Major 315.docx

DOUBLE ACTING POWER HACKSAW A Project Report Submitted to Jawaharlal Nehru Technologi cal Universi ty, Hyd erabad. In partial fulfilment of the requirements for the award of the degree of BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING By G.SAI VASANTHI(15881A0315) P.SAI KIRAN(15881A0347) P.VINEETH(15881A0357) K.SAMPATH(16885A0308)

Under the guidance of Mr. CHANDRA MOULI Associate Professor Department of Mechanical Engineering

DEPARTMENT OF MECHANICAL ENGINEERING VARDHAMAN COLLEGE OF ENGINEERING (AUTONOMOUS) (Affiliated to JNTUH & Approved by AICTE) (Accredited by NAAC with “A” Grade & ISO 9001:2015 Certified) Shamshabad – 501 218, Hyderabad. 2018 – 2019

VARDHAMAN COLLEGE OF ENGINEERING (AUTONOMOUS) (Affiliated to JNTUH & Approved by AICTE) (Accredited by NAAC with “A” Grade & ISO 9001: 2015 Certified) Shamshabad – 501 218, Hyderabad. DEPARTMENT OF MECHANICAL ENGINEERING Certificate This is to certify that the major project work entitled “DOUBLE ACTING POWER HACKSAW“ is the bonafide work done. By G.SAI VASANTHI(15881A0315) P.SAI KIRAN(15881A0347) P.VINEETH(15881A0357) K.SAMPATH(16881A0308)

at

______________________, Hyderabad is submitted to Jawaharlal Nehru Technological

University, Hyderabad in partial fulfilment of the requirements for the award of B.Tech degree in Mechanical Engineering during 2018-2019.

Project Guide: Mr. CHANDRA MOULI, Associate Professor, Department of Mechanical Engineering, Vardhaman College of Engineering, Hyderabad- 50218.

Head of the Department: Dr. B.Subbaratnam, Professor, Department of Mechanical Engineering, Vardhaman College of Engineering, Hyderabad-501218. Viva-Voce

held on………………… Internal Examiner

External Examiner

DECLARATION

We hereby declare that, this project report titled “Double acting power Hacksaw” is a genuine project work and the effort carried out by team in B. Tech ( Mechanical Engineering) degree course of Jawaharlal Nehru Technological University, Hyderabad. It has not submitted to any other course or university for award of our degree. Wherever the other sources of information have been used, they have been acknowledged.

Signature of the candidates

G.SAI VASANTHI(15881A0315) P.SAI KIRAN(15881A0347) P.VINEETH(15881A0357) K.SAMPATH(16881A0308)

ACKNOWLEDGEMENT The satisfaction that accompanies the successful completion of the task would be incomplete without the mention of the people who made it possible, whose constant guidance and encouragement crown the efforts with success. We show gratitude to Dr. S. SAI SATYANARAYANA REDDY, Principal, for providing all the facilities and support. We would also like to express sincere thanks to Dr B.SUBBARATNAM, Professor and HOD, Department of Mechanical Engineering, for his expert guidance and encouragement at various levels of our project. We are thankful to our guide Mr. CHANDRA MOULI , Associate Professor, Department of Mechanical Engineering, for his sustained, inspiring guidance and co-operation throughout the process of this project. His wise counsel and suggestions were very invaluable. We also thank to all the staff members of Mechanical Engineering department for their valuable support and generous advice We cannot forget to recall, with our deepest regards, the blessings of our parents and friends, which gave us the courage and confidence to materialize our dreams of completing this project.

ABSTRACT: The objective of this work is to automate the conventional power hacksaw machine in order to achieve high productivity of work-pieces than the power hacksaw machine using a Double hacksaw blade. The operator need not measure the length of the work-piece that is to be cut. The machine feeds the work-piece with the help of a shaft, which is driven by a DC motor. A DC motor is used to bring about the reciprocating motion required for cutting the work-pieces. With the help of this multi-way power hacksaw machine, the four metal bars can be cut simultaneously to get the high-speed cutting rate and to achieve mass production for maximum profit in related companies. This project is very much useful and easy to install by the user and also the motor used will not only operate with the help of electricity but also through conventional source of energy like solar energy. Keywords: - Scotch Yoke Mechanism, fabrication, sliding mechanism, double acting hacksaw, Designing.

INTRODUCTION : A hacksaw is a fine-toothed saw, originally and mainly made for cutting metal. The equivalent saw for cutting wood is usually called bow saw. Most hacksaws are hand saws with a C-shaped frame that holds a blade under tension. Such hacksaws have a handle, usually a pistol grip, with pins for attaching a narrow disposable blade. The frames may also be adjustable to accommodate blades of different sizes. A screw or other mechanism is used to put the thin blade under tension. On hacksaws, as with most frame saws, the blade can be mounted with the teeth facing toward or away from the handle, resulting in cutting action on either the push or pull stroke. In normal use, cutting vertically downwards with work held in a bench vice, hacksaw blades are set to be facing forwards. In present condition many electrically operated power hacksaw machines of different 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 a single piece of the 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 the 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 the user.

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 meatcarving 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 the 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 at 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 produced in the mid- 7th century BC. A. Problem Identification The 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.

BLADES:

Small hacksaw (also known as junior hacksaw) Standard hacksaw blade lengths are 10 to 12 in (250 to 300 mm). Blades can be as small as 6 in (150 mm). Powered hacksaws may use large blades in a range of sizes, or small machines may use the same hand blades. The pitch of the teeth can be from fourteen to thirty-two teeth per inch (TPI) for a hand blade, with as few as three TPI for a large power hacksaw blade. The blade chosen is based on the thickness of the material being cut, with a minimum of three teeth in the material. As hacksaw teeth are so small, they are set in a "wave" set. As for other saws they are set from side to side to provide a kerf or clearance when sawing, but the set of a hacksaw changes gradually from tooth to tooth in a smooth curve, rather than alternate teeth set left and right. Hacksaw blades are normally quite brittle, so care needs to be taken to prevent brittle fracture of the blade. Early blades were of carbon steel, now termed 'low alloy' blades, and were relatively soft and flexible. They avoided breakage, but also wore out rapidly. Except where cost is a particular concern, this type is now

obsolete. 'Low alloy' blades are still the only type available for the Junior hacksaw, which limits the usefulness of this otherwise popular saw. For several decades now, hacksaw blades have used high speed steel for their teeth, giving greatly improved cutting and tooth life. These blades were first available in the 'All-hard' form which cut accurately but were extremely brittle. This limited their practical use to benchwork on a workpiece that was firmly clamped in a vice. A softer form of high speed steel blade was also available, which wore well and resisted breakage, but was less stiff and so less accurate for precise sawing. Since the 1980s, bi-metal blades have been used to give the advantages of both forms, without risk of breakage. A strip of high speed steel along the tooth edge is electron beam welded to a softer spine. As the price of these has dropped to be comparable with the older blades, their use is now almost universal. The most common blade is the 12 inch or 300 mm length. Hacksaw blades have a hole at each end for mounting them in the saw frame and the 12 inch / 300 mm dimension refers to the center to center distance between these mounting holes. The kerf produced by the blades is somewhat wider than the blade thickness due to the set of the teeth. It commonly varies between 0.030 and 0.063 inches / 0.75 and 1.6 mm depending on the pitch and set of the teeth.

VARIANT: A panel hacksaw has a frame made of a deep, thin sheet aligned behind the blade's kerf, so that the saw could cut into panels of sheet metal without the length of cut being restricted by the frame. The frame follows the blade down the kerf into the panel.

Junior hacksaw are a small version with a half-size blade. Like coping saws, the blade has pins that are held by notches in the frame. Although potentially a useful tool for a toolbox or in confined spaces, the quality of blades in the Junior size is restricted and they are only made in the simple low alloy steels, not HSS. This restricts their usefulness. A power hacksaw (or electrfic hacksaw), is a type of hacksaw that is powered either by its own electric motor or connected to a stationary engine. Most power hacksaws are stationary machines but some portable models do exist; the latter (with frames) have been displaced to some extent by reciprocating saw such as the Sawzall, which accept blades with hacksaw teeth. Stationary models usually have a mechanism to lift up the saw blade on the return stroke and some have a coolant pump to prevent the saw blade from overheating. Power hacksaws are not as commonly used in the metalworking industries as they once were. Bandsaws and cold saws have mostly displaced them. While stationary electric hacksaws are not very common, they are still produced. Power hacksaws of the type powered by stationary engines and line shafs, like other lineshaft-powered machines, are now rare; museums and antique-tool hobbyists still preserve a few of them.

HACKSAW TERMINOLOGY:

APPLICATIONS: i. In engineering industry: A power hacksaw is used to cut large sections of steel and other metals. Since it is very difficult to cut diameters larger than 10/15mm with a regular hand-held hacksaw, power hacksaws are used to perform such difficult and time-consuming processes. Although the hand-operated hacksaw has a really long history, with the start of industrial manufacturing and the development of the first machine factories, the operation methods of hacksaws were transformed, so that they could be propelled using the transmission of a steamengine.   

Separation of materials Minimum loss of material due to a slim sawing blade Main areas of application are in the machine and steel construction industries

ii. In construction industry : In contrustion, there are many processes where there is a need to use the hacksaws. 

Cuting iron rods of diameters in pillar work.

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To cut the wood work pieces in order to furnish the house.

iii. In Workshop: In worshops there is a need to cut the wok piece before starting any other operation. It is the main step involved for any process to continue.

LITERATURE SURVEY : 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. A 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 workpiece. The sewing machine is faster and easier than a hand saw and is used principally to produce an accurate square or mitred cut on the workpiece.

Scotch Yoke Mechanism: The scotch yoke is a mechanism for converting the linear motion of a slider into rotational motion or viceversa. 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. The Scotch yoke (also known as slotted link mechanism) is a reciprocating motion mechanism, 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 location of the piston versus time is a sine wave of constant amplitude, and constant frequency is given a constant rotational speed. The yoke is shorter than the diameter of the circle made by the crank pin. For example, the side rods of a locomotive may have scotch yokes to permit vertical motion of intermediate driving axles.

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 are 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.

Types of Hacksaw Machine : i. Light duty hacksaw machine. ii. Hydraulic hacksaw machine. iii. Power hacksaw machine. iv. Circular band hacksaw machine. v. Horizontal swing type band saw machine. vi. Band hacksaw machine. vii. Jigsaw machine. viii. Universal type circular hacksaw machine. ix. Double column band saw machine. x. Chainsaw circular machine.

1. LIGHT DUTY HACKSAW MACHINE: Product Profile of Light Duty Semi Hydraulic Power Hacksaw MachineLight Duty Semi Hydraulic Power Hacksaw Machine is available with Double supported Arm that can keep vibration free movement. Creative Engineers manufactures Light Duty Semi Hydraulic Power Hacksaw Machine. Creative Engineers also manufactures wide range of Bandsaw metal cutting machine and Wire drawing machines. Light Duty Semi Hydraulic Power Hacksaw Machine is equipped with idle Stroke Lifting Mechanism to improve life of blade. An efficient Hydraulic unit gives trouble free function for long life. The machine is available with Auto Lifting & Switching OFF after completion of Job Cutting. It is available under CE-2A model.

Some salient features of Light Duty Semi Hydraulic Power Hacksaw Machine are: A quality ‘Self-Centering Vice’ with perfect grip Utilisation of full blade - adjustable cutting stroke Gear and Hydraulic are Oil Submerged An efficient Hydraulic unit gives trouble free function for long life Auto Lifting & Switching OFF after completion of Job Cutting Weight Balanced for Jurk Free working and suitable for Alloy Steel and Stainless Steel Rigid and Heavy M. S. Fabricated Body Double Oil Cups are fitted for smooth running of slide. Light Duty Semi Hydraulic Power Hacksaw Machine is equipped with idle Stroke Lifting Mechanism to improve life of blade. An efficient Hydraulic unit gives trouble free function for long life. The machine is available with Auto Lifting & Switching OFF after completion of Job Cutting.

2. HYDRAULIC POWER HACKSAW: Hydraulic movement of cutting arm The arm lifts out of contact of the work piece in the forward stroke to prevent damage to the blade or work piece Three speed cutting feed controlled by a lever allows to adjust speed according to the material Auto lift of cutting arm after job completion Motorized Coolant System allows smooth cutting operation.

3. POWER HACKSAW: Power hacksaws are used to cut large sizes (sections) of metals such as steel. Cutting diameters of more than 10/15mm is very hard work with a normal hand held hacksaw. Therefore power hacksaws have been developed to carry out the difficult and time consuming work. 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. Turning the handle tightens or loosens the vice. The vice is very powerful and locks the metal in position.

When cutting is taking place, the metal and especially the blade heats up quickly. Coolant should be fed onto the blade, cooling it down and lubricating it as it cuts through the metal. Without the use of coolant the blade will over heat and break/snap. This can be dangerous as the blade can break with powerful force, shattering.

When the metal is placed and fixed in the vice, the blade is lowered onto its top surface. The diagram below shows the ‘arm’ being lowered with the ‘adjusting handle’.

Blades of power hacksaws are graded according to the material they are made from and the number of teeth per inch. Top quality blades are manufactured from High Speed Steel. although there are cheaper alternatives such as carbon steel blades. In general the number of teeth per inch (TPI) range from 14 to 24. The more teeth per inch - the smoother the cut.

Every power hacksaw should have a foot switch / emergency switch. This allows the operator to turn the machine off quickly by using his/her foot to step on the switch. The foot switch is normally positioned at the front or side of the machine.

Power hacksaws have electric motors that power the blade through a pulley system. Some have ratchet systems. The pulley system shown below shows how rotary power is transferred from the motor and changed to reciprocating motion, allow the blade to cut through the material. Most power hacksaws have two pulley wheels. If the belt is placed on the smaller pulley wheel the speed of cut will be fast. Changing the belt so that it runs round the larger pulley wheel will reduce the speed.

4. CIRCULAR HACKSAW: A circular saw is a power-saw using a toothed or abrasive disc or blade to cut different materials using a rotary motion spinning around an arbor. A hole saw and ring saw also use a rotary motion but are different from a circular saw. Circular saws may also be loosely used for the blade itself. Circular saws were invented in the late 18th century and were in common use in sawmills in the United States by the middle of the 19th century.

A circular saw is a tool for cutting many materials such as wood, masonry, plastic, or metal and may be hand-held or mounted to a machine. In woodworking the term "circular saw" refers specifically to the hand-held type and the table saw and chop saw are other common forms of circular saws. "Skil saw" has become a generic trademark for conventional hand-held circular saws. Circular saw blades are specially designed for each particular material they are intended to cut and in cutting wood are specifically designed for making rip-cuts, cross-cuts, or a combination of both. Circular saws are commonly powered by electricity, but may be powered by a gasoline engine or a hydraulic motor which allows it to be fastened to heavy equipment, eliminating the need for a separate energy source.

5. JIGSAW POWER TOOL: A jigsaw power tool is a jigsaw made up of an electric motor and a reciprocating saw blade. A jigsaw with a bevel function on the sole plate allows cutting angles of typically up to 45 degrees relative to the normal vertical stroke for cutting miter joints. In the past, what are now usually called scroll saws were often referred to as jigsaws. A power jigsaw may also be referred to, by some manufacturers, as a "bayonet saw" or sabre saw A Jigsaw works by attaching a blade accessory to the tool. There are various types of blades in the market. Most jigsaws require a blade to be screwed into the tool, but Bosch has since added the first tool less blade change system allowing a blade to be snapped into the tool.

There are T-shank blades and U-shank blades available in the accessory market. T-Shank blades are the industry-standard professional interface that provides a longer life and a tighter fit from the blade to the tool. Tooth design is important for the performance of a blade. The tooth spacing, tooth shape, and cutting angle are important in providing speed, cleanliness of cuts, and optimal performance. A side set and ground tooth is designed for clean and fast cuts in wood and plastics. Wavy set and milled teeth will cut most metals as well as aluminum and plastics. A side set and milled tooth works with fast and rougher cuts in wood and plastics. A ground and taper ground tooth is for very precise, fine and clean cuts in wood. There is also reduced-kerf carbide and diamond grit edges for fast cutting in hard materials.

SAWING MACHINE: Gadget for cutting up bars of material or for removing shapes in plates of crude material. The cutting gadgets of sawing machines may be thin metallic plates with teeth on their edges, thin metal sharp edges or versatile gatherings with teeth on one edge, or thin pulverizing wheels.The apparatuses may utilize any of three activities in sawing:bona fide cutting, pulverizing, or crushing made condensing. The power hacksaw machine gives a tight brace to section the work and means for reacting a U-shaped packaging on which is mounted a straight steel hacksaw edge that cuts while moving one route so to speak. The saw pushes down on the work amid the cutting stroke however is raised clear of the work amid the arrival stroke. The band saw utilizes an interminable adaptable steel band with teeth on one edge; the band is carried on two huge measurement turning wheels mounted on parallel tomahawks some separation separated.Band saws that cut vertically are especially reasonable for removing shapes in thin, level plates from workpieces that lie on flat tables. Cool sawing machines with toothed plate cutters are utilized broadly in steel-moving factories and in places where vast amounts of bars are cut. A V-molded clipping tight clamp empowers packs of bars to be cinched and cut at one time. Grinding sawing machines are utilized to a great extent for cutting off steel auxiliary shapes, for example, I pillars, channels, and points. The cutting wheels, with or without teeth, pivot at such high speeds that the warmth from the rubbing of contact is adequate to expel the metal by liquefying it. Grating cut off saws, thin elastic or Bakelite-fortified rough wheels that are worked at high fringe speeds, are especially reasonable for cutting off thin tubes and solidified steel bars.

TYPES OF SAWING: Power Hacksawing : The basic forward and backward movement of the cutting edge made the hacksaw one of the principal kinds of sawing machines intended for control. The straightforwardness in the sharp edge movement has kept the cost of the saw machine generally less expensive than different kinds of sawing machines. The low introductory cost combined with the adaptability and versatility, has empowered the hacksaw to stay well known in industry. In hacksawing, a solitary sharp edge is tensioned in the bow, and responded forward and backward finished the work piece. The cutting activity is accomplished just amid half of the cycle of task.Amid the second 50% of the cycle, the arrival stroke, the sharp edge is lifted clear of the work piece, giving a spasmodic cutting activity, which is thought to be one of the disadvantages of the task. In spite of this inconvenience, when contrasted with the consistent cutting activity of the band saw, hacksaws remain similarly or much more famous elective machines. Likewise with numerous other fundamental procedures, hacksawing is an attempted and tried strategy,solid, reliably precise, fast and simple to repair, is less subject to remedy cutting edge strain and more averse to run-out.Besides control hacksaws can be left unattended for significant lots when cutting substantial distance across bar and require least administrator aptitude. Edge substitution is moderately shabby and straightforward.

Band Sawing : Band sawing, unlike hacksawing, is a continuous cutting operation. An endless blade, the band, is tensioned between two shrouded, rotating wheels, and part of the band is exposed to carry out the cutting operation of the work piece. The band travels in a continuous motion, with the teeth fed against the work piece. Whilst earlier metal sawing bands were wide (over 25 mm), and were used strictly for cut off methods, narrow blades, introduced about 50 years ago brought contouring capabilities. Furthermore, due to the small throat clearance of the early band saws, they were limited in use by the basic design, thus the length of the work piece could only be as long as the machine throat. However modern machines have been modified to give adequate throat clearance, by intentionally twisting the blade so that the toothed faces in line with the machine throat. As with hacksaw machines, band saws can be divided into two broad categories. A general purpose band saw having gravity fed system, controlled by a dash-pot and using a25 mm (1 inch) deep blade, is the most popular machine available. This machine is suitable for general

fabrication work and accurate cutting of solid bars. This type of machine is limited to about 175 mm (7 inches) diameter for mild steel. In order to meet the present day requirements for high-volume production, cutting all grades of steel and to introduce high accuracy and reliability, it has been necessary for the band saw machine manufacturers to incorporate in the design not only heavy duty construction having capacities up to 450 mm (18 inches) diameters but also innovations in the hydraulic power downfeed, to allow the cutting of difficult alloys., such as mnemonics and titanium.

Circular Sawing : Roundabout saws have a constant cutting activity; utilize sharp edges having numerous teeth, and an extensive scope of rotational velocities. This activity is like a processing task. The machines accessible range from the prior, economical, hand-stacked models to the specific vast, control stacked write and join material taking care of gadgets for semi and after that completely programmed task. Present day generation roundabout saws are worked with a few substitute essential feed components i.e. level, vertical, shaking head and varieties of these. The decision of the most appropriate kind of machine relies upon the specific application and the size and state of segment. With vertical feed, the pivoting edge ventures downwards in a straight line to draw in the work piece. On machines intended for even feed the cutting edge is sustained into the work piece from the back. A third fundamental encouraging plan is a turn movement or shaking head framework, this is as proficient as a vertical feed framework and is a tough course of action. The seat or floor mounted manual-feed round observed, when introduced together with a general obligation band saw or hacksawing a little workshop, gives an entire slicing office to the little fabricator. Completely programmed round saws, having highlights, for example, dial-in segment length, in process checking, decision of stacking magazines, and so on are broadly utilized where top notch creation is required and frequently give the generation build a troublesome decision to make between roundabout sawing and band sawing.

TYPES OF TOOLS USED : 1. SCREW DRIVER : A screwdriver is a tool,manual or powered, for screwing and unscrewing (inserting and removing) screws. A typical simple screwdriver has a handle and a shaft, ending in a tip the user puts into the screw head before turning the handle. The shaft is usually made of tough steel to resist bending or twisting. The tip may be hardened to resist wear, treated with a dark tip coating for improved visual contrast between tip and screw—or ridged or treated for additional 'grip'. Handles are typically wood, metal, or plastic and usually hexagonal, square, or oval in cross-section to improve grip and prevent the tool from rolling when set down. Some manual screwdrivers have interchangeable tips that fit into a socket on the end of the shaft and are held in mechanically or magnetically. These often have a hollow handle that contains various types and sizes of tips, and a reversible ratchet action that allows multiple full turns without repositioning the tip or the user's hand. A screwdriver is classified by its tip, which is shaped to fit the driving surfaces—slots, grooves, recesses, etc.—on the corresponding screw head. Proper use requires that the screwdriver's tip engage the head of a screw of the same size and type designation as the screwdriver tip. Screwdriver tips are available in a wide variety of types and sizes (List of screw drives). The two most common are the simple 'blade'-type for slotted screws, and Phillips, generically called "cross-recess".

A wide variety of power screwdrivers range from a simple 'stick'-type with batteries, a motor, and a tip holder all inline, to powerful "pistol" type VSR (variable-speed reversible) cordless drills that also function as screwdrivers. This is particularly useful as drilling a pilot hole before driving a screw is a common operation. Special combination drill-driver bits and adapters let an operator rapidly alternate between the two. Variations include impact drivers which provide two types of 'hammering' force for improved performance in certain situations, and "right-angle" drivers for use in tight spaces. Many options and enhancements, such as built-in bubble levels, high/low gear selection, magnetic screw holders, adjustable-torque clutches, keyless chucks, 'gyroscopic' control, etc., are available.

2. HAMMER: A modern day hammer is a tool consisting of a weighted "head" fixed to a long handle that is swung to deliver an impact to a small area of an object. This can be, for example, to drive nails into wood, to shape metal (as with a forge), or to crush rock. Hammers are used for a wide range of driving, shaping, and breaking applications.

The modern hammer head is typically made of steel which has been heat treated for hardness, and the handle (also called a haft or helve) is typically made of wood or plastic. The term "hammer" also applies to a mechanism's part that delivers a blow, such as the hammer of a firearm or of a piano. The claw hammer has a "claw" to pull nails out of wood, and is commonly found in an inventory of household tools in North America. Other types of hammer vary in shape, size, and structure, depending on their purposes. Hammers used in many trades include sledgehammers, mallets, and ball-peen hammers. Although most hammers are hand tools, powered hammers, such as steam hammers and trip hammers, are used to

deliver forces beyond the capacity of the human arm. There are over 40 different types of hammers that have many different types of uses.

3. SOLDERING: Soldering is a process in which two or more metal items are joined together by melting and then flowing a filler metal into the joint—the filler metal having a relatively low melting point. Soldering is used to form a permanent connection between electronic components.

The metal to be soldered is heated with a soldering iron and then solder is melted into the connection. a. Only the solder melts, not the parts that are being soldered. b. Solder is a metallic "glue" that holds the parts together and forms a connection that allows electrical current to flow. You can use a solderless breadboard to make test circuits, but if you want your circuit to last for more than a few days, you will want to solder the components together.

OPERATION USED: ARC WELDING:

Arc welding is a welding process that is used to join metal to metal by using electricity to create enough heat to melt metal, and the melted metals when cool result in a binding of the metals. It is a type of welding that uses a welding power supply to create an electric arc between a metal stick ("electrode") and the base material to melt the metals at the point of contact.

Arc welders can use either direct (DC) or alternating (AC) current, and consumable or nonconsumable electrodes. The welding area is usually protected by some type of shielding gas, vapor, or slag. Arc welding processes may be manual, semi-automatic, or fully automated. First developed in the late part of the 19th century, arc welding became commercially important in shipbuilding during the Second World War. Today it remains an important process for the fabrication of steel structures and vehicles.

APPLICATIONS: Here are some examples of where it is used in the world: • Structural steel • Signs • Automobiles • Furniture • Decorations • Wire • Fencing • Nails

HACKSAW MACHINE :

Working Principles Hacksaw Machine using Scotch yoke Mechanism A hacksaw machine is work on the principle of SCOTCH YOKE MECHANISM in this 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 machine 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 with electricity. Now start the electric motor so due to that the shaft of the motor and the hollow disc will be rotated and also rotate the eccentric Centre and link connect to it. Due to rotation of links the hacksaw frame will be reciprocated on the metal and cutting of metal is done.

SIMPLE HARMONIC MOTION : This mechanism converts the rotary motion into the translatory motion which issimple harmonic in nature.

Mathematical ExplanationSuppose crankshaft is rotating at an angular velocity ‘w’. If ‘r’ is the radius of crank then, Tangential velocity, V=rw

From the mechanism, we have the following relationsComponent of tangential velocity in Y-direction is given by, U=Reciprocating velocity of U-slot. If ‘a’ is the angle made by the tangential velocity with X-axis at any point of time, Component of tangential velocity in Y-direction is U=rw sin (a) U=v sin (a) So, Velocity of U-slot=V sin a As a result, Velocity of U-slot is a function of sine function of a.Now, as we know that a is directly proportional to the time. This implies that thevelocity of u-slot is a sine function of a so the motion of U-slot is a simpleharmonic motion.

ADVANTAGE OF SHMThe sinusoidal motion, the sinusoidal velocity, the sinusoidal acceleration(assuming constant angular velocity) results in smoother operation of the mechanism.

3.3 Assembly of Hacksaw Machine For assembly of hacksaw machine first of all on the base plate electric motor is mount vertically, the hollow disc having internal circle radius is same as the radius of the shaft of the motor is fit on the shaft and also the disc has an eccentric center, a metal bar is a weld at the eccentric center. The links one end is connected with the end of hacksaw frame and the second end is connected with the metal bar of eccentric centre. The buckle type elements are connected at the end of hacksaw frame and the link is connected to this buckle, pipe provides support to the hacksaw frame, the pipe is connected to the base. Vice is also fit on the pipe and which also connect with the base.

3.3 Features of Hacksaw Machine i. Power efficiency. ii. High productivity. iii. Superb performance. iv. High operational fluency. v. Sturdy and robust design.

3.4 Hacksaw Blades The hacksaw blade consists of different parts: i. 2 pin holes ii. Centerline iii. Side

3.5 Characteristics of Hacksaw Blade The hacksaw blade has 2 main characteristics: (1) Teeth pitch which is the number of teeth per 25 mm. (2) Blade length which is the length between the centres of its pin holes.

4. INDUSTRIAL PURPOSES

4.1 Advantages i. The weight of the machine is less. ii. It reduces the work of labour. iii. Easy to make because of simple construction. iv. High production rate. v. Cost is less. vi. Easy maintenance and maintenance cost is less. vii. It resists all atmospheric effects.

4.2 Disadvantages i. Time consume more. ii. Speed variation is required for cutting the different metal

X. IDEA OF FATIGUE In limit sense, the term weakness of materials and auxiliary parts implies harm and harm because of cyclic, over and again connected anxieties. In a wide sense, it incorporates countless that harm and crack under burdens and natural conditions. It is arranged between high-cycle (exemplary) and low-cycle weakness. Plastic distortions are little and limited in the region of the break tip while the primary piece of the body is disfigured flexibly, at that point one has high-cycle exhaustion. In material science, weakness is the dynamic, confined, and lasting auxiliary harm that happens when a material is subjected to cyclic or fluctuating resist ostensible burdens that have greatest esteems not as much as the static yield quality of the material. The subsequent pressure might be underneath a definitive pliable pressure, or even the yield worry of the material, yet still reason cataclysmic disappointment.

XI. FATIGUE STRENGTH Exhaustion quality is characterized as the most extreme pressure that can be continued for a predetermined number of cycles without disappointment. Low cycle weariness quality methodologies the static quality. At the point when the cycle number surpasses as far as possible, the weariness quality tumbles to portion of the static quality.

XII. SCOPE OF PAPER • The machine can take care of the issue of time utilization. • Misuse of assets in face of work cost is decreased. • The machine can be utilized as a part of the business where it is made, at the bundling area.

• It is utilized as equipment in extensive amount like in manufacture of machine. • It give other option to ventures pointing toward lessening human exertion. • It produces supportable and functional mechanization answers for the future mechanical improvement.

XIII. OBJECTIVE OF PAPER • To take into account the issue of rivalry in mechanical industry the requirement for computerization is evaluate by all the business. • To recognize the key arrangement roads thought to be fitting to address the difficulty of reasonable assembling and bundling industry for what's to come. • To give other option to ventures pointing toward decreasing human exertion and change in material taking care of framework by actualizing mechanization. • Reasonable and down to earth mechanization answers for the future mechanical condition.

XIV. METHODOLOGY

A. Introduction The plan of the paint blending machine includes the underlying phases of idea outline and their motivations. Diverse ideas of shading picking systems, utilization of sensors and microcontroller were chosen lastly a particular one was picked in the wake of assessing them based on many-

sided quality, simplicity of creation and effortlessness. At that point, a definite outline of the same was introduced which incorporates singular highlights, determinations and CAD show introduction.

B. Concept Design In the idea plan different parts have been composed like base table (24x11)inch and material utilized is gentle steel, at that point center arm (23x9x6.5)inch and material utilized is mellow steel, at that point shaft (6 inch dia) is utilized as interfacing join for hacksaws and arms and material utilized is gentle steel, at that point dc motor (35 rpm) is appended under the base table, at that point upper arm (16.4)inch is associated with the back arm and material utilized mellow steel. Figure 3 – CAD Design of Double Hacksaw Cutter XV. REQUIREMENTS OF PARTS

A. Middle Arm : It is used to balance the motor and it is attached to shaft. Its dimension is (23x9x6.5) inch. Figure 4 – Middle Arm Of Cutter

B. Bolt : It is used for the fixing of bench vice for proper alignment of shaft and flywheel.

Figure 5 – Bolt C. Nut - It is used in bench vice, connecting rod and shaft for tightening bolts.

Figure 6 – Nut

C. Base : It is stand on which all parts are mounted like dc motor, shaft.

D. Rotating Shaft : It is used here for moving of both arms carrying hacksaws. Figure 7 – Rotating Shaft

E. Shaft : A shaft is a pivoting machine component which is utilized to transmit control starting with one place then onto the next. The power is conveyed to the shaft by some unrelated power and the resultant torque (or turning minute) set up inside the shaft allows the ability to be exchanged to different machines connected up to the shaft. Keeping in mind the end goal to exchange the power starting with one shaft then onto the next, the different individuals, for example, pulleys, gears and so forth., are mounted on it. These individuals alongside the powers applied upon them makes the shaft bowing. As it were, we may state that a shaft is utilized for the transmission of torque and bowing minute. The different individuals are mounted on the shaft by methods for keys or splines.

F. Hacksaw : A hacksaw is a fine-tooth saw with an edge under pressure in a casing, utilized for cutting materials, for example, metal. Hand-held hacksaws comprise of a metal edge with a handle, and sticks for joining a thin dispensable cutting edge. A screw or other system is utilized to put the thin cutting edge under pressure. A power hacksaw (or electric hacksaw) is a sort of hacksaw that is controlled by electric engine. Most power hacksaws are stationary machines yet some helpful models do exist. Stationary models commonly have a framework to lift up the saw sharp edge on the entry stroke and some have a coolant pump to keep the saw bleeding edge from overheating.

G. DC Motor: A DC motor is an electric motor driven by an immediate current (DC). The DC motor usually comprises of two essential parts, an outside stationary stator having loops provided with substituting current to deliver a pivoting attractive field, and an inside rotor connected to the yield shaft creating a second turning attractive field. The rotor attractive field might be created by lasting magnets, hesitance saliency, or DC or AC electrical windings. The responding movement of the Hacksaw sharp edge, as a result of which the cutting procedure happens, is delivered with the assistance of a DC motor, which works by a basic wrench component to change over rotating movement of wrench into responding movement Hacksaw edge. The DC motor is turned on after the workpiece has been immovably fit in the pneumatic toss. The Torque of motor is expanded by transmission of capacity to a pulley by belt transmission.

(a) Specification of DC Motor: The electric power supply necessary to run the DC motor is obtained from a step-down transformer and a bridge rectifier – Figure 10 – Properties Of DC Motor

H. Acrylic Paint : Acrylic paint is a fast-drying paint made of pigment suspended in acrylic polymer emulsion. Acrylic paints are water-soluble, but become water-resistant when dry. Depending on how much the paint is diluted with water, or modified with acrylic gels, mediums, or pastes, the finished acrylic painting can resemble a watercolor or an oil painting, or have its own unique characteristics not attainable with other media. Acrylic paint is typically used for crafting, or in art classes in schools because it does not require any chemicals, and rinses away with just water. It also is less likely to leave a stain on clothes than oil paint.

CALCULATION: Calculation for DC Motor From Physics, Power = Torque * Angular Velocity Torque = Power/ Angular Velocity Power=50 Watts Angular Velocity = Speed in rpm * 2* pi = 32*2*3.14 =200.96 Now, Torque = 50/200.96 = 0.24 Nm

XVII. DOUBLE HACKSAW CUTTER:

XVIII. COST AND ESTIMATION:

S. NO 1 2 3 4 5 6 7

COMPONENTS DC MOTOR IRON RODS HACKSAW (2) NUT BOLT DISC PLATE BATTERY OTHER STUFF TOTAL

COST IN RUPEES 2000 2500 500 100 400 900 500 6900

TOTAL COST ESTIMATION: 1.Labour Cost: Lathe, drilling, welding and power hacksaw cost Labour cost = Rs.1000 2. Overhead charges: The overhead charges are arrived by “manufacturingcost” Manufacturing cost = Material cost + Labour cost = Rs.6900 + Rs.1000=Rs.7900 Overhead charges = 20% of the manufacturing cost= Rs.1580 3.Total Cost: Total cost = Material cost + Labour Cost + Overheadcharges =Rs.6900 + Rs.1000 + Rs.1580=Rs.9480 Total cost of the project = Rs.9480 5.CONCLUSIONS 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 the machine is helpful and completes all the expectations needed for 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 a jerk, no special training required to operate it. After studying this report, we have to know that how the A hacksaw machine will work and knowing the construction and how mechanism work in the machine. We learnt how the theoretical design is possible in practise. Another 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 compared to another machine. The cost of the machine is less and easy to operate so it affordable for all industry. The material cast iron which is used will give the high strength than alloy steels. This project is very much useful and easy to install by the user and also the motor used will not only operate with the help of electricity but also through conventional source of energy like solar energy . REFERENCES [1]. R. Subhash, C.M. Meenakshi, K. Samuel Jayakaran, C. Venkateshwara, R. Sasidharan, “Fabrication pedal power Hacksaw. [2] Peart, G. R. (1902). U.S. Patent No. 706,447. Washington, DC: U.S. Patent and Trademark Office. [3] Martin, J. A., & Erisoty, G. J. (1998). U.S. Patent Application No. 29/081,671. [4] Sawyer, W. G., Diaz, K. I., Hamilton, M. A., & Micklos, B. (2003). Evaluation of a Model for the Evolution of Wear in a Scotch-Yoke Mechanism. Journal of tribology, 125(3), 678- 681. [5] Budinski, K. G., & Budinski, M. K. (2009). Engineering materials. Nature, 25, 28. [6] Waldherr, A. (1989). U.S. Patent No. 4,835,869. Washington, DC: U.S. Patent and Trademark Office. International Conference on Mechanical Industrial System Engineering (ICMISE’2018), Graphic Era Deemed to be University, Dehradun, 1st 2nd June’2018 32

[7] Lipcha, B., Kadam, A., Gadakh, S., Yadav, A., & Pathan, F. U. RECTIFICATION OF POWER HACKSAW MACHINE. [8] Kalpakjian, S., & Schmid, S. R. (2014). Manufacturing engineering and technology (p. 913).