Design And Fabrication Of A Motorized Chain Hacksaw

ABSTRACT

This project is on the design and construction of an automatic power hacksaw machine for cutting of metal to different size and length with the help of hacksaw. The objective of this project is to save man power and time in cutting metals in order to achieve high productivity. It is a cutting machine with teeth on its blade used specially for cutting metals. The power to the hacksaw is provided by the motor. The motor drives the pulley-1 connected to the rotor of the motor. The pulley-1 is connected to the flywheel-1 by belt drive. The flywheel-1 is coupled to the one end of shaft-1 and the other end of shaft-1 is coupled to the pulley-2. Again pulley-2 is connected to the flywheel-2 by belt drive. Flywheel-2 is coupled to the one end of shaft-2 and the other end of shaft-2 is connected to the crank which in turn is connected to the connecting rod. Finally connecting rod is connected to the vertical arm connected to the horizontal arm. Rotary motion of the shaft is converted into reciprocating motion of the hacksaw with the help of crank and connecting rod. Work piece of desired length can be cut by feeding it to hacksaw by holding it into bench vice. The various component of the machine were designed and constructed. Test was carried out on the machine using different metals.

TABLE OF CONTENTS

TITLE PAGE

APPROVAL PAGE

DEDICATION

ACKNOWLEDGEMENT

ABSTRACT

TABLE OF CONTENT

CHAPTER ONE

1.0      INTRODUCTION

1.1      BACKGROUND OF THE PROJECT

1.2      AIM OF THE PROJECT

1.3      OBJECTIVE OF THE PROJECT

1.4      SCOPE OF THE PROJECT

1.5     SIGNIFICANCE OF THE PROJECT

1.6      SCOPE OF THE PROJECT

1.7      PROBLEM IDENTIFICATION

1.7      JUSTIFICATION AND RELEVANCE

CHAPTER TWO

2.0     LITERATURE REVIEW

2.1      REVIEW OF THE STUDY

2.2         REVIEW OF THE RELATED WORK

2.3      TYPES OF HACKSAWING

2.4      FEATURES OF MODERN HACKSAW

2.5      DESCRIPTION OF HACKSAW

2.6      HISTORICAL BACKGROUND OF THE STUDY

CHAPTER THREE

3.0     METHODOLOGY

3.1      PROPOSED METHODOLOGY

3.2      COMPONENTS USED AND CALCULATIONS

3.3      DESCRIPTION OF THE HACKSAW MACHINE

• DESCRIPTION OF THE PROJECT SETUP

3.5      WORKING OF THE PROJECT

1. Acquiring data from the user
2. Sequence of operation

CHAPTER FOUR

RESULT ANALYSIS

4.0      CONSTRUCTION PROCEDURE AND TESTING

4.1      CASING AND PACKAGING

4.2      ASSEMBLING OF SECTIONS

4.3      MOUNTING PROCEDURE

4.4      TESTING OF SYSTEM OPERATION

CHAPTER FIVE

5.0      CONCLUSION, FUTURE SCOPE, AND REFERENCES

5.1      CONCLUSION AND FUTURE SCOPE

CHAPTER ONE

1.0                                                      INTRODUCTION

Power hacksaws are used to cut large sections of metal or plastic shafts and rods. Cutting of solid shafts or rods of diameters more than fifteen millimeters is a very hard work with a normal hand held hacksaw. Therefore power hacksaw machine was invented during 1920s in the United States to carry out the difficult and time consuming work. This motorized chain power hacksaw machine is considered as an automatic machine because the operator need not be there to provide the reciprocating motion and downward force on the work-piece in order to cut it. Once the operator has fed the work-piece till the required length in to the machine and starts the machine, then the machine will cut until the work-piece has been completely cut in to two pieces.

The fact that the operator has to feed the work-piece to the required length in to the vice is one aspect that motivated us to automate the feeding of work-piece automatically. Another one aspect is that after a shaft has been cut for one time, the operator has to unload the work-piece and advance the rest of the work-piece to the required length again and again till the end of the work-piece is reached. The Power hacksaw machine though being able to cut the shaft or rod without requiring any human effort to cut, it does require a human intervention to feed the work-piece many times with measurements being taken each time before feeding. Therein, arose a need to completely automate the process of cutting, and here we are with a proposal which will aid in eliminate the effort of the people associated with it.

In this particular project, a motorized chain hacksaw machine was designed.

1.1                                       BACKGROUND OF THE PROJECT

Generally, a hacksaw is a handheld tool used to cut through materials like plastic tubing and metal pipes. Its cutting mechanism is provided by removable blades which feature sharp teeth along their outer edge. In most cases, a hacksaw consists of a metal frame that resembles a downward- facing. A handle of plastic, wood, or metal is typically affixed to one end of the frame. The frame’s ends feature adjustable pegs that can be tightened to secure a blade in place, and loosened to remove it. Hacksaw blades are long, thin strips of hardened steel that feature a row of teeth along their cutting edge. Each end of the blade is punched with a small hole that fits onto the saw frame’s pegs. Most blades range in length from ten to 12inches (25.4 to 30.48 cm), although six-inch (15.24 cm) blades can be purchased to fit smaller hacksaw models.

1.2                                                 AIM OF THE PROJECT

The aim of this project is to construction an automatic power hacksaw machine controlled by an electric motor for cutting of metal to different size and length with the help of hacksaw. This machine save man power and time in cutting metals and at the same time achieve high productivity

1.3                                           OBJECTIVE OF THE PROJECT

The objective of this work is:

1. To cater to the issue of competition in mechanical industry the need for automation is assess by all the industry.
2. To identify the key policy avenues considered to be appropriate to meet the challenge of sustainable manufacturing and packaging industry for the future.
3. To provide alternative for industries aiming toward reducing human effort and improvement in material handling system by implementing automation.
4. Sustainable and practical automation solutions for the future industrial environment.

1.4                                         SIGNIFICANCE OF THE PROJECT

A device that applies force, changes the direction of a force, or changes the strength of a force, in order to perform a task, generally involving work done on a load. This machine is often designed to yield a high mechanical advantage to reduce the effort needed to do that work. A simple machines a wheel, a lever or an inclined plane. All other machines can be built using combinations of these simple machines.

• The machine can solve the problem of time consumption.
• Waste of resources in face of labor cost is reduced.
• The machine can be used in the industry where it is manufactured, at the packaging sector.
• And it is used as hardware in large quantity like in fabrication of machine
• It provide alternative for industries aiming toward reducing human effort
• It generates sustainable and practical automation solutions for the future industrial development.

1.5                                                 SCOPE OF THE PROJECT

1. The machine can solve the problem of time consumption.
2. Waste of resources in face of labor cost is reduced.
3. The machine can be used in the industry where it is manufactured, at the packaging sector.
4. And it is used as hardware in large quantity like in fabrication of machine
5. It provide alternative for industries aiming toward reducing human effort
6. It generates sustainable and practical automation solutions for the future industrial development.

1.6                                             PROBLEM IDENTIFICATION

The motorized chain power hacksaw machines, which are operated by human operators as aforementioned, have the demerit of unloading and loading the work-piece many times. In industries manufacturing pumps, these machines are used to cut the motor shafts to the required lengths. It will be difficult for the operator if he has been assigned to cut a huge quantity of motor shafts and he has to measure the lengths each time for cutting. Since humans are not as versatile as machines, there is a possibility that there may be inaccuracies. Besides, if there is a slight time delay in between every cycle of cutting a piece, the cumulative delay in time will be found to have a considerable magnitude, which might  have been utilized properly if the proposed machine were in use there.

1.7                                          ADVANTAGES OF THE PROJECT

• Easy To Use
• Consistent Cutting Results
• Fast Cutting

1.8                                         JUSTIFICATION & RELEVANCE

We have found a power motorized chain power hacksaw machines to be the most useful for general shop work. Modern heavy- duty hacksaw machines provide an economical and efficient means of sawing a wide range of materials and stock sizes. Motorized chain power hacksaw machines are getting rarer all the time but they do a good job within their capacity. If you can get one that takes standard hacksaw blades then you’ll have a tremendous range of blades to choose from and will be able to cut most anything. Hacksaws are more tolerant to tensioning maladjustment and run off. A major advantage of power hacksawing is the relatively low capital investment required. Tooling and maintenance costs are low. Accuracy and finishes produced, range from fair to good depending on the material being sawed. Time saving as compared to simple hacksaw. Comfortable then ordinary hacksaw.

CHAPTER FIVE

   5.1                                 CONCLUSION AND FUTURE SCOPE

It is known that conventional power hacksaw machine can be replaced with motorized chain hacksaw machine. Motorized chain hacksaw machine gives high productivity in short time period in comparison with the conventional power hacksaw machines. The major advantage of this machine is intervention of labor is reduced to maximum level. In this rapid emerging industrial section the use of power Hacksaw machine is wide, time and labor plays a major role in production process. This can be overcome by using this type of motorized machine.

The motorized chain hacksaw machine can be made use of at any of the industries like pump manufacturing industries that involve bulk amount of shafts that have to be cut frequently. The range of size of work-pieces that can be cut using the automated hacksaw machine can be varied by changing the blade size. Currently, the machine uses 12 inch blade for cutting. An another advancement that can be implemented in automated hacksaw machines is that the user can also get cut work-pieces of different lengths in one cycle itself. This means that the user has to specify the number of work- pieces that have to be cut in each of the different length values specified.