Final Manufacturing Lab Report: Threaded Hinge Clamp
Matt Worthington & Jean Carlo SotomayorMER-101 Section 2 (Engineering Graphics)
Mechanical EngineeringProfessor Glenn P. Sanders
Introduction
The goal of this project was to manufacture a fully functioning thread-driven,
hinge clamp. Over the course of the term we would manufacture one or two parts at
a time each week. The manufacturing procedure of each individual part was usually
described to us verbally by the professor as well as through diagrams and guides.
We learned to use different machines, such as the Milling machine, the band saw, the
lathe, and the belt sander. From week to week we became more familiar with the
machinery and the process started to flow more smoothly. After several weeks, all
the necessary parts to put the clamp together had been manufactured, and it
became time to assemble the clamp.
Once assembled the clamp proved to be fully functioning. The Clamp is
driven by a threaded bolt with a crank shaft through one end. It is composed of four
braces (2 of Brace A) and (2 of Brace B) that our structurally held together by two
different sized pins (Pin A & Pin B). The clamp opens and closes by turning the
crank shaft counterclockwise or clockwise, respectively. The threaded bolt is fixed
to one hinge (Hinge B) and turns through the other Hinge (Hinge A) to open and
close the clamp. The end on each brace where the braces meet when the clamp
closes has a swivel grip on each side to tightly hold the object(s) which are being
clamped together.
Brace A
To manufacture Brace (as seen in figure 1) we started with an approximately
(6.0x4.0x0.11 inch) metal plate (as seen in figure 2). First we laid the paper
blueprint with the to scale representation of the desired product printed on it. After
creasing the edges to keep the paper in the same spot, we used the center punch and
hammer to mark the center holes on the plate. Next, we used a steel ruler, compass
and scribe to make the appropriate arcs around each center-punched hole (as seen
in figure 2) to prepare the plate for the proceeding cutting and drilling work.
Once the stainless steel plate was ready to be drilled we set it in the vice of
the milling machine and started by predrilling all the center-punched holes. Then
we proceeded to drill the five ¼ inch diameter holes on the brace (as seen in figure
3). We used the same bit to predrill a hole in the center of the fillet arc which we
proceeded to drill with a 5/8 inch bit. The digital readout on the machine was very
useful and precise and helped make this a more efficient process.
After drilling the six collective holes with the appropriate sized bits to
achieve the step (seen in figure 3), we then filed all the metal burrs in and around
the drill holes. Next, we used the steel rule and the scribe to create and connect arcs
of different sizes (seen in Figure 2) with tangent lines and prepare the plate for
cutting. Next, we moved on to the band saw in order to cut out the shape we had
just outlined (as seen in figure 4). The band saw prevented us from following the
curve with utmost precision, so their were several cuts to be made on each rounded
end in order to prepare the sheet for a reasonable amount of sanding. The sheet
grew hot a couple times due to the friction of the sander on the rather rough edges.
After several intervals of precision sanding, interrupted by dunks in the water to
cool the sheet down, we ended up with a decent quality finished
(Figure 1) (Figure 2)
This diagram shows the finished brace plate. This diagram shows the plate with the scribed arcs
and their radii/location.
(Figure 3) (Figure4)
this diagram shows the plate after the holes are drilled this diagram shows the tangent lines connecting the arcs
and outlining the figure
Brace B
The process for manufacturing Brace B was almost ientical to that of Brace A
but it involved a little less cutting and drilling due to the less complicated nature of
the part as seen in (Figure-1). Again we began by using hand-drawing techniques to
get a general layout of the drill holes, and created an outline of the part. Once the part
was mapped out, a center punch was used to create hole so the drill doesn’t slip. With all
this complete, we brought our plate to the drill, and used the digital readout to create a
hole that is accurate with the dimensions seen in (Figure 1). With the hand drawn holes
we could tell whether or not our holes are being drilled in the right spot. After the
drilling, it was necessary to smooth down any protruding metal created by the drilling.
We then carefully used the band saw to cut out the outline of the part, including the filets.
Finalizing the piece by using the electric sander to smooth down any rough edges that
were created during the cutting.
(Figure-1)
Pin A & Pin B
Both Pin A & Pin
B started from stock
metal cylinders of
roughly 1.25 in length
and 0.31 in diameter
(as seen in figure 2a &
2b). For Pin A we used
the Lathe with the
digital coordinate
readout, while for
Pin B we used the lathe with an Analog layout/adjustment knob. The steps for
manufacturing the Pins was very similar .
For Pin A in, we set the stock piece in the lathe and made 2 cuts to shorten
the piece to the required length of 1.13in (as seen in figure 3a & 4a) and zero the x-
coordinate of the machine. We then set the diameter rating on the lathe to .25 in (as
seen in figure 5a & 6a) and proceeded to cut a .19 in diameter shoulder on the piece.
We used a file while the piece was still being turned to dull the edges of the shoulder
into a slight chamfer. We then stopped the machine, turned the piece around and
repeated the same steps to make an identical cut on the other side (as seen in figure
7a). These steps resulted in a finish product (as seen in figure 1a).
The manufacturing of Pin B was slightly less efficient due to the analog
position/diameter readout, but the process was rather Identical. Again we set the
stock piece in the lathe and made 2 cuts to shorten the piece to the required
length, this time of 0.875 in (as seen in figure 3b & 4b) and zero the x-coordinate
of the machine. We then set the diameter rating on the lathe to .25 in (as seen in
figure 5b & 6b) and proceeded to cut a .188 in diameter shoulder on the piece.
We used a file while the piece was still being turned to dull the edges of the
shoulder into a slight chamfer. We then stopped the machine, turned the piece
around and repeated the same steps to make an identical cut on the other side (as
seen in figure 7b). These steps resulted in a finish product (as seen in figure 1b).
Pin A Process
Figure 1aFigure 2a Figure 3a
Figure 5a
Figure 4a
Figure 7a
Figure 6a
Pin B Process
Figure 3bFigure 2b
Figure 3b
Figure 5b
Figure 4b
Figure 6b
Figure 7b
Hing A & Hinge B
Hinge A & Hinge B (as seen in figures 1A & 1B) were manufactured one by
each lab partner. For Hinge A, we were given a stock cylindrical steel piece of about
1.01 inches in height and 0.75 inches in diameter. This piece was already cut to size
so there was no need to make a zero-cut using the lathe. Upon setting the piece in the
Lathe, two rough cuts of approximately 0.27 inches in diameter were made with
application of some oil lubricant (about half the distance of the desired length each
time). The final cut was made by setting the diameter to 0.25 inches and running it
along the face until the desired 0.125 inch shoulder length was arrived at. The edges
of the piece were then filed down, the part was flipped around and the above process
was repeated to arrive at a symmetrical part with the appearance and dimensions of
(figure-1). The part was then placed in the milling machine, which was pre-zeroed, to
center-drill and then drill a 5/16 diameter hole in the center body of the hinge. The
hand tapping machine was then used to thread the hole by first correctly positioning
the part in the vice using the guide accessory and then using the tapper to thread the
hole. It became clear the importance of using the guide accessory first to make sure
the part is lined up perfectly, when after the initial threads were a little tight and the
part was put back into the tapping machine, the guiding tool was neglected to be used
and the structural integrity of the part was nearly sacrificed. Adjusting the position to
the original tapping and running it through again managed to take care of this
problem and resulted in the finished product (as seen in Figure 1B).
A nearly identical process was undertaken for Hinge B to arrive at a part with
dimensions seen in (Figure 2B). The difference, aside from the dimensions, was that
the hole was not threaded in this piece, but rather it was center-bored using the
milling machine and as seen in (Figure-2B). But the flat edge as seen in this same
figure was created using the milling machine. The milling machine was pre-set to
make a flat swipe cut across the surface. Overall this laboratory was rather
straightforward and routine, and each student was only responsible for one hinge.
Both hinges came out rather nicely.
Grip A & Grip B
For the manufacturing of the grips we started out with two metal blocks of
dimensions seen in (Figure-1A & Figure-1B). We then drilled the blocks with .312
inch diameter holes by setting them in the milling machine, center-drilling and then
drilling all the way trough. The blocks were then set in the lathe, which had been
equipped with the appropriate readout to make a 45 degree cut into the center of
the respective blocks by sweeping the end-mill bit all the way across it. Each block
was then flipped and another 45 degree cut as made to create a perpendicular
groove all the way across one side of the block and complete the manufacturing of
the grip. The figures below show the precise dimensioning and details of each part.
(Figure-2A)(Figure-1A) (Figure-3A)
(Figure 1B) (Figure 2B) (Figure 3B)
Part List
• Brace A (2)
• Brace B (2)
• Pin A (3)
• Pin B (3) • Also supplied with threaded turn-bolt and pin
• Hinge A (1) for final assembly
• Hinge B (1)
• Grip A (1)
• Grip B (1)
Assembly Process
In the final lab, once all the necessary individual parts had been assembled, it
became time to assemble the clamp. First the two Brace Bs were connected using
three Pin Bs, Hinge B, and Grip B. This section of the clamp had to be assembled first
because the Brace Bs are held inside the two Brace A plates using a pin B. After
laying Brace A down on the table and inserting the remaining pins, hinge and Grip
into the appropriate holes, we carefully placed the second Brace A on the top
shoulder of the pins, hinge, and grip. This process proved fairly challenging, and
required a bit of filing of the holes to make all the pins fit in the right place. After the
frame of the clamp was structurally achieved, we used the rounded end of a hammer
to mushroom the tops of the pins and grips down to keep them from sliding out. We
then threaded the crankshaft through the threads of Hinge A and into the center
bore of Hinge B. After finagling the bolt into place we used an Allen wrench to screw
in the little pin through the back of Hinge B and into the threaded bolt to fix the bolt
to the Hinge. The clamp was then fully functioning and ready to use
Conclusion
Overall we both agree that this was a great-hands on project. It was really
cool to learn how to use the different types of heavy machinery. Manufacturing each
individual part was satisfying, but seeing it all come together in the end was
awesome and provided a great sense of accomplishment when everything fit
together and functioned properly. The professor and lab supervisor both did a great
job overseeing the operations in the lab, and they were very helpful when questions
came up. The lab reports grew to be a little tedious, but they were a good way to
reinforce the procedure and practice using the language and terminology. Overall
the project was an enjoyable one, and the Lab as a whole was more fulfilling and
interesting than any other we have experienced here at Union.