wjert, 2020, Vol. 6, Issue 4 255-269.

Review Article ISSN 2454-695X

Panchamoorthy et al. World Journal of Engineering Research and Technology
World Journal of Engineering Research and Technology
WJERT
[Link] SJIF Impact Factor: 5.924

FABRICATION OF AUTOMOTIVE DOUBLE HACKSAW MACHINE

*1R. Panchamoorthy, 2R. Velappan, 3P. Balashanmugam and 4G. Balasubramanian

1,2,4
Assistant Professor in Mechanical Engineering, Annamalai University, Tamilnadu.
3
Associate Professor, Department of Mechanical Engineering, Annamalai University,
Tamilnadu, Deputed to Central Polytechnic College, Tharamani, Chennai.
1
Deputed to Government Polytechnic College, Uthangarai.
2
Deputed to Government Engineering College, Thanjavur.
4
Deputed to Government Polytechnic College, Perundurai.

Article Received on 28/05/2020 Article Revised on 18/06/2020 Article Accepted on 08/07/2020

*Corresponding Author
ABSTRACT
R. Panchamoorthy These days automation is changing the world as we know. We need
Assistant Professor in more and more automated system to make human tasks faster and
Mechanical Engineering, easier. So here we automate another strenuous work of hacksaw
Annamalai University,
cutting. Human hacksaw cutting is very strenuous and requires a lot of
Tamilnadu.
effort. This is not feasible large scale and accurate cutting. So our
proposed system automates the hacksaw cutting with a double sided technique where we
operate two hacksaws using a single mechanism. We here use a motor with the shaft
attached. The motor and shaft are attached using appropriate mounts to hold it in position.
Then we use a hacksaw frame and build mounting panels for it using metal structure. We also
use a bed and holder to hold the work piece in place. Now we are driving the motor using a
supply circuit to operate it and move the shaft. We attach the shaft to saw frames in a way
that saw moves in a direction perpendicular to the work piece. Attaching two hacksaws in
either direction enables us to operate hacksaw in both direction and operate both directions
and operate both of them at the same time. Thus we put forth a smart and efficient hacksaw
that can be used for accurate bulk production.

1. INTRODUCTION
In present condition many electrically operated power hacksaw machines of different

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companies with different specifications are available for the use in the 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 two piece of
bar at a time. For industries to achieve the mass production, 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 two-way power hacksaw machine the two
metal bars can be cut simultaneously to get high speed cutting rates and to achieve mass
production for maximum profit in related companies. Cutting is the separation of a physical
object, into two or more portions, through the application of an acutely directed force.
Implements commonly used for cutting are the knife and saw, or in medicine and science the
scalpel and microtome.

The main aim objective of this work is cutting the rod with the help of a motor and using the
crank and slotted mechanism.

1.1. Types of hacksaw

1.1.1. Manual
 Hand hacksaw
 Jig saw
 Pedal hacksaw

1.1.2. Automatic
 Power hacksaw
 Lathe machine and much more.

1.2. Manual
a. Hand hacksaw

Figure 1: Hand hacksaw.

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A saw is a tool consisting of a tough blade, wire or chain with a hard toothed edge as shown
in figure 1. It is used to cut through material, very often wood, though sometimes metal or
stone. The cut is made by placing the toothed edge against the material and moving it
forcefully forth and less forcefully back or continue forward.

b. Pedal hacksaw

Figure 2: Pedal hacksaw.

Pedal power is converted into mechanical work. This circular motion of the pedal crank is
converted into reciprocating or sometime oscillatory motion to drive hacksaw blade. General
hacksaw is operated by manually, hydraulically, electrically motor or pulley commonly used
in industries and workshop as shown in figure 2.

1.3. Automatic
[Link] hacksaw

Figure 3: Power hacksaw.

Power hacksaws are used to cut large sizes (selection) of metals such as steel. The heavy
„arm‟ moves backwards and forwards, cutting on the backwards stroke. The metal to be cut
is held in a machine vice which is an integral part of the base as shown in figure 3. Turning
the handle tightens or loosens the vice.

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1.4. Proposed of Work

Figure 4: Working principle.

The proposed work of motorized hacksaw is designed with slider crank mechanism as shown
in figure 4. The slider crank mechanism converts rotating motion into reciprocating motion.
The DC motor is fed with the power supply. Due to this crank mechanism the hacksaw
operates and the material is cut. A hacksaw machine is working on the principle of rotary
motion of the shaft is to be converted into the reciprocating motion of hacksaw frame.
Working principle of hacksaw machine is very simple. First of all the hacksaw machines is
put on the ground and after that whatever metal, wood, PVC is cut is fixed on vice at required
length, after that the electric motor is connected to electricity.

1.4.1. Frame base

We want to give stability, our prototype model of two way hacksaw machine doesn't get lot
vibration the machine in running condition.

1.4.2. Connecting rod

A hole on at the end of this rod is made for joints and link connections. We have used two of
these shafts for two side hack saw. Together with the crank, it forms a simple mechanism that
converts reciprocating motion.

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[Link]

Figure 5: Vice.

A vice is a mechanical apparatus used to secure an object to allow work to be performed on it

as shown in figure 5. Vises have two parallel jaws, one fixed and the other movable, threaded
in and out by a screw and lever.

1.4.5. Pulley

Figure 6: Pulley.

A pulley is a wheel with a groove along its edge, which holds rope or cable. Usually, two or
more pulleys are used together as shown in figure 6. When pulleys are used together in this
way, they reduce the amount of force needed to lift a load. A crane uses pulleys to help it lift
heavy loads.

1.4.6.V belt

Figure 7: V-belt.

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They are commonly used in automobile engines to drive accessories, such as the power
steering pump, the air conditioning compressor, the fan and the alternator as shown in figure
7. They are replaced with toothed or grooved flat belts in many applications.

1.4.7. Hacksaw frame

Figure 8: Hacksaw frame.

The blade can be mounted with the teeth facing toward or away from the handle, resulting in
cutting. In normal use, cutting vertically downloads with work held in a bench vice; hacksaw
blade should be set to be facing forward as shown in figure 8.

1.4.8. Hacksaw
The blade can be mounted with the teeth facing toward or away from the handle, resulting in
cutting as shown in figure 9. In normal use, cutting vertically downloads with work held in a
bench vice; hacksaw blade should be set to be facing forward.

There are three types of cutters available in the market:

 Simple hacksaw which can be used for hand cutting things.
 Small Electrically Hacksaw for personal uses.

Figure 9: Pedal power hacksaw cutting system.

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1.5. A reciprocating Power Hacksaw

A reciprocating saw is a type of saw in which the cutting actions is achieved through a push
and pull reciprocating motion of the blade. The term reciprocating saw is commonly assigned
to a type of saw used in construction and demolition work. That of a jigsaw and a handle
oriented to allow the saw to be used comfortably on vertical surfaces. The typical style of this
saw has a foot at the base of the blade, also similar to a jigsaw. The user rests this foot against
the surface being cut so that the tendency of the blade to push away from or pull towards the
cut as the blade travels through its cycle can be countered.

Standard reciprocating metal cutting saws are available in sizes from 3 to 4 Diameter (400
mm to 500 mm). The saws can be fitted with many accessories, including quick-acting vises,
power stock feed, power clamping of work, and automatic cycling of the cutting operation.

The term reciprocating saw (also oscillating saw) is also applied generically to any saw which
cuts with a back and forth motion. These include:
 Jig saw
 Scroll saw
 Sabre saw
 Rotary reciprocating saw

Eccentric cam, crank and scotch yoke drives need balance weights to reduce vibration in the
plane of the rotating element, and may still exhibit vibration that is objectionable to a user of
a handheld saw and can lead to difficulty in controlling a cut. The swash plate drive has the
advantage that there is little rotational out of balance, so the principal vibration is in line with
the blade. This is generally controllable by keeping the foot of a handheld tool against the
work.

1.6. Selecting a Power Hacksaw blade

Proper blade selection is important. Use the three-tooth rule 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 as shown in figure 10.
 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.
 All-hard blade -For a majority of cutting jobs, the all-hard blade is best for straight,

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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.

Figure 10: Hacksaw blade.

1.7. Power Hacksaw blade

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 in 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.

1.8. 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 achieved, the
blade must be properly tensioned.

Many techniques have been developed for proper mounting and tensioning blades. Use a
torque wrench and consult the manufacturer‟s literature.

1.9. Selecting a Band Saw Blade

Band saw blades are made with teeth or wavy teeth. Most manufacturers also make variations
of these sets. This is preferred for general use. Tooth pattern determines the efficiency of a

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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 aluminium, magnesium,
copper, and soft brasses. The 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.

1.10. 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 a shown in figure 11.
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 the 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.

Figure 11: Power Hacksaw blade cutting operation.

Figure 12: Power supply unit.

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The transformer steps up or steps down the input line voltage and isolates the power supply
from the power line as shown in figure 12. The rectifier section converts the alternating
current input signal to a pulsating direct current. However, as you proceed in this chapter you
will learn that pulsating DC is not desirable. For this reason a filter section is used to convert
pulsating DC to a purer, more desirable form of DC voltage. The final section, the regulator,
does just what the name implies. It maintains the output of the power supply at a constant
level in spite of large changes in load current or input line voltages. All digital circuits work
only with low DC voltage. A power supply unit is required to provide the appropriate voltage
supply. This unit consists of transformer, rectifier, filter and a regulator. AC voltage typically
of 230Vrms is connected to a transformer which steps that AC voltage down to the desired
AC voltage level. The main components used in the power supply unit are Transformer,
Rectifier, Filter and Regulator. The 230V AC supply is converted into 9V AC supply through
the transformer. The output of the transformer has the same frequency as in the input AC
power. This AC power is converted into DC power through diodes. Here the bridge diode is
used to convert the AC supply to the DC power supply. This converted DC power supply has
the ripple content and for normal operation of the circuit, the ripple content of the DC power
supply should be as low as possible. Because the ripple content of the power supply will
reduce the life of the circuit. So to reduce the ripple content of the DC power supply, the
large value of capacitance filter is used as shown in figure 13.

Figure 13: Power supply block diagram.

1.12. DC Motor
A DC motor is any of a class of electrical machines that converts direct current electrical
power into mechanical power. The most common types rely on the forces produced by
magnetic fields. Nearly all types of DC motors have some internal mechanism, either

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electromechanical or electronic; to periodically change the direction of current flow in part of

the motor. Most types produce rotary motion; a linear motor directly produces force and
motion in a straight line.

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 which adjust
the voltage by "chopping" the DC current into on and off cycles which have an effective
lower voltage a shown in figure 14.

Figure 14: DC motor.

DC motors were the first type widely used, since they could be powered from existing direct-
current lighting power distribution systems. A DC motor's speed can be controlled over a
wide range, using either a variable supply voltage or by changing the strength of current in its
field windings. Small DC motors are used in tools, toys, and appliances. The universal motor
can operate on direct current but is a lightweight motor used for portable power tools and
appliances. Larger DC motors are used in propulsion of electric vehicles, elevator and hoists,
or in drives for steel rolling mills. The advent of power electronics has made replacement
of DC motors with AC motors possible in many applications.

2. LITERATURE REVIEW
David Gordon Wilson studied the vast literature to understand the concepts which affect the
performance of the machine .The concept of two ways hacksaw cutting machine mainly
carried out for production based industries.

Zoeb khan expressed that Industries are essentially implied for generation of valuable
merchandise and enterprises at low creation cost, Machinery cost and low stock cost.
Information about built up a model of a machine reach would be fit for performing diverse

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task all the while, and it ought to be monetarily productive. These machines can be utilized as
a part of remote spots where power is customary. It is planned as a versatile one which can be
utilized for cutting in different spots. It can be utilized for working on materials like thin
metals, wood. A solitary stage vertical electric engine unbendingly set at the focal point of
metallic establishment gave.

Linxu et al. research about the shaft of motor rotates at 90-100 rpm with the power 2HP. The
circular disc is mounted on the shaft of the motor with the help of key and key slot
arrangement. It consists of a pedal powered machine setup which has a simple mechanism
operate with chain and sprocket arrangement.

Chaudhary Pravinkumar k learned about the chain is put on the teeth of the haggle. The pole
is mounted on platform direction. To begin with mechanical linkage is evacuated by
expelling nut and screws and v belt drive boring connection. It is realized that the regular
power hacksaw machine can be supplanted with the robotized control Hacksaw machine.

S. G. Bahaley et al. expressed that automated power hacksaw machine gives high efficiency
in brief day and age in examination with the ordinary power hacksaw machines. The real
preferred standpoint of this machine is intercession of work is lessened to greatest level. In
this fast developing modern segment the utilization of intensity Hacksaw machine is wide,
time and work assumes a noteworthy part underway process. The Material choice and testing
of hacksaw sharp edge in light of mechanical properties expressed that the suitable saw edge
must be chosen for better activity and fine cutting by choosing the number of teeth per inch.

Boyer et al. Showed that failures could occur due to mechanisms and environmental factors.
He also suggested that failure analysis of a metal structure requires identifying the type of
failure mode. The failure mode is classified as either a deformation or fracture.

Layer et al. Concluded that the process of identifying a failure mode is complicated because
different techniques can be used to determine the actual cause of failure.

3. Working Mechanism Crank And Slider Mechanism

This mechanism is used to convert the rotary motion of the crank into the reciprocating
motion of hacksaw a shown in figure 15. The lengths of the crank and connecting rods are
made using trial and error method.A crank is an arm attached at right angles to a rotating
shaft by which reciprocating motion is imparted to or received from the shaft. It is used to

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convert circular motion into reciprocating motion. The arm may be a bent portion of the
shaft, or a separate arm or disk attached to it. Attached to the end of the crank by a pivot is a
rod, usually called a rod. The end of the rod attached to the crank moves in a circular motion,
while the other end is usually constrained to move in a linear sliding motion.

Figure 15: Crank and slider mechanism.

The term often refers to a human-powered crank which is used to manually turn an axle, as in

Figure 16: Automotive Double Hacksaw Machine.

A bicycle cranks set or a brace and bit drill. In this case a person's arm or leg serves as the
connecting rod, applying reciprocating force to the crank a shown in figure 16. There is
usually a bar perpendicular to the other end of the arm, often with a freely rotatable
handle or pedal attached.

3.1. Advantages
 The weight of the machine is less.
 High production rate.

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 The Cost is less

 Easy maintenance and maintenance cost less.
 It with stand all atmospheric effects.
 Highly skilled operators are not used.
 The Work piece can be easily handled.

CONCLUSION
This project has been able to establish that, the need for wood, PVC material cutting can
function effectively and efficiently with minimal maintenance, yet is inexpensive to
construct, is both possible and achievable. The overall cost and choice of materials would
promote mass production and hence, it can be a substitute to the expensive conventional
cutting thereby making it assessable and affordable by local farmers.

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.
2. Zoeb khan, “Design and Fabrication of Human Powered Wood Cutting machine”
International Journal on Recent and Innovation Trends in Computing and Communication
ISSN: 2321-8169, 3(2): 072– 074.
3. Linxu, Weinan Bai, Jingyu Ru,Qiang Li, “Design and Implementation of the
Reciprocating Pedal Powered Electricity Generating Device”, Advanced Materials
Research 282-283, 2011; 735-738.
4. Chaudhary Pravinkumar k, “Understanding pedal power” ISBN: 0- 86619268-9 [C],
Volunteers in Technical Assistance” Technical paper 51 VITA 1600 Wilson Boulevard
USA, 1986.
5. [Link], [Link], [Link], “Performance Analysis of Pedal Powered
Multipurpose Machine”, International Journal of Engineering Research and Development
(IJERD) (Vol.1, Issue.5,e- ISSN:2278-0181), 2012.
6. Boyer, H.E. et al, Metals Handbook 10-Failure Analysis and Prevention, eighth ed.
American Society for Metals, 1975; 1–10.
7. Layer, J., Adler, T., et al, ASM Handbook-Failure Analysis and Prevention, 11 ed. ASM
International, 2002; 14–65.

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8. Anthony Esposito „Fluid Power with applications‟, 6th Edition, Pearson Education Inc.,
2011.
9. Muhammad Ali Mazidi, Janice Gillispie Mazidi, and Rolin D. McKinlay „The 8051
Micro Controller and Embedded Systems‟, 2nd Edition, Pearson Education Inc., 2008.
10. Pneumatic cylinder and solenoid DCV from product manual of Janatics ltd.
11. Standard blade sizes used in power hacksaw machines using the link
[Link] - viewed on August 2, 2013.
12. ULN2003 IC Pin configuration (used in relay circuit) using the link
[Link] on August 10, 2013.

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