· '.

DESIGN AND FABRICATION OF A POWER HACKSAW MACHINE

BY

OTOKITI IIIIlVIA AHDIJLRAHMAN

2004/19014EM

DEPARTlVIENT OF MECHANICAL ENGINEERING

SCHOOL OF ENGINEERING AND ENGINEERING TECHNOLOGY

FEDERAL UNIVERSITY OF TECHNOLOGY

MINNA

.JANUARY, 2010
 DESIGN AND FABRICATION OF A POWER HACKSAW MACHINE

BY

OTOKITI IHIMA ABDULRAHMAN

2004/19014EM

A project Submitted to the Department of Mechanical Engineering in Partial Fulfillment of

the Requirement for the Award of Bachelor of Engineering (B.Eng.) Degree in Mechanical

Engineering. Federal University of Technology, Minna, Niger State, Nigeria.

JANUARY, 2010

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 DECLARATION

I Otoldti Ihima Abdulrahman (2004/19014EM) hereby declare that thi s proj ec t rlTScllled ill

partial I'ulfillment 10r the requirement of the awa rd of 13achclor of [ ngineering (13.Fllg.) degree

has not been presented before either wholl y or rartiall y for any other ckgree clse\\ here.

Information hereby obtained from published and unpubli shed works or others are acknowledge

accordingly

Otokiti Ihim a Abd ulrahm an

(2004/ 190 14EM) Signature and Datc

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 CERTIFICATION "

This is to certify that this project titled "DESIGN AND FABRICATION OF A POWER

HACKSAW MACHINE" was carried out by OTOKITI IIDMA AnDULRAHMAN under

, the supervision of Dr. A.B. HASSAN and submitted to the department of Mechanic&1l

Engineering, Federal University of Technology, Minna. In partial fulfillment of the requirements

for the award of Bachelor of engineering (B.Eng.) degree in Mechanical Engineeting.

Dr. A.B. HASSAN Sign & Date

Project Supervisor

Prof. R. H. Khan . Sign & Date

Head of Department

External Examiner Sign & Date

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 DEDICATION.

I dedicale this project work to Alimghty Allah and to my parent; Allwji Abu SulL' Olokili alld
Mrs. Abu Raliat.

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 ACKNOWLEDGEMENT

My invaluable gratitude goes to Allah for his inspiration, guidance and sustenance, and mercies

he bestowed on me while carrying out this academic task.

I wish to specially thank my indefatigable superVisor, Dr. A.B Hassan for his vISion and

commitment. I am very grateful.

My marks of respect to my H.O.D; Professor R. H. Khan , my level adviser; Mallam Muriana, all

the staffs and students of the department of mechanical engi neering. I also wish to compliment

the tranquil relationship of staff of mechanical engineering department FUT Minna.

I cannot but acknowledge the indefati gab le effort of my parents; Alhaji Abu Sule Otokiti and My

dearest mother Mrs. Raliyat Abu Otokiti.

My passionate words of thanks to all my siblings for being so encouraging and caring all the

while, talking about; Mall. Rufai Sezuo Otokiti , Mall. Kashim Salawudeeni , Mrs. Hassanat

Zakari , Engr. Abu Ibrahim , Mrs. Khehinde Ogunlaja, Mallam Yunus Otokiti , Abdulmumin Isah

Otokiti, Abdulrahim Otokiti, Mrs. Wosilat shuaib Wokili , Halima Sadiya, Abdulrazaq Abu

Otokiti , AbdulAzeez Otokiti, Salihat Otokiti and Fausat Otokiti.

My thanks are due to my wife Jimoh Enhezeyi Habibat for her prayer and encouragement.

In the course of carrier pursuit different individuals have been involved in my development and

guide to whom lowe a great deal of gratitude, and with the utmost regards , express my gratitude

to the following, for having availed me an enabling environment for my Engineering carrier

development: Mrs. Habiba B Audu (registry office), Mr. Abdulrahman M. C. (F.U.T Minna staff

school) and his wife; Mrs. S. K. Muhammad (FUT Minna Library), Engr. M C. Jesus

(mechanical Engineering department), Engr. Egbe (Mechanical Engineering department), Engr.

Salawu Abdulrahman (Mechanical :Engineering department) and Engr. Sadiq (Mechanical

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Engineering department).

I want to highly appreciate the encouragement and friendly relationship of the followin g people,

in the course of my career; Mall Mahmud Aliu, Ibrahim Ismail , Muftau Abdulkabir, Ibrahim

Ogunfayo, Yusuf Had i, Mohammed Tan imu, Sadiq Lawai , Isah Ademoh Abogunde (E lectri cal

department), Alhassan Ej ima (E lectrical department), Muhammad Kabir Abdussa lam (Bu ildin g

department), Engr. Tijani Aliu (Chemical department FUT Oweri) .

For their tender care and concern, my thanks are du e to Mall. Rufai Sezuo, Mrs. Taiye Hassanat,

Mrs. Fati Abdu lrahim Okuku and Miss Onozare Jimoh.

For the technical and moral support, I with deep sense of elation, thank; Engr. Ezekiel Abraham

and Engr. Egbe.

"A fr iend in need is a friend indeed" Nasir Omeiza Kolade is God sent. Abdulmaleek O. Ajanak u

(Physics department) is a friend closer than a brother.

Lastly I wish to thank Uztaz Alfa Mohammed Mahmud ; research and project paltner for hi s

inva luable contribution and assistance to the compilation of this project. May All ah bless yo u all ,

Ami n.

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 ABSTRACT

The project is on the design and construction ofa power hacksaw for cutting of metal to different

size and length with the aid of a hacksaw and a coolant. It is a cutting machine with teeth on its

blade used especially for cutting metals and driven by 1.5hp and 1400 rpm electric motor. The

various component of the machine were designed and constructed. The work was designed to

achieve a substantial part of its objective. Test was carried out on the machine usin g different

metals. For the loaded test, a 25.4mm flat bar of cross sectional area 2mm by 20mm was

clamped on the vice of the machine. It took the machine 75 seconds to cut the flat bar with a new

hacksaw blade. The cut was observed to be neat and straight. Cooling system, emergency stop

switch and automatic stop motion device were incorporated in the design. The total cost of

producing the machine was estimated at N53 , 490.5K. Reco mmendation have been made on the

operation and parameters of the machine, in addition , suggest ion have been offered on overa ll

machine performance optimization and further work on the machine.

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 TABLE OF CONTENT

CONTENT PAGE

Cover page

Title page II

Declaration III

Certi fication IV

Dedication v

Acknowledgement VI

Abstract VIII

Table of content IX

List of figures XIII

List of Tables XIV

List of symbols XV

NotationslNomenclature XVI

CHAPTER ONE - INTRODUCTION

1.0 Introduction

1.1 Scope and limitation 2

1.2 Justification 3

1.3 Significance 3

1.4 Objective 4

CHAPTER TWO - LiTERATURE REViEW

2.0 Historical Background 5

2.1 Sawing 7

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2.2 Power Hacksaw Machine 7

2.2.1 Types of Power Hacksaw 10

2.2.2 Reciprocating type of power hacksaw 10

2.2.3 Power Hacksaw Speeds 12

2.2.4 Method of feedin g 14

2.2.5 Rake Angle 16

2.2.6 Too l life 18

2.3 Heat generated during Machinin g 18

2.4 Cutting fluid 19

2.4.1 Types of cutting fluid 21

2.4.2 Function of cutting fluid 21

2.4.3 Application of cutting fluid 21

2.4.4 Characteristics of good cutting fluid 22

2.5 Automatic stop motion device 23

2.5.1 Explanation of the component involved 24

2.6 Recent design or works on the project 25

2.7 Other sawin g mach ine 26

2.7.1 Band saw machine 26

2.7.2 The Abrasive cut off saw 27

2.7.3 The cold circular cut off saw 28

2. 7.4 Friction sawing 28

2.8 Sawing hints 29

CHAPTER THREE - DESICN CONSIDERAT ION AND CALCULAT ION

x
3. 1 Design consideration 30

3. 1.1 Other factors considered 30

3.2 Design description 31

3.2.1 Mechanical assembly 31

3.2.2 Electrical assembly 31

3.2.3 Cooling system 32

3.3 Mode of operation 32

3.4 Design analysis ""

-'-'

3.4.1 Design of slider - crank mechanism 33

3.4.2 Force analysis 39

3.5 Determination of mass moment of inertia of connecting 40

rod and centre of gravity on the blade frame

3.5.1 Determination of mass moment of inertia of connecting rod 40

3.5.2 Determination of centre of grav ity on blade frame 41

3.6 Belt analysis 43

3.6.1 Determ ination of centre distance 43

3.6.2 Determination of belt length 44

3.6.3 Determination of angle of wrap 44

3.6.4 Determination of area of the v- belt 45

3.6.5 Determination of belt tension 46

3.7 Shaft design and bearing selection 47

3.8 Power analysis 53

3.8.1 Determination of power transmitted by the belt, PB 53

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3.8.2 Determination of power required to drive the reciprocating part 54

3.8.3 Determination of power req uired for cutting, Pc 54

3.9 Desi gn Ca lcul ations 55

3.9.1 Slider crank Calculation 55

3.9.2 Determ ination of forces 57

3.9.3 Calculation of mass moment of inertia of connecting rod 59

3.9.4 Calculation of center of gravity on blade flame 59

3.9.5 Belt calculation 60

3.9.6 Shaft design calculation 63

3.9.7 Ca lcu lation of power 73

CHAPTER FOUR - MATERIAL SELECTION, COST ANALYSIS AND TESTING

4.1 Material selection 75

4.2 Cost analysis 75

4.2.1 Material cost 76

4.2.2 Labour cost 77

4.2.3 Over head cost 78

4.2.4 Total cost 78

4.3 Testing 78

4.4 Result 79

4.5 Discussion of result

CHAPTER FIVE - CONCLUSION AND RECOMMEN DATIONS

5.0 Conclusion 80

5.1 Recommendation 80

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 Reference 81

LIST OF FIGURES

Pages

Figure 2. 1 Power hacksaw blade 9

Figure 2.2 Power hacksaw machine II

Figure 2.3 Heat dissipation by coolant 19

Figure 2.4 Spray mist 22

Figure 2.5 Block diagram of stop motion device 23

Figure 3.1 Electric hacksaw machine 31

Figure 3.2 Pulley system and slider-c rank mechanism 33

Figure 3.3 Slider crank mechanism 35

Figure 3.4 Free body diagram offig. 3.3 36

Figure 3.5 Connecting rod 40

Figure 3.6 Blade flam e 41

Figure 3.7 Vee belt 44

Figure 3.8 Bearing, shaft, and pulley system 47

Figure 3.9 Pulley system 48

Figure 3.10 Bearing and assembly 49

Figure 3.1 I Shaft subjected to deflection 51

Figure 3.12 Deflection of shaft 52

Figure 3.13 Bearing des ign 52

Figure 3. 14 Hacksaw blade shown the number of teeth betw-

een through length 58

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Figure 3.15 Shear force and bending system 64

Figure 3.16 Section x-x between C - 0 65

Figure 3.17 Section x-x between 8 - C 65

Figure 3. 18 Section x-x between A - 8 66

Figure 3. 19 Load, shear force and bending moment diagram 68

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