AUTOMATIC DOUBLE ACTING HACKSAW USING SCOTCH

YOKE MECHANISM

Submitted by

BARATH G 23214128
DHINESHKUMAR K 23214131
DILEEPSAMAD 23214132
GIRI T 23214133
GOKULPRASAD T 23214136

In partial fulfillment for the award of the degree of

DIPLOMA IN MECHANICAL ENGINEERING

SRI RANGANATHAR INSTITUTE OF POLYTECHNIC COLLEGE,

ATHIPALAYAM, COIMBATORE – 641110.

Directorate of Technical Education, Chennai – 600025

Government of Tamilnadu
APRIL-2025
 SRI RANGANATHAR INSTITUTE OF POLYTECHNIC COLLEGE
(Approved By Govt. of Tamilnadu and AICTE)
Athipalayam,Coimbatore-641110. Ph(0422)-2982999,2983099
E-mail:[email protected]

DEPARTMENT OF MECHANICAL ENGINEERING

Certificate
This is to certify that this project report titled
“AUTOMATIC DOUBLE ACTING HACKSAW USING SCOTCH YOKE
MECHANISM”
Is a bonafide project work done by

BARATH G 23214128
DHINESHKUMAR K 23214131
DILEEPSAMAD 23214132
GIRI T 23214133
GOKULPRASAD T 23214136

Submitted in the Partial fulfillment of the Requirements for the award of

DIPLOMA IN MECHANICAL ENGINEERING

Directorate of Technical Education, Government of Tamilnadu.
During the year 2024-2025.

Project guide Head of the Department

Certified that the candidate was examined by using the project Viva-Voce
Examination held on

Internal Examiner External Examiner

 Directorate of Technical Education, Chennai - 600025
Government of Tamilnadu

BONAFIDE CERTIFICATE
Certified that this Report titled is the bonafide work of “AUTOMATIC DOUBLE
ACTING HACKSAW USING SCOTCH YOKE MECHANISM” BARATH G
(Reg. No : 23214128 ), DHINESHKUMAR K (Reg. No : 23214131),
DILEEPSAMAD (Reg. No : 23214132), GIRI T (Reg. No : 23214133),
GOKULPRASAD T Reg .No : 23214136), Who carried out the 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 are dissertation on the basis of which a degree or
award was conferred on an earlier occasion on this or any other candidate.

Signature of the Guide with date Signature of the HOD with date
Mr. S.SASIMOHAN, B.E., Mr. S.PRAKASH, M.E.,
 ACKNOWLEDGEMENT
At this pleasing moment of having successfully completed our project, we wish
to convey our sincere thanks and gratitude to the management of our college and our
beloved Chairman Dr.V.NARAYANASAMY, who has provided all the facilities to us.

We would like to express our sincere thanks to our beloved Vice Chairman
Mr.N.HARIKRISHNAN & Our Director Mrs.B.ARTHI HARIKRISHNAN for
giving us the opportunity and support.

We would like to express our sincere thanks to our Principal

Dr.K.Kalaiselvan.,Ph.D., for forwarding us to do our project and offering adequate
duration in completing our project.

We are also grateful to the Head of Department Mr.S.PRAKASH.,M.E, for his

constructive suggestions & encouragement during our project which leads to the
successful completion of our project.

With deep sense of gratitude, we extend our earnest & sincere thanks to our
guide Mr.S.SASIMOHAN,B.E, Department of Mechanical Engineering for his kind
guidance & encouragement during this project.

We also express our indebt thanks to our Teaching and Non-teaching staff
members of mechanical engineering department, Sri Ranganathar Institute of
Polytechnic College, Athipalayam for their sincere in completion of this project.
LIST OF CONTENT
 LIST OF CONTENT

S.NO DESCRIPTION PAGE NO REMARKS

1 List of Figure 3

2 List of Material 5

3 Abstract 7

4 Introduction 9

5 Literature Review 11

6 Methodology 14

7 Parts Description 16

8 Design and Drawing 23

9 Working Principle 25

10 Merits And Demerits 27

11 Application 29

12 Cost Estimation 31

13 Conclusion 33

14 Bibliography 35

15 Photography 37

16 Internship Report 38

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 LIST OF FIGURES

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 LIST OF FIGURES

S.NO DESCRIPTION PAGE NO REMARKS

1 Crank- slider mechanism

2 Crank- slider mechanism

3 Displacement vs Rotation

4 Acceleration vs Rotation

5 Force analysis

6 Double Acting Hacksaw

7 Machine component

8 Sectional view of DC motor

9 Scotch yoke mechanism

10 Pulley and V-belt

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 LIST OF MATERIALS

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 LIST OF MATERIALS

S NO DESCRIPTION MATERIAL QUANTITY REMARKS

1. AC Motor Alloy Material 1

2. Aluminum strips and iron Aluminum 1

rods
3. Square table base Mild Steel 1

4. Bearing Mild Steel 2

5. Nut bolt Mild Steel 10

6. Pulley and disc plate Mild Steel 1

7. Switch Plastic 1

8. V belt drive Rubber 1

9. Hacksaw Mild Steel 2

10. Power supply block Plastic 1

11 Shaft Mild Steel 1

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 ABSTRACT

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 ABSTRACT

The Automatic Double Hacksaw is a cutting machine designed to enhance

productivity by simultaneously performing two cutting actions with two
reciprocating hacksaw blades. Powered by either an electric motor or pneumatic
system, this machine automates the cutting process, enabling precise and rapid
cuts on a variety of materials such as metal, wood, and plastic. The double-blade
setup allows for greater efficiency, making it ideal for industrial applications that
require high-volume, repetitive cutting.

Key components of the machine include a dual hacksaw frame,

reciprocating mechanisms for each blade, a control system, and an adjustable
work piece holder. As the blades move in a synchronized reciprocating motion,
the work pieces are evenly cut, doubling the output compared to a single
hacksaw. The automated setup reduces the need for manual operation,
minimizing worker fatigue and ensuring uniform cutting quality. The Automatic
Double Hacksaw is widely used in manufacturing facilities, workshops, and
metal fabrication shops, where it significantly improves cutting speed and
accuracy, making it a valuable tool for mass production environments.

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 INTRODUCTION

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 CHAPTER I
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.
The machine is exclusively intended for the mass production and
they represent fast and more effective way to cut the materials.
There are numerous types of cutting machines in engineering field,
which are useful in fulfilling the requirements. This new machine is
used to avoid the energy loss and save time. Scotch yoke
mechanism is used for this purpose.
2: SCOTCH YOKE MECHANISM- The Scotch yoke 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. In many internal combustion
engines, linear motion is converted into rotational motion by means
of a crankshaft, a piston and a rod that connects them. The Scotch
yoke is considered to be a more efficient means of producing the
rotational motion as it spends more time at the high point of its
rotation than a piston and it has fewer parts.
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 LITERATURE REVIEW

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 CHAPTER II
LITERATURE REVIEW

The automatic double hacksaw is a significant advancement in

material cutting technology, primarily used for metalworking in
industrial applications. The traditional hacksaw, used manually,
evolved with automation to enhance cutting efficiency and
precision. Early innovations in the 20th century, such as powered
reciprocating motion (Nelson & Smith, 1997), laid the groundwork
for more advanced automated cutting systems.
The design of the automatic double hacksaw incorporates dual
blades that cut materials simultaneously, increasing productivity
and cutting speed. Studies by Jones & Liu (2010) explored the
synchronization of the two blades to ensure uniformity in the cut,
crucial for reducing vibration and maintaining cut quality. The feed
system, often controlled by a PLC (Programmable Logic
Controller), allows for automatic adjustment of cutting parameters
such as speed, force, and pressure, making it versatile across
different materials (Singh, 2017).
Advanced materials like high-speed steel (HSS) and carbide-tipped
blades are commonly used in double hacksaw systems to extend
blade life and maintain sharpness over time (Chowdhury et al.,
2018). The integration of coolant systems further aids in
maintaining blade temperature, preventing wear and ensuring
smooth operation during long hours of cutting (Zhang et al., 2021).
Automatic double hacksaws offer substantial benefits, including
increased productivity, reduced labor costs, and improved
consistency in high-volume cutting operations. Research by Wang
et al. (2020) confirmed that these machines drastically reduce
downtime and material wastage, particularly when cutting bars,
tubes, or pipes in industries like automotive and aerospace.
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However, challenges such as high initial cost and maintenance
requirements remain. As noted by Chandra (2020), the complexity
of automation can lead to higher upfront investment, while regular
calibration and repairs are necessary for optimal machine
performance. Despite these challenges, the long-term benefits
outweigh the costs, particularly in high-demand production
environments.
Recent advancements, including AI-based predictive maintenance,
have further optimized these systems by predicting blade wear and
improving machine uptime (Jiang et al., 2023). Furthermore,
energy-efficient motors and green technologies are being explored
to reduce the environmental footprint of these machines (Thompson
et al., 2021).
In conclusion, the automatic double hacksaw is an essential tool in
modern manufacturing, offering improved speed, precision, and
efficiency. As automation and materials technology continue to
advance, its role in industries requiring high-quality cuts will
become even more crucial. Despite some challenges, the overall
benefits in productivity and cost-effectiveness make this technology
a valuable asset in industrial applications.

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 METHODOLOGY

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 CHAPTER III
METHODOLOGY

Selection of Project Topic

Introduction about Automatic Double Hacksaw

Using Scotch Yoke Mechanism

Introduction of Components

To collect the as many as possible literature papers

Selection of Material

Assembly of Components

To decide the working principle

To get experimental results

Conclusion

End

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 PARTS DESCRIPTION

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 PART DESCRIPION
CHAPTER IV
4.1.AC MOTOR :
A single-phase AC motor is a type of electric motor that operates on a single-phase
alternating current (AC) power supply. Unlike three-phase motors, which use three
separate alternating currents that are offset by 120 degrees, a single-phase AC motor is
powered by just one alternating current.

Fig.4.1: AC Motor
4.2PULLEY

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.

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 Fig 4.2 : PULLEY

4.3 BEARING:

A bearing is a machine element that constrains relative motion to only the

designed motion, and reduces friction between moving parts the simplest form of
bearing, the plain bearing consists of shaft rotating in a hole, lubrication is used
to reduce friction.

Fig.4.3 : Bearing

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 4.4 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 are hand saw
versions and powered versions (power hacksaws). 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.

Fig 4.5: Hacksaw blade with frame

4.5 V- BELT

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.
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 Fig 4.6: V- BELT
4.6 SHAFT:

Shafts are mechanical parts that transmit motion, torque or bending

moments generally round metal rods each segment can have different diameters
part that make a rotary motion in the machine are mounted on the shafts.

Fig.4.7:Shaft

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 4.7SCOTCH YOKE

Fig 4.8 : Scotch yoke

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 is 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. The pin used to connect yoke and crank is a bolt.

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 DESIGN AND DRAWING

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 CHAPTER V
DESIGN AND DRAWING

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 WORKING PRINCIPLE

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 CHAPTER V
WORKING PRINCIPLE

The Automatic Double Hacksaw works by using two reciprocating hacksaw blades to
perform simultaneous cutting actions on one or multiple work pieces, maximizing
efficiency and reducing cutting time. The principle is based on synchronized,
automated blade movement, often powered by an electric motor or a pneumatic system.

Power Source Activation: The system is powered either by an electric motor or a

pneumatic cylinder, depending on the machine's design. When the machine is turned
on, the motor or air compressor activates the reciprocating mechanisms attached to both
hacksaw blades.

Reciprocating Motion: The motor or pneumatic system drives a crank or cam

mechanism connected to each hacksaw frame, which moves both blades in a back-and-
forth (reciprocating) motion. This synchronized movement allows each blade to cut at
the same time, effectively doubling the machine's output.

Double Cutting Action: With two blades moving in parallel, the machine can cut twe
Double Cutting Ark piece or two separate work pieces simultaneous the work pieces
are held securely in an adjustable vise or holder to prevent shifting during the cuting
process, ensuring consistent cuts.

Automatic Operation: Many models are designed to run automatically with minimal
operator input once set up. The blades continue to reciprocate until the cut is complete,
at which point the machine can be programmed to stop.

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 MERITS AND DEMERITS

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 CHAPTER VI
MERITS AND DEMERITS

MERITS:

 High torque output with a small cylinder size.

 Fewer moving parts.
 Smoother operation

DEMERITS:

 Rapid wear of the slot in the yoke caused by sliding friction and high contact
pressure.

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 CHAPTER VII

APPLICATION

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 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

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 COST ESTIMATION

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CHAPTER VIII COST ESTIMATION

NAME OF THE AMOUNT

S.NO COMPONENT QUANTITY IN(RS)

1 Raw material Sufficient Qty Rs.3000

2 Standard Items 1 Nos Each Items Rs.1500
3 Machining Cost - Rs.200
4 Fabrication Cost - Rs.500
5 Design / Typing Work - Rs.500
6 Finishing Cost - Rs.1200
7 Transport Cost - Rs.300
8 Miscellaneous - Rs.500
Total Amount RS.7700

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 CONCLUSION

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 CONCLUSION

In conclusion, the Scotch Yoke Mechanism Automated Double Hacksaw system

represents a significant advancement in mechanical design, combining the principles of
the Scotch Yoke mechanism with automation for improved efficiency and precision in
cutting operations. This system effectively enhances the speed, accuracy, and
consistency of the hacksaw process, ensuring smooth motion and reducing the manual
labor required. The use of this mechanism in a double hacksaw setup optimizes the
cutting of materials, making it ideal for industrial applications. Moreover, automation
ensures reduced human error, increased safety, and the potential for 24/7 operations.
The integration of such a mechanism in industrial settings can lead to improved
productivity, cost savings, and overall operational effectiveness.

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 BIBLIOGRAPHY

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 BIBLIOGRAPHY

1. Shigley, J. E. (2001). Mechanical Engineering Design. McGraw-Hill.

2. Norton, R. L. (2009). Machine Design: An Integrated Approach. Prentice
HallManufacturing Process by O. T. Khanna and Lal.
3. Khurmi, R. S., & Gupta, J. K. (2005). Theory of Machines. S. Chand
Publishing..

4. Mishra, R. P., & Jain, S. K. (2014). Automation in Manufacturing:

Techniques and Applications. International Journal of Mechanical Engineering
and Robotics Research

5. Soni, P. & Sharma, D. (2017). Automation in Industrial Applications: A Case

Study of Hacksaw Automation. International Journal of Advanced
Engineering Technology

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 PHOTOGRAPHY

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 PHOTOGRAPHY

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 INTERNSHIP REPORT

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