Mini Project Final Report
by
D.M.W.W Dasanayake
SC/2021/12220
Supervisor: Mr K. A. S. Lakshan
Project report submitted to the
Department of physics
in partial fulfillment of the requirement for the
Level I(sp) Fundamentals of Engineering Workshop Practices
course unit (PHY4192 ω)
of the
Bachelor of Science (Honor ) Degree
in the
Faculty of Science
University of Ruhuna Matara
Sri Lanka
july 2025
ACKNOWLEDGMENTS
I would like to extend my sincere and heartfelt thanks towards all those who have
helped me in making this project. Without their active guidance, help, cooperation
and encouragement, I would not have been able to present the project on time. I
extend my sincere gratitude to my supervicer Mr. K. A. S. Lakshan for her moral
support and guidance during the tenure of my project. I also acknowledge with a
deep sense of reverence, my gratitude towards my department members and other
faculty members of the university for their valuable suggestions and cooperation given
to me in completing the project.
i
ABSTRACT
This report presents the design, fabrication, and testing of a G-Clamp as part
of the Fundamental Engineering and Workshop course module. The primary objective of the project was to apply fundamental workshop techniques—including
measuring, marking, cutting, filing, drilling, tapping, and assembly—to produce a
functional mechanical tool. The G-Clamp, a versatile clamping device commonly
used in metalworking and woodworking, was manufactured using mild steel and
aluminum components. Standard hand tools and machine tools were employed under
strict safety guidelines. Throughout the project, emphasis was placed on precision,
surface finishing, and adherence to design specifications. The successful completion of
the G-Clamp demonstrates a practical understanding of basic engineering processes
and highlights the importance of accuracy, and hands-on experience in mechanical
fabrication.
Keywords: g clamp, mechines , safety
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TABLE OF CONTENTS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iii
LIST OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
v
1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.1
Background of the Focused Problem . . . . . . . . . . . . . . . . .
1
1.2
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1.3
Significance of the Project and Expected Outcomes . . . . . . . .
2
1.4
Features of the Proposed System . . . . . . . . . . . . . . . . . . .
2
Design and Manufacturing Process . . . . . . . . . . . . . . . . . . . . .
4
2.1
Designing Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
2.2
Machines and Tools Used . . . . . . . . . . . . . . . . . . . . . . .
4
2.3
Machine Workshop Safety . . . . . . . . . . . . . . . . . . . . . .
5
2.4
Machining of Each Part . . . . . . . . . . . . . . . . . . . . . . . .
6
2.5
Assembly of the Parts . . . . . . . . . . . . . . . . . . . . . . . . .
7
Results and Discussions . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
3.1
Physical Appearance of the Product . . . . . . . . . . . . . . . . .
8
3.2
Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
2
3
iii
3.3
4
5
Cost Estimation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
4.1
Achievements . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
4.2
Accuracy and Uncertainty . . . . . . . . . . . . . . . . . . . . . .
11
4.3
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
4.4
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Further Developments . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
5.1
Suggestions for Enhancing Product Quality . . . . . . . . . . . . .
13
5.2
Design Improvements
13
. . . . . . . . . . . . . . . . . . . . . . . .
iv
LIST OF FIGURES
5.1 Auto cad design of c part
. . . . . . . . . . . . . . . . . . . . . . . .
15
5.2 Auto cad design of screw part . . . . . . . . . . . . . . . . . . . . . .
16
5.3 Auto cad design of handle part
17
. . . . . . . . . . . . . . . . . . . . .
v
CHAPTER 1
Introduction
1.1
Background of the Focused Problem
In both mechanical and woodworking industries, holding components securely in
place during fabrication or assembly is a fundamental requirement. Clamping devices
are essential tools for achieving precision, safety, and e!ciency during such operations.
Among them, the G-Clamp is widely used for temporarily securing workpieces to a
fixed position on a workbench or surface. Despite its simple structure, the G-Clamp
must be both strong and precise to apply adequate force without damaging the material. This project was undertaken in the context of the Fundamental Engineering and
Workshop module, aiming to introduce students to practical mechanical fabrication
methods. The need to understand the working principles and manufacturing processes
of basic workshop tools led to the selection of the G-Clamp as a suitable project.
By fabricating a G-Clamp from raw materials using fundamental workshop skills,
students gain hands-on experience that bridges theoretical knowledge and real-world
application.
1.2
Objectives
The primary objectives of this project are as follows:
• To design and fabricate a functional G-Clamp using basic workshop techniques
and tools.
• To apply skills in measuring, marking, cutting, filing, drilling, tapping, and
assembling mechanical components.
1
• To enhance understanding of tolerances, fits, and mechanical functionality.
• To promote teamwork, problem-solving, and adherence to safety practices in a
workshop environment.
1.3
Significance of the Project and Expected Outcomes
This project plays a significant role in introducing engineering students to
practical manufacturing processes and real-world applications of mechanical principles.
Through the fabrication of the G-Clamp, the students are expected to:
• Develop proficiency in using hand tools and machine tools.
• Understand the importance of material selection, accuracy, and surface finish.
• Experience the complete product development cycle—from design to final
testing.
• Appreciate the role of mechanical tools in supporting e!cient and safe fabrication
operations.
The successful completion of this project will result in the production of a fully
functional G-Clamp, capable of securely holding objects for various engineering tasks.
Additionally, students will have a tangible output that reflects their learning and
craftsmanship.
1.4
Features of the Proposed System
The fabricated G-Clamp consists of the following key features:
• Frame: A C-shaped or G-shaped frame made from mild steel to ensure strength
and rigidity under load.
• Screw Mechanism: A threaded screw with a swivel pad at one end, used to
apply and adjust clamping pressure.
2
• Tapping Section: Internal threading performed using taps to allow the screw to
move smoothly and precisely.
• Handle: A T-bar or sliding rod inserted through the screw head for turning the
screw easily.
• Protective Finishing: All parts are filed and finished to remove sharp edges and
provide a smooth surface, minimizing the risk of injury and material damage.
The design ensures the clamp is capable of providing a strong, stable, and
adjustable grip. While simple in function, the system showcases a range of workshop
skills and engineering concepts.
3
CHAPTER 2
Design and Manufacturing Process
2.1
Designing Steps
The design of the G-Clamp was approached through a structured process to
ensure functionality, safety, and manufacturability using available workshop tools.
The following steps were followed:
1. Initial Concept Sketch :- A basic hand-drawn sketch of the G-Clamp was
prepared, showing the C-frame, threaded screw, and handle mechanism. Dimensions were based on standard sizes suitable for small to medium clamping
tasks
2. Material Selection
• Frame: Mild steel flat bar (due to strength and machinability).
• Screw and Swivel pad: Mild steel round rod.
• Handle: mild steel, rod
3. Technical Drawing :- Using CAD software , a detailed drawing was created with
labeled dimensions, tolerances, and hole positions for tapping and clearance.
4. Process Planning :- A manufacturing plan was developed, listing the sequence
of operations, required machines, and estimated time for each task. This also
included checking tool availability in the workshop.
2.2
Machines and Tools Used
the following machines and hand tools were used:
4
2.3
Machine/Tool
Purpose
Bench vice
Holding material during cutting/filing
Hacksaw
Cutting steel rods and flat bars
File set
Smoothing surfaces and deburring
Bench drilling machine
Drilling accurate holes
Taps and tap wrench
Internal threading
Lathe machine
Shaping and finishing the screw/thread
Vernier caliper
Accurate measuring
Angle grinder
Surface preparation and rough shaping
welding machine
connect the parts
Band saw machine
cut the steel plate
Machine Workshop Safety
Strict adherence to workshop safety protocols was maintained throughout the
project. Key safety measures included:
• Wearing personal protective equipment (PPE) such as safety goggles, gloves,
and aprons.
• Ensuring loose clothing and long hair were secured.
• Using tools only for their intended purposes.
• Following proper operating procedures for machines like the drill press and
lathe.
• Checking for sharp edges and cleaning the work area regularly to avoid accidents.
• Keeping hands away from cutting zones and rotating parts.
5
A safety briefing was conducted before workshop sessions to remind all group
members of these practices.
2.4
Machining of Each Part
1. C-Frame (Body)
• Material: Mild steel flat bar
• Process:
– Measured and cut using a band saw machine.
– Shaped into a ”C” using hacksaw and bench grilling .
– cutting a metal rad and grilling it
– Threads were cut using a tap set.
– welding the C part and drilled metal rod for the screw to pass through.
– shaping the whole c part using file set and angle grinder.
2. Screw Rod
• Material: Mild steel round rod
• Process:
– Cut to the required length.
– Threads were created using a die
– A swivel pad end was filed flat to hold the pad.
– A cross-hole was drilled at one end for the handle.
6
3. Swivel Pad
• Material: Mild steel
• Process:
– Cut to a small circular shape.
– Center drilled to insert onto the screw end.
– cut the thread to fix to screw
– Lightly filed and polished for a smooth finish.
4. Handle
• Material: Mild steel rod
• Process:
– Cut to length.
– Inserted into the hole on the screw to create a turning mechanism.
2.5
Assembly of the Parts
Once all parts were machined and cleaned:
1. The screw rod was inserted into the threaded hole of the frame.
2. The swivel pad was attached and secured to the flat end of the screw.
3. The handle was inserted through the cross-drilled hole in the screw rod.
4. The entire system was tested for smooth rotation and clamping action.
5. Final finishing (filing, polishing) was done to remove burrs and sharp edges.
7
CHAPTER 3
Results and Discussions
3.1
Physical Appearance of the Product
The final product is a compact, robust, and fully functional G-Clamp, designed
and fabricated using mild steel and basic workshop tools. It features a rectangular
C-frame structure with smooth, deburred edges and a neatly applied black finish
for corrosion resistance and improved aesthetics. The screw mechanism operates
smoothly with the help of a T-bar handle, providing good mechanical advantage and
grip during clamping.
A unique identification number (12220) has been engraved on the frame to
indicate project tracking or student registration. The overall appearance reflects good
workmanship, attention to detail, and appropriate finishing techniques.
8
9
3.2
Results
The fabricated G-Clamp was tested in the workshop for its functional performance.
The testing involved clamping various objects (metal and wooden blocks) with di”erent
thicknesses. Key results observed:
3.3
Test
Observation
Thread motion smoothness
Screw rotates freely without jamming
Clamping force
Su!cient for moderate workshop holding tasks
Handle torque e!ciency
T-bar allows easy tightening with minimal e”ort
Frame strength
No visible bending or deformation under pressure
Safety
Edges properly filed; safe for handling
Cost Estimation
The following is a breakdown of the approximate cost for fabricating one G-
Clamp:
Item
Cost (LKR)
Mild steel flat bar
300.00
Mild steel threaded rod
250.00
T-bar handle rod
150.00
Workshop consumables (taps, cutting fluid, etc.)
100.00
Finishing (filing, painting)
50.00
Total Estimated Cost
850.00
(Note: Costs may vary based on local material prices and availability.)
10
CHAPTER 4
Conclusion
4.1
Achievements
The successful completion of the G-Clamp project represents a significant achieve-
ment in applying theoretical knowledge to practical workshop fabrication. Key
accomplishments include:
• Designed a functional and structurally sound G-Clamp based on standard
dimensions and use cases. machined and assembled all components using basic
workshop tools and techniques.
• Gained hands-on experience in cutting, drilling, filing, threading, and finishing.
• Followed proper workshop safety practices throughout the process.
• Produced a working mechanical tool suitable for real-world clamping operations.
The project served as a comprehensive introduction to engineering design, manufacturing, and teamwork in a controlled workshop environment.
4.2
Accuracy and Uncertainty
While the final product performs as expected, some variations in measurements
and machining tolerances were observed:
• Thread alignment was manually controlled, which could lead to slight wobbling
in the screw motion if not perfectly centered.
• Filing flatness of surfaces was dependent on operator skill, which may a”ect
parallelism between clamping faces.
• Hole diameters may slightly vary due to drill bit wear or wobble during drilling.
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• Despite these small uncertainties, the clamp operates within acceptable limits
for a general-purpose workshop tool.
These factors highlight the importance of precision, measurement tools, and calibration
in manufacturing.
4.3
Advantages
The fabricated G-Clamp o”ers several advantages:
• Reusability and durability: Made from mild steel, ensuring long service life.
• Cost-e”ective: Manufactured at low cost using locally available materials.
• Manual operation: No power source required, ideal for any workshop setting.
• Customizable: Can be scaled or modified to suit specific tasks or sizes.
• Simple design: Easy to maintain and repair if needed.
4.4
Applications
G-Clamps are versatile tools with wide-ranging applications, including:
• Holding workpieces securely during drilling, sawing, or filing.
• Woodworking and carpentry for gluing and fixing parts together.
• Metalworking for welding or assembly preparation.
• DIY and repair tasks at home or in school workshops.
• Educational use for demonstrating mechanical advantage and tool design.
The project not only resulted in a working product but also deepened our
understanding of mechanical systems and practical engineering techniques.
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CHAPTER 5
Further Developments
5.1
Suggestions for Enhancing Product Quality
Although the G-Clamp produced during this project performs its intended
function e”ectively, there are several areas where the quality and usability of the
product could be improved in future versions:
• Surface Finishing Improvements Applying a more durable finish, such as
powder coating or galvanizing, can enhance corrosion resistance and overall
appearance.
• Precision Machining Using more accurate machine tools (e.g., milling machines, CNC lathes) would improve dimensional accuracy, alignment of threads,
and smoothness of moving parts.
• Thread Quality Enhancement Replacing manually tapped threads with
machine-tapped or die-cut threads can improve thread strength and reduce
the risk of misalignment.
5.2
Design Improvements
To make the G-Clamp more functional and user-friendly, the following design
improvements can be considered:
• Swivel Pad Addition Adding a rotating swivel pad at the end of the
screw can prevent surface damage to delicate materials and provide more even
pressure distribution.
13
• Ergonomic Handle Replacing the plain T-bar with a knurled or rubbercoated handle would o”er a better grip and reduce operator fatigue.
• Larger Opening Range Designing a version with a larger clamping capacity would allow the tool to handle bigger workpieces, increasing its usefulness
in more diverse applications.
• Locking Mechanism Introducing a simple locking nut or clamp-stop feature
could maintain constant pressure without continuous adjustment.
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Figure 5.1: Auto cad design of c part
15
Figure 5.2: Auto cad design of screw part
16
Figure 5.3: Auto cad design of handle part
17