A MINI PROJECT REPORT

ON
POWER HACKSAW
Project submitted in partial fulfillment of the requirements for the award of the degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
BY

G.RAKSHITH 21C95A0311
SK.AZEEZ PASHA 21C95A0312
G.SAI KIRAN 21C95A0310
P.THARUN. 20C91A0313

Under the Esteemed guidance of

Dr.S.B.Herakal
Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

HOLY MARY INSTITUTE OF TECHNOLOGY & SCIENCE
(Approved by AICTE New Delhi, Permanently Affiliated to JNTUHyderabad, Accredited by NAAC with ‘A’ Grade)
Bogaram(V), Keesara (M), Medchal District -501 301.

2023 - 2024

i
 HOLY MARY INSTITUTE OF TECHNOLOGY & SCIENCE
(Approved by AICTE New Delhi, Permanently Affiliated to JNTU Hyderabad, Accredited by NAAC with ‘A’ Grade)
Bogaram (V), Keesara (M), Medchal Dist-501301.

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that the major project entitled “POWER HACKSAW” is being submitted by
GINNARAPU RAKSHITH (21C95A0311), SHAIK AZEEZ PASHA (21C95A0312) ,
GOPAGONI SAI KIRAN (21C95A0310), PANDENA THARUN (20C91A0313) in Partial
fulfillment of the academic requirements for the awardof the degree of Bachelor of Technology in
“(MECHANICAL ENGINEERING)” HOLY MARY INSTITUTE OF TECHNOLOGY
&SCIENCE, JNTU Hyderabad during the year 2023-2024.

INTERNAL GUIDE HEAD OF THE DEPARTMENT

Dr.S.B.Herakal Dr. N.Jeevan kumar Sir

Assistant Professor Associate Professor / HOD
Dept. of mechanical Engineering Dept. of mechanical Engineering

EXTERNAL EXAMINER

ii
 ACKNOWLEDGEMENT

The satisfaction and euphoria that accompany the successful completion of any task would be
incomplete without the mention of the people who made it possible, who’s constant guidance and
encouragement crowns all effort with success.

I take this opportunity to express my profound gratitude and deep regards to My Guide "Dr.Murali
Nayak", Assistant Professor, Dept. of Computer Science &Engineering, Holy Mary Institute of
Technology & Science for his / her exemplary guidance, monitoring and constant encouragement
throughout the project work.

My special thanks to Dr. N.Jeevan, Head of the Department, Dept. of Data Science, Holy Mary
Institute of Technology & Science who has given an immense support throughout the course of
the project.

I also thank to Dr. JBV Subramanyam, the honorable Principal of my college Holy Mary
Institute of Technology & Science for providing me the opportunity to carry out this work.

At the outset, I express my deep sense of gratitude to the beloved Chairman Dr. A. Vara Prasad
Reddy & Secretary Dr. A. VijayaSarada Reddy of Holy Mary Institute of Technology &
Science, for giving me the opportunity to complete my course of work

I am obliged to staff members of Holy Mary Institute of Technology & Science for the valuable
information provided by them in their respective fields. I am grateful for their cooperation during
the period of my assignment.

Last but not the least I thank ALMIGHTY and My Parents, and Friends for their constant
encouragement without which this assignment would not be possible.

G.RAKSHITH (21C95A0311)

SK.AZEEZ PASHA (21C95A0312)

G.SAI KIRAN (21C95A0310)

P.Tharun (20C91A0313)

iii
 DECLARATION

This is to certify that the work reported in the present project titled “POWER HACKSAW” is a
record of work done by me in the Department of Mechanical Engineering, Holy Mary Institute of
Technology and Science.

No part of the thesis is copied from books/journals/internet and whenever the portion is taken, the
same has been duly referred in the text the reported are based on the project work done entirely by
me not copied from any other source.

G.RAKSHITH (21C95A0311)

SK.AZEEZ PASHA (21C95A0312)

G.SAI KIRAN (21C95A0310)

P.THARUN (20C91A0313)

iv
 ABSTRACT
In this project work and effort has been made to develop a modernized multi blade hacksaw
machine and less stress full operation for cutting wood, metal and plastic materials. The aim of
this work is to develop a hack saw the performance difference between hands driven, pedal drive
and two way hack saw machine. This model implies a conversion of rotary motion of crank to
reciprocating motion of hack saw blades. This motion is used for hack saw machine, in this
model we can operate five hacksaws at same time. This model will overcome the traditional hack
saw machine which done material cutting of single piece at particular times interval and also
fulfils the need of more material cutting accounts to mass production. This machine works
significantly with minimum vibrations and jerks. This machine will also done cutting of
different materials, hence the purpose model of hack saw machines will be welcomed by many
industries due to compactness and efficiency. To achieve this goal the multi blade hack saw
machine is developed.

1
 TABLE OF CONTENTS
CONTENTS PAGE NO:
ABSTRACT 1
Chapter 1 4
INTRODUCTION 4
1.1 General 4
1.2 Scope of the project 4
1.3 Objectives of the project 5
1.4 Justifications & Relevance 5
Chapter 2 6
LITERATURE REVIEW 6
2.1 General 6
2.2 Literature Survey 6
Chapter 3 9
TYPES OF THE HACKSAWING MACHINES 9
3.1 History of Hacksaw Machine 9
3.2 Types of Hacksawing Machines 9
3.3 Sawing 12
3.4 Power Hacksaw Machines 14
Chapter 4 15
PROJECT METHODOLOGY 15
4.1 General 15
4.2 Working Principles-Crank Shaft Connecting Rod Mechanism 16
4.3 Components Used 17
4.4 Transmission Ratio Calculation 32
4.5 Working 32
Chapter 5 33

RESULT AND DISCUSSION 33

Chapter 6 34
Conclusion

2
Chapter 7
FUTURESCOPE 35
REFERENCES 36

3
 CHAPTER 1
INTRODUCTION

1.1 General
A hacksaw is a handheld tool used to cut through materials like plastic tubing and metal pipes.
Its cutting mechanism is provided by removable blades which featuresharp teeth along their outer
edge. In most cases, a hacksaw consists of a metal frame that resembles a downward facing. A
handle of plastic, wood, or metal is typically affixed to one end of the frame. The frame’s ends
feature adjustable pegs that can be tightened to secure a blade in place, and loosened to remove
it. Hacksaw blades are long, thin strips of hardened steel that feature a row of teeth along their
cutting edge. Each end of the blade is punched with a small hole that fits on to the saw frame’s
pegs. Most blades range in length from ten to 12inches (25.4 to 30.48 cm), although six-inch
(15.24 cm) blades can be purchased to fit smaller hacksaw models. A device that applies force,
changes the direction of a force, or changes the strength of a force, in order to perform a task,
generally involving work done on a load. Machines are often designed to yield a high
mechanical advantage to reduce the effort needed to do that work. A simple machines a wheel,
a lever or an inclined plane. All other machines can be built using combinations of these simple
machines. Example: A drill uses a combination of gears (wheels) to drive helical inclined planes
(the drill bit) to split a material and carve a hole in it.
1.2. Scope of the project

➢ The machine can solve the problem of time consumption.

➢ Waste of resources in face of labour cost is reduced.
➢ The machine can be used in the industry where it is manufactured, at thepackaging
sector.

➢ And it is used as hardware in large quantity like in fabrication ofmachine.

➢ It generates sustainable and practical automation solutions for the futureindustrial
development.

4
1.3. Objectives of the project
➢ To cater to the issue of competition in mechanical industry the need for automation is
assess by all the industry.
➢ To identify the key policy avenues considered to be appropriate to meet thechallenge of
sustainable manufacturing and packaging industry for the future.
➢ To provide alternative for industries aiming toward reducing human effort and
improvement in material handling system by implementing automation.

1.4. Justification & Relevance

We have found a “POWER HACK SAW” to be the most useful for general shop work. Modern heavy
duty hacksaw machinesprovide an economical and efficient means of sawing a wide range of materials and
stock sizes. Power hack saws are getting rarer all the time but they do a good job within their capacity. If you
can get one that takes standard hacksaw blades then you'll have a tremendous range of blades to choose from
and will be able to cut most anything. Hacksaws are more tolerant to tensioning maladjustment and run off. A
major advantage of power hacksawing is the relatively low capital investment required. Tooling and
maintenance costs are low. Accuracy and finishes produced, range from fair to good depending on the material
being sawed. Time saving as compared to simple hacksaw. Comfortable then ordinary hacksaw.

5
 CHAPTER 2
LITERATURE REVIEW
2.1 General

After the study of many literatures about design, construction and workingof POWER
HACKSAW, some of them describe the methodology of automatic power hacksaw. Lots of
factor have been considerfor the design, construction and working of automatic power hacksaw
machine such as cutting speed, cutting material, cutting time ,power ,efficiency etc. So, lots of
literatures have been found which gives the relevance information and methodology of
constructing an automatic power hacksaw machine.

2.2 LITERATURE SURVEY

1. Gored Ganesh

It is often required to machine a round and square rod on different machines to make various
products like shaft, screws, bolts etc. There is also a requirement ofcutting raw materials into
number of pieces and this is traditionally done using a power hacksaw machine or simple hacksaw
machine which consumes more time. To reduce this machining time a four way hacksaw
machine is proposed. This model helps us to cut four pieces of same or different material
simultaneously with less time expenditure. This model uses DC motor for its operation. Eccentric
cam is used for converting rotary motion of motor into reciprocating motion of hacksaw. This
model is very useful in industry due to its effectiveness, dependability and compatibility.
Result:
➢ It eliminates the problems of conventional hacksaw machine.
➢ It is easy to operate and simple in construction.
➢ The size of material to be cut can be increased by increasing the sizeof eccentric
cam and the power of the motor used.

6
2. Prof.Dipak Patil
The project is about optimization and development of multi-way hacksaw machine. In
general we use traditional hacksaw to cut each individual part. And for this reason this project
emphasizes on making changes to the conventional hacksaw machine and converting it into a
multi-way hacksaw machine. This machine is capable of cutting elements with different strength
at a time. The aim of optimization is to improve the quality and performance in optimum
sources. This machine is very effective in improving the cutting rate and decreasing the cutting
time.
Result:
➢ Due to its high efficiency, easy operation.
➢ Affordable price can overcome the problems of conventional hacksawmachine.
➢ It is useful in mini industries as its meets all the requirements.
➢ Also this machine can resist vibrations, jerks and does not require anyspecial
training for its operation.

3. Akshay N. Shirbhate
Pedal operated multi-operational machine which works on various operations without use
of electricity. By using this machine we can perform operation like cutting, electricity
generation, grinding & water lifting for agriculture. This machine is used to cut plywood and
MS materials. This works on the principle of Scotch-yoke mechanism which converts rotary
motion into thereciprocating motion which is applicable for cutting purpose. Also, pedal
operated multi-purpose machine is based on flywheel driven v-belt drives & pulleys. By using
this machine we can generate up to 12V DC power. Centrifugal assembly is used for water lifting
purpose & the pump which lift the water from 10m to 16m. The speed of grinding wheel is
3141rpm.

Result:
➢ The hacksaw machine gives 60 strokes per minute.
➢ It cuts 30mm diameter work piece of various material like PVC wood, barsand hollow
metal pipes, bar.
➢ By using this machine we can generate up to 12 volt dc power.

Industry needs machine for cutting purpose to increase mass production in minimum time.
In this, paper they can reduce the limitations of hacksaw machine which cut single piece at time.
To cut four pieces at time they introduce four way hacksaw machine. They convert rotary motion
into reciprocating motion to get proper working of machine.

7
4. Nitinchandra R. Patel
In this paper material selection and testing of blade according to material property has been
studied. Hacksaw blade is main component in hacksaw machine. Therefore it should made such
that blade should not made at the time of servicing. For that we need to analyse proper selection
of material so that it should not break. Testing of different materials like high-carbon steel, low
alloy steel, bi-metallic steel, high-speed steel. Also time require for cutting work piece, wear
resistance. To test blade performance cut the same work piece with different material, noting
time require for cutting, cutting accuracy etc. Blade profile is observed in profile projector.
Tensile test of blade is carried out in universal testing machine.
They have performed cutting operation of four blades of different material onwork pieces
of three different material i.e. aluminium, brass and mild steel. Thebi-metallic blade took less
time to cut aluminium work piece. High carbon steeltook less time to cut brass work piece and
bi-metallic blade took less time to cutmild steel work piece. Hard speed steel is preferred for
cutting hard material.

Result:

➢ Low alloy steel and high speed steel gives better hardness performance.

➢ Tooth profile for high carbon steel doesn’t wear out as much as compareto other
materials.
➢ High speed steel canbe used to cut work piece which is harden than it. high

carbon steel has lowest hardness compare to other therefore it Is use for cutting softer
material like wood, PVC pipe, aluminium, high carbon steel takes less time to cut brass
material.
➢ High carbon steel has better cutting efficiency for material like brass, copper. For
ferrous and no- ferrous material Bi-metallic and HSS performsefficiently.
➢ Tensile strength for materials are high speed steel > bi-metallic > high carbon steel >
alloy steel. Bending strength for HSS and low carbon steel is higher than other materials

8
 CHAPTER 3
TYPES OF HACKSAW MACHINES
3.1 History of Hacksaw Machine
The saw was one of the first great innovations of the Metal Age. It was developedwith smelted
copper, from which a blade could be cast. Many of the early coppersaws have the general
appearance of large meat-carving knives. Egyptian illustrations from about 1500 BC onward
show the saw being used to rip boards, the timber being lashed to a vertical post set into the
ground. Though there is no evidence of the type of saw used, Egyptians were able to saw hard
stone. The blade, was probably toothless, and rode on an abrasive material such as moistened
quartz sand. The 7 1/2-foot granite coffer still in the Great Pyramid carries saw marks. During
the Bronze Age, saws became much more widespread in woodworking. It was in this time that
the modern form of the saw began to come into play. Some of the saws used resembled hacksaw
blades of today. Iron saws started to be produces in the mid-7th century BC. The Romans,
added many improvements to simple says which made them easier to work with. For example,
they added a rib to the back of saws to reduce the buckling of the thin blade. Hacksaws today
use similar ribs to those on the ancient Roman saws. While sawsfor cutting metal had been in
used for many years, significant improvements in longevity and efficiency were made in the
1880s by George N. Clemson, a founder of Clemson Bros., Inc. of Middletown, New York,
USA, Clemson conducted tests which involved changing the dimensions, shapes of teeth, styles
of set, and variable heat treatments of blades. Clemson claimed enormous improvements to the
cutting ability of blades and built a major industrial operation manufacturing hacksaw blades
sold under the trade name Star Hack Saw.

3.1 Types of Hacksawing Machines

For a given blade and work piece the material removal rates achieved by hydraulic and gravity
fed machines are controlled solely by the thrust loads developed. Therefore, hacksawing may
be said to be a process in which the material removal rate is force controlled, unlike most other
material removal processes.
The machines available can be divided into two broad categories, according to the method
used to develop the load between the blade and the workpiece, namely gravity feed machines
and hydraulic machines. A third, but not common machine is the positive displacement
machine. Power hacksaw machines are used mainly for cutting-off operations

9
3.2.1 Gravity Feed Machines

Fig (3.1) Gravity Feed Machines

In this type of machine, which is usually of light construction for general duty, the thrust load
is developed by the gravity feed of the saw bow. In many of these machines the magnitude of
the thrust load is fixed, although some machines are provided with adjustable masses on the
overarm for thrust load adjustment. The thrust, load varies throughout the cutting stroke due
to the reciprocating.

displacement of the over arm mass and the action of the cam operated lift-off device which acts
at the beginning and the end of the stroke.
This type of machine generally has a work piece capacity between 150 - 200 mm(6 and 8 inches)
diameter and is ideal for the small workshop where the cutting requirement is only occasional
and the configuration of work pieces to be cut ranges from mild steel flat complex shaped
sections and tubular sections up to 6 inches diameter. Due to the light construction and gravity
feed the applications for this type of machine are limited.

10
3.2.2 Hydraulic Machines

fig (3.2) HydruaulicMachines

The thrust force between the blade and the work piece in this type of machine is
developed by a hydraulic device. Pressure may be developed in the load cylinder by either a
restricted back-flow system, or the pressure may be supplied from a separate pump. In some of
these machines, greater flexibility of control has been introduced by means of an arc cutting
action combined with a universally controlled hydraulic system which allows better
performance from the saw blade. The advanced types of heavy duty electro-hydraulic hacksaws
have a very wide range of operation and are available in semi-automatic or fullyautomatic form,
with provisions for automatic feeding of bar stock, cutting-off to

predetermined sizes and unloading etc. The feature of power down-feed to the saw bow
incorporated in these machines makes the machine suitable for cutting the tougher steels and
alloys. These machines are the most common and develop greater thrust loads than machines of
other type and have a reputation for sawing without problems and requiring minimum operator
skill.

11
3.2 Sawing

If all raw stock was delivered in ready-to-machine shapes and sizes, there would
be no need for sawing machines in a metal working shop. Machine operators could merely go
over to the stock, select the suitable work piece, and perform the necessary finishing operations.
Such situation rarely exists, due to

the fact that the majority of the stock requires to be cut in some way prior to starting a machining
schedule. The alternative to this primary operation of sawing is to buy-in prepared lengths and
shapes; this however introduces a service which the company has to pay for and, in the majority
of the cases, it is simpler and more economical to carry out the basic cutting to- size operation
in house. One of the major advantages of sawing over all other kinds of machining is the
narrowness ofcutop. Most sawing machines performthe cut-off operation, wherea piece of stock
is cut to a workable length prior to subsequent machining operations.

TYPES
i. Band Sawing
ii. Circular Sawing
3.3.1 Band sawing

fig(3.4)Band sawing
Band sawing, unlike hacksawing, is a continuous cutting operation.An endless blade, the band,
is tensioned between two shrouded, rotating wheels, and part of the band is exposed to carry out
the cutting operation of the work piece. The band travels in a continuous motion, with the teeth
fed against the work piece. Whilst earlier metal sawing bands were wide (over 25 mm), and were
12
used strictly for cut off methods, narrow blades, introduced about 50 years ago brought
contouring capabilities. Furthermore, due to the small throat clearance ofthe early band saws,
they were limited in use by the basic design, thus the length of the work piece could only be as
long as the machine throat. However modern machines have been modified to give adequate
throat clearance, by intentionallytwisting the blade so that the toothed faces in line with the
machine throat. As with hacksaw machines, band saws can be divided into two broad
categories. A general purpose band saw having gravity fed system, controlled by a dash-pot
and using a25 mm (1 inch) deep blade, is the most popular machine available. This machine is
suitable for general fabrication work and accurate cutting of solid bars. This type of machine is
limited to about 175 mm (7 inches) diameter for mild steel. In order to meet the present day
requirements for high-volume production, cutting all grades of steel and to introduce high
accuracy and reliability, it has been necessary for the band saw machine manufacturers to
incorporate in the design not only heavy duty construction having capacities up to 450 mm (18
inches) diameters but also innovations in the hydraulic power down-feed, to allow the cutting
of difficult alloys., such as mnemonics and titanium.

3.3.1 Circular Sawing

Circular saws have a continuous cutting action, use blades having many teeth, and a large range
of rotational speeds. This operation is similar to a milling operation. The machines available
range from the earlier, inexpensive, hand- loaded models to the very large, power loaded type
and incorporate material handling devices for semi and then fully automatic operations. Modern
production circular saws are built with several alternate basic feed mechanisms
i.e. horizontal, vertical, rocking head and variations of these. The choice of the most suitable
type of machine depends on the particular application and the size and shape of component. With
vertical feed, the rotating blade travels downwardsin a straight line to engage the work piece. On
machines designed for horizontal feed the blade is fed into the work piece from the back. A
13
third basic feeding arrangement is a pivot motion or rocking-head system, this is as efficient as
a vertical feed system and is a rugged arrangement. The bench or floor mounted manual-feed
circular saw, when installed together with a general duty band saw or hacksawing a small
workshop, provides a complete cutting facility for the small fabricator. Fully automatic circular
saws, having features such as dial-in component length, in process gauging, choice of loading
magazines, etc.

3.3 POWER HACKSAW MACHINES

Fig (3.6) POWER HACKSAW MACHINES

All power hacksaw machines are basically similar in design .Figure 6-1 shows a typical power
hacksaw and identifies its main parts, which are discussed below. The base of the saw usually
contains a coolant reservoir and pump for conveyingthe 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 vice and the metal being sawed is located on top of the base and is usually referred to as part
of the base. Vice is adjustable so that various sizes and shapes of metal may be held. Onsome
machines the vice may be swivelled 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 vice and sawed. 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. Some machines feed by
gravity, the saw frame having weights that can be shifted to give greater or less pressure on the
blade. Other machines are power fed with the feed being adjustable. On these machines, the
feed is usually stopped or reduced automatically when a hard spot is encountered in the material,
thus allowing theBlade to cut through the hard spot without breaking.

14
 CHAPTER - 4
PROJECT METHODOLOGY

4.1. General

Consist of a metal Frame with a handle and pin for attaching a narrow disposal blade, This
project is about cutting the wood, metal, pipes, angles, channel, flat plates, rods and such other
things. It is very simple mechanism but very useful to produce many typed of components in
less time. The main advantage of the project is to produce two parts in single time.
A Hacksaw is a fine tooth saw with a blade under tension in frame usedfor cutting material
such as metal. The Demand of hacksaw b lade is considerablyincreasing 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 material l like angels, channels, flat plate, rods and such other
things, it is also required in auto repairing shop, general repairing workshops, fitting shops, we
lading shops and technical institutes. Hand held hacksaw a screw or other mechanism issued to
put the thin blade under tension. Hacksaw blade cutting is a conventional machining process
where harder material which is tooth of the blades cuts the relatively softer materials per need.
In present condition many electrically operated power hacksaw machines of different
specifications are available for the use in shop floor. These machines are so precise that they
can cut metal bars with minimum times made up of different materials. For industries to achieve
the mass production, it is necessary to cut metals bars with high rate. So, it is impossible to
depend upon conventional single frame power (electric) hacksaw machine and need him
improvement in technology and design of such machines.

15
4.2 working Principles - Crankshaft-connecting rod mechanism

Fig 4. 1: crankshaft connecting rod mechanism

Connecting rod mechanism. The _rest pumps produced on a large scale were thepositive
displacement pumps and those positive displacement pump most widelyused is the piston pump
and these pump are constructed using this mechanism. If we look at (figure 4.1). We see that we
can calculate the displacement quite easy.
The displacement is x and the total length is l+r. We can distinguish two rectangular triangles,
ABB’ and CBB'.
x = l + r –AB’ – B’C
We need to calculate AB' and B'C. We need to calculate them in function of time.So as a matter
of fact in terms of the rotation speed ofthe crankshaft which is, w”
Thus we find

AB’ = l cos Φ
And, B’C = r cos θ

L/R=ƛ

We have to change the sin into a cos and for this we use

Cos2 θ= 1 - sin2Φ

This adds up to,

16
 Cos Φ= (1-ƛ2 sin2θ) 1/2
Now we get for the displacement of the crankshaft-connecting rod mechanismX=l+r-l (1-

ƛ2 sin2θ) 1/2 –r cos θ

This is clearly a non-linear and periodic motion. We can make an approximation

by using a Taylor-series for the square root.

(1-x) 1/2 = 1-x/2

In the end we get for the displacement,

X=l+r-l (1-(ƛ2 sin2θ)/2) – r cos θ

If one wants to calculate the speed and the acceleration he simply takes respectively the
first and the second derivative of the displacement.
We get respectively,

V=ώr (sin (ώt) +r/2l sin (2ώt)) A=ώ2

r (cos (ώt) + r/l cos (2ώt)).

4.3. Components Used

Following components has been used to construct this project.
i. Hacksaw frame & Blade,
ii. Bearing,
iii. Crank shaft,
iv. Connecting rods,
v. Support block,
vi. Material holding vice,
vii. Flywheel,
viii. Pulley.

17
4.2 .1 Hacksawframe & Blade
A hacksaw is a fine-tooth saw with a blade under tension in a frame, used for cutting
materials such as metal. Hand-held hacksaws consist of a metal frame with a handle, and pins
for attaching a narrow disposable blade. A screw or other mechanism is used to put the thin
blade under tension.
A power hacksaw (or electric hacksaw) is a type of hacksaw that is powered by
electric motor. Most power hacksaws are stationary machines but some portable models do
exist. Stationary models usually have a mechanism to lift up the saw blade on the return stroke
and somehave a coolant pump to preventthe saw blade from overheating.

Fig (4.1) hacksaw frame and blade

I. Different Types of Saw blade:

High Carbon Steel
▪ Bi-Metallic Steel
▪ High Speed Steel
▪ Low Alloy Steel

II. Material testing :

Hardness test:
• High speed steel blade and alloy steel blade having hardness of order of 65
HRC is higher than other materials. Hence, HSS is the best as far as the
hardness of tooth is concerned. So, for cutting harder work piece like mild steel
etc., bestoption is to employ HSSmaterial blade.
• In Bi-metallic strip blade, as only teeth are being hardened, hardness
remains almost the same including both ends. The ends are not annealed
because punch are made on relative softer shankmaterial.

18
 Cutting performance
• materials like brass, copper, bronze etc. are efficiently cut with highHigh carbon steel
blade is mainly used to cut the brass material as timefor cutting of Brass material by
High carbon steel blade is the least. So,the carbon steel as far as time is concerned.
For ferrous materials it takes lot of time to cut.

• Alloy steel blades are used to cut the non-ferrous materials like brass, aluminium
etc. as they take lower time for cutting of non-ferrous materials.

• Bi-metallic blades are the best to cut the ferrous materials like mild steel etc. as far
as the cutting time is concerned. Also for non-ferrous materials it gives good
performance.

• HSS blades cut both ferrous as well as non-ferrous materials with minimum cutting
time.

Wear test
• The high carbon steel experiences minimum wear on tooth forcutting the
aluminium, gun metal etc.

• The brass material and other non-ferrous materials can be cut withalloy steel
and high carbon steel for the minimum amount of wear.

• For cutting ferrous materials like mild steel, HSS as well as Bi- metallic blades
experience lower wear whereas alloy steel blades experience highest wear for
cutting ferrous materials.

• So, for cutting ferrous materials HSS and Bi-metallic blades are best in wear
consideration also for cutting non-ferrous materials either high carbon steel or
alloy steel is good as far as the wear is concerned.

Tensile test
• Bi-metallic and HSS blades are having higher tensile strength of the order of 900
MPa whereas high carbon steel blades is having tensile strength of the order of 600
MPa and alloy steel is having of the orderof 750 MPa.

• So, HSS and Bi-metallic blades are superior as far as the tensile
strength is concerned.

19
III. Material Selection of Saw blade:

Hardness Test of blade:

Table (4.1) Hardness Test of blade

Cutting Performance Test:

Table (4.2) Cutting Performance Test

WearResistance Testofblade:

Table (4.3) WearResistance Test ofblade

20
4.3.2. Bearing:
Bearing is a machine element that constrains relative motion to only thedesired
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 controllingthe vectors of normal forces that bear on the moving parts.
Most bearings facilitate the desired motion by minimizing friction. Bearings are classified
broadly according to the type of operation, the motions allowed, or to the directions of the loads
(forces) applied to the parts.
Rotary bearings hold rotating components such as shafts or axles within mechanical
systems, and transfer axial and radial loads from the source of the load to the structure
supporting it. The simplest form of bearing, the plain bearing, consists of a shaft rotating in a
hole. Lubrication is often used to reduce friction. In the ball bearing and roller bearing, to
prevent sliding friction, rolling elements such as rollers or balls with a circular cross-section are
located between the races or journals of the bearing assembly. A wide variety of bearing designs
exists to allow the demands of the application to be correctly met for maximum efficiency,
reliability, durability and performance The term "bearing" is derived from the verb "to bear" a
bearing being a machine element that allows one part to bear (i.e., to support) another. The
simplest bearings are bearing surfaces, cut or formed into a part, with varying degrees of control
over the form, size, roughness and location of the surface. Other bearings are separate devices
installed into a machine or machine part. The most sophisticated bearings for the most
demanding applications are very precise devices; their manufacture requires someof the highest
standards of current technology.
.

21
4.3.2.1. Types of rolling contact bearings:
1. Ball bearings
2. Roller bearings.
1. Ball bearings
A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation
between the bearing races.The purposes of a ball bearing is to reduce rotational friction and
support radial and axial loads. It achieves this by using at least two races to contain the balls
and transmit the loads through the balls. In most applications, one race is stationary and the other
is attached to the rotating assembly (e.g., a hub or shaft).
Ball bearing cut section

Fig4.3ball bearing cut section

22
4.3.2.2. Advantages of rolling contact bearings:
1. starting and running friction except at very high speeds.
2. Ability to withstand momentary shock loads.
3. Accuracy of shaft alignment.
4. Low cost of maintenance, as no lubrication is required while inservice.
5. Small overall dimensions.
6. Reliability of service.
7. Easy to mount and erect.
8. Cleanliness.

4.3.2.3. Disadvantages of rolling contact bearing:

1. More noisy at very high speeds.

2. Low resistance to shock loading.

3. More initial cost.

4. Design of bearing housing complicated.

4.3.4 CRANK SHAFT:

Fig (4.4) CRANK SHAFT

A crank is an arm attached at a right angle to a rotating shaft by which reciprocating motion
is imparted to or received from the shaft. It is used to convertcircular 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 (condor).
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 usuallya bar perpendicular to the other end of the arm, often with a freely
rotatable handleor pedal attached
23
4.3.5. Flywheel
A flywheel used in machines serves as a reservoir which stores energy during the period when
the supply of energy is more than the requirement and releases it during the period when the
requirement of energy is more than supply. Flywheels have a significant moment of inertia and
thus resist changes in rotational speed. The amount of energy stored in a flywheel is
proportional to the square of its rotational speed. Energy is transferred to a flywheel by applying
torque to it, thereby increasing its rotational speed, and hence its stored energy. Conversely,a
flywheel releases stored energy by applying torque to a mechanical load, thereby decreasing the
flywheel's rotational speed. Flywheels are typically madeof steel and rotate on conventional
bearings; these are generally limited to a revolution rate of a few thousand RPM .Some modern
flywheels are made of carbon fibre materials and employ magnetic bearings enabling them to
revolve at speeds up to 60,000 RPM.

Fig (4.4) flywheel

In case of steam engines, internal combustion engines, reciprocating

compressors and pumps, the energy is developed during one strokeand the engine is to run for
the whole cycle on the energy produced during this one stroke. For example, in I.C. engines,
the energy is developed only during power stroke which is much more than the engine load,
and no energy is being developed during suction, compression and exhaust strokes in case of
four strokeengines and during compression in case of two stroke engines. The excess energy
developed during power stroke is absorbed by the flywheel and releases it to the crankshaft during
other strokes in which no energy is developed, thus rotating the crankshaft at a uniform speed.
A little consideration will show that when the flywheel absorbs energy, its speed increases and
when it releases, the speed decreases.
Hence a flywheel does not maintain a constant speed, it simply
reduces the fluctuation of speed. In machines where the operation is intermittent like punching

24
machines, shearing machines, riveting machines, crushers etc.

4.3.5. 2 Use of flywheel:

• Flywheels are often used to provide continuous energy in systems where the energy
source is not continuous.
• In such cases, the flywheel stores energy when torque is applied by the energy source,
and it releases stored energy when the energy source is not applying torque to it. For
example, a flywheel is used to maintain constant angular velocity of the crankshaft in a
reciprocating engine.

4.3.6 Connecting rods

Connecting rods may also convert rotating motion into reciprocating motion.
Historically, before the development of engines, they were first used in this way. As a
connecting rod is rigid, it may transmit either a push or a pull andso the rod may rotate the crank
through both halves of a revolution, i.e. pistonpushing and piston pulling. Earlier mechanisms,
such as chains, could only pull.Today, connecting rods are best known through their use in
internal combustion piston engines, such as automotive engines. These are of a distinctly
different design fromearlier forms of connecting rods, used in steam engines and steam locomot

25
4.3.6 FORCE ACTING ON CONNECTING ROD
The following of the force acting on the connecting rod
Force on the piston due to gas pressure an inertia of the
reciprocating parts,
Force due to inertia of the connecting rod or inertia bending forces,

Force due to friction of the piston rings and of the piston, and

Force due to friction of the piston pin bearing and the crank-pinbearing.

TABLE: ALL ANALYTICAL DATA OF ALL I-SECTION ALLOYS

Materials 20CrMo 30CrMo 42CrMo
Total thickness (t) 2.71 mm 2.56 mm 2.44 mm
of I-section of
Width of section B 10.86 mm 10.24 mm 9.76 mm

Height of section H 13.57 mm 12.80 mm 12.2 mm

Height of I-section 11.21 mm 10.29mm 10.6 mm
of small end H1
Height of I-section 15.95 mm 15.04mm 14.33mm
of big end H2

Table (4.4)
4.3.7. Bench Vice

Vice is a mechanical apparatus used to secure an object to allow work to be

performed on it.Vices have two parallel jaws, one fixed and the other movable, threaded in and
out by a screw and lever. Vices are of various types, wehave used an engineer’s vice, also known
as a metalworking vice or fitter vice, is used to clamp metal. It is typically made of cast steel or
malleable cast iron. Cheaper vices may be made of brittle cast iron.

Fig4.7. Bench Vice

26
4.3.8 AC MOTOR

Fig (4.9) AC electric motor

An electric motor is an electrical machine that converts electrical energy into

mechanical energy. The reverse of this is the conversion of mechanical energy into electrical
energy and is done by an electric generator. In normal motoring mode, most electric motors
operate through the interaction between an electric motor's magnetic field and winding currents
to generate force within the motor. In certain applications, such as in the transportation industry
with traction motors, electric motors can operate in both motoring and generating or braking
modes to also produce electrical energy from mechanical energy.
Found in applications as diverse as industrial fans, blowers and pumps, machine
tools, household appliances, power tools, and disk drives, electric motors can be powered by
direct current (DC) sources, such as from batteries, motor vehicles or rectifiers, or by alternating
current (AC) sources, suchas from the power grid, inverters or generators. Small motors may
be found in electric watches. General-purpose motors with highly standardized dimensions and
characteristics provide convenient mechanical power for industrial use. The largest of electric
motors are used for ship propulsion, pipeline compression and pumped-storage applications
with ratings reaching 100 megawatts.
Hero of Alexandria identified the pulley as one of six simple machines used to
lift weights. Pulleys are assembled to form a block and tackle in order to provide mechanical
advantage to apply large forces. Pulleys are also assembled as part of belt and chain drives in
order to transmit power from one rotating shaftto another. This pulley also acts as a second class
lever, whereby the load is placedin between the fulcrum and the effort. The disadvantage with
these systems is thatone has to pull or push to displace a load and the main advantage is that it
requireslesser effort to be able to move the load..

27
 4.3.9 Shaft
A shaft is a rotating machine element which is used to transmit power from one place to another.
The power is delivered to the shaft by some tangential force andthe resultant torque(or twisting
moment) set up within the shaft permits the powerto be transferred to various machines linked
up to the shaft. In order to transfer the power from one shaft to another, the various members
such as pulleys, gears etc., are mounted on it. These members along with the forces exerted upon
them causes the shaft to bending. In other words, we may say that a shaft is used for the
transmission of torque and bending moment. The various members are mounted on the shaft
by means of keys or splines.

Fig. Shaft (4.10)

4.3.10 The material used for shafts should have the following
properties:
1. It should have good machinability.
2. It should have high strength.

3. It should have low notch sensitivity factor.

4. It should have good heat treatment properties.

5. It should have high wear resistant properties.

4.3.10.1 Manufacturing of Shafts

Shafts are generally manufactured by hot rolling and finished to size by cold drawing or
turning and grinding. The cold rolled shafts are stronger than hot rolled shafts but with higher
residual stresses.
The residual stresses may cause distortion of the shaft when it is machined,especially
when slots or Keyways are cut. Shafts of larger diameter are usually forged and turned to size
in a lathe.

28
4.3.10.2 Design of Shafts
The shafts may be designed on the basis of:

1. Strength
2. Rigidity
3. Stiffness
In designing shafts on the basis of strength, the following cases may beconsidered:
(a) Shafts subjected to twisting moment or torque only.
(b) Shafts subjected to bending moment only.
(c) Shafts subjected to combined twisting and bending moments.
(d) Shafts subjected to axial loads in addition to combined torsional andbending
loads.

4.3.11. V Belt
The belts or ropes are used to transmit power from one shaft toanother by
means of pulleys which rotate at the same speed or at different speeds.

Fig (4.11) V Belt

The amount of power transmitted depends upon the following factors:
1. The velocity of the belt.
2. The tension under which the belt is placed on the pulleys.
3. The arc of contact between the belt and the smaller pulley.
4. The conditions under which the belt is used.

29
It may be noted that:
(a) The shafts should be properly in line to insure uniform tension across the
belt section.
(b) The pulleys should not be too close together, in order that the arcof contact
on the smaller pulley may be as large as possible.
(c) The pulleys should not be so far apart as to cause the belt to weighheavily on
the shafts, thus increasing the friction load on the bearings.
(d) A long belt tends to swing from side to side, causing the belt to run out of
the pulleys, which in turn develops crooked spots in the belt.

(e) The tight side of the belt should be at the bottom, so that whateversag is
present on the loose side will increase the arc of contact at thepulleys.
(f) In order to obtain good results with flat belts, the maximum distance
between the shafts.

Importance of The V belts:

V belts are 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 offend 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 centre distances and high reduction ratios. The preferred
centre distance is larger than the largest pulley diameter, but less than three times the sum of both
pulleys. Optimal speed range is 1,000– 7,000ft. /min (300–2,130 m/min). V-belts need larger
pulleys for their thicker cross- section than flat belts for high-power requirements, two or more
V-belts can be joined side-by-side in an arrangement called a multi-V, running on matching
multi-groove sheaves. This is known as a multiple-V-belt drive (or sometimes a "classical V-
belt drive").

V-belts may be homogeneously rubber or polymer throughout or there may be

fibres embedded in the rubber or polymer for strength and reinforcement. The fibres may be of
textile materials such as cotton, polyamide (such as Nylon) or polyester or, for greatest strength,
of steel or aramid (such as Tarpon or Kevlar).

30
Need Of V belts:
When an endless belt does not fit the need, jointed and link V-belts may be employed. Most
models offer the same power and speed ratings as equivalently-sized endless belts and do not
require special pulleys to operate. A link v-belt is a number of polyurethane/polyester composite
links held together, either by themselves, such as Fanner Drives' Power Twist, or by metal studs,
such as Gates Nu-T-Link. These provide easy installation and superior environmental resistance
compared to rubber belts and is length adjustable by disassembling and removing links when
needed (Khurmi and Gupta 2012).

4.3.12 Bolt and Nuts

A screw thread is formed by cutting a continuous helical groove on a cylindrical surface. Ascrew
made by cutting a single helical groove on the cylinder is knownas single threaded (or single-
start) screw and if a second thread is cut in the space between the grooves of the first, a double
threaded (or double-start) screw is formed. Similarly, triple and quadruple (i.e. multiple start)
threads may be formed. The helical grooves may be cut either right hand or left-hand. A screwed
joint is mainly composed of two elements i.e. a bolt and nut. The screwed joints are widely used
where the machine parts are required to be readily connected or disconnected without damage
to the machine or the fastening. This may be for the purpose of holding or adjustment in
assembly or service inspection, repair, orreplacement or it may be for the manufacturing or
assembly reasons. The parts may be rigidly connected or provisions may be made for
predetermining.

4.3.12.1. Advantages and Disadvantages of Screwed Joints:

Following are the advantages of the screwed joints:
1. Screwed joints are highly reliable in operation.

2. Screwed joints are convenient to assemble and disassemble.

3.A wide range of screwed joints may be adapted to variousoperating conditions.

Following are the disadvantages of the screwed joints:
The main disadvantage of the screwed joints is the stress concentration in the stress
Concentration in the threaded portion which ate variable load conditions.

31
4.4 Transmission Ratio calculations
Driver pulley Diameter (d) =25mm,
Driven pulley Diameter (D) =300mm.Motor
speed (N1) = 1440 RPM
Transmission Ratio (or) Speed ratio {i} = [D/d] =N1/N2

300/25=1440/N2

12=1440/N2

Speed of crank shaft [N2] =120RPM

Transmission Ratio (i) = 12.

4.5 Working:

The working principle of crankshaft operated multi bladed hacksaw isvery simple,
it works on crankshaft mechanism. First of all the power is generatedin the motor which turns to
rotate the crankshaft through coupling the shaft of motor to shaft of crank. The rotatory moment
of shaft is then converted into reciprocating moment through ball bearing and connecting rods.
Thus the power is now converted into reciprocating moment, a number of hacksaw frame is
connected at the end of the machine in which the blade is fixed by nuts and bolts arrangements.
Thus when the machine runs it reciprocates the hacksaw frame which cuts the materials into
equal parts as needed. In present condition many electrically operated power hacksaw machines
of different specifications are available for theuse in shop floor. These machines are so precise
that they can cut metal bars withminimum times made up of different materials. For industries to
achieve the mass production, it is necessary to cut metals bars with high rate. So, it is impossible
to depend upon conventional single frame power (electric) hacksaw machine and need him
improvement in technology and design of such machines. With the helpof this multiday power
hacksaw machine the four metal bars can be cut simultaneously to get high cutting rate and to
achieve mass Production for maximum profit in related company. As the machine overcomes
all limitations and drawbacks of Conventional hacksaw machine, it is also helpful for small
scale industries due to its simple working and operating conditions along with its compatibility,
efficiency and affordable price.

32
 CHAPTER-5
RESULT AND DISCUSSION
Machine is driven by 1/4 HP and 1440 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 to both side. It took
the machine 240 seconds to cut the with a new hacksaw blade. The cut was observed to be neat
and straight. The totalcost of equipment of the machine was Rs The total cost of producing the
machine was estimated to be Rs 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.

33
 CHAPTER 6
CONCLUTION

It is known that conventional hacksaw machine can be replaced with crank shaft operate hacksaw
machine. Crank shaft operate hacksaw machine gives high productivity in short time period in
comparison with the conventional hacksaw machines. The major advantage of this machine is
that intervention of labour is reduced to maximum level. In this rapid emerging industrial era, the
use of power Hacksaw machine is wide. Time and labour plays a major role in production
process this can be overcome by using this type of automatic machines. The semi-automatic
hacksaw machine can be made use of at any of the industries like pumpmanufacturing industries
that involve bulk amount of shafts that have to be cut frequently. The range of size of work-
pieces that can be cut using the automatic hacksaw machine can be varied by changing the blade
size. Currently, the machine uses 12 inch blade for cutting.

34
 CHAPTER 7
FUTURE SCOPE

7.1 FUTURE SCOPE

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 time after a piece has been cut. The operator need to only enter the two
input namely the number of pieces to be cut and the length of each piece that is required to be
cut. The inputs can be givenby the operator with the help of a keypad and an LCD display,
which will help the user to verify the data given by him. After acquiring the two inputs from the
operator, the machine will automatically feed the given length of work-piece and start to cut till
the given number of work-pieces will be cut.

ADVANTAGES
i. Weight of the machine is less.
ii. It reduces the work of labour.
iii. Easy to make due to its simple construction.
iv. High production rate.
v. Cost is less.

APPLICATION

1. Used in mass production of equal length.

35
 REFERENCES
1. Khurmi, R. S., & Gupta, J. K. (2012). Machine Design
2. Kurvinen, E., Sopanen, J., & Mikkola, A. (2015). Ball bearing model performance on
various sized rotors with and without centrifugal and gyroscopic forces. Mechanism and
Machine Theory, 90, 240-260
3. Naresh, G.Venkatesh, N.S.Vishal, SureshKannan, Thangaprakash, A.Sivasubramanian,
Dr.G.Arunkumar Design and Fabrication of Pedal Operated Hacksaw, 2014 3(11), 197-198
4. Nelson RE Bands awing or hacksawing? 1965 109(24), Pages 90-93
5. Raj, K. J. S. D. (2012). Modelling, Control and Prototyping of Alternative Energy Storage
6. Remmerswaal. J p .Mathysen MJC Economics of the cutting-off of metals
7. Microtecnic, 1961 15(4), 140-150
8. Suzuki, A., Miyamoto, K., & Takahashi, S. (1998). U.S. Patent No. 5,791,224.Washington,
DC: U.S. Patent and Trademark Office.
9. Thompson, P. J., & Sarwar, M. (1974, September). Power hacksawing

36
37