UNIVERSITY INSTITUTE OF ENGINEERING

CHANDIGARH UNIVERSITY
GHARUAN, MOHALI, PUNJAB, INDIA-140413
Training Report
On
PEDAL OPERATED HACKSAW
For Intuitional/Summer Training Taken At
CHANDIGARH UNIVERSITY

Submitted in partial fulfillment of the

Requirements for the award of the degree

of

BACHELORS OF ENGINEERING

IN

MECHANICAL ENGINEERING

Submitted By:- PARJEET SINGH (17BME1411) Submitted To:- TARSEM SINGH

SAHIL SAINI (17BME1053)
SOURAB (17BME1060)

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 Table of contents

1. Acknowledgement …………………………………..

2. Abstract ……………………………………………

3. Introduction …………………………………………

4. Project Details …………………………………….

5. Project Design………………………………………….

6. Project fabrication methodology………………………………………….

7. Outcome ………………………………..

8. Limitations & Benefits……………………………

9. Conclusion ……………………………………..

10.References ……………………………………………

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 Index

S. No. Title Page No.

1. Acknowledgement 4
2. Abstract 5
3. Introduction 6-7
3.1 Principle 8
4. Project Details 9
4.1 component required 10
4.1.1 working of Hacksaw 11
4.1.2 Blade 12-13
4.1.3 Role of Pedal 14
4.1.4 Frame 15-16
4.1.5 Slider Crank Mechanism 17
4.1.6 Bench vise 18
4.1.7 Metal Slab 19
5. Project Design 20-27
6. Design Considerations 28
7. Advantages and disadvantages 29
8. Safe operating Procedure 30
9. Project Fabrication 31
9.1 Material Required 31
9.2 Work to be done.. 32
9.3 Approximate cost 33
9.4 Work Place 33
9.5 Work Plan 34
10. Outcome 35
11. Limitations and Benefits 36
12. Conclusion 38

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1. Acknowledgement
We would like to express our special thanks of gratitude to our teachers as well
as our Superintend sir who gave us the golden opportunity to do this wonderful
project on the topic “PEDAL OPERATED HACKSAW”, which also helped us
in doing a lot of Research and we came to know about so many new things we
are really thankful to them.
Secondly we would also like to thank my parents and friends who helped us a
lot in finalizing this project within the limited time frame.

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2. Abstract

This project work deals with the design and fabrication of a pedal powered
hacksaw cutting machine. The aim of this work is to develop a modernized and
less stressful operation for cutting wood, metals and plastic materials. It is very
useful for cutting PVC materials (pipes) and can be used widely in lather and in
furniture making industries. This work can also serve as an exercising machine
for fitness while cutting, it uses the principle of a slider crank mechanism which
converts the rotary motion of the flywheel to the reciprocating motion of the
hacksaw during pedaling. The machine was tested and continued to be very
efficient with an ideal mechanical Advantage of 0.5 (less than 1), velocity ratio
of 0.65 (less than 1), a power output of 5.72KW and an efficiency of 76.9%,
which makes it very adequate and capable for cutting.

Keywords: pedal power, Hacksaw, reciprocating, motion.

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3. Introduction

Pedal power is the transfer 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 by pedalling than by hand-cranking. At the
rate of ¼ HP, continuous pedalling can be served for only short
periods, approximately 10 minutes. However, pedaling 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, electric or other power. An abrasive saw uses an
abrasive disc or band for cutting, rather than a serrated blade. The aim
of this work is to design and construct a pedal driven hacksaw
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machine that will use a less effort pedaling power to produce uniform
cutting of PVC pipes, metals, wood and as the same time serve as an
exercising machine for fitness. It is also done to show the
performance difference between hand driven and pedal driven
hacksaw. This work is design to overcome the stress attached to hand
cutting of engineering materials by turning it into an exercise for body
fitness. In this Pedal operated hacksaw machine which can be used for
industrial applications and Household needs in which no specific
input energy or power is needed. This project consists of a crank and
slider mechanism. In the mechanism pedal is directly connected to the
hacksaw through crank and slider mechanism for the processing of
cutting the cycle chain-set , metal rods. The objective of the modal is
using the conventional mechanical process which plays a vital role.
The main aim is to reduce the human effort for machining various
materials such as wooden blocks, steel, PVC etc. The power hacksaw
machine, which runs on electrical power, works on the principle of
the conversion of rotational motion to oscillatory motion. Importance
of this project lies in the very fact that it is green project and helps us
to reduce our electricity need. Secondly, this cutter can be used and
transferred to our working place easily.

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3.1 Principle Of Pedal Operated 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. 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 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. Blades of hacksaw
are measured in TPI (Tooth Per Inch). Different TPI is needed for different jobs
of cutting.

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.

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4. Project Details

Pedal operated hacksaw is a machine which can be used for industrial

applications and Household needs in which no specific input energy
or power is needed. This project consists of a crank and slider
mechanism. In the mechanism pedal is directly connected to the
hacksaw through crank and slider mechanism for the processing of
cutting the wooden blocks, metal bars, PVC materials. The objective
of the modal is using the conventional mechanical process which
plays a vital role. The main aim is to reduce the human effort for
machining various materials such as wooden blocks, steel, PVC etc.
The power hacksaw machine, which runs on human power, works on
the principle of the conversion of rotational motion to oscillatory
motion. Importance of this project lies in the very fact that it is green
project and helps us to reduce our electricity need. Secondly, this
cutter can be used and transferred to our working place easily.

Material Used --> Mild Steel

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4.1 COMPONENTS REQUIRED
1.Hack saw

2.Hack saw blade

3.Pedal arrangement

4.Frame

5.Crank and slider mechanism

6.Hack saw assembly

7.Metal slab

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4.1.1WORKING OF HACKSAW
A hacksaw is a fine-toothed saw, originally and mainly made for cutting metal.
The equivalent saw for cutting wood is usually called Bow saw.
Most hacksaws are hands saw 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.

Typical full-size

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 are set to be facing forwards.
While saws for cutting metal had been in use for many years, significant
improvements in longevity and efficiency were made in the 1880s by Max
Flower-Nash. Clemson, a founder of Clemson Bros ..Inc of Middletown, New
York, United States,. Clemson conducted tests which involved changing the
dimensions, shapes of teeth, styles of set, and variable heat treatments of blades.
Clemson claimed enormous improvements to the cutting ability of blades and
built a major industrial operation manufacturing hacksaw blades sold under the
trade name Star Hack Saw.In 1898, Clemson was granted US Patent 601947,
which details various improvements in the hacksaw.

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4.1.2BLADE
The pitch of the teeth can be 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 clearance when 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.
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 bench work on a work piece 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.
The most common blade is the 12 inch or 300 mm length. Hacksaw blades have
two holes near the ends for mounting them in the saw frame and the 12 inch /
300 mm dimension refers to the center to center distance between these
mounting holes.
The kerf produced by the blades is somewhat wider than the blade thickness
due to the set of the teeth. It commonly varies between 0.030 and 0.063 inches /
0.75 and 1.6 mm depending on the pitch and set of the teeth.

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13
4.1.3 ROLE Of PEDAL

The pedal is the part of a bicycle that the rider pushes with their foot to propel
the bicycle. It provides the connection between the cyclist's foot or shoe and
the crank allowing the leg to turn the bottom bracket spindle and propel the
bicycle's wheels. 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. The role of pedal in pedal operated
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.

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4.1.4 FRAME OF PEDAL OPERATED HACKSAW

Frame 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.

The stand assembly is divided into two parts: the rectangular base frame and
two triangular upright supports.

1. Measure and cut pieces angle specified for the base frame. 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 pieces for each upright support.

4. Carefully assemble the upright support pieces for welding, being sure to
leave 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.

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16
4.1.5 SLIDER CRANK MECHANISM USING HACKSAW

Here we are fabricating the hacksaw machine based on crank slider

mechanism without any electronics intervention. In this project, no electricity
is needed for the operation of the wiper while raining. As the name implies, it is
a fully mechanical based project. This project consists of the following parts
Handle, Cam, Hacksaw frame and metal rods.

The hacksaw is a metal cutting machine tool designed to cut multiple metals
simultaneously byapplying cam mechanism. The machine is e!clusively
intended for mass production and theyrepresent the faster and more
efficient way to cut a metal. Hacksaws are used to cut thin and softmetals. The
operation of the unit is simplified to a few simple operations involving a motor
and a cam mechanism. There are numerous types of cutting machines in
"engineering field, which a reused to fulfill the requirements. $e are interested
to introduce multiple hacksaw cutting operation. Hacksaw machine. The
main function of this hacksaw machine is to cut thin and soft
metals by motor power. This is an era of automation where it is broadly defined
as replacement of ma n u a l effort by me c h a n i c a l power in all
d e g r e e s o f a u t o ma t i o n . Th e o p e r a t i o n r e ma i n s a n essential part of
the system although with changing demands on physical input as the degree
of mechanization is increased.

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4.1.6 The Bench Vice

The Bench Vice, which is sometimes called the Parallel Vice, is used to clamp
or hold work pieces. The body is screwed to the workbench to provide secure
holding. If you are installing a Bench Vice there are a few points that you
should take into consideration.

 The top of the vice should be at the same height as the users elbow.
 The Fixed Jaw should protrude slightly over the edge of the bench to
allow for long work pieces.

The body and jaws of the Bench Vices found in the school workshop are
usually made out of Cast Iron, which is strong in compression but brittle under
shock. As a result they should not be hammered. There are also steel vices
available but they are more expensive. The screw thread that a Bench Vice uses
is called a Buttress Thread. This Type of thread withstands heavy thrust in one
direction yet unscrews easily in the opposite direction.

The Jaws Faces of the vice are made from hardened steel. There are
also serrated which is a criss-cross pattern which provides a firmer grip on the
work piece. The Jaws Faces are screwed to the Sliding Jaw and the Fixed Jaw
so that if they are damaged they can be replaced.

The Machine Vice

The Machine Vice is used with the Drilling which enable the user to screw
the Machine Vice to the Drilling Machine table. Machine, generally. You can
see the slots in the side of the base of the vice

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4.1.7 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.

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5.Project Design

TOP VIEW

20
SIDE VIEW

21
FRONT VIEW

22
BACK VIEW

23
Isometric View

24
Isometric View

25
Isometric view

26
Isometric view

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6. 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.The device should be able to transmit power to a variety of machines, and

changing drive ratios should be as simple as possible.

10. The device should contain a ratcheting mechanism that would let the
operator "coast " periodically to rest and conserve energy.

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7. 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

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

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8. SAFE OPERATING PROCEDURE

PERSONAL PROTECTIVE EQUIPMENT

Safety glasses must be worn Long and loose hair must be Hearing protection must be
at all times in work areas. contained. worn.

Sturdy footwear must be worn Close fitting/protective Rings and jewellery must
at all times in work areas. clothing must be worn. not be worn.

PRE-OPERATIONAL SAFETY CHECKS

 Locate and ensure you are familiar with all machine operations and controls.
 Ensure all guards are fitted, secure and functional. Do not operate if guards are missing or faulty.
 Check workspaces and walkways to ensure no slip/trip hazards are present.
 Ensure the material is tightly clamped in the work vice.

OPERATIONAL SAFETY CHECKS

 Ensure no one stands in front of the saw when it is started.
 Keep clear of moving machine parts.

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9.Project fabrication methodology

9.1 Material Required

I. Hack saw blade

II. Pedal arrangement
III. Stand setup parts
IV. Crank and slider mechanism
V. Metal Frame
VI. Welding Machine
VII. Small Bench vise

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9.2 Work to be done…

Firstly we have to prepare a rectangular frame out of iron rods of

dimension

120cm X 40cm using arc welding machine, after making the frame
then we have to make pedal arrangement on the frame on one of its
breadth. In this mechanism the pedal arrangement is to be connected
with the crank and slider mechanism which is responsible for the
conversion of rotational motion into oscillation motion. Then this
crank and slider mechanism is further to be connected to the hacksaw,
which is operated in a oscillated way to perform cutting action. The
project also be consisting of a place to sit where the user can
comfortably sit and perform the cutting action.

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9.3 Approximate Cost:

S.no Component Price

1. Pedal Mechanism 500
2. Hacksaw Blade 300
3. Welding Cost -
4. Base Frame -
5. Small Bench vise -
Total 800

6.4 Work Place:

Centralized welding workshop @ CHANDIGARH UNIVERSITY

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6.5.Work Plan:

S.No Work No. Of Days

1. Gathering Material. 1
2. Making of base frame. 2
3. Fixing of pedal mechanism on base 1
frame.
4. Making of crank and slider 1
mechanism
5. Fixing of crank and slider 1
mechanism on base frame.
6. Connecting crank and slider 1
mechanism to hacksaw.
7. Fixing of a small bench-vice on the 1
base frame.
8. Rectifying the working of hacksaw 1
over the bench vice.
9. Making of a seat through which the 3
user will operate the project.
10. Finishing 1

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10.OUTCOME

The machine was tested for three different materials (mild steel pipes,
wood and plastic pipes). The ideal mechanical advantage of 0.5,
power output of 5.72KW and efficiency of 76.9% makes it very
adequate and efficient as a useful machine for exercise and as a
cutting machined compared to the existing ones.

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11.LIMITATIONS

1. Not fit for heavy production

2. It is totally manually operated

3. Time consuming as compared to electrical powered hacksaw

machines.

4. Without human effort it cannot be operated.

BENEFITS

1. No any consumption of Fuel

2. Eco-friendly

3. Efficient

4. Medium of exercise

5. Simple and Effective

6. Cheaper than Power hacksaw

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12.CONCLUSION

At the end of the design, construction and testing, a satisfactory pedal

powered hacksaw machine having Ideal Mechanical Advantage of 0.4
and a power output of 30KW was fabricated using available raw
materials and techniques. Metals pipes, plastics and pieces of wood
were cut successfully using this machine and the overall performance
was confirmed to be efficient compared to already existing ones. The
cost of production and maintenance is relatively cheap. Hence, the
machine will be welcomed by industries given its performance,
affordability and simplicity.

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