Savitribai Phule Pune University

PROJECT ON
“FABRICATION OF PEDAL OPERATED HACKSAW
MACHINE”

In partial fulfillment of requirements for degree of

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
Submitted by:
 Yassar yellurkar
 Suraj phavade
 Yash borkar
 Zaheer sheikh

Department of Mechanical Engineering

Dr. D. Y. Patil Institute of Technology, Pimpri - 411018

[2020-2021]

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Chapter - 1

Introduction

 Pedal power is the transfer of energy from a human source through the use of a foot pedal
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
used 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.

 Some third world development projects currently transform used bicycles into pedal
powered tools for sustainable development. This project concentrates on pedal powered
hacksaw machining. An individual can generate four times more power (1/4 HP) by
pedaling than 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 consequence of the brainstorming exercise, it was apparent that the primary function
of pedal power one specific product was particularly useful: the bicycle. Many devices
can be run right away with mechanical energy. A saw is a tool that uses a hard blade or
wire with an abrasive edge to cut through softer materials. The cutting edge of a saw is
either a serrated blade or an abrasive. A saw may be worked by hand, or powered by
steam, water, electric or other power. An abrasive saw uses an abrasive disc or band for
cutting, rather than a serrated blade.

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1.1Problem Statement

 Its hard to use hacksaw machine by manually by hands.

 the system with pedal working very effective by minimizing the effort.

 we have changed manual hand work to rotating manual work.

 we have minimized the energy and maximize the output.

1.2 Objectives

1) To reduce human efforts and hence don’t need more man power to perform work.

2) Enhance output for day by day household need to complete.

3) More productivity without electricity.

4) Make system that acts as a healthy and more purposeful.

1.3. Scope

The pedal power hacksaw machine has a good scope for the future as it can meet different requirements
by the following modification which can be made.

 The angle adjustment of the cutting can be increased by increasing the distance of the hacksaw
link which is attached to the round wheel.
 The improvement can be made in the lighting section of the present system by providing better
motor capacity working for night purpose.
 Arrangement of the coolant for the cooling of metal pipe at high temperature

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1.4 Methodology

Flow Chart

Mounting a power hacksaw blade

The cutting edge must be mounted to cut on the power (back)

stroke. The cutting edge should likewise lie superbly level against

Chain sprocket system

The chain and sprocket system is designed to convert the motion

to the hacksaw blade from the rotating paddle

Pedal arrangements

A couple of pedals are connected to the stand set up in which the

power will be created physically. A run of the mill bicycle plan is
utilized.

Crank and slider

The vertical development of the hacksaw will be guided by to

press poles. The vertical development will go about as a
sustaining unit. The wrench shaft is 1 foot long

Metal slab

It is utilized to manage the control of the hacksaw edge which is

utilized to cut the metal.

Seat

The stature of the seat from the floor is 3' 2" and the seat is made
of wood.

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1.5. Organization of Dissertation

Introduction: Introduction Of the Project.

Chapter 1 Problem statement: Problem to overcome by the project.
Objectives: Objective behind the project.
Scope: What is the scope for the project.
Methodology: Method of project.
Organization Dissertation: Organized chapters

Chapter 2 Literature Review: Presents the current knowledge.

Summary of all related topics: Summary

Chapter 3 Design Work: Dimensions & design.

Construction: Construction steps.
Working of System: Working system of the project.
Experimental Setup: Arrangement of the project.

Chapter 4
Possible Outcome: Outcomes that will be coming from the project.

Chapter 5 Concluding Remarks: Conclusion.

Scope for future work: Futuristic scope
References: Referred papers.

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Chapter - 2

Literature Review:-

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 the 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, with pins for attaching a narrow disposable blade. A screw
or other mechanism is used to used 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 PVC pipes. It would be useful in
many projects discussed on this site which used plastic pipes as materials. Blades of hacksaw
are measured in TPI (Tooth per Inch). Different TPI is needed for different jobs of cutting.

There are three types of cutters available in the market:

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

2.2 STAND SETUP PARTS Stands are introduced to immobilize the apparatus. Various
components used are fixed to this arrangement. The chassis of the bicycle is used as the stand
setup parts . The stand described here is designed to support most bicycle

1. The stand assembly is divided into two parts: the rectangular base frame and two triangular
upright supports. Measure and cut the five pieces of 3/4" (20mm) angle specified for the base
frame. Miter 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.
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3. Measure an cut as specified the 5 pieces for each upright support.

4. Carefully assemble the upright support pieces for welding, being sure to leave1/8" (3.2mm)
gap in the base of each support. This gap will mate with the center frame member of 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 so
that it mates with the gap.

2.3 CRANK AND SLIDER MECHANISM This mechanism is used to convert the rotary motion of
the crank into the reciprocating motion of hacksaw. The lengths of the crank and connecting
rods are made using trial and error method. The hack saw is guided by an aluminum plate. The
vertical movement of the hacksaw will be guided by to iron rods. The vertical movement will act
as a feeding unit.

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

2.4.1 A RECIPROCATING POWER HACKSAW It uses a blade that moves back and forth across the
work. The blade cuts on the backstroke. 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 pressure on the blade
that is uniform regardless of the number of teeth in contact with the work. The 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 minimum blade
bending and breakage. Standard reciprocating metal cutting saws are available in sizes from 6~
~ 6~ (150 mm ~ 150 mm) to 24~ ~ 24~ (900 mm ~ 900 mm). The saws can be fitted with many

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accessories, including quick acting vises, power stock feed, power clamping of work, and
automatic cycling of the cutting operation. The latter moves the work out the required distance,
clamps it, and makes the cut automatically. The cycle is repeated upon completion of the cut.
High-speed cutting requires use of a coolant. Coolant reduces friction, increases blade life, and
prevents chip-clogged teeth. Cast iron and some brass alloys, unlike most materials, do not
require coolant.

2.4.2 Selecting A Power Hacksaw blade Proper blade selection is important. Use the three-tooth
ruleatleast three teeth must be in con-tact with the work. Large sections and soft materials
require a coarse-tooth blade. Small or thin work and hard materials require a fine-tooth blade.
For best cutting action, apply heavy feed pressure on hard materials and large work. Use light
feed pressure on soft materials and work with small cross sections. Blades are made in two
principal types: flexible back and all-hard. The choice depends upon use. i. Flexible-back blades
-should be used where safety requirements demand a shatterproof blade. These blades should
also be used for cutting odd-shaped work if there is a possibility of the work coming loose in the
vise. ii. All-hard blade -For a majority of cutting jobs, allhard blades best for straight, accurate
cutting under a variety of conditions. When starting a cut with an all hard blade, be sure the
blade does not drop on the work when 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 carbide teeth
on steel alloy backs. “ ” The following rule-of-thumb can be followed for selecting the correct
blade: Use a 4-tooth blade for cutting large sections or readily machined metals. Use a 6-tooth
blade for cutting harder alloys and miscellaneous cutting. Use 10- and 14-tooth blades primarily
on light duty machines where work is limited to small sections requiring moderate or light feed
pressure.

2.4.3. 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 lifeand
accurate cuts are to be achieved, the blade must be properly tensioned Many techniques have
been developed for properly mounting and tensioning blades. Use a torque wrench and’

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consult the manufacturer s literature. If the information (proper torque for a given blade on a
given machine) is not available, the following methods can be used: Tighten the blade until a
low musical ring is heard when the blade is tapped lightly. A high-pitched tone indicates that
the blade is too tight. 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, the pin holes will become slightly elongated, The blade will become more firmly
seated after the first few cuts and will stretch slightly. The blade will require retensioning
(retightening) before further cutting can be done. 2.4.4 Selecting a Band Saw Blade Band saw
blades are made with raked teeth or wavy teeth. Most manufacturers also make variations of
these sets. The rakersetis preferred for general use. Tooth pattern determines the efficiency of
a blade in various materials. The standard tooth blade pattern is best suited for cutting most
ferrous metals. A skip tooth blade pattern is preferred for cutting aluminum, magnesium,
copper, and soft brasses. The hook tooth blade pattern also is recommended for most
nonferrous metallic materials. For best results, consult the blade manufacturer s chart or
manual for the proper blade characteristics (set, pattern, and number of teeth per inch) for the
particular material being cut.

2.4.5. 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 true and square with the holding device. Follow the’ manufacturer s instructions
for adjusting blade tension. Improper blade tension ruins blades and can cause premature
failure of bearings 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 regular basis. This typically includes checking wheel
alignment, guide alignment, feed pressure, and hydraulic systems.

2.5. 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.

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2.5.1. PEDAL A bicycle shoe crank bottom bracket bicycle pedal is the part of a that the rider
pushes with their foot to propel the bicycle. It provides the connection between the cyclist’s
foot 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 front) wheel. The safety
bicycle, as it is known today, came into being when the pedals were 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 and a body, on which the
foot rests or is attached, that is free to rotate on with respect to the spindle.

2.6. BEARINGS There are two types of bearings used in this attachment,

• Ball Bearings •Thrust Bearings

It consists of the pedal arrangement which rotates the crank and through it slider consists of
oscillating mechanism. The power is transmitted to the crank and slider mechanism. 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 the 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.

2.7.ADVANTAGES:

I. Time saving as compared to simple hacksaw

II. Power saving as it is manually operated

III. Easy machinery used

IV. As it is pedal operated so good for health

V. Comfortable then ordinary hacksaw

VI. It is portable

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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.

2.8.DISADVANTAGES

I. Its totally manually operated

II. Time consuming as compared to electrical power hacksaw

III. Without human effort its not operated

IV. Not fit for heavy production

2.9.APPLICATIONS

1. In a furniture making industry at production it is widely used

2. It can perform cutting operation in various kinds of industries.

3. This machine can be applied in carpentry and plumbing works also .

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Summary of all related papers

International Journal of Latest Engineering Research and Applications (IJLERA) ISSN:

2455-7137 by Sachin hulageri and Ayneendra B ;Volume – 03, Issue – 05, May 2018

In this project work an effort has been made to design and developed model of Pedal Powered
Hacksaw. The pedal powered hacksaw is a device which is used for cutting wood, plastic and
metals. The basic principles of power driven hacksaw is Slider Crank Mechanism which is an
inversion of four bar chain mechanism. In this mechanism, the connecting rod is directly
connected to the hacksaw for the processing of cutting the wooden blocks. The hacksaw move
to and fro motion when the pedal is powered, so as the rotating disc rotates. The main aim of
this project is to reduce the human effort for machining various materials.

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Research Inventory: International Journal of Engineering And Science

DESIGN & FABRICATION OF PORTABLE MOTORIZED POWER HACKSAW

MACHINE Mohammad Alam*1 , Mohammad Daud Khan2 , Mohd Nauman3 & Naseem
Ansari4 * Department of Mechanical Engineering, United College of Engineering &
Management, India

As we know that in large manufacturing industries, the cutting operation is very required for
raw material, for this purpose they use conventional hacksaw machine for cutting operation. In
that type of machine single piece can cut at a time by using an electric motor. Also, one labor
utilizes for same. So it is time-consuming and comparatively costly. Therefore we have
manufactured a four-way hack-saw machine. Conversion of rotary motion of dc motor into
reciprocating motion is obtained by using the eccentric cam. By making such type of machine,
cutting operation time as well as labor working time can be reduced. It can be also used in
industries where labor availability is less. In this present work, we manufactured a model of
four-way hacksaw machine, so we use light duty of structural parts and crank mechanism.

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Sreejith K., Aravind K.,Danie Davis and Farish K.A., George Johnson;Vol.4, Issue 7
(July 2014), PP 01-05
This project work deals with the design and fabrication of a pedal powered two way
hacksaw cutting machine. In this Pedal operated two-way hacksaw machine which can be
used for Small scale Shop applications for cutting of wooden block, PVC pipe. The machine
works on the principle of Scotch yoke mechanism. In scotch yoke mechanism rotary motion
is converted into a To and Fro (reciprocating) motion. In this machine peddle in connected
Sprocket (ratchet) through chain which is connected to scotch yoke mechanism to the
hacksaw frame from both the side and the power is supplied to the hacksaw frame by
means of chain. The main aim of this machine to reduce cutting time as well as energy. In
which no external power is required for cutting operation, it also available in minimum cost.
The peddle power two-way hacksaw machine, which runs on human power, works on the
principle of the conversion of rotational motion to oscillatory motion. This is a project which
saves electricity need and can be easily use in day today’s life.

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Chapter - 3

Design Work

3.1. Construction

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3.2.Working of System
This machine is an advanced hacksaw machine that is operated manually by pedal cycling to
eases human labor in cutting vegetables, wood, plastic and other basic light materials by
increasing mechanical advantage and reducing the requisite effort. Here, the hacksaw machine
performs in cutting objects with its sharp and replaceable hacksaw blade. With crankshaft
mechanism and revolving chain and sprocket operation, this system is made more durable and
efficient
A sitting place is affiliated to ensure comfort and longevity of operation without exhaust. In this
device, the frame is designed to grab the wood piece properly while vibrating. Moreover, the tray
in the frame collect sawdust and wheels make the device locomotive. Besides, device parts are
made individually that can be separated while necessary so that it becomes easily portable.
Converting the rotating cycling force to the reciprocal sliding blade force is the fundamental
principle behind the proposed system. The system performance is measured and results are found
satisfactory for real time application.

3.3. Experimental Setup

The Pedal Operated Hacksaw Machine consists of the pedal arrangement which rotates the crank
and through it slider consists of oscillating mechanism. The power is transmitted to the crank and
slider mechanism. 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 the
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

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Chapter - 4

Possible Outcome

• For practical applications, this is fabricated for light-duty operation.

• This machine reduces the human effort and hence does not need more than one person to
cut the material .
• By using this method any operation as per our requirement can be done without the use
of electricity.

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Chapter – 5
Cost Estimation
5.1 Electrical operated hacksaw machine

Sr. No. Parts Qty. Material Amount

i. A.C. motor 1 Electrical 1200
ii. Belt Drive 1 Rubber 65
iii. Scotch Yoke 1 Mild Steel 460
iv. Shaping Tool 1 Mild Steel 50
v. Hacksaw 1 120
iv. Shaft 1 Mild Steel 100
vii. Frame 1 Mild steel 500

Total = Rs. 2,500

Labor cost = 500
LATHE, DRILLING, WELDING, GRINDING, POWER HACKSAW, GAS CUTTING;
COST = 1000/-

Total = Rs. 4,000

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5.2 Pedal operated hacksaw machine

Parts Qty. Cost

Frame whole 800
Crank 1 200
Pedal 2
seat 1 200
hacksaw 1 150
Labor charge = 200/- Total= 1550

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5.3 Daily Charges of both machines

Electrical hacksaw machine

 power consumption

 ¼ HP = 186 Watts

 Approximate time to cut the material = 7 min

 KWH = 186/1000 * 7/60 = 0.0217

 P = 0.0217 units in theory

 In practical approx. 0.5 unit

 If 20 material are cut daily

 Charge of one unit = 10 Rs.

 Therefore, 20 * 0.5 = 10 unit

 Cost = 10 * 10 = 100

Pedal operated hacksaw machine

 Low scale workshop

 Approx. daily cutting 7 – 8 materials

 No external power sources

 Only labor charge

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Chapter - 6

Concluding Remarks and Scope for the Future Work

6.1. Concluding Remarks

• Thus a low cost can enhance day today household needs and
• daily day to day purposes and it can be also 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
wooden logs.
• This simple design of conventional design which used in for industrial applications
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

6.2. Scope for the Future Work

• The pedal power hacksaw machine has a good scope for the future as it can meet different
requirements by the following modification which can be made.
• The angle adjustment of the cutting can be increased by increasing the distance of the
hacksaw link which is attached to the round wheel.
• The improvement can be made in the lighting section of the present system by providing
better motor capacity working for night purpose.

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• Arrangement of the coolant for the cooling of metal pipe at high temperature.

References
Papers from Journal or Transactions :
 [International Journal of Latest Engineering Research and Applications (IJLERA)
ISSN: 2455-7137 by Sachin hulageri and Ayneendra B ;Volume – 03, Issue – 05,
May 2018, PP – 71-73
 Research Inventy: International Journal of Engineering And Science by
 Sreejith K., Aravind K.,Danie Davis and Farish K.A., George Johnson;Vol.4, Issue 7
(July 2014), PP 01-05

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