The document is a report on the fabrication of a c-clamp submitted by engineering students at Cairo University. It describes the objective of making the c-clamp to learn manufacturing processes. It then details the processes used, including cutting the raw material to size, drilling a hole, and welding a nut. Dimensions of the finished part are provided. Photos show the different steps of rasping, drilling, and welding. Various welding processes are also defined.

1. Cairo University
Faculty of Engineering
Fundamental of manufacturing
Report on
c-clamp
Supervised by:
Prof. -----------------------
May 2012

2. Submitted by:
Ahmed raafat 111111
Amr Hany AHMED 1101056
Kareem Hossam Ahmed 111111
Mohamed Mahmoud saber 111111
Wassim raafat shanad 111111
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3. Introduction:
A C-clamp is a type of clamp device typically
used to hold a wood or metal work piece, and is
often used in, but is not limited to, carpentry and
welding. These clamps are called "C" clamps
because of their C shaped frame, but are otherwise
often called G-clamps or G-cramps because
including the screw part they are shaped like an
uppercase letter G.

4. Objective of the project:
The main objective of the project is to learn
the techniques of the various types of machines
used in lab and learn how to operate them in
sequence of processes in order to fabricate a well
finished product that is functional and useable.

5. Usage
A C-clamp is used by turning the screw through
the bottom of the frame until the desired state is
reached. In the case that the clamp is being tightened,
this is when the objects being secured are
satisfactorily secured between the flat end of the
screw and the flat end of the frame. If the clamp is
being loosened, this is when a sufficient amount of
force has relieved to allow the secured objects to be
moved.

6. Usage of C-clamp

7. Work plan:
We start the project by applying the “Process
Planning” as follow:
 Deciding what process and methods should be
used and in what sequence.
 Determining tooling requirement.
 Selecting production equipments and systems.

8. Sequence of processes used in part fabrication
Stating raw Finished
material product
Basic Secondary Property-enhancing Finishing
process processes processes operations
Basic process:
Establishes the initial geometry of the part.
Secondary process:
Transform the basic shape into the final geometry.
Finishing operations:
Provide a coating on the work part surface.

9. Lab work
We were provided with a C section with a great
length, the first task was to cut it to the length needed
to produce the work part “C-clamp”.
Drawings and dimensions of the work piece before and after cutting it.

10. The second task was to drill a hole of 10mm
diameter for he bolt and nut to make the holding
part of the C-clamp. the following image shows a
top view of the work piece after drilling

11. The last task was welding the nut right above the
drilled hole and putting the bolt in it.
Image of the work piece after welding the nut.

12. Dimensions
We used the standard dimensions of section
except for the length. After measuring all other
dimensions on the C-clamp as sketched above and
discussing the results with the team, we conclude that
the best length to cut was 38 mm.
Part Dimension
Length 38 mm
Height 81 mm
Web width 5.7 mm
Flanshing thickness 6.7 mm
Flanshing width 44.65 mm

13. Sequence of the processes
Forging: We started forging to make the surface of
the C-clamp clean, we were instructed how to use the
Rasp;( hand files are normally held in both hands),
the file is held flat against the surface to cut / smooth.
The file is pushed forward and it cuts on the forward
stroke, then is lifted away from the metal and
returned to the starting point for the next push
forward. This is called „Through Filing‟

14. In the beginning it was difficult to use the Rasp as our
hands tend to shake which made the surface not flat.
During that process we rotate the C-clamp to get the
widest cross sectional area, but we were told that it
was wrong, as the thinner cross-sectional area is the
better ending for the product as this cross-sectional
area will be forged by more teeth so it will be better
and faster.

15. Measurements:
as mentioned above we located the center at the
top surface to drill a hole for the bolt and the nut.
The next step was to get the bolt and nut (ISO 10),
and then we were ready for welding. The final step
was to paint the product to provide a smooth surface.

16. Lab photos

18. Rasp
We use the word "rasp" to denote the entire
family of the tool when we're talking generally about
the use of the tool. When the particular details matter,
we say "Rasps" to mean a rasp with a handle at one
end.
There are many different shapes / sections of files,
some are shown below. They are used for a variety of
types of work. Files are classified according to their
length, section / shape and cut (tooth shape).

19. Hand File: Used for general filing of metals such as
steel. They are rectangular in section and are the most
common type of file used in workshops.
Half Round File: Used for filing curved surfaces. A
normal hand file with its flat cutting edges is unsuitable
for filing curved surfaces. However, the half round file
has a curved surface which is especially useful for filing
internal curves.

20. Three Square File: Is triangular in section and very
useful when filing „tight‟ corners / angles. The sharp
edges allow the file to fit into corners when filing.
Square File: The square file is quite thin and fits into
corners well. They can e used to file slots in metal or
for filing where there is little space.

21. Knife File: Knife files are very useful when filing
where there is little space. Knife files are very thin
and can fit into small gaps.

22. Shaping Plywood
Regular files do not work well on wood, the
traditional tool for shaping wood is a rasp, which has
projecting teeth to gouge out and remove wood. This
can be a bit rough on plywood.
A rasp is a tool used for shaping wood or other
material. It consists of a point or the tip, then a long
steel bar or the belly, then the heel or bottom, then the
tang. The tang is joined to a handle, usually made of
plastic or wood.

23. Welding
Process for joining separate pieces of metal in
a continuous metallic bond. Cold-pressure welding is
accomplished by the application of high pressure at
room temperature; forge welding (forging) is done
by means of hammering, with the addition of heat.

24. Arc welding
Arc welding is a type of welding that uses a welding
power supply to create an electric arc between an
electrode and the base material to melt the metals at
the welding point. They can use either direct (DC) or
alternating (AC) current, and consumable or non-
consumable electrodes.

25. Resistance welding
Resistance welding involves the generations of heat
by passing current through the resistance caused by
the contact between two or more metal surfaces. In
general, resistance welding methods are efficient and
cause little pollution, but their applications are
somewhat limited and the equipment cost can be high.

26. Water-Gas welding
Process was applied in the end of 19th century. The
flame which is produced from water-gas replaced the
blacksmith s hearth as a mean of heating the metal and
welded the metal but this is first welding.

27. Cast-welding
In this method the molten metal pouring into a
mould which has runner at the point where the
casting had failed to flow or wherever there was a
fractured place. The molten iron poured in until it was
fluid everywhere around the edge of the job and
runner was stopped up, and then the iron was allowed
to cold in the mould.

28. Cast-welding
This welding process can be said modern
fusion weld process, but this is slightly high cost
process than other types of welding.

29. Submerged Arc Welding
This process involves the
welding arc being continuously
submerged under a mound of
granular flux. The bare metal is
fed automatically at a rate which
maintains the welding arc.
As the arch and the molten metal are covered with
the mound of flux , there is no flash spatter, sparks or
smoke. The resulting weld is uniform with good
physical and chemical properties.

30. Solid State Welding
Solid state welding is a term used for welding
processes which produces joining at temperatures
essentially below the melting point of the base
materials, without the need for brazing filler metal.
Pressure is generally required but not always. These
welding processes include cold pressure welding,
diffusion welding, explosion welding, forge welding,
friction welding, hot pressure welding, roll welding, and
ultrasonic welding.

31. Electron Beam Welding
In this process a concentrated beam of electrons
bombards the base metal, causing it to melt and fuse.
The process is most efficient when done in a vacuum.
Therefore the size of the vacuum chamber limits the
size of the work pieces that can be welded. Advantages
include the ability to produce welds of extremely high
purity, ability to melt any known material, ability to
weld dissimilar metals and the ability to make welds
with depths as great as 150mm.

32. Electron beam welding is costly for two reasons,
1) the high cost of equipment,
2) the time lost in pumping out the vacuum chamber
between welds. When the welds are not made in a
vacuum, many advantages of the process are reduced.

33. Laser Welding.
The laser beam is a concentrated beam of light
with sufficient energy to generate the heat at the base
metal surface to cause fusion. There are two types of
lasers in use (1) gas lasers and 2) solid lasers. Gas lasers
provide a continuous laser beam that is best suited to
continuous welding and cutting. Solid lasers release
their energy in short bursts or pusses at a rate of 6 to 10
per minute.

34. As each pulse only lasts for a few millionths of a
second the base metal is liquid for only moments and
there is limited time for chemical reactions to
occur. Therefore flux type protection is not required
to obtain sound welds.
Laser systems can be precisely controlled and have
sufficient power to weld and even vaporize any known
material.

35. Other advantages include the ability to make welds
through transparent coverings and to make welds in
locations impossible to reach with conventional welding
gear. Limited depth of penetration however restricts
the use of laser welding to relatively thin materials.