Open-Ended Design Project

EML 4551 - Capstone Design (Fall 1996)

Goal/Purpose:

Apply the fundamentals developed in the mechanical engineering curriculum to an individual design project. The fundamentals and software for computer-aided-design and analysis are implemented into the design project.

Objectives:

Design a deep-throat C-clamp and all associated components, if necessary (see the figure below). The clamp should be designed with the following criteria in mind:

  • performance (i.e., uniform stress throughout and below allowable levels),
  • minimum weight,
  • creativity & aesthetics,
  • marketability,
  • reliability and durability,
  • cost effectiveness, and
  • manufacturability.

Constraints:

The following constraints are imposed upon the design:

  • Material can be
  • Aluminum -  = 0.100 lb/in3, E = 10 Mpsi,  = 0.30
  • Carbon Steel -  = 0.284 lb/in3, E = 30 Mpsi,  = 0.30
  • Manufacturing can be forged or cast
  • Grip length, g = 4”
  • Grip depth, d = 4”
  • Maximum clamping force, Fy = 1000lbs.
  • Safety factor, n = 2
  • Diameter of clamping surface = 1”

Assumptions:

In order to simplify the design and analysis, the following assumptions can be made:

  • Static analysis (no impact or inertia forces).
  • Symmetry about xy-plane.
  • Engineer determines allowable stresses.
  • Engineer determines material and manufacturing process.
  • Limit analysis to 4000 nodes.
  • Standard vendor parts for any associated components.
  • First pass production of 50,000 units.
  • Load is uniformly distributed on the thread surface.

Preliminary Report (due as stated on course syllabus)

The preliminary report should consist of (but is not limited to and not in order given) the following minimum requirements:

  • Background work (recognition of need, feasibility, QFD, literature survey, market analysis, etc.),
  • Material and manufacturing considerations,
  • Preliminary design and analysis,
  • Calculations for stress (bending, contact, tension, compression, etc.) weight, etc.,
  • Autocad drawing(s) completely dimensioned with drawing notes and ready for production,
  • Cost analysis (prototype & production),
  • Parts list (prototype & production), and
  • Conclusion and recommendations.

Final Report (due as stated on course syllabus)

The final report should consist of (but is not limited to) the following minimum requirements:

  • Revised preliminary report.
  • Analysis of preliminary design with Algor.

Wire frame drawing(s), Surface patch drawing(s), Rendered part drawing(s), & Mesh drawing(s).

Load and boundary condition drawing(s).

Displacement plots & Stress (Von Mises) plots.

  • Redesign and analysis with Algor.

Autocad drawing(s) completely dimensioned with drawing notes and ready for production.

Wire frame drawing(s), Surface patch drawing(s),Rendered part drawing(s), & Mesh drawing(s).

Load and boundary condition drawing(s).

Displacement plots & Stress (Von Mises) plots.

  • Conclusions and recommendations.
  • Executive summary.

Options

  • Your design may be: a casting, cavity casting, forging, welded, powder metallurgy, etc. (choose carefully).
  • You may formulate your own project and/or modify this one, however, any changes must be approved by instructor.

Ground-rules

  • Questions, directly concerning project, may be asked of instructor only in class.
  • You may work with others and discuss your designs, however, all work must be your own.