line Bisection

Refer to Module 2 – unit1 – section 3.0

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4.0 Metals

Key Learning Points

 Metal type, identification and thickness.

Not only is it essential for the industrial insulation apprentice to know the tools
and machines of his trade and how to use them safely, but it is also important
to know the materials equally well. A finished job may look very well, but it
may be useless if the wrong material were used. It is extremely important to
know the correct material for a given job.
When you have read through these notes you will learn about the various types
of sheet metal, their sizes and characteristics and where they are used. The two
main groups are ferrous (steel) and non-ferrous, each group including several
types of metal for different uses.

4.1 Sheet Steels

Steel is the most commonly used material in the sheet metal shop. This is
because it is relatively cheap and is available in alloys and with special coatings
for various uses. The most commonly used types of sheet steels are mild steel,
galvanised, stainless and tin plate. Mild steel comes in two forms: hot-rolled
commonly known as black iron, and cold-rolled commonly referred to as mild
steel. Black iron is a cheaper variety and tends to be softer than mild steel.
These two in effect would be classified as plain steel sheets. Black iron looks
bluish-black near the sides of the sheet and may have a silvery appearance near
the centre, whereby mild steel sheets have a silver grey appearance and are of
better quality overall.

4.2 Coated and Solid Sheets

Sheet steel may be coated or uncoated (solid). A commonly used coated sheets
is galvanised. Stainless steel is the most commonly used solid sheet.
Plain sheets are seldom used because of their susceptibility to rust and
corrosion. Non-ferrous sheets, which we will discuss later, are classified as solid
sheets. The apprentice should learn to identify solid and coated sheets by sight
and by manufacturer’s markings and specifications to ensure that he is using
the correct material for the job. The coating on galvanised sheets and is for
corrosion resistance. If these metals were used on a job which required welded
seams, the product would burn off the protective coating. On the other hand
stainless steel may be safely welded because it is resistant to corrosion and has
no coating.

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4.3 Galvanised Sheet Metal

It is a sheet steel coated with zinc. In the most common one, the steel is dipped
in an acid both for cleaning and then is dipped into the zinc. In the other case
the coating is done by an electroplating process. Electroplated sheets are
recognised by their even grey colour and are mainly used for their ability to
resist corrosion.
Galvanised mild steel can be easily recognised by its typical spangled
appearance. These spangles are from the molten zinc as it cools on the sheet.
Since galvanised is a coated sheet, its corrosion resistance is dependent upon
the condition of the zinc coating. Zinc is highly resistant to corrosion and, as
long as it remains intact on the sheet, galvanised mild steel will have high
corrosion resistance. A good quality galvanised sheet should last 5-10 years in
constant contact with water, but if the surface is damaged in any way by
welding, grinding or bending the steel will be exposed and the sheet will rust
through very quickly.
Of all the sheet metals, galvanised is one of the least expensive and is probably
the most commonly used. Air conditioning duct work is made almost entirely
of galvanised sheet metal. Roof flashings and gutters are made from galvanised
metal, so also are tanks, signs, boxes and cladding.
Good quality galvanised metal can be bent and straightened several times
without the zinc peeling away.
Galvanised metal can be obtained in 2000 x 1000 mm and 2500 x 1250 mm
sheets. It is also available in roll form.

4.4 Stainless Steel

Stainless steel is one of the most important materials within industry. As the
name indicates, stainless steel has high resistance to foreign or corrosive
elements. It is also very easily cleaned. For these reasons, it is widely used in
residential kitchens, institutional and restaurant kitchens, for hoods, sinks,
splash backs etc. It is also widely used in the dairy industry for milk storage
tanks and containers. It is also used for metal cladding where appearance and
fire resistance are very important.

Types of Stainless Steeln

An important point to remember is that the term “Stainless Steel” refers to a
general class of metals rather than to one particular type. There are a number of
different types of stainless steels available.
Each type of stainless steel is designed to meet a particular need. Some are
extremely resistant to corrosion, while others are not. Some will resist certain
chemicals better than others. Others are designed for special qualities i.e. weld
ability, ease of machining and work hardening. A small change in one of the
alloys will change the characteristics of the steel.

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Stainless steel is classed by type number e.g. type 304. There are a very big
number of various grades of stainless steel available, so the industrial insulator
would have to look in a handbook to find the type of stainless steel
recommended for a specific use. Type 304 is used for catering equipment,
containers, tankers, cladding etc. where corrosion is of a mild nature. Type 316
would be used to hold highly corrosive chemicals.
Stainless steel can be designated by a certain type of finish i.e. dull finish, mirror
finish etc. The cost of stainless steel is high, running at several times the cost of
galvanised mild steel. However in applications where galvanised may last only 5
years, stainless steel will last indefinitely.

4.5 Non-Ferrous Sheet Metals

Non-ferrous metals are those which have no iron or steel content such as
copper, aluminium, lead and zinc. The most common non-ferrous metals used
in the industrial insulation shop is aluminium – both plain and stucco finish.

Copper
This is a solid sheet easily recognised by its reddish colour.
The great advantage of copper is its high resistance to corrosion. There are
many examples of copper roofs on churches and buildings that were installed
in the middle ages and still in good condition. Another desirable feature of
copper is its beauty.
Copper sheet is very expensive. The greatest use of copper today is in
architectural sheet metal work. It is used extensively for high quality roofing,
gutter, downpipes, roof flashings and hoods.
Copper sheeting is available in both hot and cold rolled. Cold rolled sheets are
sheets that have been through a final process of running through finishing rolls.
This gives the metal a smooth finish and work hardens it to a half-hardened
condition.
Hot rolled copper is copper that has only the hot rolled process and has not
been rolled when cold. It does not have the shiny appearance of cold rolled
copper. It is used when the metal will be subjected to stretching when it is
formed, since it is soft enough to take severe forming. As it is being formed it
becomes work-hardened and approaches the hardness of cold rolled copper.
Copper that has been work-hardened can be annealed by heating to a cherry
red and then cooling in water or leaving to cool in the open air.

Aluminium
The main properties of aluminium are its light weight, corrosion resistance and
appearance. Sheet aluminium weighs approximately one-third as much as sheet
steel and is just as strong. For this reason aluminium is used instead of steel for
such items as exposed ductwork, gutters etc. where appearance, corrosion,
resistance and ease of handling are more important factors than economy.

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Pure aluminium is too soft to hold a permanent shape in sheet form so the
sheets are manufactured as an alloy. Alloying means that one or more metals
are added to the pure aluminium to increase its strength and hardness. Some of
the more common alloying metals are manganese, copper, chromium, silicon
and magnesium. Very small quantities of these metals are required to give the
desired properties. In fact most alloys for sheet metal are almost pure
aluminium. Sheets are available in plain, stucco or embossed finishes for the
cladding industry.

Lead
In sheet form it has a number of uses, shower pans, flashings, tanks for highly
corrosive materials and radiation shields are some of the major applications.
The use of sheet lead, for radiation shielding is increasing because of the rapid
development in the uses of atomic energy. Lead has proved to be one of the
best materials for shielding workers from radiation. In atomic energy plants,
whole rooms are lined with sheet lead for this purpose.
The chemical and physical characteristics of lead sheet make it very useful for
industry. For example, it is durable and has high resistance to corrosion from
most acids and from exposure to air. It is very soft and easy to work. Lead is
therefore commonly used on roof flashings on both corrugated and tiled roofs
where it can be adapted by hand to contours of the roof.

Zinc
Sheet zinc is highly resistant to corrosion and is used in some instances where
galvanised steel cannot provide adequate resistance. Compared to other metals,
zinc is rather brittle so care must be taken while bending it. Zinc sheets are
usually ordered by specifying decimal parts of an inch for thickness.

4.6 Properties of Metal

Hardness:
This is the property of a metal to resist penetration or scratching.
Malleability:
This indicates the extent to which a metal can be extended in all directions by
hammering or rolling without causing the material to crack. Metals are usually
more malleable when hot than when cold, therefore it is usual to heat them
when forging. Gold is the most malleable metal and may be beaten into very
thin sheets.
Ductility:
The degree to which a metal may be expanded in the direction of its length.
Ductile metals are easily hammered to shape and will yield to pressure. Ductile
metals are used for wire drawing and tubes.

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Module 1– Unit 3 Measuring, Marking & Cutting Out

Conductivity:
Can be divided into two types: thermal and electrical.
Thermal Conductivity (lambda or k) is a measure of how well heat will flow
though a material. Copper is an example of a material with good thermal
conductivity and so is aluminium. These are used to make saucepans where we
want heat to be conducted quickly. Materials which do not conduct heat well
are called thermal insulators. Thermal insulation is used to slow down heat loss
in homes (e.g. fibre glass in roof spaces, plastic foams in cavity walls). Heat
always flows from hot to cold.
Electrical Conductivity is a measure of how well electricity will flow through
the material. For a material to have good electrical conductivity it must have
low resistance (e.g. copper). Some materials are poor conductors and so have a
high resistance these are called insulators (e.g. polythene, rubber, and ceramics).
Fusibility:
All metals with the exception of mercury are solid at room temperature.
They are all capable of being melted by heating. Fusibility is the relative ease
with which they may be melted.
Elasticity:
This property enables a metal to return to its original shape after external forces
which cause distortion are removed. If the force causing distortion is increased
without limit, a point is reached when the metal fails to regain its original shape
and this point is called the 'elastic limit'.
Brittleness:
The brittleness of a material refers to sudden shattering. Some materials break
suddenly in contrast to materials that are ductile and stretch before breaking.
Materials that are brittle show only slight permanent distortion before breaking.
They are said to have a low resistance to shock.
Toughness:
Toughness is a commonly used term, but it actually has a very specific meaning.
A tough material is resistant to permanent deformation, and at the same time is
resistant to breaking after permanent deformation is begun. This means that
either a slow or a sudden stress can be applied to a tough material, and this
stress can be continuous or frequent. Also, it will deform before it breaks.

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Module 1– Unit 3 Measuring, Marking & Cutting Out

5.0 Cutting a Sheet Metal Blank

Key Learning Points

 Measuring and marking out various types of sheet metal using a steel
rule, scriber, ‘L’ square and straight edge.
 Drawing symbols, first and third angle projection, orthographic, free
hand sketches on grid paper.
 De-burring sharp edges.
 Dimension checking ± 1mm using rule.
 Vernier callipers operation and reading. Measurement of material
thickness using the vernier callipers.

Many experienced workers do many of their layouts directly onto metal.

However, for an apprentice it is better to make more difficult layouts on paper
so mistakes won’t be made thus avoiding costly errors.

5.1 Job Planning & Preparation

Job planning is important prior to starting any task. The drawing should first be
studied and understood. The drawing can initially be used to calculate the
material requirement for the component to be manufactured. The work piece is
marked out using the dimensions and datums as specified on the drawing. A
basic level of mathematics is required such as addition, subtraction,
multiplication, division, fractions, decimals and percentages.
One of the first steps in preparing to layout a pattern on metal is to square the
bottom left hand side of the piece of material. A steel square may be used for
this purpose, or a sheet maybe squared using the squaring arm on the guillotine.
The next step is to ensure that the sheet lies perfectly flat on the bench as a
sheet that is not flat will cause measurements to be inaccurate.

5.2 Drawing Symbols and Orthographic

Projections
The drawing is used to convey certain information to the industrial insulator,
helping him or her to visualize the shape description and size of a metal part.
The ability to build or to form a mental picture of the metal part before it exists
is essential. Before an apprentice can read and interpret a drawing, he or she
must be able to understand and to interpret correctly the meaning of drawing
symbols and different angles of orthographic projections used on different
drawings.
Refer to Module 2 – Unit 2 – Orthographic projections

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5.3 Marking Out

The measurements for the blank to be cut should be taken from the bottom of
the sheet and from a squared up line at the left hand side of the sheet. This
practice minimizes the waste of material when cutting out patterns. The tools
required to mark out a pattern on sheet metal are the steel rule, scriber,
circumference square and a straight edge. Once the apprentice has completed
the marking out process the pattern or blank can then be cut out using a
guillotine or hand shears.
Refer to section above - 1.1 Marking Out Tools

5.4 Cutting
Refer to Module 1 – Unit 3 – section 2.3 – The Guillotine

5.5 De-Burring
After the material has been cut on the guillotine, an edge or burr may be left on
the pattern. This edge or burr is a raised section of metal which needs to be
removed for safety reasons. A file or de-burring tool can be used to remove
this edge.
Refer to section 1.4 - Files

5.6 Checking Measurements

Using a steel rule, folding rule or a tape rule, check the measurements of the
blank piece of material you have cut. Position the start of the rule on the left
hand side of the piece and measure across to the right hand edge. Repeat the
same procedure for measuring from the bottom edge to the top edge. Record
these measurements and refer back to the drawing to ensure they correspond
to the measurements on the drawing. The measurements you have recorded
should be within the tolerance specified on the drawing and in general should
be ± 1mm.

5.7 Vernier Callipers

Named after its inventor, the vernier scale is incorporated in many measuring
instruments, the most commonly used of which is the sliding caliper gauge. It
can be used for taking both internal and external measurements. These gauges
are made from fine quality alloy steels and are very accurately finished.

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When measuring an object externally or the thickness of a particular material,

the locking screws A and B are both slackened off and the sliding jaw assembly
is moved along, almost onto the object. Locking-screw A is tightened down
and then, by turning the knurled screw C, the jaws are gently closed on to the
surfaces without putting any pressure on them. Locking screw B is then
tightened down and the calipers removed from the work for reading.
The jaw tips are stepped and rounded on the outsides so that internal
measurements can be taken and to whatever reading is obtained, the widths of
the jaws must be added. This measurement is found engraved on the jaw face
for reference.

Reading the Vernier Callipers

In the picture above, we see part of the caliper main scale is divided into
centimeters and milimetres. The actual length of the vernier scale is 49mm and
this length is divided into 50 parts. Each division of the vernier will therefore
be equal to 0.980mm, i.e each will be 1/50th mm shorter than each division on
the main scale. The reading is taken as follows: reading along the main scale up
to the vernier zero, we can see the number of whole mm in the measurement
and the line on the vernier which coincides with a line on the main scale
indicates the number of 1/50th mms to be added on.
Tools incorporating the vernier scale are also available with scales in imperial
measure.

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Module 1– Unit 3 Measuring, Marking & Cutting Out

Summary
This unit identifies the tools, equipment and machinery used in the workshop.
It introduces the apprentice to the risks and dangers associated with working in
a workshop environment and the safety precautions needed to work in a safe
and responsible manner. Safety is everyone’s concern and the apprentice needs
to develop this frame of mind early on in his/her apprenticeship.
We have looked at the different tools which are required to measure, mark out,
and cut out different materials. Tools, if used incorrectly, can cause harm and
injury. It is important that tools are stored properly during and after use. The
apprentice should operate a clean as you go policy when working so as to
eliminate the possibility of injury due to an untidy work area.
This unit also covers the various metals which are used in the industrial
insulation trade. Metals are broken into two groups-Ferrous metals which
contain iron and Non-Ferrous metals which don’t contain iron. Metals and
their alloys form a large part of the industrial insulation trade, so it is imperative
that the apprentice understands the importance of each metal, their properties
and their uses.

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Castleforbes House
Castleforbes Road
Dublin 1