MACHINE DESIGN - An Integrated Approach, 4th Ed.

Case Study 2A-1

CASE STUDY 2A

Hand-Operated Crimping-Tool Loading Analysis

Problem: Determine the forces on the elements of the crimping tool shown in Figure 3-3
during a crimp operation.
Given: The geometry is known and the tool develops a crimp force of 2000 lb (8896 N)
at closure in the position shown.
Applied crimp force Fc4x  1956.30  lbf
Fc4y  415.82 lbf
Positon vector components
Rc4x  0.454  in R12x  1.399  in R32x  2.199  in
Rc4y  0.337  in R12y  0.049  in R32y  0.077  in

R23x  0.602  in R43x  0.602  in R14x  0.161  in

R23y  0.127  in R43y  0.127  in R14y  0.758  in

R34x  0.161  in R34y  0.758  in Rhand  4.40 in

Assumptions: The accelerations are negligible. All forces are coplanar and two-dimensional.
A class 1 load model is appropriate and a static analysis is acceptable.
Solution: See Figures 3-3, 3-4, Table 3-3 parts 1 and 2, and Mathcad file CASE2A.
1. Figure 3-3 shows the tool in the closed position, in the process of crimping a metal connector onto a wire.
The user's hand provides the input forces between links 1 and 2, shown as the reaction pair Fhand. The user
can grip the handle anywhere along its length but we are assuming a nominal moment arm of Rhand for the
application of the resultant of the user's grip force (see Figure 3-4). The high mechanical advantage of the
tool transforms the grip force to a large force at the crimp.

Figure 3-3 is a free-body diagram of the entire assembly,neglecting the weight of the tool, which is small
compared to the crimp force. There are four elements, or links, in the assembly, all pinned together. Link 1
can be considered to be the "ground" link, with the other links moving with respect to it as the jaw is closed.
The desired magnitude of the crimp force Fc is defined and its direction will be normal to the surfaces at the
crimp.
2. Figure 3-4 shows the elements of the crimping tool assembly separated and drawn as free-body diagrams with
all forces applied to each element, again neglecting their weights as being insignificant compared to the
applied forces. The centers of gravity of the respective elements are used as the origins of the local,
nonrotating coordinate systems in which the points of application of all forces on the element are located.
(See footnote on page 116 of the text).

3. We will consider link 1 to be the ground plane and analyze the remaining moving links. Note that all
unknown forces and moments are initially assumed positive. Link 4 has three forces acting on it: Fc4 is the
known (desired) force at the crimp, and F14 and F34 are the reaction forces from links 1 and 3, respectively.
The magnitudes of these two forces are unknown as is the direction of F14. The direction of F34 will be the
same as link 3, since it is a two-force member. Writing equations 3.3b for this element:

ΣFx = F14x  F34x  Fc4x = 0 ΣMz =  R14x F14y  R14y F14x   = 0
  R34x F34y  R34y F34x 
ΣFy = F14y  F34y  Fc4y = 0   R  F  R  F   (a)
 c4x c4y c4y c4x 

We have three equations and four unknowns (F14x, F14y, F34x, F34y) at this point, so we need another
equation. It is available from the fact that the direction of F34 is known. We can express one component of

CASE2A.xmcd
MACHINE DESIGN - An Integrated Approach, 4th Ed. Case Study 2A-2
the force F34 in terms of its other component and the known angle 3 of link 3.

F34y = F34x tan  θ3 (b)

where θ3  168  deg (c)

Guess F14x  500  lbf F34x  1000 lbf

F14y  100  lbf F34y  100  lbf

Given F14x  F34x  Fc4x = 0  Rc4x Fc4y  Rc4y Fc4x   = 0

  R14x F14y  R14y F14x 
F14y  F34y  Fc4y = 0   R  F  R  F  
 34x 34y 34y 34x 
F34y = F34x tan  θ3

 F14x 
F 
 14y   Find  F F F F 
 F34x  14x 14y 34x 34y

 
 F34y 
Components of the unknown forces F14, and F34

F14x  442.9 lbf F34x  1513.4 lbf

F14y  94.1 lbf F34y  321.7 lbf

4. Link 3 has two forces on it, F23 and F43. Because this is a two-force link, these two forces are equal in magnitud
and opposite in direction. Also, from Newton's third law, F43 = - F34. Thus,

F43x  F34x F23x  F43x

(d)
F43y  F34y F23y  F43y

F43x  1513.4 lbf F23x  1513.4 lbf

F43y  321.7 lbf F23y  321.7 lbf

5. Link 2 has three forces acting on it: Fhand is the unknown force from the hand, and F12 and F32 are the reaction
forces from links 1 and 3, respectively. Force F12 is provided by part 1 on part 2 at the pivot pin and force F32
is provided by part 3 acting on part 2 at their pivot pin. The magnitude and direction of F32 is known and the
direction of Fhand is known. Using equations 3.3b, we can solve for the magnitude of Fhand and the two
components of F12. From the third law,

F32x  F23x F32x  1513.4 lbf

F32y  F23y F32y  321.7 lbf

ΣFx = F12x  F32x = 0 ΣFy = Fhand  F12y  F32y = 0

ΣMz = R12  F12  R32  F32   Rhand  Fhand  = 0 (e)

CASE2A.xmcd
MACHINE DESIGN - An Integrated Approach, 4th Ed. Case Study 2A-3

Guess F12x  1500 lbf F12y  100  lbf Fhand  100  lbf

Given
F12x  F32x = 0 F12y  F32y  Fhand = 0

 F12x 
 R12x F12y  R12y F12x   = 0  
  R32x F32y  R32y F32x   F12y   Find F12x F12y Fhand 
 R  F  F 
 hand hand   hand 
F12x  1513.4 lbf F12y  373.4 lbf Fhand  51.7 lbf

6. The four forces on link 1 can now be determined using the third law.

F21x  F12x F41x  F14x

F21y  F12y F41y  F14y

F21x  1513.4 lbf F41x  442.9 lbf

F21y  373.4 lbf F41y  94.1 lbf

Fc1x  Fc4x Fc1x  1956.3 lbf

Fc1y  Fc4y Fc1y  415.8 lbf

7. The solution to this problem for the scaled dimensions in Figure 3-3 assuming a 2000-lb (8896-N) force
applied at the crimp, normal to the crimp surface, is given above. The total forces at the pivot points
are:

0.5
F12   F12x  F12y
2 2
Pivot A  F12  1558.8 lbf

0.5
F32   F32x  F32y
2 2
Pivot B  F32  1547.2 lbf

0.5
F43   F43x  F43y
2 2
Pivot C  F43  1547.2 lbf

0.5
F14   F14x  F14y
2 2
Pivot D  F14  452.8 lbf

The moment that must be applied to the handles to generate the crimp force of
0.5
Fc4   Fc4x  Fc4y
2 2
Crimp force  Fc4  2000 lbf

Moment Mh  Rhand  Fhand Mh  227.4 lbf  in

8. This moment can be obtained with a force of Fhand  51.7 lbf applied at mid-handle. This force is within the
physiological grip-force capacity of the average human.

CASE2A.xmcd