PEDAL OPERATED HACKSAW

ABSTRACT

In this Pedal operated hacksaw machine which can be used for industrial applicati
ons and Household needs in which no specific input energy or power is needed. This proje
ct consists of a crank and slider mechanism. In the mechanism pedal is directly connected
to the hacksaw through crank and slider mechanism for the processing of cutting the wood
en blocks, metal bars, pvc materials. The objective of the modal is using the conventional
mechanical process which plays a vital role. The main aim is to reduce the human effort f
or machining various materials such as wooden blocks, steel, PVC etc.

The power hacksaw machine, which runs on human power, works on the principle
of the conversion of rotational motion to oscillatory motion.

Importance of this project lies in the very fact that it is green project and helps us t
o reduce our electricity need. Secondly, this cutter can be used and transferred to our work
ing place easily. Moreover, if we want we can generate electricity with our project by con
necting it to dynamo, diode and battery.

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1. INTRODUCTION

Pedal power is the transfer of energy from a human source through the use of a foot pe
dal and crank system. This technology is most commonly used for transportation and has
been used to propel bicycles for over a hundred years. Less commonly pedal power is use
d to power agricultural and hand tools and even to generate electricity. Some applications
include pedal powered laptops, pedal powered grinders and pedal powered water wells. S
ome third world development projects currently transform used bicycles into pedal power
ed tools for sustainable development. This project concentrates on pedal powered hacksa
w machining. An individual can generate four times more power (1/4 HP) by pedaling tha
n by hand-cranking. At the rate of ¼ HP, continuous pedaling can be served for only short
periods, approximately 10 minutes. However, pedaling at half this power (1/8 HP) can be
sustained for close to 60 minutes but power capability can depend upon age . As a conseq
uence of the brainstorming exercise, it was apparent that the primary function of pedal po
wer one specific product was particularly useful: the bicycle. Many devices can be run rig
ht away with mechanical energy. A saw is a tool that uses a hard blade or wire with an abr
asive edge to cut through softer materials. The cutting edge of a saw is either a serrated bl
ade 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 serra
ted blade.

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2. LITERATURE REVIEW
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 i
nput energy or power is needed. This project consists of a sprocket arrangement, th
e crank and slider mechanism, the chain drive. In the mechanism, chain drive is dir
ectly connected to the hacksaw for the processing of cutting the wooden blocks. T
he objective of the paper is using the conventional mechanical process which plays
a vital role. The main aim is to reduce the human effort for machining various mat
erials such as wooden blocks, steel, PVC etc.

Girish T. , Parameswaramurthy D., (2014):-

In this paper author has designed to development of conceptual model of w
ater pumping and battery charging cross trainer which is user friendly, easy to do e
xercise, save & stores the energy of the users muscle efforts. When the human ope
rates the lever and the pedal, the Centrifugal Pump is actuated and the water is pu
mped 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 el
ectrical energy, the generated electrical energy is stored in battery with the help of
wires. The stored electrical energy is used when we are needed.

Umesh Bokade, Zakiuddin Syed Kazi and Girish D Mehta, (2013):-

The author proposed the designed model which will convert the dirty/salin
e water into pure/ potable water using the renewable source of energy (i.e., Human
power). The machine consists of a human-powered flywheel motor using a bicycl
e-drive mechanism with speed-increasing gearing and a flywheel, which drive the
process unit though a spiral jaw clutch and torque increasing gearing. The operator
puts energy into the flywheel at a convenient power level for about one minute. A
fter enough energy is stored, pedaling is stopped and the energy in the flywheel is
made available to the process unit. International Journal of Emerging Trends in En
gineering and Development Issue 5, Vol. 3 (April.-May. 2015) Available online o

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n http://www.rspublication.com/ijeted/ijeted_index.htm ISSN 2249-6149 R S. Pub

lication (rspublication.com), [email protected] Page 227

S.G.Bahaley, Dr. A.U. Awate, S.V. Saharkar,(2012):-

In this paper the auther designed and fabricated a pedal powered multipurp
ose machine. It is a human powered machine which is developed for lifting the wat
er to a height 10 meter and generates 14 Volt, 4 ampere of electricity in most effec
tive way. Power required for pedaling is well below the capacity of an average hea
lthy human being. The system is also useful for the work out purpose because ped
aling will act as a health exercise and also doing a useful work.
David Gordon Wilson, (1986):-
According to the author, a person can generate four timer more power (1/4
horsepower (hp)) by pedaling than by hand-cranking. At the rate of1/4hp, continu
ous pedaling is for can done only short periods, about 10 minutes. However, pedali
ng at half this power (1/8 hp) can be sustained for around 60 minutes. Pedal power
enables a person to drive devices at the same rate as that achieved by hand-cranki
ng, but with far less effort and fatigue. Pedal power also lets one drive devices at a
faster rate than before (e.g. winnower), or operate devices that require too much po
wer for hand-cranking (e.g. thresher). The main use of pedal power today is still fo
r bicycling, least in the high-power at range (75 watts and above of mechanical po
wer). In the lower-power range there are a number of uses of pedal power-for agric
ulture, construction, water pumping, and electrical generation-that seem to be pote
ntially advantageous, at least when electrical or internal-combustion engine power
is unavailable or very expensive.

Design and fabrication of pedal operated hacksaw:-

The pedal powered hacksaw machine is a device which is used for cutting
wood, plastic and metals. This works on the principle of slider crank mechanism w
hich is inversion of four bar mechanism. In this rotary motion is converted into rec
iprocating motion. It was verified by cutting metal pipes, plastic in the hacksaw by
pedalling action. It was convenient, easier and more eco-friendly.

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3. COMPONENT REQUIRED :-

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3.1. Hack saw blade

3.2. Pedal arrangement

3.3. Stand setup parts

3.4. Crank and slider mechanism

3.5. Hack saw assembly

3.6. Metal slab

3.1. PEDAL POWER HACKSAW :-

The principle of pedal power hacksaw is to change circulatory motion or cycling

motion into translatory motion with the help of metal cutting rod. This is mainly used for
cutting metals and plastics. it is manually pedal operated system.

If we use dynamo then we can produce electricity which will be help to lighting th
e work piece area when electricity is not available in mechanical workshop. A hacksaw is
a fine-tooth saw with a blade under tension in a frame, used for cutting materials such as
metal or plastics.

Hand-held hacksaw consist of a metal arch with a handle, usually a pistol grip, wit
h pins for attaching a narrow disposable blade. A screw or other mechanism is used to use
d to put the thin blade under tension.

It is a fine tooth hand saw with a blade under tension. It is used to cut metals and P
VC pipes. It would be useful in many projects discussed on this site which used plastic pi
pes as materials.

Blades of hacksaw are measured in TPI (Tooth Per Inch). Different TPI is needed f
or different jobs of cutting.

There are three types of cutters available in the market:-

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1. Simple hacksaw which can be used for hand cutting things.

2. Small Electrically Hacksaw for personal uses.
3. Large Cutter Machines used for Industrial Purposes.
From the above three, first one will be used for our project

A RECIPROCATING POWER HACKSAW:-

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It uses a blade that moves back and forth across the work. The blade cuts on the ba
ckstroke. There are several types of feeds available.

Positive feed-produces an exact depth of cut on each stroke. The pressure on the blade
varies with the number of teeth in contact with the work. Definite pressure feed-yields a press
ure on the blade that is uniform regardless of the number of teeth in contact with the work. Th
e depth of the cut varies with the number of teeth contacting the work. This condition prevails
with gravity feed. Feed can be adjusted to meet varying conditions. For best performance, the
blade and feed must be selected to permit high-speed cutting and heavy feed pressure with mi
nimum blade bending and breakage. Standard reciprocating metal cutting saws are available i
n sizes from 6~ ~ 6~ (150 mm ~ 150 mm) to 24~ ~ 24~ (900 mm ~ 900 mm). The saws can b
e fitted with many accessories, including quick-acting vises, power stock feed, power clampin
g of work, and automatic cycling of the cutting operation. The latter moves the work out the r
equired distance, clamps it, and makes the cut automatically. The cycle is repeated upon comp
letion of the cut. High-speed cutting requires use of a coolant. Coolant reduces friction, increa
ses blade life, and prevents chip-clogged teeth. Cast iron and some brass alloys, unlike most
materials, do not require coolant.

3.1.1. Selecting A Power Hacksaw blade

Proper blade selection is important. Use the three-tooth rule at least three teeth mu
st be in con-tact with the work. Large sections and soft materials require a coarse-tooth bl
ade. Small or thin work and hard materials require a fine-tooth blade. For best cutting acti
on, apply heavy feed pressure on hard materials and large work. Use light feed pressure o
n soft materials and work with small cross sections. Blades are made in two principal type
s: flexible-back and all-hard. The choice depends upon use.

i) Flexible-back blades -should be used where safety requirements demand a shatterproo

f blade. These blades should also be used for cutting odd-shaped work if there is a possibil
ity of the work coming loose in the vise.

ii) All-hard blade -For a majority of cutting jobs, the all-hard blade is best for straight, ac
curate cutting under a variety of conditions.

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When starting a cut with an all-hard blade, be sure the blade does not drop on the work wh
en cutting starts. If it falls, the blade could shatter and flying pieces cause injuries.

Blades are also made from tungsten and molybdenum steels, and with tungsten car
bide teeth on steel alloy backs. The following “rule-of-thumb” can be followed for selectin
g the correct blade: Use a 4-tooth blade for cutting large sections or readily machined met
als. Use a 6-tooth blade for cutting harder alloys and miscellaneous cutting. Use 10- and 1
4-tooth blades primarily on light duty machines where work is limited to small sections re
quiring moderate or light feed pressure.

3.1.2. Mounting a Power Hacksaw blade

The blade must be mounted to cut on the power (back) stroke. The blade must also
lie perfectly flat against the mounting plates. If long life and accurate cuts are to be achie
ved, the blade must be properly tensioned Many techniques have been developed for prop
erly mounting and tensioning blades. Use a torque wrench and consult the manufacturer’s
literature. If the information (proper torque for a given blade on a given machine) is not av
ailable, the following methods can be used: Tighten the blade until a low musical ring is h
eard when the blade is tapped lightly. A high-pitched tone indicates that the blade is too ti
ght. A dull thud means the blade is too loose. The shape of the blade pin hole can serve as
an indicator of whether the blade is tensioned properly. When proper tension is achieved, t

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he pin holes will become slightly elongated, The blade will become more firmly seated aft
er the first few cuts and will stretch slightly. The blade will require retensioning(retighteni
ng) before further cutting can be done.

3.1.3. Selecting a Band Saw Blade

Band saw blades are made with raker teeth or wavy teeth. Most manufacturers also
make variations of these sets. The rakersetis preferred for general use. Tooth pattern deter
mines the efficiency of a blade in various materials. The standard tooth blade pattern is be
st suited for cutting most ferrous metals. A skip tooth blade pattern is preferred for cutting
aluminum, magnesium, copper, and soft brasses. The hooktooth blade pattern also is reco
mmended for most nonferrous metallic materials. For best results, consult the blade manuf
acturer’s chart or manual for the proper blade characteristics (set, pattern, and number of t
eeth per inch) for the particular material being cut.

3.1.4. Installing a Band Saw Blade

If the saw is to work at top efficiency, the blade must be installed carefully. Wear
heavy leather gloves to protect your hands when installing a band saw blade. Blade guides
should be adjusted to provide adequate support, Proper blade support is required to cut tr
ue and square with the holding device. Follow the manufacturer’s instructions for adjustin
g blade tension. Improper blade tension ruins blades and can cause premature failure of be
arings in the drive and idler wheels. Cutting problems encountered with the band saw are
similar to those of the reciprocating hack saw. Most problems are caused by poor machine
condition. They can be kept to a minimum if a maintenance program is followed on a reg
ular basis. This typically includes checking wheel alignment, guide alignment, feed pressu
re, and hydraulic systems.

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3.2. PEDAL ARRANGEMENT

A pair of pedals is attached to the stand setup in which the power will be generated
manually. A typical Bicycle arrangement is used.

3.2.1. PEDAL

A bicycle shoe crank bottom bracket bicycle pedal is the part of a that the rider pus
hes with their foot to propel the bicycle. It provides the connection between the cyclist’s f
oot or and the allowing the leg to turn the spindle and propel the bicycle's wheels.

Pedals were initially attached to cranks connecting directly to the driven (usually f
ront) wheel. The safety bicycle, as it is known today, came into being when the pedals wer
e attached to a crank driving a sprocket roller chain. that transmitted power to the driven
wheel by means of a

Pedals usually consist of a spindle bearings that threads into the end of the crank a
nd a body, on which the foot rests or is attached, that is free to rotate on with respect to th
e spindle.

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3.3. STAND SETUP PARTS

Stands are introduced to immobilize the apparatus. Various components used are fi
xed to this arrangement. The chassis of the bicycle is used as the stand setup parts . The st
and described here is designed to support most bicycles.

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1. The stand assembly is divided into two parts: the rectangular base frame and two triang
ular upright supports. Measure and cut the five pieces of 3/4" (20mm) angle specified for t
he base frame. Mitre the corners at 45 degrees so they fit together tightly and form square
corners.

2. Weld the rectangle together. Do not weld the center frame member to the rectangle yet.

3. Measure and cut as specified the 5 pieces for each upright support.

4. Carefully assemble the upright support pieces for welding, being sure to leave a 1/8" (3.
2mm) gap in the base of each support. This gap will mate with the center frame member o
f the base frame, allowing the upright supports to slide to accommodate different rear axle
widths. Note that the two upright supports are not identical. They are mirror reflections of
one another. Weld each upright support assembly together into a secure structure.

5. Place the upright supports onto the base frame, and position the center frame member s
o that it mates with the gap in the side supports. Mark its position, and weld it in place.

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3.4. CRANK AND SLIDER MECHANISM This mechanism is used to convert the rotar
y motion of the crank into the reciprocating motion of hacksaw. The lengths of the crank a
nd connecting rods are made using trial and error method.

The hack saw is guided by an aluminum plate. The vertical movement of the hacks
aw will be guided by to iron rods. The vertical movement will act as a feeding unit.

3.5. METAL SLAB He used a guide to control the hacksaw blade which is used to cut t
he metal. Metal slabs were fitted on the hacksaw blade to ensure pressure on the object to

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be cut and linear movement of the blade. A clamp, with 360 degree rotation, was fixed to
hold the metal pieces while cutting, and to allow them to be cut in any shape and angle.

4. WORKING PRINCIPLE

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

4.1.Bicycle Model
Proper and comfortable seating arrangement must be design so it will produce less
operating Fatigue. Seat high is selected according to ergonomics principles and using ant
hropometric data. Other dimensions of frame should be selected by considering same effe
ct. Handles should be there for proper pulling force or griping purpose. Simple pipes can
be welded together to form a frame with seating and stand arrangement.

4.2. Connecting rod

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It is a simple rod which connect the crank that is pedal shaft and hacksaw blade. T
he connection mechanism shown in fig. one end of rod is connected to pedal by using any
scrap round part for exa-bearing recess. Hacksaw blade is connected by welding to other
end of rod.

4.3.Hacksaw
A hacksaw is a fine tooth saw with a blade under tension in a frame, used for cutti
ng materials such as metal or plastics. Hand-held hacksaw consist of a metal arch with a
handle,

4.4. V block
V blocks are precisions metal working jigs typically used to hold round metal rods
or pipes for performing drilling or milling operations. They consist of a rectangular steel
or cast iron block with a 90 degree channel rotated 45 degree sides, forming a v shaped ch
annel in the top. A small groove is a cut in the bottom of the “V”. they often come with sc
rew clamps to hold the work. There are also versions with internal magnets for magnetic
work holding. V-blocks are usually sold in pairs.

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4.5.Guide to Hacksaw
Hacksaw is guided by guide mechanism. One simple plate can be guided the hacks
aw blade.

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5. DESIGN

5.1. BASE FRAME

Plan view of frame in support position. All pieces 3/4" (19mm) steel angle.

5.2. UPRIGHT SUPPORTS

Make two pieces of upright supports: one as shown and another one a reflection o
f the one shown below. All pieces are made of 3/4" (19mm) steel angle, unless specified o
therwise. Weld all joints.

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5.3. HACKSAW BLADE

LENGTH=15 inch=36 cm WIDTH=1 inch

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5.4. DESIGN CONSIDERATIONS

When designing our attachment, 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 ba
sic 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 impl

ements and for small machines used in rural industry.

6. It should employ locally available materials and skills. Standard steel pieces such as ste
el plates, iron rods, angle iron, and flat stock that are locally available should be used. Sta
ndard tools used in machine shop such as hack saw, files, punches, taps & dies; medium d
uty welder; drill press; small lathe and milling machine should be adequate to fabricate th
e parts needed for the dual-purpose bicycle.

7. It should make use of standard bicycle parts wherever possible.

8. The device should adapt easily to as many different bicycles as possible. No permanent
structural modification should be made to the bicycle.

9. Though the device should be easy to take off the bicycle, it is assumed that it would usu
ally remain attached to facilitate readiness and ease of transport from site to site. The devi
ce, therefore, should not interfere with the bicycle's transportation mode.

10. The broad stand, which provides stability during power production mode, can be flipp
ed upward during the transport mode. This stand/carrier would be a permanent fixture of t
he dual-purpose bicycle.

11. The power take-off mechanism should be as efficient as possible, and should develop
relatively high r.p.m. (close to 200) for versatility of application. We had seen designs for

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devices that take power from the rear tire by means of a friction roller pressed against it, b
ut we had doubts about the efficiency of this arrangement. In order to improve efficiency
we used hard bearing surfaces such as roller chains, sprockets and ball bearings. We decid
ed that the most appropriate location for this power take-off mechanism would be at the fr
ont of the bike near the fork tube (see photographs).

12. Care must be exercised to insure that the power take-off assembly is far enough forwa
rd so as not to interfere with pedaling. Most standard adult bicycle frames have plenty of r
oom for the power take-off mechanism and pulley. Power is supplied to the shaft by mean
s of a chain from the bike's chain wheel (crank) to a ratcheted sprocket on the shaft. Durin
g the prime-mover mode, the bike's regular chain is slipped off of the chain-wheel, and th
e specially sized chain to the power take-off mechanism is slipped on.

13. The device should be able to transmit power to a variety of machines, and changing dr
ive ratios should be as simple as possible. We decided that a V-belt and pulley arrangeme
nt would be most appropriate for this. Belts do not require the precise alignment that chain
s do. Belts can even accommodate pulleys that are slightly skewed with respect to each ot
her. Changing drive ratios is as easy as changing pulleys. Also, belts are reasonably efficie
nt.

14. The device should contain a ratcheting mechanism that would let the operator "coast "
periodically to rest and conserve energy. A free wheel from any bicycle can be easily adap
ted for this purpose.

15. Excessive weight should be avoided, as durability is a prime consideration.

6. ADVANTAGES AND DISADVANTAGES

ADVANTAGES

 Time saving as compared to simple hacksaw.

 Power saving as it is manually operated.

 Easy machinery used.

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 As it is pedal operated so good for health.

 Comfortable then ordinary hacksaw.

 It is portable.

 VII. It could be used wherever metal cutting is done in small scales, including at
construction sites and furniture units, or to cut metal for window panes.

DISADVANTAGES

 Its totally manually operated.

 Time consuming as compared to electrical power hacksaw.

 Without human effort its not operated.

 Not fit for heavy production.

7. TOTAL COST

SR.NO. NAME OF C PIECES PRICE/PIEC TOTAL

OMPONENT E

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1 Pedal 2
2 Stand 1
3 Base frame 1
4 Crank& Slider 1
mechanism

5 Clamp 2
6 Hacksaw 1
7 Nut & Bolt 7
8 Welding cost -
TOTAL

8. CONCLUSION

Thus a low cost and simple design pedal operated hacksaw machine is fabricated.
This machine reduces the human effort and hence we don’t need two persons to cut the w
ooden logs. This simple design of conventional design which can enhance day today hous
ehold needs and daily day to day purposes and it can be also used in for industrial applicat

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ions during power shut down scenarios. By using this method we can do any operation as
per our requirement without the use of electricity. so we can save the electrical power.

9. REFERENCES

[1] David Gordon Wilson “UNDERSTANDING PEDAL POWER” ISBN: 0-86619-268-

9 [C] 1986, Volunteers in Technical Assistance” Technical paper 51 VITA 1600 Wilson
Boulevard USA.

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[2] EJ Yerxa Taylor & Francis “Occupational science: A new source of power for partici
pants in occupational therapy‟- Journal of Occupational Science ISSN 1442-7591 Volume
: 13, Issue: 1, April 1993 pp254-259.
[3] Jon Leary “Putting Research into Practice: From a Steel City Drawing Board to the He
art of the Maya” The University of Sheffield-EWB-UK National Research Conference 20
10,19th February 2010.
[4]Design and fabrication of pedal operated hacksaw by Dr. G.Arunkumar, N.S. Vishal (I
SSN no.22778179,November 2014)
5. R.S.Kurmi “Design of Machine Elements”, Eurasnia publishing house 3 pvt ltd, 14 th re
vised edition.

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