DESIGN AND FABRICATION OF

4 -WAY HACKSAW MACHINE

DEPARTMENT OF MECHANICAL ENGINEERING
2018

GUIDED BY:- SUBMITTED BY:-

MR. MOHIT GUPTA SHAILENDRA KUMAR VERMA(1402940131)

(ASST. PROFESSOR) SHIVAM RAI (1402940139)
SHASHI PRAKASH (1402940136)
SHEKHAR (1402940137)
GROUP- D15
TABLE OF CONTENTS
OBJECTIVE
 In present condition many electrically operated power hacksaw
machines of different companies with different specifications are
available for the use in shop floor but they have one and major
disadvantage that those are able to cut single piece of bar at a time.

 Our objective is to demonstrate a mechanically efficient 4-way

hacksaw system which uses a single AC power source to power 4
hacksaw cutting blades simultaneously. A high torque AC Motor is
used to perform four cutting operations together in order to save
overall time and energy than repeating cutting operations with a single
power source.

 This machine is built on a rigid steel frame consisting of four hacksaw

blades connected perpendicularly in a horizontal plane. The high
torque AC Motor is fixed at one corner of the frame on the same
horizontal plane. A number of links, fixtures and movable parts are
attached between the motor as well as the blades to convert the
rotational motion of the motor shaft to reciprocating motion of the
cutting blades. It is an industrially ready to use machine with efficient
and long term usage capability.
SCOPE OF PROJECT

 The machine can solve the problem of time consumption.

 Waste of resources in face of labor cost is reduced.

 It provide alternative for industries aiming toward reducing human

effort.

 It generates sustainable and practical automation solutions for the

future industrial development.

 To cater to the issue of competition in mechanical industry.

METHODOLOGY
PROJECT IDEATION

LITERATURE SURVEY

DESIGN OF PROJECT

MARKET SURVEY

MARKETING

FABRICATION

TESTING

MODIFICATIONS
LITERATURE SURVEY
 D.V. Sabarinanda, V. Siddhartha, T. Mohanraj in their paper “Design and
Fabrication of Automated Hacksaw Machine” (April 2014) gives an idea about
the various components required for fabrication of the proposed model
.These components will help to get smooth working condition and future
automation of different mechanical actions as well as linkages.
 • Prof. Sameer Verma, Parvez Raza in their paper “Four way hack saw
machine- A Review”( March, 2016) gives an idea about the modification and
control the vibration produced by machine”.
 O. Cakir, A. Yardimen, T. Ozben in the paper “Selection of cutting fluids in
machining processes” gives directions about selection of proper cutting fluids
.The suitable cutting fluid is required to select for the purpose of cooling, to
avoid friction and making smooth operation and removal of burr.
 • R. Subash, K Samuel Jayakaran (2014) ,in this paper author has designed
pedal operated hacksaw machine which can be used for industrial
applications and households needs in which no specific input energy or power
is needed.
ISOMETRIC VIEW OF PROJECT

*(Assembled in Solidworks 2016)

ACTUAL IMAGE OF PROJECT
MAIN COMPONENTS
 Electric Motor
 Pulley
 Belt
 Hacksaw
 Hacksaw Blade

 ELECTRIC MOTOR: (CLASSIFICATION AND SPECIFICATION)

o Type: AC
o Subtype: Induction
o Power: 1 HP
o RPM: 1440
 PULLEY:
 There are 3 types of pulleys:

1.) Fixed Pulley

2.) Movable Pulley
3.) Combined Pulley

 BELT:
 The major types of belts used are:

1.) Flat belt

2.) V belt
3.) Toothed belt
 HACKSAW: A hacksaw is a fine-toothed
saw, originally and mainly made for cutting
metal. The equivalent saw for cutting wood
is usually called bow saw. Most hacksaws
are hand saws with a C-shaped frame that
holds a blade under tension.

 HACKSAW BLADE: Selection of the hacksaw blade with the

accurate tooth number per inch depends on dimensions and type of
the cutting material.
 16 teeth/ 20 mm – to cut thin materials
of all types as tubes, pipes, profiles etc.
 12 teeth / 20 mm – to cut all material
types with small and medium dimensions.
 8 teeth / 20 mm – to cut all material
types of larger thickness.
 6 teeth / 20 mm – to cut of soft material
types of greater thickness.
ASSEMBLY
WORKING PRINCIPLE
Scotch Yoke Mechanism:

The Scotch Yoke is a mechanism for changing over the rotational

movement of a crank into straight movement of slider. The cylinder
or other responding part is straight forwardly coupled to a sliding
burden with an opening that connects with a stick on the pivoting
part.
WORKING ANIMATION
COMPONENT SURVEY
1.) SURVEY FOR SAW BLADE:
 Following are the types of blades which are generally used material
cutting:-
1. High Carbon Steel
2. Bi-Metallic Steel
3. High Speed Steel
4. Low Alloy Steel
 Hardness Test of hacksaw blade:

 Cutting Performance Test:

 Wear Resistance Test of hacksaw blade:

 * CONCLUSION: On the basis of survey performed we had decided to opt for Low
alloy steel blades due to lower price and easier market availability.

2.) SURVEY FOR FRAME METAL:

After quick survey, we realized that the cost of transportation will

affect the cost of material too and since we need very less material,
we can’t buy our material from whole-sellers.

 *CONCLUSION: On the basis of survey performed, we came to conclusion that we

should buy our material from nearby local shops, as they will supply required
material at a cheaper rate and transportation cost will also get reduced to zero.
3.) SURVEY FOR MOTOR: Based on our calculations we decided to
buy an induction motor with following specifications;

PARAMETERS RATINGS

Rated Power 1 HP

Rated Voltage 220 Volts

Rated Frequency 50 Hz

Rated speed 1440 RPM

Pole Pairs 2

Stator Resistance 8.35 Ω

Rotor Resistance 8.43 Ω

Design Calculations

 MACHINE FRAME DESIGN-

 M/I = σ /y ………. (1)

b

 Bending moment (M) = force X perpendicular distance

 = 2.5 X 9.81 X 400
 Bending moment (M) = 9810 N-mm
 Moment of inertia (I) = (3.14/64) X (104) =488.83 mm4
 Y= 10/2 = 5 mm
 Therefore above value use in equation no (1).

 9810/488.83 = σ /5
b

 Therefore, σb = 91.6 N/mm2

 91.6 < 105 (for Mild steel it is safe)
 Hence design is safe.
 DESIGN OF CONNECTING ROD:

 M/I = σb/y ………….(1)

 Bending moment (M) =force X perpendicular distance
 = 2 X 380 X 9.81
 Bending moment (M) = 7455.6 N-mm
 Moment of inertia (I) = (BH3)/12 = (380 X 53)/12 = 490.8 mm4
 Y = 10/2 = 5 mm
 Therefore above value use in equation no (1).

 7455.6/490.8 = σb /5
 Therefore, σb = 75.95 N/mm 2

 75.95 < 105 (for Mild steel it is safe)

 Hence design is safe.
 Torque Calculations for Running:
 From Velocity Diagram,
 Considering cutting stroke length 5 inches = 125 mm
 (Value taken by referring hacksaw manufacturer’s catalogue)
 As we know,
 L= 2r; where r =crank radius, L= stroke length
 Therefore r = 2.5 inch = 62.5 mm
 The length of connecting rod = 300 mm
 Speed= N = 90 rpm (as per catalogue)

 So angular velocity ω =2ΠN/60 = 9.424 rad/sec

 Here OP = crank radius
 PA= PB= PC= PD= Connecting rods

 ωop = 9.42 rad/sec

 Since OP=0.0625m
 So velocity of P w.r.t O
 Vpo= Vp = 9.42 × 0.0625 = 0.588 m/sec
 From velocity diagram, we get velocities of slider
 Vap = 0.44 m/sec
 Vab = 0.44 m/sec
 Vac = 0.44 m/sec
 Vad = 0.044 m/sec
Required Torque:-
 We know forces at A, B, C, D
 FA = FB = FC = FD = 500 N

 Power output = T X ωop

 = T X 9.42 Nm/sec
 Power input = (Fa x Va) + (Fb x Vb) + (Fc x Vc) + (Fd x Vd)
 = (500 × 0.44) + (500 × 0.44) + (500 × 0.44) + (500 × 0.44)
 = 712 N-m/sec
 Neglecting losses power input is equal to power
 Output
 So,
 T X 9.42 = 712
 T = 70.58 N-m (Required torque)
Available Torque
 P = 2ΠNT/60 where N= 90 rpm
 P = 1 HP = 746 W
 T = 79.19 N-m

TIME TAKEN:-
The machine takes around 220 seconds to cut the 22 mm dia pipe by mounting 4
workpiece.
 Cost Estimation
 TOTAL COST (TC): TC=FC+VC
Where, FC= Fixed Cost &
VC= Variable Cost
Now,
Fixed Cost= (Cost of motor) + (Cost of material) + (Cost of vices)
(Cost of belt & pulley) + (Labor Cost) + (Miscellaneous)
Therefore,
Fixed Cost= 1800 + 800 + 875 + 450 + 650 + 425 = Rs. 5000
&
Now, For per day basis;
Variable Cost= (Electricity) + (Blades) + (Operator’s Salary)
(Maintenance Cost)
Therefore,
Variable Cost= 300 + 200 + 275 + 25= Rs. 800/Day

* NOTE: Some data is taken on the basis of approximate assumptions, actual

cost may vary.
Cost Comparison

Price : Rs. 8000

FUTURE MODIFICATIONS AND PLANS
1.) In order to improve accuracy and eliminate labor cost, automation
can be done.

2.) Pneumatic systems may serve as an option instead of motor.

3.) Rigidity of frame can be improved using high strength material.

4.) Vibration and Noise of the machine in operation can be further

reduced.

5.) Variac can be used to vary the speed of motor and hence the cutting
speed of machine.

6.) Precise cutting can be done using blades with less cutter-
compensation.
CONCLUSION
 On the above discussion we determined that the proposed machine
will aim on the restrictions of single piece cutting of material at an
instant of time by introducing four way cutting of material
simultaneously.

 It is compacted to the point that will be dwell in less space, cost

effective so usable in smaller industry and substantial assembling.

 As in cutting it will require less investment of cutting per unit of

workpiece, so machine sit still time is additionally diminished which
likewise experiences on advanced productivity, unwavering quality.

 Also machine takes a shot at limiting vibrations and shakes created

amid cutting activity.

 Reasonable value the proposed model of 4-way power hacksaw

machine is helpful and finishes all the prospects required in the
smaller than usual businesses.
WORKING VIDEO
THANK
YOU!