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Questions tagged [metalwork]

Questions related to shaping and reshaping of metals or metallic items by processes like shearing, bending, piercing and other metal forming or cutting operations.

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Confusion in deriving von Karman equation for strip rolling

In the derivation for von Karman equation for metal strip rolling, an infinitesimal element is chosen as shown in the picture above. The equilibrium equation for the element is as follows: Upon ...
Utility ZC's user avatar
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1 answer
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What is the hole tolerance in hand tap guide?

What is the tolerance for through hole to match the UNC 1/4-20 tap ⌀ 6mm? (tap shaft diameter ⌀ = 6mm) I want to make the diameter of the hole such that the tap stands in the hole and doesn't fall ...
minto's user avatar
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1 vote
4 answers
324 views

Making hole in 1/8" Lead sheet with minimal dust/debris

I want to cut some 6" diameter holes in 1/8" thick lead sheet that is 12"x12" up to 12" x 24" but would like to minimize dust and debris. I was thinking that the best ...
DKNguyen's user avatar
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1 answer
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How to CAD: smooth width transition in sheet-metal bends

I am working with FreeCAD 0.20 and Sheet Metal work bench 0.2.63, but universal CAD tips are also welcomed. As shown in the image, I would like to bend sheet metal with smoothly chancing width along ...
Imsa's user avatar
  • 11
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0 answers
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Fabricating a Strong Hub Shell for a Bicycle

I'd asked this question over at SE Bicycles but they think this is more an engineering question. The flange on my hub broke and I'm having to get one fabricated. The part is actually a cage that ...
Laoshi's user avatar
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2 answers
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Fabricating a Strong Hub Shell for a Bicycle

I'd asked this question over at SE Bicycles but they think this is more an engineering question. The flange on my hub broke and I'm having to get one fabricated. The part is actually a cage that ...
Laoshi's user avatar
  • 101
0 votes
1 answer
89 views

How to go from a metal sheet to a metal box using (set of) dies only?

As a hobbyist, how to go from a metal sheet to a metal box (1 hollow side) by using (set of) dies only? All videos I watched involved : bending 1 side at 90° then A) cut twice and discard a square ...
v1nce's user avatar
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1 answer
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Making a basic sprung mechanism that can withstand moderate percussive force

I'm making a game where you have to hit targets, kind of like whack-a-mole except the targets aren't actively actuated. I'd still like an element of mechanical "feel" to it, so I'm aiming to ...
sjmeverett's user avatar
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0 answers
36 views

Method to secure these two parts, with constraints

How should I complete this task? 2 aluminium discs, around 55mm diam x 20mm high. The top disc must; be able to rotate 360deg w.r.t the bottom disc once in desired rotational position, be secured to ...
construction wizard's user avatar
1 vote
1 answer
62 views

What would this fairly bulky machined piece be doing in a missile?

Ria Novosti allegedly posted an image of this fairly bulky 10x10x4 cm (or so) machined piece with a hole in the middle, reportedly part of a Storm Shadow missile that hit Luhansk. I'm wondering ...
against very long user names's user avatar
2 votes
3 answers
844 views

What is the strongest sheet metal screw for 1/16 inch aluminum sheet?

My objective is to join 1"x1" aluminum tubes (80/20 Quick Frame: https://8020.net/9000.html) with external plates. Trying M5 screws, I discovered that tapping 0.06" aluminum sheet ...
Paul Jurczak's user avatar
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Bend a metal strip to a different axis

How can I bend a metal strip (3 inches x 3 feet x 1/32th) in a different axis? I know it would need a few compound bends, but can't figure out the math. Preferably straight vends instead of just ...
cde's user avatar
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1 vote
2 answers
240 views

What is the definition of depth of cut in machining?

Calculate the machining time required to reduce the shaft diameter by 6 mm if the maximum depth of cut is 2 mm, and also the parting off (cut off) time for the shaft, knowing that: the shaft diameter =...
Youssef Mohamed's user avatar
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Cutting method, where shaving stays attached from one side

Usually shaving goes out in front of the tool, being connected only along the cutting tool width. Im interested in another case, when shaving is moved to one side and it stays connected to the ...
Surprised Seagull's user avatar
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2 answers
223 views

What material property (Young's modulus, HRC hardness, Max yield strength, etc) affects how easy it is to cut sheet metal?

Our team is looking for sheet metal that is easiest to cut (and paint over), so I was wondering if there was a specific material property (such as those listed in the title) that affected the ...
Lyrie Muse's user avatar
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1 answer
117 views

Are rusty stains allowed to happen with hot dip galvanized steel construction?

I ordered a fence and the provider agreed to deliver it made from hot dip galvanized steel covered with powder painted finishing. The price was significantly bigger thank with the electro ...
mkarczewski's user avatar
2 votes
1 answer
66 views

Metal sheet forming - material properties when switching material

What does one have to look out in material properties when changing material grade in cold sheet forming operation (example: from DC04 to DC03 or to DC01). Operation is mostly made of 90°bends and ...
branexius's user avatar
2 votes
0 answers
42 views

Springback in carbon/HSLA steel - cold forming

What are the measurements denoted on top of the YS-t steel lines? Material thickness or bend radius? ...
branexius's user avatar
0 votes
1 answer
110 views

Why do blacksmiths use these 2 tools which seem to do the same thing

In this video and in many others I've seen, smiths use 2 different "hammers" to forge metal together. One seems to hit it repetitively with less force (0:30 in the video) while the other &...
ExtraFishness's user avatar
4 votes
1 answer
345 views

What is this "clamp" place on a piece of bar stock while turning it in a lathe for?

I am watching a Youtube video depicting someone machining a crankshaft for a miniture rotary engine. Around the 4:27 mark after preparing some bar stock the person in the video places some sort of ...
KDecker's user avatar
  • 141
3 votes
1 answer
123 views

How can I build propane torch burners that have a custom configuration?

For doing hard soldering I would like to have a propane burner with a custom configuration. The reason for this is that when soldering there is a region that ideally should be heated slowly, ...
Wallace Park's user avatar
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