PROJECT REPORT ON

TITLE OF THE PROJECT

Submitted
For The Partial fulfillment of
Diploma In
Mechanical Engineering

Submitted by

Ajinkya S. Khedekar : 134110001

Raj V. Patel : 134110007

Prasad C. Ghadashi : 134110018

Vikram H. Mane : 134110076

Year 2015-2016

Under The Guidance of

Prof. K.P.Kudalkar

VEERMATA JIJABAI TECHNOLOGICAL INSTITUTE

MATUNGA, MUMBAI-400019

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 ACKNOWLEDGEMENT

“Project” is a very crucial part of every engineering student. To think of something

new and different and bringing that imagination into practical is a very tedious job.
It was not that easy for us too. But it was due to the kind co-operation & valuable
guidance rendered to us by the people we would like to mention; it became easier
for us to complete our project successfully.
We take the great pleasure to present this project report on “Pedal Powered Hacksaw
Machine”. We have taken great care that the information provided by is
satisfactorialy enough and correct, but even then we welcome any correction.

Written words have an unfortunate tendency to degenerate genuine gratitude into a

formality. However, it is the only way to record one’s feelings permanently. Hence
we take this opportunity to express our heartfelt thanks to all those who have been
associated with our project.

First of all, We are thankful to our project guide Prof. K.P.Kudalkar whose constant
encouragement, presious guidance and full-fiedge co operation has lead to the
success of this project.

We would like to thank each other for actively participating and making this project
what it is today. It was a full-blooded effort of our whole team without whom our
project would have not been fruitful. We would like to thank almighty for making
our project a full-fledged success.

We would like to express our special thanks to our Department.

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 CERTIFICATE

This is to certify that all the students of this group as mentioned earlier
have successfully completed project report on “Pedal Powered
Hacksaw Machine”, is found to be satisfactory and approved for the
partial fulfillment of Diploma in Mechanical Engg. under the guidance
of Prof.K.P.Kudalkar during the academic year 2015-2016 as
prescribed by VJTI Mumbai.

INTERNAL EXAMINER EXTERNAL EXAMINER

Date:-
Place:-

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 Contents

Chapter Page No
1 Abstract 5
2 Introduction 6
3 Future scope of the Project 7
4 Subjects Discussed 10
5 Sketch of Pedal Operated Hacksaw Machine 16
6 Main Components of Pedal Operated Hacksaw 17
Machine
7 Working Principle 36
8 Advantages and Disadvantages 37
9 Calculations 38
10 References 41

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 ABSTRACT :-
Pedal powered hacksaw machine 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. Moreover, if
we want we can generate electricity with our project by connecting it
to dynamo, diode and battery.

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 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 ¼ 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, electric or other power. An abrasive saw uses
an abrasive disc or band for cutting, rather than a serrated blade.

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 Future Scope of Pedal Powered Hacksaw Machine:-

Rice Threshing Peanut shelling

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 Winnoving

Corn Shelling

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 Operating a wood working lathe

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 SUBJECTS DISCUSSED :-
1. Stirling Engine :
A stirling engine is a heat engine that operates by cyclic compression
and expansion of air or other gas (the working fluid) at different
temperatures, such that there is a net conversion of heat energy to
mechanical work. More specifically, the Stirling engine is a closed-
cycle regenerative heat engine with a permanently gaseous working
fluid. Closed cycle , in this context, means a thermodynamic in which
the working fluid is permanently contained within the system,
and regenerative describes the use of a specific type of internal heat
exchanger and thermal store, known as the regenerator. The inclusion
of a regenerator differentiates the Stirling engine from other closed
cycle hot air engines.
Originally conceived in 1816 as an industrial prime mover to rival
the steam engine, its practical use was largely confined to low-power
domestic applications for over a century.
The Stirling engine is noted for high efficiency compared to steam
engines, quiet operation, and its ability to use almost any heat source.
The heat energy source is generated external to the Stirling engine
rather than by internal combustion as with the Otto cycle or Diesel
cycle engines. Because the Stirling engine is compatible with
alternative and renewable energy sources it could become increasingly
significant as the price of conventional fuels rises, and also in light of
concerns such as peak oil and climate change. This engine is currently
exciting interest as the core component of micro combined heat and
power (CHP) units, in which it is more efficient and safer than a
comparable steam engine. However, it has a low power-to-weight ratio
rendering it more suitable for use in static installations where space and
weight are not at a premium.

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 The energy crisis is increasing day by day, so we have to find more
ways to get useful energy. Energy saved is energy produced. Many
industries use furnaces for production processes, in which most of the
heat is lost. We can use this excess heat to run the sterling engine and
hence produce electricity.
But as the cost of the project is very high, so we decided to reject it.

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 2.Electricity Generation Using Speed Breaker :-
In this model we show that how we can generate electricity from the
busy traffic. Conversion of the mechanical energy into electrical energy
is widely used concept. It is a mechanism to generate power by
converting the potential energy generated by a vehicle going up on a
speed breaker into rotational energy.
We can use this simple concept to the project. We can connect one
mechanical rod with the dynamo and fit this rod on the surface of the
road .When any vehicle moves from this roller then due to friction,
vehicle rotate the rod or roller and roller then move the dynamo. When
dynamo move, then it generates a voltage and this voltage now
connects to the bulbs. In actual practice with the help of this voltage we
can charge the battery and then we can use this voltage to light the small
bulb. If we install this unit to the any small flyover then with the help
of this mechanism, we can generate voltage, and with the help of this
voltage we can light the bulb.
The second part of the project is the efficient use of energy by using
simple electronics. We always see that road lights continuously glow
whether vehicles are on the road or not. We can introduce a concept to
avoid this wastage of light. We can use two sensors between some
distances. When vehicle pass through first sensor it sends the signal to
the microcontroller that the vehicle is passing along that particular
distance then light will glow for that particular time and when vehicle
goes out from the second sensor.
Then the second sensor sends a signal to a microcontroller that vehicle
has been passed through that particular path then light gets off
automatically. Different types of basic electronics components has
been used to get the desired output like capacitor, resister etc.

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 We have also used a light diode resistance(LDR) when LDR senses a
light around it all the road lights gets off and when LDR senses there is
a dark around it then LDR sends a signal to microcontroller then all the
road lights gets on. By using a LDR we can avoid a waste of light that
glow in a day time. The two sensors are made from the concept of
electronics. These sensors are called an infrared sensor which is made
from photo diode and light emitting diode each. When any vehicle pass
from first sensor then first sensor becomes on, for that time the road
lights gets on and when it pass from second sensor the second sensor
become on and the first sensor gets off then the road light gets off.
It gives low and non-uniform voltage. Also, it is difficult to achieve
proper balance between speed and torque, hence we decided
against it.

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 3.Modification In Local Train’s Compartment :-
1.For ventilation in local compartments, we use fans which needs
electricity. Sufficient energy loss takes place in ventilation. we can
make easy and eco-friendly ventilation system in the compartments
using natural air flowing around the compartment due to movement of
train.
We can attach hollow structures on the roof of compartment as shown
in figure which forces the air to come inside and flows through the
windows and doors.
2.If we reduce one seat from the row of three seats which is close to
door, it will help people for comfortable boarding and alighting.
Since we cannot use this modification in rainy seasons, hence we
decided to reject it.

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 4. Crop Cutter:-
India is an agricultural country. The economy of our nation is mostly
dependent on agriculture. So for the development of our country, the
agricultural sector of our economy should be developed.
There are many steps in agriculture field like Ploughing, Sowing,
Harvesting etc.
Harvesting is the operation of cutting, picking, plucking and digging or
a combination of these operations for removing the crop from under the
ground or above the ground or removing the useful part or fruits from
plants.Harvesting action can be done by four ways:
 Slicing action with a sharp tool.
 Tearing action with a rough serrated edge
 High velocity single element impact with sharp edge.
 Two elements scissors type action.
In India harvesting is done by sickle which is time consuming process.
By using crop cutter, it speeds up the harvesting process. Since, trials
of this project are not possible in urban cities like Mumbai, hence
we decided to reject it.

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 5. Pedal Powered Hacksaw Machine :-

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 Main Components of Pedal Powered Hacksaw Machine :-
1. Pedal
2. Sprocket
3. Chain
4. Crank
5. Connecting Rod
6. Flywheel
7. Clutch
8. Bearing Blocks
9. Brake
10. Hacksaw
11. Blade

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 1. Pedal :-
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
cyclist’s 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.

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 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, 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.

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 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
'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.

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 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
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.

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

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 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.
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.

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 6.Flywheel:
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:

 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.

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  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.
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, we have 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.

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 7.Clutch:
A clutch is a mechanical device that engages and disengages the
power transmission, especially from driving shaft to driven shaft.
Clutches are used whenever the transmission of power or motion must
be controlled either in amount or over time (e.g., electric screwdrivers
limit how much torque is transmitted through use of a clutch; clutches
control whether automobiles transmit engine power to the wheels).
In the simplest application, clutches connect and disconnect two
rotating shafts (drive shafts or line shafts). In these devices, one shaft
is typically attached to an engine or other power unit (the driving
member) while the other shaft (the driven member) provides output
power for work. While typically the motions involved are rotary, linear
clutches are also possible.
In a torque-controlled drill, for instance, one shaft is driven by a motor
and the other drives a drill chuck. The clutch connects the two shafts so
they may be locked together and spin at the same speed (engaged),
locked together but spinning at different speeds (slipping), or unlocked
and spinning at different speeds (disengaged).
When we will start the machine, we will press the clutch lever so
that clutch will get disengaged and prevent the connection of
flywheel and crank. As the speed of the flywheel increases, we will
release the clutch so that it will get engaged and will connect the
flywheel and crank.

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 Friction clutches:
The vast majority of clutches ultimately rely on frictional forces for
their operation. The purpose of friction clutches is to connect a
moving member to another that is moving at a different speed or
stationary, often to synchronize the speeds, and/or to transmit power.
Usually, as little slippage (difference in speeds) as possible between
the two members is desired.

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 8. 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. 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.

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 9. Brake :-
A brake is a mechanical device that inhibits motion, slowing or
stopping a moving object or preventing its motion.
Most brakes commonly use friction between two surfaces pressed
together to convert the kinetic energy of the moving object into heat,
though other methods of energy conversion may be employed. For
example, regenerative braking converts much of the energy
to electrical energy, which may be stored for later use. Other methods
convert kinetic energy into potential energy in such stored forms
as pressurized air or pressurized oil. Eddy current brakes use magnetic
fields to convert kinetic energy into electric current in the brake disc,
fin, or rail, which is converted into heat. Still other braking methods
even transform kinetic energy into different forms, for example by
transferring the energy to a rotating flywheel.
Brakes are generally applied to rotating axles or wheels, but may also
take other forms such as the surface of a moving fluid (flaps deployed
into water or air). Some vehicles use a combination of braking
mechanisms, such as drag racing cars with both wheel brakes and a
parachute, or airplanes with both wheel brakes and drag flaps raised
into the air during landing.

Magnetic brake system:

Disclosed is a magnetic brake system for a vehicle, comprising: a
plurality of brake disk solenoids for generating the magnetic force; a
plurality of brake pad solenoids for generating the magnetic force; a
braking sensor for detecting whether a brake pedal is applied; a wheel
speed sensor for detecting wheel speed; a magnetic polarity sensor for
detecting magnetic polarity of the brake disk solenoids; and a control

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 unit for controlling the brake pad solenoids using signals from the
braking sensor, the wheel speed sensor and the magnetic polarity
sensor.
Sometimes, if we have to stop the machine in case of emergency,
then we will press the brake lever so that it will decrease the speed
of the hack saw assembly.

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 10. 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. Panel hacksaws 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
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.

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 11. 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
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.

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 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
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.

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 Selection of blade:-
Proper blade selection is important. Use the three-tooth rule at least
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.
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
life and 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 after the first few cuts and
will stretch slightly. The blade will require re-tensioning
(retightening) before further cutting can be done.

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 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
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. It’s totally manually operated
II. Time consuming as compared to electrical power hacksaw
III. Without human effort it’s not operated
IV. Not fit for heavy production

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 Calculations:-
Chain Driver Sprocket

Driven 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 = п (R1 + R2) + 2x + (R1 – R2)2/x

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 Input Power = 2 п 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
Now, we can increase the torque by increasing the length of pedal
from its centre.

The cutting force required = п x D x t x τs

where D = Diameter of workpiece
t = Cutting Depth

τs = Shear strength of material

In case of rectangular workpiece,

Fmax = 2 x (B+L) x t x τs
where, B = Breadth of workpiece
L = Length of workpiece
Maximum power required = Fmax x V
where, V = velocity of blade

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 SHEAR STRENGTH OF VARIOUS MATERIALS
Metal τs N/mm2
Carbon steel
0.10% C 245 to 310
0.20% C 308 to 385
0.30% C 364 to 469
High strength low alloy steel 315 to 446
Silicon Steel 420 to 490
Stainless steel 399 to 903
Aluminium alloys 49 to 322
Copper and Bronze 154 to 490
Lead alloys 12.8 to 41
Magnesium alloys 119 to 203
Nickel alloys 245 to 812
Tin alloys 20.5 to 77.5
Titanium alloys 420 to 490
Zinc alloys 98 to 266

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 References:
1. Theory of Machines By R.S. Khurmi and J.K Gupta,1st
multicolour edition .
2. ‘A Textbook of Production Engineering ‘ by P.C.Sharma

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