Forming marine sheet metal components using hand and machine tools

This standard identifies the competences you need to form marine sheet metal (up to and including 3mm) components using hand tools and machine tools, in accordance with approved procedures. You will be required to select the appropriate equipment to use, based on the operations required, the material to be formed and the accuracy to be achieved, and this will include using such tools and equipment as hammers and stakes, formers, bending machines, rolling machines, wiring and swaging machines. The components/shapes to be produced will include bends/upstands, folds, box sections, wired edges, cylinders and curved sections, square-to-round trunking, lobsterback trunking, and the stretching and shrinking of materials to form cowlings and rounded covers, curved panels with balled corners, concertina ducting or trunking.

Your responsibilities will require you to comply with organisational policy and procedures for the marine sheet metal forming activities undertaken and to report any problems with the tools and equipment, materials or activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying marine sheet metal forming procedures. You will understand the forming processes, the equipment used and its application and will know about the materials and forming techniques, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and producing the components to the required specification.

You will understand the safety precautions required when working with the forming machines and their associated tools and equipment. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.

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1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines

2. follow the correct component drawing and any other related specifications for the component to be produced

3. determine what has to be done and how this will be achieved
4. use the appropriate tools and equipment for the pressure shaping operations and check that they are in a safe and usable condition
5. shape the materials to the required specification using appropriate methods and techniques
6. check that all the required shaping operations have been completed to the required standard
7. deal promptly and effectively with problems within your control and report those that cannot be solved
8. complete relevant documentation in line with organisational procedures

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1. the specific safety precautions to be taken when working with sheet metal equipment and materials in a marine fabrication environment (including general workshop and site safety, appropriate personal protective equipment, accident procedure; statutory regulations, risk assessment procedures and COSHH regulations, safe disposal of waste materials)
2. the personal protective clothing and equipment (PPE) to be worn when carrying out the fabrication activities (such as leather apron and gloves, eye/ear protection, safety helmets)
3. the correct methods of moving or lifting sheet or plate materials
4. the hazards associated with marine sheet metalwork (such as handling sheet/fabricated components, using machinery, using dangerous or badly maintained tools and equipment) and how they can be minimised
5. how to obtain the necessary drawings, specifications and work instructions
6. how to extract information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS or ISO standards) in relation to work undertaken
7. how to carry out currency/issue checks of the specifications you are working with
8. how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
9. marking out conventions used in sheet metalwork and how to recognise cutting detail, bending and folding lines
10. hand tools used in sheet metal forming activities and typical operations that they are used for (such as range of hammers, stakes, formers, sand bags)
11. the types of machine tool forming equipment that can be used to produce a range of shapes (such as bends, box sections, cylinders and curved sections, wired edges and swages)
12. methods of stretching and shrinking materials and the tools, equipment and techniques used
13. how to set up the various machines to produce the required forms (such as setting up of rolls; setting fingers on bending machines; setting forming tools for swaging)
14. ways of limiting distortion, marking, creases and flats (in curved sections)
15. how the materials are to be prepared for the forming operations and why some materials may require a heating process prior to forming
16. the characteristics of the various materials used with regard to the bending and forming process
17. tool and equipment care and maintenance procedures 
18. organisational quality control procedures and the recognition of pressure forming defects
19. dimensional and forming inspection checks to be carried out, and the tools and equipment to be used
20. limitations of the various forming processes, and the accuracy that may realistically be achieved
21. ways of avoiding and correcting inaccuracies during forming activities
22. the problems that can occur with bending and forming sheet metal and how these can be avoided
23. the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve

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1. Ensure that the tools and equipment to be used are appropriate to the application and are in a safe and usable condition, by carrying out all of the following checks:

   1. hand tools are in a usable condition (hammer shafts secure; stakes, formers and striking faces free from defects and damage)
   2. the appropriate machine is selected for the operation being performed
   3. the machine guards and safety devices are in position and function correctly
   4. forming tools are appropriate and are in a serviceable condition (secure, correct shape, free from damage)
   5. machine settings are suitable for the material thickness and operations to be performed

2. Use four of the following types of forming equipment/techniques:

   1. hammers/panel beating equipment                   
   2. wheeling machine
   3. stakes and formers                                           
   4. jenny/wiring machine
   5. bending machine (hand)
   6. bending machine (powered)                 
   7. swaging machine
   8. rolling machine (hand)
   9. rolling machine (powered)          
   10. spot heating techniques

3. Carry out forming operations which produce seven of the following shapes:

   1. bends/upstands                   
   2. curved panels                        
   3. lobsterback trunking
   4. folds                                   
   5. cylindrical sections                  
   6. domed corners
   7. box sections                     
   8. cowlings and rounded covers        
   9. concertina ducting or trunking
   10. wired edges                         
   11. square to round trunking          
   12. ribbed components
   13. swages                             
   14. other specific shape

4. Form sheet metal components for marine applications, to include three of the following

   1. stowage racks                    
   2. stores                              
   3. pyrotechnic lockers
   4. galley equipment                    
   5. trunking and ducting            
   6. bunk spaces
   7. toilet (head)/shower cubicles     
   8. kit lockers                              
   9. cladding
   10. tanks/reservoirs                       
   11. covers                                  
   12. other specific components

5. Produce components from two different materials from the following:

   1. mild-steel                         
   2. stainless steel                      
   3. brass
   4. tinned steel                              
   5. titanium/special steels        
   6. copper
   7. galvanised plate                     
   8. aluminium

6. Produce components which meet all of the following:

   1. dimensional accuracy is within specification tolerances
   2. finished components meet the required shape/geometry (to the template profile)
   3. completed components are free from excessive tooling marks, deformation or cracking

7. Complete the relevant documentation in line with organisational procedures, to include one from the following and pass it to the appropriate people:

   1. build records
   2. log cards
   3. job cards
   4. quality documentation
   5. other specific recording methods

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Behaviours:

You will be able to apply the appropriate behaviours required in the workplace to meet the job profile and overall company objectives, such as:

• strong work ethic
• positive attitude
• team player
• dependability
• responsibility
• honesty
• integrity
• motivation
• commitment

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3

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29 Apr 2021

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Current

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Original

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Semta

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SEMME3154

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Marine Engineering Trades

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2122

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Engineering; marine; manual; machining; sheet metal; form; bending; rolling; stakes and formers; swaging

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