Power Hacksaw

Design & Fabrication of Power Hacksaw Machine
1. INTRODUCTION
1.1 POWER HACKSAW MACHINE
A hacksaw is a handheld device used to slice through materials like plastic tubing
and metal funnels. Its cutting system is given by removable edges which include sharp
teeth along their external edge. As a rule, a hacksaw comprises of a metal casing that takes
after a descending confronting. A handle of plastic, wood, or metal is regularly joined to
one end of the casing. The edge's closures highlight customizable pegs that can be fixed to
anchor a sharp edge set up, and extricated to expel it. Hacksaw sharp edges are long, thin
portions of solidified steel that element a line of teeth along their front line. Each finish of
the edge is punched with a little gap that fits onto the saw edge's pegs. Most sharp edges
extend long from ten to 12inches (25.4 to 30.48 cm), albeit six-inch (15.24 cm) edges can
be acquired to fit littler hacksaw models. A gadget that applies compel, alters the course of
a power, or changes the quality of a power, with a specific end goal to play out an errand,
by and large including work done on a heap. Machines are regularly intended to yield a
high mechanical preferred standpoint to decrease the exertion expected to do that work. A
straightforward machines a wheel, a lever or a slanted plane. Every single other machine
can be constructed utilizing mixes of these straightforward machines. Illustration: A
penetrates utilizes a blend of riggings (wheels) to drive helical slanted planes (the bore) to
part a material and cut an opening in it.
Power hacksaws are used to cut large sections of metal or plastic shafts and rods.
Cutting of solid shafts or rods of diameters more than fifteen millimeters is a very hard
work with a normal hand held hacksaw. Therefore power hacksaw machine was invented
during 1920s in the United States to carry out the difficult and time consuming work. This
power hacksaw machine shown in figure 1 is considered as an automatic machine because
the operator need not be there to provide the reciprocating motion and downward force on
the work-piece in order to cut it. Once the operator has fed the work-piece till the required
length in to the machine and starts the machine, then the machine will cut until the work-
piece has been completely cut in to two pieces.
Dept. of Mechanical Engg. S. S. M. Adsul Poly. Chas, Ahmednagar 2018-19 Page 1

Fig 1.1 Power Hacksaw Machine
The fact that the operator has to feed the work-piece to the required length in to the vice is
one aspect that motivated us to automate the feeding of work-piece automatically. Another
one aspect is that after a shaft has been cut for one time, the operator has to unload the
work-piece and advance the rest of the work-piece to the required length again and again
till the end of the work-piece is reached. The Power hacksaw machine though being able
to cut the shaft or rod without requiring any human effort to cut, it does require a human
intervention to feed the work-piece many times with measurements being taken each time
before feeding. Therein, arose a need to completely automate the process of cutting, and
here we are with a proposal which will aid in eliminate the effort of the people associated
with it.
1.1 Problem Statement

Water to water combination in thermal heat exchanger having no heat storing capacity.
Hence we can’t take benefit of hot fluids thermal energy in the heat exchanger. So our
problem is that we have to use heat energy of hot fluid in heat exchanger.
1.2 Objectives of the Study

The present study is designed to investigate the performance of heat transfer of phase
change materials in a heat exchanger.
1. With PCM and without PCM.

2. With various flow rates & temperatures
3. To check the heat transfer properties at different time intervals
1.3 Scope of the work
For that above objective we are using shell and tube type heat exchanger and phase
change material PCM OM65 we are using.
1.4 Methodology
Following methodology is used
i. Study the basics of modes of heat transfer, Heat exchanger types, thermal energy
storage and PCM material
ii. Finding out the scope of research and objective of research.
iii. Find out research gap from various researchers.
iv. Finalizing the problem definition and objective.
v. Selection of dimensions and equiments for experimental setup
vi. Manufacturing the setup.
vii. Testing and data collection.
viii. Calculations of results and Conclusion.
1.5 Organisation of Thesis
Chapter 1 - Introduction

This chapter includes Problem Statement, background for research work and objectives of
current work. It also covers need for dissertation work, problem statement, definition of
methodology to achieve desired objectives.
Chapter 2 - Literature Review
Here study of various researchers is summarised shortly. The papers from various journals
and conferences, which are relevant to the topic of dissertation are included.
Chapter 3 – Thermal Energy Storage
In this chapter we have studied types of Energy storage, TES and PCM
Chapter 4 – Experimentation
In this chapter we have discuss the method of experimentation.
Chapter 5-Result & Discussion
Performance of PCM material carried here.
Chapter 6. Manufacturing Processes
In this chapter various manufacturing processes related to project mentioned here.
Chapter 7. Cost Estimation
Cost of brought out material and manufacturing processes both are added here.
Chapter 8. Outcomes of Project
In that advantages & disadvantages of projects are discussed.
Chapter 9. Conclusion
Based on the concept and test result conclusion has been made, which is mentioned
in this chapter.

2.LITERATURE RIVIEW
Sreejith et. al. The2.PDH consists of mainly four parts, the first one is sprockets,
the second is the chain, the third and fourth ones are the connecting rod and flywheel. The
chain used is simplex chain. The function of a flywheel is to reduce the fluctuations of
speed caused by the fluctuation of pedaling and also to provide uniform cutting. Figure 2.1.
shows the pedal driven hacksaw.
The pedal powered hacksaw set up, has a simple mechanism operate with chain
and sprocket arrangement. The chain is placed on the teeth of the wheel and pinion. Pedal
and connecting rod are interconnected to each other with the help of bolts. Bearing is
provided between the centre of the wheel or pedal and to delivers a smooth running of the
hacksaw in to and fro motion during pedaling. The hacksaw is connected to the end of a
rod. As by pedaling the wheel, the flywheel connected nearer to the pinion also rotates and
to reduce the fluctuation of speed and also provide a uniform cutting. The work piece is
placed on the work piece holder, which is to prevent the movement of work piece during
cutting. The size and shape of this setup is similar to cycle. Here for reducing the power,
loss chain mechanism is used.
Fig.2.1 Pedal Driven Hacksaw
Sabariananda et. al. The objective of this work is to automate the conventional
power hacksaw machine in order to achieve high productivity of work-pieces than the

power hacksaw machine using Microcontroller. The automated machine acquires two
inputs from the user namely the number of pieces to be cut and the length of each piece
that is required to be cut. The inputs are given by the user with the help of a keypad and an
LCD display, which will help the user to verify the data given by him. The operator need
not measure the length of the work-piece that is to be cut and to load and unload the work-
piece from the chuck each time after a piece has been cut. After acquiring the two inputs
from the user, the machine automatically feeds the given length of work-piece in to a chuck
and starts to cut till the given number of work-pieces has been cut. The machine feeds the
work-piece with the help of a conveyor, which is driven by a DC motor and an IR sensor
ensures that the feeding stops when the specified length has been reached. A pneumatic
cylinder is used for holding the work-piece when cutting operation is done. An AC motor
is used to bring about the reciprocating motion required for cutting the work-pieces. There
is a self-weight attached with the reciprocating mechanism to provide the necessary
downward force required for penetration of hacksaw blade in to the work-piece. When a
single piece has been cut, a limit switch will get triggered by the self-weight mechanism,
which is sensed by the microcontroller to start the cyclic operation again provided if the
specified number of work-pieces has not been cut.
There are three main parts in the Automated Hacksaw machine namely the conveyor,
base and self-weight attached with the hacksaw blade. The DC motor is located on the
conveyor setup along with the IR sensor and toothed disc, which are connected to the
microcontroller. The base setup consists of the AC motor and the setup which consists of
the pneumatic chuck. On the side of the AC motor, there are two upward projecting
structures in between which the self-weight mechanism is pivoted. The Hacksaw blade can
be adjusted along its length so as to be stiff while cutting by means of a threaded screw
arrangement at the free end of the self-weight mechanism. Fig 12 shows the photographic
view of mechanical setup.

Fig. 2.2 Photographic view of mechanical setup
Tanuj Joshi tells that, Machine is driven by 32 rpm electric engine. Test was
done on machine utilizing wooden example. For the stacked test, a pole of distance across
6 inch and the material of the pole was gentle steel was clasped on the bad habit of the
machine. It took the machine 240 seconds to cut the with another hacksaw cutting edge.
The slice was seen to be flawless and straight. The aggregate cost of hardware of the
machine was Rs. 4048. The aggregate cost of creating the machine was evaluated to be Rs.
4000. Suggestion has been made on the activity and parameters of the machine. Proposals
have been offered on general machine execution improvement and further work on the
machine.
It is realized that ordinary hacksaw machine can be supplanted with programmed

twofold hacksaw machine. Programmed twofold hacksaw machine gives high efficiency
in brief era in examination with the regular hacksaw machines. The real favorable position
of this machine is that intercession of work is diminished to greatest level. In this fast
developing modern time, the utilization of twofold Hacksaw machine is wide. Time and
work assumes a noteworthy part underway process this can be overwhelmed by utilizing

this sort of programmed machines. The programmed hacksaw machine can be made
utilization of at any of the ventures like furniture enterprises. The scope of size of work-
pieces that can be cut utilizing the programmed hacksaw machine can be shifted by
changing the sharp edge estimate. Right now, the machine utilizes 12 inch edge for cutting.
Fig.2.3 Final Model of Double Hacksaw Cutter
Chapter No.-3
METHODOLOGY
3.1 MATERIAL REMOVAL MECHANISM
A. Gravity Feed Machines - In this sort of machine, which is as a rule of light
development for general obligation, the push stack is produced by the gravity feed of the
saw bow. In a large number of these machines the size of the push stack is settled, albeit a
few machines are given flexible masses on the overarm for push stack change. The push,
stack differs all through the slicing stroke because of the responding relocation of the over
arm mass and the activity of the cam worked liftoff gadget which acts toward the start and
the finish of the stroke. This kind of machine for the most part has a work piece limit
between 150 – 200 mm (6 and 8 inches) breadth and is perfect for the little workshop where
the cutting prerequisite is just infrequent and the design of work pieces to be cut extents
from mellow steel level complex formed areas and tubular segments up to 6 inches width.

Because of the light development and gravity feed the applications for this kind of machine
are restricted.
B. Hydraulic Machines - The push drive between the sharp edge and the work piece in
this kind of machine is created by a pressure driven gadget. Weight might be created in the
heap chamber by either a confined reverse framework, or the weight might be provided
from a different pump. In a portion of these machines, more prominent adaptability of
control has been presented by methods for a curve cutting activity joined with an all-around
controlled water powered framework which permits better execution from the saw sharp
edge. The propelled kinds of uncompromising electro-pressure driven hacksaws have an
extensive variety of task and are accessible in self-loader or completely programmed frame,
with arrangements for programmed sustaining of bar stock, slicing off to foreordained sizes
and emptying and so forth. The component of shut down-feed to the saw bow consolidated
in these machines makes the machine reasonable for cutting the harder steels and
compounds. These machines are the most widely recognized and create more prominent
push loads than machines of other sort and have notoriety for sawing without issues and
requiring least administrator aptitude.
C. Positive Displacement Machines - While these machines are not as prevalent as the
gravity feed or water driven machines, a couple of machines are accessible where the feed
rate of the edge and subsequently, the metal expulsion rate is straightforwardly controlled
by a mechanical screw gadget, giving a positive feed. This kind of machine can prompt
overburdening of the sharp edge giving untimely edge disappointment especially when the
cutting edge is worn. Positive removal machines are not inclined to variety in push loads
amid the cutting stroke-since the push stacks straightforwardly emerge because of the
consistent rate of entrance of the sharp edge teeth.
Hacksaw
While saws for cutting metal had been being used for a long time, noteworthy
upgrades in life span and effectiveness were made in the 1880s by Max Flower-Nash.
Clemson, an author of Clemson Bros., Inc of Middletown, New York, United States,.
Clemson directed tests which included changing the measurements, states of teeth, styles
of set, and variable warmth medications of cutting edges. Clemson guaranteed tremendous

changes to the cutting capacity of edges and constructed a noteworthy mechanical activity
fabricating hacksaw sharp edges sold under the exchange name Star Hack Saw. In 1898,
Clemson was conceded US Patent 601947, which points of interest different changes in the
hacksaw.
A hacksaw is a fine-tooth saw with an edge under pressure in a casing, utilized for
cutting materials, for example, metal. Hand-held hacksaws comprise of a metal edge with
a handle, and sticks for joining a thin dispensable cutting edge. A screw or other system is
utilized to put the thin cutting edge under pressure. A power hacksaw (or electric hacksaw)
is a sort of hacksaw that is controlled by electric engine. Most power hacksaws are
stationary machines yet some helpful models do exist. Stationary models commonly have
a framework to lift up the saw sharp edge on the entry stroke and some have a coolant
pump to keep the saw bleeding edge from overheating..
Fig3.1Hacksaw Terminology
A screw or other mechanism is used to the thin blade under tension. The blade can
be mounted with the teeth facing toward or away from the handle, resulting in cutting action
on either push or pull stroke. On the push stroke, the arch will flex slightly decreasing the
tension on the blade, often resulting in an increased density of the blade to buckle and
crack. Cutting on the pull stroke increases the blade tension and will result in greater control
of the cut and longer blade life.

Blades:
Blades are available in standardized lengths, usually 10 or 12 inches for a standard
hand hacksaw. "Junior" hacksaws are typically 150mm long. Powered hacksaws may use
large blades in a range of sizes, or small machines may use the same hand blades. The pitch
of the teeth can be anywhere from fourteen to thirty-two teeth per inch (tips) for a hand
blade, with as few as three tips for a large power hacksaw blade. The blade chosen is based
on the thickness of the material being cut, with a minimum of three teeth in the material.
As hacksaw teeth are so small, they are set in a "wave" set. As for other saws they are set
from side to side to provide a kerf or clearance when sawing, but the set of a hacksaw
changes gradually from tooth to tooth in a smooth curve, rather than alternate teeth set left
and right. Hacksaw blades are normally quite brittle, so care needs to be taken to prevent
brittle fracture of the blade. Early blades were of carbon steel, now termed 'low alloy'
blades, and were relatively soft and flexible. They avoided breakage, but also wore out
rapidly. Except where cost is a particular concern, this type is now obsolete. 'Low alloy'
blades are still the only type available for the junior hacksaw, which limits the usefulness
of this otherwise popular saw.
For several decades now, hacksaw blades have used high speed steel for their teeth,
giving greatly improved cutting and tooth life. These blades were first available in the 'All-
hard' form which cut accurately but were extremely brittle. This limited their practical use
to bench work on a work piece that was firmly clamped in a vice. A softer form of high
speed steel blade was also available, which wore well and resisted breakage, but was less
stiff and so less accurate for precise sawing. Since the 1980s, bi-metal blades have been
used to give the advantages of both forms, without risk of breakage. A strip of high speed
steel along the tooth edge is electron beam welded to a softer spine. As the price of these
has dropped to be comparable with the older blades, their use is now
almost universal.
3.2 SLIDER CRANK MECHANISM
A slider-crank linkage is a four-link mechanism with three revolute joints and one
prismatic, or sliding, joint. The rotation of the crank drives the linear movement the slider,

or the expansion of gases against a sliding piston in a cylinder can drive the rotation of the
crank.
There are two types of slider-cranks: in-line and offset.
In-line: An in-line slider-crank has its slider positioned so the line of travel of the hinged
joint of the slider passes through the base joint of the crank. This creates a symmetric slider
movement back and forth as the crank rotates.
Offset: If the line of travel of the hinged joint of the slider does not pass through the base
pivot of the crank, the slider movement is not symmetric. It moves faster in one direction
than the other. This is called a quick-return mechanism.
Fig. 3.2 Slider Crank Mechanism
Slider-crank chain inversion arises when the connecting rod, or coupler, of a

slider-crank linkage becomes the ground link, so the slider is connected directly to the
crank. This inverted slider-crank is the form of a slider-crank linkage that is often used to
actuate a hinged joint in construction equipment like a crane or backhoe, as well as to open
and close a swinging gate or door.
A slider-crank is a four-bar linkage that has a crank that rotates coupled to a slider
that the moves along a straight line. This mechanism is composed of three important parts:
The crank which is the rotating disc, the slider which slides inside the tube and the
connecting rod which joins the parts together. As the slider moves to the right the
connecting rod pushes the wheel round for the first 180 degrees of wheel rotation. When

the slider begins to move back into the tube, the connecting rod pulls the wheel round to
complete the rotation.
Different mechanism by fixing different link of slider crank chain are as follows :
First inversion
This inversion is obtained when link 1 (ground body) is fixed. Application- Reciprocating
engine, Reciprocating compressor etc...
Second inversion
This inversion is obtained when link 2 (crank) is fixed. Application- Whitworth quick
return mechanism, Rotary engine, etc...
Third inversion
This inversion is obtained when link 3 (connecting rod) is fixed. Application- Slotted crank
mechanism, Oscillatory engine etc..,
Fourth inversion
This inversion is obtained when link 4 (slider) is fixed. Application- Hand pump, pendulum
pump or Bull engine, etc.
3.3 DC MOTOR
An electric motor is a machine which converts electrical energy to mechanical
energy. Its action is based on the principle that when a current-carrying conductor is placed
in a magnetic field, it experiences a magnetic force whose direction is given by Fleming’s
left hand rule.
Fig. 3.3.1 DC MOTOR Principle & symbol

3.3.1 Fleming’s Left Hand Rule.

Keep the force finger, middle finger and thumb of the left hand mutually
perpendicular to one another. If the fore finger indicates the direction of magnetic field and
middle finger indicates the direction of current in the conductor, then the thumb indicates
the direction of the motion of conductor.
When a motor is in operation, it develops torque. This torque can produce mechanical
rotation. DC motors are also like generators classified into shunt wound or series wound
or compound wound motors.
Fig.3.3.3 Fleming’s Left Hand Rule.

3.3.2 Principle of Operation of Dc Motor
A simplified model of such a motor is shown in figure. The conductors are wound
over a soft iron core. DC supply is given to the field poles for producing flux. The
conductors are connected to the DC supply through brushes A simple 2-pole DC electric
motor has 6 parts, as shown in the diagram below.

Fig. 3.3.2 Principle of Operation of Dc Motor
1. An armature or rotor
2. A commutator
3. Brushes
4. An axle
5. A field magnet
6. A DC power supply of some sort
An electric motor is all about magnets and magnetism: A motor uses magnets to create
motion. Opposites attract and likes repel. So if there are 2 bar magnets with their ends
marked north and south, then the North end of one magnet will attract the South end of the
other. On the other hand, the North end of one magnet will repel the North end of the other
(and similarly south will repel south). Inside an electric motor these attracting and repelling
forces create rotational motion..
Wiper Motor, the power source of the wiper blade, is the core of the whole wiper
system. Therefore, the quality of the wiper motor must be guaranteed to ensure its
performance. The wiper motor is a permanent-magnet direct current (DC) one. It is
equipped on the front windscreen glass with the mechanical parts of the worm gear. The
worm gear functions to slow down and increase torque. Its output shafts spur four-bar
linkage, by which the movement is changed from rotary to swinging.Three-brush structuris

adopted to make speed change more convenient. The intermittent relay, by which the
interval is controlled, utilizing the return of switch contacts and the charge-discharge
function of the resistor-capacitor in the relay, drives the wiper to wipe in a certain cycle.
3.6 BENCH VISE
A vice is a job or work piece holding device. It is a mechanical apparatus used to

secure an object to allow work to be performed on it. Vises consists two parallel jaws, one
fixed and the other movable, threaded in and out by a screw and lever as shown in Figure
3.6 Vice are generally fixed to the table or bench so as to provide necessary force for
holding work piece during machining and also for reducing the vibrations generated due to
machining.
Fig. 3.6 Bench Vise
CRANK SHAFT
The crankshaft, sometimes casually called the crank, is the part of an engine which
changes the up and down motion of the pistons into rotation. To convert the motion, the
crankshaft has one or more offset shafts. The pistons are connected to the crankshaft by
these shafts. When the piston moves up and down, it pushes the offset shaft. This in turn
rotates the crankshaft. The pistons cause a pulsing affect in the rotation. A crankshaft
usually connects to a flywheel. The flywheel smooths out the rotation. Sometimes there is
a torsion or vibration damper on the other end of the crankshaft. This helps reduce
vibrations of the crankshaft.

Large engines usually have several cylinders. This helps to reduce pulsations from
individual firing strokes. For some engines it is necessary to provide counterweights. The
counterweight is used to offset the piston and improve balance. While counterweights add
a lot of weight to the crankshaft, it provides a smoother running engine. This allows higher
RPMs to be reached and more power produced.
Fig. Crank shaft Automobile4

The distance between the center of the main journal and the center of the crankshaft pin is
called the crank radius , also called the crank throw . This measurement determines the
range of piston travel as the crankshaft rotates - this distance from top to bottom is known
as the stroke . The stroke of the piston will be twice the crank radius.
The rear end of the crankshaft extends outside the crankcase and ends with a flywheel
flange . This precision machined flange is bolted to the flywheel , whose heavy mass
helps smooth the pulsation of the pistons firing at different times. Through the flywheel,
the rotation makes its way, through the transmission and final drive, to the wheels. In an
automatic, the crankshaft is is bolted to the ring gear , that carries the torque converter,
passing drive into the automatic transmission. This is basically the output of the engine -
and power is taken to where it’s needed: propellers for boats and aircraft, induction coils
for generators, and to the road wheels in a vehicle.
The front end of the crankshaft, sometimes called the nose, is a shaft which extends
beyond the crankcase. This shaft will be locked to a toothed gear which drives the valve
train through a timing belt or chain [or in highly technical applications, gear sets], and a
pulley which provides power through a drive belt to accessories such as the alternator and
water pump.
Crankshaft parts
Main journals
The main bearing journals , or just main journals, are clamped into the engine block and
it is around these journals that the engine rotates. All crankshaft journals will be
machined perfectly smooth and round, and often hardened The main journals are secured
into saddles, in which a replaceable bearing insert will sit. The bearing is softer than the
journal, and can be replaced as it wears and is designed to absorb small amounts of
contaminants, if there are any, to save damaging the crankshaft. A main bearing cap is
then bolted over the journal and tightened to an exact torque specification.

The journals run on a film of oil which is forced into the space between the journal and
the bearing through a hole in the crankshaft saddle and a corresponding hole in the
bearing insert. With the correct oil pressure and supply of oil, the journal and the bearing
should not make contact.
Connecting rod journals
The connecting rod journals are offset from the axis of rotation, and are attached to
the big ends of the pistons’ connecting rods. Confusingly, they are commonly also called
crank pins or rod bearing journals . A feed of pressurised oil comes through an angled oil
passage drilled from the main journal. Some connecting rods have an oilway drilled
through them to to allow oil to be sprayed onto the cylinder wall. When this is the case,
the connecting rod journal bearings will have a groove to allow a feed of oil into the
connecting rod.
Crankshaft lubrication
Metal-to-metal contact is the enemy of an efficient engine, therefore the main

journals and rod journals both ride on a film of oil that sits on the bearing surface.
Supplying oil to the main journal bearing is easy: Oil galleries from the engine block lead
to each crankshaft saddle, and a matching hole in the bearing shell allows this oil to reach
the journal. X-ray view of crankshaft showing oilways running between main and rod
journals. The rod journal bearings require the same lubrication but they are rotating
around the crankshaft at an offset. To get the oil to these bearings, oil passageways run
inside the crankshaft - through the main journal, diagonally through the web, and out
through holes in the rod journals. A groove in the main rod bearing allows oil to be
continually forced down the passageway to the rod journals, assisted by being flung
outwards by the centrifugal force of the rotating crankshaft.
The clearances between the journals and bearings are the main source of oil
pressure in the engine. If the clearances are too high then oil flows out freely, and
pressure is not maintained. Clearances that are too low will cause high oil pressure and

risk metal-to-metal contact. It is therefore essential that the clearance between the
bearings and journals are measured when an engine is rebuilt.
Counterweights
The crankshaft is subject to strong rotational forces, and the mass of the connecting
rod and piston moving up and down exerts a significant force. Counterweights are cast as
part of the crankshaft to balance out these forces. These counterweights allow for a
smoother running engine and higher RPM.
A crankshaft will be balanced at the factory. In this process, the flywheel is attached
and the entire assembly is spun on a machine which measures where it is out of balance.
Balance holes are drilled in the counterweights to reduce weight. If weight needs to be
added, a hole is drilled and then filled with heavy metal or mallory. This is repeated until
the crankshaft is balanced.
How a crankshaft is made
Most production engines use a cast iron crankshaft which is made by pouring molten
iron into a mould. Forged crankshafts are used in some performance engines. A forged
crankshaft is made by heating a block of steel until red hot, and then using extremely
high pressure to form it into shape. Undefined Once a crankshaft has been forged or cast,
its journals and bearing surfaces are machined perfectly smooth. Oil passageways, or
oilways, are drilled. Production engines will generally leave the webs with their original
rough casting finish but performance engines will machine every part of the crankshaft to
reduce oil drag.
The journals must be harder than their bearings to ensure that any wear occurs on the
replaceable bearings and not the crankshaft, which should last for the lifetime of the
engine. The manufacturing process will include hardening of these areas through
nitriding or heat treatment.Extremely high performance and custom crankshafts, are
machined from a block of solid material, producing a billet crankshaft. Producing a one-
off crankshaft by this process would cost a minimum of around $3,000 so it is reserved
for competition racing and restoration situations.

Chapter No.-4
CONSTRUCTION & WORKING

4.1 CONSTRUCTION OF PROJECT
The project consist of following main parts.
1. Frame
2. battery
3. wiper motor

4. slider Crank mechanism

5. Hacksaw
6. Guide Mechanism
7. Bench Vice
Fig. 4.1 Construction of Project
4.2 WORKING OF PROJECT

Fig. 4.2 working of project
When we On the wiper motor then crank of wiper motor gets rotate. Due to this
of slider crank mechanism oscillates the connecting rod and hacksaw acts as slider. Hence
due to rotation of crank hacksaw gets reciprocating motion in the guide pipe.
This reciprocating motion of hacksaw cutter is useful for cut the workpiece which
held in the bench vice.
Chapter No.-5

DESIGN OF PROJECT
5.1 MATERIAL SELECTION
The proper selection of material for the different part of a machine is the main
objective in the fabrication of machine. For a design engineer it is must that he be familiar
with the effect which the manufacturing process and heat treatment have on the properties
of materials. The choice of material for engineering purpose depends upon the following
factors.
1. Availability of the materials.
2. Suitability of materials for the working condition in service.
3. The cost of materials.
4. Physical and chemical properties of material.
5. Mechanical properties of material.
The mechanical properties of the metals are those, which are associated with the
ability of the material to resist mechanical forces and load. We shall now discuss these
prosperities as follows. Required properties for the selection of material are Strength,
stress, stiffness, elasticity, plasticity, ductility, brittleness, toughness, resilience, creep,
hardness. The science of the metal is a specialized and although it overflows in to realms
of knowledge it tends to shut away from the general reader. The knowledge of material and
their properties is of great significance for a design engineer. The machine elements should
be a material which has properties suitable for the conditions of operations. In addition to
this a design engineer must be familiar with the manufacturing processes and the heat
treatments have on the properties of the materials. In designing the various part of the
machine it is necessary to know how the material will function in service. For this certain
characteristics or mechanical properties mostly used in mechanical engineering practice
are commonly determined from standard tensile tests. In engineering practice, the machine
parts are subjected to various forces which may be due to either one or more of the
following.

1. Energy transmitted
2. Weight of machine
3. Frictional resistance
4. Inertia of reciprocating parts
5. Change of temperature
6. Lack of balance of moving parts
The selection of the materials depends upon the various types of stresses that are
set up during operation. The material selected should with stand it. Another criterion for
selection of metal depends upon the type of load because a machine part resist load more
easily than a live load and live more easily than a shock load. Selection of the material
depends upon factor of safety which in turn depends upon the following factors.
1. Reliabilities of properties.
2. Reliability of applied load.
3. The certainly as to exact mode of failure
4. The extent of simplifying assumptions.
5. The extent of localized.
6. The extent of initial stresses set up during manufacturing.
7. The extent loss of life if failure occurs.
8. The extent of loss of property if failure occurs.
9. Materials selected in machine.

The machine is basically made up of mild steel. The reasons for the selection are
Mild steel is readily available in market .It is economical to use and is available in standard
sizes. It has good mechanical properties i.e. it is easily machinable. It has moderate factor
of safety, because factor of safety results in unnecessary wastage of material and heavy

selection. Low factor of safety results in unnecessary risk of failure. It has high tensile
strength. Low coefficient of thermal expansion. The materials of the sheets to be cut are
taken as aluminium and plastic as they are replacing many metals in the present scenario
because of their distinguished properties and features.
Mild steel contains –
Carbon 0.16 to 0.18 % (maximum 0.25% is allowable)
Manganese 0.70 to 0.90 %
Silicon maximum 0.40%
Sulphur maximum 0.04%
Phosphorous maximum 0.04%
Mildest grade of carbon steel or mild steel contains a very low amount of carbon - 0.05 to
0.26%
Properties of mild steel
Mild steel is the most commonly used steel. It is used in the industries as well in the
different everyday objects we use. Even the pans and spoons of the kitchen are sometimes
made of mild steel. The main target of this article is to discuss about different mild steel
properties. The mild steel is very important in the manufacturing of metal items. Almost
90% steel products of the world is made up of mild steel because it is the cheapest form of
steel. Mild steel is the most widely used steel which is not brittle and cheap in price. Mild
steel is not readily tempered or hardened but possesses enough strength.
The use of mild steel is huge and a person who is into manufacturing or production business
need to know a lot about the important characteristics of mild steel. The study of mild steel
becomes more significant for a student of mechanical engineering or metallurgical
engineering. Mild steel is an alloy. And alloy is a product made by mixing metals and non-
metals. Sometimes a pure metal cannot full fill all the properties needed for manufacturing
product. So additives are included in the pure metal to obtain some specific properties
necessary for the production. Mild steel is made by adding carbon and other elements in
the iron. These elements improve the hardness, ductility and tensile strength of the metal.
A small amount of carbon makes mild steel to change it properties. Different amount of
carbon produces different types of steels. There are small spaces between the iron lattices.

Carbon atoms get attached to this spaces and makes it stronger and harder. The harder the
steel the lesser the ductility.
The modulus of elasticity calculated for the industry grade mild steel is 210,000 Mpa. It
has an average density of about 7860 kg/m3.
Mild steel is a great conductor of electricity. So it can be used easily in the welding process.
Because of its malleability, mild steel can be used for constructing pipelines and other
construction materials. Even domestic cook wares are made of mild steel. It is ductile and
not brittle but hard.
Mild steel can be easily magnetized because of its ferromagnetic properties. So electrical
devices can be made of mild steel.
Mild steel is very much suitable as structural steel. Different automobile manufacturers
also use mild steel for making the body and parts of the vehicle.
Mild steel can be easily machined in the lathe, shaper, drilling or milling machine. Its
hardness can be increased by the application of carbon.
Mild steel is very much prone to rust because it has high amount of carbon. When rust free
products are needed people prefer stainless steel over mild steel.
OUTCOMES OF PROJECT
8.1 ADVANTAGES

Some of the basic merits of the Pneumatic powered hacksaw are as follows:-
1. Semi automatic machine, no need of man power during its working.
2. It can work efficiently in the work environment which is not suitable for workers, like
heated zone in industry, smoky gas area, toxic gases. Hence reduces life risk.
3. Very helpful for the manufacturing industries having mass production.
4. Reduces labour cost as only one worker can operate two or three machines
simultaneously.
5. Less power consumption as compared to other motorized power hacksaw.
6. No need of compressed air.
7. Less costly than other power hacksaw.
8.2 LIMITATIONS
1. Large cross section work piece takes more time.
8.3 APPLICATIONS
Applications of motor powered hacksaws are:-
1. Power hacksaw can be used in used in mass production industries for quick cutting
operations.
2. It can be used in automating the industry.
3. It can also be used in the workshops.
4. It can be used in locations where regular power cuts are seen.
5. It can be used to reduce the labour cost and in areas where less labour is available.
SUMMARY
In that way for reducing labor effort we have introduced power hacksaw run by wiper
motor which consumes electrical energy. It can work efficiently in the work environment
which is not suitable for workers, like heated zone in industry, smoky gas area, toxic gases.

Hence reduces life risk. It Very helpful for the manufacturing industries having mass
production. It Reduces labour cost as only one worker can operate two or three machines
simultaneously also Less power consumption as compared to other motorized power
hacksaw.
REFERENCES

1. “Experimental Investigation of Pedal Driven Hacksaw” 1Sreejith K., 2Aravind K.,

3Danie Davis, 4Farish K.A., 5George Johnson , Vol.4, Issue 7 (July 2014),
International Journal of Engineering And Science
2. “Design and Fabrication of Automated Hacksaw Machine”, D.V.Sabariananda1,
V.Siddhartha1, B.Sushil Krishnana1, T.Mohanraj2, Volume 3, Special Issue 2, April
2014, IJIRSET
3. “Automated Double Hacksaw Cutter”, Tanuj Joshi, IJERT, Vol. 7 Issue 07, July-2018
4. R. S. Khurmi and J. K .Gupta, “A textbook of Machine Design”, S Chand Publication

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Design & Fabrication of Power Hacksaw Machine

Dept. of Mechanical Engg. S. S. M. Adsul Poly. Chas, Ahmednagar 2018-19 Page 1

Fig 1.1 Power Hacksaw Machine

1.1 Problem Statement

Dept. of Mechanical Engg. S. S. M. Adsul Poly. Chas, Ahmednagar 2018-19 Page 2

1. With PCM and without PCM.

Following methodology is used

ii. Finding out the scope of research and objective of research.

iii. Find out research gap from various researchers.

iv. Finalizing the problem definition and objective.

v. Selection of dimensions and equiments for experimental setup

vi. Manufacturing the setup.

vii. Testing and data collection.

viii. Calculations of results and Conclusion.

1.5 Organisation of Thesis

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Chapter 2 - Literature Review

Chapter 3 – Thermal Energy Storage

In this chapter we have discuss the method of experimentation.

Chapter 5-Result & Discussion

Performance of PCM material carried here.

Chapter 6. Manufacturing Processes

In this chapter various manufacturing processes related to project mentioned here.

Chapter 7. Cost Estimation

Chapter 8. Outcomes of Project

In that advantages & disadvantages of projects are discussed.

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Fig.2.1 Pedal Driven Hacksaw

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Fig. 2.2 Photographic view of mechanical setup

It is realized that ordinary hacksaw machine can be supplanted with programmed

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Fig.2.3 Final Model of Double Hacksaw Cutter

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Fig. 3.2 Slider Crank Mechanism

Slider-crank chain inversion arises when the connecting rod, or coupler, of a

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Fig. 3.3.1 DC MOTOR Principle & symbol

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3.3.1 Fleming’s Left Hand Rule.

Fig.3.3.3 Fleming’s Left Hand Rule.

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Fig. 3.3.2 Principle of Operation of Dc Motor

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3.6 BENCH VISE

A vice is a job or work piece holding device. It is a mechanical apparatus used to

Fig. 3.6 Bench Vise

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Fig. Crank shaft Automobile4

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Connecting rod journals

Metal-to-metal contact is the enemy of an efficient engine, therefore the main

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How a crankshaft is made

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CONSTRUCTION & WORKING

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4. slider Crank mechanism

Fig. 4.1 Construction of Project