Project report on

POWER HACK SAW

Submitted by
Name 1

Name 2

Name 3

Name 4

Name 5

B. Tech. (MECH) 6th Semester (Section–A)

DEPT. OF MECHANICAL ENGINEERING

Institute of Technical Education and Research
SIKSHA ‘O’ ANUSANDHAN
DEEMED TO BE UNIVERSITY
Bhubaneswar, Odisha, India.
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 CERTIFICATE
It is certified that the work contained in the project report titled “Power Hack-
Saw,” by “Group 1(a),” has been carried out under my/our supervision and that
this work has not been submitted elsewhere for a degree.

Signature of Supervisor(s)
Mechanical Department
ITER, SOA DEEMED TO BE UNIVERSITY
June, 2024

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 DECLARATION
I declare that this written submission represents my ideas in my own words and
where others' ideas or words have been included, I have adequately cited and
referenced the sources. I also declare that I have adhered to all principles of
academic honesty and integrity and have not misrepresented, fabricated, or
falsified any idea/data/fact/source in my 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 that have thus not been properly
cited or from whom proper permission has not been taken when needed.

Name 1

Name 2

Name 3

Name 4

Name 5
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1. Introduction
A hacksaw is an essential tool in any workshop or DIY enthusiast's arsenal, designed primarily
for cutting metal and plastic. The hacksaw operates through a manual back-and-forth sawing
motion, featuring a fine-toothed blade mounted on a sturdy frame. The blades are typically
made from high-speed steel, allowing them to cut through tough materials with precision. The
adjustable frames of some hacksaws accommodate various blade lengths, enhancing their
versatility for different tasks.
A power hacksaw is an advanced version of the traditional hacksaw, designed to automate the
cutting process and handle larger, more demanding jobs. Unlike manual hacksaws, power
hacksaws use an electric motor to drive the blade back and forth, significantly reducing the
physical effort required and increasing cutting speed and efficiency. These machines are
commonly used in industrial settings where precision and the ability to cut through thick metal
bars, rods, and pipes are paramount. The consistent, rhythmic motion of the power hacksaw
ensures uniform cuts, which is critical for maintaining the quality and integrity of the
workpiece.
Designing a power hacksaw involves several critical considerations to ensure it meets the
demands of efficiency, durability, and user safety. The frame, usually constructed from heavy-
duty cast iron or steel, provides the necessary rigidity and stability to handle the intense forces
exerted during cutting operations. This robust construction helps minimize vibrations and
maintain accuracy, essential for producing clean, precise cuts. The frame's design often
incorporates a base or stand to secure the machine during use, enhancing its stability and safety.
The blade mechanism is a central focus in the design of a power hacksaw. Engineers must
ensure the blade is easily replaceable and adjustable to accommodate different cutting tasks.
This typically involves designing a quick-release mechanism that allows users to change blades
swiftly without the need for additional tools. The tensioning system, which keeps the blade taut
during operation, must be adjustable to cater to various blade types and thicknesses, ensuring
consistent cutting performance. Additionally, incorporating a variable speed control allows the
machine to adapt to different materials, optimizing cutting efficiency and blade lifespan.
This report will encompass the design, construction, and testing of the power-driven hacksaw,
ensuring it meets the rigorous demands of industrial use. It aims to contribute to these goals by
developing a power-driven hacksaw, a tool designed to streamline the cutting process in various
industrial applications. The report focuses on designing a portable power hacksaw for cutting
small workpieces like wood, plastic, and metal. The design was based on theoretical
calculations, CAD design, and structural analysis. Design optimization was carried out using
an optimistic design approach. The finite element analysis results indicated the design was
structurally safe and optimized. By leveraging electric power to drive the cutting mechanism,
this mechanical tool promises to enhance productivity, reduce manual labor, and improve
cutting accuracy.

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1.1. Literature Review
Important theories, formulae, and methodologies used by various researchers are reviewed to
understand and report the working of the hacksaw, a general understanding of raw materials,
and different machining processes. Considering the requirements for the manufacturing of the
motor power-driven hacksaw, some of the research works are considered while reporting and
analyzing the results.
Stephen. et. al. (2015) [1] performed a technical report on the design and construction of a
pedal-powered hacksaw-cutting machine. Essam Ali Al-Bahkali. et. al. (2018) [2] analyzed the
failure of vise jaw holders for the hacksaw machine. P.J. Thompson. (1974) [3] performed a
theoretical report of the cutting action of power hacksaw blades. Bijay Lipcha. et. al. (2016)
[4] worked on the rectification of the power hacksaw machine which focused on cutting
different metal rod pieces of various cross-sections with high rate and accuracy to minimize
idle time. Raunika Anand. et.al. (2021) [5] analyzed and designed a portable power hacksaw
with a coolant and lubricant system. Aman Kumar Maini. et.al. (2021) [6] studied the dynamics
of the power hacksaw mechanism, contact interaction with the workpiece, and material
removal processes.

2. Materials and Methodology

Methodology acts as a comprehensive road map outlining the report or project's execution. It
is crucial because it offers a methodical and transparent explanation of the methods and
processes followed, guaranteeing that the report can be verified and repeated by other
investigators. A well-stated methodology shows that the report was carried out methodically
and rigorously, which raises the trustworthiness of the results. Since they can comprehend the
precise procedures involved in data collecting and analysis, it also enables readers to evaluate
the validity and dependability of the findings. A critical assessment of the report's findings is
also made possible by the methodology section, which describes the techniques employed and
aids in identifying potential biases, constraints, and sources of mistakes.
The product development process is a comprehensive journey that involves multiple stages
from ideation to market launch. Here is an in-depth guide to the entire process:
1. Ideation and Concept Development:
Market Research: Identify market needs, customer pain points, and opportunities
through surveys, focus groups, and market analysis.
Idea Generation: Brainstorm ideas using techniques like mind mapping, brainstorming
sessions, and innovation workshops.
Concept Development: Develop initial concepts, sketches, and descriptions. Evaluate
these ideas based on feasibility, market potential, and alignment with company goals.

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2. Feasibility Analysis:
Technical Feasibility: Assess the technical requirements and feasibility of the product
idea, including available technologies and resources.
Market Feasibility: Conduct a detailed market analysis to understand the target
audience, competition, and potential demand.
Financial Feasibility: Estimate costs, potential revenue, and profitability. Conduct a
break-even analysis and financial projections.
3. Concept Design and Prototyping:
Detailed Design: Create detailed drawings and specifications for the product. Utilize
CAD software for precise design.
Prototyping: Develop physical or digital prototypes to visualize the product. Prototypes
can be low-fidelity (rough models) or high-fidelity (close to final product).
Testing and Feedback: Test prototypes for functionality, usability, and performance.
Gather feedback from stakeholders and potential users to refine the design.
4. Product Development and Engineering:
Engineering Design: Finalize technical specifications, materials, and manufacturing
processes. Create detailed engineering drawings.
Software Development: If the product involves software, begin the software
development process, including coding, testing, and debugging.
Integration: Ensure all components (mechanical, electrical, software) integrate
seamlessly.
5. Testing and Validation:
Functional Testing: Conduct rigorous testing to ensure the product functions as
intended. This includes stress tests, durability tests, and performance tests.
Compliance and Certification: Ensure the product meets industry standards and
regulations. Obtain necessary certifications (e.g., CE, FCC, ISO).
User Testing: Conduct usability testing with real users to identify any issues and gather
feedback for final adjustments.
6. Pre-production Planning:
Manufacturing Planning: Develop a detailed manufacturing plan, including process
flows, production schedules, and quality control measures.
Supply Chain Management: Identify and secure suppliers for materials and
components. Establish logistics and inventory management systems.
Tooling and Equipment: Design and procure any special tooling, molds, or equipment
required for production
Now the whole process from modelling to drawing generation of respective components is
discussed in detail:

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Creating a process flow for transitioning from modeling to drawing generation in SolidWorks
involves several key steps, each integral to ensuring that the final drawings accurately reflect
the design intent and are suitable for manufacturing. Here’s a detailed process flow:
1. Start with a New Part or Assembly:
Open SolidWorks: Launch the SolidWorks application.
New Part/Assembly: Go to File -> New -> Select Part or Assembly.
2. 3D Modeling:
Sketch Creation:
Select a Plane: Choose a plane (Top, Front, Right) to start your sketch.
Draw the Sketch: Use sketch tools (lines, arcs, circles) to create the 2D outline of the part.
Define Dimensions: Use the Smart Dimension tool to define critical dimensions and
constraints.
Feature Creation:
Extrude/Boss/Base: Convert the sketch into a 3D model using features like Extrude, Revolve,
Sweep, or Loft.
Add Additional Features: Add other features such as holes, fillets, chamfers, and cuts using
appropriate commands.
Assemblies: If working on an assembly, insert multiple parts and define relationships (mates)
between them to create the full assembly.
3. Model Refinement:
Check for Errors: Use tools like "Check Geometry" and "Evaluate" to identify and fix any
issues.
Material Assignment: Assign materials to the parts to define physical properties.
Appearance Settings: Apply appearances and colors to the model for better visualization.
4. Prepare the Model for Drawing:
Final Review: Ensure the model is complete and all design intent is captured.
Save the Model: Save the part or assembly file.
5. Create a Drawing from the Model:
Open New Drawing:
Go to File -> New -> Drawing.
Select a drawing template (standard formats such as A4, A3, A2, etc.).
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 Insert Model Views:
Model View: Insert the main views (Top, Front, Right, Isometric) of the part or assembly.
Projected View: Create additional views by projecting from the main views.
Section View: Create sectional views to show internal features.
Detail View: Create detailed views for intricate features.
6. Add Dimensions and Annotations:
Automatic Dimensioning:
Use "Model Items" to import dimensions directly from the 3D model.
Manual Dimensioning:
Use the Smart Dimension tool to add dimensions manually.
Annotations:
Add necessary annotations such as notes, hole callouts, surface finishes, and welding symbols.
7. Formatting and Detailing:
Title Block: Fill in the title block with information like part name, drawing number, scale,
material, and revision.
Drawing Borders: Ensure borders are correctly formatted and include necessary information.

2.1. Bill of Materials

In this section, various parameters of the component are discussed like its functional
analysis, manufacturing process, dimension, material, surface, finish, etc. The details of
the respected component are represented below:

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 Bill of Material
Power Hacksaw

Part Name Qty Functional Analysis DFM Cost Analysis

Flow Flow Manuf. Dimensions
Function Material
In Out Process (in mm)
SUPPORT SUBSYSTEM
To support the whole Cutting
1 Base frame 1 Nil Nil 800 x 200 x 350 Mild steel
mechanism Welding
Cutting
2 Motor base plate 1 To support the motor Nil Nil 200 x 148 x 5 Mild steel
Drilling
To support the upper
3 Base plate 1 Nil Nil Cutting 300 x 200 x 10 Mild steel
mechanism
To support the motor Turning
4 Base plate rod 1 Nil Nil 280 length, ⌀12 Mild steel
base plate Facing
Support screw for To support the motor
5 1 Nil Nil Nil 300 length, ⌀12 Mild steel
motor base base plate along with
6 Hinge 2 Used as stepper v-belt Nil Nil Welding 30 x 32 x 3 Mild steel
ROTATING SUBSYSTEM
Transmission of power
7 Motor pulley 1 to the 1st stage Nil Nil Nil ⌀60 Cast iron
reduction pulley
1st stage reduction Used to transmit power
8 1 Nil Nil Nil ⌀200 Cast iron
pulley to the crank
Rotating subsystem Support and easy
9 2 Nil Nil Nil ⌀25 Mild steel
support movement of spindle
Support the plumber Cutting
10 Bearing support 2 Nil Nil 75 x 40 x 63.5 Mild steel
block Welding
Rotating one end of the Rotary Rotary Facing ⌀180, 15
11 Crank 1 Mild steel
connecting rod motion motion Welding (thickness)
Bearing support Turning ⌀24, 210
12 1 Rotation for crank Nil Nil Mild steel
shaft Facing (length)
Support for blade Turning
13 Shaft either side 1 Nil Nil ⌀24, 40 (length) Mild steel
holder base Facing
Transmission of motion Rotary Linear Cutting
14 Connecting Rod 1 240 x 20 x 8 Mild steel
and power motion motion Grinding
CUTTING SUBSYSTEM
To support the
Guide Cutting
15 1 guideway and Nil Nil 590 x 100x 16 Mild steel
base Milling
correspondingly the
Blade holder base To support the blade Milling
16 2 Nil Nil 100 x 16 x 130 Mild steel
support holder Drilling
To support the guide
17 Reinforcement 1 Nil Nil Cutting 400 x 40 x 10 Mild steel
base
Box for holding Welding
18 1 To hold the guide way Nil Nil 200 x 140 x 30 Mild steel
guideway Grovving
To provide a way for Milling
19 Guideway 2 Nil Nil 200 x 26 x 16 Mild steel
the upper half to move Drilling
Cutting
20 U-frame 1 Hold the blade Nil Nil 350 x 150 x 15 Mild steel
Welding

Table 1. Bill of material

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2.2. Component Details
In this section, one can understand all the major subsystems and their related components
used in making the power hack saw. The manufacturing of the subsystems is further
divided into different groups that will be discussed here.

Figure 1. Power Hack-Saw

This is the whole assembled image of the power hack saw with all its components numbered
accordingly
There are mainly 3 subsystems implemented here:
• The 1st subsystem is the support for the whole machine which includes the components
such as the Base frame, base plates, motor base plates, hinges, support rods, and support
screws.

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 Figure 2. Support subsystem

• The 2nd subsystem is also called the rotating subsystem which contains all the rotating
components of the machine including the support shaft, reduction pulley, motor pulley,
crank, connecting rod, guideway support, etc.

Figure 3. Rotating subsystem

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 • The 3rd subsystem is called the cutting subsystem which includes all the support
components for holding and relative motion of the blade which will cut the material.
The components involved are Dovetail guideways, support path, Guideway supports,
blade holders, Vice, etc.

Figure 4. Cutting subsystem

The detailed components and related assemblies are shown below:

Support Sub-System:

Figure 5. Base Frame

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Figure 6. Motor Base Plate

Figure 7. Base Plate

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 Figure 8. Base Plate Rod

Figure 9 Support Screw for Motor Base

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 Figure 10. Hinge

Rotating Sub-System:

Figure 11. Motor Pulley

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Figure 12. First Stage Reduction Pulley

Figure 13. Rotating Sub-System Support

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Figure 14. Bearing Support

Figure 15. Crank

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Figure 16. Bearing Support Shaft for Crank

Figure 17. Support Shaft either side

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 Figure 18. Connecting Rod

Cutting Sub-System:

Figure 19. Guide Base

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Figure 20. Blade holder Base Support

Figure 21. Reinforcement

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Figure 22. Box of holding Guideway

Figure 23. Guideway

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Figure 24. Blade support (U-Frame)

Figure 25. Bush

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2.3. Operation Performed
In this section, the operations performed for all components issued to various
groups are described in detail:

Support Sub-System:
➢ Base Frame:
o Raw material used: Mild Steel: Chosen for its strength, ductility, and weldability. It is
often used in sheet or plate form.
o Raw Material Dimensions (square tubes): 50 mm x 50 mm x 2.5 mm
o Operations performed:
o Cutting operation: Saw Cutting: Bandsaws or circular saws can be used for the initial
cutting of raw material stock.
o Machining operation: Arc welding: It is a process used to join metals by using an
electric arc to melt the workpieces and the filler material, forming a strong joint upon
cooling.
o Finishing operation: Grinding: To smooth rough edges and achieve the desired surface
finish.
o Assembly operation- Alignment: Ensuring all components are properly aligned and
the frame meets the required specifications through welding and joining.

➢ Motor Base Plate:

o Raw material used: Mild Steel: Chosen for its strength, ductility, and weldability. It is
often used in sheet or plate form.
o Raw Material Dimensions: 200 mm x 148 mm x 5mm
o Marking is done as per the dimensions and required punches are used for the permanent
marking and indications for the places to be drilled.
o The slots were then done for proper motor placement with the help of slot milling with
a slot mill cutter.
o The holes were then drilled with the help of a vertical drilling machine.

➢ Base Plate Rod:

o Raw material used: Mild Steel: Chosen for its strength, ductility, and weldability. It is
often used in sheet or plate form.
o Raw Material Dimensions: 280 mm x Ø12 mm
o The marking is done per the required dimensions using the chalk.
o The cutting is done as per the markings using a circular saw.
o Required diameter is obtained by turning and finishing done by facing.

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➢ Base Plate:
o Raw material used: Mild Steel: Chosen for its strength, ductility, and weldability. It
is often used in sheet or plate form.
o Raw Material Dimensions: 300 mm x 225 mm x 10 mm
o Cutting:
o Marking: Mark the dimensions on the raw material using a marking gauge or
template.
o Cutting:
o Use a cutting method such as a bandsaw, waterjet cutter, laser cutter, or plasma
cutter to cut the material to the specified dimensions (300.00 mm x 225.40 mm).
o Machining:
o Surface Milling: If required, mill the surface to ensure it is flat and smooth.
o Edge Finishing: Use a milling machine or grinder to finish the edges and ensure
they are straight and smooth.
o Finishing Operations:
o Deburring: Remove any burrs or sharp edges from the cut and machined surfaces
using a deburring tool or file.
o Surface Finishing: Apply necessary surface treatments like polishing, grinding, or
sandblasting to achieve the required surface finish.

➢ Support Screw for Motor Base:

o Raw material used: Mild Steel: Chosen for its strength, ductility, and weldability. It is
often used in sheet or plate form.
o Raw Material Dimensions: 370 mm x Ø 12 mm.
o Machining Process:
o Setup:
o Secure the raw material in a lathe.
o Turning:
o Turn the rod down to Ø12.00 mm along its entire length (370.00 mm).
o Cutting to Length:
o Cut the rod to the exact length of 370.00 mm
o Finishing Operations:
o Deburring:
o Remove any burrs from the ends using a deburring tool or file.
o Surface Finishing:
o Apply necessary surface treatments to achieve the required finish.

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Rotating Sub-System:
➢ Connecting Rod:
o Raw material used: Mild Steel: Chosen for its strength, ductility, and weldability. It is
often used in sheet or plate form.
o Raw Material Dimensions: 240 mm x 20 mm x 8 mm
o Marking is done on the job according to the respective dimensions and then punching
is done using prick punch at small dimensions to ensure accuracy in dimensioning.
o Face milled with a feed of 0.5 mm to 1 mm using a face end mill cutter.
o The job is then inclined to an angle of 45 degrees and then cut according to the
dimensional depth using a face-end mill cutter.
o The relative surfaces are ground to ensure no extra material is there.
o Then two circles of diameter 10 mm are done using a Drilling machine, whose centers
are 200 mm apart.
o Then chamfering is done at the end of the rods having a radius of 10 mm using chamfer
milling.

➢ Crank:
o Raw material used: Mild Steel: Chosen for its strength, ductility, and weldability. It is
often used in sheet or plate form.
o Raw Material Dimensions: Ø 180 mm x 15 mm
o Machining Process:
o Setup:
o Secure the raw material in a lathe or CNC machine.
o Align and center the material properly to ensure accurate machining.
o Facing:
o Perform facing operations to create flat surfaces on both ends of the material.
o Turning:
o Turn down the diameter to the specified Ø80.00 mm.
o Turn the inner diameter to Ø24.00 mm.
o Finishing Operations:
o Deburring:
o Remove any burrs or sharp edges from the machined part.
o Surface Finishing:
o Apply necessary surface treatments like polishing, grinding, or sandblasting to
achieve the required surface finish.

➢ Support Shaft:
o Raw Material dimensions: 50 mm x Ø 25 mm
o Related operations performed:
o Marking is done on the job according to the respective dimensions and then punching
is done using prick punch at small dimensions to ensure accuracy in dimensioning.
o Facing was done with a feed of 0.5 mm to 1 mm using a lathe machine.

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 o The relative surfaces are ground to ensure no extra material is there.
o The diameter is also reduced to the required dimensions which is 24 mm.

Cutting Sub-System:
➢ Guide Base:
o Raw material used: Mild Steel: Chosen for its strength, ductility, and weldability. It is
often used in sheet or plate form.
o Raw Material Dimensions: 590 mm x 100 mm x 16 mm
o Related operations performed:
o Marking is done on the job according to the respective dimensions and then punching
is done using prick punch at small dimensions to ensure accuracy in dimensioning.
o Face milled with a feed of 0.5 mm to 1 mm using a face end mill cutter.
o The job is then inclined to an angle of 45 degrees and then cut according to the
dimensional depth using a face-end mill cutter.
o The relative surfaces are ground to ensure no extra material is there.

➢ Blade Holder Base Support:

o Raw material used: Mild Steel: Chosen for its strength, ductility, and weldability. It is
often used in sheet or plate form.
o Raw Material Dimensions: 140 mm x 100 mm x 16 mm
o Related operations performed:
o Initially marking is done on the job according to the respective dimensions and then
punching is done using prick punch at small dimensions to ensure accuracy in
dimensioning.
o Face milled with a feed of 0.5 mm to 1 mm using a face end mill cutter.
o Then 30 mm is drilled with its center at 100 mm from the base and 50 mm from the
side and then boring of 2 mm is done to give its final dimension.
o The relative surfaces are ground to ensure no extra material is there.

➢ Guideway:
o Raw material used: Mild Steel: Chosen for its strength, ductility, and weldability. It is
often used in sheet or plate form.
o Raw Material Dimensions: 200 mm x 26 mm x 16 mm
o Related operations performed:
o Marking is done on the job according to the respective dimensions and then punching
is done using prick punch at small dimensions to ensure accuracy in dimensioning.
o Face milled with a feed of 0.5 mm to 1 mm using face end mill cutter.
o The job is then inclined to an angle of 45 degrees and then being cut according to the
dimensional depth using a face-end mill cutter.

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➢ U-Frame:
o Raw material used: Mild Steel: Chosen for its strength, ductility, and weldability. It is
often used in sheet or plate form.
o Raw Material Dimensions: 450 mm x 50 mm x 5 mm
o Cutting:
o Use a bandsaw or laser cutter to cut the material to the required initial dimensions (450
mm x 50 mm x 5 mm).
o Bending:
o Bend the material to form the U-shape with inner radii of R50.00 mm, ensuring the
specified dimensions (160 mm and 150 mm) for the legs and top of the U-shape are
achieved.
o Drilling:
o Drill the holes as per the specified dimensions:
o Four Ø10 mm holes on the top horizontal section, spaced 100 mm apart.
o Two Ø5 mm holes on each vertical leg, spaced 12.5 mm and 25 mm from the ends.
o Slotting:
o Create slots at the ends of the vertical legs with dimensions 12 mm x 5 mm, positioned
5 mm from the bottom edge.
o Deburring:
o Deburr all edges and holes to remove sharp edges and ensure a smooth finish.
o Inspection:
o Inspect the part to ensure all dimensions, hole sizes, and slot dimensions conform to the
drawing specifications.
o Finishing:
o Apply any required surface finish (e.g., painting, powder coating) if specified in the
design requirements.

➢ Box for holding Guideway:

o Raw material used: Mild Steel: Chosen for its strength, ductility, and weldability. It is
often used in sheet or plate form.
o Raw Material Dimensions: 200 mm x 70 mm x 40 mm
o Milling:
o Use a milling machine to create the central slot that is 10 mm wide, 16 mm deep, and
200 mm long.
o Mill the two side slots, each 10 mm wide and 14 mm deep, with a length of 40 mm.
o Machining Details:
o Machine the material to achieve the required profile dimensions:
o 30 mm wide base
o 2 mm thick sides (vertical walls) on either side of the central slot
o 16 mm deep central slot with 10 mm wide walls on either side
o Finishing:
o Apply any required surface finish (e.g., painting, powder coating) if specified in the
design requirements.
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➢ CNC Programs for Blade Holder Base Support and Rotating Sub-system Support:
o Refer to Fig. 13 and 20

O0001 G01 Z-3.6 F300

G40G54G80 M98 P1111
G21 G94 G01 Z-4.0 F300
G91 G28 Z0.0 X0.0 Y0.0 M98 P1111
M06 T01 G01 Z-4.4 F300
M03 S1500 M98 P1111
G90 G41 X0.0 Y100 G01 Z-4.8 F300
G01 Z0.2 F300 M98 P1111
M98 P1111 G01 Z-5.2 F300
G01 Z0.2 F300 M98 P1111
M98 P1111 G01 Z-5.6 F300
G01 Z-0.4 F300 M98 P1111
M98 P1111 G01 Z-6.0 F300
G01 Z-0.8 F300 M98 P1111
M98 P1111 G01 Z-6.4 F300
G01 Z-1.2 F300 M98 P1111
M98 P1111 G01 Z-6.8 F300
G01 Z-1.6 F300 M98 P1111
M98 P1111 G01 Z-7.2 F300
G01 Z-2.0 F300 M98 P1111
M98 P1111 G01 Z-7.6 F300
G01 Z-2.4 F300 M98 P1111
M98 P1111 G01 Z-8.0 F300
G01 Z-2.8 F300 M98 P1111
M98 P1111 G01 Z-8.4 F300
G01 Z-3.2 F300 M98 P1111
M98 P1111 G01 Z-8.8 F300

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M98 P1111 G01 Z-14.4 F300
G01 Z-9.2 F300 M98 P1111
M98 P1111 G01 Z-14.8 F300
G01 Z-9.6 F300 M98 P1111
M98 P1111 G01 Z-15.2 F300
G01 Z-10.0 F300 M98 P1111
M98 P1111 G01 Z-15.6 F300
G01 Z-10.4 F300 M98 P1111
M98 P1111 G01 Z-16.0 F300
G01 Z-10.8 F300
M98 P1111 G00 Z50.0
G01 Z-11.2F300 G40 M03
M98 P1111 G91 G28 X0.0 Y0.0 Z0.0
G01 Z-11.6 F300 M06 T03
M98 P1111 M03 S800
G01 Z-12.0 F300 G90 X50.0 Y100.0 Z5.0
M98 P1111 G83 Z-16.0 Q1.0 R0.5 F150
G01 Z-12.4 F300 G80 G00 Z10.0
M98 P1111 G91 G28 Z0.0 X0.0 Y0.0
G01 Z-12.8 F300
M98 P1111 0111 (Subprogram number)
G01 Z-13.2 F300 G02 X100.0 Y100.0 R50.0
M98 P1111 G01 X100.0 Y200.0
G01 Z-13.6 F300 G01 X0.0 Y0.0
M98 P1111 G01 X0.0 Y100.0
G01 Z-14.0 F300 G00 Z5.0
M98 P1111 M99

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➢ Process Planning

Figure 26. Flowchart for process planning

3. Results and Discussion

Part: Base frame
From the original dimension the of raw material of 100 x 16 x 130mm it has been converted to
the required dimension with various machining processes.

Fig 3.1 (a): Original Design Fig 3.1 (b): Final product

Part: Motor base plate

From the original dimension the of raw material of 200 x 148 x 5 mm it has been converted to
the required dimension with various machining processes.

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 Fig 3.2 (a): Original Design Fig 3.2(b): Final product

Part: Base plate rod

The original dimension the of raw material of 280 length, ⌀12 mm it has been converted to the
required dimension with various machining processes.

Fig 3 3 (a): Original Design Fig 3.3 (b): Final product

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Part: Support screw for motor base
From the original dimension the of raw material of 400 mm x 20 mm it has been converted to
the required dimension with various machining processes.

Fig 3.4 (a): Original Design Fig 3.4 (b): Final product

Part: Motor pulley

From the original dimension the of raw material of ⌀60 mm it has been converted to the
required dimension with various machining processes.

Fig 3.5 (a): Original Design Fig 3.5 (b): Final product

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Part: 1st stage reduction pulley
From the original dimension the of raw material of ⌀200 mm it has been converted to the
required dimension with various machining processes.

Fig 3.6 (a): Original Design Fig 3.6 (b): Final product

Part: Rotating subsystem support

From the original dimension the of raw material of ⌀25 mm it has been converted to the
required dimension with various machining processes

Fig 3.7 (a): Original Design Fig 3.7 (b): Final product

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Part: Crank
From the original dimension the of raw material of ⌀180, 15 (thickness) mm it has been
converted to the required dimension with various machining processes

Fig 3.8 (a): Original Design Fig 3.8 (b) : Final product

Part: Support shaft for crank

From the original dimension the of raw material of ⌀24, 210 (length) mm it has been converted
to the required dimension with various machining processes

Fig 3.9 (a): Original Design Fig 3.9 (b): Final product

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Part: Shaft either side
From the original dimension the of raw material of ⌀24, 40 (length) mm it has been converted
to the required dimension with various machining processes.

Fig 3.10 (a): Original Design Fig 3.10 (b): Final product

Part: Blade holder base support

From the original dimension the raw material of 100 x 16 x 130 mm has been converted to the
required dimension with various machining processes.

Fig 3.11 (a): Original Design Fig 3.11 (b): Final product

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Part: Guide base
From the original dimension the of raw material of 590mm x 100 mm x 16 mm it has been
converted to the required dimension with various machining processes.

Fig 3.12 (a): Original Design Fig 3.12 (b): Final product

Part: Blade holder base support

From the original dimension the of raw material of 200 x 140 x 30 mm it has been converted
to the required dimension with various machining processes

Fig 3.13 (a): Original Design Fig 3.13 (b): Final product

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Part: Guideway
From the original dimension the of raw material of 200 x 26 x 16 mm it has been converted to
the required dimension with various machining processes

Fig 3.14 (a): Original Design Fig 3.14 (b) : Final product

Part: Connecting Rod

From the original dimension the of raw material of 240 mm x 20 mm x 8 mm it has been
converted to the required dimension with various machining processes.

Fig 3.15 (a): Original Design Fig 3.15 (b): Final product

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Part: Bearing Support
From the original dimension the of raw material of 240 x 20 x 8 mm it has been converted to
the required dimension with various machining processes

Fig 3.16 (a): Original Design Fig 3.16 (b): Final product

Part: U-frame
From the original dimension the of raw material of 350 x 150 x 15 mm it has been converted
to the required dimension with various machining processes.

Fig 3.17 (a): Original Design Fig 3.17 (b): Final product

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➢ Brief Overview of the whole Assembly:

Fig 3.18 (a): Original Design Fig 3.18 (b): Final product

Assembling a power hack saw involves several steps, ensuring that each component is correctly
installed for safe and efficient operation. Here’s a brief discussion of the main steps and
considerations involved in the assembly process:

➢ Unpacking and Inventory

• Unpack all components: Ensure all parts are included as per the manufacturer’s
instruction manual.
• Inventory check: Verify that all parts and hardware are present and in good condition.

➢ Frame Assembly

• Main frame setup: Assemble the base frame first, securing it on a stable surface. The
frame typically includes legs or a stand to support the machine.
• Mount the motor: Attach the motor to the designated section of the frame. Ensure it is
securely bolted and aligned properly.

➢ Blade Arm Installation

• Install the blade arm: Connect the blade arm to the pivot point on the frame. This arm
will hold the saw blade and allow it to move up and down.
• Tension adjustment: Ensure the blade tension mechanism is correctly installed to
allow proper adjustment of the saw blade.

➢ Blade Installation

• Attach the blade: Install the hack saw blade onto the blade arm, securing it with the
appropriate fasteners. Ensure the blade is oriented correctly (teeth facing the correct
direction).
• Adjust tension: Use the tensioning mechanism to adjust the blade tension as per the
manufacturer's recommendations.
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➢ 5. Drive Mechanism

• Connect the drive mechanism: Depending on the design, this may involve installing
belts, pulleys, or direct drive connections between the motor and the blade arm.
• Check alignment: Ensure all drive components are aligned properly to avoid
unnecessary wear and tear or operational issues.

➢ 6. Safety Features

• Install safety guards: Attach all safety guards around the blade and moving parts to
prevent accidental contact.
• Check safety switches: Ensure any safety switches or emergency stop mechanisms are
properly installed and functioning.

➢ 7. Testing and Adjustments

• Power on and test: Once assembly is complete, turn on the power hack saw to test its
operation.
• Make adjustments: Fine-tune the blade tension, alignment, and any other adjustable
components to ensure smooth and accurate cutting.

➢ 8. Maintenance Checks

• Lubrication: Lubricate moving parts as needed, following the manufacturer's

guidelines.
• Regular inspection: Periodically check for loose fasteners, wear on the blade, and the
condition of the drive mechanism.

➢ Safety Considerations

• Read the manual: Always follow the manufacturer's assembly instructions and safety
guidelines.
• Wear protective gear: Use appropriate personal protective equipment (PPE) such as
gloves and safety glasses during assembly and operation.
• Disconnect power: Ensure the power source is disconnected while assembling and
making adjustments to avoid accidental startups.

4. Calculations
Let
N1= rpm of the driver pulley
N2= rpm of the driven pulley
D1= diameter of the driver pulley
D2= diameter of the driven pulley

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Motor power rating = 0.5 HP, Max Rpm = 1420
Motor – pulley – 60 mm => D1
Driver – 200 mm => D2
Mild steel: (assuming negligible thickness)
D1/D2= 60/200 = 0.3 = N2/N1
So, if N1 = 700 (let's say)
Then N2 = 0.3x700
N2 = 210 rpm

For mild steel, the cutting speed is 30 m/min

Converting it to rpm
V = PiD1N/1000
So, N2 = Vx1000/PixD1
Hence, N2 = 160 rpm (approx.)
Hence N1 = N2/0.3
N1 = 534 rpm (approx.)

Hence it is known that the pully diameter ratio must be between 0.2 to 0.3.

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5. Conclusion
The detailed analysis of the power hacksaw machine, broken down into its three primary
subsystems—support, rotating, and cutting—reveals the critical importance of each component
in ensuring the machine's overall functionality and efficiency.

1. Support Subsystem: This subsystem provides the necessary stability and foundation for
the entire machine. Its components must be robust and precisely aligned to prevent
vibrations and misalignments that could compromise cutting accuracy.
2. Rotating Subsystem: Responsible for driving the cutting motion, the rotating subsystem
must operate smoothly and efficiently. Proper maintenance and alignment of its
components are crucial for consistent power transmission and blade motion.
3. Cutting Subsystem: This subsystem ensures the precision of the cutting action. High-
quality materials and meticulous assembly are essential to maintain the alignment and
stability of the blade and workpiece, resulting in accurate and efficient cuts.

For optimal performance, each subsystem must be meticulously designed, assembled, and
maintained. Key recommendations include using high-quality materials, implementing regular
maintenance schedules, ensuring precise assembly, and providing thorough operator training.
By addressing these areas, the power hacksaw machine can achieve enhanced durability,
efficiency, and cutting precision, ultimately leading to improved productivity and operational
safety.

The successful completion of the power hack saw project demonstrates the importance of
thorough preparation, adherence to guidelines, and meticulous execution. Looking forward:

1. Continuous Improvement: Regular feedback and performance reviews will help

identify areas for improvement and ensure the saw remains in top condition.
2. Skill Development: Continued training and skill enhancement for operators will
maximize the effectiveness and safety of the saw.
3. Innovation: Exploring potential upgrades or modifications can enhance the
capabilities of the saw, adapting it to future needs and projects.

In conclusion, this project not only equips the workshop with a valuable tool but also
reinforces the commitment to quality, safety, and continuous improvement in all endeavours.

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6. Student Outcome:

Students will be able to

CO1 Analyse real-time problems and provide sustainable solutions
while protecting the environment.
CO2 Evaluate and select the right kind of manufacturing and
assembly processes for all intended applications.
Course Outcomes CO3 Design, model, analyse, and manufacture well defined
components for a product suitable for the intended application
following engineering specifications and standards.
CO4 Select the cutting condition in a machining operation.
CO5 Communicate effectively to a group of peers the technical
aspects of part manufacturing and work in a team.
CO6 Imbibe the practice of professional ethics used for lifelong
learning.

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7. References
• Groover's Principles of Modern Manufacturing SI Version, Wiley India Edition by Mikell
P. Groover
• Stephen, T., Gloria, D.O., Diabi, O.W. and Victor, A., 2015. Technical study on the design
and construction of a pedal-powered hacksaw cutting machine. IOSR Journal of
Mechanical and Civil Engineering, 12(4), pp.48-52.
• Al-Bahkali, E.A. and Abbas, A.T., 2018. Failure analysis of vise jaw holders for hacksaw
machine. Journal of King Saud University-Engineering Sciences, 30(1), pp.68-77.
• Thompson, P.J., 1974. A theoretical study of the cutting action of power hacksaw blades.
International Journal of Machine Tool Design and Research, 14(2), pp.199-209.
• Lipcha, B., Kadam, A., Gadakh, S., Yadav, A. and Pathan, F.U., 2016, March. Rectification
of power hacksaw machine. In International Conference on Emerging Trends in
Engineering and Management Research.
• Anand, R., Gupta, Y. and Desai, J., 2021, May. Design and analysis of portable power
hacksaw with coolant and lubrication system. In AIP Conference Proceedings (Vol. 2341,
No. 1). AIP Publishing.
• Maini, A.K., Vaz, A. and Dauphin-Tanguy, G., 2022. Dynamics of a power hacksaw
mechanism, contact interaction with the workpiece, and material removal. International
Journal of Modelling and Simulation, 42(1), pp.117-142.

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