Final Year Project

on

PEDAL OPERATED HACKSAW

​submitted in partial fulfillment of the requirements

of the degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

By

Vinay Yadav(1514101282)

​ ​Supervisor:
​Dr. MANIRAJ M

SCHOOL OF MECHANICAL ENGINEERING

GALGOTIAS UNIVERSITY
GREATER NOIDA
2019
 CERTIFICATE

This is to certify that this project report on “PEDAL OPERATED HACKSAW” with an
innovation in power generation ​is in partial fulfillment of the requirements for the award
of Bachelor of Technology​, is a record of bonafide work done under my guidance. The
contents of this project work, in full or in parts, have neither been taken from any other
source nor have been submitted to any other Institute or University for award of any
degree or diploma.

Dr. Maniraj M

Internal Examiner External Examiner

I
 Approval Sheet

This project report entitled ​Power operated Hacksaw ​by ​Vinay Yadav is approved for
the​ degree of ​Bachelor of Technology​ in mechanical engineering.

Examiners

_______________________

_______________________

_______________________

Supervisor

_______________________

Dean

_______________________

Date: ____________

Place: ___________

​ ​II
 Declaration

I declare that this written submission represents my ideas in my own words and where
other's ideas or words have been included, i have adequately cited and referenced the
original sources. I also declare that i have adhered to all principles of academic honesty
and integrity and have not misrepresented or fabricated or falsified any
idea/data/fact/source in our submission. I understand that any violation of the above will
be cause for disciplinary action by the Institute and can also evoke penal action from the
sources which have thus not been properly cited or from whom proper permission has
not been taken when needed.

​ Vinay Yadav(1514101282)

Date: __________

III
 ACKNOWLEDGEMENT

The contributions of many different people, in their different ways, have made this
possible. I would like to extend my gratitude to the following.
I am grateful to our guide ​Mr. Kapil Rajput for providing us the proper guidance for
this project.
I am also grateful to project coordinator ​Dr. Maniraj. M for granting us permission to
work on our project and giving us some important feedback on different occasion which
helps us to improve our project idea.

​Vinay Yadav

​ IV
 ​ABSTRACT

The Pedal Operated Hacksaw has a very simple mechanism operated with pedal by
pedalling the wheel rotary motion is converted into to and fro motion of the cutting tool.
The aim of this machine is to cut materials like wood, plastic etc., with less effort and
quickly. That is by connecting a hacksaw to the pedal of a cycle and pedalling the
pedals the forces are transmitted and get the work done.The size and shape of the pedal
power hacksaw setup is similar to the cycle. It is like a cycle added with a bed for the
cutting tool. It can be used in the place where electricity is not available. The end of the
cutting tool is placed on the workpiece.The continuous pedalling gives a good result of
cutting.Since this uses no electric power and fuel, this is very cheap and the best. But in
order to save the wastage of mechanical power we also used the dynamo which converts
mechanical rotation into electrical power during pedaling and serves as an energy
reservoir and can be used when the input is cut off. The main aim is to reduce human
effort for machining and cutting various materials such as wooden blocks, steel, PVC,
etc.The performance of the POH was compared with Hand Hacksaw at different rpm.
The results indicate that the POH had given better, accurate and faster cuts when
compared with hand hacksaw at different rpm. POH reduces the effort of cutting
plywood to a great extent.

V
 TABLE OF CONTENT
​Page No.

Certificate ​I

Approval sheet ​II

Student declaration ​III

ACKNOWLEDGEMENT IV

Abstract ​V

Table of content ​VI

List of abbreviation ​VII

List of figures ​ VIII

Chapter 1 Introduction 1

​1.1​ ​Project background ​1

​1.2 ​Research purpose ​2

​1.3​ Objectives of work ​3

​1.4 ​Future scope ​4

Chapter 2 Literature review ​5

​2.1 ​Introduction ​5

​2.2​ Reviews ​5

Chapter 3 Theoretical Information 7

​3.1 ​Components ​7

​3.2 ​ Design and Modelling ​12

​3.3​ Fabrication ​16

​ 3.3​ Calculations ​22

​3.4 ​ Results ​23

Chapter 4 Problem description 25

​ 4.1​ ​Problem Identification 25

​ 4.2 ​ Proposed Methodology 25

Chapter 5 Conclusion 26

REFERENCES

​VII
List of abbreviations

1. POH Pedal Operated Hacksaw

2. IMA Ideal Mechanical Advantage
3. CNC ​Computerized Numerical Control
4. PVC Poly Vinyl Chloride
5. RPM Rotation per minute
6. SSI Small scale industries
7. HSS High Carbon Steel

​VIII
List of figures
2

​ Figure Title

Figure 3.1 Pedal

Figure 3.2 Sprocket

Figure 3.3 Chain

Figure 3.4 Connecting rod

Figure 3.5 Hacksaw

Figure 3.6 Outline of POH model

Figure 3.7 Base stand

Figure 3.8 Crankshaft

Figure 3.9 Connecting rod model

Figure 3.10 Hacksaw frame

Figure 3.11 Fabricated Model

Figure 3.12 Project

​ ​IX
 Chapter 1

Introduction

1.1 Project background

The pedal operated hacksaw machine is a cutting machine which runs without
electricity and consumes less human power as compared to hand operated hacksaw. It is
used for cutting different metals; ferrous and non- ferrous materials. It has been
observed that if the machine is designed ergonomically to suit human comfort, more
power output can be obtained out of the same input. The energy from the pedal is
transferred to the hacksaw blade via a slider crank mechanism an individual can
generate four times more power by pedaling than by hand-cranking. But, at the rate of ¼
HP, continuous pedaling can be served for only short periods, approximately 10
minutes. However, if pedaling is done at half of this power , it can be sustained for close
to 60 minutes. Power capability depends upon age too. The reciprocating rod moves to
and fro, and the hacksaw moves with the rod. The light material to be cut is placed
under the hacksaw. By pedaling the pedal, the sprocket rotates and it will make the
connecting rod move to and fro, which is further connected to the hacksaw blade. Thus,
the light material can be cut without any external energy like fuel or current. Many
devices can be run right away with mechanical energy. A saw is a tool that uses a hard
blade or wire with an abrasive edge to cut through softer materials. The cutting edge of
a saw is either a serrated blade or an abrasive. A saw may be worked by hand, or
powered by steam, water, electric or other power. An abrasive saw uses an abrasive disc
or band for cutting, rather than a serrated blade.The history of the hacksaw machine is
associated with regular hand saws. Handsaws have been present since the time of the
ancient Egyptians. Hieroglyphics in that era showcased the importance of wood in the
community and how the Egyptians dealt in cutting it. Modern versions of the hand saw

1
are based on the first one developed by the Kulibert Saw Company. As the demand to
cut and saw harder types of materials grew, the power hacksaw was developed and
created to alleviate the effort in doing the procedure.

1.2 Research Purpose

Every machine is constructed for the purpose of performing certain mechanical

operations, each of which supposes the existence of two other things besides the
machine in question, namely, a moving power, and an object subject to the operation,
which may be termed the work to be done. Increasing the productivity is one of the
main requirements of production engineering in any kind of manufacturing industry.
Either by reducing the operation time or by improving the capability of the machine to
produce the components in an increased number at the same time is very essential for an
industry to achieve the same. This project employs the Single slider crank mechanism in
power hacksaw machine which enables it to cut two components at a time thereby
improving the productivity. In today’s world time a machine should be less time
consuming. Power hacksaw cut one piece at one time so there was a loss in production
rate. Power hacksaw overcome this time consuming problem. Power hacksaw is a fine
tooth power saw with blade held under tension in the frame. So the production rate
increase twice then that of power hacksaws. The fact that the operator has to feed the
workpiece to the required length in to the vice is one aspect that motivated us to
automate the feeding of workpiece automatically. Another one aspect is that after a shaft
has been cut for one time, the operator has to unload the workpiece and advance the rest
of the workpiece to the required length again and again till the end of the workpiece 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
workpiece many times with measurements being taken each time before feeding. There
in arose a need to completely automate the process of cutting, and here we are with a
proposal which will aid in eliminating the effort of the people associated with it.

Machines, in fact, are interposed between the power and the work, for the purpose of
adapting the one to the other.” In some fields, mechanization includes the use of hand

2
tools. In modern usage, such as in engineering or economics, mechanization implies
machinery more complex than hand tools and would not include simple devices such as
an ungeared horse or donkey mill. Devices that cause speed changes or changes to or
from reciprocating to rotary motion, using means such as gears, pulleys or sheaves and
belts, shafts, cams and cranks, usually are considered machines. After electrification,
when most small machinery was no longer hand powered, mechanization was
synonymous with motorized machines.

1.3 Objectives of work

In recent competitive environment, every organization focuses on increase in production

rate with higher quality, least Price & least resources by using latest technology and
automation. But cost of automation is much higher, So Medium and Small Scale
Industries (SSI) can’t afford such high cost that’s why modification of existing systems
is optimal solution for those industries. Based on concept of Modification of existing
Machine we have tried to Design and Manufacture “Hacksaw Machine” The objective
behind this project is to develop the Machine which cuts the material. These hacksaw
machines are used to cut the large size diameter of metals such as steel. Cutting
diameter of more than 5 mm is very hard work with a normal hand held hacksaw.
Therefore hacksaw have been developed to carry out the difficult and time consuming
work.

The overall objectives of modelling a machine like Pedal operated hacksaw can be
stated as follows:

1. The cutting work can be completed at places where electricity is not at reach.
2. The rotary motion of the pedalling operation performed to our requirement on
the cutting job.
3. Can provide a basic framework for other useful mechanical mechanical devices.
4. Introducing the scope for the development of machining operations.

3
1.4 Future scope:

The Pedal operated hacksaw machine can be made use of at any of the industries like
pipe manufacturing and wood industries that involve bulk amount of shafts that have to
be cut frequently. The range of size of work-pieces that can be cut using the Pedal
operated hacksaw machine can be varied by changing the blade size. Currently, the
machine uses 12 inch blade for cutting. An another advancement that can be
implemented in Pedal operated hacksaw machines is that the user can also get cut
work-pieces of different lengths in one cycle itself. This means that the user has to
specify the number of work-pieces that have to be cut in each of the different length
values specified. This will be possible with the help of an advanced solar power
generation system with dynamo, which should have high programmable capacity.

4
 Chapter ​2

Literature review

2.1 Introduction

Pedal operated Hacksaw can be used for industrial applications like cutting the wooden
blocks, metal bars as well as Household purposes like cutting pvc pipes and other
materials. Initially modeling is done in solidworks as per dimensions to achieve
required stroke and velocity for the cutter. The slider in the crank slider mechanism is
replaced by hacksaw cutter to get the required model of Hacksaw cutter machine. The
Kinematic analysis is also carried out in Solidworks to obtain the Displacement,
Velocity and Acceleration of the Cutter for the given configuration. The Fabrication of
Hacksaw cutter includes various operations like drilling, cutting, welding, grinding etc.,
Importance of this project lies in the very fact that it is reducing the human effort.
Secondly, this cutter can be used and transferred to our working place easily

2.2 Reviews

R. Subash, K. Samuel Jayakaran, (2014), In this paper author has designed Pedal
operated hacksaw machine which can be used for industrial applications and Household
needs in which no specific input energy or power is needed. This project consists of a
sprocket arrangement, the crank and slider mechanism, the chain drive. In the
mechanism, chain drive is directly connected to the hacksaw for the processing of
cutting the wooden blocks. The objective of the paper is using the conventional
mechanical process which plays a vital role.

5
Girish T. , Parameswara murthy D., (2014), In this paper author has designed to
development of conceptual model of water pumping and battery charging cross trainer
which is user friendly, easy to do exercise, save & stores the energy of the users muscle
efforts. When the human operates the lever and the pedal, the Centrifugal Pump is
actuated and the water is pumped from ground sump to the tank. At the same time the
attached dynamo (i.e., is mounted near the V-belt) operates and the mechanical energy
is converted in to electrical energy, the generated electrical energy is stored in battery
with the help of wires. The stored electrical energy is used when we are needed.

S.G.Bahaley, Dr. A.U. Awate, S.V. Saharkar,(2012), ​In this paper the author designed
and fabricated a pedal powered multipurpose machine. It is a human powered machine
which is developed for lifting the water to a height 10 meter and generates 14 Volt, 4
ampere of electricity in most effective way. Power required for pedaling is well below
the capacity of an average healthy human being. The system is also useful for the work
out purpose because pedaling will act as a health exercise and also doing a useful work.

Prof. Nitin Chandra R. Patel, Ravi Thakkar, Miteshkumar Rathwa (2013) ​In his
research paper “Material selection and testing of hacksaw blade based on mechanical
properties” stated that the appropriate saw blade must be selected for better operation
and fine cutting by selecting number of teeth per inch. There are four types of blades
based on material namely High Carbon steel, Alloy Steel, Bimetallic strip and High
speed steel blades. Out of these four the best suitable for cutting hard materials like
Mild steel bar and Aluminium is Bimetallic blade on the basis of Properties of
materials, Wear resistance and Cutting performance.

6
 Chapter ​3

​Theoretical information

3.1 Components
1. Pedal
A 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.
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. 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.

​ ​ fig 3.1

2. Sprocket
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'

7
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.
Sprockets are used in bicycles, motorcycles, cars, tracked vehicles, and other machinery
either to transmit rotary motion between two shafts where gears are unsuitable or to
impart linear motion to a track, tape etc. Perhaps the most common form of sprocket
may be found in the bicycle, in which the pedal shaft carries a large sprocket-wheel,
which drives a chain, which, in turn, drives a small sprocket on the axle of the rear
wheel .

​fig 3.2

3. Chain
Roller chain or bush roller chain is the type of chain drive most commonly used for
transmission 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.

8
 ​fig 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.

​5. Connecting Rod

The connecting rod connects the hacksaw to the crank or crankshaft. Together with the
crank, they form a simple mechanism that converts circulatory motion into reciprocating
motion. Historically, before the development of engines, they were first used in this
way.

9
 ​ fig 3.4

6. Dynamo
A dynamo is an electrical generator that creates direct current using a commutator.
Dynamos were the first electrical generators capable of delivering power for industry,
and the foundation upon which many other later electric-power conversion devices were
based, including the electric motor, the alternating-current alternator, and the rotary
converter.

​7. 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.

10
 ​ fig 3.5

​8. 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 (tpi) for a
hand blade, with as few as three tpi for a large power hacksaw blade.
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.

11
3.2 Design and modelling
The exercise bicycle frame is fixed with the base mild steel by the process of welding.
The chain sprocket is connected to the cycle frame and it is connected to the pedals. The
one end of the connecting rod is connected to the big sprocket and the other end is
connected to the hacksaw. The circular rod is inserted into the bearing and is welded
with the sprocket at one end. The connecting rod is connected to the rotating disc at one
end and to the hacksaw at the other end. The hacksaw moves in fro motion when the
pedal is powered, so as the rotating disc rotates. The vice is fixed at the stand to hold the
work piece tightly in a straight position. As the pedal is powered by the human energy,
the hacksaw blade to move in one and fro motion. When the hacksaw moves, the work
piece metal will be cut into a desired shape.Hence, all the models designed in solid-
works.

While designing this project, the following considerations were taken into account:
1. The device should be suitable for local manufacturing capabilities.
2. The attachment should employ low-cost materials and manufacturing methods.
3. It should be accessible and affordable by low-income groups, and should fulfill their
basic need for mechanical power.
4. It should be simple to manufacture, operate, maintain and repair.
5. It should be as multi-purpose as possible, providing power for various agricultural
implements and for small machines used in rural industry.
6.. Excessive weight should be avoided, as durability is a prime consideration.

12
Outline of the model:

​fig 3.6

Modeling of base stand:

fig 3.7

13
Modeling of crankshaft:

​fig 3.8

Modeling of connecting rod:

​fig 3.9

14
Modeling of hack saw frame:

​fig 3.10

15
3.3 Fabrication of hacksaw machine

Metal fabrication is the building of metal structures by cutting, bending, and assembling
processes: Cutting is done by sawing, shearing, or chiselling (all with manual and
powered variants); torching with hand-held torches (such as oxy-fuel torches or plasma
torches); and via numerical control (CNC) cutters (using a laser, mill bits, torch, or
water jet). Bending is done by hammering (manual or powered) or via press brakes and
similar tools. Modern metal fabricators utilize press brakes to either coin or air-bend
metal sheet into form. CNC-controlled back gauges utilize hard stops to position cut
parts in order to place bend lines in the correct position. Off-line programming software
now makes programming the CNC-controlled press brakes seamless and very efficient.
Assembling (joining of the pieces) is done by welding, binding with adhesives, riveting,
threaded fasteners, or even yet more bending in the form of a crimped seam. Structural
steel and sheet metal are the usual starting materials for fabrication, along with the

​ fig 3.11

16
welding wire, flux, and fasteners that will join the cut pieces. As with other
manufacturing processes, both human labor and automation are commonly used. The
product resulting from fabrication may be called a fabrication. Shops that specialize in
this type of metal work are called fab shops. The end products of other common types
of metalworking, such as machining, metal stamping, forging, and casting, may be
similar in shape and function, but those processes are not classified as fabrication.

Machining operations:
Cutting: ​The raw material has to be cut to size. This is done with a variety of tools.

The most common way to cut material is by Shearing (metalworking); Special band
saws designed for cutting metal have hardened blades and a feed mechanism for even
cutting. Abrasive cut-off saws, also known as chop saws, are similar to miter saws but
with a steel cutting abrasive disk. Cutting torches can cut very large sections of steel
with little effort.
Drilling: Drilling is used to produce holes in the objects. In this project plates requires
holes for making assembly. These holes are done by vertical type drilling machine.
Machining: Machining is a trade, in and of it, although Fab shops will generally entail
a limited machining capability including; metal lathes, mills, magnetic based drills
along with other portable metal working tools.
Welding: Welding is the main focus of steel fabrication. The formed and machined
parts will be assembled and tack welded into place then re-checked for accuracy. A
fixture may be used to locate parts for welding if multiple elements have been ordered.
The welder then completes welding per the engineering drawings, if welding is detailed
or per his own judgment if no welding details are provided.

17
 ​fig 3.12
Pedal arrangement with the base.

18
Selection of blade on the basis of performance:
Hardness :
● High speed steel blade and alloy steel blade having hardness of order of 65

HRC is higher than other materials. Hence, HSS is the best as far as the hardness
of tooth is concerned. So, for cutting harder work piece like mild steel etc., best
option is to employ HSS material blade.
● In Bimetallic strip blade, as only teeth are being hardened, hardness remains
almost the same including both ends. The ends are not annealed because punch
are made on relative softer shank material.
● In low alloy and HSS blades, the hardness throughout remains almost constant
except two ends as ends are being annealed for easy installation. Also variation
in hardness along the length of blade is more in case of alloy steel blade
compared to HSS blade.
● Hardness of high carbon steel is lower than other materials. Therefore, this kind
of blade is used only to cut softer material like copper, brass, aluminum etc.

Cutting performance :
● High carbon steel blade is mainly used to cut the brass material as time for
cutting of Brass material by High carbon steel blade is the least. So, the
materials like brass, copper, bronze etc. are efficiently cut with high carbon steel
as far as time is concerned. For ferrous materials it takes lot of time to cut.
● Alloy steel blades are used to cut the non-ferrous materials like brass,
aluminium etc. as they take lower time for cutting of non-ferrous materials.
● Bi-metallic blades are the best to cut the ferrous materials like mild steel etc. as
far as the cutting time is concerned. Also for non-ferrous materials it gives good
performance.
● HSS blades cut both ferrous as well as non-ferrous materials with minimum
cutting time.

19
Wear test :
● The high carbon steel experiences minimum wear on tooth for cutting
the aluminium, gun metal etc.
● The brass material and other non-ferrous materials can be cut with alloy
steel and high carbon steel for the minimum amount of wear.
● For cutting ferrous materials like mild steel, HSS as well as Bi-metallic
blades experience lower wear whereas alloy steel blades experience
highest wear for cutting ferrous materials.
● So, for cutting ferrous materials HSS and Bi-metallic blades are best in
wear consideration also for cutting non-ferrous materials either high
carbon steel or alloy steel is good as far as the wear is concerned.

Tensile test :
● Bi-metallic and HSS blades are having higher tensile strength of the
order of 900 MPa whereas high carbon steel blades is having tensile
strength of the order of 600 MPa and alloy steel is having of the order of
750 MPa.
● So, HSS and Bi-metallic blades are superior as far as the tensile strength
is concerned.

20
3.4 Dimensions:

Hacksaw frame:
​ Length=480mm
Breadth=240mm
Thickness=5.5mm
Hacksaw blade (hole to hole):
​ Length = 300mm
Connecting rod:
​Length=450mm
Sprocket(driven):
Diameter=90mm
No. of teeth=18
Sprocket(driver):
Diameter=170mm
No. of teeth=44

21
3.5 Calculations:

Teeth Ratio​ = T1/T2

Velocity Ratio​ = (T1/T2 = N2/N1)
​Input Power ​= 2 п N T / 60
where, N = Sprocket speed in rpm
T = Torque applied by human in Nm
T=Fxr
where, F = Force applied by human in N
r = Length of pedal arm
Now, we can increase the torque by increasing the length of pedal from its centre.
​The cutting force required = ​π​ x D x t x τs
where D = Diameter of workpiece
t = Cutting Depth
τs = Shear strength of material
Maximum power required = Fmax x V
where, V = velocity of blade
Ideal mechanical advantage(IMA) ​=D(driven)/D(driver)
=Work input/Work out
=90/170
=0.53

Work input = 2​π*N/60

​=2*3.14*60/60
=6.28 rad/sec

Work out = Workinput/IMA

​ =​ 6.28/0.53
=11.84 rad/sec

22
3.6 Results
1. POH can be used in distant places where electricity is not accessible. It is
designed as a transportable one which can be used for cutting in various places.
2. The plywood can be cut devoid of any peripheral energy like fuel or current.
Since POH uses no electric power and fuel, this is very economical and best.
3. POH can be used for light duty cutting process of plywood. It is also effective
for the human health
4. Pedal operated hacksaw helps to obtain less effort uniform cutting. The results
specify that the POH had given better, accurate and faster cuts when evaluate
with hand hacksaw at different rpm.
For cast iron pipes:
Performance of Pedal powered hacksaw for light duty cutting operations on cast iron
pipes

S.No. R.P.M TIME(min) DEPTH OF

CUT(mm)

1 30 2 11

2 40 2 13

3 50 2 16

For pvc pipes:

Performance of Pedal powered hacksaw for light duty cutting operations on pvc pipes

S.No. R.P.M TIME(min) DEPTH OF

CUT(mm)

1 30 2 14

2 40 2 18

3 50 2 22

23
For wood block:
Performance of Pedal powered hacksaw for light duty cutting operations on wood
block

S.No. R.P.M TIME(min) DEPTH OF

CUT(mm)

1 30 2 17

2 40 2 22

3 50 2 28

24
 Chapter 4

Problem description

4.1 Problem identification

The power hacksaw machines, which are operated by human operators as

aforementioned, have the demerit of unloading and loading the workpiece many times.
In industries manufacturing pumps, these machines are used to cut the motor shafts to
the required lengths. It will be difficult for the operator if he has been assigned to cut a
huge quantity of motor shafts and he has to measure the lengths each time for cutting.
Since humans are not as versatile as machines, there is a possibility that there may be
inaccuracies. Besides, if there is a slight time delay in between every cycle of cutting a
piece, the cumulative delay in time will be found to have a considerable magnitude,
which might have been utilized properly if the proposed machine were in use there.
One of the main problem faced during the fabrication of this project is the dis-balancing
of the model during seat fabrication.

4.2 Proposed Methodology

The demerit of the Pedal operated hacksaw machine is to apply continue supply of
human power for the machining operation, but it can me eliminated by using a dynamo
in connection with the sprocket so that it may trap extra human work and convert it to
electrical power, which further can be used to operate the POH machine in the absence
of human labour.

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 Chapter ​5

​Conclusion

Thus a low cost and simple design of hacksaw machine is fabricated. This machine
reduces the human effort and hence we don’t need two persons to cut the wooden logs.
This simple design can enhance day to day household needs and it can be also used for
industrial applications. Thus the Hacksaw cutter machine is fabricated using the
principle of crankshaft mechanism to achieve required stroke and velocity for the cutter
with the innovation of using extra human power by trapping it with the help of
dynamo,a mechanical device which converts mechanical work to electrical energy. It is
known that conventional Pedal Operated hacksaw machine can be replaced with
Innovated Pedal Operated hacksaw machine. Innovated Pedal Operated hacksaw
machine gives high productivity in short time period in comparison with the
conventional Pedal Operated hacksaw machines.

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 ​REFERENCES

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2. Subash R., Meenakshi C.M., Samuel Jayakaran K., Venkateswaran C.,.Sasidharan R,

“Fabrication of pedal powered hacksaw using dual chain drive”, International Journal of
Engineering & Technology, 3 (2) (2014).

3. Vivek Kumar Chauhan, Faheem khan, Chandresh Kumar Joshi (2015) “Design and
Development of Pedal Powered Hacksaw”, International Journal of Emerging Trends in
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4. Prof. Nitin chandra 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
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5. Bahaley S.G., Dr. Awate A.U., Saharkar S.V (2012) “Performance Analysis of Pedal
Powered Multipurpose Machine”, International Journal of Engineering Research &
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6. Sabariananda .D.V., Siddhartha V., Sushil Krishnan B., Mohanraj.T (2014) “Design
and Fabrication of Automated Hacksaw Machine”, International Journal of Innovative
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