M ACHINE

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Theory & Practice

Power Hacksaws, Power Band

Saws, and Circular Saws

MODULE 1
 Module 1
OBJECTIVES

1. Illustrate the basic construction and identify the

fundamental parts.
2. Discuss the operation of power hacksaw, power bandsaw,
and circular saw.
3. Identify the safety precautions, and general principles on
the operation.

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Theory & Practice
 Module 1
POWER HACKSAW

What is a Power Hacksaw?

Power hacksaws are used to cut large sizes
(sections) of metals such as steel. Cutting
diameters of more than 10-15 mm is very hard
work with a normal hand held hacksaw.
Therefore power hacksaws have been
developed to carry out the difficult time
consuming work.

https://youtu.be/8CdRztw8CzU
Figure 1. Power Hacksaw.
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Theory & Practice
POWER HACKSAW Basic Construction

Arm or Frame
The heavy arm moves backwards and
forwards, cutting on the backwards stroke.

Figure 3. Vice and handle/thread

Figure 2. Basic construction of Power Hacksaw Vice and Handle/Thread

The metal to be cut is held in a machine which is an integral part of the base. Turning the handle
tightens or loosens the vice. The vice is very powerful and locks the metal in position.

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Theory & Practice
 POWER HACKSAW Basic Construction
Adjusting Handle
When the metal is placed and fixed in the vice, the blade is
lowered onto its top surface. The diagram below shows the arm
being lowered with the adjusting handle.

Figure 4. Coolant in cutting action.

Coolant Feed
When cutting is taking place, the metal and especially
the blade heats up quickly. Coolant should be fed
onto the blade, cooling it down and lubricating it as it
cuts through the metal.

Without the use of coolant the blade will overheat and

break/snap. This can be dangerous as the blade can
break with a powerful force, shattering.
Figure 5. Lowering the arm with the adjusting handle.
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Theory & Practice
POWER HACKSAW Basic Construction

Blades Foot/Emergency Switch

Every power hacksaw should have a foot
switch/emergency switch. This allows the operator to
turn the machine off quickly by using his/her foot to
step on the switch. The foot switch is normally
positioned at the front or side of the machine.

Figure 6. Power hacksaw blades.

Blades of power hacksaws are graded according to the

material they are made from and the number of teeth per
inch. Top quality are manufactured from High Speed Steel,
although there are cheaper alternatives such as carbon
steel blades.
In general the number of teeth per inch (TPI) range from Figure 7. Foot switch/emergency switch.
14 to 24. The more teeth per inch – the smoother the cut.

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Theory & Practice
 POWER HACKSAW Basic Construction

Drive Mechanism
Power hacksaws have electric motors
that power the blade through a pulley
system. Some have ratchet systems.
The pulley system shown below shows
how rotary power is transferred from the
motor and changed to reciprocating
motion, allowing the blade to cut through
the material.

Figure 8. Drive mechanism of a power hacksaw.

Most power hacksaws have two pulley wheels. If the bel is placed on the smaller
pulley wheel the speed of cut will be fast. Changing the belt so that it runs through
the larger pulley will reduce the speed.
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Theory & Practice
 POWER HACKSAW Operation

Operating Procedures and Guides

1. Remove any obstructions that may cause accidents.

2. Measure and mark the workpiece to be cut.
3. Fasten the workpiece securely in the vise so that the blade will saw in the
proper place. The blade will break if the work loosens in the vise.
4. Lower the saw blade carefully to start the cut. On some machines this can
be done automatically. The points of the teeth will be broken or damaged if the
blade is permitted to strike the work suddenly.
5. Make sure that the saw blade lifts about 1/8 inch on the return stroke. If
the blade fails to lift, adjustments should be made immediately, as the blade
will be damaged if operation is continued.

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Theory & Practice
 POWER HACKSAW Operation

Operating Procedures and Guides

6. When making angular cuts, make sure that the saw frame does not touch
either the work or the vise. Serious damage to the machine can result from
failure to observe this precaution.
7. When a saw blade is replaced, or a new blade is started in a new cut, it
should be noted that the new blade is wider. The new blade will stick in the
old cut unless the work is rotated in the vise a quarter turn. If the work cannot
be rotated, the new blade should be guided into the old cut.
8. The cutting speed of the power hacksaw should be varied with the
material being cut. Suggested cutting speeds are as follows: for mild steel,
130; for tool steel (annealed), 90; for tool steel (unannealed), 60. For example,
on a machine with a 6-inch stroke, the revolutions per minute of the driving
crankshaft should be 130.

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 POWER HACKSAW Safety
Safety Precautions
1. DON’T use your hands to clear the scraps from a sawing worktable.
2. DON’T wear loose clothing, jewelry or work gloves. They may get caught in
the blade.
3. DON’T drink alcohol while operating.
4. DON’T leave the machine running unattended.
5. DON’T disable safety guards, and always read instructions first.
6. DON’T cut very small items.
7. DON’T cut material other than metal.
8. When stopping or starting the saw, make sure the work is not touching the
blade.
9. Use sharp blades. Dull blades cause binding, stalling and possible kickback.

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 POWER HACKSAW Safety
Safety Precautions

Safety glasses must be worn Close fitting / protective

at all times in work areas. clothing must be worn.

Sturdy footwear must be worn Rings and jewelries must

at all times in work areas. not be worn.

Long and loose hair must

be contained.

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Theory & Practice