The purpose of this project is to gain hands-on experience in reverse engineering by creating a Toggle Clap Assembly using CAD software Fusion 360 and bringing the design to life through 3D printing.Â
The approach taken for the reverse engineering of the clamp in this project will be the Direct Measurement method. The clamp will be measured both in inches and metrics, and it is believed that the original design was done using the metric system.
During the design process of the clamp, I found it necessary to add additional measurements that were previously overlooked or deemed unnecessary. To ensure a comprehensive design, the Top-Down approach was utilized, which involved creating individual components and subsequently joining them together to form the final product.
Based on a thorough visual analysis of the components of the clamp, it is estimated that there are four types of materials used: Cast Steel, Stainless Steel, Carbon Steel, and Aluminum.
Base - Cast steel black painted
Plunger - Stainless steel
Grip - Rubber in red
Links - Carbon Steel
Rivet - Aluminum
Choosing materials
I encountered difficulties while rendering the design, as the lighting did not meet my desired outcome. The foreground of the image was consistently dark, making it difficult to showcase the texture of the cast iron. I devoted a significant amount of time to adjusting various settings and environment lights. After several hours of trial and error, I discovered that the issue was due to the choice of material color, which was too dark and prevented any reflection of light. Upon changing the color to a lighter shade, the render was achieved perfectly.
To simulate the movement of a model, we must add joints to its parts. Fusion 360 offers various types of joints, including those that connect two parts without any moving component, joints that facilitate one-axis motion, such as sliding or revolute joints, and even joints that allow for movement across two or three axes, such as planar or ball joints.
Creating animation for this clamp is quite challenging due to the non-linear and non-radial movement of the links. I had to adjust the handle every 10 degrees and synchronize the movement of all other parts accordingly.Â