project report (mechanical engineer)

1. 1
CHAPTER 1
INTRODUCTION
1.1. General
A hacksaw is a handheld tool used to cut materials like metal pipes and rods. Its cutting
mechanism is provided by removable blades which feature sharp teeth along their outer edge.
In most cases, a hacksaw consists of a metal frame that resembles a downward facing. A
handle of plastic, wood, or metal is typically affixed to one end of the frame. The frame’s ends
feature adjustable pegs that can be tightened to secure a blade in place, and loosened to remove
it. Hacksaw blades are long, thin strips of hardened steel that feature a row of teeth along their
cutting edge. Each end of the blade is punched with a small hole that fits on the saw frame’s
pegs. Most blades range in length from ten to 12inches (25.4 to 30.48 cm), although Twelve-
inch (30.48cm) blades can be purchased to fit hacksaw machine. A device that applies force,
changes the direction of a force, or changes the strength of a force, in order to perform a task,
generally involving work done on a load. Machines are often designed to yield a high
mechanical advantage to reduce the effort needed to do that work. A simple machines a wheel,
a lever or an inclined plane. All other machines can be built using combinations of these simple
machines.

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1.2. Working Principle
This machine is based on Scotch Yoke Mechanism. Scotch yoke is a mechanism for 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. The shape of the motion of the piston is a pure sine wave over time given a
constant rotational speed.
The Scotch Yoke mechanism is best for this machine because it provides less vibration as
compared to slider crank mechanism (which convert reciprocating motion into sliding motion
or vice versa).
Fig.1.1
1.3. Scope of the project
1. The machine can solve the problem of time consumption.
2. Waste of resources in face of labor cost is reduced.
3. The machine can be used in the industry where it is manufactured, at the packaging
sector.
4. It is used as hardware in large quantity like in fabrication of machine.
5. It provides alternative for industries aiming toward reducing human effort.
6. It generates sustainable and practical automation solutions for the future industrial
development.

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1.4. Objectives of the project
1. To cater to the issue of competition in mechanical industry the need for automation is
assess by all the industry.
2. To identify the key policy avenues considered to be appropriate to meet the challenge
of sustainable manufacturing and packaging industry for the future.
3. To provide alternative for industries aiming toward reducing human effort and
improvement in material handling system by implementing automation.
4. Sustainable and practical automation solutions for the future industrial environment.
1.5. Justification & Relevance
We have found an automatic four-way hacksaw cutting machine to be the most useful for
general shop work. Modern heavy-duty hacksaw machines provide an economical and
efficient means of sawing a wide range of materials and stock sizes. An Automatic four-way
hacksaw cutting machine are getting rarer all the time but they do a good job within their
capacity. If you can get one that takes standard hacksaw blades, then you'll have a tremendous
range of blades to choose from and will be able to cut most anything. Hacksaws are more
tolerant to tensioning maladjustment and run off. A major advantage of an automatic four-way
hacksaw cutting machine is the relatively low capital investment required. Tooling and
maintenance costs are low. Accuracy and finishes produced, range from fair to good
depending on the material being sawed. Time saving as compared to simple hacksaw.
Comfortable then ordinary hacksaw.

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1.6. Approach and Methodology
CONSTRUCTION OF BASE TABLE
MOUNTING OF BASE
FOR HOLDING SHAFT
CONNECTED TO THE
FLYWHEEL, PULLEY,
CRANK &
CONNECTING ROD
MOUNTING
MOUNTING OF CLAMP &
INSERTING SHAFT INTO
THE CLAMP
MOUNTING OF
BENCH VICE TO THE
BASE TABLE
INSERTING THE PULLEY IN THE SHAFT AT
THE MIDDLE
FIXING THE SLOTTED BAR ON THE DISC
WITH THE HELP OF PIN
JOINING THE CONNECTING ROD WITH THE
SLOTTED BAR
MOUNTING THE DISC AT THE SHAFT ON
TOP SIDE

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FIXING OF HACKSAW TO THE HORIZONTAL
CONNECTING ROD
FINAL ASSAMBLING
SUPPLY OF ELECTRIC POWER
WORKING
RESULT & DISCUSSION

6. 6
CHAPTER 2
LITERATURE REVIEW
2.1. General
After the study of many literatures about design, construction and working of automatic power
hacksaw machine, some of them describe the methodology of automatic power hacksaw. Lots
of factor have been considering for the design, construction and working of automatic power
hacksaw machine such as cutting speed, cutting material, cutting time, power, efficiency etc.
So, lots of literatures have been found which gives the relevance information and methodology
of constructing an automatic power hacksaw machine.
2.2. Historical Background
The problem of cutting-off material to size is common to practically every industry. Often,
sawing is the first operation carried out on bar stock. Therefore, it is surprising that so little
work has been done to understand the problems of this common operation. Many reasons have
been given for this such as lack of interest, it is a routine operation and that there is no need to
consider better methods. Often the foreman will assign a new trainee to a sawing task, on the
principle that it is easy to learn and difficult to foul up. Furthermore, cut-off machines are
frequently housed in stores away from the main production areas and the operation of the
sewing machines appears to be simple. The fact remains that cutting-off operations can account
for a significant part of the cost per piece (Remmerswaa and Matheson, 1961).
The reason for carrying out the present work is the growing realization on the part of
manufacturers of both blades and machines, that the factors which control the mechanics and
economics of power hacksawing are complex. Also, power hacksawing has been receiving
increased competition from other cutting off processes, such as band and circular sawing.
Whilst the British Standard BS 1919: 1974 gives specifications for hacksaw blades regarding
dimensions etc. the standard relates to testing of hacksaw blades for hand use only and does
not include power hacksaw blade testing. Thus, both manufacturers of hacksaw blades and
users have experienced considerable difficulty in establishing standard testing procedures and
in obtaining consistency in test data using power hacksaw machines. Preliminary investigations
by the author have revealed that existing blade testing methods were not independent of the
machine characteristics, which could contribute to one of the reasons for the inconsistency in
the test data. Hence, there has been requirement to identify the machine characteristics under
normal working conditions and to investigate the mechanics of the sawing process and the

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variables affecting metal removal rate. Most of the early published work on cutting-off has
been primarily concerned with circular and band sawing and cost comparisons between
alternative processes. Whilst these alternative processes are frequently, quicker than power
hacksawing, their costs are in many applications higher. Whilst the impact of these alternative
processes on the application of power hacksawing cannot be denied there remains a significant
field of application for power hacksawing which is likely to remain unchallenged. A factor of
prime interest to manufacturers is that, if the costs of power hacksawing can be reduced by
developing the blade and the saw machine, the potential field of application will be widened.
During the past fifty years, very little attention has been devoted to developing the geometry
of the hacksaw blade or the machine, although, some improvements in the blade material,
together with methods of applying the load and mechanized work handling, have been achieved
(Nelson,1965).
2.3. Sawing
If all raw stock was delivered in ready-to-machine shapes and sizes, there would be no need
for sawing machines in a metal working shop. Machine operators could merely go over to the
stock, select the suitable work piece, and perform the necessary finishing operations. Such
situation rarely exists, due to the fact that the majority of the stock requires to be cut in some
way prior to starting a machining schedule. The alternative to this primary operation of sawing
is to buy-in prepared lengths and shapes; this however introduces a service which the company
has to pay for and, in the majority of the cases, it is simpler and more economical to carry out
the basic cutting to-size operation in house. One of the major advantages of sawing over all
other kinds of machining is the narrowness of cut op. Most sawing machines perform the cut-
off operation, where a piece of stock is cut to a workable length prior to subsequent machining
operations. Machines that accomplish this job include hacksaws, band saws and circular saws.
2.4. Power Hacksawing
The simple back-and-forth motion of the blade made the hacksaw one of the first types of
sawing machines designed for power. The simplicity in the blade motion has kept the price of
the saw machine relatively cheaper than other types of sawing machines. The low initial cost
coupled with the flexibility and adaptability, has enabled the hacksaw to remain popular in
industry. In hacksawing, a single blade is tensioned in the bow, and reciprocated back and forth
over the work piece. The cutting action is achieved only during half of the cycle of operation.

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During the second half of the cycle, the return stroke, the blade is lifted clear of the work piece,
giving a discontinuous cutting action, which is considered to be one of the drawbacks of the
operation. Despite this disadvantage, as compared to the continuous-cutting action of the band
saw, hacksaws remain equally or even more popular alternative machines. As with many other
basic processes, hacksawing is a tried and tested method, reliable, consistently accurate, quick
and easy to repair, is less dependent on correct blade tension and less likely to run-out.
Furthermore, power hacksaws can be left unattended for long periods when cutting large
diameter bar and require minimum operator skill. Blade replacement is relatively cheap and
simple. (Thompson and Sarwar, 1974).
2.5. Types of Hacksawing Machines
For a given blade and work piece the material removal rates achieved by hydraulic and gravity
fed machines are controlled solely by the thrust loads developed. Therefore, hacksawing may
be said to be a process in which the material removal rate is force controlled, unlike most other
material removal processes. The machines available can be divided into two broad categories,
according to the method used to develop the load between the blade and the work piece, namely
gravity feed machines and hydraulic machines. A third, but not common machine is the positive
displacement machine. Power hacksaw machines are used mainly for cutting-off operations.
2.5.1. Gravity Feed Machines
In this type of machine, which is usually of light construction for general duty, the thrust load
is developed by the gravity feed of the saw bow. In many of these machines the magnitude of
the thrust load is fixed, although some machines are provided with adjustable masses on the
overarm for thrust load adjustment. The thrust, load varies throughout the cutting stroke due to
the reciprocating displacement of the over arm mass and the action of the cam operated lift-off
device which acts at the beginning and the end of the stroke. This type of machine generally
has a work piece capacity between 150 - 200 mm (6 and 8 inches) diameter and is ideal for the
small workshop where the cutting requirement is only occasional and the configuration of work
pieces to be cut ranges from mild steel flat complex shaped sections and tubular sections up to
6 inches’ diameter. Due to the light construction and gravity feed the applications for this type
of machine are limited.

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2.5.2. Hydraulic Machines
The thrust force between the blade and the work piece in this type of machine is developed by
a hydraulic device. Pressure may be developed in the load cylinder by either a restricted back-
flow system, or the pressure may be supplied from a separate pump. In some of these machines,
greater flexibility of control has been introduced by means of an arc cutting action combined
with a universally controlled hydraulic system which allows better performance from the saw
blade. The advanced types of heavy duty electro-hydraulic hacksaws have a very wide range
of operation and are available in semi-automatic or fully automatic form, with provisions for
automatic feeding of bar stock, cutting-off to predetermined sizes and unloading etc. The
feature of power down-feed to the saw bow incorporated in these machines makes the machine
suitable for cutting the tougher steels and alloys. These machines are the most common and
develop greater thrust loads than machines of other type and have a reputation for sawing
without problems and requiring minimum operator skill.
2.5.3. Positive Displacement Machines
Whilst these machines are not as popular as the gravity feed or hydraulic machines, a few
machines are available where the feed rate of the blade and hence, the metal removal rate is
directly controlled by a mechanical screw device, giving a positive feed. This type of machine
can lead to overloading of the blade giving premature blade failure particularly when the blade
is worn. Positive displacement machines are not prone to variation in thrust loads during the
cutting stroke-since the thrust loads directly arise as a result of the constant rate of penetration
of the blade teeth.
2.6. Band Sawing
Band sawing, unlike hacksawing, is a continuous cutting operation. An endless blade, the band,
is tensioned between two shrouded, rotating wheels, and part of the band is exposed to carry
out the cutting operation of the work piece. The band travels in a continuous motion, with the
teeth fed against the work piece. Whilst earlier metal sawing bands were wide (over 25 mm),
and were used strictly for cut off methods, narrow blades, introduced about 50 years ago
brought contouring capabilities. Furthermore, due to the small throat clearance of the early
band saws, they were limited in use by the basic design, thus the length of the work piece could
only be as long as the machine throat. However modern machines have been modified to give
adequate throat clearance, by intentionally twisting the blade so that the toothed faces in line

10. 10
with the machine throat. As with hacksaw machines, band saws can be divided into two broad
categories. A general-purpose band saw having gravity fed system, controlled by a dash-pot
and using a 25 mm (1 inch) deep blade, is the most popular machine available. This machine
is suitable for general fabrication work and accurate cutting of solid bars. This type of machine
is limited to about 175 mm (7 inches) diameter for mild steel. In order to meet the present-day
requirements for high-volume production, cutting all grades of steel and to introduce high
accuracy and reliability, it has been necessary for the band saw machine manufacturers to
incorporate in the design not only heavy duty construction having capacities up to 450 mm (18
inches) diameters but also innovations in the hydraulic power down-feed, to allow the cutting
of difficult alloys., such as mnemonics and titanium.
2.7. Circular Sawing
Circular saws have a continuous cutting action, use blades having many teeth, and a large range
of rotational speeds. This operation is similar to a milling operation. The machines available
range from the earlier, inexpensive, hand-loaded models to the very large, power loaded type
and incorporate material handling devices for semi and then fully automatic operations.
Modern production circular saws are built with several alternate basic feed mechanisms i.e.
horizontal, vertical, rocking head and variations of these. The choice of the most suitable type
of machine depends on the particular application and the size and shape of component. With
vertical feed, the rotating blade travels downwards in a straight line to engage the work piece.
On machines designed for horizontal feed the blade is fed into the work piece from the back.
A third basic feeding arrangement is a pivot motion or rocking-head system, this is as efficient
as a vertical feed system and is a rugged arrangement. The bench or floor mounted manual-
feed circular saw, when installed together with a general duty band saw or hacksawing a small
workshop, provides a complete cutting facility for the small fabricator. Fully automatic circular
saws, having features such as dial-in component length, in process gauging, choice of loading
magazines, etc. are widely used where high quality production is required and often present
the production engineer with a difficult choice to make between circular sawing and band
sawing.

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2.8. Features of Modern Hacksaw
The simplicity of design and operation, coupled with the low initial cost, has made the hacksaw
grow in popularity. Its limitations are due to its mode of operation, i.e. cutting only on half of
the stroke, the slow cutting speed, and the fact that not all the length of the blade is utilized.
Some of the features in a modern hacksaw which achieve improved performance are:
1. A range of cutting speeds, uniform over the cutting stroke, and a fast return stroke.
2. Means to regulate and monitor the cutting pressure.
3. Adjustable stroke.
4. Automatic relief of the blade on the return stroke.
5. Some means of indicating and correcting blade tension.
6. Automatic stopping device when the cut is complete.

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CHAPTER 3
PROJECT MATHODOLOGY
3.1. General
Automatic four-way hacksaw cutting machine are used to cut large sections of metal shafts and
rods. Therefore, an automatic four-way hacksaw cutting machine is used to carry out the
difficult and time consuming work. This Automatic four-way hacksaw machine shown in
figure 3.1 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. The Automatic four-way 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.
Fig.3.1

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3.2. Design of Automatic Power Hacksaw Machine
3.2.1. Introduction
The design of an automatic four-way hacksaw cutting machine involves the initial stages of
concept design and their purposes. Different concepts of an automatic four-way hacksaw
cutting machine, use of study and research were decided and finally a specific one was chosen
after evaluating them on the basis of complexity, ease of fabrication and simplicity. Then, a
detailed design of the same was presented which includes individual features, specifications
and CAD model presentation.
3.2.2. Part Design
3.2.2.1. Base Frame
It is a balance structure made of mild steel of size 650mm x 650mm x 350mm. We take 650
mm in base length because; we want to give stability our model of automatic four-way hacksaw
cutting machine not get lot of vibration when the machine in running condition. A rectangular
hollow pipe is used for making the frame because it provides good strength as compared to
solid rectangular bar. The cross-section of the hollow pipe is 25 x 55mm with pipe thickness
of 3mm.
Fig.3.2

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Fig.3.3
3.2.2.2. Disc
A circular disc is used for converting rotary motion into reciprocating motion. This disc is made
of mild steel of diameter 300mm with of thickness 10mm. A groove of size (16mm x 100mm)
is provided on the disc for supporting the slotted bar with the help of pin. A hole of diameter
20mm is drilled in the center of disc. A cast iron block of diameter 20mm is fitted eccentrically
to the disc center for holding the shaft. This cast iron block is fitted on this disc with help of
four bolts.
It is act as a flywheel which stores energy during the period when the supply of energy is more
than the requirement and releases it during the period when the requirement of energy is more
than supply. Flywheels have a significant moment of inertia and thus resist changes in
rotational speed. The amount of energy stored in a flywheel is proportional to the square of its
rotational speed. Energy is transferred to a flywheel by applying torque to it, thereby increasing
its rotational speed, and hence its stored energy. Conversely, a flywheel releases stored energy
by applying torque to a mechanical load, thereby decreasing the flywheel's rotational speed.

15. 15
Fig.3.4
Fig.3.5
3.2.2.3. Slotted bar
It is the most important part of the machine. Slotted bar converts rotary motion of disc into
reciprocating motion. It is made of mild steel of size 300mm x 55mm with of thickness 5mm.

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A rectangular groove of size (15mm x 250mm) is provided in center of the bar. This groove
cut is generally used for supporting a pin.
Fig.3.6
3.2.2.4. Connecting rod
It is circular drawn rod, made of mild steel of 14mm diameter and of length 44mm. This is used
for transferring reciprocating motion of the slotted bar to hacksaw.
Fig.3.7
3.2.2.5. Connecting pin
It is a circular pin, made of mild steel. It is used for connecting the slotted bar and disc. With
the help of pin, motion is transmitted from disc to slotted bar. It consists of two parts. Lower
part of the pin is hold on the disc with the help of nut and attached with the lower slotted bar.
Upper part of the pin is attached with the upper slotted bar.

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Fig.3.8
Fig.3.9
3.2.2.6. Shaft
A shaft is a rotating machine element which is used to transmit power from one place to
another. The power is delivered to the shaft by some tangential force and the resultant torque
(or twisting moment) set up within the shaft permits the power to be transferred to various
machines linked up to the shaft. In order to transfer the power from one shaft to another, the

18. 18
various members such as pulleys, gears etc., are mounted on it. These members along with the
forces exerted upon them causes the shaft to bending. In other words, we may say that a shaft
is used for the transmission of torque and bending moment. The various members are mounted
on the shaft by means of keys or splines.
A shaft of diameter 20mm with of length 42mm is used in this cutting machine.
Fig.3.10
The material used for shafts should have the following properties:
1. It should have high strength.
2. It should have good machinability.
3. It should have low notch sensitivity factor.
4. It should have good heat treatment properties.
5. It should have high wear resistant properties.
3.2.2.6.1. Manufacturing of Shafts
Shafts are generally manufactured by hot rolling and finished to size by cold drawing or turning
and grinding. The cold rolled shafts are stronger than hot rolled shafts but with higher residual
stresses.
The residual stresses may cause distortion of the shaft when it is machined, especially when
slots or Keyways are cut. Shafts of larger diameter are usually forged and turned to size in a
lathe.

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3.2.2.6.2. Design of Shafts
The shafts may be designed on the basis of:
1. Strength
2. Rigidity
3. Stiffness
In designing shafts on the basis of strength, the following cases may be considered:
1. Shafts subjected to twisting moment or torque only.
2. Shafts subjected to bending moment only.
3. Shafts subjected to combined twisting and bending moments.
4. Shafts subjected to axial loads in addition to combined torsional and bending loads.
3.2.2.7. Plumber block (Ball bearing)
A Plumber block is a type of rolling-element bearing that uses balls to maintain the separation
between the bearing races. The purpose of a ball bearing is to reduce rotational friction and
support radial and axial loads. It achieves this by using at least two races to contain the balls
and transmit the loads through the balls. In most applications, one race is stationary and the
other is attached to the rotating assembly (e.g., a hub or shaft). As one of the bearing races
rotates it causes the balls to rotate as well. Because the balls are rolling they have a much lower
coefficient of friction than if two flat surfaces were sliding against each other. Ball bearings
tend to have lower load capacity for their size than other kinds of rolling-element bearings due
to the smaller contact area between the balls and races. However, they can tolerate some
misalignment of the inner and outer races.
In rolling contact bearings, the contact between the bearing surfaces is rolling instead of sliding
as in sliding contact bearings. ordinary sliding contact bearing starts from rest with practically
metal-to-metal contact and has a high coefficient of friction. It is an outstanding advantage of
a rolling contact bearing over a sliding contact bearing that it has a low starting friction. Due
to this low friction offered by rolling contact bearings, these are called antifriction bearings.
A Plumber block of diameter 20mm is used for holding the shaft in this cutting machine.
3.2.2.7.1. Advantages of rolling contact bearings:
1. Low starting and running friction except at very high speeds.
2. Ability to withstand momentary shock loads.

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3. Accuracy of shaft alignment.
4. Low cost of maintenance, as no lubrication is required while in service.
5. Small overall dimensions.
6. Reliability of service.
7. Easy to mount and erect.
8. Cleanliness.
Fig.3.11
3.2.2.7.2. Disadvantages of rolling contact bearing:
1. Noisier at very high speeds.
2. Low resistance to shock loading.
3. More initial cost.
4. Design of bearing housing complicated.
3.2.2.8. Pulley
A pulley is a wheel on an axle or shaft that is designed to support movement and change of
direction of a cable or belt along its circumference. Pulleys are used in a variety of way a pulley
may also be called a sheave or drum and may have a groove between two flanges around its
circumference. The drive element of a pulley system can be a rope, cable, belt, or chain that
runs over the pulley inside the grooves to lift loads, apply forces, and to transmit power. We
have used two pulleys of size 3-inch and 10-inch.

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Note- 3-inch pulley
Fig.3.12 Fig.3.13
The application of pulleys can be for many different functions; lifting loads, applying forces
or transmitting power. For simple, single fixed pulleys, the load is attached to one end of the
rope while the wheel is secured at a higher position with the rope running through it and the
force being applied to one end of the rope to lift the load on the other end. This is one of the
simplest models of a pulley system demonstrating how it works. There are several different,
more complex models of pulley systems that work in different ways to serve different
functions. The wheel can be secured at the top in some pulley systems and can be movable in
some. It is easier to lift a load when the wheel is secured at the top and the rope is pulled
downwards to lift the load rather than having to pull the rope upwards to lift a load in some
movable pulley systems. The output force or work done by a pulley system can be calculated
by multiplying the effort required to pull the rope to lift a load with the distance the that the
rope moves. Some pulley systems can make use of more than one or more pulleys which are
linked. The advantage of using such systems is that they reduce the amount of effort required
to get work done.

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Note- 10-inch Pulley
Fig.3.14
There are three types of pulleys: -
The simplest type of pulleys is the fixed pulley systems. These pulleys are the only pulley
systems though which, if used individually, require an equal amount of effort to the load to
lift it off the ground. In this system, the wheel is secured at a fixed place and does not move.
What this system does is that it changes the direction of the force in order to complete a task.
The advantage with this is that one does not have to push or pull a load to be able to move the
load as it allows for easy displacement of the load. The disadvantage being that more effort is
required to move the load as compared to other pulley systems.
Unlike a fixed pulley system, in the movable pulley systems, the wheel used in the pulley
moves along with the load that is being displaced. This function of the pulleys allows it to use
lesser effort to be able to move the load. Unlike fixed pulley systems that exert only as much
force on the load as that of which is applied on the rope, movable pulley systems are able to
multiply the force that a user applies to the machine to carry out a task, in turn making the job
seem easier. This way, lesser force is required by the user to carry out the same task if using a

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fixed pulley system. This pulley also acts as a second-class lever, whereby the load is placed
in between the fulcrum and the effort. The disadvantage with these systems is that one has to
pull or push to displace a load and the main advantage is that it requires lesser effort to be able
to move the load. The third type of pulley systems present today is the compound pulley
systems. These are a combination of fixed and movable pulleys. These systems have the
advantages of both the fixed and movable pulley systems as one would not require pushing and
pulling a load to be able to transfer it.
3.2.2.9. Hacksaw
A hacksaw is a fine-tooth saw with a blade under tension in a frame, used for cutting materials
such as metal. Hand-held hacksaws consist of a metal frame with a handle, and pins for
attaching a narrow disposable blade. A screw or other mechanism is used to put the thin blade
under tension.
A power hacksaw (or electric hacksaw) is a type of hacksaw that is powered by electric motor.
Most power hacksaws are stationary machines but some portable models do exist. Stationary
models usually have a mechanism to lift up the saw blade on the return stroke and some have
a coolant pump to prevent the saw blade from overheating.
Fig.3.15

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Hacksaw blades (both hand & power hacksaw) are generally made up of carbon steel or high
speed steel strip rolls. The blank of required size is obtained by fixing the strip rolls on the
stand of semi-automatic strip cutting machine and punched a hole at their both ends. Then,
teeth are being made on the blank by milling or hobbling process. Once teeth are being cut, the
hacksaw blades are heat treated and tempered for the required hardness. The last step in the
manufacturing process is surface cleaning, painting, printing and packing of the hacksaw
blades for market supply.
Features of Hacksaw Machine
1. Power efficiency.
2. High productivity.
3. Superb performance.
4. High operational fluency.
5. Sturdy and robust design.
3.2.2.10. Hacksaw blade
The hacksaw blade consists of different parts:
1. 2 pin holes
2. Center line
3. Side
4. Back edge
Fig.3.16

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3.2.2.10.1. Characteristics of Hacksaw Blade
The hacksaw blade has 2 main characteristics:
1. Teeth pitch which is the number of teeth per 25 mm.
2. Blade length which is the length between the centers of its pin holes.
Fig.3.17
Fig.3.18

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3.2.2.11. V Belt
The belts or ropes are used to transmit power from one shaft to another by means of pulleys
which rotate at the same speed or at different speeds.
Fig.3.19
The amount of power transmitted depends upon the following factors:
1. The velocity of the belt.
2. The tension under which the belt is placed on the pulleys.
3. The arc of contact between the belt and the smaller pulley.
4. The conditions under which the belt is used.
It may be noted that:
1. The shafts should be properly in line to insure uniform tension across the belt section.
2. The pulleys should not be too close together, in order that the arc of contact on the smaller
pulley may be as large as possible.
3. The pulleys should not be so far apart as to cause the belt to weigh heavily on the shafts,
thus increasing the friction load on the bearings.
4. A long belt tends to swing from side to side, causing the belt to run out of the pulleys,
which in turn develops crooked spots in the belt.

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5. The tight side of the belt should be at the bottom, so that whatever sag is present on the
loose side will increase the arc of contact at the pulleys.
6. In order to obtain good results with flat belts, the maximum distance between the shafts
should not exceed 10 meters and the minimum should not be less than 3.5 times the
diameter of the larger pulley.
V belts are 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.
For high-power requirements, two or more V-belts can be joined side-by-side in an
arrangement called a multi-V, running on matching multi-groove sheaves. This is known as a
Multiple-V-belt drive.
V-belts may be homogeneously rubber or polymer throughout or there may be fibers embedded
in the rubber or polymer for strength and reinforcement. The fibers may be of textile materials
such as cotton, polyamide (such as Nylon) or polyester or, for greatest strength, of steel or
aramid.
3.2.2.12. Bush
Bush is the mechanical element that provides smooth motion between two parts. It also guides
the sliding or reciprocating parts. It may be made of many materials such as copper, brass, cast
iron etc. but in this machine a mild steel bush is used. The connecting rod passes through the
bushes and hold the hacksaw.

28. 28
Fig.3.20
3.2.2.13. Motor
An AC motor is an electric motor driven by an alternating current (AC). The AC motor
commonly consists of two basic parts, an outside stationary stator having coils supplied with
alternating current to produce a rotating magnetic field, and an inside rotor attached to the
output shaft producing a second rotating magnetic field. The rotor magnetic field may be
produced by permanent magnets, reluctance saliency, or DC or AC electrical windings. The
reciprocating motion of the Hacksaw blade, because of which the cutting process takes place,
is produced with the help of an AC motor, which operates by a simple crank mechanism to
convert rotary motion of crank into reciprocating motion Hacksaw blade. The AC motor is
turned on after the work-piece has been firmly fit in the pneumatic chuck. The Torque of motor
is increased by transmission of power to a pulley by belt transmission.
Fig.3.21

29. 29
The torque of the AC motor must be increased so as to bring about the necessary power for
cutting of work-pieces efficiently. This is achieved by coupling the rotor of the AC motor to a
pulley by a belt drive. So, this will reduce the rotating speed while increasing the torque. The
pulley is coupled to the reciprocating mechanism.
Note- Motor specification (single phase 1HP, 1440rpm AC motor).
3.2.2.14. Bench Vice
Vice is a mechanical apparatus used to secure an object to allow work to be performed on it.
Vices have two parallel jaws, one fixed and the other movable, threaded in and out by a screw
and lever. Vices are of various types, we have used an engineer’s vice, also known as a
metalworking vice or fitter vice, is used to clamp metal. It is typically made of cast steel or
malleable cast iron. Cheaper vises may be made of brittle cast iron. The jaws are often separate
and replaceable, usually engraved with serrated or diamond teeth. Soft jaw covers made of
aluminum, lead, or plastic may be used to protect delicate work.
Fig.3.22
An engineer's vice is bolted onto the top surface of a workbench, with the face of the fixed jaws
just forward of its front edge. The vice may include other features such as a small anvil on the
back of its body.

30. 30
3.2.2.15. Bolt and Nuts
A screw thread is formed by cutting a continuous helical groove on a cylindrical surface. A
screw made by cutting a single helical groove on the cylinder is known as single threaded (or
single-start) screw and if a second thread is cut in the space between the grooves of the first, a
double threaded (or double-start) screw is formed. Similarly, triple and quadruple (i.e. multiple
start) threads may be formed. The helical grooves may be cut either right hand or left-hand.
A screwed joint is mainly composed of two elements i.e. a bolt and nut. The screwed joints are
widely used where the machine parts are required to be readily connected or disconnected
without damage to the machine or the fastening. This may be for the purpose of holding or
adjustment in assembly or service inspection, repair, or replacement or it may be for the
manufacturing or assembly reasons. The parts may be rigidly connected or provisions may be
made for predetermining.
3.2.2.15.1. Advantages and Disadvantages of Screwed Joints:
1. Screwed joints are highly reliable in operation.
2. Screwed joints are convenient to assemble and disassemble.
3. A wide range of screwed joints may be adapted to various operating conditions.
4. Screws are relatively cheap to produce due to standardization and highly efficient
manufacturing processes.
3.2.2.15.2. Disadvantage of Screwed Joints:
1. The main disadvantage of the screwed joints is the stress concentration in the threaded
portions which are vulnerable points under variable load conditions.

31. 31
3.2.2.15.3. Important Terms Used in Screw Threads
The following terms used in screw threads are important from the subject point of view:
Fig.3.23
1. Major diameter- It is the largest diameter of an external or internal screw thread. The
screw is specified by this diameter. It is also known as outside or nominal diameter.
2. Minor diameter- It is the smallest diameter of an external or internal screw thread. It is
also known as core or root diameter.
3. Pitch diameter- It is the diameter of an imaginary cylinder, on a cylindrical screw thread,
the surface of which would pass through the thread at such points as to make equal the
width of the thread and the width of the spaces between the threads. It is also called an
effective diameter.
4. In a nut and bolt assembly, it is the diameter at which the ridges on the bolt are in complete
touch with the ridges of the corresponding nut.
5. Pitch- It is the distance from a point on one thread to the corresponding point on the next.
This is measured in an axial direction between corresponding points in the same axial
plane.
6. Mathematically,

32. 32
7. Lead- It is the distance between two corresponding points on the same helix. It may also
be defined as the distance which a screw thread advances axially in one rotation of the
nut. Lead is equal to the pitch in case of single start threads; it is twice the pitch in double
start, thrice the pitch in triple start and so on.
8. Crest- It is the top surface of the thread.
9. Root- It is the bottom surface created by the two adjacent flanks of the thread.
10. Depth of thread- It is the perpendicular distance between the crest and root.
11. Flank- It is the surface joining the crest and root.
12. Angle of thread- It is the angle included by the flanks of the thread.
13. Slope- It is half the pitch of the thread.

33. 33
3.3. Cost & Estimation
Table 3.3.1. Cost & Estimation
Sr.
No.
Name Specification Material Quantity Cost
(Rupees)
1. AC Motor Single phase, 1HP,
1440rpm
Cast iron,
Copper
1 3500
2. Base Frame 650mm x 350mm x
650mm
Mild Steel 1 2000
3. Disc Dia. 300mm Mild Steel 1 1000
4. Shaft Dia. 20mm, Length
440mm
Mild Steel 1 500
5. Plumber Block Dia. 20mm Stainless Steel 2 750
6. Pulley 1 Dia. 10 inch Cast Iron 1 350
7. Pulley 2 Dia. 3 inch Cast Iron 1 150
8. Connecting
Rod
Dia. 14mm, Length
45mm
Mild Steel 8 450
9. Bush Dia. 14mm Mild Steel 8 400
10. V Belt Length 55 inch Neoprene
Polyester
1 150
11. Hacksaw
Frame
For 12 inch (Blade) Mild Steel 4 200
12. Hacksaw
Blade
12 inch High Speed
Steel
4 100
13. Connecting
Pin
Dia. 16mm Mild Steel 2 200

34. 34
14. Nut Dia. 9.6mm Mild Steel 20 100
15. Bolt 1 Length-3inch,
Dia.9.5mm
Mild Steel 12 120
16. Bolt 2 Length-5inch,
Dia.9.5mm
Mild Steel 8 120
17.
18.
19.
Washer
Groove Screw
Bench Vice
Dia. 10mm
Length-1inch
Mild Steel
Stainless Steel
Stainless Steel
20
8
4
100
160
1000
20. Transportation
Charge
500
TOTAL 107 11,850

35. 35
CHAPTER 4
PROJECT MANAGEMENT
Project management is the process and activity planning, organizing, motivating and
controlling resources, procedures and protocols to achieve specific goals in specific or daily
problems. A project is a temporary endeavor designed to produce a unique product, service or
result with a defined beginning and end (usually time constrained, and often constrained by
funding or deliverables) undertaken to meet unique goals and objectives, typically to bring
about beneficial change or added value. The temporary nature of projects stands in contrast
with business as usual (or operation), which are repetitive, permanent, the management of these
two systems is often quite different, and as such requires the development of distinct technical
skills and management strategies.
The primary challenge of project management is to achieve all of the projects goals and
objective while honoring the preconceived constraints. The primary constraints are scope, time,
quality and budget. The secondary and more ambitious challenge is to optimize the allocation
of necessary inputs and integrate them to meet pre-defined objective.
Fig.4.1
Initiating Planning Executing
Monitoring
and Controlling
Closing

36. 36
CHAPTER 5
PARTS DESIGN
5.1. Base Frame
5.2. Slotted Bar

37. 37
5.3. Frame Supporting Bar

38. 38
5.4. Disc
5.5. Connecting Pin

39. 39
5.6. Shaft

40. 40
CHAPTER 6
DESIGN ANALYSIS
6.1. Simulation of Base Frame
Date:01 February 2017
Designer: Vineet Kumar Singh
Study name: Study 1
Analysis type: Static

41. 41
6.1.1. Model Information
Model name: body2
Current Configuration: Default
Solid Bodies
<L_MdInf_SldBd_
Nm/>
Treated As Volumetric Properties
Document
Path/Date
Modified
Fillet3
Solid Body
Mass:100.781 kg
Volume:0.0130884 m^3
Density:7700 kg/m^3
Weight:987.654 N
E:final year
projectsattubody2.
SLDPRT
Feb 01 22:34:46
2017
<L_MdInf_ShlBd_N
m/>
<L_MdIn_ShlBd_
Fr/>
<L_MdInf_ShlBd_VolPr
op/>
<L_MdIn_ShlBd_D
tMd/>
<L_MdInf_CpBd_Nm
/>
<L_MdInf_CompBd_Props/>
<L_MdInf_BmBd_N
m/>
<L_MdIn_BmBd_
Fr/>
<L_MdInf_BmBd_VolPr
op/>
<L_MdIn_BmBd_D
tMd/>

42. 42
6.1.2. Study Properties
Study name Study 1
Analysis type Static
Mesh type Solid Mesh
Thermal Effect: On
Thermal option Include temperature loads
Zero strain temperature 298 Kelvin
Include fluid pressure effects from
SolidWorks Flow Simulation
Off
Solver type FFEPlus
In plane Effect: Off
Soft Spring: Off
Inertial Relief: Off
Incompatible bonding options Automatic
Large displacement Off
Compute free body forces On
Friction Off
Use Adaptive Method: Off
Result folder SolidWorks document (E:final year
projectAutomatic Four-way Hacksaw
Cutting Machine)

43. 43
6.1.3. Units
Unit system: SI (MKS)
Length/Displacement mm
Temperature Kelvin
Angular velocity Rad/sec
Pressure/Stress N/mm^2 (MPa)
6.1.4. Material Properties
Model Reference Properties Components
Name: Alloy Steel
Model type: Linear Elastic
Isotropic
Default failure
criterion:
Max von Mises
Stress
Yield strength: 6.20422e+008
N/m^2
Tensile strength: 7.23826e+008
N/m^2
Elastic modulus: 2.1e+011 N/m^2
Poisson's ratio: 0.28
Mass density: 7700 kg/m^3
Shear modulus: 7.9e+010 N/m^2
Thermal expansion
coefficient:
1.3e-005 /Kelvin
Solid Body
1(Fillet3)
(body2)

44. 44
6.1.4. Loads and Fixtures
Fixture name Fixture Image Fixture Details
Fixed-1
Entities: 1 face(s)
Type: Fixed Geometry
Resultant Forces
Components X Y Z Resultant
Reaction force(N) -0.046814 -1087.81 0.0449295 1087.81
Reaction
Moment(N-m)
0 0 0 0
Load name Load Image Load Details
Gravity-1
Reference: Top Plane
Values: 0 0 9.81
Units: SI
Force-1
Entities: 1 face(s)
Type: Apply normal
force
Value: 100 N
Temperature-
1
Entities: 1 face(s)
Temperature: 25 Celsius

45. 45
Load name Load Image Load Details
Temperature-
2
Entities: 2 face(s)
Temperature: 15 Celsius
6.1.5. Mesh Information
Mesh type Solid Mesh
Masher Used: Standard mesh
Automatic Transition: Off
Include Mesh Auto Loops: Off
Jacobian points 4 Points
Element Size 25.4151 mm
Tolerance 1.27075 mm
Mesh Quality High
6.1.6. Mesh Information – Details
Total Nodes 32173
Total Elements 16317
Maximum Aspect Ratio 22.663
% of elements with Aspect Ratio < 3 53.9

46. 46
% of elements with Aspect Ratio > 10 0.306
% of distorted elements(Jacobian) 0
Time to complete mesh (hh; mm;ss): 00:00:38
Computer name: AWWWWWWW
6.1.7. Resultant Forces
6.1.7.1. Reaction Forces
Selection
set
Units Sum X Sum Y Sum Z Resultant
Entire Model N -0.046814 -1087.81 0.0449295 1087.81
6.1.7.2. Reaction Moments
Selection set Units Sum X Sum Y Sum
Z
Resultant
Entire Model N-m 0 0 0 0

47. 47
6.1.8. Study Results
Name Type Min Max
Stress1 VON: von Mises Stress 0.0648182 N/mm^2 (MPa)
Node: 28047
39.9842 N/mm^2 (MPa)
Node: 21464
Base Frame-Study 1-Stress-Stress1

48. 48
Name Type Min Max
Displacement1 URES: Resultant Displacement 0 mm
Node: 1607
0.0595235 mm
Node: 17006
Base frame-Study 1-Displacement-Displacement1

49. 49
Name Type Min Max
Strain1 ESTRN: Equivalent Strain 2.68572e-007
Element: 7832
8.70298e-005
Element: 12008
Base Frame-Study 1-Strain-Strain1

50. 50
Name Type
Displacement1{1} Deformed Shape
Base Frame-Study 1-Displacement-Displacement1

51. 51
Name Type
Design Insight1 Design Insight
body2-Study 1-Design Insight-Design Insight1
Conclusion
From above analysis, it is clear that this structure is so strong for all type of load and can wear
all stresses. Hence it is more suitable for this project.

52. 52
CHAPTER 6
DESIGN ANALYSIS
6.2. Simulation of Hacksaw
Date: 01 February 2017
Designer: Vineet Kumar Singh
Study name: Study 2
Analysis type: Static
6.2.1 Model Information

53. 53
Model name: Hacksaw Frame
Current Configuration: Default
Solid Bodies
<L_MdInf_SldBd
_Nm/>
Treated
As
Volumetric Properties
Document
Path/Date
Modified
Chamfer1
Solid
Body
Mass:0.00601488 kg
Volume:7.81153e-007 m^3
Density:7700 kg/m^3
Weight:0.0589458 N
E:final year
projectdyan zayas-
US6mm.SLDPRT
Jan 25 19:03:20 2017
Chamfer1
Solid
Body
Mass:0.00601488 kg
Volume:7.81153e-007 m^3
Density:7700 kg/m^3
Weight:0.0589458 N
E:final year
projectdyan zayas-
US6mm.SLDPRT
Jan 25 19:03:20 2017
Chamfer1
Solid
Body
Mass:0.00601488 kg
Volume:7.81153e-007 m^3
Density:7700 kg/m^3
Weight:0.0589458 N
E:final year
projectdyan zayas-
US6mm.SLDPRT
Jan 25 19:03:20 2017
Chamfer1 Solid
Body
Mass:0.00601488 kg
Volume:7.81153e-007 m^3
Density:7700 kg/m^3
Weight:0.0589458 N
E:final year
projectdyan zayas-
US6mm.SLDPRT
Jan 25 19:03:20 2017
Chamfer1 Solid
Body
Mass:0.00601488 kg
Volume:7.81153e-007 m^3
Density:7700 kg/m^3
Weight:0.0589458 N
E:final year
projectdyan zayas-
US6mm.SLDPRT
Jan 25 19:03:20 2017
LPattern1 Solid
Body
Mass:0.335251 kg
Volume:4.35391e-005 m^3
Density:7700 kg/m^3
Weight:3.28546 N
E:final year
projectblade
holder.SLDPRT
Jan 30 12:56:51 2017

54. 54
Mirror1 Solid
Body
Mass:0.0362689 kg
Volume:4.71025e-006 m^3
Density:7700 kg/m^3
Weight:0.355435 N
E:final year
projectblade.SLDPR
T
Jan 25 19:03:20 2017
Fillet10
Solid
Body
Mass:1.73934 kg
Volume:0.000225888 m^3
Density:7700 kg/m^3
Weight:17.0455 N
E:final year
projectsawguide.SL
DPRT
Jan 30 12:48:14 2017
<L_MdInf_ShlBd_N
m/>
<L_MdIn
_ShlBd_F
r/>
<L_MdInf_ShlBd_VolProp/>
<L_MdIn_ShlBd_Dt
Md/>
<L_MdInf_CpBd_N
m/>
<L_MdInf_CompBd_Props/>
<L_MdInf_BmBd_N
m/>
<L_MdIn
_BmBd_
Fr/>
<L_MdInf_BmBd_VolProp/>
<L_MdIn_BmBd_Dt
Md/>
6.2.2 Study Properties
Study name Study 3
Analysis type Static
Mesh type Solid Mesh
Thermal Effect: On
Thermal option Include temperature loads
Zero strain temperature 298 Kelvin
Include fluid pressure effects from
SolidWorks Flow Simulation
Off
Solver type FFEPlus
In plane Effect: Off
Soft Spring: Off
Inertial Relief: Off
Incompatible bonding options Automatic

55. 55
Large displacement Off
Compute free body forces On
Friction Off
Use Adaptive Method: Off
Result folder SolidWorks document (E:final year
projectAutomatic Four-way Hacksaw Machine)
6.2.3 Units
Unit system: SI (MKS)
Length/Displacement mm
Temperature Kelvin
Angular velocity Rad/sec
Pressure/Stress N/mm^2 (MPa)
6.2.4. Material Properties
Model Reference Properties Components
Name: Alloy Steel
Model type: Linear Elastic
Isotropic
Default failure
criterion:
Max von Mises
Stress
Yield strength: 6.20422e+008
N/m^2
Tensile strength: 7.23826e+008
N/m^2
Elastic modulus: 2.1e+011 N/m^2
Poisson's ratio: 0.28
Mass density: 7700 kg/m^3
Shear modulus: 7.9e+010 N/m^2
Thermal
expansion
coefficient:
1.3e-005 /Kelvin
Solid Body 1(Chamfer1)
(6mm-1),
Solid Body 1(Chamfer1)
(6mm-2),
solid Body 1(Chamfer1)
(6mm-5),
solid Body 1(Chamfer1)
(aari-1/6mm-1),
solid Body 1(Chamfer1)
(aari-1/6mm-2),
solid Body 1(LPattern1)
(aari-1/blade holder-1),
solid Body 1(Mirror1)
(aari-1/blade-1),
Solid Body
1(Fillet10)(sawguide-1)

56. 56
6.2.5 Loads and Fixtures
Fixture name Fixture Image Fixture Details
Fixed-1
Entities: 2 face(s)
Type: Fixed Geometry
Resultant Forces
Components X Y Z Resultant
Reaction force(N) 64.0035 20.0017 0.0055637 67.0561
Reaction Moment(N-m) 0 0 0 0
Load
name
Load Image Load Details
Gravity-1
Reference: Top Plane
Values: 0 0 -9.81
Units: SI
Force-1
Entities: 64 face(s)
Type: Apply
normal
force
Value: 1 N

57. 57
Load
name
Load Image Load Details
Force-2
Entities: 1 face(s)
Type: Apply normal
force
Value: 1 N
6.2.6. Contact Information
Contact Contact Image Contact Properties
Global Contact
Type: Bonded
Components: 1 component(s)
Options: Compatible
mesh
6.2.7. Mesh Information
Mesh type Solid Mesh
Mesher Used: Standard mesh
Automatic Transition: Off
Include Mesh Auto Loops: Off
Jacobian points 4 Points
Element Size 6.52864 mm
Tolerance 0.326432 mm
Mesh Quality High

58. 58
6.2.8. Mesh Information – Details
Total Nodes 32051
Total Elements 17779
Maximum Aspect Ratio 18.525
% of elements with Aspect Ratio < 3 65.2
% of elements with Aspect Ratio > 10 0.472
% of distorted elements(Jacobian) 0
Time to complete mesh(hh;mm;ss): 00:00:24
Computer name: AWWWWWWW

59. 59
6.2.9. Resultant Forces
6.2.9.1. Reaction Forces
Selection
set
Units Sum X
Sum Y Sum Z Resultant
Entire
Model
N 64.0035 20.0017 0.0055637 67.0561
6.2.9.2. Reaction Moments
Selection
set
Units Sum X
Sum Y Sum Z Resultant
Entire Model N-m 0 0 0 0

60. 60
6.2.10. Study Results
Name Type Min Max
Stress1 VON: von Mises Stress 9.27275e-006 N/mm^2 (MPa)
Node: 27579
10.1337 N/mm^2 (MPa)
Node: 4925
Hacksaw study-Stress-Stress1

61. 61
Name Type Min Max
Displacement1 URES: Resultant Displacement 0 mm
Node: 13570
0.0639019 mm
Node: 3094
Hacksaw Study 3-Displacement-Displacement1

62. 62
Name Type Min Max
Strain1 ESTRN: Equivalent
Strain
2.96562e-010
Element: 13749
3.80436e-005
Element: 5587
Hacksaw Study 3-Strain-Strain1

63. 63
Name Type Min Max
Factor of Safety1 Automatic 38.13
Node: 3451
6.69081e+007
Node: 27579
Hacksaw Study 3-Factor of Safety-Factor of Safety1

64. 64
Name Type
Design Insight1 Design Insight
Hacksaw-Study 3-Design Insight-Design Insight1
Conclusion
From above analysis, it is clear that this frame is so strong for all type of load and can wear all
stresses. Hence it is more suitable for this project.

65. 65
CHAPTER 7
ADVANTAGES, DISADVANTAGE, APPLICATIONS
5.1. Advantages
1. It is easy to operate.
2. It reduces the work of labor.
3. Easy to make because of simple construction.
4. High production rate.
5. Cost is less.
6. Easy maintenance and maintenance cost is less.
7. It resists all atmospheric effects.
5.2. Disadvantage
1. Speed variation is required for cutting the different metal.
5.3. Applications
1. In engineering industry.
2. In construction industry.
3. In Workshop.

66. 66
CHAPTER 8
FULLY ASSEMBLED AUTOMATIC FOUR-WAY HACKSAW
CUTTING MACHINE
Fig. 8.1

67. 67
CONCLUSION
It is known that conventional hacksaw machine can be replaced with an automatic four-way
cutting hacksaw machine. Automatic four-way hacksaw machine gives high productivity in
short time period in comparison with the conventional hacksaw machines. The major
advantage of this machine is that intervention of labor is reduced to maximum level. In this
rapid emerging industrial era, the use of automatic four-way Hacksaw machine is wide. Time
and labor plays a major role in production process this can be overcome by using this type of
automatic machines. The automatic four-way hacksaw machine can be made use of at any of
the industries like pump manufacturing industries that involve bulk number of shafts that have
to be cut frequently. The range of size of work-pieces that can be cut using the automatic four-
way hacksaw machine can be varied by changing the blade size. Currently, the machine uses
12-inch blade for cutting.

68. 68
FUTURE SCOPE
The machine can be fully automated by using Microcontroller. In fully automated machine the
operator need not measure the length of the work-piece that is to be cut and to load and unload
the work-piece each time after a piece has been cut. The operator need to only enter the two
input namely the number of pieces to be cut and the length of each piece that is required to be
cut. The inputs can be given by the operator with the help of a keypad and an LCD display,
which will help the user to verify the data given by him. After acquiring the two inputs from
the operator, the machine will automatically feed the given length of work-piece and start to
cut till the given number of work-pieces will be cut.
Automatic lifting up mechanism for frame when cutting operation is finished to introduce next
portion of bar for cutting.

69. 69
REFERENCES
1. D.V. Sabarinanda, Siddhartha, B. Sushil Krishnana, T. Mohanraj, “Design and
Fabrication of Automated Hacksaw Machine”, International Journal of Innovative
Research in Science, Engineering and Technology, ISSN (Online): 2319-8753, volume
3, April 2014.
2. Raj, K. J. S. D. (2012). Modeling, Control and Prototyping of Alternative Energy
Storage Systems for Hybrid Vehicles (Doctoral dissertation, The Ohio State
University).
3. Khurmi, R. S., & Gupta, J. K. (2012). Machine Design, S. Chand Publication [page
no.730]
4. Khurmi, R. S., & Gupta, J. K. (2012). Machine Design, S. Chand Publication [page
no.998]
5. Build a power hacksaw with vise, Authors: - Vincent Gingery
6. Prof. Nitinchandra R. Patel, Mohammad A. Vasanwala, Balkrushna B. Jani, Ravi
Thakkar, Miteshkumar D. Rathwa,” Material selection and testing of hacksaw blade
based on mechanical Properties”, International Journal of Innovative Research in
Science, Engineering and Technology, ISSN: 2319-8753, volume 2, Issue 6, June 2013.
7. R. Subhash, C.M. Meenakshi, K. Samuel Jayakaran, C. Venkateswaran, R. Sasidharan,
“Fabrication pedal powered hacksaw using dual