DESIGN AND FABRICATION

OF
DOUBLE ACTING HACKSAW
MACHINE

A MINI PROJECT REPORT

Submitted by

P.HARI RAJ (953018114006)

A.KABIL (953018114010)
K.MEENAKSHI SUNDARAM (953018114018)
T.XAVIER AGAN (953018114041)

in partial fulfilment for the award of the degree

Of
BACHELOR OF ENGINEERING
in
MECHANICAL ENGINEERING

ST.MOTHER THERESA ENGINEERING COLLEGE

THOOTHUKUDI – 628 102.
ANNA UNIVERSITY: CHENNAI 600 025.
 BONAFIED CERTIFICATE

Certified that this project report “DESIGN AND FABRICATION OF

DOUBLE ACTING HACKSAW MACHINE” is the Bonafide work of
“P.HARI RAJ (953018114006), A.KABIL (953018114010),
K.MEENAKSHI SUNDARAM (953018114018), T.XAVIER AGAN
(953018114041)”who carried out the project work under my supervision.
Certified further that to the best of my knowledge the work reported herein
does not form part of any other thesis or dissertation on the basis of which a
degree or award was conferred on an earlier occasion on this or any other
candidate.

SIGNATURE SIGNATURE
MR.R.SAMUEL SAANJAY RAJA M.E., MR.K.M.MUTHUKRISHNAN M.E.,
SUPERVISOR HEAD OF THE DEPT
ASSISTANT PROFESSOR ASSISTANT PROFESSOR
DEPT OF MECHANICAL ENGINEERING DEPT OF MECHANICAL ENGINEERING
ST.MOTHER THERESA ENGG COLLEGE, ST.MOTHER THERESA ENGG COLLEGE
THOOTHUKUDI – 628 108. THOOTHUKUDI-628 108.

Submitted for Semester Mini-Project viva-voce examination held on _________

INTERNAL EXAMINER EXTERNAL EXAMINER

 AKNOWLEDGEMENT

First of all, I would like to thank God, the almighty, for

having made everything possible by giving us strength and courage to
complete our mini project with grand success. At very outset, we express our
sincere thanks to our beloved parents, who have blessed us with healthy
constitution and have bestowed upon us the required skill to pursue the High
Tech courses.

We pour our profound gratitude to our respected

Ass.Prof.K.M.MUTHU KRISHNAN M.E., Head of the Department of
Mechanical Engineering for providing amble facilities made available to
undergo our mini project a great success.

We thank our project Guide

Prof.Dr. C.SUBHA RAJ M.E.Phd., Department of Mechanical Engineering
for his excellent guidance patiently throughout our project work.

We would like to thank our project supervisor

Ass.Prof.R.SAMUEL SANJAY RAJA M.E., Department of Mechanical
Engineering for his continuous support, encouragement and guidance.

We also bound to thank our Faculty members and

laboratory Technicians of the Department of Mechanical Engineering, whose
support and cooperation contributed to complete this project work.
ABSTRACT

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 a Double hacksaw blade. Increasing
the productivity is one of the main requirements of production engineering in
any kind of manufacturing industry. Either by reducing the operation time or by
improving the capability of the machine to produce the components in an
increased number at the same time is very essential for an industry to achieve
the same. This project employs the Scotch yoke mechanism in power hacksaw
machine which enables it to cut two components at a time thereby improving
the productivity. In today’s world time a machine should be less time
consuming. Power hacksaw cut one piece at one time so there was a loss in
production rate. Double acting power hacksaw overcome this time consuming
problem.
Power hacksaw is a fine tooth power saw with blade held
under tension in the frame. Double acting power hacksaw cuts two material
simultaneously by its scotch yoke mechanism, so the production rate increase
twice then that of power hacksaw. Double acting power hacksaw works under
by the scotch yoke mechanism. The scotch yoke mechanism convert the rotary
motion into the reciprocating motion. With the help of this multi-way power
hacksaw machine, the four metal bars can be cut simultaneously to get the high-
speed cutting rate and to achieve mass production for maximum profit in related
companies. This project is very much useful and easy to install by the user and
also the motor used will not only operate with the help of electricity but also
through conventional source of energy like solar energy.

INTRODUCTION
In this project, we have designed a double acting hacksaw
machine. In industries saving the time and saving the manpower is an important
thing all over the world. To satisfy the needs of the industries, we have designed
a machine. This new machine is used to avoid the energy loss and save time.
Scotch yoke mechanism is used for this purpose.
These machines are so precise that they can cut metal bars
with minimum time made up of different materials but they have one and major
disadvantage that those are able to cut a single piece of the bar at a time. For
industries to achieve the mass production, it is necessary to cut metal bars with
high rate.
With the help of this multi-way power hacksaw machine, the
four metal bars can be cut simultaneously to get the high-speed cutting rate and
to achieve mass production for maximum profit in related companies. As this
machine overcomes all the limitations and drawbacks of conventional hacksaw
machines, it is also helpful for small-scale industries due to its simple working
and operating conditions along with its compatibility, efficiency and affordable
price.
Double acting power hacksaw cuts two materials
simultaneously by its scotch yoke mechanism, so the production rate increase
twice then that of power hacksaw. The scotch yoke mechanism converts the
rotary motion into the reciprocating motion. This project is design and
construction of double acting hacksaw for cutting wood and metal to different
length. The power is given by a motor it drives the pulley which holds he main
screw. the main screw holds two connecting rods.
 In this double acting hacksaw machine, we can able to cut materials
such as wood, steel, etc. This machine makes the cutting operation much easier
and also it reduces the production time. Since two work pieces can be cut at the
same time the total time is also reduced. This project is very much useful and
easy to install by the user. The handling of the machine is much simple.

 This setup is most commonly used in control valve actuators in high

pressure oil and gas pipelines.

 It has been used in various internal combustion engines, such as the

Bourke engine and many hot air engines and steam engines.

 It is also used in I.C. engines.

OBJECTIVES:

When we searching for our project in the market we show

the demand of hacksaw blade is considerably increasing day by day with the
growth of industrialization, engineering sector, real estate, automobile sector
etc. It is used in almost every sector for cutting of materials like the angle,
channel, flat plates, rods and such other things. It is also required in auto repair
shops, general repairing workshops, fitting shops, welding shops and technical
institutes. Govt. Department of Railway, Defense, PWD, Postal & Telegraph
and others are one of the main users of it. In India large number of small
enterprises are engaged in its manufacturing. By considering its demand, new
production unit has a great prospect. So from that, we have concluded that the
future base hacksaw machine is used for very costly machinery and in
locomotives. The user can use this project in small industry, which cannot
afford costly machinery.

MATERIALS USED:
 MILD STEEL [FRAME]
 ELECTRIC MOTOR
 PULLEY
 BUSH BEARING
 BELT
 HACKSAW
 STAINLESS STEELS [Nuts and Bolts]
MILD STEEL [FRAME]:

"Mild steel" refers to low carbon steel; typically the AISI

grades 1005 through 1025, which are usually used for structural applications.
With too little carbon content to through harden, it is weldable, which expands
the possible applications.
 Mild steel also known as plain-carbon steel, is now the most
common form of steel because its price is relatively low while it provides
material properties that are acceptable for many applications. Low-carbon steel
contains approximately 0.05–0.25% carbon making it malleable and ductile.
Mild steel has a relatively low tensile strength, but it is cheap and easy to form;
surface hardness can be increased through carburizing. These mild steel rods are
used for preparing frame in this pedal power hacksaw.

AC MOTOR:
An AC motor is an electric motor driven by an alternating current
(AC). The AC motor commonly consists of two basic parts, an outside
stationary stator having coils supplied with alternating current to produce a
rotating magnetic field, and an inside rotor attached to the output shaft
producing a second rotating magnetic field. The rotor magnetic field may be
produced by permanent magnets, reluctance saliency, or DC or AC electrical
windings.
Less commonly, linear AC motors operate on similar principles as rotating
motors but have their stationary and moving parts arranged in a straight-line
configuration, producing linear motion instead of rotation. When an AC motor
is in steady-state rotation (motion), the magnetic fields of the rotor and stator
rotate (move) with little or no slippage (near synchrony). The magnetic forces
(repulsive and attractive) between the rotor and stator poles create average
torque, capable of driving a load at rated speed. The speed of the stator rotating
magnetic field and the speed of the rotor rotating magnetic field, relative to the
speed of the mechanical shaft, must maintain synchronism for average torque
production by satisfying the synchronous speed relation. Otherwise,
asynchronously rotating magnetic fields would produce pulsating or non-
average torque.
 A single phase motor has only one stator winding. This winding
generates a field which merely pulsates, instead of rotating. When the rotor is
stationary, the expanding and collapsing stator field induces currents in the
rotor. These currents generate a rotor field opposite in polarity to that of the
stator. The opposition of the field exerts a turning force on the upper and lower
parts of the rotor trying to turn it 180° from its position. Since these forces are
exerted through the centre of the rotor, the turning force is equal in each
direction. As a result, the rotor does not turn. If the rotor is started turning, it
will continue to rotate in the direction in which it is started, since the turning
force in that direction is aided by the momentum of the rotor.

The stator of the single phase induction motor has laminated

stamping to reduce eddy current losses on its periphery. The slots are provided
on its stamping to carry stator or main winding. In order to reduce the hysteresis
losses, stamping are made up of silicon steel. When the stator winding is given a
single phase ac supply, the magnetic field is produced and the motor rotates at a
speed slightly less than the synchronous speed Ns.
 Stator and Rotor
The construction of the rotor of the single-phase induction motor is
similar to the squirrel cage three phase induction motor. The rotor is cylindrical
in shape and has slots all over its periphery. The slots are not made parallel to
each other but are bit skewed as the skewing prevents magnetic locking of stator
and rotor teeth and makes the working of induction motor more smooth and
quieter. The squirrel cage rotor consists of aluminium, brass or copper bars.
These aluminium or copper bars are called rotor conductors and are placed in
the slots on the periphery of the rotor.
We know that for the working of any electrical motor whether its ac
or dc motor, we require two fluxes as, the interact of these two fluxes produced
the required torque, which is desired parameter for any motor to rotate.
When single phase ac supply is given to the stator winding of
single phase induction motor, the alternating current starts flowing through the
stator or main winding. This alternating current produces an alternating flux
called main flux. This main flux also links with the rotor conductors and hence
cut the rotor conductors. According to the Faraday’s law of electromagnetic
induction, emf gets induced in the rotor. As the rotor circuit is closed one so, the
current starts flowing in the rotor. This current is called the rotor current.
This rotor current produces its own flux called rotor flux. Since this flux is
produced due to induction principle so, the motor working on this principle got
its name as induction motor. Now there are two fluxes one is main flux and
another is called rotor flux. These two fluxes produce the desired torque which
is required by the motor, to rotate.

PULLEY:
A pulley is a wheel on an axle or shaft that is designed to support
movement and change of direction of a taut 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 a basic device or machine made of a wheel with a rim
that a cord or rope fits around. The wheel and axle of a pulley make it easier to
lift heavy objects with the rope.

V belts solved the slippage and alignment problem. It is now the

basic belt for power transmission. They provide the best combination of
traction, speed of movement, load of the bearings, and long service life. They
are generally endless, and their general cross-section shape is trapezoidal (hence
the name "V"). The "V" shape of the belt tracks in a mating groove in the pulley
(or sheave), with the result that the belt cannot slip off. The belt also tends to
wedge into the groove as the load increases—the greater the load, the greater
solution, needing less width and tension than flat belts.

BUSH BEARING:

A Bush Bearing is a machine element that constrains relative motion

to only the desired motion, and reduces friction between moving parts. 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.

BELT:
A belt is a loop of flexible material used to link two or more rotating
shafts mechanically, 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 carry a load continuously
between two points.
Cogged V belts solved the slippage and alignment problem. It is
now the basic belt for power transmission. They provide the best combination
of traction, speed of movement, load of the bearings, and long service life. They
are generally endless, and their general cross-section shape is trapezoidal.

V belts (also style V-belts, vee belts, or, less commonly, wedge rope)
solved the slippage and alignment problem. It is now the basic belt for power
transmission. They provide the best combination of traction, speed of
movement, load of the bearings, and long service life. They are generally
endless, and their general cross-section shape is trapezoidal (hence the name
"V"). The "V" shape of the belt tracks in a mating groove in the pulley (or
sheave), with the result that the belt cannot slip off.
 The belt also tends to wedge into the groove as the load increases the
greater the load, the greater the wedging action improving torque transmission
and making the V-belt an effective solution, needing less width and tension than
flat belts.
V-belts trump flat belts with their small center distances and high
reduction ratios. The preferred center distance is larger than the largest pulley
diameter, but less than three times the sum of both pulleys. Optimal speed range
is 1,000–7,000 ft/min (300–2,130 m/min). V-belts need larger pulleys for their
thicker cross-section than flat belts.

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 is hand saw versions and powered versions (power
hacksaws).

Hacksaw

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. 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.

Teeth pitch:
Teeth pitch which is the number of teeth per 25 mm.

Choosing of the hacksaw blade with the correct tooth number per inch depends
on dimensions and type of the cutting material.
14 teeth/ 25 mm - cutting of thin materials of all types as tubes, pipes, profiles
etc.
10 teeth / 25 mm - cutting of all material types with small and medium
dimensions
6 teeth / 25 mm - cutting of all material types of greater thickness
4 teeth / 25 mm - cutting of soft material types of greater thickness

Small tooth number is suitable for thicker material cutting and

greater tooth number is better for thin profile cutting.

STAINLESS STEEL [BOLTS AND NUTS]:

Stainless steel does not readily corrode, rust or stain

with water as ordinary steel does. However, it is not fully stain-proof in low-
oxygen, high-salinity, or poor air-circulation environments. There are different
grades and surface finishes of stainless steel to suit the environment the alloy
must endure. Stainless steel is used where both the properties of steel and
corrosion resistance are required.
MECHANISM USED:

The scotch yoke mechanism is used in double acting hacksaw

machine.

SCOTCH YOKE MECHANISM:

The scotch yoke is a mechanism for converting the linear motion
of a slider into rotational motion or vice-versa. The piston or other reciprocating
part is directly coupled to a sliding yoke with a slot that engages a pin on the
rotating part. The shape of the motion of the piston is a pure sine wave over
time given a constant rotational speed.
 The Scotch yoke (also known as slotted link mechanism)
is a reciprocating motion mechanism, converting the linear motion of a slider
into rotational motion, or vice versa. The piston or other reciprocating part is
directly coupled to a sliding yoke with a slot that engages a pin on the rotating
part. The location of the piston versus time is a sine wave of constant amplitude,
and constant frequency is given a constant rotational speed. The term scotch
yoke continues to be used when the slot in the yoke is shorter than the diameter
of the circle made by the crank pin. For example, the side rods of a locomotive
may have scotch yokes to permit vertical motion of intermediate driving axles.

The scotch yoke mechanism is constructed with iron bars. Here the
crank is made in some length and the yoke is also made using the same material.
It is noted that the minimum length of the yoke should be double the length of
the crank. The crank and yoke are connected with a pin. Iron bars are welded to
both sides of the yoke to get the reciprocating motion The yoke with the iron
bars is fixed on the display board with the help of c clamp. Now the crank is
welded to the end of the shaft of the motor. Now the pin on the crank is
connected to the yoke.
 Scotch yoke mechanism

The pin used to connect yoke and crank is a bolt. The Scotch yoke
mechanism is most commonly used in control valve actuators in high-pressure
oil and gas pipelines, as well as in various internal combustion engines, such as
the Bourke engine, SyTech engine and many hot air engines and steam engines.
This mechanism does not create lateral forces on the piston.

Fabrication Of Double Acting Hacksaw Machine:

Machine has the prime mover at the bottom of the
machine. The pulley is attached to the body at the top and end of the side
portion. Pulley is connected with disc type plate. The pulley and disc have
separate connection with one small metal rod through the bearings.

The following are considered in this process

 It consists of single-phase ac motor which is fixed to the frame.

 The spindle of the motor is connected to the pulley with the help of the
stepped v belt.
 The pulley is also connected to the centre of the frame.
 A plywood of circular shape is cut and attached to the driven pulley with
the help of bolts and nuts.
 A main screw is connected to the pulley at one of its extreme ends.
 Two connecting rods are connected to the main screw at its one end.
 The other ends of connecting rod are connected to handle of the hacksaw.
 The hacksaw is constrained to move along a linear path.
 The hacksaw act as slider with the help of two rings which is welded on
the top of hacksaw frame.
 A spring arrangement is provided at the two extreme ends of the frame.
  The entire setup is held together with the help of a frame.

Working Of Double Acting Hacksaw Machine:

Single Phase Ac Motor Is Connected to The Power Supply.

 The motor is switched on.
 The motor rotates with the speed of 800 rpm which in turn rotates the
pulley which is connected to the motor with the help of toothed v belt.
 The main screw rotates along with the pulley.
 The two connecting rods which are connected to the main screw
rotates along with the main screw.
 Tighten the hack saw blade in the machine in correct position and
straighten it properly.
 The hacksaw handle which is connected to the other end of the
connecting rod reciprocates along the constrained path.
 The frame which holds the hollow pipe acts as the guide way for the
reciprocating motion of the hacksaw frame.
 The other end of the hollow pipe is connected to the handle which is
used to give the feed manually.
 An open coil helical spring is provided at the bottom of the handle
which acts as a stopper and also to control the feed rate.
 The work piece is held with the help of vice which is attached to the
frame.
 The handle lowered to give the gradual depth of cut.
BLOCK DIAGRAM:

DESIGN CALCULATIONS:

Calculation The torque of the AC motor must be increased so as to

bring about the necessary power for cutting of work-pieces efficiently. This is
achieved by coupling the rotor of the AC motor to a pulley by a belt drive. So,
this will reduce the rotating speed while increasing the torque. The pulley is
coupled to the reciprocating mechanism.

Given:
i) Driving Pulley (1) diameter= 0.0508 m
Driven Pulley (1) diameter= 0.2286 m
Speed of motor, N (driving) = 920 rpm
Driven Pulley speed N (1) = 204.44 rpm
Power = 0.25 hp = 0.186 kw
Therefore,
 Reduction Ratio= 4.5:1

DRIVING PULLEY (1)

Power (p) = 2πnt/60
T = (60*p)/(2*π*n)
= (60*0.186*103)/ (2*3.14*920)
=1116/5777.6
Torque T (Driving) = 1.935 Nm

DRIVEN PULLEY (2)

Power (p) = 2πnt/60
T = (60*p)/(2*π*n)
= (60*0.186*103)/ (2*3.14*204.44)
=1116/5777.6
Torque T (Driven) = 8.7113 Nm

Given:
ii) Driving Pulley (2) diameter= 0.0889 m
Driven Pulley (2) diameter= 0.2286 m
Driving Pulley speed N (2) = 204.44 rpm
Driven Pulley speed N (2) = 79.5 rpm
Power = 0.25 hp = 0.186 kw

DRIVING PULLEY (2)

Power (p) = 2πnt/60
T = (60*p)/(2*π*n)
 = (60*0.186*103)/ (2*3.14*204.44)
=1116/128.388
Torque T (Driving) (2) = 8.7113Nm

DRIVEN PULLEY (2)

Power (p) = 2πnt/60
T = (60*p)/(2*π*n)
= (60*0.186*103)/ (2*3.14*79.5)
=1116/499.26
Torque T (Driven) (2) = 22.401 Nm

Advantages Of Double Acting Hacksaw Machine:

 This process is suitable for cutting all materials.

 High torque output with a small cylinder size.
 Fewer moving parts.
 Smoother operation
 Higher percentage of the time spent.
 Low initial investment.
 Very simple design.
 Equipment is safe to operate.
 High accuracy and good surface finish can be easily obtained.
 Time taken for the process is low.
 Work piece can be easily handled.
 Setting up and rejection of work piece is easy.
  High skilled operators are not needed.

Disadvantages Of Double Acting Hacksaw Machine:

 High specific energy consumption.
 Accuracy is less.
 Heat is generated during the process.
 The hacksaw blades have to be replaced often.
 Time consumes more.
 Speed variation is required for cutting the different metal
 Rapid wear of the slot in the yoke caused by sliding friction and high
contact pressure.
 Increased heat loss during combustion due to extended dwell at top
dead centre offsets any constant volume combustion improvements in
real engines.

APPLICATION:
 This setup is most commonly used in control valve actuators in high
pressure oil and gas pipelines.
 It has been used in various internal combustion engines, such as the
Bourke engine, Sytech engine and many hot air engines and steam
engines.
 It is also used in multipurpose machine and I.C. engines.
 It is used for cutting wood, steel, PVC pipes and many other materials
using double acting hacksaw.
 Tool Rooms.
  Educational Institutes.
 Workshops.
 Rolling Mills Etc.

RESULTS AND DISCUSSION:

As per the above discussion, we concluded that to

overcome problems in conventional hacksaw machines, due to high efficiency,
easy to operate and affordable price the proposed model of multi-way power
hacksaw the machine is helpful and completes all the expectations needed for
the mini-industries. Future scope of proposed research work to increase the
production rate cuts the metal bars easily. It can withstand the vibrations, no
hazards from a jerk, no special training required to operate it. After studying
this report, we have to know that how the A hacksaw machine will work and
knowing the construction and how mechanism work in the machine. We learnt
how the theoretical design is possible in practise. Another hacksaw machine is
only cut one part at one time but this machine cut the four parts at a time, this
hacksaw machine has lighter weight compared to another machine.
The double acting hacksaw is able to cut materials like
wood, ms tubes, and other materials. It makes the cutting process much
easier as compared to the normal manual handsaw. Machine is driven by
120W and 920 rpm electric motor. Test was carried out on machine using
different metal. For the loaded test, a shaft of diameter 25 mm and length 12
inch and the material of the shaft was mild steel was clamped on the vice of
the machine. It took the machine 240 seconds to cut the with a new hacksaw
blade. The cut was observed to be neat and straight. Recommendation has
been made on the operation and parameters of the machine. Suggestion have
been offered on overall machine performance optimization and further work
on the machine.
 The machine can be fully automated by using Microcontroller.
In fully automated machine the operator need not measure the length of the
work-piece that is to be cut and to load and unload the work-piece each after a
piece has been cut.
Currently many electrically operated power hacksaw machines
manufactured by different companies with different specifications are available
for the use in shop floor. These machines are so designed that they can cut metal
or plastic rods/bars with minimum time made up of different materials but they
have one and major disadvantage that they can cut single piece of bar at a time.
At the end we conclude that the conventional Power
Hacksaw Machine have low efficiency, low accuracy and takes more time per
unit. So, by doing necessary changes and incorporating devices like limit
switch, feeder and stoppers will increase efficiency and idle time per unit.
The cost of the machine is less and easy to operate so it
affordable for all industry. The material cast iron which is used will give the
high strength than alloy steels. This project is very much useful and easy to
install by the user and also the motor used will not only operate with the help of
electricity but also through conventional source of energy like solar energy.