DESIGN AND FABRICATION OF PEDAL

DRIVEN DUAL HACK SAW CUTTING

MACHINE
PROJECT REPORT 2019-2020

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COLLEGE LOGO

Under the guidance of

Mr. xxxxxxxxxxxx

Submitted In partial fulfillment of the requirement for the award

of Diploma in Mechanical Engineering of the State Board

of Technical Education, Government of Tamilnadu.

DEPARTMENT OF MECHANICAL ENGINEERING

COLLEGE NAME
 PLACE

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

COLLEGE NAME

PLACE,

SALEM-637504

PROJECT REPORT-2019-2020

CERTIFICATE

Register No: …………………………………...Certificate that this is the Bonafide Record of the

Project Work done by Mr.……………………………………………..Of Final year Diploma in

Mechanical Engineering During the academic year 2014-2015 In partial fulfillment of the

requirements for the award of Diploma in Mechanical Engineering of the board of technical

education Tamilnadu

Head of the Department Faculty

Guide

Submitted for the board of examination held on…………………………

Internal Examiner External
Examiner

DEDICATED TO OUR BELOVED

PARENTS
ACKNOWLEDGEMENT
 ACKNOWLEDGEMENT

At this pleasing movement of having successfully completed our project, we wish to

convey our sincere thanks and gratitude to the management of our college and our beloved
chairman Mr. Lion.xxxxxxxxxxxxxx, xxx., provided all the facilities to us.

We would like to express our sincere thanks to our principal Mr.cxxxxx for forwarding
us to do our project and offering adequate duration in completing our project.

We are also grateful to the Head of Department MR.xxxxxxxxxxxxxxxx., for her

constructive suggestions &encouragement during our project.

With deep sense of gratitude, we extend our earnest &sincere thanks to our guide
Mr.xxxxxxxxxxxxx Department of Mechanical for her/him kind guidance and encouragement
during this project.

we also express our indebt thanks to our teaching staff of MECHANICAL

ENGINEERING DEPARTMENT.
DESIGN AND FABRICATION OF PEDAL DRIVEN
DUAL HACK SAW CUTTING MACHINE
CONTENTS
 CONTENTS

CHAPTER NO TITLE

SYNOPSIS
LIST OF FIGURES
1 Introduction
2 Literature Survey
3 Description of equipments
3.1 Linkages
3.2 Pedal
3.3 Spring
3.4 Hacksaw
3.5 Vice
4 Design and drawing
5 Working principle
6 Merits & demerits
7 Applications
8 List of materials
9 Cost Estimation
10 Conclusion
BIBLIOGRAPHY

PHOTOGRAPHY
LIST OF FIGURES
 LIST OF FIGURES

Figure
number Title

1 Seat
2 Linkage
3 Seat with column
4 Bearing housing
5 Frame
SYNOPSIS
 SYNOPSIS

Pedal power hacksaw is an Innovative project which can be used in all

residences, offices in which no specific input power is needed. It consists of
a cycle pedal which is directly connected to the hacksaw for the processing
of cutting the wooden blocks.
 CHAPTER I

INTRODUCTION
 CHAPTER I

INTRODUCTION

The main objective of our project is to perform various machine

operations using machine with the help of cam sources. For a developing
industry the operation performed and the parts (or) components produced
should have it minimum possible production cost, and then only industry
runs profitability. A pedal power hacksaw needs less human power to cut the
wood unlike the actual hand hacksaw.

NEED FOR AUTOMATION:

Nowadays almost all the manufacturing process is being atomized in

order to deliver the products at a faster rate. The manufacturing operation is
being atomized for the following reasons.

 Less maintenance
 A hacksaw is a fine-tooth saw with a blade under tension in a frame,
used for cutting materials such as metal or bone. Some have pistol grips
which keep the hacksaw firm and easy to grip.

Small hand-held hacksaws consist of a metal arch with a handle that

fits around a narrow, rigid blade. One edge of the blade has many small saw
teeth along almost its entire length. The blade can either be attached such
that the teeth face away from the handle, resulting in sawing action when
pushing, or be attached such that the teeth face toward the handle, resulting
in sawing action when pulling. On the push stroke, the arch will bend a little,
releasing the tension on the blade. The blade is normally quite brittle, so care
needs to be taken to prevent brittle fracture of the blade.

A panel hacksaw eliminates the frame, so that the saw can cut into
panels of sheet metal without the length of cut being restricted by the frame.
Junior hacksaws are the small variant, while larger mechanical hacksaws are
used to cut working pieces from bulk metal. Large, power hacksaws are
sometimes used to replace a band saw in machine shops.
 CHAPTER -2

LITRATURE SURVEY
 CHAPTER -II

LITRATURE SURVEY

SAW:

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.

In a modern serrated saw, each tooth is bent to a precise angle called

its "set". The set of the teeth is determined by the kind of cut the saw is
intended to make. For example, a "rip saw" has a tooth set that is similar to
the angle used on a chisel. The idea is to have the teeth rip or tear the
material apart. Some teeth are usually splayed slightly to each side the blade,
so that the cut width (kerf) is wider than the blade itself and the blade does
not bind in the cut.

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

According to Chinese tradition, the saw was invented by Lu Ban. In Greek

mythology, Talos, the nephew of Daedalos, invented the saw. In fact, saws
date back to prehistory, and likely evolved from Neolithic tools or bone
tools. The early ancestors of man, in the Pleistocene era, likely first used a
jaw bone of a bovid animal as a saw.

Types of Saw Blades and the Cuts They Make

BLADE TEETH ARE OF TWO GENERAL TYPES:

Tool steel or carbide. Carbide is harder and holds a sharp edge much longer.

CROSSCUT:

In woodworking, a cut made at (or near) a right angle to the direction

of the grain of the work piece. A crosscut saw is used to make this
type of cut.

RIP CUT:

In woodworking, a cut made parallel to the direction of the grain of

the work piece. A rip saw is used to make this type of cut.

PLY TOOTH:

A circular saw blade with many small teeth designed for cutting
plywood with minimal splintering.

MATERIALS USED FOR SAWS

THERE ARE SEVERAL MATERIALS USED IN SAWS, WITH EACH

OF ITS OWN SPECIFICATIONS.

BRASS:

Mostly used in back saws because of its low price, its flow
characteristics that make the material relatively easy to cast, and unlike other
types of saw, the forces that take place in back saws are relatively low
because of the pulling motion used.
STEEL:

Used in almost every existing kind of saw. Because steel is cheap,

easy to shape, and very strong, it has the right properties for most kind of
saws.

DIAMOND:

Used only in saws for the really heavy cutting. It is very expensive
and comes in two shapes: ropes and circular saws. Mostly used for cutting
concrete and other materials with rock-like structures or in softer materials,
such as wood, where the precision and high volume of work justifies the
expense of diamond-edged cutting tools. Diamond saws are made by
combining powder metal with diamond crystals, which are then heated and
pressed into a molding to form the diamond segments.

USES:

 Saws are most commonly used for cutting hard materials. They are
used extensively in forestry, construction, demolition, medicine, and
hunting.
 Some saws are used as instruments to make music.

 Chainsaw carving is a flourishing modern art form. Special saws have

been developed for this purpose.

HACKSAW:

A hacksaw is a fine-tooth saw with a blade under tension in a frame,

used for cutting materials such as metal or bone. Some have pistol grips
which keep the hacksaw firm and easy to grip.
 A power hacksaw is a type of hacksaw that is powered either by its
own electric motor (also known as electric hacksaw) or connected to a
stationary engine. Most power hacksaws are stationary machines but some
portable models do exist. Stationary models usually have a mechanism to lift
up the saw blade on the return stroke and some have a coolant pump to
prevent the saw blade from overheating.

While stationary electric hacksaws are reasonably uncommon they are

still produced but saws powered by a stationary engine have gone out of
fashion. The reason for using one is that they provide a cleaner cut than an
angle grinder or other types of saw.

CUTTING:

Cutting sheet metal can be done in various ways from hand tools called tin
snips up to very large powered shears. With the advances in technology,
sheet metal cutting has turned to computers for precise cutting.

Cutting is the separation of a physical object, or a portion of a physical

object, into two portions, through the application of an acutely directed
force. An implement commonly used for cutting is the knife or in medical
cases the scalpel. However, any sufficiently sharp object is capable of
cutting if it has a hardness sufficiently larger than the object being cut, and if
it is applied with sufficient force. Cutting also describes the action of a saw
which removes material in the process of cutting.
Cutting is a compressive and shearing phenomenon, and occurs only when
the total stress generated by the cutting implement exceeds the ultimate
strength of the material of the object being cut. The simplest applicable
equation is stress = force/area: The stress generated by a cutting implement
is directly proportional to the force with which it is applied, and inversely
proportional to the area of contact. Hence, the smaller the area (i.e., the
sharper the cutting implement), the less force is needed to cut something.

When referring to propagating plants, cutting is one of the methods that can
be used. It involves cutting a part of the plant typically a healthy shoot, with
sharp and sterile scissors or any other cutting device, and then placing the
removed part in water. Some cuttings do not require water. Certain shoots
when cut are able to grow when placed in vermiculite or potting soil.
However, the former is the easiest to do as most shoots when cut from the
main plant need time to grow roots, and then they are able to be transferred
to potting soil.
 CHAPTER II

DESCRIPTION OF EQUIPMENTS
 CHAPTER II

DESCRIPTION OF EQUIPMENTS

3.1.LINKAGE:

Linkage is made-up of mild steel. It is connect to cam shaft and rack.

Linkages are an essential part of many mechanisms. They can be used to
change direction, alter speed and change the timing of moving parts.In this
example two linked linkages are used to convert the small linear movement
of the drive shaft (bottom left) into first a rotational body movement and
secondly a fast hammer movement. Compare the speed of the hammer with
the speed of the drive shaft.

Linear motion is the most basic of all motions. Uninterrupted objects will
continue to move in a straight line indefinitely. Under every day
circumstances gravity and friction conspire to bring objects to rest.Linear
motion is measured in two parts. Speed, and direction. Together these make
up the velocity.Linear motion, is not often used as a starting point for
mechanisms.

3.2. PEDAL

Pedal is the part of the rider push for foot to propel by the vehicle.
Pedal were initially Attached to crank connecting directly to the driven front
plate. The pedals were attached to a plate; it is transmit power to drum.
3.3HACKSAW:

A hacksaw is a fine-tooth saw with a blade under tension in a frame,

used for cutting materials such as metal or bone. Hand-held hacksaws
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
put the thin blade under tension. The blade can mounted with the teeth
facing toward or away from the from the handle, resulting in cutting action
on either the push or pull stroke. On the push stroke, the arch will flex
slightly, decreasing the tension on the blade.

Blades are available in standardized lengths, and with anywhere from

three to thirty-two teeth per inch (tpi). The blade used is based on the
thickness of the material being cut, with a minimum of three teeth in the
material. Hacksaw blades are normally quite brittle, so care needs to be
taken to prevent brittle fracture of the blade. Bi-metal blades are meant to
minimize this risk, by fusing a strip of harder metal along the tooth edge to a
softer spine.

A panel hacksaw eliminates the frame, so that the saw can cut into
panels of sheet metal without the length of cut being restricted by the frame.
Junior hacksaws are the small variant, while larger mechanical hacksaws are
used to cut working pieces from bulk metal.
3.4 VICE

A vise or vice (see under miscellaneous spelling differences) is a

mechanical screw apparatus used for holding or clamping a work piece to
allow work to be performed on it with tools such as saws, planes, drills,
mills, screwdrivers, sandpaper, etc. Vises usually have one fixed jaw and
another, parallel, jaw which is moved towards or away from the fixed jaw by
the screw.

WOODWORKING VISES

For woodworking, the jaws are made of wood, plastic or from metal, in the
latter case they are usually faced with wood to avoid marring the work piece.
The top edges of the jaws are typically brought flush with the bench top by
the extension of the wooden face above the top of the iron moveable jaw.
This jaw may include a dog hole to hold a bench dog. In modern metal
woodworkers' vises, a split nut is almost universally used. The nut in which
the screw turns is in two parts so that, by means of a lever, it can be removed
from the screw and the moveable jaw can be quickly slid into a suitable
position at which point the nut is again closed onto the screw so that the vise
may be closed firmly onto the work.

METALWORKERS' VISES

For metalworking, the jaws are made of metal which may be hardened steel
with a coarse gripping finish. Quick change removable soft jaws are being
used more frequently to accommodate fast change-over on set-ups. They are
also kept for use where appropriate, to protect the work from damage.
Metalworking bench vises, known as engineers' or fitters' vises, are bolted
onto the top surface of the bench with the face of the fixed jaws just forward
of the front edge of the bench. The bench height should be such that the top
of the vise jaws is at or just below the elbow height of the user when
standing upright. Where several people use the one vise, this is a counsel of
perfection but is still a good guide.

The nut in which the screw turns may be split so that, by means of a lever, it
can be removed from the screw and the screw and moveable jaw quickly slid
into a suitable position at which point the nut is again closed onto the screw.
Many fitters prefer to use the greater precision available from a plain screw
vise. The vise may include other features such as a small anvil on the back
of its body but it is in general, better to separate the functions of the various
tools.

Vise screws are usually either of an Acme thread form or a buttress thread.
Those with a quick-release nut use a buttress thread.

The word 'vise' comes ultimately, from the Latin word vitis (vine), referring
to the helical tendrils of the vine. The more direct source is the French vis,
screw.

METALWORKING VISES IN MACHINE SHOPS

In high production machine work, work must be held in the same location
with great accuracy so CNC machines may perform operations on an array
of vises. To assist this, there are several machine-shop specific vises and
vise accessories.
Hard and soft machine jaws have a very important difference between other
metalworking vise jaws. The jaws are precision ground to a very flat and
smooth surface for accuracy. These rely on mechanical pressure for
gripping, instead of a rough surface. An unskilled operator has the tendency
to over-tighten jaws, leading to part deformation and error in the finished
workpiece. The jaws themselves come in a variety of hard and soft jaw
profiles, for various work needs. One can purchase machinable soft jaws,
and mill the profile of the part into them to speed part set-up and eliminate
measurement. This is most commonly done in gang operations, discussed
below. For rectangular parts being worked at 45 degree angles, prismatic
hard jaws exist with V grooves cut into them to hold the part. Some vises
have a hydraulic or pneumatic screw, making setup not only faster, but more
accurate as human error is reduced.

For large parts, an array of regular machine vises may be set up to hold a
part that is too long for one vise to hold. The vises' fixed jaws are aligned by
means of a dial indicator so that there is a common reference plane for the
CNC machine.

For multiple parts, several options exist, and all machine vise manufacturers
have lines of vises available for high production work.

 The first step is a two clamp vise, where the fixed jaw is in the center
of the vise and movable jaws ride on the same screw to the outside.
 The next step up is the modular vise. Modular vises can be arranged
and bolted together in a grid, with no space between them. This allows
the greatest density of vises on a given work surface. This style vise
also comes in a two clamp variety.
 Tower vises are vertical vises used in horizontal machining centers.
They have one vise per side, and come in single or dual clamping
station varieties. A dual clamping tower vise, for example, will hold
eight relatively large parts without the need for a tool change.

 Tombstone fixtures follow the same theory as a tower vise.

Tombstones allow four surfaces of vises to be worked on one rotary
table pallet. A tombstone is a large, accurate, hardened block of metal
that is bolted to the CNC pallet. The surface of the tombstone has
holes to accommodate modular vises across all four faces on a pallet
that can rotate to expose those faces to the machine spindle.

 New work holding fixtures are becoming available for five-axis

machining centers. These specialty vises allow the machine to work
on surfaces that would normally be obscured when mounted in a
traditional or tombstone vise setup.
 CHAPTER III

DESIGN AND DRAWING

 CHAPTER III

DESIGN AND DRAWING

3.1. SEAT
DRAWING FOR DESIGN AND FABRICATION OF PEDAL

DRIVEN DUAL HACK SAW CUTTING MACHINE

 CHAPTER IV

WORKING PRINCIPLE
 CHAPTER IV

WORKING PRINCIPLE

It contains the Pedal arrangement which rotates the wheel. The

pedal is connected to the hacksaw directly by means of a linkage. the linkage

is also connected to a stand in which the cutting operation takes place. As

the user pedals the wheel, the hack saw cuts the wooden block automatically

with less power. The spring is for compressive force while the user pedals

the wheel.
 CHAPTER V

MERITS & DEMERITS

 CHAPTER V

MERITS & DEMERITS

MERITS

 Low Installation cost.

 Easy Maintenance

 No need of Electricity.

 No need of two persons for cutting a wooden log.

 CHAPTER VI

APPLICATIONS
 CHAPTER VI

APPLICATIONS

 Can be useful while power shut down & in urgent situations.

 It is also an exercise for our body.

 Can be used for all carpenters who make the work easier.
 CHAPTER VII

LIST OF MATERIALS
 CHAPTER VII

LIST OF MATERIALS

FACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are

discussed below.

1. PROPERTIES
The material selected must posses the necessary properties for the
proposed application. The various requirements to be satisfied

Can be weight, surface finish, rigidity, ability to withstand

environmental attack from chemicals, service life, reliability etc.

The following four types of principle properties of materials

decisively affect their selection

 Physical
 Mechanical
 From manufacturing point of view
 Chemical

The various physical properties concerned are melting point, thermal

Conductivity, specific heat, coefficient of thermal expansion, specific
gravity, electrical conductivity, magnetic purposes etc.

The various Mechanical properties Concerned are strength in tensile,

 Compressive shear, bending, torsion and buckling load, fatigue
resistance, impact resistance, elastic limit, endurance limit, and modulus of
elasticity, hardness, wear resistance and sliding properties.

The various properties concerned from the manufacturing point of

view are,

 Cast ability
 Weld ability
 Surface properties
 Shrinkage
 Deep drawing etc.
2. MANUFACTURING CASE

Sometimes the demand for lowest possible manufacturing cost or surface

qualities obtainable by the application of suitable coating substances may
demand the use of special materials.

3. QUALITY REQUIRED

This generally affects the manufacturing process and ultimately the

material. For example, it would never be desirable to go casting of a less
number of components which can be fabricated much more economically by
welding or hand forging the steel.

4. AVAILABILITY OF MATERIAL

Some materials may be scarce or in short supply, it then becomes

obligatory for the designer to use some other material which though may not
be a perfect substitute for the material designed. The delivery of materials
and the delivery date of product should also be kept in mind.
5. SPACE CONSIDERATION

Sometimes high strength materials have to be selected because the

forces involved are high and space limitations are there.

6. COST

As in any other problem, in selection of material the cost of material

plays an important part and should not be ignored.

Some times factors like scrap utilization, appearance, and non-

maintenance of the designed part are involved in the selection of proper
materials.
 CHAPTER VIII

COST ESTIMATION
 CHAPTER VIII

COST ESTIMATION

1. MATERIAL COST

2. LABOUR COST

Lathe, drilling, welding, drilling, power hacksaw, gas cutting cost

3. OVERGHEAD CHARGES

The overhead charges are arrived by” manufacturing cost”

Manufacturing Cost = Material Cost + Labor Cost

Overhead Charges = 20%of the manufacturing cost

4. TOTAL COST

Total cost = Material Cost +Labor Cost +Overhead Charges

Total cost for this project =

CHAPTER IX

CONCLUSION
 CHAPTER IX

CONCLUSION

This project is made with pre planning, that it provides flexibility in

operation.

This innovation has made the more desirable and economical. This
project “DESIGN AND FABRICATION OF PEDAL DRIVEN DUAL
HACK SAW CUTTING MACHINE” is designed with the hope that it is
very much economical and help full to pump manufacturing industries in
QC departments.

This project helped us to know the periodic steps in completing a

project work. Thus we have completed the project successfully.
BIBLIOGRAPHY
 BIBLIOGRAPHY

1. Design data book -P.S.G.Tech.

2. Machine tool design handbook –Central machine tool Institute,

Bangalore.

3. Strength of Materials - R.S.Kurmi

4. Manufacturing Technology - M.Haslehurst.

5. Design of machine elements - R.S.Kurmi

6. Pneumatic handbook -R.H.warrning

7. Automobile Engineering – Dr. Kirpal Singh

PHOTOGRAPHY