Fundamental of manufacturingReport on

c-clamp

Supervised by:

Prof. -----------------------

May 2012

Cairo UniversityFaculty of Engineering

Submitted by:

Ahmed raafat 111111

Amr Hany AHMED 1101056

Kareem Hossam Ahmed 111111

Mohamed Mahmoud saber 111111

Wassim raafat shanad 111111

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Introduction:

A C-clamp is a type of clamp device typically

used to hold a wood or metal work piece, and is

often used in, but is not limited to, carpentry and

welding. These clamps are called "C" clamps

because of their C shaped frame, but are otherwise

often called G-clamps or G-cramps because

including the screw part they are shaped like an

uppercase letter G.

Objective of the project:

The main objective of the project is to learn

the techniques of the various types of machines

used in lab and learn how to operate them in

sequence of processes in order to fabricate a well

finished product that is functional and useable.

Usage

A C-clamp is used by turning the screw through

the bottom of the frame until the desired state is

reached. In the case that the clamp is being tightened,

this is when the objects being secured are

satisfactorily secured between the flat end of the

screw and the flat end of the frame. If the clamp is

being loosened, this is when a sufficient amount of

force has relieved to allow the secured objects to be

moved.

Usage of C-clamp

Work plan:

We start the project by applying the “Process

Planning” as follow:

Deciding what process and methods should be

used and in what sequence.

Determining tooling requirement.

Selecting production equipments and systems.

Stating rawmaterial

Finishedproduct

Basicprocess

Secondaryprocesses

Property-enhancingprocesses

Finishingoperations

Sequence of processes used in part fabrication

Basic process:Establishes the initial geometry of the part.

Secondary process:Transform the basic shape into the final geometry.

Finishing operations:Provide a coating on the work part surface.

Lab work

We were provided with a C section with a great

length, the first task was to cut it to the length needed

to produce the work part “C-clamp”.

Drawings and dimensions of the work piece before and after cutting it.

The second task was to drill a hole of 10mm

diameter for he bolt and nut to make the holding

part of the C-clamp. the following image shows a

top view of the work piece after drilling

The last task was welding the nut right above the

drilled hole and putting the bolt in it.

Image of the work piece after welding the nut.

Dimensions

We used the standard dimensions of section

except for the length. After measuring all other

dimensions on the C-clamp as sketched above and

discussing the results with the team, we conclude that

the best length to cut was 38 mm.

Part Dimension

Length 38 mm

Height 81 mm

Web width 5.7 mm

Flanshing thickness 6.7 mm

Flanshing width 44.65 mm

Sequence of the processes

Forging: We started forging to make the surface of

the C-clamp clean, we were instructed how to use the

Rasp;( hand files are normally held in both hands),

the file is held flat against the surface to cut / smooth.

The file is pushed forward and it cuts on the forward

stroke, then is lifted away from the metal and

returned to the starting point for the next push

forward. This is called ‘Through Filing’

In the beginning it was difficult to use the Rasp as our

hands tend to shake which made the surface not flat.

During that process we rotate the C-clamp to get the

widest cross sectional area, but we were told that it

was wrong, as the thinner cross-sectional area is the

better ending for the product as this cross-sectional

area will be forged by more teeth so it will be better

and faster.

Measurements:

as mentioned above we located the center at the

top surface to drill a hole for the bolt and the nut.

The next step was to get the bolt and nut (ISO 10),

and then we were ready for welding. The final step

was to paint the product to provide a smooth surface.

Lab photos

Rasp

We use the word "rasp" to denote the entire

family of the tool when we're talking generally about

the use of the tool. When the particular details matter,

we say "Rasps" to mean a rasp with a handle at one

end.

There are many different shapes / sections of files,

some are shown below. They are used for a variety of

types of work. Files are classified according to their

length, section / shape and cut (tooth shape). 

Hand File:  Used for general filing of metals such as steel. They are rectangular in section and are the most common type of file used in workshops.

Half Round File: Used for filing curved surfaces. A normal hand file with its flat cutting edges is unsuitable for filing curved surfaces. However, the half round file has a curved surface which is especially useful for filing internal curves.

Three Square File: Is triangular in section and very useful when filing ‘tight’ corners / angles. The sharp edges allow the file to fit into corners when filing.

Square File: The square file is quite thin and fits into corners well. They can e used to file slots in metal or for filing where there is little space.

Knife File: Knife files are very useful when filing where there is little space. Knife files are very thin and can fit into small gaps.

Shaping Plywood

Regular files do not work well on wood, the

traditional tool for shaping wood is a rasp, which has

projecting teeth to gouge out and remove wood. This

can be a bit rough on plywood.

A rasp is a tool used for shaping wood or other

material. It consists of a point or the tip, then a long

steel bar or the belly, then the heel or bottom, then the

tang. The tang is joined to a handle, usually made of

plastic or wood.

Welding

Process for joining separate pieces of metal in

a continuous metallic bond. Cold-pressure welding is

accomplished by the application of high pressure at

room temperature; forge welding (forging) is done

by means of hammering, with the addition of heat.

Arc welding

Arc welding is a type of welding that uses a welding

power supply to create an electric arc between an

electrode and the base material to melt the metals at

the welding point. They can use either direct (DC) or

alternating (AC) current, and consumable or non-

consumable electrodes.

Resistance welding

Resistance welding involves the generations of heat

by passing current through the resistance caused by

the contact between two or more metal surfaces. In

general, resistance welding methods are efficient and

cause little pollution, but their applications are

somewhat limited and the equipment cost can be high.

Water-Gas welding

Process was applied in the end of 19th century. The

flame which is produced from water-gas replaced the

blacksmith s hearth as a mean of heating the metal and

welded the metal but this is first welding.

Cast-welding

In this method the molten metal pouring into a

mould which has runner at the point where the casting

had failed to flow or wherever there was a fractured

place. The molten iron poured in until it was fluid

everywhere around the edge of the job and runner

was stopped up, and then the iron was allowed to cold

in the mould.

This welding process can be said modern

fusion weld process, but this is slightly high cost

process than other types of welding.

Cast-welding

Submerged Arc Welding

This process involves the

welding arc being continuously

submerged under a mound of

granular flux. The bare metal is

fed automatically at a rate which

maintains the welding arc.

As the arch and the molten metal are covered with

the mound of flux , there is no flash spatter, sparks or

smoke. The resulting weld is uniform with good

physical and chemical properties.

Solid State Welding

Solid state welding is a term used for welding

processes which produces joining at temperatures

essentially below the melting point of the base

materials, without the need for brazing filler metal.

Pressure is generally required but not always. These

welding processes include cold pressure welding,

diffusion welding, explosion welding, forge welding,

friction welding, hot pressure welding, roll welding, and

ultrasonic welding.

Electron Beam Welding

In this process a concentrated beam of electrons

bombards the base metal, causing it to melt and fuse.

The process is most efficient when done in a vacuum.

Therefore the size of the vacuum chamber limits the

size of the work pieces that can be welded. Advantages

include the ability to produce welds of extremely high

purity, ability to melt any known material, ability to

weld dissimilar metals and the ability to make welds

with depths as great as 150mm.

Electron beam welding is costly for two reasons,

1) the high cost of equipment,

2) the time lost in pumping out the vacuum chamber

between welds.    When the welds are not made in a

vacuum, many advantages of the process are reduced.

Laser Welding.

The laser beam is a concentrated beam of light

with sufficient energy to generate the heat at the base

metal surface to cause fusion. There are two types of

lasers in use (1) gas lasers and 2) solid lasers. Gas lasers

provide a continuous laser beam that is best suited to

continuous welding and cutting. Solid lasers release

their energy in short bursts or pusses at a rate of 6 to 10

per minute. 

As each pulse only lasts for a few millionths of a

second the base metal is liquid for only moments and

there is limited time for chemical reactions to occur.   

Therefore flux type protection is not required to

obtain sound welds.

Laser systems can be precisely controlled and have

sufficient power to weld and even vaporize any known

material.   

Other advantages include the ability to make welds

through transparent coverings and to make welds in

locations impossible to reach with conventional welding

gear.     Limited depth of penetration however restricts

the use of laser welding to relatively thin materials.