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This Project Proposal is submitted in Partial Fulfilment of the Requirement for the
award of the Bachelor Degree in Mechanical Engineering of the National Institute
of Transport
MARCH 2021
DESIGN AND MANUFACTURING OF MOTORIZED HACKSAW
CUTTER MACHINE WITH AN AUTOMATIC COOLING SYSTEM
This Project Proposal Submitted in Partial Fulfilment of the Requirements for the
award of the Bachelor Degree in Mechanical Engineering of the National Institute
of Transport
……………………………………….
MR. IBRAHIM JOSEPH MWASUBILA
(PROJECT SUPERVISOR)
DATE……………………………………….
i
TABLE OF CONTENT
CERTIFICATION..............................................................................................................3
LIST OF FIGURES............................................................................................................3
LIST OF TABLES.............................................................................................................4
2.3 Relay.......................................................................................................................12
2.5 Microcontroller.......................................................................................................14
2.6 Hacksaw..................................................................................................................14
3.1 Introduction............................................................................................................15
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3.3 Data collection........................................................................................................15
REFERENCES.................................................................................................................27
iii
LIST OF FIGURES
Figure 2. 1 power hacksaw ................................................................................................7
Figure 2. 2 Pneumatic Operated Hacksaw ........................................................................8
Figure 2. 3 Pedal Operated Hacksaw.................................................................................9
Figure 2. 4 Thermocouple temperature sensor.................................................................10
Figure 2. 5 Relay..............................................................................................................11
Figure 2. 6 Coolant pump ................................................................................................12
Figure 2. 7 Microcontroller .............................................................................................13
Figure 2. 8 Hacksaw ........................................................................................................13
iv
LIST OF TABLES
Table 3. 1 Average marks for alternative A.....................................................................16
Table 3. 2 Average marks for alternative B.....................................................................17
Table 3. 3 Average marks for alternative C.....................................................................18
Table 3. 4 Determination of weighting factors................................................................19
Table 3. 5 operation sequence..........................................................................................21
Table 3. 6 Cost estimation................................................................................................25
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CHAPTER ONE: INTRODUCTION
A hacksaw is a handheld device used to slice through materials like plastic tubing and
metal funnels. Its cutting system is given by removable edges which include sharp teeth
along their external edge. As a rule, a hacksaw comprises of a metal casing that takes
after a descending confronting. A handle of plastic, wood, or metal is regularly joined to
one end of the casing[ CITATION Tan18 \l 1033 ].
The first flint saws appeared during the early Paleolithic Era, between 60,000 and
10,000 B.C. Stone saws and composite saws made of stone bladelets or "microliths" set
into a bone handle also were made during this time. The first metal blades were made
possible by the discovery of copper about 4,000 years ago. As the Iron Age began, the
weaker copper and bronze were discarded and raked teeth were finally made possible.
Eventually it became apparent that increasing the number of teeth in a saw increased the
efficiency of its use. Small saws were used for carpentry, with the Asian style of pull-
saws being specifically used by the Ancient Egyptians. Saws continued to be improved
as innovations in metallurgy were developed. Leonardo da Vinci[ CITATION Lea08 \l
1033 ].
Invented a marble saw during the fifteenth century, and many developers in Europe and
abroad took advantage of improvements in steel to create a better cutting edge.
Throughout the seventeenth century, the strongest blades were still the narrowest. The
bow saw named for its structural similarity to the bow and arrow continued to be popular
because of this limitation. The popularity of the wooden frame saw among the early
European settlers in America has been attributed to the scarcity of metal in the colonies
at that time, as well as to the lack of wide-rolled steel. With the advent of the Industrial
Revolution, stronger, more durable saws were produced[ CITATION Tan18 \l 1033 ].
1
1.2 Problem statement
Sawing machine operations are achieved with dry cutting machines that is, they are not
designed for use with liquid coolants. As a result of that the machine operators
sometimes stop operation for few minutes to apply coolant on the sawing blade and this
interception usually result in downtime depending on the interception time. However,
some indications during cutting operation such as blue, brown, or burned chips implies
the lack of coolant, insufficient cooling, incorrect coolant or incorrect coolant feed. The
heat generated during cutting may increase the blade temperature, reduce its mechanical
strength, thereby causing plastic deformation in the shear zone of the cutting blade and
possible failure such as braking of saw blade, curved cutting, teeth braking. This
challenge could have been avoided through an alternative way of cooling system. This
proposed aimed at design and manufacturing the motorized hacksaw machine which will
have an automatic cooling system. In this machine there will be a temperature sensor
that sensing the temperature of the work piece and saw blade during cutting operation
then gives temperature signals to microcontroller. Microcontroller will give voltage
signal that actuate a coolant pump which will pour coolant to work piece in order to
reduce the heat generated during the cutting process.
2
1.3 Project Objectives
1.3.1 Main Objective
The main objective of the project is to design and develop of hacksaw cutter machine
with an automated cooling system.
i. To study the existing and different hacksaw and other related engineering
literature concerns about hacksaw machine.
ii. To prepare an engineering details and assembly drawings of machine
iii. To manufacture prototype.
iv. To testing of prototype.
3
CHAPTER TWO: LITERATURE REVIEW
2.1 Different types and designs of hacksaw
It is important to classify what types of products are available, their intended purpose,
and their target audience. By Looking into patents was also necessary while
benchmarking the product in order to determine related concepts to the design that may
not have made it to the market yet. This provides a deeper understanding of designs that
were created for hacksaw [ CITATION Owu04 \l 1033 ].
4
An automated power hacksaw machine gives high efficiency in brief day and age in
examination with the ordinary power hacksaw machines. The real preferred standpoint
of this machine is intercession of work is lessened to greatest level. In this fast-
developing modern segment the utilization of intensity Hacksaw machine is wide, time
and work assume a noteworthy part underway process. The Material choice and testing
of hacksaw sharp edge in light of mechanical properties expressed that the suitable saw
edge must be chosen for better activity and fine cutting by choosing number of teeth per
inch[ CITATION Bah12 \l 1033 ].
5
2.1.3 Pedal Operated Hacksaw
The pedal operated hacksaw machine is cutting machine which runs without electricity
and consumes less human power as compared to hand operated hacksaw. It is used for
cutting different metals, and ferrous materials. It has been observed that if the machine is
designed ergonomically to suit human comfort more power output can be obtained out
of the same input. The energy from the pedal is transferred to the hacksaw blade via a
slider crank mechanism[ CITATION Ash16 \l 1033 ].
6
This happens on account of the phenomena called the thermoelectric effect.
Thermocouples are generally inexpensive, as their design and materials are simple. The
other type of contact temperature sensor is called a thermistor. In thermistors, resistance
decreases as temperature increases. There are two main types of thermistors: Negative
Temperature Coefficient and Positive Temperature Coefficient. Thermistors are more
precise than thermocouples (capable of measuring within 0.05-1.5 degrees Celsius), and
they are made of ceramics or polymers. Resistance Temperature Detectors are
essentially the metal counterpart of thermistors, and they are the most precise and
expensive type of temperature sensors. Temperature sensors are used in automobiles,
medical devices, computers, cooking appliances, and other types of machinery [ CITATION
Tho17 \l 1033 ].
7
2.3 Relay
A relay is an electromagnetic switch operated by a relatively small electric current that
can turn on or off a much larger electric current. The heart of a relay is an electromagnet
a coil of wire that becomes a temporary magnet when electricity flows through it. It is
like a kind of electric lever, switch it on with a tiny current and it switches on
("leverages") another appliance using a much bigger current. As the name suggests,
many sensors are incredibly sensitive pieces of electronic equipment and produce only
small electric currents. But often we need them to drive bigger pieces of apparatus that
use bigger currents. Relays bridge the gap, making it possible for small currents to
activate larger ones. That means relays can work either as switches turning things on and
off or as amplifiers converting small currents into larger ones[ CITATION Tho17 \l 1033 ]
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2.4 Coolant Pump
The role of the coolant pump is to ensure that coolant is distributed evenly throughout
the structure in which it is situated. Coolant is any substance (generally speaking a liquid
or gas though) that is used to regulate the temperature of a system. In industrial
processing, the term ‘heat transfer fluid’ often replaces the term ‘coolant.’ Coolant
pumps are used in a range of industries, which has led coolant pumps to specialize in a
number of different ways. Typically though, a coolant pump is a submersible multistage
centrifugal pump. Put in simpler terms, a coolant pump is capable of operating fully
submerged in liquid, and works by imparting energy from the rotation of multiple shaft-
driven impellers to the coolant. It is important to differentiate machine tool coolant
pumps (which are the kind we deal in here at Pump Sales Direct) from the coolant
pumps you might find in your car, or further still, in a nuclear reactor. Although
functionally similar – they all work by pumping a coolant around – there are a number
of subtle differences that distinguish them from one another in practice. A coolant pump
designed for a pressurized water reactor for example, is more elaborate and technical as
it needs to be able to transfer heat in a steam generator to water across different pressure
circuits. Meanwhile, in car engines and machine tools, the role of the coolant pump is
more straightforward as they are only needed to circulate coolant irrespective of pressure
differentials[ CITATION Ale18 \l 1033 ].
9
2.5 Microcontroller
A microcontroller is an integrated circuit (IC) device used for controlling other portions
of an electronic system, usually via a microprocessor unit (MPU), memory. These
devices are optimized for embedded applications that require both processing
functionality and agile, responsive interaction with digital, analog, or electromechanical
components[ CITATION Ben19 \l 1033 ].
10
CHAPTER THREE: MATERIAL AND METHODS
3.1 Introduction
For the purpose of carrying off the objective of designing and manufacturing of
motorized hacksaw with automatic cooling system the following methods will be used.
i. Literature review
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3.5 Selection of a suitable design
In order to get the best alternative solution of this design, the following factors should be
considered:
i. Production cost
ii. Durability
iii. Capacity
iv. Maintainability
v. Efficiency
vi. Ergonomics
vii. Safety.
3.6.1 Alternative A
Hacksaw machine that is connected to pulley using connecting rod that is rotated along
with motor that is located on the rear side.
Advantages
Disadvantages
12
Table 3. 1 Average marks for alternative A
3.6.2 Alternative B
Hacksaw machine that is connected to pulley using connecting rod that is rotated along
with a motor located on the top of supporting frame.
Advantages
Disadvantages
i. It is complex to manufacture.
ii. There is no space for location of coolant tank and pump.
13
Judges Produ Space Maintain safet Ergono Power Efficien
ction Utilization ability y mics consumptio cy
Cost n
1 3 3 4 4 3 4 4
2 4 4 4 3 4 3 3
3 3 3 4 4 4 3 4
AVARA 3.3 3.3 4 3.7 3.7 3.3 3.7
GE
3.6.3 Alternative C
Hacksaw machine that is connected to pulley using connecting rod that is rotated along
with motor that is located on the rear side and it has large space for location of coolant
tank.
Advantages
i. It is simple to manufacture.
ii. There is space for location of coolant tank.
iii. It has more efficiency compared to alternative A and B.
iv. It easy to operate.
Disadvantages
14
ction Utilization ability y mics consumptio cy
Cost n
1 4 4 4 4 3 4 4
2 4 5 4 3 4 3 3
3 4 3 4 4 4 3 4
AVARA 4 4 4 3.7 3.7 3.3 3.7
GE
15
3.6.5 Best alternative
Production cost
Total score
Safety
Rank order
Ergonomic
Space utilization
maintainability
Power consumption
efficiency
Alternatives
From the above table the best alternative is the one with the highest rank which is
alternative C that is a motorized hacksaw with motor located at rear side and it has large
space for location of coolant tank
16
3.7 Manufacturing of prototype
The motorized hacksaw machine with cooling system it consists of the following
hacksaw belt and pulley, shaft, hacksaw main frame
17
The transmission system is a V-belt transmitting power via a pulley. Thus, the pulley
speed can be determined using the general formula given in equation
D1 N 1
= (3.1).
D2 N 2
Where,
The formula for determining the length of the belt drive is given by equation
(D 2−D 1)2
L = 2C + 1.57(D2 + D1) (3.2).
4C
C = Centre distance
18
The power required by the hacksaw to cut the work piece given by equation
P = FV (3.3).
Where
V = speed
𝑇 = 𝐹𝑙 (3.4).
Where
T = Torque
F = Force
R−r
sin𝛽 =
C
(3.5).
Where
19
vi. Determination of Tension in the Tight Side of the Belt
T 1=A∗σ (3.6).
Where
T 1−mv 2 μθ
sinβ
=e (3.7).
T 2−mv 2
Where
θ = groove angle
μ = coefficient of friction
20
3.9 Cost estimation
According to literature review these are cost of components and materials that will be
used to manufacture motorized hacksaw machine.
GRAND 525000
TOTAL
21
3.10 Gantt chart
Chart 3.1 showing project activities schedule
weeks
0 2 4 6 8 10 12 14 16
Title defending
Proposal writing
Literature Revew
Report writing
Final presentation
22
REFERENCES
Joseph E Shigley. (2008). Automated Double Hacksaw Cutter. International Journal of
Engineering Research & Technology (IJERT).
23
Learn about hack saws. (2008, 10 31). Retrieved from bright hub Engineering:
https://www.brighthubengineering.com/machine-design/13709-what-is-a-hack-
saw
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