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Design of Machine Elements

Analysis of a Toggle Clamp

Nicholas Fornaciari
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Executive Summary

This study was to determine the factor of safety and stress acting on different parts in a
mechanical assembly under a specified loading. This assembly is a vice clamp. In order to find
the factor of safety for each part the material AISI 1020 must be applied to the part. After
applying the material, a static analysis can be done through a Solidworks simulation rather than
performing hand calculations. After applying fixtures and forces on the assembly from
predetermined reactionary forces, we are able to create stress and factor of safety plots. These
plots gave us the stress at any given point for any part as well as where the part falls below a
specified factor of safety. Having a factor of safety plot is useful in determining if a part will fail
under a load and meet ASME standards. In Solidworks, we are able to set the desired minimum
factor of safety as well as a maximum factor of safety in order to ensure the part fits specification
for failure. Once the plots are created they can then be used to make adjustments to the parts to
make them meet the design standards. FEA allows these calculations to be done easily and
efficiently, while still maintaining the accuracy of using statics to perform hand calculations. We
were able to determine the Link Strap passes the factor of safety analysis while the Base and
Arm failed due to not maintaining a factor of safety of at least two as shown in figures six, eight,
and ten. This mechanical assembly would need to be redesigned in order to meet the required
factor of safety for the project.
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Table of Contents

Executive Summary Error! Bookmark not defined.

Table of Contents 3

List of Figures 4

List of Tables 4

Statement of problem / description of system under study 5

[6] Theoretical Analysis 6

[6.1] Loading Analysis 6

Free body diagrams 6

Description of loading equations 10

[6.2] FEA Simulation and Design Check Error! Bookmark not defined.

[7] Detailed Drawings Error! Bookmark not defined.

[8] Findings Error! Bookmark not defined.

Discussion 23

Conclusions 23

[9] References 24
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List of Figures

Figure 1: Free body diagram of spindle carrier 7

Figure 2: Free body diagram of link strap 8
Figure 3: Free body diagram of rivet pins 9
Figure 4: Free body diagram of arm 10
Figure 5: Free body diagram of base 11
Figure 6: Factor of safety on the rivet pins (Hand Calculations) 13-14
Figure 7: Stress analysis for assembly closed 15
Figure 8: Stress analysis for assembly (152 degrees open) 15
Figure 9: FEA simulation and stress plot for one link strap w/ maximum loading (150lb)
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Figure 10: Factor of Safety simulation and plot for one link strap 16
Figure 11: FEA simulation and Stress Plot on the arm w/ maximum loading (150lbs) 17
Figure 12: Factor of safety simulation and plot for the arm, probed on lower edge 17
Figure 13: FEA simulation and Stress plot on the one base w/ maximum loading (150lbs) 18
Figure 14: Factor of safety simulation/plot for the one base, probed at max stress point. 18
Figure 15: FEA simulation and stress plot of the spindle carrier w/ maximum loading
(150lbs) 19
Figure 16: Factor of safety simulation and plot of the spindle carrier, probed at max stress
point. 19
Figure 17: Three (3) view dimensioned drawings with isometric projection: link strap 20
Figure 18: Three (3) view dimensioned drawings with isometric projection: arm 20
Figure 19: Three (3) view dimensioned drawings with isometric projection: base 21
Figure 20: Three (3) view dimensioned drawings with isometric projection: spindle
carrier 22
Figure 21: Assembly drawing with 3 views and isometric projection w/ mounting
dimensions 22
Figure 22: Exploded assembly drawing in isometric view w/ bill of materials 23

List of Tables
Table 1. Maximum loading position for each part during the normal toggle clamp
operation form the lowest position to the highest position 12
Table 2: Max load position for each part 12
Table 3: Comparison of max load and FOS for each part. 24
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Case Study Introduction:

Statement of problem / description of system under study

This case study was done in order to help determine the safety and loading of the clamp
assembly under a given load. We were given predesigned parts and a desired factor of safety and
had to determine if a part would fail or not meet the required factor of safety. In order to achieve
this information free body diagrams were needed for each major part to determine the internal
forces at every point. Once these free body diagrams are created we are able to use them to do a
Finite Element Analysis to find the stress, displacement and factors of safety. Once the factor of
safety and stress at any point is given we can find the maximum and minimum to determine
where the part is most likely to fail. Anywhere the part is likely to fail would then enter the
redesign phase to achieve the desired minimum factor of safety.

Detailed performance specification

The company we are working for has purchased another company’s intellectual property
of a toggle clamp. Our company’s goal is to use this technology to create detailed simulation of
the toggle clamp and to adapt a functionally and structurally superior toggle clamp prototype. To
do so we must reverse engineer the toggle clamp by running a performance simulation and an
interface design. Then conduct a loading analysis and design check for each component of the
toggle clamp. The final step in this project will to make a recommendation to our company and
comparing the performance of the clamp the required specifications to see if it is an adequate
design.
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[6] Theoretical Analysis:

[6.2] Design interface
Link strap (hole) 𝟎. 𝟏𝟎+𝟎.𝟎𝟏
−𝟎.𝟎𝟏
Arm (hole) 𝟎. 𝟏𝟎+𝟎.𝟎𝟏
−𝟎.𝟎𝟏
Base (hole) 𝟎. 𝟏𝟎+𝟎.𝟎𝟏
−𝟎.𝟎𝟏
Spindle carrier (hole) 𝟎. 𝟏𝟎+𝟎.𝟎𝟏
−𝟎.𝟎𝟏
Pin 𝟎. 𝟏𝟎+𝟎.𝟎𝟎𝟓
−𝟎.𝟎𝟎𝟓
Spindle 𝟎. 𝟏𝟖𝟓+𝟎.𝟎𝟏
−𝟎.𝟎𝟏
Hex Nut 𝟎. 𝟏𝟖𝟓+𝟎.𝟎𝟏
−𝟎.𝟎𝟏
Spindle washer 𝟎. 𝟏𝟖𝟓+𝟎.𝟎𝟎𝟓
−𝟎.𝟎𝟎𝟓
[6.1] Loading Analysis

Free body diagrams:

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Figure 1: Free body diagram of spindle carrier

Figure 2: Free body diagram of link strap

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Figure 3: Free body diagram of rivet pins

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Figure 4: Free body diagram of arm

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Figure 5: Free body diagram of base

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Table 1. Maximum loading position for each part during the normal toggle clamp operation
form the lowest position to the highest position

Table 2: Max load position for each part

Force Member Load Max Load Position
(lbs) Degrees

Ay 150 181

Ax 645.2 (Compression) 181

By 0 181

Bx 645.2 181

Cy 0 181

Cx 645.2 (Compression) 181

Dy 150 (Compression) 181

Dx 645.2 181
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[6.2] FEA Simulation and Design Check

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Figure 6: Factor of safety on the rivet pins (Hand Calculations)

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Figure 7: Stress analysis for assembly closed

Figure 8: Stress analysis for assembly (152 degrees open)

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Figure 9: FEA simulation and stress plot for one link strap w/ maximum loading (150lb)

Figure 10: Factor of Safety simulation and plot for one link strap
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Figure 11: FEA simulation and Stress Plot on the arm w/ maximum loading (150lbs)

Figure 12: Factor of safety simulation and plot for the arm, probed on lower edge
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Figure 13: FEA simulation and Stress plot on the one base w/ maximum loading (150lbs)

Figure 14: Factor of safety simulation and plot for the one base, probed at max stress point.
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Figure 15: FEA simulation and stress plot of the spindle carrier w/ maximum loading (150lbs)

Figure 16: Factor of safety simulation and plot of the spindle carrier, probed at max stress
point.
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[7] Detailed Drawings:

Figure 17: Three (3) view dimensioned drawings with isometric projection: link strap

Figure 18: Three (3) view dimensioned drawings with isometric projection: arm
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Figure 19: Three (3) view dimensioned drawings with isometric projection: Base Right (T)
Base Left (B)
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Figure 20: Three (3) view dimensioned drawings with isometric projection: spindle carrier

Figure 21: Assembly drawing with three (3) views and isometric projection w/ mounting
dimensions
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Figure 22: Exploded assembly drawing in isometric view w/ bill of materials

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[8] Findings:

Table 3: Comparison of max load and FOS (Factor of Safety) for each part.
Part Max Stress (kpsi) FOS

Link Strap 15.0 Pass

Arm 44.0 Fail

Base 50.5 Fail

Spindle Carrier 92.1 Fail

Discussion:
When defining the parameters for the Factor of Safety, there is the option to set a minimal factor
of safety. As defining in the project overview, each part should have a factor of safety of around
2. By looking at the blue and red plots of the Figures 6 through 10, the red indicates any area
under a Factor of Safety of 2, and any area blue indicating an area above a Factor of Safety of 2.

Conclusions:
After performing a simulation using the modeled clamp assembly as well as the
important components of the clamp, it is shown that only the link strap meets the factor of safety
requirement. Based on a FOS of 2, only the max load of 15 kpsi on the link strap passed, leaving
the arm, base and spindle carrier to fail. This shows that were the model to go into production, a
redesign of those components is required before release. There are potential improvements that
can be made, such as different materials or adjusted geometry, but as the part is now it cannot
meet the set factor of safety requirements.
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[9] References:
[1] Search Engineering Material by Property Value, accessed October 21,2018,
www.matweb.com/search/PropertySearch.aspx.
[2] Department of Mechanical Engineering “MECH 3000 Minor Project.” handout.
[3]Dimensioning and Tolerancing, accessed October 21,2018
Engineering.pages.tcnj.edu/files/2012/02/dimensioning_and_tolerancing.pdf.