Pedal Operated Hacksaw

PROJECT WORK 2018-2019
CHAPTER-1
INTRODUCTION
DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 1

INTRODUCTION
PEDAL
(Fig:-1.1)
1.1 PEDALING :-
The bicycle pedal is the part of a bicycle that the rider pushes
with their foot to propel the bicycle. It provides the connection between
the cyclist's foot or shoe and the crank allowing the leg to turn the
bottom bracket spindle and propel the bicycle's wheels. A pedal usually
consists of a spindle that threads into the end of the crank, and a body
on which the foot rest is attached, that is free to rotate on bearings with
respect to the spindle.
Pedals were initially attached to cranks connecting directly to the

driven (usually front) wheel. The safety bicycle, as it is known today,
came into being when the pedals were attached to a crank driving a
sprocket that transmitted power to the driven wheel by means of a
roller chain

1.2 DRILL OPERATION:-
(Fig:-1.2)
Drilling is the operation of producing circular hole in the work piece by

using a rotating cutter called drill. The hand feed drilling machine are the
simplest and the most common type of drilling machines in use today.
These are the light duty machine that are operated by the operator, using
a feed handled, so that the operator is able to feel the action of the cutting
tool as it cuts through the work piece. These drilling machine can be
bench or floor mounted.
The power feed drill machine are usually larger and heavier than the
hand feed drills. They are equipped with the ability to feed the cutting
tool into the work automatically duty work or the work that uses large
drills that required power feed larger, work piece is usually clamped
directly to the table or base using t-bolts and clamps by a small work
places are held in a vise. A depth-stop mechanism is located on the head,
near the spindle, to aid in drilling to a precise depth.
1.3 GRINDING OPERATION

CHAPTER-2
LITERATURE REVIEW

LITERATURE REVIEW
In cutting operation as or blade descends upon the metal, the pressure
exerted by the blade first cause the plate deformation of the
metal.Cutting is a collection of processes wherein material is brought to
a specified geometry by removing excess material using various kinds
of tooling to leave a finished part that meets specifications. The net
result of cutting is two products, the waste or excess material, and the
finished part. In woodworking, the waste would be sawdust and excess
wood. In cutting metals the waste is chips or swarf and excess metal.
Cutting processes fall into one of three major categories:
 Chip producing processes most commonly known as machining

 Burning, a set of processes wherein the metal is cut by
oxidizing a kerf to separate pieces of metal
 Miscellaneous specialty process, not falling easily into either of
the above categories
There are many technologies available to cut metal and wood, including:
 Manual technologies: saw, chisel, shear or snips.

 Machine technologies: turning, milling, drilling, grinding,
sawing.
 Welding/burning technologies: burning by laser, oxy-fuel
burning, and plasma.
Brief description of all the types is as follows

1) Manual technologies:
For smaller cutting jobs, hand tools, including hand shears and
hacksaws may be used for cutting metal into the desired shape.
this cutting method is best suited for projects using more pliable
metals, such as thinner-gauge aluminum. using hand tools to cut
metal is not recommended if the metal must be cut into extremely
small pieces because the force needed to cut the metal may simply
break it, instead of cutting it as intended.
Chisels can also be used to remove excess metal and to make a
shape more precise. Depending upon the job, you may opt to use a
cold chisel, with a sharpened edge or a hot chisel, which is heated
before being hammered through metal.
2) Machine technologies:
For larger projects or those that use thicker or more robust metals,
manual cutting is not always practical. There are numerous
machine-based cutting methods to choose from, based on your
metal cutting needs.
 Grinder – For projects that require the finished part to be
extremely smooth, a grinding machine may be your tool of
choice. Using a rotating blade or wheel made of an
abrasive material; a grinder uses friction to wear down the
surface of the metal until it is smooth, similar to sanding
wood.
 Lathe – Using a sharpened cutting tool against a rapidly
spinning piece of material, a lathe will cut a piece of metal
to its desired shape. This machine is very common in the
machining industry because it allows for a higher degree of
precision.
 Punch – This machine uses an extreme amount of pressure
to force sharpened blades into or through metal to cut it

into the shape desired. The amount of pressure generated

by a machine punch is far greater than any human worker
could produce, thus this cutting method is suitable for
metals that are more robust. Some machine punches are
capable of up to 1,000 hits per minute, making this cutting
method very productive.
 Water jet – Using water or water mixed with an abrasive
compound, this machine directs an intense and
concentrated stream into metal and cuts it. This method is
best suited for metals that may be sensitive to extreme heat
or temperature changes because it does not use heat in the
process.
 Flame and plasma – This process is similar to a water jet,
but instead a flammable gas is pumped through a torch to
create an intense hot flame. The flame then cuts the metal
by burning and melting it. Flame torches, such as
oxyacetylene torches are very efficient for cutting. Plasma
cutters are known for their high degree of precision
because they burn much hotter.
3) Welding/burning process
Laser cutting is one of the newest and most exciting methods in
cutting technology. These cutters apply an intense beam of light to
the metal, heating it past its melting point, and then cut through the
metal. A laser cutter is able to concentrate light onto a very small
area, which makes this method suitable for projects that require a
very high degree of precision. However, this method is slower and
more expensive than other methods of metal cutting.

CHAPTER-3
COMPONENTS AND DESCRIPTION

3.1 COMPONENTS OF PEDAL AND

POWER OPERATED HACKSAW
MACHINE:-
3.1.1 RAW MATERIAL USED
 Cast iron bars for base frame

 Connecting links
 Connecting rods
 Shaft
3.1.2 READY MATERIALS USED

 pedals
 sprocket with chain
 1HP motor
 Open belt drive
 Hack saw frame
 Hack saw blade
 Bolts and nuts
 Bearings
3.1.3 MACHINES AND TOOLS USED
 Cutting machine
 Welding machine
 Surface grinding machine

 Files
 Hacksaw
3.2 PEDALS
(Fig:-3.1)
Pedals were initially attached to cranks connecting directly to the
driven wheel. The safety bicycle, as it is known today, came in to being
when the pedals were attached to crank driving sprocket that
transmitted power to the driven wheel by means of a roller chain.
Pedals usually consist of a spindle that threads into the end of the crank
and a body, on which the foot rests or is attached, that is free to rotate
on bearings with respect to the spindle. Pedal will be used to transfer
our muscular energy to the large sprocket
3.3 SPROCKET WITH CHAIN

A sprocket or sprocket- wheel is a profiled wheel with teeth, cogs, or
even sprockets that mesh with a chain; track or other perforated or
indented material. The name sprocket applies generally to any wheel
upon which radial projections engage a chain passing over it. It is
distinguished from a gear in that sprockets are never meshed together
directly, and differs from a pulley in that sprockets have teeth and
pulleys are smooth.

Roller chain or bush roller chain is the type of chain drive most
commonly used for transmission of manual power into rotary motion.
(fig:-3.2)
(fig:-3.3)
3.4 CRANK
A crank is a mechanical part able to perform a conversion

between reciprocating motion and rotational motion. In a reciprocating
engine, it translates reciprocating motion of the piston into rotational
motion; whereas in a reciprocating compressor, it converts the
rotational motion into reciprocating motion. In order to do the
conversion between two motions, the crankshaft has "crank throws" or
"crankpins", additional bearing surfaces whose axis is offset from that
of the crank, to which the "big ends" of the connecting rods from each
cylinder attach.
Crank will convert rotary motion of shaft into the reciprocating motion
which will further transmit to the hack saw assembly.

(Fig:-3.4)
3.5 1H P MOTOR
Power hacksaws are used to cut large sizes (sections) of metals
such as steel. Cutting diameters of more than 10/15 mm is very hard
work with a normal hand held hacksaw. Therefore power hacksaws
have been developed to carry out the difficult and time consuming
work.
Motor is used to reduce the effort of a worker which helps by giving

rotary motion to the crank and further rotary motion is converted into
reciprocating moment. The heavy ‘arm’ moves backwards and
forwards, cutting and the backwards stroke.

(Fig:-3.5)
3.6 CONNECTING RODS

The connecting rod connects the piston to the crank or
crankshaft. Together with the crank, they form a simple mechanism
that converts reciprocating motion into rotating motion. Connecting
rods may also convert rotating motion into reciprocating motion.
Historically, before the development of engines, they were first used in
this way.
(Fig:-3.6)

3.7 BEARING BLOCKS

A bearing is a machine element that constrains relative motion to
only the desired 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 controlling the vectors of normal forces
that bear on the moving parts. Many bearings also facilitate the desired
motion as much as possible, such as 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.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 some of the highest standards of current
technology.
(Fig:-3.7)

3.8 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. Panel hacksaws forgo the frame and instead
have a sheet metal body; they can cut into a sheet metal panel further
than a frame would allow. These saws are no longer commonly
available, but hacksaw blade holders enable standard hacksaw blades to
be used similarly to a keyhole saw or pad saw. Power tools including
nibblers, jigsaws, and angle grinders fitted with metal-cutting blades
and discs are now used for longer cuts in sheet metals.
(Fig:-3.8)

3.9 BLADE
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 for a hand blade, with as few as three tpi 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 provides 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
(fig:-3.9)

3.10 SPECIFICATIONS
1) PEDAL ARRANGEMENT
Bycycle crank :- 1
Pedals :- 2
Shaft :- 1
 Diameter :- 15mm
 Length :- 200mm
Bearings :- 2
2) MOTOR
Capasity :-1HP
Type of motor :- AC motor
Phase :- single phase
RPM :- 400
3) PULLEY
Diameter :- 250mm
Thickness :- 15mm
Weight :- 750g
Belt used :- V-Belt
Belt length :- 34 inch
4) CONNECTING ROD
NO of rods :- 2
Diameter of rod :-15mm
Length of the rod :- 350mm

5) CRANK
Diameter :- 250mm
Thickness :- 10mm
Weight :-1.2kg
6) BASE FRAME 1
Type of material :- mild steel
Length :- 1300mm
Width :- 650mm
Height :- 150mm
Flat width :- 50mm
Flat thickness :- 6mm
Angle plate angle :- 900
Angle palte dimensions :- 50*50 mm
Angle plate thickness :- 6mm
7) BASE FRAME 2
Type of material :- mild steel
Length :- 800mm
Width :- 300mm
Height :- 300mm
Flat width :- 25mm
Flat thickness :- 5mm
Angle plate dimensions :-25*25 mm
Angle plate angle :- 900
Angle plate thickness :- 5mm

PEDAL AND CRANK ARRANGEMENT
(Fig:-3.10)
CUTTING POSITION
(Fig:-3.11)

APPROACH AND METHODOLOGY

CHAPTER-4
WORKING PROCEDURE

WORKING PROCEDURE
(Fig:- 4.1)
 The pedal and power operated hacksaw is a device which is

used for cutting wood, plastics and metals. The basic
principles of power driven hacksaw is slider crank
mechanism which is inversion of four bar chain
mechanism. The hacksaw move to and fro motion when the
pedal is powered, so as the rotating disc rotates.
 Power operated system consists of a 1HP motor which is
connected to a driven pulley and pulley is connected to a
crank by the shaft. When the motor runs by the electrical
power which rotates the driven pulley and that rotates the
crank connected through a shaft. Crank converts the rotary
motion into reciprocating motion which makes the blade to
move.

(Fig:-4.2)
 The pedal operated system consists of the pedal arrangement

which rotates the crank and through it slider consists of
oscillating mechanism the power is transmitted to crank and
slider mechanism. This mechanism is used to rotate the crank
disc; the disc which is having an extended rod is connected to
the sliding portion of the hacksaw directly by means of a
linkage. The hacksaw is passed through a guide ways by means
of maintaining the cutting axis. As the user operated the pedal,
the hacksaw cuts the various materials automatically with less
power. The dead weight is for compressive force while the user
operated the foot pedal.

PROCESS FLOWCHART

CHAPTER- 5
ESTIMATION, COSTING,
ADVANTAGES AND
DISADVANTAGES

5.1 ESTIMATION SHEET

5.2 COST SHEET

5.3 ADVANTAGES AND DISADVANTAGES
ADVANTAGES:-
 It could be assemble and dissemble
 Less efforts needed
 It is very useful into rural areas and normal workshop
 Time saving as compared to simple hacksaw
 Power saving as it is manually operated
 Easy machinery used
 Comfortable than ordinary hacksaw
DISADVANTAGES:-
 More number of loads cannot be taken

 Not fit for heavy operations
 Light material as wood, pipes, iron rods can be cutted
 It is heavy in weight
 Structure is complex

CHAPTER-6
CONCLUSION AND FUTURE SCOPE

CONCLUSION
This project work has provided us an excellent opportunity and

experience, to use our limited knowledge. we gained a lot of practical
knowledge regarding, planning, designing, drawing, purchasing,
computing and machining while doing this project work. We feel that
the project work is a good solution to bridge the gates between
institution industries
.
we are proud that we have completed the work with the limited time
successfully. the machine is working with satisfactory conditions. We
are able to understand the difficulties in maintaining the tolerances and
also quality. We have done to our ability and skill making maximum
use of available facilities.
In conclusion remarks of our project work, let us add a few more lines
about our impression project work.
The chief advantage of our system is that, it cutting speed is varied
The fast operation is done by the power operated unit. The project is a
low cost automation project.

FUTURE SCOPE
 It can be given high power motor so that work can be done faster and
productivity can be increased and indirectly it will lead to profit to
companies.
 Thickness of the blade can be increased and it can easily cut large
thickness of metal pipe at any large diameter of work piece.
 It can be made hydraulically power operated by installing the gear oil
pump at the place of pedal arrangement and power system arrangement.
 In future it is very useful into rural areas and normal workshop.
 The machine can be fully automated by using microcontroller. In fully
automated machine the operator need not measure the length of the
workpiece that is to be cut and to load and unload the work piece each
time after a piece has been cut.

REFERENCES
1. Theory of Machines By R.S. Khurmi and J.K Gupta,1multicolour

edition .
2. ‘A Textbook of Production Engineering ‘byP.C.Sharma
3. J.P. Denharton, advanced strength of materials (McGraw-Hill,
NEW YORK 1953), TA 405 D4, 1952; Author name, conference
name, year etc.
4. http://google.com
http://www.engineeringsedge.com/
http://www.scribd.com/
http://www,slideshare.com/
http://www.emjmetals.com/
http://www.usstubular.com/
5. Machine tool design handbook.

PHOTOGRAPHY:-
(Fig:-6.1)
(Fig:-6.2)

(Fig:-6.3)
(Fig:-6.4)

(Fig:-6.5)
(Fig:-6.6)

(Fig:-6.7)
(Fig:-6.8)

(Fig:-6.9)
(Fig:-6.10)

Pedal Operated Hacksaw

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PROJECT WORK 2018-2019

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 1

Pedals were initially attached to cranks connecting directly to the

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 2

1.2 DRILL OPERATION:-

Drilling is the operation of producing circular hole in the work piece by

1.3 GRINDING OPERATION

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 3

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 4

Cutting processes fall into one of three major categories:

 Chip producing processes most commonly known as machining

 Manual technologies: saw, chisel, shear or snips.

Brief description of all the types is as follows

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 5

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 6

into the shape desired. The amount of pressure generated

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 7

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 8

3.1 COMPONENTS OF PEDAL AND

3.1.1 RAW MATERIAL USED

 Cast iron bars for base frame

3.1.2 READY MATERIALS USED

3.1.3 MACHINES AND TOOLS USED

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 9

3.3 SPROCKET WITH CHAIN

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 10

A crank is a mechanical part able to perform a conversion

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 11

Motor is used to reduce the effort of a worker which helps by giving

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 12

3.6 CONNECTING RODS

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 13

3.7 BEARING BLOCKS

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 14

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 15

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 16

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 17

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 18

PEDAL AND CRANK ARRANGEMENT

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 19

APPROACH AND METHODOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 20

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 21

 The pedal and power operated hacksaw is a device which is

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 22

 The pedal operated system consists of the pedal arrangement

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 23

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 24

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 25

5.1 ESTIMATION SHEET

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 26

5.2 COST SHEET

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 27

5.3 ADVANTAGES AND DISADVANTAGES

 More number of loads cannot be taken

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 28

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 29

This project work has provided us an excellent opportunity and

The chief advantage of our system is that, it cutting speed is varied

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 30

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 31

1. Theory of Machines By R.S. Khurmi and J.K Gupta,1multicolour

5. Machine tool design handbook.

DEPARTMENT OF MECHANICAL ENGINEERING, R RPOLYTECHNIC Page 32