DESIGN AND FABRICATION OF AUTOMATIC

PNEUMATIC GROUND CLEARANCE ADJUSTMENT

SYSTEM

A PROJECT REPORT

Submitted by

NAME OF THE CANDIDATES

K.VIGNESH (411515114221)

E.YOGESH (411515114240)

B.SHIVANESAN (411515114195)

B.SURESH (411515114208)

In partial fulfilment for the award of the degree

Of

BACHELOR OF ENGINEERING
In
MECHANICAL ENGINEERING

PERI INSTITUTE OF TECHNOLOGY, MANNIVAKKAM

ANNA UNIVERSITY, CHENNAI-600048

 APRIL 2019

ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE

DEPARTMENT OF MECHANICAL ENGINEERING

Certified that this project report “ AUTOMATIC PNEUMATIC GROUND

CLEARANCE ADJUSTMENT SYSTEM ”is the bonafide work of

“K.VIGNESH (411515114221), E.YOGESH (411515114240),

B.SHIVANESAN (411515114195)& B.SURESH (411515114208)

who carried out the project work under my supervision.

SIGNATURE SIGNATURE

Mr. Bertram Nirmal Philip B.E,, Mr. P. Dhilip Kumar M.E.,

M.E.,
HEAD OF DEPARTMENT
Department of Mechanical
Engineering,
Peri Institute Of Technology,
Chennai-600 028.
ASSISTANT PROFESSOR
Department of Mechanical
Engineering,
Peri Institute Of Technology,
Chennai-600 028.

Submitted for project viva-Voice held on ________________

 CERTIFICATE OF EVALUATION

COLLEGE NAME: PERI INSTITUTE OF TECHNOLOGY

BRANCH: MECHANICAL ENGINEERING

SEMESTER: VI

S. Name of the Students Title of the Name of the

who Project Supervisor with
No. have done the project designation

1. K.VIGNESH Mr. P. Dhilip

PEDAL POWER Kumar M.E.

2. E.YOGESH HACKSAW Associate Professor

Department of
3. B.SIVANESAN Mechanical
Engineering
4. V.VINEETH KUMAR

This report of project work submitted by the above students in partial

fulfilment for the award of Bachelor of Mechanical Engineering Degree in Anna
University were evaluated and conformed to be reports of the work done by the
above students and then evaluated.

Submitted for UNIVERSITY VIVA EXAMINATION held on…………………

INTERNAL EXAMINER EXTERNAL EXAMINER

 ACKNOWLEDGEMENT

We would like to express our sincere thanks and gratitude to our

collegeChairman Mr. SARAVANAN PERIASAMY, Peri Institute Of
Technology & CEO,PERI SOFTWARE SOLUTIONS INC., U.S.A.,

Principal Mr. R. PALSON KENNEDY, Peri Institute of

Technology, for giving us this opportunity to carry out this project.
We extend our thanks to the Head of the Department of
Mechanical Engineering, Mr. Bertram Nirmal Philip B.E, M.E., for his
valuable support and cooperation.
We also thank, Mr. Dhilip Kumar B.E, M. Tech. Associate
Professor Lecturer-Department of Mechanical Engineering for his
guidance and timely suggestions which helped us to complete this
project.
Finally, Mr. SENTHIL M.E, of Mechanical Engineering for his
constant support and guidance throughout the process of the project.
 ABSTRACT

The handling of vehicle depends upon the various parameters, centre of

gravity of the vehicle is one of them. For better handling of the vehicle

we need to keep centre of gravity as low as possible. For sport cars it is

always kept low but for the passenger cars it compromises with its ground

clearance. The designers prefer to maintain fixed ground clearance and

design the system to acquire needed suspension parameters. For different

type of tracks, the ground clearance of vehicle is designed actually for

Off-road vehicles have to face the rough terrain, where we need the high

ground clearance of the vehicle, on the other hand we run the same

vehicle on a road where high ground clearance is not necessary. Whereas

a sedan car or hatchback has to run on smooth roads as well as on rough

terrains sometime with its fixed lower ground clearance which tends to

create dents on the bottom portion of the car. In both cases we need an

adjustable ground clearance system in the vehicle to have optimum

performance. Here this paper introduces the pneumatic lifting technique

which is used to provide the higher ground clearance at the time of rough

roads/breakers and lower the same to get proper ground clearance to

maintain the stability at high speed on smooth roads automatically by

introducing IR sensors.
 TABLE OF CONTENTS

CHAPTER NO TITLE PAGE NO

ABSTRACT I

LIST OF TABLES II

LIST OF FIGURES III

LIST OF ABBREVATION

1. INTRODUCTION

2. LITERATURE REVIEW

3. COMPONENTS REQUIRED

3.1 Pedal power hacksaw

3.1.1 Selecting A Power Hacksaw

blade

3.1.2 Mounting a Power Hacksaw

blade

3.1.3 Selecting a Band Saw Blade

3.1.4 Installing a Band Saw Blade

3.2 Pedal arrangement

3.2.1 Pedal
 3.3 Stand Setup Parts

3.4 Metal Slab

3.5 Bench vice

3.6 Crank

4. WORKING PRINCIPLE

5. DESIGN

5.1 Base Frame

5.2 Upright Support

5.3 Hacksaw blade

5.4 Design Consideration

5.5 Fabrication

5.6 Machining

5.6.1 Cutting

5.6.2 Drilling

5.6.3 machining

5.6.4 Welding

6. DESIGN CALCULATION

7. ADVANTAGES,DISADVANTAGES

,APPLICATIONS&FUTURE
 SCOPE

7.1 Advantages

7.2 Dis advantages

7.3 Applications

7.4 Future scope

8. CONCLUSION

9. REFERENCES

10.
 LIST OF FIGURES

Figure no Figure name Page no

2.1. A reciprocating power hacksaw
2.2 Pressure feed
2.3 Bandsaw blade
2.4 Pedal
2.5 Pedal power attachment
2.6 Bicycle stand
2.7 Metal slab
2.8 Stop gauge
2.9 Vise
2.10 Crank
2.11 Ball bearing
2.12 Crank &slider mechanism
3.1 Working
4.1 Base assembling
4.2 Upright support assembling
4.3 Hacksaw blade
4.4 Drilling machine
4.5 Lathe machine
4.6 Welding machine
6.1 Rice threshing
6.2 Winnowing
6.3 Corn shelling
6.4 Pedal power lathe
 LIST OF ABBREVIATIONS

S.NO ACRONYM EXPANSION

1. H.P HORSE POWER
2. TPI TOOTH PER INCH
3. PVC POLYMERIZING VINYL CHLORIDE
4. RPM REVOLUTION PER MINUTE
5. CNC COMPUTER NUMERICAL CONTROL

LIST OF TABLES

S.NO TABLE NO. PAGE NO.

1. Table 1
 CHAPTER 1

INTRODUCTION

1.1 PROBLEMS FACED WITH NORMAL GROUND CLEARANCE

City at different sectors like school, hospital there are speed breakers of
different dimensions. Most of the people buy only one four wheeler which they
use that at all this condition. Hence it’s necessary to give some standard ground
clearance to the vehicle. But still there are some obstructions while driving the
car on highway and in city. To obtain the good performance at high speed and
low speed it is necessary to build one system which can vary the ground
clearance. This can achieve by changing the suspension height so that the
chassis height can be adjusted with respect to the speed and the quality of roads.
Due to the difficulty of operating automobile jacks while in condition of
puncture or breakdown, various forms of electric jacks have been prefered. With
the development of such electric jacks has gradually come an understanding of
some of the problems associated with.

(a) On road

(b) Off road

 1.2 PROBLEMS OVERCOMED BY:

We have designed a simple pneumatic linkage mechanism for ground

clearance adjustment. The adjustment is possible with the help of an active and
a passive suspension ,which are linked together in series. Active suspension is
placed below the passive suspension. With the help of this system we can vary
ground clearance of the vehicle. Pneumatic cylinders are mechanical devices
which use the power of compressed gas to produce a force in a reciprocating
linear motion. Due to the torque needed to lift something as heavy as most
automobiles, as a severe mechanical advantage must be utilized. Jacks that are
built into an automobile have not been accepted due to expense and the need to
at least lift each side of an auto, if not all corners individually. To reduce the
human effort for operating any kind of jack Separately. This will most
appropriately benefit senior citizens to provide a safe and simple automatic
pneumatic jacking system without manual effort. To provide a novel jacking
system that can be operated from within the vehicle by means. With the help of
this system we can vary ground clearance of the vehicle up to 200mm.
CHAPTER 2
LITERATURE REVIEW

S.G.Bahaley, Dr. A.U. Awate, S.V. Saharkar [5] designed and fabricated a
pedal powered multipurpose machine. It is a human powered machine wich is
developed for lifting the water to a height 10 meter and generates 14 Volt, 4
ampere of electricity in most effective way. Power required for pedaling is well
below the capacity of an average healthy human being. The system is also
useful for the work out purpose because pedaling will act as a health exercise
and also doing a useful work
Prof. Kshirsagar Prashant R [6] metal researched on Theoretical Analysis of
pedal Power Hacksaw Machine and concluded that to overcome problems in
conventional hacksaw machines, due to high efficiency, easy to operate and
affordable price the proposed model of multi-way power hacksaw machine is
helpful and completes all the expectations needed in the pedal power hacksaw
machine will efficiently cut the workpiece.
 CHAPTER 3

COMPONENTS REQUIRED

I. Hack saw blade

II. Pedal arrangement

III. Stand setup parts

IV. Crank and slider mechanism

V. Hack saw assembly

VI. Metal slab

3.1 PEDAL POWER HACKSAW

The principle of pedal power hacksaw is to change circulatory motion or

cycling motion into translatory motion with the help of metal cutting rod. This
is mainly used for cutting metals and plastics. it is manually pedal operated
system. If we use dynamo then we can produce electricity which will be help to
lighting the work piece area when electricity is not available in mechanical
workshop. A hacksaw is a fine-tooth saw with a blade under tension in a frame,
used for cutting materials such as metal or plastics. Hand-held hacksaw consist
of a TPI (Tooth Per Inch). Different TPI is needed for different jobs of cutting
metal arch with a handle, usually a pistol grip, with pins for attaching a narrow
disposable blade. A screw or other mechanism is used to used to put the thin
blade under tension. It is a fine tooth hand saw with a blade under tension. It is
used to cut metals and PVC pipes. It would be useful in many projects discussed
on this site which used plastic pipes as materials.

There are three types of cutters available in the market: 1. Simple

hacksaw which can be used for hand cutting things. 2. Small Electrically
Hacksaw for personal uses. 3. Large Cutter Machines used for Industrial
Purposes. From the above three, first one will be used for our project

FIG 3.1 A RECIPROCATING POWER HACKSAW

It uses a blade that moves back and forth across the work. The blade cuts on the
backstroke. There are several types of feeds available. Positive feed-produces an
exact depth of cut on each stroke. The pressure on the blade varies with the
number of teeth in contact with the work. Definite pressure feed-yields a
pressure on the blade that is uniform regardless of the number of teeth in contact
with the work. The depth of the cut varies with the number of teeth contacting
the work. This condition prevails with gravity feed. Feed can be adjusted to
meet varying conditions. For best performance, the blade and feed must be
selected to permit high-speed cutting and heavy feed pressure with minimum
blade bending and breakage. Standard reciprocating metal cutting saws are
available in sizes from 6~ ~ 6~ (150 mm ~ 150 mm) to 24~ ~ 24~ (900 mm ~
900 mm). The saws can be fitted with many accessories, including quick-acting
vises, power stock feed, power clamping of work, and automatic cycling of the
cutting operation. The latter moves the work out the required distance, clamps
it, and makes the cut automatically. The cycle is repeated upon completion of
the cut. High-speed cutting requires use of a coolant. Coolant reduces friction,
increases blade life, and prevents chip-clogged teeth. Cast iron and some brass
alloys, unlike most materials, do not require coolant.

3.1.1 Selecting a Power Hacksaw 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 materials
require 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.

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.
 FIG3.2PRESSURE FEED

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.

3.1.2 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 manufacturer s 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 high-pitched tone indicates that the blade is too
tight. A 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 afterthe first few cuts and will stretch
slightly. The blade will require retensioning(retightening) before further cutting
can be done.

3.1.3 Selecting a Band Saw Blade

Band saw blades are made with raker teeth or wavy teeth. Most
manufacturers also make variations of these sets. The rakersetis preferred for
general use. Tooth pattern determines the efficiency of a blade in various
materials. The standard tooth blade pattern is best suited for cutting most
ferrous metals. A skip tooth blade pattern is preferred for cutting aluminum,
magnesium, copper, and soft brasses. The hooktooth blade pattern also is
recommended for most nonferrous metallic materials. For best results, consult
’
the blade manufacturer s chart or manual for the proper blade characteristics
(set, pattern, and number of teeth per inch) for the particular material being cut.

3.1.4 Installing a Band Saw Blade

If the saw is to work at top efficiency, the blade must be installed

carefully. Wear heavy leather gloves to protect your hands when installing a
band saw blade. Blade guides should be adjusted to provide adequate support,
Proper blade support is required to cut true and square with the holding device.
’
Follow the manufacturer s instructions for adjusting blade tension. Improper
blade tension ruins blades and can cause premature failure of bearings in the
drive and idler wheels. Cutting problems encountered with the band saw are
similar to those of the reciprocating hack saw. Most problems are caused by
poor machine condition. They can be kept to a minimum if a maintenance
program is followed on a regular basis.This typically includes checking wheel
alignment, guide alignment, feed pressure, and hydraulic systems.
 FIG3.3 band saw blade

3.2 PEDAL ARRANGEMENT

A pair of pedals is attached to the stand setup in which the power will be
generated manually. A typical Bicycle arrangement is used

3.2.1 PEDAL

A bicycle shoe crank bottom bracket bicycle pedal is the part of a that the
rider pushes with their foot to propel the bicycle. It provides the connection
between the cyclist’s foot or and the allowing the leg to turn the spindle and
propel the bicycle's wheels.
 FIG3.4PEDAL

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 roller chain. that
transmitted power to the driven wheel by means of a

Pedals usually consist of a spindle bearings 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 with
respect to the spindle.

Fig 3.5- Pedal power attachment

3.3 STAND SETUP PARTS

Stands are introduced to immobilize the apparatus. Various components

used are fixed to this arrangement. The chassis of the bicycle is used as the
stand setup parts . The stand described here is designed to support most
bicycles.

Fig 3.6- Bicycle Stand/Carrier

1. The stand assembly is divided into two parts: the rectangular base frame and
two triangular upright supports. Measure and cut the five pieces of 3/4" (20mm)
angle specified for the base frame. Mitre the corners at 45 degrees so they fit
together tightly and form square corners.

2. Weld the rectangle together. Do not weld the center frame member to the
rectangle yet.

3. Measure and cut as specified the 5 pieces for each upright support.

4. Carefully assemble the upright support pieces for welding, being sure to leave
a 1/8" (3.2mm) gap in the base of each support. This gap will mate with the
center frame member of the base frame, allowing the upright supports to slide to
accommodate different rear axle widths. Note that the two upright supports are
not identical. They are mirror reflections of one another. Weld each upright
support assembly together into a secure structure.

5. Place the upright supports onto the base frame, and position the center frame
member so that it mates with the gap in the side supports. Mark its position, and
weld it in place.

3.4 METAL SLAB

He used a guide to control the hacksaw blade which is used to cut the
metal. Metal slabs were fitted on the hacksaw blade to ensure pressure on the
object to be cut and linear movement of the blade. A clamp, with 360 degree
rotation, was fixed to hold the metal pieces while cutting, and to allow them to
be cut in any shape and angle.
 FIG3.7 METALSLAB

FIG3.8 STOP GAUGE

3.5BENCH VICE:

A vice is a job or workpiece holding device. It screw lever. Vice are

generally fixed to the table is a mechanical apparatus used to secure an object to
allow work to be performed on it. Vises consists two parallel jaws, one fixed
and the other movable, threaded in and out by a and or bench so as to provide
necessary force for holding workpiece during machining and also for reducing
the vibrations generated due to machining.
 3.9.VISE
3.6 Crank:-

The bicycle drive train reciprocating motion legs chain belt, which in turn
drives the rear wheel. It have pedal, crank to the bicycle frame at the bottom
bracket, and also at the rear sprocket, cassette freewheel crank set is the
component that converts the human pedal effort into rotational motion used to
drive chain wheels attached to the arms.

3.10 CRANK

3.7Circular Ball Bearings: A rolling-element bearing balls made up of steels

or alloys bearing races. The sole purpose of a ball bearing is to reduce rotational
friction and support radial axial loads of the rotating shafts. This is done by
using by using at least two races to contain the balls and transmit the loads
through the balls.
 FIG 3.11 BALL BEARING

3.8 CRANK AND SLIDER MECHANISM

This mechanism is used to convert the rotary motion of the crank into the
reciprocating motion of hacksaw. The lengths of the crank and connecting rods
are made using trial and error method.

Fig 3.12- crank and slider mechanism

The hack saw is guided by an aluminum plate. The vertical movement of the
hacksaw will be guided by to iron rods. The vertical movement will act as a
feeding unit.
 CHAPTER 4

WORKING PRINCIPLE

When the IR transmitter in sensor emits radiation, it reaches the object and
some of the radiation reflects back to the IR receiver , sends signals to the
arduino board circuit. the arduino board sends power supply to the solenoid
valve . Pneumatic lift in a vehicle can be achieved by pneumatic cylinder
employing a reciprocating compressor. Compressor compresses the gas to a
high pressure. This high pressurized gas then send to pneumatic cylinders to
exert force against the piston head inside it to have the piston movement to
create a linear motion outwards. By lowering the pressure of gas the piston
movement can be reversed. And with this mechanism ground clearance of the
vehicle can be increased or decreased

4.1 Block diagram

 CHAPTER 5

DESIGN

5.1 BASE FRAME

Plan view of frame in support position. All pieces 3/4" (19mm) steel angle.

Fig 5.1-Base Assembly

5.2 UPRIGHT SUPPORTS

Make two pieces of upright supports: one as shown and another one a
reflection of the one shown below. All pieces are made of 3/4" (19mm) steel
angle, unless specified otherwise. Weld all joints.

Fig 5.2-Upright Support Assembly

5.3 HACKSAW BLADE

FIG5.3HACKSAW BLADE

5.4 DESIGN CONSIDERATIONS

When designing our attachment, the following considerations were taken

into account

1. The device should be suitable for local manufacturing capabilities.

2. The attachment should employ low-cost materials and manufacturing

methods.

3. It should be accessible and affordable by low-income groups, and should

fulfill their basic need for mechanical power

4. It should be simple to manufacture, operate, maintain and repair.

5. It should be as multi-purpose as possible, providing power for various

agricultural implements and for small machines used in rural industry.

6. It should employ locally available materials and skills. Standard steel pieces
such as steel plates, iron rods, angle iron, and flat stock that are locally available
should be used. Standard tools used in machine shop such as hack saw, files,
punches, taps & dies; medium duty welder; drill press; small lathe and milling
machine should be adequate to fabricate the parts needed for the dual-purpose
bicycle.

7. It should make use of standard bicycle parts wherever possible.

8. The device should adapt easily to as many different bicycles as possible. No

permanent structural modification should be made to the bicycle.

9. Though the device should be easy to take off the bicycle, it is assumed that it
would usually remain attached to facilitate readiness and ease of transport from
site to site. The device, therefore, should not interfere with the bicycle's
transportation mode.

10. The broad stand, which provides stability during power production mode,
can be flipped upward during the transport mode. This stand/carrier would be a
permanent fixture of the dual-purpose bicycle.

11. The power take-off mechanism should be as efficient as possible, and

should develop relatively high r.p.m. (close to 200) for versatility of application.
We had seen designs for devices that take power from the rear tire by means of
a friction roller pressed against it, but we had doubts about the efficiency of this
arrangement. In order to improve efficiency we used hard bearing surfaces such
as roller chains, sprockets and ball bearings. We decided that the most
appropriate location for this power take-off mechanism would be at the front of
the bike near the fork tube (see photographs).

12. Care must be exercised to insure that the power take-off assembly is far
enough forward so as not to interfere with pedaling. Most standard adult bicycle
frames have plenty of room for the power take-off mechanism and pulley.
Power is supplied to the shaft by means of a chain from the bike's chain wheel .
5.5 FABRICATION :
Fabrication of machine:
Metal fabrication is the building of metal structures by cutting, bending,
assembling processes:
Cutting is done by sawing, shearing, or chiselling (all with manual and powered
variants); torching with hand-held torches (such as oxy-fuel torches or plasma
torches); and via numerical control (CNC) cutters (using a laser, mill bits, torch,
or water jet).Bending is done by hammering (manual or powered) or via press
brakes and similar tools. Modern metal fabricators utilize pressbrakes to either
coin or air-bend metal sheet into form. CNC-controlled backgauges utilize hard
stops to position cut parts in order to place bend lines in the correct position.
Off-line programming software now makes programming the CNC-controlled
pressbrakes seamless and very efficient.
Assembling (joining of the pieces) is done by welding, binding with adhesives,
riveting, threaded fasteners, or even yet more bending in the form of a crimped
seam. Structural steel and sheet metal are the usual starting materials for
fabrication, along with the welding wire, flux, and fasteners that will join the cut
pieces. As with other manufacturing processes, both human labor and
automation are commonly used. The product resulting from fabrication may be
called a fabrication. Shops that specialize in this type of metal work are called
fab shops. The end products of other common types of metalworking, such as
machining, metal stamping, forging, and casting, may be similar in shape and
function, but those processes are not classified as fabrication.
There are few types of fabrication methods done on the machine.
They are:
1. Cutting 2. Drilling 3. Machining 4. Welding 5. Cleaning 6. Assembly
5.6 MACHINING OPERATIONS
5.6.1 Cutting:
The raw material has to be cut to size. This is done with a variety of tools.
The most common way to cut material is by Shearing (metalworking); Special
band saws designed for cutting metal havehardened blades and a feed
mechanism for even cutting. Abrasive cut-off saws, also known as chop saws,
are similar to mitersaws but with a steel cutting abrasive disk. Cutting torches
can cut very large sections of steel with little effort.
5.6.2 Drilling:
Drilling is used to produce holes in the objects. In this project plates
requires holes for making assembly. These holes are done byvertical type
drilling machine.

FIG 5.4 DRILLING MACHINE

5.6.3 Machining:
Machining is a trade, in and of it, although Fab shops will generally entail
a limited machining capability including; metal lathes, mills, magnetic based
drills along with other portable metal working tools.
 FIG 5.5 LATHE MACHINE
5.6.4 Welding:
Welding is the main focus of steel fabrication. The formed and machined
parts will be assembled and tack welded into place then re-checked for
accuracy. A fixture may be used to locate parts for welding if multiple elements
have been ordered. The welder then completes welding per the engineering
drawings, if welding is detailed or per his own judgment if no welding details
are provided.

FIG 5.6 WELDING

5.7 COST:

Factors like scrap utilization, appearance, and non-maintenance of the

Designed part are involved in the selection of proper materials.

S.NO. NAME OF PIECES PRICE PER TOTAL

COMPONENT
PIECE

1. Pedal 2 200 400

2. Stand 1 350 350
3. Base frame 1 750 750
4. Crank and slider 1 900 900
Mechanism
5. Clamp 2 130 260
6. Hacksaw 1 550 550
7. Nut and bolt 7 10 70
8. Welding cost - 380 380
TOTAL 3660
 CHAPTER 6

DESIGN CALCULATION: -

Hacksaw frame: (L×W×H) = 300×18×5.5 mm

Hacksaw blade (hole to hole): (L) = 300mm

Connecting rod: (L×W×H) =317.5×5×5 mm

Circular disc (Bush): 6203z (38mm diameter)

Vice: (L×W×H) = 105×35×30

A solid shaft 4130 (chrome molybdenum steel alloy) of diameter 16 mm. The
shear stress must not exceed 150 MPa.

Maximum torque transmitted (T) = {(π/16)×τ×d3)} =120 N-m.

Maximum Power applied (P) = (2×π×N×T)/60 =1.515978 KW.

 CHAPTER 7

ADVANTAGES , DISADVANTAGES , APPLICATIONS & FUTURE

SCOPE

7.1ADVANTAGES

1. Time saving as compared to simple hacksaw

2. Power saving as it is manually operated

3. Easy machinery used

4. As it is pedal operated so good for health

5. Comfortable then ordinary hacksaw

6. It is portable

7. 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.

7.2DISADVANTAGES

1. Its totally manually operated

2. Time consuming as compared to electrical power hacksaw

3. Without human effort its not operated

4. Not fit for heavy production

7.3APPLICATION:

1. Cutting of two metal piece at the same time.

2. Cutting of wooden workpieces.

3. Cutting of plastic materials and PVC pipes.

7.4 FUTURE SCOPE

For more faster operations in particular areas such as in workshops , the pedal
mechanism can be replaced by a electric motor which will increase the speed of
cutting further more thereby reducing more time. But the electricity
consumption by the electric motor should also be taken into account and the
machine also needs to be bolted to the base to cancel out the vibrations created
by the motor.

Following all types of operation can be carried out by the proper pedal
attachment as per the requirement. Here are some operation.

Fig7.1- Rice Threshing

Fig7.2-Winnowing
 FIG7.3CORN SHELLING

FIG7.4PEDAL POWER LATHE

 CHAPTER 8

CONCLUSION

Thus a low cost and simple design pedal operated hacksaw machine is
fabricated. This machine reduces the human effort and hence we don’t need two
persons to cut the wooden logs. This simple design of conventional design
which can enhance day today household needs and daily day to day purposes
and it can be also used in for industrial applications during power shut down
scenarios. By using this method we can do any operation as per our requirement
without the use of electricity. So we can save the electrical power.
 CHAPTER 9

REFERENCES

1. David Gordon Wilson “UNDERSTANDING PEDAL POWER” ISBN: 0-

86619-268-9 [C] 1986, Volunteers in Technical Assistance” Technical paper 51
VITA 1600 Wilson Boulevard USA.

2. EJ Yerxa Taylor & Francis “Occupational science: A new source of power

for participants in occupational therapy‟- Journal of Occupational Science ISSN
1442-7591 Volume: 13, Issue: 1, April 1993 pp254-259.

3. Jon Leary “Putting Research into Practice: From a Steel City Drawing Board
to the Heart of the Maya” The University of Sheffield-EWB-UK National
Research Conference 2010,19th February 2010.