A

PROJECT REPORT ON

PEDAL OPERATED HACKSAW MACHINE

A Dissertation Submitted
in partial fulfilment of the requirement for the award of the degree of
DIPLOMA
IN

MECHANICAL ENGINEERING
SUBMITTED BY
K.PRUDHVI RAJ 15235-M-029
CH.MANOJ KUMAR 15235-M-012
K.MOUNIKA 15235-M-030
G.RAJU 15235-M-021

Under the esteemed guidance of

MS. ASIYA
M.Tech
Asst.professor

DEPARTMENT OF MECHANICAL ENGINEERING

INDUR INSTITUTE OF ENGINEERING AND TECHNOLOGY

(Affiliated to SBTET, HYDERABAD)
DIST: SIDDIPET, TS

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 DEPARTMENT OF MECHANICAL ENGINEERING
INDUR INSTITUTE OF ENGINEERING AND TECHNOLOGY
(Affiliated to SBTET, HYDERABAD SIDDIPET, DIST. TS

CERTIFICATE
This is to certify that the dissertation work entitled “PEDAL OPERATED HACKSAW
MACHINE”. Is the bonafide work done Submitted
by
K.PRUDHVI RAJ 15235-M-029
CH.MANOJ KUMAR 15235-M-012
K.MOUNIKA 15235-M-030
G.RAJU 15235-M-021

In Partial fulfilment of the requirement for the award of DIPLOMA in MECHANICL

ENGINEERING by (SBTET Hyderabad), during the academic year of 2018

ASIYA (Asst.Prof)

PROJECT GUIDE

HEAD OF DEPARTMENT EXTERNAL EXAMINER PRINCIPAL

Dr. Prabhu G Benkop

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 DECLARATION

We, the undersigned, declare that the project entitled PEDAL OPERATED HACKSAW
MACHINE is the original work done by us.

To the best of us knowledge and belief we here declare that this project bears to
resemblance to any other project submitted at Indur Institute Of Engineering And
Technology College, Siddipet or any other college affiliated to State Board of Technical
Education and Training, Hyderabad for the diploma degree.

Place :
Date :

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 ACKNOWLEDGEMENT

This satisfaction and euphoria that company the successful completion of any task
would be incomplete without the mentioning of the people whose constant guidance made it
possible. We take pleasure in presenting before you, our project, which result of studied
blend of both research and knowledge.

We express our earnest gratitude to our internal guide, Assistant professor ASIYA
Department Of Mechanical Engineering. Our project guide, for her support, encouragement
and guidance.

We express our thanks to Head of the Department, principal and college management
for all their support and encouragement.

Finally, we express our gratitude to all other members who are involved either
directly or indirectly for the completion of the project.

K.PRUDHVI RAJ (15235-M-029)

CH.MANOJ KUMAR (15235-M-012)
G.RAJU (15235-M-021)
K.MOUNIKA (15235-M-030)

ABSTRACT
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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 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.

11

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 INDEX
SR. TOPICS NAME PAGE NO.
NO

1. Introduction Of Project 17

2. Component required 18

3. Working principle 30

4. Designing Aspects and Parts Details/Drawings 31

5. Advantages and Disadvantages 35

6. Future Modifications 37

7. Conclusions 40

8. References 41

CONTENT
NAME OF CONTENT PAGE NO
TITLE 1
CERTIFICATE 2

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STUDENT PARTICULARS 4
ABSTRACT 5
LIST OF FIGURE 9
CHAPTER 1 10
1.INTRODUCION 10
CHAPTER 2
2.1 COMPONENTS REQUIRD 11
2.1.1 Pedal power hacksaw 11
2.1.2 Selecting A Power Hacksaw blade 14
2.1.3 Mounting a Power Hacksaw blade 15
2.1.4 Selecting a Band Saw Blade 15
2.1.5 Installing a Band Saw Blade 16
2.2 PEDAL ARRANGEMENT 17
2.2.1) Pedal 17
2.3 STAND SETUP PARTS 19
2.4 CRANK AND SLIDER MECHANISM 19
2.5 METAL SLAB 20
2.6 BICYCLE SEAT 26
CHAPTER 3
3.1 WORKING PRINCIPLE 23
CHAPTER 4
DESIGN 24
4.1 Base Frame 24
4.2 Upright Support 25
4.3 Hacksaw blade 26
4.4 Design Consideration

CHAPTER 5 FF
Advantages
Disadvantages
CHAPTER 6
Future Scope
CHAPTER 7
Conclusion
CHAPTER 8
References

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 LIST OF FIGURE

S.NO FIGURE NAME PAGE NO

1 Pedal power Hacksaw cutting system 14

2 Power Hacksaw blade 14
3 Power Hacksaw blade cutting operation 16
4 Pedal 16
5 Pedal power attachment 18
6 Bicycle Stand/Carrier 18
7 crank and slider mechanism 19
8 Metal slab 20
9 Metal slab 22
10 Bicycle sea 24
11 Working 25
12 Base Assembly 26
13 Upright Support Assembly 26
14 Hacks blade 29
15 Rice Threshing 29
16 Winnowing 29
17 Corn Shelling 30
18 Peanut Shelling 31
19 Operating a Circular Saw 31
20 Water Pumping from a Shallow Well 32
21 Operating a Wood Working Lathe 34

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 CHAPTER 1
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 (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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 CHAPTER 2
COMPONENTS REQUIRED

 Hack saw blade

 Pedal arrangement
 Stand setup parts
 Crank and slider mechanism
 Hack saw assembly
 Metal slab

2.1.1 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 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.

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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 1 :- Pedal Power Hacksaw cutting system

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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 vices, 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.

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2.1.2 Selecting A Power Hacksaw 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 vice.

ii) All-hard blade :- For a majority of cutting jobs, the all-hard blade is best for straight, accurate
cutting under a variety of condition then 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 injurie

Fig .2 Power hacksaw blade

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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.

2.1.3 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.

2.1.4 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 raker set is 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 aluminium,
magnesium, copper, and soft brasses. The hook tooth blade pattern also is recommended for most

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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.
2.1.5 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.

Fig 3- Power Hacksaw blade cutting operation

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2.2 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.

2.2.1 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.

Fig 4- pedal

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.

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Fig 5- pedal power attachment

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2.3 STAND SETUP PART

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.

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 centre 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 centre 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.

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

2.4 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.
The hack saw is guided by an aluminium plate. The vertical movement of the hacksaw will be
guided by to iron rods. The vertical movement will act as a feeding unit.

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 Fig 7- Crank and slider mechanism
2.5 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.

FIG 9- MEAL SLAB

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 Fig 8- METAL SLAB

2.6 BICYCLE SEAT

Fig 10- Bicycle seat

A Bicycle seat, unlike a bicycle saddle, is designed to support the rider's buttocks and back,
usually in a semi-reclined position. Arthur Graford is credited with inventing the padded bicycle
seat in 1892, and they are now usually found on recumbent bicycles. Bicycle seats come in three
main styles; mesh, hard shell and combination

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 i)MESH
A typical mesh seat consists of a metal frame with mesh stretched over it and secured with
adjustable straps, zip ties, string or shock cord.

ii)HARDSHELL
Hard shell seats are normally made of a composite material such as GRP or carbon fibre
although metal and wood versions do exist. A hard-shell seat is normally covered with some-
form of padding, this is usually closed or open cell foam although some extreme racing
machines do not have any padding on the seat to reduce weight and increase efficiency. Hard-
shell seats are generally used at more reclined angles than mesh seats.

iii)COMBINATION
A combination seat has a padded hard seat base with a mesh back.

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 CHAPTER 3

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.

fig 11- working

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 CHAPTER 4

DESIGN
4.1 BASE FRAME:-

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

Fig 12-Base Assembly

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4.2 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 13-Upright Support Assembly

4.3 HACKSAW BLADE:-

LENGTH=15 inch=36 cm

WIDTH=1 inch

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 Fig 14- Hacksaw Blade

4.4 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 fulfil 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.

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7. Excessive weight should be avoided, as durability is a prime consideration.

8. It should make use of standard bicycle parts wherever possible. 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 pedalling. 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 (crank) to a ratcheted sprocket on the shaft. During the prime-mover mode,
the bike's regular chain is slipped off of the chain-wheel, and the specially sized chain to the
power take-off mechanism is slipped on.

13. The device should be able to transmit power to a variety of machines, and changing drive ratios
should be as simple as possible. We decided that a V-belt and pulley arrangement would be most
appropriate for this. Belts do not require the precise alignment that chains do. Belts can even
accommodate pulleys that are slightly skewed with respect to each other. Changing drive ratios is

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 as easy as changing pulleys. Also, belts are reasonably efficient.

14.The device should contain a ratcheting mechanism that would let the operator "coast "
periodically to rest and conserve energy. A free wheel from any bicycle can be easily adapted for
this purpose.

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 CHAPTER 5
ADVANTAGES AND DISADVANTAGES

ADVANTAGES
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.

DISADVANTAGES

1.It is totally manually operated

2.Time consuming as compared to electrical power hacksaw
3.Without human effort it is not operated
Not fit for heavy production

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 CHAPTER-6

FUTURE SCOPE

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

Fig 15- Rice Threshing Fig 16-Winnowing

Fig 17-Corn Shelling

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Fig 18- Peanut Shelling Fig 19- Operating a Circular Saw

Fig 20-Water Pumping from a Shallow Well

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Fig 21-Operating a Wood Working Lathe

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 CHAPTER-7

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.

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 CHAPTER-8

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.

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.

[2] 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.

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14.

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