Break out and Lay out Stock

MakeaBBQFlipper

Description

Thepurposeof this activity is tointroduce students tothemetal shopthroughpractical activity.This activity is an introductionto sheet metal fabricationand basic hand tools used inworkingwith sheet metal.It also includes a designelement thatallows studentstopersonalize theirfinishedproductwhileincreasingtheirskilllevel.

LessonObjectives

The student willbeableto:

•Break out and lay out stock

•Cutsheet metal

•Form sheet metal

•Assemble sheet metal

•Finish sheet metal

Assumptions

Theteacher will:

•Be a certifiedtechnologyeducation/industrialeducationteacher

•Befamiliar withthemetal shopwherethis Activity Planis beingconducted

•Haveexperience withall aspectsof the given metal shop,includingmachines,toolsandprocesses

The student will:

•Beattentive andparticipatory

•Recognizethat appropriateattitudesarethebest insurance for safety

•Cut, form and join sheetmetalmaterial tocreate thedesiredproject

•Safely work inthe metal shop

•Demonstratesafe andappropriate useofhandtoolsand equipment

•Useappropriate layouttools

•Demonstrateappropriatefinishingtechniques

Thisworkis licensedunder aCreativeCommonsAttribution-NonCommercial-ShareAlike4.0InternationalLicenseunlessotherwiseindicated.

Terminology

Aviationsnips:ahandtooldesignedtocutsheetmetalintointricatedesigns.Canbeusedtocutcompoundcurves.Red=leftcutting;Green=rightcutting;Yellow=universal,abletocutinanydirection.

Boxandpanbrake:asheetmetalmachinethatisusedtocreatebends,hemsandboxes insheetmetal.

Breaking:bendingthesheetmetalalongaline.

Centrepunching:markingthecentreofahole.

Combinationsquare:aruledbladewithboth45°and90°heads.Usedtolayoutrightanglesand45°angles.

Emerycloth:anabrasiveclothusedtoremovematerialandsmoothsurfaces.

File:ahandtooldesignedtoshapeandsmoothmetal.Available inavarietyofshapesandsizestofitdifferentprojects.Madeofhardenedsteelwithvaryingtexturesto remove largeorveryminimalamountsofmaterial.

Finishing:theprocessofusingsanding,polishing,sandblastingorpaintingtocreateadesirableendproductappearance.

Jewellerssaw:ahandsawwithveryfineteeth usedtocutinternaldesigns into metal.

Layout:theprocessoftransferringapatternfrompapertothematerialusingpens,scribes,centrepunches,squaresandscales.

Letterandnumberstamps:hardenedsteelbarswithlettersandnumbers.Usedtopermanentlylabelmetalprojects.

Pattern:amodelordesignusedasa guide.

Riveting:amechanicaljoiningtechniqueusedtojointwoormorepiecesofsheetmetaltogetherwitharivet.

RoperWhitneypunch:ahandtoolusedtopunchholesinsheetmetalstock.

Ruler:aprecision measurementtoolthatisalengthofsteel withmarksatregularintervals.Scribe:along,pointedpieceofhardened steelthatisusedtomark layoutlinesonmetal.Sheetmetal:atermusedtodescribeavarietyofthinrolledmetalsheetstock.

Squaringfootshear:afoot-controlledmachineusedtocutsheetmetalstock.

EstimatedTime

2–3 hours

RecommendedNumberofStudents

20, basedontheBCTechnology EducationAssociationBest PracticesGuide

Facilities

Metalshopfacilitywithall necessary equipment

Tools

•Aviationsnips

•Barfolder

•Box andpan brake

•Centre punch

•Emerycloth

•Files –both coarseand smooth

•Hammer

•Jewellerssaw

•Letterstamps

•Poprivet gun

•Personalprotectionequipment

•Ruler

•Scribe

•Squaringfoot shear

•Vise – withsoftjaws/vise caps

•Whitney punch with a3⁄16" die (other diesmaybe required on anindividual basisdependingon studentdesign choices)

Resources

“HEADSUP!forSafety”handbook

BCTechnologyEducationAssociationBestPracticesGuide

Videos

Boxandpanbrake

RoperWhitneypunch

Barfolder

Footshear

Poprivetgun

Aviationsnips

Materials(perstudent)

Numberofpieces / Materialandsize specifications
1Handle / 1"× 14"14 gaugestainless steel
1 Head / 4" ×6¾"14gaugestainless steel
2 / 1"×6" ×3⁄16"plywood (plus paint orstain)
2 / 3⁄16"machine screws, countersunkheads
2 / 3⁄16"nuts
2 / 3⁄16" shanktinner’srivets(or blind/pop rivets)
5⁄16"long– aluminum

StudentActivity

1.On a blanksheetofpaper,sketchout 6 designideasfortheheadofyourflipper(e.g.,flames,#1griller,starburst).Thesedesignsshould be inpencil,neatanddetailed.

2.Chooseoneofyourdesigns,and on a separate piece ofpaperdrawoutyour BBQ flipperheadto scale, including yourchosendesign.Thehead should measure 4" ×6¾",includingthe1¾"fold line.(See Dimension diagram on page7.)

3.Once yourdesignandtemplatearecomplete,showyourteacherandgatheryourmaterials:1 handlepiece, 1 flipperheadpiece.

Note:Sheetmetalisverysharpandcancutskin easily.

4.Usingthedimensioneddiagramattached,layoutall holes on boththehandleandtheflipperheadusing thescribe and ruler. There should be6 holes in total.

5.Layoutthefoldline on boththehandleandflipperhead.Thisshould be a solid scribed line.

Showyourteacherbeforeproceeding.

6.Centrepuncheach hole location on both pieces ofyourflipper.

7.Punch both holes on theflipper headusingtheRoperWhitneypunch and a3⁄16" die.

8.Punch all 4 ofthe holes on yourflipper handleusingthe 3⁄16" die on the Roper Whitneypunch. Be sure to centretheRoperWhitney punchonthe layout marks.

9.With a smoothcutfile,makesurethereare no burrs or sharpedgeswhereyour holes havebeenpunched.

10.Test fit toensureyourhandle holes lineupwiththeflipperhead.

11.Set yourhandle aside.Using apermanentmarkerand layouttools, traceoutyourchosendesignontotheflipperhead. Be carefultocentreyourdesignandleavespacealongtheoutsideedges.

12.Showyourteacheryourlayoutand confirm youarereadytocutoutthedesign.

13.Usingthe Roper Whitneypunchand ajewellerssaw,cut outyour design carefully. Thismaytake sometime.

14.Fileanyroughor sharp edges until smoothand freeof burrs.

15.Sharpentheedgeofyourflipperheadoppositeyour holes forthehandleattachment.Use afile first, thenemery cloth tosmooththeedge.

16.Usingtheviseandsoftjawstosecureyourflipperhead,slightlyroundthefour corners toensurethereare no sharpedges.This could be doneusing a smoothcut file or emerycloth.

17.Nowthatall surfaces andedgesaresmooth,thehandleandflipperheadneedto be benttoa30° angle using either the boxand pan brake or barfolder.Lineup yourfoldline evenly toguaranteeagoodbend.

18.Finishoffyourhandle piece andflipperheadwith400 grit emerycloth.Makesureyousandinthesamedirectiontoensureyourflipperpartshave a uniformfinish.

19.Ask yourteacherfor 2 rivetsandjointhehandle piece totheflipperheadusingtherivetgun.Makesureyour pieces arelinedup correctly beforeyoucompletetheriveting process.

20.Gather 2pieces of 1" ×6" ×3⁄16" woodfrom your teacher and therequired hardware

(3⁄16"machinescrews,countersunkheadsandnuts)to attach thewoodtoyourflipperhandle.

21.Sandthewood pieces with120 grit sandpaperandfinishusing a woodstain or oil.22.Using theletterstampsand a hammer,stampyour initials or nameinto ONE ofthetwo

woodenhandle pieces.

23.Attach thewood pieces toyourflipperhandle,beingsuretotightenthescrews.

24.Hand informarkingalongwithyour designdrawings.

ExtensionActivity

IfAutoCAD or similardesign software isavailable,useittocreatetheflipperheaddesign,theneither laserengraveor CNC machine yourdesign,depending on the equipmentavailable in theshop.

Assessment

Consider co-creating theevaluationcriteriawithyourstudentsatthebeginningoftheactivity/project. You maywanttoincludethe following:

•Safeworking procedures atall times

•Personalandproject management: gooduseof time, attitude, effort

•Designdrawingsare neatand organized andinclude details

•Accurate measurements andlayout

•Appropriateuseof tools

•Allburrs are removed and sharp edgesaresmooth

•Project is assembled correctly andsecurely

•Namestamp located onwooden handleiseasy to read.Equally spaced and lined uphorizontally

•Allfoldsareeven andsquare

BBQ Flipper Body

4.0000

Slightradiuscreatedby filing edges

Studentdesignedcenter

6.7500

Fold line for handle attachment

0.5000

1.7500

0.5000

3/16" hole

Note:Allholesare3/16"indiameter

0.5000

7.25004.0000

1.0000

Foldlineforhandleattachment