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CHAPTER-1
INTRODUCTION
INTRODUCTION
PEDAL
(Fig:-1.1)
1.1 PEDALING :-
Pedaling is a lever like part worked by the foot to supply power in
various mechanisms, as the bicycle.
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.
Most hacksaws are hand saws with a C-shaped frame that holds a blade
under tension. Such hacksaws have a handle, usually a pistol grip, with
pins for attaching a narrow disposable blade. The frames may also be
adjustable to accommodate blades of different sizes. A screw or other
mechanism is used to put the thin blade under tension.
On hacksaws, as with most frame saws, the blade can be mounted with
the teeth facing toward or away from the handle, resulting in cutting
action on either the push or pull stroke. In normal use, cutting vertically
downwards with work held in a bench vice, hacksaw blades are set to
be facing forwards.
(Fig:-1.2)
CHAPTER-2
LITERATURE REVIEW
LITERATURE REVIEW
In cutting operation as or blade descends upon the metal, the pressure
exerted by the blade first cause the plate deformation of the
metal.Cutting is a collection of processes wherein material is brought to
a specified geometry by removing excess material using various kinds
of tooling to leave a finished part that meets specifications. The net
result of cutting is two products, the waste or excess material, and the
finished part. In woodworking, the waste would be sawdust and excess
wood. In cutting metals the waste is chips or swarf and excess metal.
There are many technologies available to cut metal and wood, including:
2) Machine technologies:
For larger projects or those that use thicker or more robust metals,
manual cutting is not always practical. There are numerous
machine-based cutting methods to choose from, based on your
metal cutting needs.
Grinder – For projects that require the finished part to be
extremely smooth, a grinding machine may be your tool of
choice. Using a rotating blade or wheel made of an
abrasive material; a grinder uses friction to wear down the
surface of the metal until it is smooth, similar to sanding
wood.
Lathe – Using a sharpened cutting tool against a rapidly
spinning piece of material, a lathe will cut a piece of metal
to its desired shape. This machine is very common in the
machining industry because it allows for a higher degree of
precision.
Punch – This machine uses an extreme amount of pressure
to force sharpened blades into or through metal to cut it
into the shape desired. The amount of pressure generated
by a machine punch is far greater than any human worker
could produce, thus this cutting method is suitable for
metals that are more robust. Some machine punches are
3) Welding/burning process
Laser cutting is one of the newest and most exciting methods in
cutting technology. These cutters apply an intense beam of light to
the metal, heating it past its melting point, and then cut through the
metal. A laser cutter is able to concentrate light onto a very small
area, which makes this method suitable for projects that require a
very high degree of precision. However, this method is slower and
more expensive than other methods of metal cutting.
CHAPTER-3
COMPONENTS AND DESCRIPTION
Cutting machine
Welding machine
Surface grinding machine
Files
Hacksaw
3.2 PEDALS
(Fig:-3.1)
Pedals were initially attached to cranks connecting directly to the
driven wheel. The safety bicycle, as it is known today, came in to being
when the pedals were attached to crank driving sprocket that
transmitted power to the driven wheel by means of a roller chain.
Pedals usually consist of a spindle that threads into the end of the crank
and a body, on which the foot rests or is attached, that is free to rotate
on bearings with respect to the spindle. Pedal will be used to transfer
our muscular energy to the large sprocket
(fig:-3.2)
(fig:-3.3)
3.4 CRANK
Crank will convert rotary motion of shaft into the reciprocating motion
which will further transmit to the hack saw assembly.
(Fig:-3.4)
3.5 1H P MOTOR
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 and time consuming
work.
(Fig:-3.5)
(Fig:-3.6)
(Fig:-3.7)
3.8 HACKSAW
A hacksaw is a fine-toothed saw, originally and principally for
cutting metal. They can also cut various other materials, such as plastic
and wood; for example, plumbers and electricians often cut plastic pipe
and plastic conduit with them. There are hand saw versions and
powered versions (power hacksaws). Most hacksaws are hand saws
with a C-shaped frame that holds a blade under tension. Such hacksaws
have a handle, usually a pistol grip, with pins for attaching a narrow
disposable blade. The frames may also be adjustable to accommodate
blades of different sizes. A screw or other mechanism is used to put the
thin blade under tension. Panel hacksaws forgo the frame and instead
have a sheet metal body; they can cut into a sheet metal panel further
than a frame would allow. These saws are no longer commonly
available, but hacksaw blade holders enable standard hacksaw blades to
be used similarly to a keyhole saw or pad saw. Power tools including
nibblers, jigsaws, and angle grinders fitted with metal-cutting blades
and discs are now used for longer cuts in sheet metals.
(Fig:-3.8)
3.9 BLADE
Blades are available in standardized lengths, usually 10 or 12 inches for
a standard hand hacksaw. "Junior" hacksaws are typically 150mm long.
Powered hacksaws may use large blades in a range of sizes, or small
machines may use the same hand blades.
The pitch of the teeth can be anywhere from fourteen to thirty-two teeth
per inch for a hand blade, with as few as three tpi for a large power
hacksaw blade. The blade chosen is based on the thickness of the
material being cut, with a minimum of three teeth in the material. As
hacksaw teeth are so small, they are set in a "wave" set. As for other
saws they are set from side to side to provides kerf or clearance when
sawing, but the set of a hacksaw changes gradually from tooth to tooth
in a smooth curve, rather than alternate teeth set left and right
(fig:-3.9)
3.10 SPECIFICATIONS
1) PEDAL ARRANGEMENT
Bycycle crank :- 1
Pedals :- 2
Shaft :- 1
Diameter :- 15mm
Length :- 200mm
Bearings :- 2
2) MOTOR
Capasity :-1HP
Type of motor :- AC motor
Phase :- single phase
RPM :- 400
3) PULLEY
Diameter :- 250mm
Thickness :- 15mm
Weight :- 750g
Belt used :- V-Belt
Belt length :- 34 inch
4) CONNECTING ROD
NO of rods :- 2
Diameter of rod :-15mm
Length of the rod :- 350mm
5) CRANK
Diameter :- 250mm
Thickness :- 10mm
Weight :-1.2kg
6) BASE FRAME 1
Type of material :- mild steel
Length :- 1300mm
Width :- 650mm
Height :- 150mm
Flat width :- 50mm
Flat thickness :- 6mm
Angle plate angle :- 900
Angle palte dimensions :- 50*50 mm
Angle plate thickness :- 6mm
7) BASE FRAME 2
Type of material :- mild steel
Length :- 800mm
Width :- 300mm
Height :- 300mm
Flat width :- 25mm
Flat thickness :- 5mm
Angle plate dimensions :-25*25 mm
Angle plate angle :- 900
Angle plate thickness :- 5mm
(Fig:-3.10)
CUTTING POSITION
(Fig:-3.11)
CHAPTER-4
WORKING PROCEDURE
WORKING PROCEDURE
(Fig:- 4.1)
(Fig:-4.2)
PROCESS FLOWCHART
CHAPTER- 5
ESTIMATION, COSTING,
ADVANTAGES AND
DISADVANTAGES
ADVANTAGES:-
It could be assemble and dissemble
Less efforts needed
It is very useful into rural areas and normal workshop
Time saving as compared to simple hacksaw
Power saving as it is manually operated
Easy machinery used
Comfortable than ordinary hacksaw
DISADVANTAGES:-
CHAPTER-6
CONCLUSION AND FUTURE SCOPE
CONCLUSION
In conclusion remarks of our project work, let us add a few more lines
about our impression project work.
The fast operation is done by the power operated unit. The project is a
low cost automation project.
FUTURE SCOPE
It can be given high power motor so that work can be done faster and
productivity can be increased and indirectly it will lead to profit to
companies.
Thickness of the blade can be increased and it can easily cut large
thickness of metal pipe at any large diameter of work piece.
It can be made hydraulically power operated by installing the gear oil
pump at the place of pedal arrangement and power system arrangement.
In future it is very useful into rural areas and normal workshop.
The machine can be fully automated by using microcontroller. In fully
automated machine the operator need not measure the length of the
workpiece that is to be cut and to load and unload the work piece each
time after a piece has been cut.
REFERENCES
PHOTOGRAPHY:-
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