Final Manufacturing Lab

Report: Threaded Hinge Clamp

Matt Worthington & Jean Carlo Sotomayor

MER-101 Section 2 (Engineering Graphics)
Mechanical Engineering
Professor 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 centerpunched 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 centerpunched holes. Then we proceeded to drill the five 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)

this diagram shows the plate after the holes are drilled
connecting the arcs
figure

(Figure4)

this diagram shows the tangent lines

and outlining the

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 doesnt 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

from

stock

started
metal

cylinders of

roughly

1.25

length

in

and 0.31 in

diameter

(as seen in

figure

& 2b).

For

Pin A we

used

the

Lathe

with

the

digital

2a

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 1a

Figure 2a

Figure 5a
Figure 4a

Figure 7a

Figure 3a

Figure 6a

Pin B Process

Figure 2b

Figure 3b

Figure 3b

Figure 4b

Figure 5b
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-1A)

(Figure 1B)

(Figure-2A)

(Figure 2B)

(Figure-3A)

(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.