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 CHAPTER 1
INTRODUCTION
There are many industrial applications where round bar or square bars are
required to be operated on different machines to make machine components
such as Shafts,Bolts, Screws etc. This needs more and more number of pieces to
be cut for mass production of those components. Four way hacksaw blade
machine is basically a cutting device, which cut in four directions at a same
time .

A hacksaw is a fine –toothed saw, originally and principally for cutting metal.
They can also cut various other materials, such as plastic, wood and steel etc.
This project proposes the prototype model of four-way hacksaw machine which
is able to cut four pieces simultaneously without any jerk and minimum
vibrations. The prototype model implies conversion of rotary motion into the
reciprocating motion for proper working of hacksaw.

This prototype model overcomes the limitations of conventional hacksaw

machines which can cut single piece at time. It is able to cut metal bars of
different materials at same time and will be helpful in many industries due its
compatibility, reliability and efficiency. In present condition many electrically
operated power hacksaw machines. The hacksaw is a metal cutting machine tool
designed to cut multiple metals simultaneously by applying cam mechanism.
The operation of the unit is simplified to a few simple operations involving a
motor and a scotch yoke mechanism There are numerous types of cutting
machines in Engineering field, which are used to fulfil the requirements. We are
interested to introduce multiple hacksaw cutting operation in Hacksaw
machine.The main function of this hacksaw machine is to cut thin and soft
metals by motor power.

This is an era of automation where it is broadly defined as replacement of

manual effort by mechanical power in all degrees of automation. Degrees of
automation are of two types :-
Full automation.
Semi automation

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OBJECTIVE OF MODEL:-

1) The main objective of this project is to reduce the

human effort for machining various materials.

2) The objective of principles of this project is to save

man power and time in cutting materials in order to
achieve high productivity.

3) Implementation in the existing technology.

4) To show the innovative idea on existing system.

5) To make use of electronic component that are is

readily available and chipset.

6) To prepare and efficient and cost effective system.

SELECTION OF HACKSAW BLADE: A hacksaw is a fine-tooth saw with a

blade under tension in a frame, used for cutting materials such as plastics,
metals etc. The principle of metal cutting is working principle for hacksaw
blade cutting operation. For cutting operation to be done the hacksaw blade
should be of harder material than material to be cut. The well known power
hacksaw machine is powered by electric motor. So the saw or saw blade is
important component in consideration for high rates of cutting to be done.

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Different Types of Saw blades: Following are the types of blades which are
generally used material cutting
1. High Carbon Steel

2. Bi-Metallic Steel

3. High Speed Steel

4. Low Alloy Steel

Scotch Yoke Mechanism:-

The Scotch yoke is a mechanism for converting the rotational motion of a crank
into linear motion of slider. The piston or other reciprocating part is directly
coupled to a sliding yoke

Applications of Scotch Yoke Mechanism:

This setup is most commonly used in control valve actuators in high pressure
oil and gas pipelines.

Although not a common metal working machine nowadays, a Shaper uses a

Scotch yoke which has been adjusted to provide a slow speed forward stroke
and a faster return.

It has been used in various internal combustion engines, such as the Bourke
engine, Sy Tech engine, and many hot air engines and steam engines

It consists of the same elements as slider-crank mechanism and is early used in

steam pumps and in computing machines as a harmonic generator.

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Problem Identification
The conventional hack saw machine are operated by human operators as
mentioned, have the demerit of unloading and loading the work-piece many
times. In mechanical industries need to cut no. of ideal parts. It is very difficult
for operator to cut the individual parts. It takes more time for cutting.

DESIGN SPECIFICATIONS:-

Base frame=430*430mm

Height from base to hacksaw=220mm

Height of the base frame=120mm

Cutting stroke length=150mm

Thickness of blade=1.4mm

Lenghtof the blade=300mm

Length of the connecting rod=340Mm

Different types of saw blades:-

1. High Carbon Steel

2. Bi-Metallic Steel

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3. High Speed Steel
4. Low Alloy Steel

1. High Speed Steel has less wear working with Mild Steel.
2. Low Alloy Steel has good wear resistance working with Brass.
3. High Carbon Steel when working with Alluminium.

High-speed steel (HSS or HS) is a subset of tool steels, commonly used as

cutting tool material.

It is often used in power-saw blades and drill bits. It is superior to the older
high-carbon steel tools used extensively through the 1940s in that it can
withstand higher temperatures without losing its temper (hardness). This
property allows HSS to cut faster than high carbon steel, hence the name high-
speed steel. At room temperature, in their generally recommended heat
treatment, HSS grades generally display high hardness (above Rockwell
hardness 60) and abrasion resistance (generally linked to tungsten and vanadium
content often used in HSS) compared with common carbon and tool steels.

Bimetallic steel:-
Bimetal refers to an object that is composed of two separate metals joined
together. Instead of being a mixture of two or more metals, like alloys,
bimetallic objects consist of layers of different metals. ... A bimetal bar is
usually made of brass and iron

Carbon steels:-

Carbon steels which can successfully undergo heat-treatment have a

carbon content in the range of 0.30–1.70% by weight. Trace
impurities of various other elements can have a significant effect on
the quality of the resulting steel. Trace amounts of sulfur in particular
make the steel red-short, that is, brittle and crumbly at working temperatures.
Low-alloy carbon steel, such as A36 grade, contains about 0.05% sulfur and

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melts around 1,426–1,538 °C (2,599–2,800 °F).[8] Manganese is often added to
improve the hardenability of low-carbon steels. These additions turn the
material into a low-alloy steel by some definitions, but AISI's definition of
carbon steel allows up to 1.65% manganese by weight

HIGH CARBON STEELS:-

Steel that has more than 0.3 percent carbon, and is thus harder and less formable
and machinable than low-carbon steel. Used mainly for cutting EDGEs,
compression springs, farming and gardening equipment, and other high-wear
applications.

LOW ALLOY STEELS:-

Among alloy steels, when Ni, Cr, Mo, and other alloy elements content consist of less than 10.5%
are defined as low alloy steels.

Company products compatible with low alloy steels

• High heat resistance steel (Chromium- Molybdenum Steel)

• Low temperature use steel (Nickel Steel)

• Weathering Steel

• High yield and high tensile strength steel

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SYSTEM ARCHITECTURE:
The experimental setup of our project consists of a frameon which the hacksaw
blades are mounted on the four sides of the frame. The circular cam plate is
mounted in the centre of the frame which is operated by a motor. The power to
the motor is given with the help of an AC supply. Connecting rods
are used to connect the cam wheel and the hacksaw blades. The scotch yoke
mechanism is used to convert the rotary motion into the reciprocating motion.
Hence when the motor is switched on, the power from the motor is delivered to
the cam wheel. The cam wheel rotates such that the hack saw blades
reciprocate. The work pieces are mounted on the machine vice firmly and
the entire system is switched on. Thus the four work pieces are cut
simultaneously using the motor and the scotch yoke mechanism

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 CHAPTER 2
LITERATURE SURVEY

Theoretical Analysis Of Four Way Hacksaw BladeMachine Rishi Anand,

Khomesh, Shrawan Kumar,
Alok Verma ,April 2016 :-

In this paper presents the concept of four way hacksaw blade machine mainly
carried out for production based industries. Industries are basically meant for
production of useful goods and services at low production cost, Machinery cost
and low inventory cost. Knowledge about developed a model of a machine
reach would be capable of performing different operation simultaneously, and
it should be economically efficient. These machines can be used in remote
places where electricity is regular. It is designed as a portable one which can be
used for cutting in various places. It can be used for operating on materials like
thin metals,wood

Material Selection and Testing of Hacksaw Blade Based on mechanical

Oproperties Nitin Chandra R Patel, Md. A. Vasanwala , Balkrushna B.Jani,
Mitesh kumar D Rathwa, Ravi A. Thakkar ,June 2013:-

In his research paper “Material selection and testing of hacksaw blade based
on mechanical properties” stated that the appropriate saw blade must be
selected for better operation and fine cutting byselecting number of teeth per
inch. There are four types of blades based on material namely High Carbon
steel, Alloy Steel, Bi-metallic strip and Highspeed steel blades. Out of these
four the best suitable for cutting hard materials like Mild steel bar and
Aluminium is Bi-metallic blade on the basis of Properties of materials, Wear
resistance and Cutting performance.

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Design & Fabrication of Human Powered Multi-Purpose Machine Rakesh
Ambade , Amit Sartabe , Meghraj Arekar ,Vaibhav Khachane,Prajakta
Gawali,April 2015:-

In their paper states that it consist the pedal poweredmachine setup , has a
simple mechanism operate with chain and sprocket arrangement. The chain is
placed on the teeth of the wheel and pinion. The shaft is mounted on pedestal
bearings. First mechanical linkage is removed by removing nut and bolts and v
belt drive drilling attachment.

Theoretical Analysis of Multi-way Power HacksawMachine Kshirsagar Prashant

R, Rathod Nayan,Rahate Prashant P,Halaye Prashant P, April 2015 :-

In his research paper stated that it consist of singlephase vertical electric

motor rigidly placed at the center of metallic foundation provided. The shaft of
motor rotates at 90-100 rpm with the power 2HP. The circular disc is mounted
on the shaft of motor with the help of key and key slot arrangemnt

Design and Fabrication of Automate d HacksawMachine, D. V. Sabariananda, V.

Siddhartha, B Sushil Krishnana,T.Mohanraj, April 2014:-

It is known that conventional power hacksaw machin ecan be replaced with

automated power Hacksaw machine. Automated power 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 labour is reduced to maximum level

CHAPTER 3
EXPERIMENTAL METHODOLOGY

FLOWCHART:-

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 MOTOR
(220V,50HZ,750RP
M )

CIRCULAR DISC(DIA:-
125MM)

HACKSAW(LENGTH=300MM,
THICKNESS=1.4MM)

CONNECTING RODS
(LENGTH=300MM)

WORKPIECE

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Components required:-
1.frame
2.circular disc
3.connecting rods
4.motor
5.hacksaws
6.roller slides

COMPONENT DETAILS:

FRAME:

Base frame design: WE design a basic frame for a prototype by mild

steel channel (L beam), L Channel-MS Angles are L-shaped structural
steel represented by dimension of sides & thickness. For e.g.
25x25x3 means, both the sides of angles are 25 mm & thickness is of
3mm. There are various sizes of angles which are as follows :-( there
are also equal & unequal angles). Equal angles: - They are angles
having both the sides of equal dimensions. For e.g. refer below given

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Universal Motor – Construction,WorkingandApplication
A universal motor is a special type of motor which is designed to run
either on DC or single Phase AC supply. Universal Motors are so
named because they can run both on AC as well as DC.A universal
motor has a high starting torque and variables peed characteristics.
Such motor Runs at dangerously high speeds during no load.The
universal motor is basically a series DC motor which is specially
designed to operate on AC As well as on DC. A standard C series
motor has very poor characteristics when operated on AC mainly due
to two reasons:-

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The high reactance of both the armature and fieldwindings limits AC
current to a much lower Value than DC current for the same line
voltage. If solid steel is used for the stator frame ,AC flux will produce
large eddy currents in the frame With consequent heating

Circular disc:-
In mechanical engineering, an eccentric is a circular disk fixed
to a rotating axle with its centre offset from that of the axle
(hence the word "eccentric", out of the centre). It is used to
convert rotary motion. In this project circular disc using
because of rotary motion. It is connected to shaft. A pin is
hold in this slot

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 Dia=125mm

CONECTING RODS :-
It is a straight rod of length of 300 mm
It is of mild steel material
It is connected to the slotted bar and hacksaw frame
It is mounted on the frame with the help of bush

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HACKSAW:-
1. It is the most important oart of the machine
2. Hacksaw blade is holded by the hacksaw frame
3. The length of the blade is 30mm

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 CHAPTER-4
DESIGN CALCULATION
DEGREES OF FREEDOM:
Degrees of freedom or mobility is defined as the no. of
independent motion a boby can have.

• Types of degrees of freedom

• 1.Kutzbach’s equation
• 2.Grubler equation

Degrees of freedom (kutzbach’s equation)

n =3(L-1)-2J1-J2

L=no. of links, including ground link

J1=no. of lower pair

ex: nut and bolt,shaft rotating in bearing.

J2=no. of higher pair

ex: belt, rope and chain drives,rolling bearing,

gears,cam and follower.

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Where,
No. of links L = 4
No.of lower pair J1 =3
No of higher pair J2=0

DOF(n)= 3(L-1)-2(J1)-J2
n=3(4-1)-2(3)-0
=3(3)-6-0
=9-6-0
n =3

•
ANGULAR SPEED:-
W=2πN/60
W=angular speed
W=2*3.14*100/60
W=10.466rad/s

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we know that ,
Ac=300m;CB1=120mm
Sin <CAB1=90˚-α/2
=CB1/AC=120/300=.4
<CAB1=90˚-α/2
=1/sin.4
=23.6
α/2=90˚-23.6˚=66.4˚
α=2*66.4=132.8˚
we know that
time of cutting stroke/time of return stroke
=(360˚-α)/α
=(360˚-132.8˚)/132.8˚
=1.72

FOR INITIAL TORQUE:-

• From velocity diagram,
• Considering cutting stroke 5 inches= 125mm
• As we know l=2r
• Where r = crank radius
• Therefore r = 62.5mm
• The length of connecting rod =300mm
• Speed 90 rpm
• Angular velocity ω=2ΠN/60 =9.424rad/sec

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• Here OP = crank radius
• OA= OB=OC=OD=connecting rods
• ωpo= 9.42rad/sec
• Since op =0.0625m
• So velocity of p wrt o
• Vpo=Vp=9.42*0.0625=0.588 m/sec
• Vap=4.4 cm/sec=0.44m/sec
• Vbp=4.1 cm/sec=0.41m/sec
• Vcp=4.4cm/sec=0.44m/sec
• Vdp=4.1cm/sec=0.41m/sec
• Required torque
• We know forces at A,B,C,D
• FA=FB=FC=FD =500N
• Power input =(Fa*Va)+(Fb*Vb)+(Fc*Vc)+(Fd*Vd)
• =(500*0.44)+(500*0.41)+(500*0.44)+(500*0.41)
• = 850 Nm/sec
• Neglecting losses power input is equal to power output
• Power P = 850Nm/sec
• P=1.13HP
• Speed N = 100 Rpm
• P =2πNT/60
• T=P*60/2ΠN
• T =81.21 Nm/sec

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 CHAPTER 5
RESULT

As per the above discussion we conclude that to overcome problems

in conventional hacksaw machine due to high efficiency, easy to
operate. The proposed model of multi way hacksaw is helpful and
complete all the expectations needed in the mini industries. As a
result benefits would be achieved such as longer tool life, easy chip
flow and higher machining quality in the machining process.

The selection of cutting fluid should be carefully carried out to

obtain optimum result in machining process. Various factors are
affecting the selection of cutting fluid type in machining operation
such a type of work piece and the method of machining process

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DISCUSSION:-
In this project we came to found many use full elements by doing easy jobs.
We can cut four pieces of any material in without any effort and work will be
completed in less time. The cutting for four pieces in this machine will be four
times less than the normal way of cutiing with hacksaws. This project is also
low cost high production.
For this project we have to used steel to make the frame as we used wood for
the frame but during the process the stability lossed due to the high RPM of
motor.In this project we have used a universal motor and we have got it from a
unused washing machine

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Hence, we can conclude that inspite of all the difficulties of vibrations and
more number of moving parts, four way hacksaw machine proves to be useful.
We were required to increase the cutting force. For this we connected the
frame side rods and slider using hinge joint. Further, by increasing the overall
weight of slider, pressure is generated which gives the cutting force. Since, the
fabricated machine is capable of cutting wooden blocks with accuracy, so, the
modification is appropriate. Since, we have considered the maximum values of
shear stresses for calculating the power requirement, this machine is capable
of cutting almost all types of woods taken according to the assumed
dimensions. This machine proves to be useful as it is motor operated, so,
human effort is reduced. The required speed can be easily modulated by
changing the reducing gear arrangement. Instead of motor, pulley
arrangement can also be used.

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 CHAPTER 6
CONCLUSION
A strong multidiscipline team with a good engineering base is necessary for the
Development and refinement of advanced computer programming, editing
techniques, diagnostic Software, algorithms for the dynamic exchange of
informational different levels of hierarchy. This project work has provided us an
excellent opportunity and experience, to use our limited knowledge. We gained
a lot of practical knowledge regarding, planning, purchasing, assembling and
machining while doing this project work. We are proud that we have completed
the work with the limited time successfully. The “FABRICATION OF FOUR
WAY HACKSAW MACHINE” is working with satisfactory conditions. We are
able to understand the difficulties in maintaining the tolerances and also quality.
We have done to our ability and skill making maximum use of available
facilities. In conclusion remarks of our project work. Thus we have developed a
“FOUR WAY HACK SAW MACHINE”. By using more techniques, they can
be modified and developed according to the applications.

Future work
The maximum size of Round or Square bar can be increased by increasing the
motor power and dimensions of different parts.

Automatic feeding mechanism for material can be introduced by using limit

switches or sensors.

Automatic lifting up mechanism for frame when cutting operation is finished

to introduce next portion of bar for cutting

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ADVANTAGES

• Simple in construction.

• Easy to fabricate.

• The components used for the fabrication of the are easily available.

• Repairing and replacing is not a difficult task.

• Multiple work pieces can be cut simultaneously.

• The time taken for cutting operation is less.

• Increased productivity.

DISADVANTAGES

• More number of moving parts.

• Must be handled with care.

• The loading and unloading of the work pieces must be done manually

APPLICATIONS

These types of motorized high speed four way hack saw machines have a wide
range of applications in the fields like,

• In all industries.

• Small scale industries.

• All manufacturing plants.

• Highly suitable for production industries and workshops.

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 CHAPTER 7
REFERENCES
[1] Prof. Kshirsagar Prashant R en all, “Theoretical Analysis of Multi-Way
Power Hacksaw Machine,” International Journal of Research in Advent
Technology, Vol.3, No.4, April 2015 E-ISSN: 2321-9637

[2] Rishi Anand,Khomesh,Shrawan Kumar,Prof. Alok Verma,” Theoretical

Analysis Of Four Way Hacksaw Blade Machine”, International Journal of
Advance Research and Innovative Ideas in Education, ISSN(O)-2395-4396,
Vol-2 ,Issue-2 ,April2016

[3] Prof. Nitinchandra R. Patel, Mohammad A. Vasanwala, Balkrushna B.Jani,

Miteshkumar D. Rathwa, Ravi A. Thakkar,” Material Selection and Testing of
Hacksaw Blade Based on Mechanical properties”, International Journal of
Innovative Research in Science, Engineering and Technology, ISSN: 2319-
8753, volume 2, Issue6, June 2013.

[4] D.V.Sabarinanda, V.Siddhartha, B. Sushil Krishnana, T.Mohanraj , “Design

and Fabrication of Automated Hacksaw Machine”, International Journal of
Innovative Research in Science, Engineering and Tech nology, ISSN
(Online):2319-8753, volume 3, April 2014.
[5] Rakesh Ambade,Amit Sartabe,Meghraj Arekar,Vaibhav Khachane,Prajakta
Gawali ,” Design & Fabrication of Human Powered Multi-Purpose Machine”,
International Journal of Advanced Technology in Engine ering and
Science,ISSN(Online):2348-7550,Volume No 03,Special Issue No.01,April
2015.

[6] Kshirsagar Prashant R, Rathod Nayan,Rahate Prashant P,Halaye Prashant P

,”Theoretical Analysis of Multi-way Power Hacksaw Machine”,International
Journal of Research in Advent Technology,E-ISSN:2321-
9637,Vol.3,No.4,April2015.

[7] Muhammad Ali Mazidi, Janice Gillispie Mazidi, and Rolin D. McKinlay
‘The 8051 Micro Controller and Embedded Systems’, 2nd Edition, Pearson
Education Inc. 2008
http://www.ssiproject.com/mechanical_project.php?cool=160/
mechanical/production projects

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