Padal Oprated Hacksaw

AJAY KUMAR/ 3068140001/MECHANICAL ENGINEERING/ GET GROUP INSTITUTE
INTRODUCTION :-
Pedal power is the tr.ansfer of energy from a human source through the
use of a foot pedal and crank system. This technology is most commonly
used for transportation and has been used to propel bicycles for over a
hundred years. Less commonly pedal power is used to power
agricultural and hand tools and even to generate electricity. Some
applications include pedal powered laptops, pedal powered grinders and
pedal powered water wells. Some third world development projects
currently transform used bicycles into pedal powered tools for
sustainable development.
This project concentrates on pedal powered hacksaw machining. An

individual can generate four times more power (1/4 HP) by pedalling
than by hand-cranking. At the rate of HP, continuous pedalling can be
served for only short periods, approximately 10 minutes. However,
pedalling at half this power (1/8 HP) can be sustained for close to 60
minutes but power capability can depend upon age. As a consequence of
the brainstorming exercise, it was apparent that the primary function of
pedal power one specific product was particularly useful: the bicycle.
Many devices can be run right away with mechanical energy. A saw is a
tool that uses a hard blade or wire with an abrasive edge to cut through
softer materials. The cutting edge of a saw is either a serrated blade or an
abrasive. A saw may be worked by hand, or powered by steam, water,
1
electric or other power. An abrasive saw uses an abrasive disc or band

for cutting, rather than a serrated blade.
2
Main Components of Pedal Powered Hacksaw Machine :-
Pedal
Sprocket
Chain
Crank
Connecting Rod
Flywheel
Bearing Blocks
Hacksaw
Blade
3
A bicycle pedal is the part of a bicycle that the rider pushes with their
foot to propel the bicycle. It provides the connection between the
cyclists foot or shoe and the crank allowing the leg to turn the bottom
bracket spindle and propel the bicycle's wheels.
Pedals were initially attached to cranks connecting directly to the driven

(usually front) wheel. The safety bicycle, as it is known today, came into
being when the pedals were attached to a crank driving a sprocket that
transmitted power to the driven wheel by means of a roller chain. Pedals
usually consist of a spindle that threads into the end of the crank and a
body, on which the foot rests or is attached, that is free to rotate on
bearings with respect to the spindle.
Pedal will be used to transfer our muscular energy to the large

sprocket.
4
2. Sprocket:-
A sprocket or sprocket-wheel is a profiled wheel with teeth, cogs,or

even sprockets that mesh with a chain,track or other perforated or
indented material. The name 'sprocket' applies generally to any wheel
upon which radial projections engage a chain passing over it. It is
distinguished from a gear in that sprockets are never meshed together
directly, and differs from a pulley in that sprockets have teeth and
pulleys are smooth.
Sprockets are used in bicycles, motorcycles, cars, tracked vehicles, and

other machinery either to transmit rotary motion between two shafts
where gears are unsuitable or to impart linear motion to a track, tape
etc. Perhaps the most common form of sprocket may be found in the
bicycle, in which the pedal shaft carries a large sprocket-wheel
which drives a chain, which, in turn, drives a small sprocket on the axle
of the rear wheel . Early automobiles were also largely driven by
sprocket and chain mechanism, a practice largely copied from bicycles.
Sprockets are of various designs, a maximum of efficiency being

claimed for each by its originator. Sprockets typically do not have
aflange. Some sprockets used with timing belts have flanges to keep the
timing belt centered. Sprockets and chains are also used for power
transmission from one shaft to another where slippage is not admissible,
5
sprocket chains being used instead of belts or ropes and sprocket-wheels

instead of pulleys. They can be run at high speed and some forms of
chain are so constructed as to be noiseless even at high speed.
Larger sprocket will take the energy from pedal and transfer it to
the smaller sprocket which will further transmit it to the shaft.
3. Sprocket chain :-
Sprocket Chain:
Roller chain or bush roller chain is the type of chain drive most
commonly used for transmission A sprocket or sprocket-wheel is a
profiled wheel with teeth, cogs, or even sprockets that mesh with
a chain, track or other perforated or indented material. The name
6
'sprocket' applies generally to any wheel upon which radial projections

engage a chain passing over it. It is distinguished from a gear in that
sprockets are never meshed together directly, and differs from
a pulley in that sprockets have teeth and pulleys are smooth.
It consists of a series of short cylindrical rollers held together by side

links. It is driven by a toothed wheel called a sprocket. It is a simple,
reliable, and efficient means of power transmission.
Construction of the Chain:
There are actually two types of links alternating in the bush roller chain.
The first type is inner links, having two inner plates held together by two
sleeves or bushings upon which rotate two rollers. Inner links alternate
with the second type, the outer links, consisting of two outer plates held
together by pins passing through the bushings of the inner links. The
"bushingless" roller chain is similar in operation though not in
construction; instead of separate bushings or sleeves holding the inner
plates together, the plate has a tube stamped into it protruding from the
hole which serves the same purpose. This has the advantage of removing
one step in assembly of the chain.
The roller chain design reduces friction compared to simpler designs,

resulting in higher efficiency and less wear. The original power
transmission chain varieties lacked rollers and bushings, with both the
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inner and outer plates held by pins which directly contacted

the sprocket teeth; however this configuration exhibited extremely rapid
wear of both the sprocket teeth, and the plates where they pivoted on the
pins. This problem was partially solved by the development of bushed
chains, with the pins holding the outer plates passing through bushings
or sleeves connecting the inner plates. This distributed the wear over a
greater area; however the teeth of the sprockets still wore more rapidly
than is desirable, from the sliding friction against the bushings. The
addition of rollers surrounding the bushing sleeves of the chain and
provided rolling contact with the teeth of the sprockets resulting in
excellent resistance to wear of both sprockets and chain as well. There is
even very low friction, as long as the chain is sufficiently lubricated.
Continuous, clean, lubrication of roller chains is of primary importance
for efficient operation as well as correct tensioning.
Sprocket chain will transfer motion from the large sprocket to the
small sprocket.
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4. Crank :-
A crank is a mechanical part able to perform a conversion

between reciprocating motion and rotational motion. In a reciprocating
engine, it translates reciprocating motion of the piston into rotational
motion; whereas in a reciprocating compressor, it converts the rotational
motion into reciprocating motion. In order to do the conversion between
two motions, the crankshaft has "crank throws" or "crankpins",
additional bearing surfaces whose axis is offset from that of the crank, to
which the "big ends" of the connecting rods from each cylinder attach.
It is typically connected to a flywheel to reduce the pulsation

characteristic of the four-stroke cycle, and sometimes a torsional or
vibrational damper at the opposite end, to reduce the torsional
vibrations often caused along the length of the crankshaft by the
cylinders farthest from the output end acting on the torsional elasticity of
the metal.
Crank will convert rotary motion of shaft into the reciprocating

motion which will further transmit to the hack saw assembly.
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5. Connecting Rod :-
The connecting rod connects the piston to the crank or crankshaft.

Together with the crank, they form a simple mechanism that converts
reciprocating motion into rotating motion.
Connecting rods may also convert rotating motion into reciprocating

motion. Historically, before the development of engines, they were first
used in this way.
As a connecting rod is rigid, it may transmit either a push or a pull and

so the rod may rotate the crank through both halves of a revolution, i.e.
10
piston pushing and piston pulling. Earlier mechanisms, such as chains,

could only pull. In a few two-stroke engines, the connecting rod is only
required to push.
Today, connecting rods are best known through their use in internal
combustion piston engines, such as automotive engines. These are of a
distinctly different design from earlier forms of connecting rods, used in
steam engines and steam locomotives.
We are using the connecting rod to convert the rotary motion of

crank into reciprocating motion and supplied it to the hack saw
assembly.
6.Flywheel:
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A flywheel is a rotating mechanical device that is used to store rotational

energy. Flywheels have an inertia called the moment of inertia and thus
resist changes in rotational speed. The amount of energy stored in a
flywheel is proportional to the square of its rotational speed. Energy is
transferred to a flywheel by the application of a torque to it, thereby
increasing its rotational speed, and hence its stored energy. Conversely, a
flywheel releases stored energy by applying torque to a mechanical load,
thereby decreasing the flywheel's rotational speed.
Common uses of a flywheel include:

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Providing continuous energy when the energy source is

discontinuous. For example, flywheels are used in reciprocating
engines because the energy source, torque from the engine, is
intermittent.
Delivering energy at rates beyond the ability of a continuous

energy source. This is achieved by collecting energy in the flywheel
over time and then releasing the energy quickly, at rates that exceed
the abilities of the energy source.
Controlling the orientation of a mechanical system. In such

applications, the angular momentum of a flywheel is purposely
transferred as a torque to the attaching mechanical system when
energy is transferred to or from the flywheel, thereby causing the
attaching system to rotate into some desired position.
Flywheels are typically made of steel and rotate on conventional

bearings; these are generally limited to a revolution rate of a few
thousand RPM. Some modern flywheels are made of carbon fibre
materials and employ magnetic bearings, enabling them to revolve at
speeds up to 60,000 RPM.
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Carbon-composite flywheel batteries have recently been manufactured

and are proving to be viable in real-world tests on mainstream cars.
Additionally, their disposal is more eco-friendly.
As our hack saw assembly is inclined, wehave to provide more

energy to lift up the hack saw assembly. Flywheel will store the
energy during downward stroke and supply the stored energy
during upward stroke to lift up the hack saw assembly.
Bearing Blocks :-
A bearing is a machine element that constrains relative motion to only

the desired motion, and reduces friction between moving parts. The
design of the bearing may, for example, provide for
free linear movement of the moving part or for free rotation around a
fixed axis; or, it may prevent a motion by controlling
the vectors of normal forces that bear on the moving parts. Many
bearings also facilitate the desired motion as much as possible, such as
by minimizing friction. Bearings are classified broadly according to the
type of operation, the motions allowed, or to the directions of the loads
(forces) applied to the parts.
The term "bearing" is derived from the verb "to bear"; a bearing being a
machine element that allows one part to bear (i.e., to support) another.
14
The simplest bearings are bearing surfaces, cut or formed into a part,
with varying degrees of control over the form, size, roughness and
location of the surface. Other bearings are separate devices installed into
a machine or machine part. The most sophisticated bearings for the most
demanding applications are very precise devices; their manufacture
requires some of the highest standards of current technology.
Bearing blocks will be used to provide support to the rotating shaft

on which flywheel, crank, clutch, brakes, and sprocket are mounted.
15
. HackSaw:-
A hacksaw is a fine-toothed saw, originally and principally for

cutting metal. They can also cut various other materials, such as plastic
and wood; for example, plumbers and electricians often cut plastic
pipe and plastic conduit with them. There are hand saw versions and
powered versions (power hacksaws). Most hacksaws are hand saws with
a C-shaped frame that holds a blade under tension. Such hacksaws have
a handle, usually a pistol grip, with pins for attaching a narrow
disposable blade. The frames may also be adjustable to accommodate
blades of different sizes. A screw or other mechanism is used to put the
thin blade under tension. Panelhacksaws forgo the frame and instead
have a sheet metal body; they can cut into a sheet metal panel further
than a frame would allow. These saws are no longer commonly
available, but hacksaw blade holders enable standard hacksaw blades to
be used similarly to a keyhole saw or pad saw. Power tools including
nibblers, jigsaws, and angle grinders fitted with metal-cutting blades and
discs are now used for longer cuts in sheet metals.
On hacksaws, as with most frame saws, the blade can be mounted with
the teeth facing toward or away from the handle, resulting in cutting
action on either the push or pull stroke. In normal use, cutting vertically
downwards with work held in a bench vice, hacksaw blades should be
set to be facing forwards. Some frame saws, including Fret Saws and
16
Piercing Saws, have their blades set to be facing the handle because they
are used to cut by being pulled down against a horizontal surface.
Blade:-
Blades are available in standardized lengths, usually 10 or 12 inches for

a standard hand hacksaw. "junior" hacksaws are typically 150mm long.
Powered hacksaws may use large blades in a range of sizes, or small
machines may use the same hand blades.
The pitch of the teeth can be anywhere from fourteen to thirty-two teeth
per inch (tpi) for a hand blade, with as few as three tpi for a large power
hacksaw blade. The blade chosen is based on the thickness of the
material being cut, with a minimum of three teeth in the material. As
hacksaw teeth are so small, they are set in a "wave" set. As for other
saws they are set from side to side to provide a kerf or clearance when
17
sawing, but the set of a hacksaw changes gradually from tooth to tooth
in a smooth curve, rather than alternate teeth set left and right.
Hacksaw blades are normally quite brittle, so care needs to be taken to

prevent brittle fracture of the blade. Early blades were of carbon steel,
now termed 'low alloy' blades, and were relatively soft and flexible.
They avoided breakage, but also wore out rapidly. Except where cost is
a particular concern, this type is now obsolete. 'Low alloy' blades are
still the only type available for the Junior hacksaw, which limits the
usefulness of this otherwise popular saw.
18
For several decades now, hacksaw blades have used high speed steel for
their teeth, giving greatly improved cutting and tooth life. These blades
were first available in the 'All-hard' form which cut accurately but were
extremely brittle. This limited their practical use to benchwork on a
workpiece that was firmly clamped in a vice. A softer form of high speed
steel blade was also available, which wore well and resisted breakage,
but was less stiff and so less accurate for precise sawing. Since the
1980s, bi-metal blades have been used to give the advantages of both
forms, without risk of breakage. A strip of high speed steel along the
tooth edge is electron beam welded to a softer spine. As the price of
these has dropped to be comparable with the older blades, their use is
now almost universal.
Selection of blade:-
Proper blade selection is important. Use the three-tooth ruleatleast three

teeth must be in con-tact with the work. Large sections and soft
materialsrequire a coarse-tooth blade. Small or thin work and hard
materials require a fine-tooth blade.
For best cutting action, apply heavy feed pressure on hard materials and
large work. Use light feed pressure on soft materials and work with
small cross sections.
Blades are made in two principal types: flexible-back and all-hard. The
choice depends upon use.
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i) Flexible-back blades -should be used where safety requirements

demand a shatterproof blade. These blades should also be used for
cutting odd-shaped work if there is a possibility of the work coming
loose in the vise.
ii) All-hard blade -For a majority of cutting jobs, theall-hard bladeis best
for straight, accurate cutting under a variety of conditions.
When starting a cut with an all-hard blade, be sure the blade does not
drop on the work when cutting starts. If it falls, the blade could shatter
and flying pieces cause injuries.
Power Hacksaw blade :-
Blades are also made from tungsten and molybdenum steels, and with
tungsten carbide teeth on steel alloy backs. The following rule-of-
thumb can be followed for selecting the correct blade:
Use a 4-tooth blade for cutting large sections or readily machined

metals.
Use a 6-tooth blade for cutting harder alloys and miscellaneous cutting.
Use 10- and 14-tooth blades primarily on light duty machines where
work is limited to small sections requiring moderate or light feed
pressure.
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Mounting a Power Hacksaw blade:-
The blade must be mounted to cut on the power (back) stroke. The blade
must also lie perfectly flat against the mounting plates. If long lifeand
accurate cuts are to be achieved, the blade must be properly tensioned.
Many techniques have been developed for properly mounting and

tensioning blades. Use a torque wrench and consult the manufacturers
literature. If the information (proper torque for a given blade on a given
machine) is not available, the following methods can be used:
Tighten the blade until a low musical ring is heard when the blade is
tapped lightly. A highpitched tone indicates that the blade is too tight. A
21
dull thud means the blade is too loose. The shape of the blade pin hole
can serve as an indicator of whether the blade is tensioned properly.
When proper tension is achieved, the pin holes will become slightly
elongated, The blade will become more firmly seated after the first few
cuts and will stretch slightly. The blade will require re-tensioning
(retightening) before further cutting can be done.
WORKING PRINCIPLE
It consists of the pedal arrangement which rotates the crank and through
it slider consists of oscillating mechanism. The power is transmitted to
the crank and slider mechanism. This mechanism is used to rotate the
crank disc; the disc which is having an extended rod is connected to the
sliding portion of the hacksaw directly by means of a linkage. The
hacksaw is passed through the guide ways by means of maintaining the
cutting axis. As the user operated the pedal, the hack saw cuts the
various materials automatically with less power. The dead weight is for
compressive force while the user operated the foot pedal.
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ADVANTAGES:-
I. Time saving as compared to simple hacksaw
II. Power saving as it is manually operated
III. Easy machinery used
IV. As it is pedal operated so good for health
V. Comfortable then ordinary hacksaw
VI. It is portable
23
VII. It could be used wherever metal cutting is done in small scales,

including at construction sites and furniture units, or to cut metal for
window panes.
DISADVANTAGES:-
I. Its totally manually operated
II. Time consuming as compared to electrical power hacksaw
III. Without human effort its not operated
IV. Not fit for heavy production
Calculations:-
Chain Driver Sprocket
Driven Sprocket
Radius of Driver Sprocket = R1

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Radius of Driven Sprocket = R2
No. of teeths on Driver Sprocket = T1
No. of teeths on Driven Sprocket = T2
Pitch of the Chain = P
Teeth Ratio = T1/T2
Velocity Ratio = (T1/T2 = N2/N1)
R1 = P/2 cosec ( 180 / T1 )
R2 = P/2 cosec ( 180 / T2)
Length of the chain = (R1 + R2) + 2x + (R1 R2)2/x
Input Power = 2 N T / 60
where, N = Sprocket speed in rpm
T = Torque applied by human in Nm
T=Fxr
where, F = Force applied by human in N
r = Length of pedal arm
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Now, we can increase the torque by increasing the length of pedal from
its centre.
The cutting force required = x D x t x s
where D = Diameter of workpiece
t = Cutting Depth
s= Shear strength of material
In case of rectangular workpiece,
Fmax = 2 x (B+L) x t x s
where, B = Breadth of workpiece
L = Length of workpiece
Maximum power required = Fmax x V
where, V = velocity of blade
26
References:
1. Theory of Machines By R.S. Khurmi and J.K Gupta,1st

multicolour edition .
2. A Textbook of Production Engineering byP.C.Sharma
27

Padal Oprated Hacksaw

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AJAY KUMAR/ 3068140001/MECHANICAL ENGINEERING/ GET GROUP INSTITUTE

This project concentrates on pedal powered hacksaw machining. An

electric or other power. An abrasive saw uses an abrasive disc or band

Main Components of Pedal Powered Hacksaw Machine :-

Pedals were initially attached to cranks connecting directly to the driven

Pedal will be used to transfer our muscular energy to the large

A sprocket or sprocket-wheel is a profiled wheel with teeth, cogs,or

Sprockets are used in bicycles, motorcycles, cars, tracked vehicles, and

Sprockets are of various designs, a maximum of efficiency being

sprocket chains being used instead of belts or ropes and sprocket-wheels

'sprocket' applies generally to any wheel upon which radial projections

It consists of a series of short cylindrical rollers held together by side

Construction of the Chain:

The roller chain design reduces friction compared to simpler designs,

inner and outer plates held by pins which directly contacted

A crank is a mechanical part able to perform a conversion

It is typically connected to a flywheel to reduce the pulsation

Crank will convert rotary motion of shaft into the reciprocating

The connecting rod connects the piston to the crank or crankshaft.

Connecting rods may also convert rotating motion into reciprocating

As a connecting rod is rigid, it may transmit either a push or a pull and

piston pushing and piston pulling. Earlier mechanisms, such as chains,

We are using the connecting rod to convert the rotary motion of

A flywheel is a rotating mechanical device that is used to store rotational

Common uses of a flywheel include:

Providing continuous energy when the energy source is

Delivering energy at rates beyond the ability of a continuous

Controlling the orientation of a mechanical system. In such

Flywheels are typically made of steel and rotate on conventional

Carbon-composite flywheel batteries have recently been manufactured

As our hack saw assembly is inclined, wehave to provide more

A bearing is a machine element that constrains relative motion to only

Bearing blocks will be used to provide support to the rotating shaft

A hacksaw is a fine-toothed saw, originally and principally for

Blades are available in standardized lengths, usually 10 or 12 inches for

Hacksaw blades are normally quite brittle, so care needs to be taken to

Proper blade selection is important. Use the three-tooth ruleatleast three

i) Flexible-back blades -should be used where safety requirements

Power Hacksaw blade :-

Use a 4-tooth blade for cutting large sections or readily machined

Mounting a Power Hacksaw blade:-

Many techniques have been developed for properly mounting and

I. Time saving as compared to simple hacksaw

II. Power saving as it is manually operated

III. Easy machinery used

IV. As it is pedal operated so good for health

V. Comfortable then ordinary hacksaw

VII. It could be used wherever metal cutting is done in small scales,

I. Its totally manually operated

II. Time consuming as compared to electrical power hacksaw

III. Without human effort its not operated

IV. Not fit for heavy production

Chain Driver Sprocket

Radius of Driver Sprocket = R1

Radius of Driven Sprocket = R2

No. of teeths on Driver Sprocket = T1

No. of teeths on Driven Sprocket = T2

Pitch of the Chain = P

Teeth Ratio = T1/T2

Velocity Ratio = (T1/T2 = N2/N1)

R1 = P/2 cosec ( 180 / T1 )

R2 = P/2 cosec ( 180 / T2)

Length of the chain = (R1 + R2) + 2x + (R1 R2)2/x

where, N = Sprocket speed in rpm