MINI BENCH SAW MACHINE

PROJECT In partialsAfulfillment
project report submitted
for the award of degree
DIPLOMA
IN
MECHAN
D.Ganesh ICAL- 20158-M-026
M.Hemanth
ENGINEE -20158-M-059
Sk.Mahamad rafi
RING-20158-M-091
SK.Baji -20158-M-089
D.Dinesh -20158-M-024
M.Bhrammendra -20158-M-055
M.Praveen kumar -20158-M-067
Under the esteemed guidance of
Mr. L.VIJAY KUMAR (B. tech)

DEPARATMENT OF MECHANICAL ENGINEERING

Page 1
 NUZVID POLYTECHNIC COLLEGE
Approved by AICTE , Permanently Afficilated to SBTET

(VENKATADRIPURAM,NUZVID,KRISHNA DIST,ANDRA PRADESH – 521201)

DEPARATMENT OF MECHANICAL
ENGINEERING

This is to certify that project work entitled “MINI BENCH SAW MACHINE” being submitted by
SK.MAHAMAD RAFI (20158-M-091) in partial fulfilment for the award of degree of Nuzvid polytechnic in
MECHANICAL ENGINEERING is a record of bonified work done by them under our supervision during the
academic year

2020-2023

Project Guide: Head of the department:

Mr.L.VIJAY KUMAR B. tech Mr.S.PRAKASH RAO
LECTURER SENIOR LECTURER

EXTERNAL EXAMINAR

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 CANDIDATES DECLARATION

We hereby certify that project work entitled “MINI BENCH SAW MACHINE” being submitted to
Department of Mechanical Engineering of Nuzvid Polytechnic college

It is an authentic record of our own work carried out during the final year under the guidance of
Mr.L.VIJAY KUMAR B. tech , Department of Mechanical Engineering ,in Nuzvid Polytechnic
college

The matter presented in the major project has not been report has not been submitted by us to any
other University/Institute foe award of any Degree/diploma. This project has been successfully
completed by the following student to our Institute for the award of Bachelor of Technology Degree.

D.Ganesh - 20158-M-026

M.Hemanth -20158-M-059

Sk.Mahamad rafi -20158-M-091

SK.Baji -20158-M-089

D.Dinesh -20158-M-024

M.Bhrammendra -20158-M-055

M.Praveen kumar -20158-M-067

This is to certify that the above statement made by the candidate

is correct to the best of my knowledge

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 ACKNOWLEDGEMENT
We take this opportunity to express my profound gratitude and deep regard to our GUIDE
Mr.L.VIJAY KUMAR B.tech Asst. Professor for his exemplary guidance , monitoring and constant
encouragement throughout the course of this thesis. The blessing, help and guidance given by him time
to time shall carry me a long way in the journey of life on which I am about to embark.

We also take this opportunity to express the deep sense of gratitude for his cordial support, valuable
information and guidance, which helped me in completing this task through various stages

We are obliged to S.Prkash Rao M. tech, Head of the Mechanical department & Lab Technicians
for the valuable information and technical help provided by them in their respective field. We grateful
for their cooperation during the period of my assignment.

Lastly, we thank almighty, my parents, family /70 and friends for their constant Encouragement without
which this assignment would not be possible.

D.Ganesh - 20158-M-026

M.Hemanth -20158-M-059

Sk.Mahamad rafi -20158-M-091

SK.Baji -20158-M-089

D.Dinesh -20158-M-024

M.Bhrammendra -20158-M-055

M.Praveen kumar -20158-M-067

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 MACHANICAI ENGINEERING BATCH-
07

ABSTRACT

MINI BENCH SAW MACHINES

PROJECT
A bench saw or table saw has long being used for wood works and metal works, itcan be used with a
variety of blades to achieve various fabrication applications
like cutting polishing dust cleaning. Table saw’s consists of electric motor that are
used to drive rotating saw blades.Our system demonstrates fabrication of bench saw using mini
bench
saw modelthat uses an electric motor with a shaft to mount various blades an achieveefficient
cutting.We use an arm with spring mounted pullback system whenpressure is not applied. The machine
has a frame bed with a cavity parallel to theblade in order to achieve full cutting when blade passes
though the work piece. The entire system is integrated and fabricated accordingly to achieve
requiredmechanism.

Keywords: 775motor of 12V, Battery, saw blades.

D.Ganesh - 20158-M-026

M.Hemanth -20158-M-059

Sk.Mahamad rafi -20158-M-091

SK.Baji -20158-M-089

D.Dinesh -20158-M-024

M.Bhrammendra -20158-M-055

M.Praveen kumar -20158-M-067

PROJECT CO-ORDINATOR PROJECT GUIDE HOD-ME

(L.VIJAY KUMAR) ( L.VIJAY KUMAR ) (S.PRAKASH RAO)

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 INDEX
Chapter 1
1. Introduction of bench saw machine
2. components used
1.2.1 775motor (12V)
2. Battery
3. Saw blades
4. Arm
5. Bed fram
e1.2.6 Supporting rubbers
7. Momentary push button
8. Spring
9. Mounts and fixtures
Chapter 2
Literature survey
3. Literature Review
4.saw blade
Highlight
Add Note
Share Quote
5. metal
cutting
saw
Chapter 3
6. Fabricati
on
1. Fram
2. Upper
T-joint
3. Arm
2. Operation
s
performe
d Page 6
1. Weldin
g
2. Carpent
ry
3. Drilling
3. Materials
1. Iron pipes
2. G.I sheet
3. Wood
3.4. Mounting of motor into the arm
5. Electric Connections
6. Final assembly
Chapter 4
4 Working principle
1. Working
2. Advantages and Disadvantages
4.3 Applications

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 Chapter 1
1.1 Introduction

Introduction of Bench saw Machine:-

Bench saw also known as Table Saw is a wood working tool consisting of acircular saw blade mounted on an
arbor that is driven by an electric motor eitherdirectly or by belt or gears.We use direct connection from motor to
the battery push button as a medium.Although the majority of table saws are used for cutting wood, table saw can
alsobe used for cutting sheet plastic, iron rod, aluminium sheet etc.Depth of the cut in bench saw can be varied
using hand pressure applied on anaim.

1.2Components

1.2.1 775motor (12V)

775motor has an rpm of 2500 of 12V which is mounted into an arm with the help of an arbor which rotates the
cutting tool

Fig no.1: 775 motor

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 1.2.2Battery

An amptek rechargeable battery of 12v is used for power supply to themotor momentary push button as a
medium.

Fig02: Battery1.2.3

Saw blades

Wood and steel cutting blades.

In which wood cutting blades is a frame blade and can be applicable If or cutting wooden pieces in an precise
direction.For steel cutting, fine grinding blade can be used for good accuracy.

Fig.BLADE

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 1.2.4Arm

Wood material is used to build an arm with the dimensions of (32*5*2cm)for cutting the materials applying hand
pressure on it accordingly.Also it is the main component which holds push button, motor. The arm is used as
cutting tool holder.

Fig03: Arm1.2.5

Bed Frame
4 Iron pipes of length (47cm) and breadth (47cm) with thickness of (2.5cm)which makes a square by joints of V-
shape welding. At the middle of one of the side of frame two rods of dimensions (13*0.5*5cm) is jointed in order
to hold and give vertical moment to arm.

Fig04: Bed Frame

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 1.2.6Rubbers

4 Rubbers of dia (4.5cm) and length (6.5cm) to support the frame and toavoid friction developed due to the
cutting mechanisms.

Fig05: Rubbers

1.2.7 Momentary Push Button

Push button is used to control the start and stop of the machine manually.Uneven motions of the machine is
restricted using push button.

Fig06: Momentary Push Button

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 1.2.7Spring

A 3inch spring which links to T-joint of bed and arm is a pullback systemwhen pressure is not applied and also it
provides free movement to applydepth of cut on workpiece.

Fig07: Spring

1.2.8Fixtures
To attach and change easily the discs and motor on arm screws and nutsare used
accordingly

Fig08: Fixtures

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 Chapter 2
Literature Survey
2.1 Review

1. In the United States, perhaps the first recorded patent for the circular saw was issued in 1777 to an Englishman,
Samuel Miller; it refers to a circular saw that was created in Holland in the 16th or 17th centuries. The 1885
catalog of the W.F.& John Barnes Co., Rockford, Il. clearly shows a classic table saw and it is labeledas a "Hand
[Powered] Circular Rip Saw".2.

Proceedings of the 2016 International Conference on Industrial Engineering andOperations Management Detroit,
Michigan, USA, September 23-25,

A table saw machine is a woodworking tool consisting of a circular saw blade,mounted on an arbour, that is
driven by an electric motor in turn the drive powerfrom motor is passed to the blade either directly or by belt. The
blade protrudesthrough the surface of a table top, which provides support for the wood being cut. The first record
of patent for that machine was issued in 1777 to an English man,Samuel Miller. In a modern table saw, the depth
of the cut is varied by moving theblade up and down: the higher the blade protrudes above the table, the deeper
thecut that is made in the material. In some early table saws, the blade and arbourwere fixed, and the table was
moved up and down to expose more or less of theblade. The angle of cut is controlled by adjusting the angle of
blade.

Prof. Zoeb khan, Mr.SushilDopekar “Design and Fabrication of Human PoweredWood Cutting machine”
International Journal on Recent and Innovation Trends in

Computing and Communication. (ISSN: 2321-8169)

In this paper, improved design of the human powered wood cutting machinewhich gives the less efforts of man
and commonly used in rural areas where thereis no power supply. The design ensures a smooth operation during
the cutting process. It is light inweight and portable machine4.

Safety automation in the existing circular saw machines

The project emphasis is on preventing hand movement leading to hazards and fornon-contact detection of fingers
intended to permit comprehensive and economical protection on circular saws.(Dietmar Reinert, 2009). With an
automatic blade guard an improved integration of the protection system can be achieved. The distinction between
skin and wood or other material is achieved by a dedicated spectral analysis in the near infrared region using LED
and photodiodes. With a kind of light curtain the intrusion ofhands or fingers into the dangerous zone near the
blade guard can be prevented and the guard will enclose the spinning blade within itself (Dietmar Reinert,
2009). The maladies of the mechanism are:

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It uses spectral analysis of light is focused in the cutting area this means detection of light rays fringing on an
interior or exterior defect of wood is likely to activate the safety guard hence method is not reliable and accurate.

Both the wood and human skin/flesh are not conductive hence are more likely to give the same results which
makes the method inconvenient.

Since the guard is the one which moves to hide the spinning blade within it it might injure the finger if they have
already entered the proximity vicinity.

2.2 Circular Saw blade

A circular saw is a power-saw using a toothed or abrasive disc or blade to cut different materials using a rotary
motion spinning around an arbor. A hole saw and ring saw also use a rotary motion but are different from a
circular saw Circular saws may also be loosely used for the blade itself. Circular saws were invented in the late
18th century and were in common use in sawmills in the United States by the middle of the 19th century. A
circular saw is a tool for cutting many materials such as wood, masonry, plastic or metal and may be hand-held or
mounted to a machine. In woodworking the term "circular saw" refers specifically to the hand-held type and the
table saw and chop saw are other common forms of circular saws. Typically, the material to be cut is securely
clamped or held in a vise, and the saw is advanced slowly across it. In variants such

Fabrication3.1.1 Bed Frame

Fig11: Bed Frame

3.1.2 Upper T-jointFig12: Upper T-joint

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 Operations Performed

3.2.1.1. Gas welding:

The most common gas welding process is oxyfuel welding also known asoxyacety lene welding.Gas welding
process is quite simpler compare to arc welding. In this process allthe equipment are connected carefully. The gas
cylinder and oxygen cylinder Connected to the welding torch through pressure regulators. Now the
regulatepressure of gas and oxygen supplied to the torch where they properly mixed. Theflame is ignited by a
striker. Take care the tip of torch is pointing downward. Nowthe flame is controlled through valves situated in
welding torch. The flame is set atnatural flame or carburizing flame or oxidizing flame according to the
weldingcondition. Now the welding torch moved along the line where joint to be created. This will melt the
interface part and join them permanently

.Fig13: Gas welding3.2.1.2

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 Fillet welding:
Fillet welding refers to the process of joining two pieces of metal together whetherthey be perpendicular or at an
angle. These welds are commonly referred to as Tee joints which are two pieces of metal perpendicular to each
other or Lap jointswhich are two pieces of metal that overlap and are welded at the edges. The weldis aesthetically
triangular in shape and may have a concave, flat or convex surface

depending on the welder’s technique. Welders use fillet welds when connecting

flanges to pipes, welding cross sections of infrastructure, and when fasteningmetal by bolts isn't strong enough
and wear off easily.

Fig14: Fillet Welding

3.2.2 Carpentry
Carpentry is a skilled trade and a craft in which the primary work performed is the cutting, shaping and
installation of building materials during the construction of buildings, ships, timber bridges, concrete formwork,
etc. Carpenterstraditionally worked with natural wood and did the rougher work such as framing, but today many
other materials are also used.

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 3.2.3 Drilling
Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in solid materials. The drill
bit is usually a rotary cutting tool, often multi-point. The bit is pressed against the work-piece and rotated at rates
from hundreds to thousands of revolutions per minute. This forces the cutting edgeagainst the work-piece, cutting
off chips (swarf) from the hole as it is drilled

Fig16: Drilling3.2.2

Tin smithy
Tin smithy is used for cutting a galvanized sheet using sniper. Using other tools like hammer bends of sheet
according to the bed frame size Is adjusted and welded using gas welding.

Fig17: Tin Smithy3.2.3

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 Surface Grinding
Surface grinding is the most common of the grinding operations. It is a finishingprocess that uses a rotating
abrasive wheel to smooth the flat surface of metallicor nonmetallic materials to give them a more refined look by
removing the oxidelayer and impurities on work piece surface.

Fig18: Surface Grinding3.2

Materials
3.3.1. Iron pipe
Square iron rods are used for bed support. They are welded from all its edges toform a square.

Fig19: Iron Pipe

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 3.3.2. GI Sheet
Galvanized iron (GI) sheets are steel sheets which are basically coated with zin cand include a range of hot dip
galvanized and electro-galvanized steel sheets. Zincweathers at a very slow rate, so the coating generally has a
long life. Zinc has a greater electro-negativity than iron and hence provides cathodic protection to the steel. This
results in the zinc corroding in preference to the steel if the coating is chipped or damaged to expose the base
metal.

Fig20: GI Sheet

3.3.3. Wood

Wood can be made into any desired shape by performing some carpentry on it.Wehave used wood for making an
arm.

. Fig21: wood

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 3.4 Mounting of motor

775 motor is mounted on an arm. The shaft along with cutting tool is arranged using mounts and fixtures.

Electric connections
The terminals of push button are connected to battery and motor.

Fig23: Electrical connections

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 Chapter 4
METHODOLOGY

1. Working
The operation of the machine is simple as there is no any complexity of assembled parts. The connections are
already fixed so that the machine is made ON by pressing the power button (push button) and by adjusting the
length of cut and depth of cutter over the table surface by the application of hand pressure on arm.

2. Advantages and Disadvantages

Advantages

1. Easy to operate.

2. Single person can operate.

3. Skilled operator is not required.

4. No need of electricity as battery is used

5. Simple in construction.6. Low maintenance.

7. More than one operation can be performed.

8. fast and smooth cuttings.

Disadvantages

9. Difficult Cannot cut materials of large thickness.

10.Rough cutting tool need to be replaced after some days.

11.Cleaning is necessary.

12.Risk of physical injury to the operator if proper care is not taken.

Applications

13.It can be used in small carpentry workshop.

14.It is use for cutting wood where power source not available.

15.In rural areas where electricity cut-off problems occurs.

16.It is used in fabrication workshops for cutting iron pipes.

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 Chapter 5
Results & Discussions

Thus a low cost and simple design operated wood working machine is fabricated. This machine reduces
the human effort to cut the wooden logs. This simple design of conventional design which can enhance
day-to-day household needs and day-to-day purposes and it can be also used in for industrial
applications during power shut down scenarios.

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 Chapter 6
Conclusion and Future Scope
Conclusion

The machine is proposed by keeping in mind the two most crucial factors of manufacturing, the accuracy and the
cost. The machine is good woodcutting instrument with cost effectiveness. It is made for cutting a variety of
wooden work pieces with varying length and dimensions. Proper evaluation of the design will be performed and
created something even better instead of electrically operated operations. Finally we conclude that this machine is
better option to use for Carpenter. By using this method we can do Cutting operation without the use of electricity.
So we can save the electrical power. The ply wood can be cut without any external energy like fuel or current.
The manually operated wood working machine is easy to use hence does not require any skilled person.

Future Scope

1. Arm can be made to fabricate to revolve in 360degrees in order to cutmaterial in different angles.

2.Heavy motor and battery can be used for cutting large components and longlife of machine.

3.Solar panel can be used instead of battery.

4.To utilize the full potential, safety mechanism should be retrofitted to allcircular saw machines (table saw, panel
saw and bench saw machine)

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 Reference
1. Engineering and Operations Management Detroit, Michigan,USA, September 23-25,

2. Prof. Zoeb khan, Mr.Sushil Dopekar “Design and Fabrication of Human Powered Wood Cutting machine”

International Journalon Recent and Innovation Trends in Computing and Proceedings of the 2016 International

Conference on Industrial Communication. (ISSN: 2321-8169)

3.https://ujcontent.uj.ac.za/vital/access/services/Download/uj:21614/SOURCE1

4.https://nevonprojects.com/mini-bench-saw-machine-project/ 5.https:/

/www.alce.vt.edu/content/dam/alce_vt_edu/teacher-resources/lab-safety-resources/tablesaw.pdf

6.https://en.wikipedia.org/wiki/Welding

7. http://www.rsisinternational.org/IJRSI/Issue42/49-56.pdf

8.Barcík, S., Pivolusková, E. and Kminiak, R. (2008). "Effect of technological parameter and wood properties on

cutting power in plane milling of juvenile poplar wood." Drvna Industrija 59(3), 107-112

9.Eyma, F.. Méausoone, P. L. and Martin, P. (2004). "Strains and cutting forces involved in the solid wood

rotating cutting process," J. Mater. Process Technol. 148(2), 220 225.

10.Klement. I. Reh, R. and Detvaj, J. (2010) "Basic characteristics of wood species - Wood processing in forestry."

National Forest Centre Zvolen, 82. Kopecky, Z, and Rousek. M. (2005). "Determination of cutting

Kovič, J, and Mikles. M (2009) "Analysis of cutting-edge geometry influence on circular saw teeth at the process

of crosscutting wood," Acta Universitas Agriculturae et Silviculturae Mendelianae Brunensis 47(5), 177-183.

11.Kovač, J., and Mikles, M. (2010), "Research on individual parameters for cutting power of woodcutting

process by circular saws." Journal of Forest Science 56(6), 271-277.

12.Méausoone, P. J. (2001). "Choice of optimal cutting conditions in wood machining using the coupled tool-

material method," Proceedings of the 15th International Wood Machining Seminar, pp. 37-47.

13.Sustck, J., and Siklienka, M. (2012). "Effect of saw blade overlap setting on the cutting wedge wear." Aacta

Facultatis Xylologiae Zvolen 54(1), 73-80.forces in cutting wood materials. Drvna Industrija 56(4), 171-

176.8.https://en.wikipedia.org/wiki/Table_saw

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