Contents

List of Figures

List of Tables

1 Introduction

2 Literature Survey

3 Problem identification and project objectives

4 Design Methodology /Analysis and Implementation / Fabrication

/ Assembly
4.1 The Design Methodology /Analysis..............................................................4
4.2 Implementation / Fabrication / Assembly.....................................................4

5 Result and Discussion

6 Conclusion

7 Project Management and Bill of Material

7.1 Project Management......................................................................................7
7.2 Bill of Material..............................................................................................8

References
Chapter 1
Introduction
A beam engine is a type of steam engine where a pivoted overhead beam is used
to apply the force from a vertical piston to a vertical connecting rod. This configuration,
with the engine directly driving a pump, was first used by Thomas Newcomen around
1705 to remove water from mines in Cornwall. The efficiency of the engines was
improved by engineers including James Watt who added a separate condenser, Jonathan
Hornblower and Arthur Woolf who compounded the cylinders, and William McNaught
(Glasgow) who devised a method of compounding an existing engine. Beam engines
were first used to pump water out of mines or into canals, but could be used to pump
water to supplement the flow for a waterwheel powering a mill. The rotative beam
engine is a later design of beam engine where the connecting rod drives a flywheel, by
means of a crank. These beam engines could be used to directly power the line-
shafting in a mill. They also could be used to power steam ships.

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Chapter 2
Literature Survey
This section summarizes the literature giving background to the project, in
particular the operation of the Boulton & Watt Beam Engine.

Watt’s Beam Engine

The Watt steam engine, also referred to as the Boulton and Watt (B&W) engine,
is a later version of the Newcomen Engine, one of the earliest forms of beam engine
used predominantly for pumping water. Newcomen engines were widely used in the
18th century, particularly in the South West of England for pumping water out of
mineshafts.

The Watt Engine, circa. 19th century, differed from the Newcomen engine, as it
used the hot, pressurized steam to push the cylinder, and the cooling/condensing steam
from the previous cycle to create a vacuum and pull the cylinder; the Newcomen Engine
only did the latter. Watt’s developments, including insulating the pipework and
cylinders, meant that lower pressure steam could be used, which increased engine
efficiency, reduced wear and the severity of accidents. High-pressure steam leakage had
been responsible for many injuries and fatalities during the early years of the steam
engine. Watt’s beam engine was regarded as a key driver for the Industrial Revolution
and the SI unit of power ‘Watt’ was named in recognition of him.
An additional improvement in the Watt engine was the parallel linkage system.
As the beam pivots on its center, the ends travel through an arc, i.e., rotational motion.
Linear motion was necessary to push and pull the cylinder and this was achieved using a
series of metal bars and pin-joints as creating vertical, linear motion at the end of the
beam. Predecessors to the Watt engine had used chains and ropes to achieve the pulling
force and purely relied on the weight of the beam to return it to its original position.
With these technological developments, many of the older Newcomen engines were
upgraded to improve performance and save energy.

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 Chapter 3

Problem Identification and Project Objectives

3.1 Problem
i. Only small size and soft metal can be cut.
ii. It is costly than the mechanical hacksaw because of compressor unit.
iii. Less efficiency when compressor to mechanical device.

3.2 Project Objective

i. To cater to the issue of competition in mechanical industry the need for automation is
asses by all the industry.
ii. To provide alternative aim toward reducing human effort and improvement in
material handling system by implementing automation.

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Chapter 4
Design System
In our attempt to design a special purpose machine we have adopted a very a
very careful approach, the total design work has been divided into two parts mainly;
i. System design.
ii. Mechanical design.

System design mainly concerns with the various physical constraints and
ergonomics, space requirements, arrangement of various components on the main
frame of machine no of controls position of these controls ease of maintenance scope of
further improvement; weight of m/c from ground etc.
In Mechanical design for design parts detail design is done and dimensions thus
obtained are compared to next highest dimension which are readily available in market
this simplifies the assembly as well as post production servicing work.
The various tolerance on work is specified in the manufacturing drawings the process
charts are prepared & passed on to the manufacturing stage. The parts are to be
purchased directly are specified &selected from standard catalogues.

4.1 System Design

In system design we mainly concentrate on the following parameter.
4.1.1 System selection based on physical constraints
While selecting any m/c it must be checked whether it is going to be used in
large scale or small-scale industry in our care it is to be used in small scale industry so
space is a major constrain. The system is to be very compact it can be adjusted to
corner of a room. The mechanical design has direct norms with the system design
hence the foremost job is to control the physical parameters so that the distinction
obtained after mechanical design can be well fitted into that.

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4.1.2 Arrangement of various component
Keeping into view the space restriction the components should be laid such that
their easy removal or servicing is possible moreover every component should be easily
seen & none should be hidden every possible space is utilized in component
arrangement.
4.1.3 Components of system
As already stated, system should be compact enough so that it can be
accommodated at a corner of a room. All the moving parts should be well closed &
compact A compact system gives a better look & structure.
4.1.4 Man –m/c Interaction
The friendliness of m/c with the operation is an important criterion of design. It
is application of anatomical
Following are some e.g., of this section
 Design of machine height
 Energy expenditure in hand operation
 Lighting condition of m/c

4.1.5 Chances of failure

The losses incurred by owner in case of failure of a component are important
criteria of design. Factor of safety while doing the mechanical design is kept high so
that there are less chances of failure there over periodic maintenance is required to keep
the m/c trouble free.
4.2 Mechanical Design
Mechanical design phase is very important from the view of designer as
whole success of the project depends on the correct deign analysis of the problem.
Many preliminary alternatives are eliminated during this phase. Designer should have
adequate knowledge above physical properties of material, loads stresses, deformation,
and failure. Theories and wear analysis, He should identify the external and internal
forces acting on the machine parts.
These forces may be classified as;
a) Dead weight forces
b) Friction forces
c) Inertia forces
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d) Forces generated during power transmission etc.
Designer should estimate these forces very accurately by using design equations.
If he does not have sufficient information to estimate them, he should make certain
practical assumptions based on similar conditions which will almost satisfy the
functional needs. Assumptions must always be on the safer side.

Fig. 01 3D Model

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 Fig. 02 Model Projection View

Chapter 5
7
Construction and Working
5.1 Construction
A beam engine mechanism is one where we use an overhead beam to create
motion. Here we use a beam engine motion-based assembly in order to achieve hack saw
cutting motion using a circular cutting disc. Our system uses a manual disc to drive a
connector which is in turn connected to an overhead beam. The overhead bean has a
connecting rod in turn connected to a mini hacksaw blade. When the manual disc below
is turned on the connecting arm starts reciprocating the overhead beam. This beam now
heals achieve a cutting motion as required by the hacksaw blade.

5.2 Working
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 manual handle power. In our project we take a hacksaw for cutting
purpose, The beam engine reciprocating high- speed hacksaw machine has an advantage
of working in high pressure, the hacksaw used in this is reciprocate such that required
shape can be catted according to the requirement. The hacksaw is the metal cutting
machine tool designed to cut metal by applying pressure. Hacksaws are used to cut thin
and soft wood the operation of the unit is simplified to a few simple operations involving
a cylinder block and piston arrangement. There are numerous systems in hacksaw
machine. The machine exclusively intended for mass production and they represent
fasten and more efficient way to cut a metal.

Fig. 03 Beam Engine

Chapter 6
8
 Project Components

6.1 Components
i. Base
Base is a structural member which is fixed on the floor. it holds the entire set up of
the punching machine on it. Material used for the base or frame is low carbon steel or
mild steel.

Fig. 04 Base

ii. Connecting Rod

A connecting rod is a shaft which connects a lever to a crank or crankshaft in a beam
engine. Together with the crank, it forms a simple mechanism that converts rotary
motion into reciprocating motion. A connecting rod may also convert reciprocating
motion into rotating motion.

Fig. 05 Connecting Rod

iii. lever
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 A lever is a machine member which is used to transmit the motion from the
connecting rod to a cutter.

Fig. 06 Lever

iv. Supporting Beam

It is fixed on the floor and it supports the lever while transmitting the motion during
punching of the metal sheets.

Fig. 07 Supporting Beam

v. Blade
Cutter is connected to leaver and beam to rotate and cut the work piece.
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 Fig. 08 Blade

vi. Bolts
In this project bolts use for joint cutter, beam connecting rod, etc.

Fig. 09 Bolt

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Chapter 7
Bill of Material
It contains cost table for each part required in the project.

SR. NO DESCRIPTION QUANTITY COST

1 Handle 01 50
2 Hacksaw 01 50
4 M6 Bolts 06 35
5 Wood flat 12*12*1000 01 100

Chapter 8
12
Conclusion
This being a creative project, there are no particular instances of this type of
machine being available in the commercial market. But the aim of this project is to
show that this type of machine too is an option for wood working industry in remote
places in the absence of electricity. Further improvements include using reduction gears,
to vary the speed of the circular saw, having an adjustable bed with slots for adjusting
the table length, so that even large sizes of timber can be sawed by varying the distance
of the table and the size of the circular saw.

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References
[1] C.S. Sharma and K.Purohit [2010], Theory of Mechanisms and Machines, PHI
Publishers, New Delhi 4. Ballaney [2005], Theory of Machines, Khanna Publishers,
New Delhi.
[2] Thomas Bevan [2005], Theory of Machines, CBS Publishers, New Delhi.
[3] J.S. Rao and R.V. Dukkipati [2008], Mechanisms and Machine Theory, NAI
Publishers, New Delhi
[4] Sadhu Singh [2012], Theory of Machines, Pearson Education, New Delhi
[5] S. S. Rattan [2009], Theory of Machines, TMH Publishers, New Delhi.