MINI BENCH SAW MACHINE

A PROJECT REPORT
Submitted
In the partial fulfillment of the Requirements for the Award of the Degree of
BACHELOR OF TECHNOLOGY (B.Tech)
In
MECHANICAL ENGINEERING
By

S RAJITH [15311A03K8]
G SAITEJA [15311A03N9]
P RAGHU [16315A0349]

UNDER THE GUIDANCE OF

DR. K. CHANDAR RATHOD
Asst PROFESSOR

DEPARTMENT OF MECHANICAL ENGINEERING

SREENIDHI INSTITUTE OF SCIENCE & TECHNOLOGY
(Approved by AICTE, New Delhi and Affiliated JNTUH: Hyderabad)
Yamnampet, Ghatkesar, Hyderabad – 501 301

i
 October, 2014.

SREENIDHI INSTITUTE OF SCIENCE AND TECHNOLOGY

Yamnampet, Ghatkesar, Hyderabad – 501 301

Date: 02-05-2019

CERTIFICATE
This is to certify that the project report entitled “MINI BENCH SAW MACHINE” being

submitted by S RAJITH bearing the Roll No.15311AO3K8, G SAITEJA bearing the Roll No.

15311A03N9, P RAGHU bearing the Roll No. 16315A0349 in partial fulfillment for the award

of Bachelor of Technology degree in MECHANICAL ENGINEERING ,Sreenidhi Institute of

Science & Technology affiliated to Jawaharlal Nehru Technological University, Kukatpally,

Hyderabad (Telangana), is a record of bonafide work carried out by them under our guidance and

supervision.

The results embodied in the report have not been submitted to any other University or

Institution for the award of any degree or diploma.

(Mr. K. Chandar Rathod)

Project Guide Dr.T.Ch. Shiva Reddy

HOD, MECH

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 SREENIDHI INSTITUTE OF SCIENCE AND TECHNOLOGY
Yamnampet, Ghatkesar, Hyderabad – 501 301

DECLARATION

We hereby declare that the work described in this thesis “MINI

BENCH SAW MACHINE” which is being submitted by us in partial
fulfillment for the award of Bachelor of Technology in the Department
of Mechanical Engineering, Sreenidhi Institute Of Science &
Technology affiliated to Jawaharlal Nehru Technological University
Hyderabad, Kukatpally, Hyderabad (Telangana) is the result of
investigations carried out by us under the Guidance of Mr.K. CHANDAR
RATHOD, Asst Professor, Department of Mechancial, Sreenidhi
Institute Of Science & Technology , Hyderabad.

The work is original and has not been submitted for any
Degree/Diploma of this or any other university.

Place: Hyderabad

Date: 02-05-2019

Signature
S RAJITH 15311AO3K8

G SAITEJA 15311A03N9

P RAGHU 16315A0349

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 ACKNOWLEDGEMENTS
We thank Mr. K.Chandar Rathod, Asst Professor, Dept of MECH, Sreenidhi Institute of

Science & Technology, Hyderabad for his valuable comments and suggestions that greatly

helped in improving quality of thesis.

We would like to express our sincere gratitude to Dr. T. Ch. Shiva Reddy, Professor, Head

of the department,Mechanical Engineering, Sreenidhi Institute of Science & Technology,

Hyderabad for his continued support and valuable guidance and encouragement extended to us

during our research work. We thank him for his painstaking efforts to guide us throughout our

research work.

We thank Mr.k.chandar rathod, Associate Professor of MECH, Sreenidhi Institute of

Science & Technology, Hyderabad for her valuable advice, support and help during our research

work.

We We thank all our teachers and professors for their valuable comments after reviewing

our research papers.

We wish to extend our special thanks to all our colleagues and friends who helped

directly or indirectly to complete our research work.

We extend my thanks to our parents and all our family members for their unceasing

encouragement and support who wished us a lot to complete this work.

S RAJITH

G SAITEJA

P RAGHU

iv
 INDEX
Acknowledgements iv

Abstract vii

List of Figures viii

CHAPTER 1 Page. No:

1. Introduction 01

CHAPTER 2

2. Literature Review
2.1. Mini bench saw. 02
2.2. Historical Background. 03
2.3. Sawing. 03
2.4. Circular Sawing. 05
2.5. Advantages and Disadvantages. 07

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CHAPTER 3

3. Design Details and Description

3.1. Design Details. 09
3.2. Description. 10

CHAPTER 4

4. Working
4.1. Working Model. 16
4.2. Procedure of Working. 17

CHAPTER 5

5. Calculations of Required parameters using WOOD 20

CHAPTER 6

6. Conclusion 23

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 Abstract

This project is on the design and construction of an automatic mini bench saw
machine for cutting of wood to different size and length with the help of cutting
wheel. The objective of this project is to save man power and time in cutting
wood in order to achieve high productivity. It is a cutting machine with teeth on
its blade used specially for cutting wood. The power to the cutting wheel is
provided by the motor. The motor is mounted on the handle which will swing up
and down in order to cut the wood. A support is provided to slide the wood after
a piece is cutted. The swinging arm is mounted between the two pillars for its
stability. A spring is used to pull back the arm up when force is released to ensure
safety. Test was carried out on the machine using different size of wood.

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 List of Figures

NUMBER NAME PAGE NO

1 775 DC MOTOR 17
2 CIRCULAR SAW BLADE 17
3 SPRING 19
4 FASTENERS 20
5 MODEL DIAGRAM OF 21
MINI BENCH SAW
6 MINI BENCH SAW 23
FRONT VIEW
7 BACK VIEW 24
8 TEETHS OF BLADE 24

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 CHAPTER-1

INTRODUCTION

A hacksaw is a hand held tool used to cut wood.

Its cutting mechanism is provided by removable blades which feature sharp teeth
along their outer edge. In most cases, a hacksaw consists of a metal frame that
resembles a downward facing.A handle of plastic, wood, or metal is typically
affixed to one end of the frame. The frame’s ends feature adjustable pegs that
can be tightened to secure a blade in place, and loosened to remove it. Hacksaw
blades are long, thin strips of hardened steel that feature a row of teeth along
their cutting edge. Each end of the blade is punched with a small hole that fits on
to the saw frame’s pegs. Most blades range in length from ten to 12inches (25.4
to 30.48 cm),
Although six-inch (15.24 cm) blades can be purchased to fit smaller hacksaw
models. A device that applies force, changes the direction of a force, or changes
the strength of a force, in order to perform a task, generally involving work done
on a load. Machines are often designed to yield high mechanical advantage to
reduce the effort needed to do that work. A simple machines a wheel, a lever or
an inclined plane. All other machines can be built using combinations of these
simple machines. Example: A drill uses a combination of gears (wheels) to drive
helical inclined planes (the drill bit) to split a material and carve a hole in it.

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 CHAPTER-2

LITERATURE REVIEW

2.1 MINI BENCH SAW

After the study of many literatures about design, construction and working
of bench saw machines, some of them describe the methodology of bench
saw machine. Lots of factor have been consider for the design, construction
and working of bench saw machine such as cutting speed, cutting material,
cutting time, power, efficiency etc. So, lots of literatures have been found
which gives the relevance information and methodology of constructing an
bench saw machine.
This is probably a woodworkers first major purchase, there are three basic
categories of table saws on the market, bench, contractor's and cabinet.
Though they all are sold with blade guards and guides there are custom
products available that offer advantages over the stock parts. There are
also many attachments and jigs that can be made for more accurate cuts.

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2.2 HISTORY BACKGROUND

The problem of cutting-off material to size is common to practically every

industry. Often, sawing is the first operation carried out on bar stock. Therefore, it
is surprising that so little work has been done to understand the problems of this
common operation. Many reasons have been given for this such as lack of
interest, it is a routine operation and that there is no need to consider better
methods. Often the foreman will assign a new trainee to a sawing task, on the
principle that it is easy to learn and difficult to foul up. Furthermore cut-off
machines are frequently housed in stores away from the main production areas
and the operation of the sawing machines appears to be simple. The fact remains
that cutting-off operations can account for a significant part of the cost per piece.

2.3 SAWING

If all raw stock was delivered in ready-to-machine shapes and sizes, there would
be no need for sawing machines in a working shop. Machine operators could
merely go over to the stock, select the suitable work piece, and perform the
necessary finishing operations. Such situation rarely exists, due to the fact that
the majority of the stock requires to be cut in some way prior to starting a
machining schedule. The alternative to this primary operation of sawing is to buy-
in prepared lengths and shapes; this however introduces a service which the
company has to pay for and, in the majority of the cases, it is simpler and more
economical to carry out the basic cutting to-size operation in house. One of the
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major advantages of sawing over all other kinds of machining is the narrowness of
cut op. Most sawing machines perform the cut-off operation, where a piece of
stock is cut to a workable length prior to subsequent machining operations.
Machines that accomplish this job include hacksaws, band saws and bench saws.

VARIOUS TYPES OF SAWING:

Hand Saws
Even with the popularity and ease of power tools, sometimes a hand saw is the
easiest and most convenient tool around. Hand saws should have comfortable
handles and have 8-10 teeth per inch (2.5 cm). Hand saws are often used for
cutting in tight spaces.

Circular Saws
Circular saws can be used to cut metal, plaster, concrete, and wood, depending
on which blade is being used. The base plate should be adjustable, letting the user
set the blade depth desired. Adjustable base plates also perform bevel cuts well
as pivoting from side to side. Circular saw blades cut wood and other material in
an upward direction. That can cause splintering on the top face of the project, so
measurements and cutting should be done from the back, with the good side
facing down.

Smaller circular saw blades can be used in saws that are smaller and lighter.
However, this convenience must be weighed against the fact that smaller saws

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are often less powerful and don't cut thick material well. Circular saw blades
measuring 7.25 inches (18.4 cm) and 6.5 inches (16.5) are the most popular for
home repair use.

Jig Saws
Jig saws are portable and especially good for cutting curves. Variable speed jig
saws allow for the speed to be adjusted depending on which blade style is used.
Coarse tooth blades generally need a faster blade speed than fine tooth blades.
Jig saw blades are available for cutting various types of material, including wood,
metal, vinyl, and leather, as well as making different shapes and styles of cuts.

A good jig saw should be able to cut softwood that is 2 inches (5.1 cm) thick and
hardwood that is 0.75 inches (1.9 cm) thick. A heavy steel base plate helps reduce
vibration from the jib saw blades up and down movement. Jig saws with a
pivoting base plate allow for bevel cuts to be made as well.

Band Saws
A band saw can take the form of a small machine on top of a bench or a taller one
that sits directly on the floor. Band saws contain a serrated metal band which has
two pulleys to hold it in place and move it in a circular motion. This band, or
blade, cuts the material being fed into it. Band saws do well in cutting rounded or
curved shapes. Different blades, or bands, are available for each type of material
to be cut, including a diamond blade to cut glass.

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Table Saws
Table saws are a bigger investment, both in space and money. A table saw makes
miter cuts, rip cuts, cross cuts, and bevel cuts, as well as producing various kinds
of joints for different woodworking projects. Portable table saws cost less and
take up less space than regular table saws, and still perform most of the functions
of a full size table saw. Eye and ear protection should be worn when working with
a table saw, and care should be taken to keep hands far away from the saw's
blade

2.4 CIRCULAR SAWS:

Circular saws have a continuous cutting action, use blades having many teeth, and
a large range of rotational speed. This operation is similar to a milling operation.
The machines available range from the earlier, inexpensive, hand-loaded models
to the very large, power loaded type and incorporate material handling devices
for semi and then fully automatic operations. Modern production circular saws
are built with several alternate basic feed mechanisms i.e. horizontal, vertical,
rocking head and variations of these. The choice of the most suitable type of
machine depends on the particular application and the size and shape of
component. With vertical feed, the rotating blade travels downwards in a straight
line to engage the work piece. On machines designed for horizontal feed the
blade is fed into the work piece from the back. A third basic feeding arrangement

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is a pivot motion or rocking-head system, this is as efficient as a vertical feed
system and is a rugged arrangement. The bench or floor mounted manual-feed
circular saw, when installed together with a general duty band saw or hack sawing
a small workshop, provides
a complete cutting facility for the small fabricator. Fully automatic circular saws,
having features such as dial-in component length, in process gauging, choice of
loading magazines, etc. are widely used where high quality production is required
and often present the production engineer with a difficult choice to make
between circular sawing and band sawing.

2.5 Advantages and Disadvantages

Advantages:

 The portable table saws can be used for off-shop jobs. They can be used
anywhere, in the workshop and even in trucks or on construction sites.
 They are compact and smaller in size. They save on space, especially when
one uses many machines or when one wants to use these machines out in
other places, out of the workshops and on construction sites.
 Though the machine is compact, it comes along with a box in which the
motor, the blade mechanics and the controls can be placed in. Even the
table can be fitted into the box.
 The portable machines are designed more elegantly and fitted with more
accessories that have evolved with technology.

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  Older machines have good accuracy while the newly introduced portable
machines are also good and can be enhanced with more tools. This helps
to acquire good results in all the work done. The speed is greater and
quality of the finished work is much better
 Portable bench top saws are more economically priced.
 These machines can be used by both hobbyists as well as by professionals.

Disadvantages:

 Smaller Jobs. A stationary table saw, that’s meant to handle large stock, will
not perform better on smaller stock, like pine or floorboards, versus a
smaller portable table saw
 Portable table saws are typically smaller than stationary saws, which can
make cutting thick plywood and other large wood stock more difficult.
 Vibrations. Portable table saws, because they are not fixed in place, can
result in more vibrations across the saw making straight cuts more
challenging.
 Noise. Portable table saws can be noisier than stationary saws that have
their motor mounted inside a cabinet.

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 CHAPTER-3

DESIGN DETAILS AND DESCRIPTION

3.1 Design Details:

We made this mini bench saw machine by using following components/parts:

a) Rectangular wooden blocks

b) A 775 dc motor
c) Sawing blade
d) Metallic led driver
e) Switch
f) Spring and Fasteners

Material of Sawing blade is Stainless steel. Withstand the high heat that is
generated by cutting through metal while ensuring clean cuts and a long blade
life. The blades are then heat-treated at high temperatures to reduce heat build-
up and prevent excessive sparking.

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Compsotion of stainless steel 316:

3.2 Description:

Gas turbine engine rotor castings are manufactured by vacuum investment

casting, usually these are casted using nickel based super alloy. The
manufacturing of turbine rotor is done under vacuum condition so as to avoid
oxidation and to create better surface finished product.

PART /COMPONENTS USED:

 Frame

 Motor

 Blade

 Spring

 Fasteners

FRAME:

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 A wooden frame is used for the set up of the machine parts and
components

These are in rectangular shape in 6 number

It consists of two pillars on left side to support the Movable arm on which
the blade is mounted.

The base supports the motor and movable arm

Frame consists of fasters and one spring .

MOTOR:

A DC motor is used for rotating the blade in very high speed.

It is widely used as they can be powered from existing direct current lighting

Power distributions systems. Speed can be controlled by a variable supply

voltage or by changing the current input in its field windings

A 775 DC motor is used to rotate the blade

Rpm ranges from 3000 to 6000 rpm

Its a 6-12V dc motor

It has 5mm shaft to which the blade is fixed

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 FIG. 1: 775 DC MOTOR

BLADE:

FIG. 2: CIRCULAR TYPE SAW BLADE

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Hacksaw blade material is stainless steel and the teeth of blade is made of
hardened steel that feature a row along their cutting edge.

It consists of 40 teeth with inserted hardened steel. stainless steel 316 is more
corrosion and wear resistance.

It also has abrasion resistance and durability.

More strength helps in easy cutting. The blade is cross type which makes the
wood works and metal works easier.

It is designed cut wood,pvc and metal

This is a Crosscutting blade

DIMENSIONS :

Diameter of the blade = 10 cm

Thicknes of teeth = 2 mm

SPRING:

A spring is an elastic object that stores mechanical energy.

Springs are typically made of spring steel. There are many types in everyday use
the term often refers to coil spring.

Made from a variety of elastic materials the most common being spring is steel

A spring of length 6cm is used to connect movable arm to wooden pillar

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Which acts as an automatic return system, when there is no force applied on the
movable arm.

FIG.3: SRPINGS

Fasteners:

A fasteners is a hardware device that mechanically joins or fix. Two or more

objects together in general fasteners are used to create non permanent joins.

That is joints can be removed or dismantled from without damaging the joining
components.

Fasteners are made from carbon steel,stainless steel or alloy steel.

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FIG. 3: FASTENERS

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 CHAPTER-4

WORKING

4.1 Working Model

FIG. 5: MODEL DIAGRAM OF MINI BENCH SAW

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4.2 Procedure of working:

 Construction of base.
 Mounting two pillars on the base.
 Mounting swinging arm (handle) between the two pillar in such a way that
it is free to swing up and down.
 Mounting motor on swinging arm and cutting wheel on the motor.
 Providing support for cutting wood.
 Circular blade is mounted on the motor which rotates at high rpm.
 Motor is mounted on the swinging arm which is mounted in between the
two vertical pillars.
 Support is provided on the base to hold the work piece properly.
 Swinging arm will swing up and down along with the rotating circular blade
which will cut the wood placed on the base.

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FIG. 6:MINI BENCH SAW MACHINE (front view)

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 FIG.7:BACK VIEW

FIG.8: TEETHS OF BLADE

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 CHAPTER-5

5.1 Calculation

The calculations are done to find out the required parameters which helps in
making a conclusion o for different materials

PARAMETERS:

 TORQUE
 FEED RATE
 CUTTING SPEED

SAMPLES DATA:
 WOOD WORKPIECE
 MILD STEEL

WOOD WORKPIECE:

LENGTH OF WORK PIECE = 15 CM

WIDTH OF WORKPIECE = 5 CM

THICKNESS OF WORKPIEC = 5 CM

Number of teeth : 40 number

Thickenss of teeth: 2 mm

Diameter of blade: 10 cm(4 inches)

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Speed : 4000 R.P.M

Power :24 watts

POWER-TORQUE EQUATION:

P = 2𝜋𝑁𝑇
60
P = Power of motor

N = speed in rpm

T = Torque

T = 𝑃×60
2𝜋𝑁

T = 24×1000×60
2𝜋×4000

T =572.9 N-m

CUTTING SPEED :

πDN
𝑉𝑐 =
1000

𝑉𝑐 =cutting speed of blade

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D = diameter of blade

N = speed in rpm

π×10×4000
=
1000

𝑉𝑐 = 125.6 m/sec

FEED RATE:

FEED RATE = N n f

N = Rotational speed

n = number of teeth on cutter

f=feed (inch/tooth)

FEED RATE = N n f

=3.9×40×0.12

=23.7 dist/min

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 CHAPTER-6

CONCLUSION:

It is known that conventional sawing process can be replaced by any sawing

process.Benchsaw machine gives high productivity in short time period in
comparison with the conventional hacksaw machines. The major advantage of
this machine is that intervention of labour is reduced to maximum level. In this
rapid emerging industrial era, these of bench saw machine is wide. Time and
labour plays a major role in production process this can be overcome by using this
type of automatic machines. The bench saw machine can be made use of at any
of the industries which manufacture wood products. The range of size of work-
pieces that can be confusing the mini bench saw machine can be varied by
changing the blade size.

The machine can be fully automated by using Microcontroller. In fully automated

machine the operator need not measure the length of the work-piece that is to be
cut and to load and unload the work-piece each time after a piece has been cut.
The operator need to only enter the two input namely the number of pieces to be
cut and the length of each piece that is required to be cut. The inputs can be given
by the operator with the help of a keypad and an LCD display, which will help the
user to verify the data given by him.

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