Projects
C-Clamp Reverse Engineering and Failure Analysis
Reverse engineered a commercial C-clamp, recreated it in SOLIDWORKS, and performed finite element analysis to identify structural failure points under extreme loading conditions.
Overview
This project focused on reverse engineering and structural analysis of a commercially manufactured C-clamp. The objective was to accurately recreate the product in SOLIDWORKS, assemble the individual components, and evaluate the clamp's structural performance under increasingly severe loading conditions.
By combining precise measurements, CAD modeling, assembly design, and finite element analysis, the project investigated how the clamp would behave under extreme use and identified the location most susceptible to structural failure.
My Contributions
- Measured and documented a commercial C-clamp for reverse engineering
- Created a 1:1 CAD model in SOLIDWORKS using physical measurements
- Modeled the frame, threaded bolt, and handle as separate components
- Built a complete assembly using SOLIDWORKS mates
- Assigned material properties to replicate the real product
- Performed finite element analysis under extreme loading conditions
- Identified the load path, failure location, and limiting structural features
- Evaluated how geometry influenced overall clamp strength
Process
The project began by selecting a commercially available C-clamp and recording physical dimensions to create an accurate digital representation. Each component was measured and recreated individually in SOLIDWORKS to closely match the geometry of the original product.
The frame, threaded bolt, and handle were modeled as separate parts and assembled into a complete working assembly. Material properties were then assigned to approximate the behavior of the actual clamp during loading.
Finite element analysis was performed to evaluate structural behavior under increasingly large clamping forces. Stress concentrations were examined to determine where failure would occur and how the load was distributed throughout the assembly.
Analysis showed that the highest stresses developed at the neck of the clamp frame, making it the most likely location for failure under extreme loading conditions. The results demonstrated how geometry and load paths influence structural performance and product durability.
Tools Used
SOLIDWORKS • SOLIDWORKS Simulation • Finite Element Analysis (FEA) • Reverse Engineering • Assembly Modeling