GOVERNMENT POLYTECHNIC COLLEGE

THOOTHUKUDI- 628 008

PROJECT REPORT
ON
FABRICATION OF SOLAR POWER HACKSAW MACHINE

Under the Guidance of

Thiru.B.RAMESHKUMAR, B.E, MBA,
Submitted by

S.NO REG.NO NAME

1 12200839 K.THANGARAJ
2 12200840 L.THIRUMANI
3 12200841 M.VADIVELAN
4 12247104 S.ANANTH
5 12247105 S.BALASIVA
6 12247106 M.DURAI MURUGAN

Submitted in partial fulfillment for the award of

Diploma In Mechanical Engineering of
State Board of Technical Education, Tamilnadu.

DEPARTMENT OF MECHANICAL ENGINEERING

ACADAMIC YEAR 2013-2014
 GOVERNMENT POLYTECHNIC COLLEGE
THOOTHUKUDI -628 008

BONAFIDE CERTIFICATE

This is to certify that the project entitled

“FABRICATION OF SOLAR POWER HACKSAW MACHINE” is a
Bonafide record work submitted by selvan. _______________________________

RegNo. ________________________ in the sixth semester Diploma in

MECHANICAL ENGINEERING course during the year 2013– 2014.

Guide Head of the Department

Thiru.B.RAMESH KUMAR, B.E, MBA Thiru.P.Muthurasu, M.E,MIE,

Submitted for Board Practical Examination held on_______ ____________

 OBJECTIVES

The prolonged convention of covering the vast syllabus

with in the short of time resulted in lack of technical knowledge and unaware of
modern mechanics and versatile applications. So in order to revise this situation
and have to clear knowledge about modern mechanics and machine tools project
work has been undertaken.

The project resulted in acquiring well defined knowledge

about the modern machine tools and equipments, Mechanism and their versatility.
The Project work includes the Physical and mental co-operation of each individual.

It evolves out the concept of group activity. It further

promotes co-operation, co-ordination and ability of individual.

That is a way applying the above concepts, we have carry

out our project is fabrication of solar power hack saw machine.

We ourselves planned organized and executed to bring

our project as successful one.
 CONTENTS

 ACKNOWLEDGEMENT
 PREFACE
 SYNOPSIS
 INTRODUCTION
 COMPONENTS
 CONSTRUCTION
 SPECIFICATIONS
 DRAWINGS
 DESIGN CONSIDERATION
 WORKING PRINCIPLE
 BILL OF MATERIALS
 COST ANALYSIS
 APPLICATIONS
 ADVANTAGES
 CONCLUSION
 PHOTOGRAPHY
 BIBLIOGRAPHY
 ACKNOWLEDGEMENT
The successful completion of this project is
only due to the joint work of us but also it includes the
unforgettable guidance given by our staff members of
department of mechanical Engineering.
We convey our deepest gratitude towards
Er. V.SUBBARAJ, M.E, B.Tech., Ed. Our beloved principal
for providing the opportunity to do this project work and
offering the the encouragement for successful completion, which
increase our optimism.
We express our sincere thanks to our Head
of Mechanical Engineering Department Er. P.MUTHURASU,
ME,MIE., for providing all facilities in time and for this
encouragement throughout the project.
We express heartfelt gratitude to our guide
Er. B. RAMESH KUMAR, B.E, MBA., who has given
suggestions and valuable guidance towards our project which
made a successful one.
Finally , we pay out hearty thanks to all the
staffs of our department and other who helped either directly or
indirectly for the successful completion of this project.
 PREFACE

We thank our director of Technical Education who has

introduced the subject project work in the curriculum of final semester in

mechanical engineering .this subject has helped us to improve our practical

knowledge. We have gained much practical skill by doing this project which will

be very use full our future It has given confidence to every one of us for starting a

small scale industry of our own.

 INTRODUCTION

Nowadays almost all the manufacturing process is being

atomized in order to deliver the products at a faster rate.

Our aim is to design a hacksaw machine which is

actuated by a solar power. Today electric power is a main need for all the

machinery works. We decided to reduce the electric power and gain the power

from renewable energy. The project is on the design consideration of a solar power

hack saw machine for cutting of metal to different size and length with the aid of a

hacksaw and a coolant. It is a cutting machine with teeth on its blade used specially

for cutting metals driven by 1 hp and 1400 rpm dc motor. The various component

of the machine were designed and constructed. The work was designed to archive a

substantial part of its objective. Test was carried out on the machine using different

metals. For loaded the test 10 mm flat bar of cross section area 2mm by 10 mm

was clamped on the vice of the machine. it took the machine 75 seconds to cut the

flat bar with a new hacksaw blade. the cut was observed to a neat and straight .

Cooling system, emergency stop switch and automatic stop motion device were

incorporated in the design.

COMPONENTS REQUIRED

Hacksaw Flame
Crank Shaft
Bearing
Belt
Pulley
Shaft
Solar Panel
Connecting Rod
Motor
Battery
HACKSAW

A hacksaw is a fine-tooth hand saw

with a blade held under tension in a frame, used for cutting materials such as metal

or plastics. 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 be mounted

with the teeth facing toward or away 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, often resulting in an increased tendency of the

blade to buckle and crack. Cutting on the pull stroke increases the blade tension

and will result in greater control of the cut and longer blade life.

BASE

The base of the saw usually contains a coolant reservoir and a

pump for conveying the coolant to the work. The reservoir contains baffles which
cause the chips to settle to the bottom of the tank. A table which supports the vise

and the metal being sawed is located on top of the base and is usually referred to as

part of the base.

VISE

The vise is adjustable so that various sizes and shapes of metal

may be held. On some machines the vise may be swiveled so that stock may be

sawed at an angle. The size of a power hacksaw is determined by the largest piece

of metal that can be held in the vise and sawed

FRAME

The frame of the saw supports and carries the hacksaw blade.

The machine is designed so that the saw blade contacts the work only on the

cutting stroke. This action prevents unnecessary wear on the saw blade. The

cutting stroke is on the draw or back stroke.

SPEED-CHANGE MECHANISM

The shift lever allows the number of strokes per minute to be

changed so that a variety of metals may be sawed at the proper speeds. Some saws

have a diagram showing the number of strokes per minute when the shift lever is in
SAFETY PRECAUTIONS

Keep hands away from the saw blade of the hack sawing

machine when in operation. Ensure the power supply is disconnected prior to

removal or installation of saw blades.

HACKSAW BLADES

Hacksaw blades differ from hand hacksaw blades in that

they are generally heavier, made in longer sizes, and have fewer teeth per inch.

Hacksaw blades are discarded when they become dull; sharpening is not practical.

Materials commonly used in manufacturing power hacksaw blades are high-speed

tungsten steel and high-speed molybdenum steel. On some blades only the teeth

are hardened, leaving the body of the blade flexible. Other blades are hardened

throughout. The set is the amount of bend given the teeth. The set makes it possible

for a saw to cut a kerf or slot wider than the thickness of the band back (gage), thus

providing side clearance

COOLANTS

Most sawing machines used in military operations are dry

cutting machines; that is, they are not intended for use with liquid coolants.

However, some power hacksaws are equipped with a coolant attachment. Soluble

oil products, when mixed with water to form emulsions, are used for these

machines. This type of coolant has proven very satisfactory for sawing where

cooling is an important factor. Most manufacturers of water oil emulsion coolants

add a rust inhibitor to the solution to prevent rusting caused by the water in the

coolant.

CRANK MECHANISM

A crank is an arm attached at right angles

to a rotating shaft by which reciprocating motion is imparted to or received from
the shaft. It is used to convert circular motion into reciprocating motion, or vice-
versa. The arm may be a bent portion of the shaft, or a separate arm or disk
attached to it. Attached to the end of the crank by a pivot is a rod, usually called a
connecting rod. The end of the rod attached to the crank moves in a circular
motion, while the other end is usually constrained to move in a linear sliding
motion. The term often refers to a human-powered crank which is used to
manually turn an axle, as in a bicycle crank set or a brace and bit drill. In this case
a person's arm or leg serves as the connecting rod, applying reciprocating force to
the crank. There is usually a bar perpendicular to the other end of the arm, often
with a freely rotatable handle or pedal attached.

BEARING

A bearing is a machine element that constrains

relative motion and reduces friction between moving parts to only the desired

motion. The design of the bearing may, for example, provide for free linear

movement of the moving part or for free rotation around a fixed axis; or, it may

prevent a motion by controlling the vectors of normal forces that bear on the

moving parts. Many bearings also facilitate the desired motion as much as

possible, such as by minimizing friction. Bearings are classified broadly according

to the type of operation, the motions allowed, or to the directions of the loads

applied to the parts.

BELT

A belt is a loop of flexible material

used to mechanically link two or more rotating shafts, most often parallel. Belts
may be used as a source of motion, to transmit power efficiently, or to track
relative movement. Belts are looped over pulleys and may have a twist between the
pulleys, and the shafts need not be parallel. In a two pulley system, the belt can
either drive the pulleys normally in one direction (the same if on parallel shafts), or
the belt may be crossed, so that the direction of the driven shaft is reversed (the
opposite direction to the driver if on parallel shafts). As a source of motion, a
conveyor belt is one application where the belt is adapted to continuously carry a
load between two points.

PULLEY

A pulley is a wheel on an axle that is

designed to support movement and change of direction of a cable or belt along its
circumference. Pulleys are used in a variety of ways to lift loads, apply forces, and
to transmit power. In nautical contexts, the assembly of wheel, axle, and
supporting shell is referred to as a "block."

A pulley is also called a sheave or drums and may have a groove between two
flanges around its circumference. The drive element of a pulley system can be a
rope, cable, belt, or chain that runs over the pulley inside the groove.
SHAFT

A mechanical shaft is a long cylindrical rod that rotates

in order to transmit power. A mechanical shaft is used to transmit mechanical
power from a motor to an area of application. Examples of mechanical shafts are
drive shafts, propeller shafts and colt shafts.

A drive shaft is a tubular piece

of pipe, usually made of metal. The shaft extends from the back of the
transmission to the real axle and is considered part of the drive train.

SOLAR PANEL

Solar power is the most popular form of alternative

energy in North America. Solar power can be used to; heat water and pools, cook,
and light homes and buildings Solar power is electricity that is gotten from
sunlight either directly using photovoltaic’s (PV) or indirectly by using
concentrated solar power (CSP). Concentrated solar power systems use mirrors or
lenses to focus a large percentage of sunlight into a small beam. Photovoltaic
converts light into electric current by using the photoelectric effect.

Solar power is energy from the sun that is converted into

thermal or electrical energy. Solar power needs no fuel and produces no
waste.Solar power is power that we get from the sun. Since the sun emits so much
energy and power, we are able to sustain ourselves from this energy. Solar energy
is free, it's available anywhere on earth and it will never run out.

CONNECTING ROD

The small end attaches to the piston pin,

gudgeon pin or wrist pin, which is currently most often press fit into the connecting
rod but can swivel in the piston, a "floating wrist pin" design. The big end connects
to the bearing journal on the crank throw, in most engines running on replaceable
bearing shells accessible via the connecting rod bolts which hold the bearing "cap"
onto the big end. Typically there is a pinhole bored through the bearing and the big
end of the connecting rod so that pressurized lubricating motor oil squirts out onto
the thrust side of the cylinder wall to lubricate the travel of the pistons and piston
rings. Most small two-stroke engines and some single cylinder four-stroke engines
avoid the need for a pumped lubrication system by using a rolling-element bearing
instead, however this requires the crankshaft to be pressed apart and then back
together in order to replace a connecting rod
ELECTRIC MOTOR

This DC or direct current motor works on the principal, when a

current carrying conductor is placed in a magnetic field, it experiences a torque and
has a tendency to move. This is known as motoring action. If the direction
of electric current in the wire is reversed, the direction of rotation also reverses.
When magnetic field and electric field interact they produce a mechanical force,
and based on that the working principle of dc motor established.

The direction of rotation of a this motor is given by Fleming’s left hand rule, which
states that if the index finger, middle finger and thumb of your left hand are
extended mutually perpendicular to each other and if the index finger represents
the direction of magnetic field, middle finger indicates the direction of electric
current, then the thumb represents the direction in which force is experienced by
the shaft of the dc DC motors consist of one set of coils, called armature winding,
inside another set of coils or a set of permanent magnets, called the stator.
Applying a voltage to the coils produces a torque in the armature, resulting in
motion.
STATOR

 The stator is the stationary outside part of a motor.

 The stator of a permanent magnet dc motor is composed of two or more
permanent magnet pole pieces.
 The magnetic field can alternatively be created by an electromagnet. In this
case, a DC coil (field
 winding) is wound around a magnetic material that forms part of the stator.

ROTOR

 The rotor is the inner part which rotates.

 The rotor is composed of windings (called armature windings) which are
connected to the external
 circuit through a mechanical commutator.
 Both stator and rotor are made of ferromagnetic materials. The two are
separated by air-gap.

WINDING

A winding is made up of series or parallel connection of coils.

 Armature winding - The winding through which the voltage is applied or

induced.
 Field winding - The winding through which a current is passed to produce
flux (for the electromagnet)
 Windings are usually made of copper.
BATTERY

Even though most car, motorcycle and tractor batteries are sold as "12-volt"
batteries, the nominal voltage of a fully charged battery is closer to 12.6 volts. The
electrochemical reaction between the lead plates and the battery electrolyte is what
produces the voltage differential between the positive and negative terminals on a
battery. Over time, the lead plates within the battery will become covered with lead
sulfate crystals. These crystals inhibit the electrochemical reaction between the
lead plates and the electrolyte, causing a drop in battery voltage.

TYPES OF BATTERIES

The rechargeable battery used in ICE cars is a single 12 V lead-

acid battery. The two main types of batteries used in the battery packs in HEVs
today are nickel-metal hydride and lithium-ion. The name of the battery
corresponds to the electrolyte used and the material of the electrodes. Each type of
battery has different chemical reactions within its cells. The batteries also differ in
their amount and type of harm to humans, the environment, and society.

LEAD-ACID BATTERIES

The battery used in every internal combustion engine (ICE)

car on the road is a 12 V lead-acid battery. This single battery is responsible for
powering the alternator, or the engine starter. It also supplies power to the
accessories that the car may have, such as the air conditioning, radio, power
windows and locks, etc.
 SPECIFICATION
BEARING

Outer Diameter = 40mm

Inner Diameter = 15mm

Thickness = 15mm

CRANK SHAFT

Length = 180mm

Diameter = 15mm

Sliding Post = 300mm

Crank Shaft = 240mm

ELECTRIC MOTOR

Type = AC/DC

Horse Power = 1/12

Voltage = 210/220V

Current = 0.32A

Speed = 6000RPM

SOLAR PANEL

Photo voltaic cell – 12V/ 450MA

BATTERY

Alkaline Battery – 12V / 80A

CRANK PIN
Length = 60mm
Diameter = 13mm
CRANK DISK

Diameter = 160mm

PULLEY :

LARGE PULLEY

Outer Diameter = 80mm

Inner Diameter = (80-12.5) = 67.5mm

SMALL PULLEY

Outer Diameter = 35mm

Inner Diameter = (35-15) = 20mm

Sliding Bush = 63mm

HACKSAW

Hacksaw movement = 150mm

VICE
Capacity = 30 mm

TABLE

Length = 900 mm

Breath = 450 mm

Thickness = 18 mm

Height = 900 mm

CONNECTING ROD

Length = 280 mm

Outer Diameter = 22 mm

Inner Diameter = 10 mm
 WORKING PRINCIPLE

Our Aim of our project is to run this

machine with both AC as well as DC power. First of all we gain the energy from

solar power. This gained energy is stored in the battery. Then we actuate the motor

with the help of this battery power. This project is worked under by the crank

mechanism. The crank mechanism converts the rotary motion into the

reciprocating motion. The machine has the prime mover at the bottom of the

machine The pulley is attached to the body at the top and the end of the side

portion The pulley is connected with the disc type plate The pulley and the disc has

separate connection with the one small metal rod through the bearing .The motor

and pulley is connected with one V-type belt .The clamp is fixed with the disc. The

clamp is fixed with the shaft at one end this shaft is act as reciprocating motion

through the crank .The hack saw connected to the shaft at the end. If the motor is

turned on the pulley is getting rotating motion that rotation motion is convert into

the reciprocating motion by the disc under the crank mechanism.

Power Hacksawing

The power hacksaw machine is designed primarily for

straight-line sawing. A typical sawing operation is outlined below:

Select a hacksaw blade of the proper length for the machine and proper pitch for

the material to be cut. Install the hacksaw blade with the teeth pointing downward

and toward the motor end of the hacksawing machine. Check the alignment of the

vise and hacksaw blade and mount the workpiece in the vise. Make sure the vise

holds the workpiece securely. Check the stroke of the hacksawing machine and

adjust if necessary. After adjusting the stroke, move the hacksaw blade and sawing

machine frame through one cycle (draw stroke and return stroke) by hand to check

the blade clearance at each end of the workpiece. Readjust the position of the vise

if necessary. Position the hacksaw blade about 1/4 inch above the workpiece and

set the feed control to its lightest feed setting. Set the desired speed of the

hacksawing machine.Start the machine and let the blade feed lightly into the

workpiece for about 1/4 inch. Readjust the feed to whatever the material will stand

for normal cutting. Permit the hacksaw blade to cut completely through workpiece.

The blade frame will trip a switch on sawing machine bed to stop the sawing

machine.

Power hacksaws are used to cut large sizes of metals such as

steel. Cutting diameters of more than 10/15mm 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.

The heavy ‘arm’ moves backwards and forwards, cutting on the backwards stroke.

The metal to be cut is held in a machine vice

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.

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
over heat and break. This can be dangerous as the blade can
break with powerful force, shattering.

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’.
 Blades of power
hacksaws are graded according to the material they are
made from and the number of teeth per inch. Top quality
blades 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 14 to 24. The more teeth
per inch - the smoother the cut.

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, allow the blade to cut through the material.

Most power hacksaws have two pulley wheels. If the belt is

placed on the smaller pulley wheel the speed of cut will be fast. Changing the belt
so that it runs round the larger pulley wheel will reduce the speed.
DRAWING
 BILL OF MATERIALS

Sl.No COMPONENTS MATERIAL QUANTITY

1 Stand Material Steel 1

2 Ply Wood Wood 1

3 Hacksaw Steel 1

4 Belt Rubber 1

5 Small Pulley Steel 1

6 Large Pulley Steel 1

7 Bolts & Nuts Mild Steel 2

8 Shaft Mild steel 1

9 Slider Mild Steel 1

10 connecting Rod Mild steel 2

 COST ANALYSIS

SL. NO DESCRIPTION MATERIAL COST

1 Motor 1/12 HP, 0.32 A 800

2 Battery 7A , 12V 700

3 Connecting Rod Mild Steel 60

4 Solar Panel 12V , 450MA 450

5 Pulleys Mild Steel 240

6 Ply Wood Wood 200

Total 2450

Material Cost = 2450

Over head cost = 150

Prime Cost = (Material cost + Over head cost)

= 2450+150 = 2600

Labor Cost = 2200

Total Cost = Prime Cost + Labor Cost

= 2600 + 2200 = 4800

 APPLICATIONS

 Mainly use for tool rooms

 Educational Institutes

 Small Scale Industries

 Workshops

 Rolling mills etc.

 ADVANTAGES

 It is portable
 Less maintenance
 Simple in construction than mechanical hacksaw
 High Torque Output
 Smoother Operation
 Fewer Moving Parts
 CONCLUSION

We can say our project can be a success considering

the changes we had to make

The project work facilities the students in knowing

the difficulties in the practical field and also it shows the way of solving these

difficulties it also gives us a confidence for standing on our own legs by

employment after finishing studies

This idea in view we have completed the project

with the existing facility the project with the existing facility. Through it offered to

be difficult and in its initial stage. We could overcome all the difficulties.

Situations may easy in the latter stage to complete

the project within the prescribed short period of the course. We have provided

that we could accomplish the project work to the satisfaction of all.

 BIBLIOGRAPHY

TEXT BOOK :

 A text book of Manufacturing Technology , author –R.K.Rajput

 Automation, Production Systems, and Computer-Integrated

Manufacturing 3rd Edition, author - Mikell P. Groover

WEBSITE :

 http://www.technologystudent.com
 http://www.google.com
 http://www.wikipedia.com