DESIGN AND ANALYSIS OF

C-CLAMP WITH VARIOUS MATERIALS

 ABSTRACT

Design & Analysis of Mechanical Systems plays a backbone Role of

success of particular Systems. The engineering design & Analysis process is a
multi-step process including the research, conceptualization, feasibility
assessment, establishing design requirements, preliminary design, detailed design,
production planning and tool design, and finally production.

C-Clamp Mechanical Systems, studied in this project has many

applications starting from bench to rocket science. in this project we taken a two
different material in consideration and find which one is preferable for the hold
the work piece under the clamping principle.
What is Clamping?

Once work piece is located, it is necessary to press it against locating

surfaces and hold it there against the force acting upon it. The tool Designer
refers to this action as clamping and the mechanisms used for this action are
known as clamps.

Clamping Principles

Clamp should firmly hold the work piece without distorting it.

Should overcome the maximum possible force exerted on work piece by using
minimum clamping force

Easy to operate
Types of Clamping

Mechanical Actuation Clamps

Pneumatic and Hydraulic Clamps

Vacuum Clamping

Magnetic Clamping

Electrostatic Clamping

Non Mechanical Clamping

Special Clamping Operations

C-CLAMP:

Name of this clamp is because of its C shaped body. C-clamp has a

fixed jaw on one end and screw type jaw on other. Adjusting the screw

closed the jaw and applies pressure.

C-clamp is use to hold two object flush together.

It is also use for carried out various operations on small job of wood

& metal like filing, finishing, axe saw cutting etc.

Clamps or G-clamps are typically made of steel or cast iron.

PROBLEM SPECFICATION

It is required to design a C-clamp for holding the jobs on the shop floor
limiting dimension of the job are as follows
Hmax =150 mm
Wmax =150mm
The maximum clamping force required to hold the job is 10kN. The
clamp is manually operated
Sr. no Name of the component quantity Material

1 C-frame 1 Cast-steel grade 26-52

2 Screw 1 Steel 45C8

3 Nut 1 Phosphor bronze grade-1

4 Handle 1 Steel 30C8

5 Thrust pad 1 Steel 30C8

6 Set screw 1 Commercial steel

7 Hexagonal nut 1 Commercial steel

CALCULATION
Formula used in frame design and screw design

Two types of threads are popular for power screws- square and trapezoidal. In

applications like lead-screw of lathe, trapezoidal threads are use because wear is series

problem. The axial wear of trapezoidal threads is compensated by drawing the two

halves of a split type nut to gather.

3 ( )( 2)
=
6

[(48 603) ( 48 12 16 24 ]
=
6 60

Z = 24,134 mm3
 A = (H 2t)t + 2(B t)
= (60-24)12+2(4812)

RESULTANT STRESSES

1 = t1 c2
= (0.189 1.367)
=-1.178 N/mm2
2 = t1 + t2
=0.189 + 1.367
= 1.556 N/mm2

From above we can see that 2 is greater than 1 so compare the

permissible stress with 2.Here, 2 [ c]

So, c-frame is safe in compression.

DESIGN OF SCREW ROD:

Here, the screw rod is subjected to the compressive stress so check the
rod in compression as under:

Formula uses in screw rod design

c = 95N/mm2

Hence c, < [c ] so screw rod is safe in compression

DESIGN OF CAP SCREW

In the cap screw area at the thread section is minimum hence; there is
possibility of failure in Compression so checking it in the compression:
Formula uses in cap screw design

c = 44.06 N/mm2 Hence, c < [c] so cap screw is safe in compression

DESIGN OF JAW

The jaw is also check in compression:

Formula uses in jaw design

c = 32.28 N/mm2

Hence, c < [c]

so cap jaw is safe in compression

DESIGN OF HANDLE

Formula uses in handle design

When we applied the effort p1 at the end of handle, it is

subjected to the bending. So check the handle in bending:

= 4.666
tan =
= 5.711
 Now, torque transmitted through screw rod:

Mt =17,854.14 N/mm2

The torque transmitted through the handle is same as in screw rod:

M * L = (100*270) N/mm2
b=p
Now, find the bending stress induced in handle due to effort p1 and compare it
with the permissible bending stress. As, per bending equation:
=32Mb/d
b
b =100 N/mm2 d= 15 mm

Hence, b < [b ] so handle is safe in bending.

In this whole design of c-clamp, we found that the dimensions which are
selected for modeling is safe in all the failures.
MODEL AND ANALYSIS

Static Structural
Object Name
(B5)
State Solved
Definition
Physics Type Structural
Analysis Type Static Structural
ANSYS
Solver Target
Mechanical
Options
Environment Temperature 22. C
Generate Input Only No
 Structural Steel > Constants
Density 7850 kg m^-3
Coefficient of Thermal Expansion 1.2e-005 C^-1
Specific Heat 434 J kg^-1 C^-1
Thermal Conductivity 60.5 W m^-1 C^-1
Resistivity 1.7e-007 ohm m

Aluminum Alloy > Constants

Density 2770 kg m^-3
Coefficient of Thermal Expansion 2.3e-005 C^-1
Specific Heat 875 J kg^-1 C^-1
Static load distribution graph
Uploaded IGES model of C-clamp in Workbench
Mesh model of C-clamp
For structural steel:

stress model of C-clamp

For aluminum alloy

stress model of C-clamp

For structural steel

safety factor model of C-clamp

For aluminum alloy

safety factor model of C-clamp

RESULT AND DISCUSSION

In the project of C-clamp, we mainly consider the factor of

griping of workspace at load condition without failure
The whole design focuses on how the values of stresses
Here, the basic concept is established for choosing the best
material combination for given load
The above analysis is fully made of structural steel and
aluminum alloy
compared to both material structural steel had a good safer value
in all kind of analysis
The handle part and the thrust pad are become safer than the
structural steel, because the handle part more affected in the
aluminum alloy.
RESULT AND DISCUSSION

Function Aluminum alloy Steel

Stress value Min = 1.901 e05 pa Min = 4.15 e04 pa

Max = 1.122 e10 pa Max =1.05 e09 pa

Safety factor Min =2.27 e-02 Min =0.2381

REFERENCES

1) INTRODUTION TO MACHINE DESIGN V.B BANDARI - TATA McGraw-

HILL EDUCATION PRIVATE LIMITED 2ND EDDITION

2) MACHINE DESIGN DATA BOOK, -2003 - PSG Publication.

3) MACHINE DESIGN J.K GUPTA EURASI PUBLISHING HOUSE (PVT.) LTD.

4) ANSYS WORKBENCH 14.0 FOR ENGINEERING DESIGNER

5) Djordje Vukelic, Uros Zuperl & Janko Hodolic Complex system for fixture

selection, modification, and design Int J Adv Manuf Technol

6) J. Cecil A Clamping Design Approach for Automated Fixture Design Int J Adv

Manuf Technol