2 1

3
4
B B

1 6

Parts List
ITEM DESCRIPTION MATERIAL/PART NUMBER 8
1 FRAME CAST ALUMINUM
2 FOOT 6061-T6 ALUMINUM
A 3 4040-C SS BALL MSC# 00073452 A
7
4 HEX JAM NUT, ZINC PLATED MSC# 87921573
5 HELICOIL MSC# 00060814
6 3/8-16 THREADED ROD MSC# 06056741
7 HANDLE 6061-T6 ALUMINUM
8 HEX SOCKET SET SCREW MSC# 75548032
TITLE:
SCALE: 3/4 TOLERANCES UNLESS OTHERWISE SPECIFIED: DEVELOPED AT: UTAH STATE UNIVERSITY

SHEET 1 OF 3 C-Clamp X/XX = `1/64 ; X.XX = `.010 ; X.XXX = `.005 DRAWN BY: CODY VALDEZ REV: 1.0
2 1
 2 1
#14 CENTER DRILL
BELL TYPE
2 `1/2 THREADS
n.266
BLEND BOTH ENDS

B B
.25 .25 .125 `.010
.20
NOTES:
5

1/32 CHAMFER ON ALL 90~ ARRISES
SCREW MATERIAL: SAE-AISI 4140B-7

CHAMFER ALL INTERNAL AND
EXTERNAL THREADS ONE
+1/64
THREAD DEPTH - 0
3 1/8 1 1/8

3/8 - 16 x .9
HELICOIL INSERT

A A

FRAME MATERIAL: CAST ALUMINUM

TITLE:
SCALE: FULL TOLERANCES UNLESS OTHERWISE SPECIFIED: DEVELOPED AT: UTAH STATE UNIVERSITY

SHEET 2 OF 3 C-Clamp X/XX = `1/64 ; X.XX = `.010 ; X.XXX = `.005 DRAWN BY: CODY VALDEZ REV: 1.0
2 1
 2 1

3/4
.60
C
.35
n.75

.609 `.003 .375 `.003

B B

3/8-16 UNC - 2B
C SECTION C-C

FOOT
SECTION B-B
1.50
A
n.750
NOTES:

MATERIAL: 6061-T6 ALUMINUM

1/32 CHAMFER ON ALL 90~ ARRISES
B B

CHAMFER ALL INTERNAL AND
A A
10-24 UNC - 2B EXTERNAL THREADS ONE
+1/64
A SECTION A-A
THREAD DEPTH - 0

HANDLE

TITLE:
SCALE: FULL TOLERANCES UNLESS OTHERWISE SPECIFIED: DEVELOPED AT: UTAH STATE UNIVERSITY

SHEET 3 OF 3 C-Clamp X/XX = `1/64 ; X.XX = `.010 ; X.XXX = `.005 DRAWN BY: CODY VALDEZ REV: 1.0
2 1
 Utah Pre-Engineering Program
Materials and Processes

Procedures for C-Clamp Activity

Frame

1. Ram up split pattern of frame and cast in aluminum.

2. Remove gates and flashing. Finish surfaces as necessary taking care not to
change the physical dimensions of the frame.
3. Temper aluminum casting (anneal & solution heat treat).
4. Scribe and center punch location of 3/8-16 hole for Helicoil insert.
5. Clamp frame in fixture or vise so 3/8-16 hole is secured and vertical.
6. Drill pilot hole for 3/8-16 hole, 1 deep.
7. Drill tap hole for 3/8-16 Helicoil insert (letter X, .397), 1 deep.
8. While frame is still secured vertically in fixture or vise, tap hole to receive
3/8-16 Helicoil. Secure tap so it is also held vertical. Tap the hole as deep as
possible without bottoming the tap.
9. Cut rough opening (3 1/8 dimension) in C-clamp. Leave 1/16 to 3/32 of
material at each end. Keep the material removed for a tensile test coupon (see
tensile test coupon below).
10. Finish tapping hole for 3/8-16 Helicoil insert.
11. Mill opening to 3 1/8.
12. Chamfer all 90 degree arrises and 3/8-16 hole.

Screw

1. Cut to rough length (hacksaw).

2. Grind both ends and chamfer to finish length.
3. Center drill end of screw. Hold screw in a 5C collet. Center drill deep enough
to engage the 90 degree chamfer on the bell style center drill.
4. Turn groove in screw. Hold screw in a 5C collet and support the end with a live
center.
5. Mill slot in screw, hold in a 5C collet.
6. Deburr all sharp edges and make sure the 3/8-16 jam nut screws freely onto
both ends of screw.

Handle

1. Cut to rough length.

2. Face both ends to finish length and chamfer.
3. Center drill, pilot drill, and tap drill 3/8-16 hole. Use a vertical mill, hold work
in a 5C collet, and locate hole with an edge finder and digital readout or
calibrated hand wheels.
4. Index handle 90 degrees, and center drill and tap drill 10-24 hole.
5. Tap and chamfer both holes (3/8-16 & 10-24).
Foot

1. Cut to rough length.

2. Face both ends to finish length and chamfer. Hold foot in a 5C collet.
3. Center drill and drill .375 hole.
4. Drill .609 hole.
5. Chamfer .609 hole.

Assembly

Frame Sub-Assembly
1. Insert Helicoil into frame, visually center into threaded area of frame.
2. After the Helicoil is inserted into the correct position, break off the Helicoil
tang.

Foot Sub-Assembly
1. Insert 3/8 stainless steel ball into cup of foot. Ball should seat into .375 hole.
It may need to be pressed into position.
2. Press fit 3/8-16 jam nut into cup of foot.

Final Assembly
1. Screw handle onto screw and secure into position with 10-24 set screw. The set
screw should contact the flat machined surface on the screw.
2 Screw handle and screw through the Helicoil in the frame. The screw should
extend through the frame by about one inch.
3. Screw foot assembly onto the screw until it is able to slide and flop on the
groove machined on the screw.
Tensile Test Coupon

NOTE: The dimensions and procedures to make your tensile test coupon may need to
be modified to meet the requirements of the jaws used on various tensile testing
machines. See the graphic below to assist in making your tensile test coupon.

1. In a four jaw chuck, face both ends of the test coupon flat. Try to keep the test
coupon as long as possible by minimizing the amount of material removed.
2. Find the center of both ends of the test coupon by scribing two lines connecting
opposite corners on each end of the coupon.
3. Center punch and center drill (#4 center drill, drill press) both ends of the test
coupon.
4. Between centers, turn the middle third of the test coupon to 1/2.
5. With a large radius lathe tool and the cross feed, neck down the center of the
test coupon to 3/8.
6. Mill both sides of the test coupon equally (finished dimension less than 5/8) so
it will fit in the jaws of the tensile testing machine.
7. Pull your test coupon to determine the tensile strength of the cast material that
your C-clamp is made from.
8. Use this value with the equation or chart provided by your instructor to
determine the strength of your C-clamp.
 1553 20706.84
1546 22146.45 Clamp Strength
2281 38747.47
2347 40379.52
2500
0 0 Series1
Poly. (Series1)
2000
Tensile Load (lb) =
Clamp Strength (lb)

Tensile Diameter (in) =

Area (in) =
1500

0.1875 0.035156 0.110391 20717.34 Force (psi) =

1000

Clamp Strength Equation

500 y = -8E-07x2 + 0.0886x

0 Clamp Strength (lb) =

0 10000 20000 30000 40000 50000
Tensile Sample Force (PSI)