Aim:

To fabricate a rectangular tray of dimensions 100 mm × 60 mm from a G.I. (Galvanized Iron) sheet using sheet metal tools and operations.

Materials Required:

• Sheet Metal (Galvanized Iron (G.I.)) of sheet thickness 25 gauge  = 0.54mm

• Measuring Tools: Steel rule, divider, scriber, Try square, Standard wire gauge

• Cutting Tools: Tin Snips (Straight & Curved)

• Forming Tools: Bench vice, Stake, wooden mallet or ball peen hammer.

• Joining Tools: Rivets (if required)

• Finishing Tools: File, Emery paper (if required)

• Surface Cleaning material: Cotton Waste (if required) 

Operations:

1. Measuring and Marking

2. Cutting (Snipping)

3. Bending (Angle Bending, U-Bending, V-Bending, Edge Bending)

4. Folding

5. Riveting (if needed)

6. Rolling (if needed)

7. Joining (Spot Welding) (if needed)

8. Finishing (Polishing, Surface Coating) (if required)

Procedure:

1. Select a sheet metal piece of suitable size. Using a steel rule and scriber, mark a rectangle of 120 mm × 80 mm (including an extra 10 mm on each side for folding). Mark the bending lines at 10 mm from the edges. At each corner, mark a 10 mm × 10 mm square to be cut out for folding.

2. Use tin snip (Straight snip) to cut along the outer marked lines (120 mm × 80 mm). Carefully cut out the four 10 mm × 10 mm corner squares to allow proper bending. If required smooth the edges using a metal file and emery paper.

3. Secure the sheet in a bench vice or use a folding bar for bending. Bend the four edges upward along the 10 mm bending lines using a wooden mallet to form a rectangular tray. Ensure all bends are at 90° using a try square for accuracy.

4. For getting proper corner Joints, fold the corner flaps inwards neatly using a grooving stake. Secure the corners by hammering them flat or using rivets if necessary.

5. Check overall dimensions (100 mm × 60 mm × 10 mm height). Remove any sharp edges using emery paper if required and clean the final product for a smooth finish.

6. In the final process, ensure dimensions are accurate and check if the tray is rigid and holds shape.

7. Also verify that all edges and corners are smooth and properly joined.

Precautions:

• Handle sharp tools and sheet metal carefully.

• Mark accurately before cutting.

• Check alignment before bending to avoid errors.

• Use safety gloves and goggles to protect hands and eyes.

Result:

A rectangular tray of dimensions 100 mm × 60 mm × 10 mm (height) is successfully fabricated using sheet metal operations.