The pipe clamp – teacher guide
Abstract
How can you install a doorway pull-up bar? A simple and common way to do
this is to use pipe clamps. But how are pipe clamps produced? In this task,
students not only think about this question - they actually produce their own
pipe clamp. Which group of students is able to produce a pipe clamp exact
enough to secure the pull-up bar in a doorway?
Discipline: Mathematics/mechanical engineering
Duration: 4 lessons
Target Group: lower secondary school
Age range: 11 - 15
WoW context: Mechanical engineering
Use the PowerPoint presentation ‘Introduction’ to give your students a general idea of the task. Then
show them a pipe clamp.
Student task:
You want to install a pull-up bar with a diameter of 37mm between two
doorposts and plan to secure the bar with two pipe clamps. Make your
own pipe clamps out of 1mm thick sheet metal. The difficulty is: once
you have bent the sheet metal, you can no longer cut it. This means you
have to calculate the total length of the strip of sheet metal needed in
advance. Proceed with this task just like a real mechanical engineer would: First, prepare a sketch
that includes all the specifications and then make a prototype. Prepare a presentation for your
classmates that includes your sketch, work process steps and results.
Calculating the flat length (length before bending):
For classes with younger students, you could ignore some parts of the task, for example, the bending
radii of the 90° angle and/or the observation of the neutral fibres. With older students, you can
deepen the task by having the class include other aspects (such as those described in the background
information). Further, you could have students consider the aspect of metal extension in the bending
process, i. e. the so-called bending allowance. Students can look up the bending allowance on a table
und include it in their calculations.
Author: mascil team Freiburg, Germany in cooperation with SSS Siedle company
CC BY-SA mascil consortium 2014
The mascil project has received funding from the European Union’s Seventh Framework Programme for research, technological
development and demonstration under grant agreement no 320 693
Equipment:
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3 vices
3 bending cylinders (37mm circumference)
3 rectangular bending blocks (2.5mm radius)
Note: You can order the bending forms from, for example, the German company Siedle.
3 plastic-faced hammers (you can order these online)
paper strips, carton strips
pieces of flexible (sheet) metal circa 2cm wide and 20 cm long, and non-flexible metal (1mm
thick, 2cm wide)
Note: They can be purchased, for example, at a construction supply shop.
Lesson plan example:
15 min Acquaint your students with the task by using the PowerPoint presentation ‘Introduction’.
Then give your students the worksheet to look at so they have the actual task in front of
them.
30 min Students work in groups to try to find out the exact flat length of the sheet metal. To do this,
provide them with strips of paper, carton and flexible metal. Students should show the
results of their planning stage to the instructor. The instructor must give their okay before
students begin making the actual product.
30 min Students make their prototype and when doing so, can use the instructions for bending a
pipe clamp found on the back of their worksheet. Alternatively, let students watch the
PowerPoint presentation about the procedure for producing a pipe clamp.
15 min A feedback session in the form of a plenary includes desired improvements and suggestions
for achieving the optimal product.
30 min Students produce their pipe clamps.
15 min Groups prepare their presentations.
45 min In a plenary session, students present their flat length calculations and pipe clamps.
Author: mascil team Freiburg, Germany in cooperation with SSS Siedle company
CC BY-SA mascil consortium 2014
The mascil project has received funding from the European Union’s Seventh Framework Programme for research, technological
development and demonstration under grant agreement no 320 693