- The choice of the interdisciplinary object was mixed in its difficulty. As it was a much more generic and simple shape it was quite easy to fabricate, however as it is traditionally an object produced using factory machinery it is quite difficult to duplicate.
- A chosen shape for metal shaping should ideally be a more curvilinear and organic object, due to the nature of the tools available for metal shaping. Factory / machine made objects are much more difficult to replicate using human hands and tools, whereas a shape more commonly hand-made is easier to reproduce.
- The procedure of metal shaping requires thought and decision of where to begin, whereby completing a task which does not obstruct or restrict a task which is required later on. This was exhibited where bending was first applied to the shape in order to create a shovel tray; a task which needed to be complete first as following the shaping of the central curve it would be impossible to fit the skin within the bending brake.
- Caution must be utilised in using the bending brake, in order not to over-compensate / over-bend more than required. Although reversible, this creates slight stretching and scratching of the sheet.
Overbending created by bending brake
- Additionally, it is also optimal to use the correct amount and size of plates, as it is more functional and effective to create a single bend as opposed to multiple consecutive bends. This also reduces the creation of cracks and scratches.
Using a single bending plate can cause buckling and unwanted movements within sheet
Overuse of bending brake can create unwanted scratches and tears
- In order to fabricate a smooth and accurate curve, a variety of anvils (of which are available in the Squarehouse workshop) can be applied to use. However, these should be used sparingly and with caution as the incorrect size of the anvil may result in over-stretching (requiring re-shrinking) or possibly irreversible changes.
Oval steel dolly anvil
Tapered Steel T-Dolly anvil; although a curve can be achieved with both, correct selection of anvil will allow for more efficient less time-consuming work
- The process of cutting and trimming should be a task that is completed at the beginning of the metal shaping process. This allows for cleaner and more accurate cuts to be made, as there are no indentations or contours within the metal sheet. Where possible the guillotine should be used, due to its ability to create a long, quick cut, with the least chance of an off-cut or inaccuracy.
Manual Treadle Guillotine
- In order to create a curved or angled cut, the hand lever shear should be chosen over the tin-snips due to its stronger and more accurate cut. The improved accuracy and strength is reflected in its ability to reduce miscuts and burred edges.
Hand lever shear
Burred edges and miscuts from bad cutting
Bent, protruding miscut
- Through the use of different hammers and tools, different types of indentations and changes can be implemented into the metal sheet. The different radius ends of the nyoln bossing mallet can create different indents into the sheet metal, with a choice to be made of which is more suitable and necessary (with the least chance of creating an unwanted or reversible effect). The cross chisel steel hammer can produce a indent that is much more sharp and pointed, and due to its strength of material is can create a bolder more visible indentation.
Flat end mallet
Small end of bossing mallet
Large end of bossing mallet
Steel cross chisel hammer
- A major lesson learnt during metal fabrication was to use other materials to create your own 'anvils' or metal shaping tools. Through the simple use of space timber pieces or cutting suitable pieces, it is quite easy to produce an 'anvil' to allow for implementation of a desired shape or effect on the sheet metal.
Timber pieces can be used to 'mould' metal sheet
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