Metals 1 and 2 Model

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Lesson Plan Industry Sector
Manufacturing & Product Development

Lesson Plan Originally Created By: Mike Morris

Pinwheel Project

Part of Unit: Sheet Metal Projects, Characteristics and Sheet Metal Machines

Lesson Plan Overview / Details


This is the second sheet metal project (15 points)made in the first week of a Metals 1 Class. This lesson will challenge the entry-level student to make a small toy called the pinwheel from two pieces of 24 gauge galvanized sheet metal. The student will use basic sheet metal machines and processes to construct this small toy.

Lesson Time

Class Demo each day
15 Minutes
Lab Time
3 - 5 Class Periods

Objectives and Goals

  • The student will be able to safely use hand tools in the lab setting.
  • The student will be able to layout lines on a piece of sheet metal from a working drawing or blueprint.
  • The student will be able understand the importance of measurement and tolerance when making projects in the metal's lab.
  • The student will be able to use proper sheet metal hand tools and machines to form the project.
  • The student will be able to measure and confirm 90 and 45 degree angles.
  • The student will be able to complete the procedural steps used when making the pinwheel project.

Activities in this Lesson

  • Can You Make a Toy Like Mattel? - Hooks / Set

    When the students enter the class the video clip will be playing the Mattel Toy Commercial from the 1960's. 

    They will see this on the front board:
    Get a Pinwheel Project Sheet from the classroom handout box.

    On the back of the project sheet, write down two of your most favorite toys from your childhood.

    After the clip,  I will take a survey on what toys were their favorites. We will discuss and choose the two most popular ones. We will dicuss what they were made of and how they were made.

    The pinwheel is introduced to the class by blowing on the pinwheel and letting it spin.

    The students are asked what tools and machines from the 1st project(Vise Jaws) will be used to    make this new toy.

    They are listed on the board:

    Combination square, awl or scribe,  ball-peen hammer, aviation snips.

    Bar folder, Box and Pan break, Cornice break.

     

    We then go to the Powerpoint on the project.

    See PPT. slides 1 thru 4.

    Transition to the lab:

    Each student must have their project sheet with their name on it and the two toys neatly written on the back of the sheet.

    I release the students to the lab by rows and use the handout as a ticket to get into the lab.

  • Making the Pinwheel Project - Demo / Modeling

    I will show the class how to make the layout lines from their drawing to the sheet metal blank(1.5" by 7.5" 24ga. galvanized) See photo attached.

    Note to teacher:
    I show the entire Powerpoint to the students and then demo the pinwheel each lab day.
    Layout -day one
    Bending and checking bended parts - day two
    Stamping and assembly - day three.

  • Lets make a toy - Lab / Shop

    Note to teacher:

    I do not hold students back who are ahead of my demos. I will keep the Powerpoint on in the class area for those students to watch and return to the lab.  If you care to, the photos from the Powerpoint can be saved and printed to make a notebook that is given to the student to follow at their own pace.


    Before bending the hems on this project the student is shown how to punch relief holes using a hand Whitney Punch and how to cut the four angle slices to help in bending of the hem. See PPT. slide 5 and 6.

    The hems are now made on the bar folder.

    The pinwheel hole placement is laid out and the holes are punched using the Whitney Punch. See slides on the Powerpoint.

    The two frames sides are bent to 90 deg. using the Cornice Brake or the Box and Pan Brake.

    Layout the pinwheel corners using a combination square.

    Bend the opposite corners 45 deg. on either brake.

    Stamp your last name in the bottom of the pinwheel frame and initials on the pinwheel. Letter stamps were used on the first project.

    Assemble and test.

    Complete the procedure steps on the project sheet and submit for grading.

  • Pinwheel reviewed - Closure

    Note to teacher:

    This may take the students 3-5 days to complete this project.  Each day the following closure procedure should be followed.  After clean-up the students meet in the classroom for the closure. When the first pinwheel has been completed, have that student present it to the class.

    Following a five minute cleanup the students meet again in the classroom.

    I ask the group if they had any problems, and saw any mistakes being made on the machines or any safety violations.

    I then explain what they will be doing the next day.

Assessment

Assessment Types:
Projects, Writing Samples, Demonstrations, Observations,

Demonstrate and then check for understanding by questioning the students on procedural steps and sheet metal tools.

The students must show the instructor all layout lines before any cutting or bending operation.

The students must show the instructor the completed project for the final inspection.

The completed project must be turned in with a complete procedural list on how the project was formed.

Materials/Resources

  • Pinwheel Project Photos Pinwheel Project Photos [ Download ] This PowerPoint can be used in part or whole for demo purposes.