HIGH SPEED 4-WAY HACKSAW MACHINE

PROJECT REPORT
SUBMITTED IN PARTIAL FULFILLMENT FOR THE AWARD
OF THE DEGREE OF
BACHELOR OF TECHNOLOGY
BRANCH - MECHANICAL ENGINEERING
SUBMITTED BY -
1. RISHABH GUPTA (ROLL NO. - 1402840075)
2. ANURAG DUBEY (ROLL NO. - 1402840015)
3. SHUBHAM SINGH RAGHUVANSHI (ROLL NO. - 1402840100)
4. VISHAL KUMAR (ROLL NO. - 1402840108)
5. SUMEET KUMAR (ROLL NO. - 1402840105)
6. SANDEEP PAL (ROLL NO. -1402840083)
UNDER THE SUPERVISION OF
MR. RAHUL JAIPURIAR
(ASSISTANT PROFESSIOR)

IDEAL INSTITUTE OF TECHNOLOGY, GOVINDPURAM, GHAZIABAD

DR. A.P.J. ABDUL KALAM TECHNICAL UNIVERSITY, LUCKNOW (2017-18)
 DECLARATION

We hereby declare that we are the student of Mechanical engineering, IIT Ghaziabad.
We are working on a project under the guidance of MR. RAHUL JAIPURIAR. Further
this work has been submitted in full to obtain degree of Bachelor of Technology that the
studies described in this report entitled “HIGH SPEED 4-WAY HACKSAW” in subject
Mechanical engineering is carried out by us

S.NO NAME ROLL NO. SIGNATURE

1 RISHABH GUPTA 1402840075
2 ANURAG DUBEY 1402840015
3 SHUBHAM SINGH RAGHUVANSHI 1402840100
4 VISHAL KUMAR 1402840108
5 SUMEET KUMAR 1402840105
6 SANDEEP PAL 1402840083
 CERTIFICATE
This is to certified that project report entitled “HIGH SPEED 4-WAY HACKSAW” which is
being submitted by RISHABH GUPTA, ANURAG DUBEY, SHUBHAM SINGH
RAGHUVANSHI, VISHAL KUMAR, SUMEET KUMAR and SANDEEP PAL in partial
fulfillment for the requirement for the award of the degree of Bachelor of Technology in
department of mechanical engineering in IDEAL INSTITUTE OF TECHNOLOGY,
GOVINDPURAM, GHAZIABAD under DR. A.P.J. ABDUL KALAM TECHNICAL
UNIVERSITY, LUCKNOW. They have worked under the guidance of Mr. RAHUL
JAIPURIAR and have fulfilled the requirement for the submission of the project. The matter
embodied in this thesis is original and has not been submitted for award of any degree.

Signature of Supervisor Signature of HOD Signature of External Examiner

Ms. DEEPIKA SINGH Mr. RAHUL JAIPURIAR
Assistant Professor Head of Department
Dept. of Mech. Engg. Dept. OF Mech. Engg.

Date: -
 ACKNOWLEDGEMENT
Our first and foremost gratitude is to our HOD Almighty who has been with us all along and giving
us the strength to complete this project. We would also like to acknowledge our deepest gratitude
to our HOD Mr. RAHUL JAIPURIAR for his guidance, constant attention, valuable suggestion,
enthusiastic support and personal concern during the project. Furthermore, our appreciation also
goes to our Assistant Professor Ms. DEEPIKA SINGH from the Mechanical Engineering
workshop for their time, attention and guidance. Special thanks go to the Department of
Mechanical Engineering for their permission to use the facilities and equipment available at the
Department which aided us to complete this project successfully. Special appreciation goes to our
loving parents especially our moms who brought us here, and are always on our side, riding along
with us on our ups and downs as well as giving us the encouragement to pursue our dreams. We
say a big thank you.

S.NO NAME ROLL NO. SIGNATURE

1 RISHABH GUPTA 1402840075
2 ANURAG DUBEY 1402840015
3 SHUBHAM SINGH RAGHUVANSHI 1402840105

4 VISHAL KUMAR 1402840108

5 SUMEET KUMAR 1402840105
6 SANDEEP PAL 14028400
 ABSTRACT
In this project work and effort has been made to develop a modernized four-way hacksaw machine
and less stress full operation for cutting wood, metal and plastic materials. The aim of this work is
to develop a hacksaw machine that will use a less effort to produce uniform cutting of PVC pipes,
metals, wood. It is also done to show the performance difference between hand driven, pedal drive
and four-way hacksaw machine. This model implies a conversion of rotary motion of crank to
reciprocating motion of hacksaw blades, which is done by using Scotch Yoke Mechanism. This
motion is used for hacksaw machine, in this model we can operate four hacksaws at same time.
This model will overcome the traditional hacksaw machine which done material cutting of single
piece at particular times interval and also fulfills the need of more material cutting accounts to
mass production. This machine works significantly with minimum vibrations and jerks. This
machine will also done cutting of different materials, hence the purposed model of hacksaw
machines will be welcomed by many industries due to compactness and efficiency. To achieve
this goal the four-way hacksaw machine is developed.
 Chapter-1
INTRODUCTION

1. INTRODUCTION
In present condition many electrically operated power hacksaw machines of different
companies with different specifications are available for the use in shop floor. These machines are
so precise that they can cut metal bars with minimum time made up of different materials but they
have one and major disadvantage that those are able to cut single piece of bar at a time. For
industries to achieve the mass production, it is necessary to cut metal bars with high rate. So it is
impossible to depend upon conventional single frame power hacksaw machines and need the
improvement in technology and design of such machines. With the help of this multi-way power
hacksaw machine the four metal bars can be cut simultaneously to get high speed cutting rate and
to achieve mass production for maximum profit in related companies. As this machine overcomes
all the limitations and drawbacks of conventional hacksaw machines, it is also helpful for small
scale industries due to its simple working and operating conditions along with its compatibility,
efficiency and affordable price.
This project is about cutting the wood, metal, pipe, angle, channel, flat plates, rods and
such other things. This project is very much useful and easy to install by user.

1.1 Scotch Yoke Mechanism

Scotch yoke is a mechanism for converting the linear motion of a slider into rotational
motion or vice-versa. The piston or other reciprocating part is directly coupled to a
sliding yoke with a slot that engages a pin on the rotating part. The shape of the motion of the
piston is a pure sine wave over time given a constant rotational speed.

Fig 1.1 Sectional view of Scotch yoke mechanism

1.2 Construction

The scotch yoke mechanism is constructed with iron bars. Here the crank is made in some
length and the yoke is also made using the same material. It is noted that the minimum length of
the yoke should be double the length of the crank. The crank and yoke is connected with a pin.
Iron bars are welded to both sides of the yoke to get the reciprocating motion. The yoke with the
iron bars is fixed on the display board with the help of c clamp. Now the crank is welded to the
end of the shaft of the motor. Now the pin on the crank is connected to the yoke. The pin used to
connect yoke and crank is a bolt.

Fig 1.2 Front view of Scotch Yoke Mechanism

1.3 Working principle

When the power is supplied to the 12v Dc motor, shaft and crank attached to the shaft start
rotating. As the crank rotates the pin slides inside the yoke and also moves the yoke forward. When
the crank rotates the forward direction. The maximum displacement will be equal to the length of
the crank. When the crank completes the next of rotation the yoke comes back to its initial position.
For the next of rotation, yoke moves in the backward direction. When the crank completes a full
rotation, the yoke moves back to the initial position. For a complete rotation of crank the yoke
moves through a length equal to double the length of the crank. The displacement of the yoke can
be controlled by varying the length of the crank.

1.4 Motivation
When we searching for our project in market we show the demand of hacksaw blade is
considerably increasing day by day with the growth of industrialization, engineering sector, real
estate, automobile sector etc.
It is used in almost every sector for cutting of materials like angle, channel, flat plates, rods
and such other things. It is also required in auto repairing shops, general repairing workshops,
fitting shops, welding shops and technical institutes. Govt. department like Railway, Defense,
PWD, Postal & Telegraph and others are one of the main users of it.
In India large nos. of small enterprises are engaged in its manufacturing. By considering its
demand, new production unit has great prospect. So, from that we have concluded that the future
base hacksaw machine is use for very costly machinery and in locomotives.
User can use this project in small industry, which cannot afford costly machinery.
 Chapter-2
LITRATURE SURVEY
2.1 Definition: -
Hacksaw Machines offered by us are used for metal cutting ranging from transportable
model to giant size machine. Owing to smooth & speedy functioning abilities, these hacksaw
machines operations spontaneously for aiding the worker in consistently carrying his work with
ultimate competence.
The sewing machine is a machine tool designed to cut material to a desired length or
contour. It functions by drawing a blade containing cutting teeth through the work piece. The
sewing machine is faster and easier than hand sawing and is used principally to produce an accurate
square or mitered cut on the work piece.

2.2 History of Hacksaw Machine: -

The saw was one of the first great innovations of the Metal Age. It was developed with
smelted copper, from which a blade could be cast. Many of the early copper saws have the general
appearance of large meat-carving knives. Egyptian illustrations from about 1500 BC onward show
the saw being used to rip boards, the timber being lashed to a vertical post set into the ground.
Though there is no evidence of the type of saw used, Egyptians were able to saw hard stone.
The blade, was probably toothless, and rode on an abrasive material such as moistened quartz sand.
The 7 1/2-foot granite coffer still in the Great Pyramid carries saw marks.
During the Bronze Age, saws became much more widespread in woodworking. It was in
this time that the modern form of the saw began to come into play. Some of the saws used
resembled hacksaw blades of today.
Iron saws started to be produces in the mid-7th century BC. The Romans, added many
improvements to simply says which made them easier to work with.

For example, they added a rib to the back of saws to reduce the buckling of the thin blade.
Hacksaws today use similar ribs to those on the ancient Roman saws.
While saws for cutting metal had been in used for many years, significant improvements
in longevity and efficiency were made in the 1880s by George N. Clemson, a founder of Clemson
Bros., Inc of Middletown, New York, USA, Clemson conducted tests which involved changing
the dimensions, shapes of teeth, styles of set, and variable heat treatments of blades. Clemson
claimed enormous improvements to the cutting ability of blades and built a major industrial
operation manufacturing hacksaw blades sold under the trade name Star Hack Saw. In 1898,
Clemson was granted US Patent 601947, which details various improvements in the hacksaw.
 Chapter-3
HACKSAW MACHINE

3.1 Types of Hacksaw Machine: -

(1) Light duty hacksaw machine.
(2) Hydraulic hacksaw machine.
(3) Power hacksaw machine.
(4) Circular band hacksaw machine.
(5) Horizontal swing type band saw machine.
(6) Band hacksaw machine.
(7) Jigsaw machine.
(8) Universal type circular hacksaw machine.
(9) Double column band saw machine.
(10) Chain saw circular machine.

3.1.1 Light duty hacksaw machine: -

Your quest for finest quality hydraulic hacksaw machine ends with us. We are recognized
as one of the chief power hacksaw machine manufacturers of India. The hacksaw machine
manufactured by us is used at length in number of industries.

Fig 3.1.1 Light duty hacksaw machine

Features of Light Duty Hacksaw Machine

(1) A quality ‘Self-Centering Vice’ with perfect grip.
(2) Gear and hydraulic are oil submerged.
(3) Full function coolant pump with fitting.
(4) Rigid and heavy M.S. fabricated body.
3.1.2 Hydraulic Hacksaw Machine: -
We supply a huge collection of precisely-engineered hydraulic hacksaw machine which is
very effective in performing a series of cutting operations in workshops with its easy automation.
Acclaimed among the established hacksaw machine suppliers, we offer these machines in
different cutting capacities, sizes, models etc. As per the needs and specifications of our end
customers.

Fig 3.1.2 Hydraulic hacksaw machine

Features of Hydraulic Hacksaw Machine

(1) High productivity.
(2) Corrosion-resistance.
(3) Trouble free service.
(4) Optimum performance.

3.1.3 Power Hacksaw Machine: -

Power hacksaw machine fabricated by us is precision engineered so as to meet the modern
demands of several industries. Due to their smooth & swift functioning ability they are able to
operate in a spontaneous way which aids the worker in consistently carrying his work with ultimate
efficiency.

Fig 3.1.3 Power hacksaw machine

Features of Power Hacksaw Machine
(1) Fine cutting.
(2) Longer service life.
(3) Self lubrication.
(4) Infinitely variable feed rate.
(5) Cutting arm of high tension bearing capacity.

3.1.4 Circular Band Saw Hacksaw Machine: -

Supreme efficiency and long-term durability are blended in Circular Band Saw Machine
provided by us. Being durable and rendering unparalleled service, band saw machine
manufactured by us is gaining lot of popularity in appreciation of customer's requirement. We offer
circular band saw machines in varied sizes ranging from 10' to 14'.

Fig 3.1.4 Circular band saw hacksaw machine

Types of Band Saw Machines

(1) Double column construction horizontal band saw machines.
(2) Vertical Band Saw Machines.
(3) Circular Sawing Machines.
Features of Circular Band Saw Hacksaw Machine
(1) LM Guide way 1000-meter length.
(2) Ball screw.
(3) Servo motor.
(4) S.S. Fabricator safety cover.
(5) Harden plate for griping the job.
3.1.5 Horizontal Swing Type Band saw Machine: -
Horizontal swing type band saw is manufactured by us in integral front and rear bed design.
The entire assortment of these machines has large cross section of swing frame and ensures high
speed productivity. All these horizontal swing type band saw machines are widely demanded in
engineering industries for various cutting applications.

Features of Horizontal Swing Type Band saw Machine

(1) High speed.
(2) Heavy duty.
(3) High productivity.
(4) Integral front & rear bed design.
(5) Large cross section of swing frame.

Fig 3.1.5 Horizontal sawing type band saw hacksaw machine

3.1.6 Band Hacksaw Machine: -

Very useful for preparing specimen of big size in anatomy and meat departments. Fitted
with large moving table and extension table operated on four ball-bearing rollers.
Used extensively in the meat packing, and wholesale fish industry, for handling swordfish
and large halbutes etc.

Features of Band Hacksaw Machine

(1) Cast iron table with trunnion system.
(2) Tool holder for easy handling of tools.
(3) Enclosed cabinet support for storage of extra blades.
(4) Adjustable blade guide bearings.
(5) Heavy-duty fence with resew bar and others.
 Fig 3.1.6 Band hacksaw machine

3.1.7 Jigsaw Machine:

The top maker of jig saws is Skill, A jig saw is both versatile and very safe to use. A jigsaw
combines the functions of band saw, a router, circular saw, and a scroll saw into one portable tool.

Fig 3.1.7 Jigsaw machine

 There are both corded jig saws and cordless jig saws - each offering its advantages and
disadvantages.
The corded jig saws are extremely convenient in remote areas and are best suited to cut
wood and wood products. They are available from 12 to 18 volts and higher voltage equates to a
battery that lasts longer.

Features of Jigsaw Machine

(1) Sturdy model and Vibration free.
(2) Graded heavy duty casting body.
(3) Totally dust proof oil immersed.
(4) Gear box and main parts made of alloy steel.
(5) Easy & smooth trouble-free operation.

3.1.8 Universal Type Circular Hacksaw Machine: -

Universal Type Circular Saw machines which are used for paneling, cutting or ripping lumber.
It is generally utilized in projects where fast straight cuts of respective precision are needed
through heavier material.
This wonderful circular saw machine is available in two different ways which are automatic
circular saw and semi-automatic circular saw.

Fig 3.1.8 Universal type circular hacksaw machine

Features of Universal Type Circular Hacksaw Machine

(1) Fast straight cuts of respective precision.
(2) It is also available in automatic circular saw and semi-automatic circular saw.

3.1.9 Double Column Band Saw Machine: -

Double Column Band Saw Machine is equipped with rigid chrome plated double column,
separate electrical panel, infinitely variable feed with flow control valves and power-driven wire
brush.
 The range of band saw machine is hydraulically operated dual clamping system. Its
application is used in engineering industry and construction industry.

Fig 3.1.9 Double column band saw machine

Features of Double Column Band Saw Machine

(1) Automatic height control.
(2) Power driven chip brush for chip removal.
(3) Manual band tension.
(4) Split front vice.
(5) Complete hydraulic.
(6) Length setting can be done.
(7) Complete electrical system integrated.
(8) Complete coolant system integrated.

3.1.10 Chain Saw Circular Machine: -

Available with us is an extensive range of Chain Saw Machines. Manufactured using high
quality raw material, which facilitates fabrication of high quality products, our range is ideal for
square whole operation.
Chain Saw Machines is specially designed for square hole in wood for doors and windows.
This machine is used for mass production of square hole operation.
 Fig 3.1.10 Chain saw circular machine

Features of Chain Saw Circular Machine

(1) Highly efficient.
(2) Easy to operate.
(3) Accurate dimension.
 CHAPTER - 4
CONSTRUCTION AND WORKING OF HACKSAW MACHINE

4.1 Construction of Hacksaw Machine: -

Hacksaw Machines offered by us are used for metal cutting ranging from transportable
model to giant size machine. Owing to smooth & speedy functioning abilities, these hacksaw
machines operations spontaneously for aiding the worker in consistently carrying his work with
ultimate competence.

Fig 4.1 Construction of hacksaw machine

(a) Bed: - The bed is available as a single piece casting. It has wide rigid casting for the collection
of coolant, swarf and also houses the V-belt device.

(b) Saw Frame: - The rigid saw frame ensures a square & parallel cut & the cut takes place on
the backward pull stroke. To prevent the wear of the blade, it is hydraulically lifted out of contact
with work place on the forward stroke up.
There are two types of saw frame:
 Solid frame
 Adjustable frame
(1) Solid Frame: - In this type, only one particular standard length of blade can be used with
this frame.

Fig 4.1.1Solid frame

(2) Adjustable Frame: - In this type different standard lengths of blades can be fitted to this frame.

Fig 4.1.2 Adjustable frame

(c) The Drive: - The drive is attached through V-Pulleys with provision to adjust the complete
tension of the V-Belts. The shafts are fitted with ball bearings and taper and ball bearings to
eliminate friction.
(d) Speed: - Specific speeds have been provided for different kind of metals in order to make it
suitable. High speed for metals like mild steel, brass, copper etc. and low speed for cast iron.
(e) Feed saw: - Two levers are provided to hydraulically control the Feed Saw at the dash-pot.
One controls the rate of feed and the other enables the bow slide to be raised or lowered and after
the completion of the cut, the motor gets automatically switched off.
(f) Vice: - The vice is rigid construction. It has two jaws; one jaw remains fixed and the other is
adjusted according to the size of the material to be cut.
(g) Coolant: - A coolant tank is enclosed within the base of machines with constant speed to
supply continuous cooling to the saw blade.
(h) Electricals: - A Push button starter is fitted with an adjustable trip mechanism that helps in
stopping the machine soon when the blade is clear from the work at extra cost.

Features of Hacksaw Machine

 Power efficiency.
 High productivity.
 Super performance.
 High operational fluency.
 Sturdy and robust design
4.2 Hacksaw Blades
The hacksaw blade consists of different parts:
 2 pin holes
 Center line
 Side
  Back edge

Fig 4.2 Hacksaw blade

4.2.1 Characteristics of Hacksaw Blade: -

The hacksaw blade has 2 main characteristics: -
(1) Teeth pitch which is the number of teeth per 25 mm.

Fig 4.2.1 Teeth pitch

(2) Blade length which is the length between the centers of its pin holes.
 Chapter - 5
HIGH SPEED 4-WAY HACKSAW MACHINE

5.1 Working Principles of High Speed 4 Way Hacksaw Machine: -

4-way hacksaw machine is work on principle of SCOTCH YOKE MECHANISM . in this
rotary motion of shaft is to be convert into the reciprocating motion of hacksaw frame.
Working principle of hacksaw machine is very simple. First of all, the hacksaw machine is
put on ground and after that whatever metal, wood, pvc, is cut is fixed on vice at required length,
after that the electric motor is connect with electricity.
Now start the electric motor so due to that the shaft of motor and hollow disc will be
rotate and also rotate the eccentric Centre and link connect to it.
Due to rotation of links the hacksaw frame will be reciprocate on the metal and cutting of
metal is done.

5.2 Assembly of 4-Way Hacksaw Machine: -

 For assembly of 4-way hacksaw machine first of all on base plate electric motor is
mount vertically, hollow disc having internal circle radius is same as the radius of
shaft of motor is fit on shaft and also the disc has eccentric Centre, metal bar is
weld at the eccentric Centre.
 The links one end is connected with the end of hacksaw frame and second end is
connect with the metal bar of eccentric Centre.
 The buckle type elements are connected at the end of hacksaw frame and link is
connect in this buckle, pipe provide support to the hacksaw frame, the pipe is
connected to the base. Vice is also fit on pipe and which also connect with the base.

Fig 5.2 High speed 4-way hacksaw machine

 Chapter-6
COMPONENTS DETAILS
6.1 List of Components: -
 Hacksaw frame
 Hacksaw blade
 Electric motor
 Disc
 Base frame
 Connecting rods
 Vice
 Cable
 Buckle
 Metal pipe

6.2 Description of Components: -

(1) Hacksaw Frame
The main and very important of the project is hacksaw, the blade is fit on hacksaw frame
and this hacksaw is connect with the connecting rod (links) through a buckle type element.
Hacksaw frame is adjustable type to fit the blade.

Fig. 6.1. Hacksaw Frame

(2) Hacksaw Blade
Blade is fit on frame the standard length of blade is 300 mm and its end radius is 3mm, its
thickness is very small. One side of blade has cutting edge.

Fig 6.2 Hacksaw blade

(3) First Link

First link is connect with the first hacksaw frame and eccentric Centre of disc. The link is
either round or rectangular shape.
The hole is cut at its both end for fit into the buckle shape element.

Fig 6.3 First, second, third, fourth and fifth link

(4) Second Link

Second link is connect with the second hacksaw frame and eccentric Centre of disc. The
shape of link is same as the first link.
(5) Third and Fourth Link
Third link is connect with third hacksaw frame and eccentric Centre of disc, fourth link is
connect with the fourth hacksaw frame and eccentric Centre of disc.
Shape of both link is same as the first link.

(6) Fifth Link

This is a fix link the eccentric Centre of disc is known as the fifth link, the shape of this
link is cylinder type. It rotates with the rotation of disc.

(7) Electric Motor

Electric motor is fit vertically on base due to that the shaft rotate vertically, speed of motor
is slow. Bolt is use for fitting the motor.

Fig 6.4 Electric motor

6.7.1 Dc motors
At the most basic level, electric motors exist to convert electrical energy into mechanical
energy. This is done by way of two interacting magnetic fields - one stationary, and another
attached to a part that can move. A number of types of electric motors exist, but most BEAM bots
use DC motors1 in some form or another. DC motors have the potential for very high torque
capabilities (although this is generally a function of the physical size of the motor), are easy to
miniaturize, and can be "throttled" via adjusting their supply voltage. DC motors are also not only
the simplest, but the oldest electric motors.
The basic principles of electromagnetic induction were discovered in the early 1800's by
Oersted, Gauss, and Faraday. By 1820, Hans Christian Oersted and Andre Marie Ampere had
discovered that an electric current produces a magnetic field. The next 15 years saw a flurry of
cross-Atlantic experimentation and innovation, leading finally to a simple DC rotary motor. A
number of men were involved in the work, so proper credit for the first DC motor is really a
function of just how broadly you choose to define the word “motor”.
A DC motor is a mechanically commutated electric motor powered from direct current
(DC). The stator is stationary in space by definition and therefore so is its current. The current in
the rotor is switched by the commutator to also be stationary in space. This is how the relative
angle between the stator and rotor magnetic flux is maintained near 90 degrees, which generates
the maximum torque.
DC motors have a rotating armature winding but non-rotating armature magnetic field and
a static field winding or permanent magnet. Different connections of the field and armature
winding provide different inherent speed/torque regulation characteristics. The speed of a DC
motor can be controlled by changing the voltage applied to the armature or by changing the field
current. The introduction of variable resistance in the armature circuit or field circuit allowed speed
control. Modern DC motors are often controlled by power electronics systems called DC drives.
The introduction of DC motors to run machinery eliminated the need for local steam or
internal combustion engines, and line shaft drive systems. DC motors can operate directly from
rechargeable batteries, providing the motive power for the first electric vehicles. Today DC motors
are still found in applications as small as toys and disk drives, or in large sizes to operate steel
rolling mills and paper machines.

6.7.2 Principles of Operation of DC Motor

In any electric motor, operation is based on simple electromagnetism. A current-carrying
conductor generates a magnetic field; when this is then placed in an external magnetic field, it will
experience a force proportional to the current in the conductor, and to the strength of the external
magnetic field. As you are well aware of from playing with magnets as a kid, opposite (North and
South) polarities attract, while like polarities (North and North, South and South) repel. The
internal configuration of a DC motor is designed to harness the magnetic interaction between a
current-carrying conductor and an external magnetic field to generate rotational motion.
Let's start by looking at a simple 2-pole DC electric motor (here red represents a magnet
or winding with a "North" polarization, while green represents a magnet or winding with a "South"
polarization).
Every DC motor has six basic parts: axle, rotor (a.k.a., armature), stator, commutator, field
magnet(s), and brushes. In most common DC motors (and all that Beamers will see), the external
magnetic field is produced by high-strength permanent magnets. The stator is the stationary part
of the motor, this includes the motor casing, as well as two or more permanent magnet pole pieces.
The rotors (together with the axle and attached commutator) rotate with respect to the stator. The
rotor consists of windings (generally on a core), the windings being electrically connected to the
commutator.
 Fig 6.5 Sectional view of DC motor

The geometry of the brushes, commutator contacts, and rotor windings are such that
when power is applied, the polarities of the energized winding and the stator magnet(s) are
misaligned, and the rotor will rotate until it is almost aligned with the stator's field magnets. As
the rotor reaches alignment, the brushes move to the next commutator contacts, and energize the
next winding. Given our example two-pole motor, the rotation reverses the direction of current
through the rotor winding, leading to a "flip" of the rotor's magnetic field, driving it to continue
rotating.
The DC Motor or Direct Current Motor to give it its full title, is the most commonly used
actuator for producing continuous movement and whose speed of rotation can easily be controlled,
making them ideal for use in applications were speed control, servo type control, and/or
positioning is required. A DC motor consists of two parts, a "Stator" which is the stationary part
and a "Rotor" which is the rotating part. The result is that there are basically three types of DC
Motor available.

i. Brushed Motor - This type of motor produces a magnetic field in a wound rotor (the
part that rotates) by passing an electrical current through a commutator and carbon brush
assembly, hence the term "Brushed". The stators (the stationary part) magnetic field is
produced by using either a wound stator field winding or by permanent magnets. Generally
brushed DC motors are cheap, small and easily controlled.
ii. Brushless Motor - This type of motor produces a magnetic field in the rotor by using
permanent magnets attached to it and commutation is achieved electronically. They are
generally smaller but more expensive than conventional brushed type DC motors because
they use "Hall effect" switches in the stator to produce the required stator field rotational
sequence but they have better torque/speed characteristics, are more efficient and have a
longer operating life than equivalent brushed types.
iii. Servo Motor - This type of motor is basically a brushed DC motor with some form of
positional feedback control connected to the rotor shaft. They are connected to and
controlled by a PWM type controller and are mainly used in positional control systems and
radio-controlled models.
 Normal DC motors have almost linear characteristics with their speed of rotation being
determined by the applied DC voltage and their output torque being determined by the current
flowing through the motor windings. The speed of rotation of any DC motor can be varied from a
few revolutions per minute (rpm) to many thousands of revolutions per minute making them
suitable for electronic, automotive or robotic applications. By connecting them to gearboxes or
gear-trains their output speed can be decreased while at the same time increasing the torque output
of the motor at a high speed.

6.7.3 Brushed DC Motor

A conventional brushed DC Motor consist basically of two parts, the stationary body of
the motor called the Stator and the inner part which rotates producing the movement called
the Rotor or "Armature" for DC machines. The motors wound stator is an electromagnet circuit
which consists of electrical coils connected together in a circular configuration to produce the
required North-pole then a South-pole then a North-pole etc, type stationary magnetic field system
for rotation, unlike AC machines whose stator field continually rotates with the applied frequency.

The current which flows within these field coils is known as the motor field current. These
electromagnetic coils which form the stator field can be electrically connected in series, parallel
or both together (compound) with the motors armature. A series-wound DC motor has its stator
field windings connected in series with the armature. Likewise, a shunt wound DC motor has its
stator field windings connected in parallel with the armature as shown.

6.7.4 Series and Shunt Connected DC Motor

Fig 6.6 series and shunt DC motor

The rotor or armature of a DC machine consists of current carrying conductors connected

together at one end to electrically isolated copper segments called the commutator. The
commutator allows an electrical connection to be made via carbon brushes (hence the name
"Brushed" motor) to an external power supply as the armature rotates.
The magnetic field setup by the rotor tries to align itself with the stationary stator field
causing the rotor to rotate on its axis, but cannot align itself due to commutation delays. The
rotational speed of the motor is dependent on the strength of the rotors magnetic field and the more
voltage that is applied to the motor the faster the rotor will rotate. By varying this applied DC
voltage, the rotational speed of the motor can also be varied.

6.7.5 Conventional (Brushed) DC Motor

Fig 6.7 Conventional (Brushed) DC Motor

Permanent magnet (PMDC) brushed motors are generally much smaller and cheaper than
their equivalent wound stator type DC motor cousins as they have no field winding. In permanent
magnet DC (PMDC) motors these field coils are replaced with strong rare earth (i.e. Samarium
Cobalt, or Neodymium Iron Boron) type magnets which have very high magnetic energy fields.
This gives them a much better linear speed/torque characteristic than the equivalent wound motors
because of the permanent and sometimes very strong magnetic field, making them more suitable
for use in models, robotics and servos.
Although DC brushed motors are very efficient and cheap, problems associated with the
brushed DC motor is that sparking occurs under heavy load conditions between the two surfaces
of the commutator and carbon brushes resulting in self-generating heat, short life span and
electrical noise due to sparking, which can damage any semiconductor switching device such as a
MOSFET or transistor. To overcome these disadvantages, Brushless DC Motors were developed.
(8) Hollow Disc
Disc is fitted on the shaft of motor the internal diameter of disc is same as the diameter of
shaft. The cylinder shape metal bar is fit on the eccentric Centre of disc this is known as the fifth
and fix link.
 Fig 6.8 Hollow disk
(9) Vice: -
Vice is use for fit the job. Vice is fit on the base frame by the extension of pipe. Generally,
vice is made from the iron metal.

Fig 6.9 Vice

(10) Buckle: -

Fig 6.10 Buckle

 Buckle is use for proper movement of connecting rods, connecting rod is connect with
hacksaw frame through this buckle.
(11) Frame: -
The base frame is made from the sheet metal, the shape of the frame is either square or
rectangular type, support pipe and pipe for fit the vice is provide the base frame through the
extension of pipe by application of welding process. Motor is fit at middle of frame. Function of
frame is to provide the support to all mechanism.

Fig. Assembled CAD 3 -D Model of 4 Way Hacksaw

(12) Selection of Cutting Fluid: -

Different method have been reported to protect cutting tool from the generated heat
during machining operations. Another alternative is to apply cutting fluids in machining
operations. They are used to provide lubrication and cooling effects between cutting tool and
work piece and chip during machining operation. Hence the influence of generated heat on
cutting tool would be prevented.
 CHAPTER -7
BLOCK DIAGRAM, SPECIFICATIONS AND CALCULATIONS

7.1 BLOCK DIAGRAM: -

D.C. Motor Eccentric Cam Connecting Rods

Work-piece Hack-saw

Fig -1: Block Diagram of Four Way Hack-saw Machine

7.2 SPECIFICATIONS
1. Base frame = 90 * 90 cm
2. Height from base frame to hack-saw frame = 20 cm
3. Length of holding vice connecting rod = 15 cm
4. Cross-section of holding vice connecting rod = 80 cm sq.
5. Cutting stroke length = 9 cm
6. Thickness of Blade = 1 mm
7. Length of Blade = 15 mm

7.3 CALCULATION

With the given power and speed of D.C. motor, we will calculate the torque given out by the
motor.
2* pie * N * T
P= Watt
60

Where,
Power, P = watts, Speed N = rpm, Pie = 3.147
Torque, T =?

7.4 Time Calculations: -

1. Time required for cutting a wooden job of 50 mm base and 25 mm thickness manually = 30 sec.
2. Time required for cutting the same job on single hack-saw blade of the machine = 22.5 sec.
 Chapter-8
ADVANTAGES AND DISADVANTAGES
ADVANTAGES: -
 Weight of machine is less.
 It reduces the work of labor.
 Easy to make because of simple construction.
 High production rate.
 Cost is less.
 Easy maintenance and maintenance cost is less.
 It resists all atmospheric effects.

DISADVANTAGES: -
 Time consume more.
 Speed variation is required for cutting the different metal.
 APPLICATIONS: -
 In engineering industry.
 In construction industry.
 In Workshop.
 Chapter-9
CONCLUSION AND FUTURE SCOPE

CONCLUSION: -
As per the above discussion we concluded that to overcome problems in conventional
hacksaw machines, due to high efficiency, easy to operate and affordable price the proposed model
of multi-way power hacksaw machine is helpful and completes all the expectations needed in the
mini industries. Future scope of proposed research work to increase the production rate, cuts the
metal bars easily. It can withstand the vibrations, no hazards from jerk, no special training required
to operate it.

After studying this report, we have known that how the 4-way hacksaw machine will work,
and knowing the construction and how mechanism work in the machine. We learnt how the
theoretical design is possible in practical. Other hacksaw machine is only cut one part at one time
but this machine cut the four parts at a time, this hacksaw machine has lighter weight compare to
another machine. The cost of machine is less and easy to operate so it affordable for all industry

FUTURE SCOPE: -
The maximum size of Round or Square bar can be increased by increasing the motor power
and dimensions of different parts.
Automatic feeding mechanism for material can be introduced by using limit switches or sensors.
Automatic lifting up mechanism for frame when cutting operation is finished to introduce
next portion of bar for cutting
 REFERENCES: -
(1) Build a power hacksaw with vise, Authors: - Vincent Gingery
(2) D.V. Sabarinanda, Siddhartha, B. Sushil Krishnan, T. Mohanraj , “Design and Fabrication
Of Automated Hacksaw Machine”, International Journal of Innovative Research in Science,
Engineering and Technology, ISSN (Online):
2319-8753, volume 3, April 2014.
(3) R. Subhash, C.M. Meenakshi, K. Samuel Jayakaran, C. Venkateswaran, R. Sasidharan,
“Fabrication pedal powered hacksaw using dual
(4) Prof. Nitin Chandra R. Patel, Mohammad A. Vasanwala, Balkrushna B. Jani, Ravi Thakkar,
Mitesh Kumar D. Rathwa,” Material selection and testing of hacksaw blade based on mechanical
Properties”, International Journal of Innovative Research in Science, Engineering and Technology,
ISSN: 2319-8753, volume 2, Issue 6, June 2013.