APPENDIX 1

FABRICATION OF MINI
HACKSHAW POWERED BY BEAM
ENGINE

PROJECT REPORT 2021-2022

Submitted by
Ashiq Salman
Santhosh
Prasanth Kumar
Kishore Tk

in partial fulfillment for the award of the degree

Of
BACHELOR OF ENGINEERING
In

MECHANICAL ENGINEERING
SREE SAKTHI ENGINEERING COLEGE,
COIMBATORE

ANNA UNIVERSITY :: CHENNAI 600 025

JUNE 2022
 APPENDIX 2

ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report “MINI HACKSHAW POWEERED

BY BEAM ENGINE is the Bonafide work of “ASHIQ SALMAN,
SANTHOSH PRASANTH KUMAR, KISHORE” who carried out
the project work under my supervision.

SIGNATURE SIGNATURE

HEAD OF DEPARTMENT SUPERVISOR

 APPENDIX 3

CHAPTER TITLE PAGE No.

ABSTRACT iii
LIST OF TABLES xvi
LIST OF FIGURES xviii
LIST OF SYMBOLS xxvii
FABRICATION MINI HACKSHAW
POWERED BY BEAM ENGINE
PROJECT TITLE

Design & fabrication of Beam Engine

powered reciprocating saw

Abstract:
In this project, the output of a Beam Engine is used to
drive a reciprocating saw to cut timber.
Here, instead of the rotating fly wheel, it is intended to
have a rotating reciprocating saw. This rotating
reciprocating saw is used to cut timber. Reciprocating
saws driven with electric power are a common feature.
But in places where electricity is scarce, or absent, it is
difficult to operate these Equipements. But since the
Beam Engine powered saw runs on fuel, it can be
operated even in places where electricity is totally
absent. A beam engine is a design of stationary steam
engine [1]. A stationary engine is an engine whose
framework does not move.
Usually, a stationary engine is used not to propel a
vehicle but to drive a piece of immobile
equipment such as a pump or power tools.
In a beam engine, the piston is mounted vertically, and
the piston rod does not connect directly to the
connecting rod, but instead to a rocker or beam above
both the piston and flywheel. The beam is pivoted in the
middle, with the cylinder on one side and the flywheel,
which incorporates the crank, on the other. The
connecting rod connects to the opposite end of the beam
to the piston rod, and then to the flywheel.

INTRODUCTION:

A beam engine is a type of steam engine where a

pivoted overhead beam is used to apply the force from a
vertical piston to a vertical connecting rod. This
configuration, with the engine directly driving a pump,
was first used by Thomas Newcomen around 1705 to
remove water from mines in Cornwall. The efficiency
of the engines was improved by engineers including
James Watt who added a separate condenser, Jonathan
Hornblower and Arthur
Woolf who compounded the cylinders, and William
McNaught (Glasgow) who devised a method of
compounding an existing engine. Beam engines were
first used to pump water out of mines or into canals, but
could be used to pump water to supplement the flow for
a waterwheel powering a mill.

The rotative beam engine is a later design of beam

engine where the connecting rod drives a flywheel, by
means of a crank (or, historically, by means of a sun
and planet gear). These beam engines could be used to
directly power the line-shafting in a mill. They also
could be used to power steam ships.

In this project, the output of a beam Engine is used to

drive a reciprocating saw to cut timber. Here, instead of
the rotating fly wheel, It is intended to have a rotating
reciprocating saw. This rotating saw is used to cut
timber. Reciprocating saws driven with electric power
are a common feature. But in places where electricity is
scarce, or absent, it is difficult to operate these
equipements. But since Beam Engine powered saw runs
on fuel, it can be operated even in places where
electricity is totally absent. A beam engine is a design
of stationary steam engine.
A stationary engine is an engine whose framework does
not move, Usually, a stationary engine is used not to
propel a vehicle but to drive a piece of immobile
equipment such as a pump or power tools. In a beam
engine, the piston is mounted vertically, and the piston
rod does not connect directly to the connecting rod, but
instead to a rocker or beam above both the piston and
flywheel. The Beam is pivoted in the middle, with the
cylinder on one side and the flywheel, which
incorporates the crank, on the other. The connecting rod
connects to the opposite end of the beam to thew piston
rod, and then to the flywheel.

DEVELOPMENT OF IDEA, DISCUSSION AND

SIGNIFICANCE

As mentioned earlier the motivation for this project

being the course ME 637, the course required each
student to submit a project using the Pro-E modeling
tool and the instructor emphasized that the project
should be creative and something new.
This made me think about something new and finally I
arrived at the Beam Engine idea. The word “power
tools” caught my attention and I just started to think
why not I use a beam engine to drive a circular saw to
cut timber. While electric powered saws are a common
feature as also diesel and gasoline powered saws, a saw
that works on the principle of a beam engine is
something that I thought of. This saw, which can run
either on diesel or gasoline, can be used in places where
electricity is sparse or absent.

STAGES IN NEW PRODUCT DEVELOPMENT

1. Idea generation.
2. Idea screening.
3. Concept development & testing.
4. Market strategy development.
5. Business Analysis.
6. Test Marketing.
7. Commercialization
People always welcome change and new product
development is an opportunity for the firms to meet the
changes in consumer demands.
They are a source of competitive advantage. Your new
product may infuse a fresh lease of life to your sagging
profits.
New products may turn out to be the star performers of
your firm and provide long term financial return on
your investment. Some firms take the smart strategic
choice of using the idle capacity of their plant for
manufacture of a new product that may utilize the
existing production and operation resources to an
optimum level.
They capitalize on research and development. Products
that create a wave are a result of research on market
trend and consumer preference. Firms can make it, if
their research is customer-centric rather than product-
centric.
METHODOLOGY
DESIGN OF MACHINE: In our attempt to design a
special purpose machine we have adopted a very a very
careful approach, the total design work has been
divided into two parts mainly;

System design
Mechanical design
System design mainly concerns with the various
physical constraints and ergonomics, space
requirements, arrangement of various components on
the main frame of machine no of controls position of
these controls ease of maintenance scope of further
improvement; height of m/c from ground etc.

In Mechanical design the components are categorized in

two parts.
Design parts
Parts to be purchased.
For design parts detail design is done and dimensions
thus obtained are compared to next
highest dimension which are readily available in market
this simplifies the assembly as well as post production
servicing work. The various tolerances on work pieces
are specified in the manufacturing drawings. The
process charts are prepared & passed on to the
manufacturing stage.
The parts are to be purchased directly are specified
& selected from standard catalogues.
Methodology can properly refer to the theoretical
analysis of the methods appropriate to a field of study
or to the body of methods and principles particular to a
branch of knowledge. In this chapter, it talks about the
methods used to gather information in order to finish
the research. It was involving the process flow of every
step-in archive the objective of this project.
There are many methods use in this project such as
internet references, interviewing lecturers and
technicians and the most important is group discussion.
DIAGRAM: 1 METHODOLOGY
METHODOLOGY OF WORKING PROCESS
Working Process
• Study of different Research papers
• Framing of project setup (Line diagram of the
Model)
• Dimensioning of frame, Specification of the
component for setting up a conceptual model
• Assembling Of different components
• Results & discussion about the error in the
conceptual model

MATERIAL SELECTION &;METHODOLOGY.

I.1 Material Selection
The proper selection of material for the different part of
a machine is the main objective. In the
fabrication of machine. For a design engineer it is must
that he be familiar with the effect, which
the manufacturing process and heat treatment have on
the properties of materials. The Choice of material for
engineering purposes depends upon the following
factors:
1. Availability of the materials.
2. Suitability of materials for the working condition in
service.
3. The cost of materials.
4. Physical and chemical properties of material.
5. Mechanical properties of material.

The mechanical properties of the metals are those,

which are associated with the ability of the material to
resist mechanical forces and load. We shall now discuss
these properties as follows:
A. Strength B. Elasticity
C. Stress D. Plasticity
E. Stress F. Ductility
G. Brittleness H. Malleability
I. Toughness J. Resilience
When a part is subjected to a constant stress at high
temperature for long period of time, it will undergo a
slow and permanent deformation called creep.
This property is considered in designing internal
combustion engines, boilers and turbines.

Hardness
It is a very important property of the metals and has a
wide verity of meanings. It embraces many different
properties such as resistance to wear scratching,
deformation and match inability etc. It also means the
ability of the metal to cut another metal. The hardness is
usually expressed in numbers, which are dependent on
the method of making the test.
The hardness of a metal may be determined by the
following test.

1. Brinell hardness test

2. Rockwell hardness test
3. Vickers hardness (also called diamond pyramid)
test and
4. Share scaler o scope.
In engineering practice, the machine parts are subjected
to various forces, which may be due to either one or
more of the following.
1. Energy transmitted
2. Weight of machine
3. Fictional resistance
4. Inertia of reciprocating parts
5. Change of temperature
6. Lack of balance of moving parts
The selection of the materials depends upon the various
types of stresses that are set up during
operation. The material selected should with stand it.
Another criterion for selection of metal
depends upon the type of load because a machine part
resist load more easily than a live load and live load
more easily than a shock load.
Selection of the material depends upon factor of safety,
which in turn depends upon the
following factors.
1. Reliabilities of properties
2. Reliability of applied load
3. The certainty as to exact mode of failure
4. The extent of simplifying assumptions
5. The extent of localized
6. The extent of initial stresses set up during
manufacturing
7. The extent loss of life if failure occurs
8. The extent of loss of property if failure occurs

4.4 Methodology of Design & Analysis

A parameter study is done to evaluate the most crucial
parameters for FE analysis of axial ball bearings. The
parameters that are evaluated are mesh density, contact
stiffness, osculation, load level, geometrical
nonlinearity and material nonlinearity. The studies are
performed by means of the FE software Ansys. The
accuracy of finite element analysis depends on different
parameters such as element type, boundary condition
and how the loads are applied etc. Therefore, the FE
model is nothing else but an approximate realization of
the reality. The parameter study can be done by
physical tests. However, it will increase the cost, time
and resources consumed and therefore,
 FE analysis is more suitable choice, at least for
parameter evaluation.

4.5 Theoretical aspects of the work

In this study the finite element method is adopted using
Pro Engineer and Ansys as a commercial CAD and FE
program. The following chapter contains some
fundamentals of the applied theories provided that the
reader has an initial knowledge of basic structural
mechanics, machine components, and fundamentals of
the finite element method.

4.6 Finite element method

Finite element method (FEM) is a method for
approximate solutions of partial differential
equations. The domain of interest is divided into finite
elements on which the solution is approximated by
piecewise-polynomials.
The finer the partition (Mesh) is, the more accurate the
solution.
4.7 Nonlinear Analysis
Nonlinear analysis is used when a structure behaves
nonlinear when loaded i.e., the deformation and the
stress state does not have a linear relation to the applied
load. The three main sources to nonlinear behaviors are:
contact, geometric nonlinearities and material
nonlinearities. In order to manage such calculations
with a linear process the Newton Raphson method can
be used.
4.7.1 Newton-Raphson method
Newton-Raphson is an iterative method for finding
solution to nonlinear equations and equation systems.
In FE calculations the method is used for non-linear
problems and the relations between force and
displacement is shown in Figure 2.1 for one degree of
freedom. The procedure for Newton-Raphson method is
as follows: The load is applied and the displacements
are calculated. From the displacements new conditions
are calculated and the displacements are recalculated.
This procedure is repeated until the solution is
converged i.e., reach a certain value or level.
The iterative procedure is as follows:
Material nonlinearities
A nonlinear stress-strain relationship results in a
nonlinear behavior. Plasticity is a nonlinear
stress-strain relationship as shown in Figure 2.4.
Definition of Plasticity according Ansys (2007) is:
“When a ductile material experiences stresses beyond
the elastic limit, it will yield, acquiring large permanent
deformations.”

Relationship Between Stress & Strain

4.8 Ansys
Ansys is a commercial, general purpose FE software
which has been on the market since 1971.

It can be used in several applications for example to

study the thermal heat flow, fluid flow, magnetic fields,
acoustics/vibrations and last but not least structural
mechanical problems.
4.9 Contact in Ansys
A handful of ways to handle contact are available in
Ansys. However, the one described here is
penalty based contact since it provides short calculation
times and therefore is used.
4.10 Penalty based contact
When a penalty-based contact is used, Ansys adds a
spring coefficient (k factor) when two
surfaces come in contact with each other, in order to
prevent penetration and to transfer load. However
penetration will occur in order to transfer force, which
is not the case in
reality. Therefore, the penalty-based methods
are sensitive to the choice of the spring coefficient.
The spring coefficient Ansys uses during calculations is
the product between the “normal stiffness factor”
specified by the user and a reference factor calculated
by the program. An additional aspect (apart from the
accuracy) to consider when selecting the “normal
stiffness factor” is the convergence behavior. A stiffer
contact will result in more calculation iterations, since
bouncing might occur.

4.11 Asymmetric behavior

A contact condition can be either symmetric or
asymmetric. When the contact condition is
symmetric none of the surfaces can penetrate each
other, while when the contact is specified

as being asymmetric only one of the surfaces is

prevented from penetrating the other i.e., the
contact surface cannot penetrate the target surface but
the opposite is possible. Figure 2.8 illustrates the
importance of selecting the correct contact pair.
4.12 Bilinear stress-strain curve
In context of the license version used, Ansys tender a
bilinear approximation of the stress-strain
relationship as in figure 2.9. The bilinear stress-strain
curve requires two input values, yield
strength and tangent modulus. The yield strength is the
value when plastics straining occurs and the tangent
modulus is the slope of
the stress-strain curve after yielding.
4.13 Meshing controls
Ansys offers several tools to control the meshing
procedure. The mesh densities of the whole
model can be controlled by global settings for relevance
center in three steps: coarse, medium or fine.
4.14 Method
Method is a meshing control that provides the
possibility to select different elements shapes.
The different elements that are available are:
tetrahedron or quadrilateral. Tetrahedron elements are
triangular pyramid like elements with 10 or 4 nodes
and quadrilateral elements are cube elements with 20
or 8 nodes.
4.15 Sizing
Sizing is a meshing control that provides the possibility
to mesh with different mesh densities at selected
regions. By meshing fine in the area of interest and
using coarse mesh in the remaining parts one is able to
reduce CPU time and memory usage. There are a
couple of ways to select the region of a sizing control
available in Ansys. The region can be a surface. This
will produce a fine mesh (or actually a mesh with the
size specified) on the surface only. The region can also
be an entire body which will produce a fine mesh all
over the body. If a contact region is to be analyzed,
Ansys offers the possibility to specify the mesh size in
the contact region. And to capture a local behavior it is
possible to specify a so called sphere of influence which
makes it possible to set the element size (mesh size)
within the volume of a sphere. The sphere of influence
can be used to enclose both faces and bodies.

SYSTEM DESIGN & COMPONENT

In our attempt to design a special purpose machine we
have adopted a very a very careful approach, the total
design work has been divided into two parts mainly;

System design
Mechanical design

System design mainly concerns with the various

physical constraints and ergonomics, space
requirements, arrangement of various components on
the main frame of machine no of controls position of
these controls ease of maintenance scope of further
improvement; weight of m/c from ground etc.
In Mechanical design the component in two categories.
Design parts
Parts to be purchased.

For design parts detail design is done and dimensions

thus obtained are compared to next
highest dimension which are readily available in market
this simplifies the assembly as well as
post production servicing work.
The various tolerance on work is specified in the
manufacturing drawings the process charts are prepared
& passed on to the manufacturing stage. The parts
are to be purchased directly are specified &
selected from standard catalogues.

3.1 System Design

In system design we mainly concentrate on the
following parameter

3.1.1 System selection based on physical constraints

While selecting any m/c it must be checked whether it
is going to be used in large scale or

small scale industry in our care it is to be used in small

scale industry so space is a major
constrain. The system is to be very compact it can be
adjusted to corner of a room. The
mechanical design has direct norms with the system
design hence the foremost job is to
control the physical parameters so that the distinction
obtained after mechanical design can be well fitted into
that.
3.1.2 Arrangement of various component
Keeping into view the space restriction the components
should be laid such that their easy removal or servicing
is possible moreover every component should be easily
seen none should be hidden every possible space is
utilized in component arrangement.

3.1.3 Components of system

As already stated, system should be compact enough so
that it can be accommodated at a
corner of a room. All the moving parts should be well
closed & compact A compact system gives a better
look & structure.

3.1.4 Man –m/c Interaction

The friendliness of m/c with the operation is an
important criterion of design. It is application
of anatomical. Following are some e.g., of this section

Design of machine height

Energy expenditure in hand operation
Lighting condition of m/c
3.1.5 Chances of failure
The losses incurred by owner in case of failure of a
component are important criteria of design.
Factor of safety while doing the mechanical design is
kept high so that there are less chances of failure there
over periodic maintenance is required to keep the m/c
trouble free.
3.1.6 Servicing facility
The layout of components should be such that easy
servicing is possible especially those
components which required frequent servicing can be
easily disassembled.
3.1.7 Weight of machine
The total weight of m/c depends upon the selection of
material components as well as
dimension of components. A higher weighted m/c is
difficult for transportation & in case of major
break down it becomes difficult to repair.

3.2 Mechanical Design

Mechanical design phase is very important from the
view of designer as whole success of the
project depends on the correct deign analysis of the
problem.

Many preliminary alternatives are eliminated during

this phase. Designer should have adequate knowledge
above physical properties of material, loads stresses,
deformation, and failure. Theories and wear analysis,
He should identify the external and internal forces
acting on the machine parts

These forces may be classified as;

a) Dead weight forces
b) Friction forces
c) Inertia forces
d) Centrifugal forces
e) Forces generated during power transmission etc.

Designer should estimate these forces very accurately

by using design equations. If he does not have sufficient
information to estimate them he should make certain
practical assumptions based on similar conditions which
will almost satisfy the functional needs. Assumptions
must always be on the safer side.

WORKING PRINCIPLE
When the piston in the cylinder reciprocates, it imparts
an oscillating motion to the rocker arms,
as shown in figure 1 on page 2. This oscillating motion
of the rocker arm is converted
into rotary motion by the crankshaft. The crankshaft,
which is connected to the circular saw, makes the
circular saw rotate. This rotary action of the circular
wood saw is used to saw timber or wood blocks. There
is a small table attachment for supporting the wooden
block. The wooden block is placed on the table and
pushed towards the rotating wood saw, which results in
the sawing action. The main advantage of this machine
is that it can be used in places where electricity is not
economical or in places where electricity is absent.
Fig. Linkage line diagram for beam engine

EXPERIMENTAL SETUP:
A beam engine mechanism is one where we use an
overhead beam to create motion. Here we use a beam
engine motion-based assembly in order to achieve hack
saw cutting motion using a circular cutting disc.
Our system uses a motorized disc to drive a connector
which is in turn connected to an overhead beam. The
overhead bean has a connecting rod in turn connected to
a mini hacksaw blade. When the motorized disc below
is turned on the connecting arm starts reciprocating the
overhead beam. This beam now heals achieve a back
and forth cutting motion as required by the hacksaw
blade. We construct a small bed in order to rest the
work piece to achieve desired cutting. Thus, we study
the design and fabrication of mini hacksaw using beam
engine mechanism.

WORKING OF RECIPROCATING HACKSAW

The objective of this work is to automate the
conventional power hacksaw machine in order to
achieve high productivity of work-pieces than the
power hacksaw machine using pneumatic power.
Pneumatic is a huge topic of science and engineering
dealing with the mechanical properties of air. In our
project we take this pneumatic and a hacksaw for
cutting purpose, the pneumatic reciprocating high-
speed hacksaw machine has an advantage of working in
high pressure, the hacksaw used in this is reciprocate
such that required shape can be cutted according to the
requirement. The hacksaw is the metal
cutting machine tool designed to cut metal by applying
pneumatic pressure. Hacksaws are used to cut thin and
soft metals the operation of the unit is simplified to a
few simple operations involving a cylinder block and
piston arrangement. There are numerous systems in
hacksaw machine.
The hacksaw is the metal cutting machine tool designed
to cut metal by applying pneumatic pressure.

The machine exclusively intended for mass production

and they represent fasten and more efficient way to cut
a metal. Hacksaws are used to cut thin and soft metals
the operation of the unit is simplified to a few simple
operations involving a cylinder block and piston
arrangement. There are numerous systems in hacksaw
machine.
The main function of pneumatic hacksaw is to cut thin
and soft metals by pneumatic power.

System Drawings
Parts
• DC Motor
• Disc
• Connecting Arms, Joints & Screws
• Overhead Beam
• Cutting Blade
• Support bed
• Supporting Frame

ADVANTAGES
1. The cutting speed can be varied according to our
needs by adjusting the timer.
2. It is portable.
3. It does not have any prime mover like electric motor.
4. Simple in construction than mechanical hacksaw.
5. It is compact one.
6. Less maintenance.

LIMITATION
1. Only smaller size and soft metal can be cut.
2. It is costlier than the mechanical hacksaw because of
compressor unit.
3. Less efficiency when compressor to mechanical
device.
4. Leakage of air affects the working of the unit.
APPLICATION
1. It is used in small scale industries and in large scale
industries.
2. It is useful when materials need to be cut in
hazardous areas such as oil & gas refineries,
chemical factories or oil rigs as well as duty and
wet as dusty and wet environments where electric
tools are not effective.
3. It is valuable tools in production environments such
as pallet repair, ship building or fiber glass
workshops, because they will last longer than
electric tools.
DISADVANTAGES OF MINI HACKSHAW
POWERED BY BEAM ENGINE:

1. Only smaller size and soft metal can be cut.

2. It is costlier than the mechanical hacksaw because
of compressor unit.
3. Less efficiency when compressor to mechanical
device.
4. Leakage of air effects the working of the unit
CONCLUSIONS
This being a creative project, there are no particular
instances of this type of machine being available in the
commercial market. But the aim of this project is to
show that this type of machine too is an option for
wood working industry in remote places in the absence
of electricity.

Further improvements include using reduction gears, to

vary the speed of the circular saw, having an adjustable
bed with slots for adjusting the table length, so that
even large sizes of timber can be sawed by varying the
distance of the table and the size of the circular saw.
REFERENCES
[1] http://en.wikipedia.org/wiki/Beam_engine
[2] http://www.answers.com/topic/stationary-engine
[3] http://www.keveney.com/unkbeam.html
[4] https://www.mechanical-farm.com/
[5] http://en.wikipedia.org/wiki/Stationary_engine