mem05010c apply fabrication, forming and shaping techniques - learner guide

8/10/2019 MEM05010C Apply Fabrication, Forming and Shaping Techniques - Learner Guide

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MEM05 Metal and Engineering

Training Package

Learner guide

Version 1

Training and Education Support

Industry Skills Unit

Meadowbank

Product Code: 5776

MEM05010CApply fabrication, forming and shaping

techniques(Heavy Edition)


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MEM05010C - Apply fabrication, forming and shaping techniques (Heavy Edition)

TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013

CONTENTS

Introducon ..........................................................................................................5

Topic 1 Square and Rectangular Ducng ........................................... .....................9

1.1 Truncated Rectagular Ducng ..........................................................................22

Topic 2 Cylindrical Fabricaon ..................................... ........................................ 29

2.1 Theory & Calculaons relang to Rolling a Cylinder ........................................29

2.2 Truncated Cylinder with Flanges ......................................................................53

2.3 Therory & Calculaons Relang to Lobster-back Bends ..................................59

2.4 Theory & Calcuaons Relang to Cylindrical Square Branches &

Wrap Around Templates ..................................................................................75

2.5 Inclined Branch On-Centre ...............................................................................85

2.6 Inclined Rectangular Branch on a Cylinder (On-Centre) ..................................93

Topic 3 Concial Fabricaons ......................................... ...................................... 101

3.1 Forming Main Barrel ......................................................................................118

3.2 Frustum of Right Cone with Flange................................................................122

3.3 Truncated Right Cone .....................................................................................127

3.4 Forming Truncated Right Cones .....................................................................138

3.5 Mul-strake Cone ..........................................................................................151

Topic 4 Transional Fabricaons ........................................ ............................... 165

4.1 Theory & Calculaons ....................................................................................167

4.2 Rectangular to Square Hopper Transion ......................................................178

4.3 Square/Rectangular to Round Transion .......................................................183

4.4 Square to Round Transion............................................................................189

4.5 O-Centre Square to Round Transion ..........................................................195

4.6 Cylinder Joining Piece ....................................................................................203

4.7 Sub Assemble of Job 4.5 & 4.6 .......................................................................207

4.8 Square to Round Transion (Round Corners) ................................................208

4.9 Final Assembly - Transion Pieces .................................................................220

Project Manager:

Stephen DaviesEducation Programs ManagerTAFE NSW

Enquiries

Enquiries about this and other publications can be made to:

Training and Education Support Industry Skills Unit, MeadowbankMeadowbank TAFELevel 3, Building J,See Street,MEADOWBANK NSW 2114

Tel: 02-9942 3200 Fax: 02-9942 3257

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 UnitMeadowbank. Reproduction or transmittal in whole or in part, other than for the purposes of privatestudy or research, and subject to the provisions of the Copyright Act, is prohibited without the writtenauthority of TAFE NSW Training and Education Support, Industry Skills Unit Meadowbank.

ISBN: 978 1 74236 484 1


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TAFE NSW (Training & Education Support, Industry Skills unit Meadowbank), 2013Page 9 of 224

Topic 1 - Square and Rectangular DuctingTheory and calculations square/rectangular fabrications

Student Organiser

Topic Activity

1 Square/Rectangular Ducting

1.1 Truncated Rectangular Duct

Theory/Calculations

Job 1.1 - Truncated Rectangular Duct

Review questions

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

nished product meet the r equired standard of quality.

There are three (3) stages to the job planning process.

NOTE: All employees in the workplace are responsible for quality control and safety.

To ensure the finished product

is made to specifications, the

fabricator will need toprogressively check each step

of the fabrication process

Stage 2

Fabrication

Careful pre-planning

from the start gives you

more control over the entire

fabrication process

Stage 1

Pre-planning

Stage 3

Finished productEffective 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

Ducting with anges


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Drawing Interpretation of Square/Rectangular Fabrication

Correct interpretation of workshop drawings is vital if the nished fabrication is to meet its specied 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 ow. Ducting can also be made from stainless steel, aluminium, copper and plastic materials.

Development methodParallel 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 at.

Marking outInvolves three main steps:

1. Calculating required dimensions

2. Laying out and developing the pattern/template

3. Following production instructions

800mm

200mm 200mm 200mm 200mm

H=600mm

115mm231

mm

h=485mm

DIAGON

ALS=

1000

mm

60

Pattern calculationsPattern length

Length = Sides x 4

= 200 x 4

= 800mm

Diagonal length check of pattern

=Pattern length + Pattern height

=800 + 600

=640000 + 360000

=1000000

=1000 mm

60 Height check Tan = opp Tan30 = X

adj 200

therefore X = 200 x tan 30

= 200 x 0.577 = 115.4

= 115 mm

True length check of truncated slope

=115 +200

=13225 + 40000

=53225

= 231mm

Pattern little height (h)

= Pattern height - 60 height

= 600 - 115

= 485mm

800 mm

600mm

Diago

nallength=1000mm

60

200 mm

115mm

Truncatedlength=231mm

60

200 mm

X=115mm

30

Truncation Angle

Example

Example

Example

Pattern


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Bend calculations/allowances

When calculating the stretchout length of a pattern for square/rectangular ducting you must allow for the

thickness of material.

Stretchout lengths for material 3mm thick (or under) are ca lculated using the inside measurements of the

ducting, because the amount of material loss in the bend to 90 is small.

600m

m

200mm O/S

200mmO

/S

radius

3mm sheet

NOTE

O/S= outside dimension

t = material thickness

Calculation:

I/S Length = (O/S 2 x t) + (O/S 2 x t)

= (200 - 2 x 3) + (200 2 x 3)

= (200 6 ) + (200 6)

= 194 + 194

= 388mm

Half stretch pattern

2 required @ 3mm by 388 x 600 mm sheet

194mm I/S 194mm I/S

388mm

600mm

B

endupto90

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.

IR 9mm

600m

m

194mm I/S

194mmI

/S

6mm plate

NOTE

I/S = inside dimension

IR = inside radius

ID = inside diameter

MD = mean diameter

MC = mean circumference

Calculating distance around 90 bend

ID = IR x 2 MD = ID + t

= 9 x 2 = 18 + 6

ID = 18 MD = 24

MC = MD x 3.1416 ()

4

= 24 x 3.1416

4

= 75.3984

4

= 18.8496Say = 19mm

Half stretch pattern

2 required @ 407 x 600 x 6mm plate

600

mm

19mm allowance

194mm 194mm

Bendupto90

407mm


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Practical method to calculate the bend allowance

An outside ange 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.

STEP (1)

Measure a distance from a pre-marked datum lines for the bend, as shown below:

150mm 150mm

50 50

10mmplate

STEP (2)

Now bend this to the required angle (i.e. 90)

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 nished outside ange width of 160mm.

158mm

58

158mm

58

50

50

10mm

50mm

distance

each side of

the centreline

158mm

158mm

Production instructions

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 carr ied out. The sketch below shows

a typical example:

P

ressoverto90

Pressoverto90

Guillotinecut

Guillotine cut

BAP

BAP

Guillotine cut

Guillotinecut

beforepressing

Oxy cut beforepressing

J/N 373/4

O/N 8/3/07Item A

Plate edge

Materials are cut by mechanical or thermal processes, the following are typical examples.

Mechanical cutting

1. Guillotines

2. Bench shears

3. Nibblers

4. Shears

When using mechanical cutting equipment you must comply with all safe operating procedures and OHS

requirements.

Thermal cutting

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.


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The choice of cutting procedures depends on:

Material thickness

Type of material

Machine cutting capacity

On some jobs, there are sections which stay uncut until forming has been completed.

This is shown by using the following initials:

BAR(Burn or cut after rolling)

BAP(Burn or cut after pressing)

Forming lines and bends

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

Machines used for this purpose include:

Gap press

H-frame press

Brake press

Folder

Bending techniques

The bending of metal parts in a brake press can be done by air bending or bottoming.

Air bendingmeans 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.

Bottomingmeans the material is formed between the upper and lower dies, which close completely with

only the material separating them.

General rule:-

The Vee die (Vee block) opening should be at least8 timesthe material thickness with the die angle between80 to 88.

Vee block

8 x material

thickness

Vee

blade

60 - 88

Radius equal to

material thickness

80 - 88

Example calculating Vee die opening:

Material: 5mm plate

Vee width = 8 x 5

= 40mm Vee block

Minimum bend radius is calculated by:

Inside radius = 1.5 x thickness of plate

Example: 5mm plate

Bend radius = 1.5 x thickness

= 1.5 x 5

= 7.5mm minimum bend radius

t

R = 1.5t

Note: Vee-Blade angle must

always be less than Vee-Block

angle.

Brake press


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Data sheet from manufacturers give information regarding: - material thickness, minimum bend radius, die

opening and required force (tonnes/lineal metre).

The chart below is from an 80 tonne hydraulic press brake, for material up to 10mm thickness.

MIN. LEG LENGTH B (mm)

5 6 8 9 12 15 18 22 26 29 33

INSIDE RADIUS OF BEND (mm)

0.8 1.0 1.25 1.5 2.0 2.5 3.12 3.75 4.4 5.0 5.6

FEMALE DIE OPENING (mm)MAT'LTHICKNESS

(mm)

6 8 10 12 16 20 25 30 35 40 45

1 11.4 8.55 6.84 5.70 4.28

1.2 16.4 12.3 9.85 8.21 6.16 4.93

1.6 21.9 17.5 14.6 11.0 8.76 7.01

2 27.4 22.8 17.1 13.7 11.0 9.12 7.82

2.5 35.5 26.7 21.4 17.1 14.3 12.2 10.7

3 38.5 30.8 24.7 20.5 17.6 15.4 13.7

4 54.7 43.8 36.5 31.3 27.4 24.3

5 85.5 68.4 57.0 48.9 47.8 38.0

6 98.5 82.1 70.4 61.6 54.7

8 146.0 125.0 110.0 97.3

10 171.0 152.0

TONNES FORCE REQUIRED PER LINEAR METRE TO BEND LC STEEL

THIS CHART BASED ON STEEL 440 MPa U. T.S.

Data Chart

The sketch below shows the minimum return bend allowance.

Inside bend radius

B

Die opening

Die BlocksAre available in many different shapes and forms.

Vee BlocksTypes of Vee blocks used to form bends include:

Knife and Vee

Acute angle knife and Vee

Radius knife and Vee/former

Knife & Vee

Acute angle Knife & Vee

Radius knife & Vee


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Checking pressed shapes

Methods include:

Internal template

External templates

Check over layout

Internal template

External template

Check over layout

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.

Assembly procedures include:

Line up one edge corner to corner, using clamps, magnetic links or jigs and xtures

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

Regular checks will minimise errors, you should be especially careful when, aligning longitudinal corners

joints such as:

Corner to corner Single bevel Corner lap

Aligning ends of component parts

Square ends

Plates aligned and parallel


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Progressive checking

Regular checking is essential to prevent errors, if a minor error occurs, spread it around the job rather than

conning it to one place.

152

150

correct

152

150

6mm plate corner to corner, the 152mm wide

plate laps each side by 1mm (not to scale).

149

150

correct

149

150

6mm plate corner to corner, the149 mm wide

plate is placed so 0.5mm gap is left each side

incorrect

incorrect

1mm

overlap

0.5 mm

gap

(not to scale).

Progressive checking should include:

Alignment of joints

Squaring of side plates

Checking for twist

Checking ends for squareness

Square off

the side

plates with a square.

Checking for twist

using a square and

a flat surface.


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Measure down both

sides of the straight

edge, ensuring

distances are equal.

This is an alternative method for checking for twist, using a straight edge.

Checking for square by measuring across the diagonals, to see if they are the same.

Checking ends for squareness using an Engineers square

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


12/22



G - Clamps

Magnets

Fixed dogs and wedges

To moveTack top only

tack

Tack weld

Tack weld

Pivotpoint

Wedges

To pull a stiffener into position

Temporary or permanent bracing

Cleat

Brace

90

Packing

Gusset

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 sufcient clearance for lifting and turning the sub-assembly


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Fabricating a Flange for Square and Rectangular Ducting

Flanges for square and rectangular ducting are made from plate, at bar or angle. Types of anges include:

1 piece flange

from plate4 piece flange from

flat bar or angle

mitred corners

and welded

4 piece flange from

flat bar or angle

butt welded

corners

Production procedures include:

Marking out

Cutting

Drilling/punching

Assembly (for 4 piece ange) Tack welding

Checking

Marking out

Square and rectangular anges 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 ange.

Step 2

From an approximate centre point,

mark out the ange length,

then use these points to bisect

top and bottom to locate the

vertical centre line as shown.

Step 3

Measure out the ange

width using the vertical centre

line, then use these points

to locate the four corner points.

Step 4

Mark out the out side shape

of the ange.

Step 5

From the four corners

scribe arcs equal to the

ange width.

Step 6

Mark out the inside

ange shape.


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Step 7

Mark out in the vertical and horizontal

centre lines to locate hole centres.

Step 8

Tack weld ange and locate holes

in the required places.

Cutting

One piece anges are manually ame cut

Prole cutting machines are used to cut large numbers

A guillotine can be used to cut outside edges if the material thickness is within the machines capacity Four piece anges can be cut with a guillotine, cropper or manually ame cut.

Drilling

The method you use will depend on the number of anges to be drilled. Remember small numbers of anges

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.

Template used for

stack drilling

Assembly

This can be done on a layout or in a jig. Make sure your work is accurate and joints are correctly aligned.

Correct Incorrect

Fitting flanges to ducting

Alignment of anges to ducting must be within tolerance. Check that your work has:

Correct overall length measurement

Flanges are square to duct

Flanges are correctly located.

Plate square

flange

duct

Equal dimensions

gooseneck

flangeduct

Welding flanges

Fillet weld

duct

preparationCorner weld

For the best distortion control, you should weld the corner joint rst and then the llet joint.

NOTE:

Corner weld should have

min 6mm insertion or equal to the

material thickness or whichever is

less.


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Final fabrication checking

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 ange and duct

Position of holes

Diameter of holes Squareness of ange and duct

Alignment of joint of the ange and duct

Quality of work.

Surface finish (painting or galvanising)

The job should include:

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.

Student Notes

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________

____________________________________________________________________________________


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Assessment Cr iteria

1. To be dimensionally correct to within 2mm

2. Flange is at, i.e., free from twist and distortion

3. Holes located as specied to within 2mm

4. Flange is square to the centre line of the truncated square duct

5. Flanges positioned as specied to within 2mm

6. Seam alignment to be within 2mm.

7. To be well constructed and neat in appearance

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.

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, ame cutting and welding equipment.

Job procedure

Student A

1. Complete the associated exercises

2. Mark and cut items 1&2

3. Press items 1&2


5. Assemble the ange items 5&7

6. Mark and drill holes in the ange

7. Assemble items 1 to 2

8. Assemble the ange to Part A.

Student B

1. Complete the associated exercises


3. Press items 3&4


5. Assemble the ange items 6&8

6. Mark and drill holes in the ange

7. Assemble items 3 to 4

8. Assemble the ange to Part B.

Final assembly

Student A & B

1. Assemble Parts A to B.2. Present your completed job for assessment.


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300

4

2

3

1

A A

60

60

7&8

5&6

12 hls

Detail C

Flange detail Detail B

94

4794 322

94

20

20105105

250

142

inside

dimension

Duct detail

Section A-A (without flange)

214Inside dimension

250

Detail A

FRONT VIEW

PART A

90

PART B

Corner to corner joint

Detail CPressed corner joint

Detail B

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

2mm

Flange

face

End of duct3mm

Detail A

3mm

DRAWN

DATE

A Trainer SCALE

NTS01/07/09

A3 RECT / DUCT FAB IssueATITLE:- Rectangular duct

Job 1.1 Trunca ted Rectangular Duct


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Review Questions (Theory and Practical)

Job 1.1: Truncated rectangular duct

Question 1

a) Name the three (3) stages of job planning required to make a rectangular duct.

Stage 1:- _____________________________________________________________________

Stage 2:- _____________________________________________________________________

Stage 3:- _____________________________________________________________________

b) Give two (2) examples of each stage.

Stage 1:-

_________________________________________________________________________

_________________________________________________________________________

Stage 2:-

_________________________________________________________________________

_________________________________________________________________________

Stage 3:-

_________________________________________________________________________

_________________________________________________________________________

Question 2 (Calculations)

From the rectangular truncated duct drawing, calculate the following:-

a) What is the ange allowance for (Parts A & B)?

_____________________________________________________________________________

b) What are the pattern heights (Parts A & B)?

Part A = Overall height - ange allowance = _____________ = ________

Part B = Overall height - ange a llowance = _____________ = ________

c) The pattern length (PL) for Parts A & B = (length + width) x 2

ie. PL = 2 x (L+W)

PART A PART B

= _______________________ = ________________________

= _______________________ = ________________________

d) The diagonal length of pattern:-

Part A

Part B

Answer =

Diagonal A = Pattern length + Pattern height

=

=

=

Diagonal =

=

=

=

Answer =

Pattern length + Pattern height


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e) The 60 height check (PARTS A & B)

Slant Height = Length x Tan (90 - truncation angle)

=

Answer =

f) Checking truncated slope length (PARTS A & B)

PART A

g) Small pattern height

Small pattern height = Pattern height - Slope height

h = H - SH

= ____________________________________

= ____________________________________

Answer = ____________________________________

PART B

Small pattern height = ____________________________________

= ____________________________________

Answer = ____________________________________

Slope length (SL) =

=

=

=

Answer =

Slant height + Pattern length

Question 3

On the patterns drawn below, ll in the missing dimensions and calculations:-

PART A

PL =

W = L = W = L =

H=

DIAGO

NALS

=

SH=

SL=

h=

PART B

PL =

W = L = W = L =

H=

D

IAGON

ALS=

SH=

SL=

h=


20/22



Question 4

Complete the parts list below for the truncated rectangular ducting job 1.1.

8

7

6

5

4

3

2

1

Item No. Description Length No. Reqd Matl

Question 5

On the pattern drawn below, insert the required production procedures for the rec tangular truncated duct.

Part A & Part B

=

=

=

=

=

=

=

=

J/N 1.1

PART A

Plate edge

Question 6

How many items are pressed to form Parts A & B.

__________________________________________________________________________________

Question 7

What type of joints are used for the rectangular truncated duct?

_____________________________________________________________________________

_____________________________________________________________________________

Question 8

Describe in point form how to assemble the rectangular duct.

_____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________


21/22



Question 9

Draw to a scale of 1:2 the ange detail for the rectangular truncated duct using the centre line below.

Question 10

What diameter holes are specied for the ange?

_____________________________________________________________________________

Question 11

What tolerances are given to fabricate the rectangular truncated duct?

Ducts _______________________________________________________________________

Flanges ______________________________________________________________________

Question 12

List the essential checking methods you should use on the completed rectangular truncated duct:

_______________________________________________________________________________

_______________________________________________________________________________

_______________________________________________________________________________

_______________________________________________________________________________

_______________________________________________________________________________

_______________________________________________________________________________

_______________________________________________________________________________


22/22



Student Notes

__________________________________________________________

__________________________________________________________

__________________________________________________________

__________________________________________________________

__________________________________________________________

__________________________________________________________

__________________________________________________________

__________________________________________________________

__________________________________________________________

__________________________________________________________

__________________________________________________________

Student Dr awings/Sketches

mem05010c apply fabrication, forming and shaping techniques - learner guide

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