Project Description
Im after it being made on Fusion Autodesk/ Freecad, To make sure I can tweak the design later for different machine setups and dimensions on the floor, I need to ensure the final CAD files are fully editable on my end.
Please follow these file delivery instructions:
Software Match: Please build the model using fusion/freecad
Native File Delivery: Send over the native working file (e.g., .FCStd, .f3d, or .sldprt). I need the full feature tree, sketches, and timeline intact so I can adjust the parameters.
No Locked Files: Please avoid sending only macro-generated, Python-locked, or "view-only" models where the base dimensions cannot be directly edited.
Universal Backup: Alongside the native file, please include a standard .STEP file as a generic backup.
Let me know if you have any questions about this.
Solution A is the concept implied by the original PDS: a 360 degree rotating turret on a bolted base plate, carrying a hardened 42CrMo4 ball seated in a steel socket. The ball is locked by two grub screws fitted with handles so no Allen key is required. A conventional lead screw and T handle drive the moving jaw, giving the full 0-180mm opening and easily exceeding the 500kg clamping force at well under the 150N of hand input.
Design brief
A clamp has been requested that can be used to glue two pieces of wood together
permanently to aid a small manufacturing company in their operations. It is stressed
that the clamp is made to a budget and should be a permanent fixture on the
workbench.
Proposition
A clamp which is bench mounted with rotating base allowing 360 degrees of rotation.
Swivel action achieved by ball joint allowing adjustment to any angle Clamping force
applied by typical screw with handle to clamp the item between two jaws.
Performance
1.1-Must be strong
1.2-Have a clamping force of 500kg
1.3-Must rotate
1.4-Must swivel
1.5-Must be able to be attached to workbench
1.6- Must hold two components securely during glue application
1.7- Clamp shall provide base rotation of 360 degrees with mechanical friction lock
1.8 - Jaw opening range 0-180mm minimum (assumed due to lack of detail in the
brief)
1.9- Must remain stable when fully loaded
Environment -The clamp will be installed inside the warehouse of the manufacturing company,
being located inside means there is no need for extensive weatherproofing.
However, as it is being used as part of the manufacturing supply chain it must be
durable due to its expected high use in the workshop. - Temperature exposure extremities –10c - +35c (Assumed European extremities) - Humidity levels – 40%-60% (typical indoor industrial environment) - Components will be subject to frequent manual contact therefore exposed to hand
oils and sweat residues, if not accounted for in the finish selection this will affect the
longevity of the clamp.
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Product life span -15 years minimum (not specified by customer) -Must be serviceable in case of failures (not specified by customer)
Costs - - -
Customer specifies the need for affordability. For high quality clamp maximum
price will be no more than £150 for manufacturing
The product cost should be no more than £380
Packing shipping and processing costs should be no more than 8% of the
manufacturing cost.
Quantity - -
The customer has not specified how many units are required so we will
assume one unit
Any further units required will have a 10% surcharge
Upkeep - - - - - -
Minimal upkeep due to busy working environment, small amounts of moving
parts will prevent failures and keep maintenance low.
Replacement components will be available at a fee.
There will be no servicing contract
No special tools required to maintain
Ball joint to be greased with EP2 periodically
Lead screw to be lubricated using Synthetic NLGI-2 grease
Shipping -
The clamp will be shipped in a budget friendly manner. It will be shipped via
courier service. (aligning with budget friendly request from customer)
Marketing -
Not required due to item being bespoke
Manufacturing Processes - - - - - -
Frame body to be made from machined steel- C45/1045
Screw for adjustment to be made with hardened steel 42CrMo4
All bolts for construction must adhere to ISO metric thread forms
Nickel plated body to promote longevity and quality feel
Ball made from 42CrMo4 heat treated to ensure hardness
Socket also made from hardened steel but not as hard as ball
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Appearance - - - - -
Brief does not specify any specific appearance traits therefore the product will
be made as strong as possible while disregarding aesthetics.
Length 600mm long at full 180mm jaw opening, 420 mm retracted
Width 150mm
Height- 240mm
Mass- 18kg
Ergonomics - - -
The clamp must be comfortable for the operative to use, therefore a smooth
handle with considerable leverage to minimise force needed to apply 500kg of
force (preferable less than 150n of hand force)
Locking device should be easily accessible and easily toggled and removed.
Rotational locking supplied by locking screw, fasten to lock, unfasten to
release. Swivel lock to be applied by two grub screws to lock the ball joint in
place.
Should be fastened to the table using 3x 19mm nuts requiring 3x holes to be
drilled in work surface (template included)
Competition -
The main competition would be standard bench vices; however, they lack the
accessibility due to having no adjustability. In contrast with the swivel and
rotate clamp here.
Standards and Specifications to adhere to - -
Metric threads as per ISO 68-1, ISO 261, ISO 724
PUWER principles taken into consideration for workshop use
Safety considerations - -
Manual application, therefore decreased risk of crushing injury
Clamp handle will be painted yellow to ensure visibility, to prevent injury.
Testing - -
Legal -
Functional load test at 750 kg of force, using compression load cell, leave for
period of 24 hours to ensure there is no drop off in force applied
Using torque wrench ensure force applied is under 150n to achieve the 750
kg of force.
User injury must be eradicated by safe design, manual and training guides will
also be provided.
Installation
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-
Installation to bench via three 19mm nuts and bolts.
Documentation -
User instructions will be provided upon delivery
Disposal -
The product is designed to be long lasting however if the product is to be
disposed of it can be recycled due to its recyclable components. Which aligns
with company ethics.