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ACKNOWLEDGEMENT

I would like to articulate my deep gratitude to my project guide Prof. who has
always been source of motivation and firm support for carrying out the project.
Head of the Department, MECHANICAL Engineering for his invaluable
suggestions and constant encouragement all through the Project work. I would
also like to convey our sincerest gratitude and indebtedness to all other faculty
members and staff of Department of Mechanical Engineering, SCET Kalol, who
bestowed their great effort and guidance at appropriate times without which it
would have been very difficult on my project work. An assemblage of this
nature could never have been attempted with my reference to and inspiration
from the works of others whose details are mentioned in references section. We
acknowledge our indebtedness to all of them. Further, I would like to express
our feeling towards my parents and God who directly or indirectly encouraged
and motivated us during this dissertation.
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ABSTRACT

In this Pedal power 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, and
PVC materials. The objective of the model 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 and power 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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TABLE OF CONTENT

Chapter 1 Introduction.................................................................................09
1.1 Introduction…………………………………..
Chapter 2 Literature……………………….12
Chapter 3 Design Consideration……………………….12
3.1 Performance
3.2 Safety
3.3 Reliability
Chapter 4 Design Calculation……………………….12
Chapter 5 Measuring Instrument’s ……………………….12
Chapter 6 Comparison of methods, tools, component….12
Chapter 7 Analysis ……………………….12
Chapter 8 Conclusion...............................................................................................38

Chapter 9 Future scope...........................................................................................4

Chapter 10 References................................................................................................42
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CHAPTER: - 1
INTRODUCTION
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1.1 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.

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.

In 3rd semester we are go in some plastic industries and observe

company,workers activities, employee’s activities, behavior between each other,
machineries and after then asked some questions about their faults. We learn
three sheet like Empathy Mapping, Ideation Canvas & last one is Product
Development Canvas.
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1. EMPATHY CANVAS:-
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 Our USER is TECHNICIAN

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2.IDEATION CANVAS
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3. PRODUCT DEVELOPMENT CANVAS

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2.LITERATURE SURVEY:-
R. Subash, K. Samuel Jayakaran

In this paper author has designed 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 sprocket
arrangement, the crank and slider mechanism, the chain drive. In the
mechanism, chain drive is directly connected to the hacksaw for the processing
of cutting the wooden blocks. The objective of the paper 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.

UmeshBokade, Zakiuddin Syed Kazi and Girish D Mehta

The author proposed the designed model

which will convert the dirty/saline water into pure/ potable water using the
renewable source of energy (i.e., Human power). The machine consists of a
human-powered flywheel motor using a bicycle-drive mechanism with speed-
increasing gearing and a flywheel, which drive the process unit though a spiral
jaw clutch and torque increasing gearing. The operator puts energy into the
flywheel at a convenient power level for about one minute. After enough energy
is stored, pedaling is stopped and the energy in the flywheel is made available to
the process unit.

S.G.Bahaley, Dr. A.U. Awate, S.V. Saharkar

In this paper the author designed and fabricated a pedal powered

multipurpose machine. It is a human powered machine which is developed for
lifting the water to a height 10 meter and generates 14 Volt, 4 ampere of
electricity in most effective way. Power required for pedaling is well below the
capacity of an average healthy human being. The system is also useful for the
work out purpose because pedaling will act as a health exercise and also doing a
useful work
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2.1 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.

2.2 PROBLEM DEFINITION: -

In the earlier days, using of hacksaw
from hand required more effort so that to overcome this effort, it has tried to
make a device (pedal powered hacksaw) which can reduce the effort because
powered transmit through the human leg to the pedal. This device makes less
effort as compared to the earlier devices.

2.3 DESIGN AND CONSTRUCTION: -

The exercise bicycle frame is
fixed with the base mild steel by the process of welding. The chain sprocket
is connected to the cycle frame and it is connected to the pedals. The one end
of the connecting rod is connected to the big sprocket and the other end is
connected to the hacksaw. The circular rod is inserted into the bearing and is
welded with the sprocket at one end. The connecting rod is connected to the
rotating disc at one end and to the hacksaw at the other end.

The hacksaw moves in one

and fro motion when the pedal is powered, so as the rotating disc rotates.
The vice is fixed at the stand to hold the work piece tightly in a straight
position. As the pedal is powered by the human energy, the hacksaw blade to
move in one and fro motion. When the hacksaw moves, the work piece metal
will be cut into a desired shape.
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2.4 COMPONENT OF PEDAL POWER HACKSAW:-

1. Pedal arrangement

2. Stand setup parts

3. Supporting frame

4. Crank and slider mechanism

5. Hack saw assembly

6. Dual chain drive assembly

7. Sprockets

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
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2.5 STEP OF CONSTRUCTION:-

Design and construction of pedal
powered hacksaw are completed in mainly four steps.

1. Design and improvement

2. Modification and development

3. Design and development of work piece stand frame

4. Complete assembly of equipment’s

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2.6 ADVANTAGE OF PEDAL POWER HACKSAW

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.

2.7 DISADVANTAGE OF PEDAL POWER HACKSAW

1. it’s totally manually operated

2. Time consuming as compared to electrical power hacksaw

3. Without human effort it’s not operated

4. Not fit for heavy production

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CHAPTER 3
DESIGN CONSIDERATION
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3. DESIGN CONSIDERATIONS: -
When designing our attachment, the following considerations were taken
into account:

1. The device should be appropriate for local manufacturing competence.

2. The attachment should employ low-cost materials and mechanized methods.

3. It should be accessible and reasonable by low-income groups, and should

accomplish their basic need for mechanical power.

4. It should be simple to manufacture, maneuver, maintain and repair.

5. It should be as multi-purpose as possible, on condition that power for various

agricultural implements and for small machines used in rural industry

3.1 PERFORMANCE:-
This machine works in all season so by performance wise it
is good.

3.2 SAFETY:-
1. Wear gloves

2. Use safety goggles and safety shoes

3.3 Reliability:-
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CHAPTER 4
DESIGN CALCULATION
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4.1 CALCULATIONS:-
1. Hacksaw frame: (L×W×H) =

2. Hacksaw blade (hole to hole): (L) =

3. Connecting rod: (L×W×H) =

4. Circular disc (Bush):

5. Vice: (L×W×H) =

Maximum Power applied (P) = (2×π×N×T)/60 =

SR NO NAME OF COMPONENT MATERIAL

1. Pedal S.S

2. Stand & Base Frame Metal

3. Crank & Slider Mechanism Cast Iron

4. Hacksaw Tungsten &

Molybdenum Steels

5. Nut & Bolts S.S

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4.2 COST ESTIMATION:-

NAME OF PIECE PRICE/PIEC TOTA

SR.NO COMPONEN S E L
. T
1. Pedal 2 200 400

2. Stand 1 350 350

3. Base Frame 1 750 750

4. Crank & Slider 1 900 900

Mechanism

5. Clamp 2 130 130

6. Hacksaw 1 550 550

7. Nut & Bolts 7 10 70

8. Welding Cost 380 380

Total 3660
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CHAPTER 5
MEASURING INSTRUMENTS
.

5.1 MEASURING INSTRUMENTS

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List of measuring
instruments
Measuring tap
Scale
Scale
Micrometer
Vernier caliper
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CHAPTER 6
COMPARISON OF TOOLS\MATERIAL &
COMPONENT

6.1 COMPARISON OF TOOLS & COMPONENT

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SR NO NAME OF COMPONENT MATERIAL

1. Pedal S.S

2. Stand & Base Frame Metal

3. Crank & Slider Mechanism Cast Iron

4. Hacksaw Tungsten &

Molybdenum Steels

5. Nut & Bolts S.S

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CHAPTER 8
CONCLUSION

8.1 CONCLUSION:-
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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
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CHAPTER 9
FUTURE SCOPE
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9.1 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:-Rice Threashing Fig:-Winnoning

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Fig:- Water Pumping From a shallow Well

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CHAPTER 10
REFERENCES
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10.1 REFERENCES: -
1. Venkatesh.G., Thanga p., Naresh., Vishal N., Khanna S.,
Sivaubramanian A., Arunkumar G., “ Design and Fabrication of Pedal Operated
Hacksaw “, International Journal of Scientific Research (IJSR), Vol. 3, Issue
11,2014

2. Subash R., Meenakshi C.M., Samuel Jayakaran K., Venkateswaran

C.,.Sasidharan R, “Fabrication of pedal powered hacksaw using dual chain
drive”, International Journal of Engineering & Technology, 3 (2) (2014). .

3. Umesh B. ,Zakiuddin Syed K., Girish M., “Design and development of

manually energized water distillation device”, International Journal of
Mechanica engineering and Robotics research, Vol. 2, No. 1, January 2013.

4. Bahaley S.G., Dr. Awate A.U., SaharkarS.V,”Performance Analysis of

Pedal Powered Multipurpose Machine”, International Journal of Engineering
Research & Technology (IJERT), Vol. 1 Issue 5, July – 2012.

6. John F., Lawrence M. Halls, Lauren H., “Understanding Pedal Power”,

Volunteers in Technical Assistance (VITA), 1815 North Lynn Street, Suite 200.