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Toggle Clamp Mechanism Simulator

Over-center force amplification, lock-margin design, pin and link stress sizing, and a design recipe for selecting a real clamp from catalog references. Covers four manual geometries plus pneumatic actuation.

Toggle Clamp Experiments FreeCAD Parametric Lesson Product Page

Parameters

Geometry (mm)
40 mm
110 mm
80 mm
55 mm
110 mm
-44°
70 mm
5°
Forces and material
100 N
0.12
0.75
8 mm
6 mm
20 mm
Material strength
350 MPa
2.0

Allowable stress = yield ÷ safety factor. The dashed lines on the stress chart show the bending (σ) and shear (τ) limits.

Manual handle position
80.0°

Drag the slider to manually move the handle from open through TDC to the locked stop.

Analysis Charts

Every curve is swept across the handle's travel from open through top-dead-centre (TDC) to the locked stop. On each chart the red line marks TDC, the amber line the lock position, and the teal line the current handle angle. Drag the handle or any parameter and the charts update live.

Compare two configurations:
Force amplification
Mechanical advantage
Clamping force
Transmission angle

Mechanical advantage

MA at lock (engineering)
–
Peak MA over travel
–
Rigid MA at lock
–

Clamping force

F_pad at lock
–
Peak F_pad over travel
–
Handle force input
–

Transmission angle

μ at lock
–
Minimum μ over travel
–
Quality (≥ 40° good)
–
Loads and sizing
Pin reactions
Link & pin stress
Pad position

Pin reactions

Max reaction at O₂
–
Max reaction at O₄
–
Reaction at lock (O₄)
–

Stress

Link bending at lock
Pin shear at lock
–
Allowable σ / τ
–
Sizing verdict
–

Pad output

Pad travel (open → lock)
–
Pad height at lock
–
Handle sweep
–

Download Professional Resources

Generated for your exact clamp parameters: data, design specs, and a complete lab report.

📊
Lab Report
Complete report with watermark-free mechanism diagram and all 6 analysis graphs. Includes .MD, .PNG images, and a .DOCX converter.
1 USD
📈
Experimental Data
Full analysis dataset (241 points, 11 variables: MA, clamping force, transmission angle, pin reactions, stresses) in .CSV format for your exact parameters.
1 USD
📐
Design Data + Animation
Manufacturing specs and sizing check in .TXT, watermark-free .PNG, and the full open-to-lock cycle as a .WEBM video.
1 USD

All resources generated for your exact clamp parameters. 1 USD per item, or buy all as a package.