Abstract
Toggle mechanism is commonly used in manufacturing industry for several applications ranging from injection molding machines to tools and fixtures. Toggle clamps are available in numerous types to outfit specific applications. This paper explores the design optimization of the toggle clamping mechanism. Toggle mechanism considered here is actuated by hydraulic cylinder used in CNC bending machines. Force amplification ratio is the key design parameter of toggle clamping mechanism. Performance of toggle clamp mechanism is based upon the force available at the clamping location which is output link. Clamping force available at the output link is the function of the input cylinder force, geometric position of all the links, coefficient of friction between moving and turning parts. Hydraulic cylinder is available in different standard sizes and is operated on specific system pressure. Input cylinder force is the function of cylinder size and the system operating pressure. Mathematical modeling of the toggle clamp mechanism is presented in this paper. Analytical approach and computer-aided design model force analysis are also carried out. Resulting clamping force computed from the analytical approach is compared with the CAD model analysis. The ultimate aim of this work is to develop a new toggle mechanism to reduce the input efforts to get the same output as in existing toggle clamping mechanism.
Similar content being viewed by others
References
Balli SS, Chand S (2004) Synthesis of a five-bar mechanism of variable topology type with transmission angle control. ASME J Mech Des 126(1):128–134
Chen T, Yang CM (2005) Multidisciplinary design optimization of mechanisms. Adv Eng Softw 36(5):301–311
Dai JS, Huang Z, Lipkin H (2004) Mobility of over constrained parallel mechanisms. ASME J Mech Des 128(1):220–229
Feng B, Morita N, Torii T (2002) A new optimization method for dynamic design of planar linkage with clearances at joints—optimizing the mass distribution of links to reduce the change of joint forces. J Mech Des 124(1):68–73
Hassaan GA, Al-Gamil MA, Lashin MM (2011) Optimal synthesis of a 4-bar simple toggle. J Am Sci 7(11):522–528
Huang MS, Lin TY, Fung RF (2011) Key design parameters and optimal design of a five-point double-toggle clamping mechanism. J Appl Math Model 35(9):4304–4320
Huang MS, Hsu YL, Fung RF (2012) Minimum-energy point-to-point trajectory planning for a motor-toggle servomechanism. IEEE/ASME Trans Mechatron 17(2):337–343
Li X, Jin Z, Zhang Y, Zhuang J, Zhou G, Wang L (2010) Kinematic calculation analysis of micro injection molding machine with double-toggle clamping mechanism based on MATLAB. In: 2nd International conference on electronic and mechanical engineering and information technology (EMEIT-2012), pp 1746–1750. https://doi.org/10.2991/emeit.2012.387
Lu Y, Ye N, Lu Y, Mao B, Zhai X, Hu B (2012) Analysis and determination of associated linkage, redundant constraint, and degree of freedom of closed mechanisms with redundant constraints and/or passive degree of freedom. J Mech Des 134(6):061002-1–061002-9
Pedersen CBW, Fleck NA, Ananthasuresh GK (2006) Design of a compliant mechanism to modify an actuator characteristic to deliver a constant output force. J Mech Des 128(5):1101–1112
Pennock GR, Hasan A (2002) A polynomial equation for a coupler curve of the double butterfly linkage. J Mech Des 124(1):39–46
Pennock GR, Israr A (2009) Kinematic analysis and synthesis of an adjustable six-bar linkage. Mech Mach Theory 44(2):306–323
Persinger JA, Schmiedeler JP, Murray AP (2009) Synthesis of planar rigid-body mechanisms approximating shape changes defined by closed curves. J Mech Des 131(7):071006-1–071006-7
Rao AC, Srinath A (2007) Planar linkages: structural influence on mechanical advantage and function generation. Mech Mach Theory 42(4):472–481
Shi Z, Yang X, Yang W, Cheng Q (2005) Robust synthesis of path generating linkages. J Mech Mach Theory 40(1):45–54
Tsai M, Lai TH (2004) Kinematic sensitivity analysis of linkage with joint clearance based on transmission quality. J Mech Mach Theory 39(11):1189–1206
Tso P (1998) The kinematic synthesis of toggle clamps. J Manuf Sci Eng 120(3):648–655
Acknowledgements
Authors would like to thank Mr. S. B. Nandeppagoudar, Managing Director of Naveen Hydro-Controls, Pune, Maharashtra, India, for providing the required technical and experimental support.
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interests
The authors declare that there is no conflict of interest regarding the publication of this paper.
Rights and permissions
About this article
Cite this article
Gawande, S.H., Bhojane, S.A. Numerical and Experimental Design Optimization of Toggle Clamping Mechanism. Iran J Sci Technol Trans Mech Eng 43, 763–779 (2019). https://doi.org/10.1007/s40997-018-0237-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s40997-018-0237-y