An Industry Oriented Mini Project Report On

Fabrication of Portable Saw Machine

Submitted in partial fulfillment of the requirement of the award of the degree of

BACHELORS OF TECHNOLOGY
IN

MECHANICAL ENGINEERING
Under
JNTU HYDERABAD
BY
AUSAF AHMAD USMANI 16H11A0309
IMRAN KHAN 16H11A0314
MOHAMMED ALI 16H11A0344
MOHAMMED AZEEZ MOHIUDDIN 16H11A0345
MOHAMMED AZMATH 16H11A0347

Under the Esteemed Supervision of

Mr. ROSHAN ZAMEER AHAMED
Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

LORDS INSTITUTE OF ENGINEERING AND TECHNOLOGY
Accredited by NAAC, NBA, Approved by AICTE &Affiliated by JNTU Hyderabad
Survey No. 32, Himayat Sagar, Hyderabad-500019, India.

2019

1
 LORDS INSTITUTE OF ENGINEERING & TECHNOLOGY
Approved by AICTE/Affiliated to JNTUH/Estd.2002.
Accredited ‘A’ grade by NAAC Accredited by NBA

DEPARTMENT OF MECHANICAL ENGINEERING

Certificate
This is to certify that the dissertation work entitled “Fabrication Of Portable
Saw Machine”, is a bonafide record of successfully completed the project of
work entitled.
Under the guidance of Mr. Roshan Zameer Ahamed, Assistant Professor,
Mechanical Engineering Department for the Requirement of partial fulfillment for
the award of degree of Bachelor of Technology in Mechanical Engineering
during the academic year 2016-2019 from JNTUH, Hyderabad.

AUSAF AHMAD USMANI 16H11A0309

IMRAN KHAN 16H11A0314
MOHAMMED ALI 16H11A0344
MOHAMMED AZEEZ MOHIUDDIN 16H11A0345
MOHAMMED AZMATH 16H11A0347

Mr. Roshan Zmaeer Ahamed Dr. Syed Azam Pasha Quadri

Internal Guide Head Of The Department

Dr. Mohammed Yousuf Ali

Principal External examiner

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 LORDS INSTITUTE OF ENGINEERING & TECHNOLOGY
Approved by AICTE/Affiliated to JNTUH/Estd.2002 .
Accredited ‘A’ grade by NAAC Accredited by NBA

DEPARTMENT OF MECHANICAL ENGINEERING

Declaration
we hereby declare that the project document entitled “Fabrication

of Portable Saw Machine” is a bonafide work done during the 4th year
of Bachelor of Technology in Department of Mechanical Engineering. I also
declare that the work carried out is an authentic record of my own work
under the guidance and supervision of Mr.ROSHAN ZAMEER AHAMED
Department of Mechanical Engineering, of Lords Institute of Engineering
and Technology.

This report has not been submitted to any other institute or university
for the award of any degree or diploma and neither this project is being used
by another person or people at any other place.

AUSAF AHMAD USMANI 16H11A0309

IMRAN KHAN 16H11A0314
MOHAMMED ALI 16H11A0344
MOHAMMED AZEEZ MOHIUDDIN 16H11A0345
MOHAMMED AZMATH 16H11A0347

3
 LORDS INSTITUTE OF ENGINEERING & TECHNOLOGY
Approved by AICTE/Affiliated to JNTUH/Estd.2002.
Accredited ‘A’ grade by NAAC Accredited by NBA

DEPARTMENT OF MECHANICAL ENGINEERING

Acknowledgement

Ausaf Ahmad Imran Khan Mohammed Ali Mohammed Mohammed

Usmani 16H11A0314 16H11A0344 Azeez Azmath
16H11A0309 8978630127 6303641047 Mohiuddin 16H11A0347
9346432026 haqeer9999@ Mohammed. 16H11A0345 8801701965
aau2778692 gmail.com Aliips344@gma 8801256634 Mdazmath96@
@gmail.com il.com mohammedaze gmail.com
ezmohiuddin@
gmail.com

Lords Institute of Engineering and Technology. My experience here has been full of
opportunities to learn from faculty with a wide and deep expertise in Engineering. we
would like to thank our Guide Assistant Professor Mr. Roshan Zameer Ahamed for his
aspiring guidance and friendly advice during the project work. He was a constant
motivation throughout the project and took out some of his valuable time whenever it was
required for which I am very grateful to him. we would always be grateful for his
motivation and co-operation at various stages, which provided us the knowledge base and
the understanding of the potential projects in this field. we express our sincere and deep
gratitude to Dr. Syed Azam Pasha Quadri Professor and Head of the Mechanical
Department for his support throughout our project and all the teaching and non-teaching
staff of Lords Institute of Engineering and Technology who has helped and cooperated
with us. It gives me great pleasure in acknowledging the support. Finally we would like to
thank our beloved principal Dr. Mohammed Yousuf Ali. And also we would like to
directly thank those people in the department who were particularly instrumental in
contributing to our experience at Lords Institute of Engineering and Technology. Finally
we also appreciate the concern of my parents, friends and other staff members at the
college.

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 LORDS INSTITUTE OF ENGINEERING & TECHNOLOGY
Approved by AICTE/Affiliated to JNTUH/Estd.2002.
Accredited ‘A’ grade by NAAC Accredited by NBA

DEPARTMENT OF MECHANICAL ENGINEERING

Project Assessment process

PSO

Professional Skills

Problem- Solving Skills

Course Name: -ME705PC industry oriented mini project report : 2019-2020

C0.1. Exhibit good teamwork skills and serves as effective members of multi-
disciplinary project teams
C0.2. Articulate and justify technical solution to diverse audiences through oral,
written and graphical communication.
C0.3. Analyze the importance of professional and ethical responsibilities of
mechanical engineering.
C0.4. Experimentally analyze the innovative approach with respect to research
&development

PEO’S:-

PEO 1: Shall apply fundamental and advance knowledge skills in basic and engineering
science and in Mechanical engineering to find suitable solution to technology challenges
and problem in various areas of engineering and real life areas using modern tools

PEO 2: Shall practice mechanical engineering in a responsible, professional, and

dedicated manner by functioning effectively either as an individual or as a member of
plenty disciplinary team, for the benefit of the industry and society at large without
detriment to environment and sustainable development

PEO 3: Shall acquire good job opportunities in industries or pursue higher studies.

PEO 4: Shall develop the ability to engage in lifelong learning, research and development
in a responsible, professional, dedicated and ethical manner for the benefit of the
industry and society at large.

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 Abstract
A bench saw or table saw has long being used for wood works and metal works, it
can be used with a variety of blades to achieve various fabrication applications
like cutting polishing dust cleaning. Table saw’s consists of electric motor that are
used to drive rotating saw blades.

Our system demonstrates fabrication of bench saw using mini bench saw model
that uses an electric motor with a shaft to mount various blades an achieve
efficient cutting.We use an arm with spring mounted pullback system when
pressure is not applied. The machine has a frame bed with a cavity parallel to the
blade in order to achieve full cutting when blade passes though the work piece.

The entire system is integrated and fabricated accordingly to achieve required

mechanism.

Keywords: 775motor of 12V, Battery, saw blades.

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 Contents
Certificate
Declaration
Acknowledgement
Project assessment process
Abstract
List of figures
List of Tables
Abbreviations

Chapter 1 Introduction

1.1 Introduction of bench saw machine

1.2 components used

1.2.1 775motor (12V)

1.2.2 Battery

1.2.3 Saw blades

1.2.4 Arm

1.2.5 Bed frame

1.2.6 Supporting rubbers

1.2.7 Momentary push button

1.2.8 Spring

1.2.9 Mounts and fixtures

Chapter 2 Literature survey

2.1 Literature Review

2.2 saw blade

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2.3 metal cutting saw

Chapter 3 Fabrication

3.1. Fabrication

3.1.1. Frame

3.1.2 Upper T-joint

3.1.3 Arm

3.2 Operations performed

3.2.1 Welding

3.2.2 Carpentry

3.2.3 Drilling

3.2.4 Tin smithy

3.2.5 Surface grinding

3.3 Materials

3.3.1 Iron pipes

3.3.2 G.I sheet

3.3.3 Wood

3.4. Mounting of motor into the arm

3.5 Electric Connections

3.6 Final assembly

Chapter 4 Working principle

4.1. Working

4.2. Advantages and Disadvantages

4.3 Applications

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Chapter 5 Results and Discussions

Chapter 6 Conclusions and future scope

6.1 Conclusions

6.2 Future scope

References

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 List of Figures

FIG01: 775motor
FIG02: Battery
FIG03: Arm
FIG04: Bed frame
FIG05: Rubbers
FIG06: momentary push button
FIG07: Spring
FIG08: Fixtures
FIG09: saw blade
FIG10: Metal cutting tool
FIG11: Bed frame
FIG12: upper T-joint
FIG13: Gas welding
FIG14: Fillet welding
FIG15: Carpentry
FIG16: Drilling
FIG17: Tin smithy
FIG18: Surface grinding
FIG19: Iron pipe
FIG20: GI sheet
FIG21: Wood
FIG22: Mountings of motor
FIG23: Electrical connections
FIG24: Final assembly

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 Chapter 1
Introduction

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 Chapter1
Introduction

1.1 Introduction of Bench saw Machine:-

Bench saw also known as Table Saw is a wood working tool consisting of a
circular saw blade mounted on an arbor that is driven by an electric motor either
directly or by belt or gears.

We use direct connection from motor to the battery push button as a medium.

Although the majority of table saws are used for cutting wood, table saw can also
be used for cutting sheet plastic, iron rod, aluminium sheet etc.

Depth of the cut in bench saw can be varied using hand pressure applied on an
aim.

1.2 Components

1.2.1 775motor (12V)

775motor has an rpm of 2500 of 12V which is mounted into an arm with
the help of an arbor which rotates the cutting tool.

Fig no.1: 775 motor

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1.2.2 Battery

An amptek rechargeable battery of 12v is used for power supply to the

motor momentary push button as a medium.

Fig02: Battery

1.2.3 Saw blades

Wood and steel cutting blades.

In which wood cutting blades is a frame blade and can be applicable ifor
cutting wooden pieces in an precise direction.
For steel cutting, fine grinding blade can be used for good accuracy.

1.2.4 Arm

Wood material is used to build an arm with the dimensions of (32*5*2cm)

for cutting the materials applying hand pressure on it accordingly.
Also it is the main component which holds push button, motor.
The arm is used as cutting tool holder.

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 Fig03: Arm

1.2.5 Bed Frame

4 Iron pipes of length (47cm) and breadth (47cm) with thickness of (2.5cm)
which makes a square by joints of V-shape welding.
At the middle of one of the side of frame two rods of dimensions
(13*0.5*5cm) is jointed in order to hold and give vertical moment to arm.

Fig04: Bed Frame

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1.2.6 Rubbers

4 Rubbers of dia(4.5cm) and length (6.5cm) to support the frame and to

avoid friction developed due to the cutting mechanisms.

Fig05: Rubbers

1.2.7 Momentary Push Button

Push button is used to control the start and stop of the machine manually.
Uneven motions of the machine is restricted using push button.

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 Fig06: Momentary Push Button

1.2.7 Spring

A 3inch spring which links to T-joint of bed and arm is a pullback system
when pressure is not applied and also it provides free movement to apply
depth of cut on workpiece.

Fig07: Spring
1.2.8 Fixtures

To attach and change easily the discs and motor on arm screws and nuts
are used accordingly.

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Fig08: Fixtures

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 Chapter 2
Literature Survey

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 Chapter 2

Literature Survey

2.1 Review

1.In the United States, perhaps the first recorded patent for the circular saw was
issued in 1777 to an Englishman, Samuel Miller; it refers to a circular saw that
was created in Holland in the 16th or 17th centuries. The 1885 catalog of the W.F.
& John Barnes Co., Rockford, Il. clearly shows a classic table saw and it is labeled
as a "Hand [Powered] Circular Rip Saw".

2. Proceedings of the 2016 International Conference on Industrial Engineering and

Operations Management Detroit, Michigan, USA, September 23-25,
A table saw machine is a woodworking tool consisting of a circular saw blade,
mounted on an arbour, that is driven by an electric motor in turn the drive power
from motor is passed to the blade either directly or by belt. The blade protrudes
through the surface of a table top, which provides support for the wood being cut.
The first record of patent for that machine was issued in 1777 to an English man,
Samuel Miller. In a modern table saw, the depth of the cut is varied by moving the
blade up and down: the higher the blade protrudes above the table, the deeper the
cut that is made in the material. In some early table saws, the blade and arbour
were fixed, and the table was moved up and down to expose more or less of the
blade. The angle of cut is controlled by adjusting the angle of blade.

3.Prof. Zoeb khan, Mr.SushilDopekar “Design and Fabrication of Human Powered

Wood Cutting machine” International Journal on Recent and Innovation Trends in
Computing and Communication. (ISSN: 2321-8169)
In this paper, improved design of the human powered wood cutting machine
which gives the less efforts of man and commonly used in rural areas where there
is no power supply.
The design ensures a smooth operation during the cutting process. It is light in
weight and portable machine

4.Safety automation in the existing circular saw machines

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The project emphasis is on preventing hand movement leading to hazards and for
non-contact detection of fingers intended to permit comprehensive and economical
protection on circular saws.
(Dietmar Reinert, 2009). With an automatic blade guard an improved integration
of the protection system can be achieved. The distinction between skin and wood
or other material is achieved by a dedicated spectral analysis in the near infrared
region using LED and photodiodes. With a kind of light curtain the intrusion of
hands or fingers into the dangerous zone near the blade guard can be prevented
and the guard will enclose the spinning blade within itself (Dietmar Reinert, 2009).
The maladies of the mechanism are:
 It uses spectral analysis of light is focused in the cutting area this means
detection of light rays fringing on an interior or exterior defect of wood is
likely to activate the safety guard hence method is not reliable and accurate.
 Both the wood and human skin/flesh are not conductive hence are more
likely to give the same results which makes the method inconvenient.
 Since the guard is the one which moves to hide the spinning blade within it,
it might injure the finger if they have already entered the proximity vicinity.

2.2 Circular Saw blade

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.

Typically, the material to be cut is securely clamped or held in a vise, and the saw
is advanced slowly across it. In variants such as the table saw, the saw is fixed

20
and the material to be cut is slowly moved into the saw blade. As each tooth in the
blade strikes the material, it makes a small chip. The teeth guide the chip out of
the work piece, preventing it from binding the blade

Fig09: Saw blade

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2.3 Metal cutting saw
An abrasive saw, also known as a cut-off saw or chop saw, is a circular saw (a
kind of power tool) which is typically used to cut hard materials, such as metals,
tile, and concrete. The cutting action is performed by an abrasive disc, similar to a
thin grinding wheel. Technically speaking this is not a saw, as it does not use
regularly shaped edges (teeth) for cutting.

These saws are available in a number of configurations, including table top, free
hand, and walk behind models. In the table top models, which are commonly used
to cut tile and metal, the cutting wheel and motor are mounted on a pivoting arm
attached to a fixed base plate. Table top saws are often electrically powered and
generally have a built-in vise or other clamping arrangement. The free hand
designs are typically used to cut concrete, asphalt, and pipe on construction sites.
They are designed with the handles and motor near the operator, with the blade at
the far end of the saw. Free hand saws do not feature a vise, because the
materials being cut are larger and heavier. Walk-behind models, sometimes called
flat saws are larger saws which use a stand or cart to cut into concrete floors as
well as asphalt and concrete paving materials.

Fig10: Metal Cutting Saw

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 Chapter 3
Fabrication

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 Chapter 3
Fabrication
3.1 Fabrication
3.1.1 Bed Frame

Fig11: Bed Frame

3.1.2 Upper T-joint

Fig12: Upper T-joint

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3.2 Operations Performed

3.2.1. Welding
3.2.1.1. Gas welding:
The most common gas welding process is oxyfuel welding also known as
oxyacetylene welding.
Gas welding process is quite simpler compare to arc welding. In this process all
the equipment are connected carefully. The gas cylinder and oxygen cylinder
Connected to the welding torch through pressure regulators. Now the regulate
pressure of gas and oxygen supplied to the torch where they properly mixed. The
flame is ignited by a striker. Take care the tip of torch is pointing downward. Now
the flame is controlled through valves situated in welding torch. The flame is set at
natural flame or carburizing flame or oxidizing flame according to the welding
condition. Now the welding torch moved along the line where joint to be created.
This will melt the interface part and join them permanently.

Fig13: Gas welding

3.2.1.2 Fillet welding:

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Fillet welding refers to the process of joining two pieces of metal together whether
they be perpendicular or at an angle. These welds are commonly referred to as Tee
joints which are two pieces of metal perpendicular to each other or Lap joints
which are two pieces of metal that overlap and are welded at the edges. The weld
is aesthetically triangular in shape and may have a concave, flat or convex surface
depending on the welder’s technique. Welders use fillet welds when connecting
flanges to pipes, welding cross sections of infrastructure, and when fastening
metal by bolts isn't strong enough and wear off easily.

Fig14: Fillet Welding

3.2.2 Carpentry
Carpentry is a skilled trade and a craft in which the primary work performed is
the cutting, shaping and installation of building materials during the construction
of buildings, ships, timber bridges, concrete formwork, etc. Carpenters
traditionally worked with natural wood and did the rougher work such as framing,
but today many other materials are also used.
3.2.3 Drilling
Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-
section in solid materials. The drill bit is usually a rotary cutting tool, often multi-
point. The bit is pressed against the work-piece and rotated at rates from
hundreds to thousands of revolutions per minute. This forces the cutting edge
against the work-piece, cutting off chips (swarf) from the hole as it is drilled.

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 Fig16: Drilling

3.2.2 Tin smithy

Tin smithy is used for cutting a galvanized sheet using sniper. Using other
tools like hammer bends of sheet according to the bed frame size is
adjusted and welded using gas welding.

Fig17: Tin Smithy

3.2.3 Surface Grinding

Surface grinding is the most common of the grinding operations. It is a finishing

process that uses a rotating abrasive wheel to smooth the flat surface of metallic
or nonmetallic materials to give them a more refined look by removing the oxide
layer and impurities on work piece surface.

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 Fig18: Surface Grinding

3.2 Materials
3.3.1. Iron pipe
Square iron rods are used for bed support. They are welded from all its edges to
form a square.

Fig19: Iron Pipe

3.3.2. GI Sheet
Galvanized iron (GI) sheets are steel sheets which are basically coated with zinc
and include a range of hot dip galvanized and electro-galvanized steel sheets. Zinc
weathers at a very slow rate, so the coating generally has a long life. Zinc has a
greater electro-negativity than iron and hence provides cathodic protection to the
steel. This results in the zinc corroding in preference to the steel if the coating is
chipped or damaged to expose the base metal.

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 Fig20: GI Sheet
3.3.3. Wood
Wood can be made into any desired shape by performing some carpentry on it.We
have used wood for making an arm.

. Fig21: wood

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3.4 Mounting of motor
775 motor is mounted on an arm. The shaft along with cutting tool is arranged
using mounts and fixtures.

3.5 Electric connections

The terminals of push button are connected to battery and motor.

Fig23: Electrical connections

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3.6 Final Assembly

Fig24: Final Assembly

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32
Chapter 4
Methodology

Chapter 4
METHODOLOGY
4.1 Working

The operation of the machine is simple as there is no any complexity of

assembledparts.The connections are already fixed so that the machine is made ON
by pressing the power button (push button) and by adjusting the length of cut and
depth of cutter over the table surface by the application of hand pressure on arm.

4.2 Advantages and Disadvantages

4.2.1 Advantages
1. Easy to operate.
2. Single person can operate.
3. Skilled operator is not required.
4. No need of electricity as battery is used.

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5. Simple in construction.
6. Low maintenance.
7. More than one operation can be performed.
8. fast and smooth cuttings.

4.2.2 Disadvantages
1. Difficult Cannot cut materials of large thickness
2. Rough cutting tool need to be replaced after some days
3. Cleaning is necessary
4. Risk of physical injury to the operator if proper care is not taken.

4.3 Applications
1. It can be used in small carpentry workshop.
2. It is use for cutting wood where power source not available.
3. In rural areas where electricity cut-off problems occurs.
4. It is used in fabrication workshops for cutting iron pipes.

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 Chapter 5
Results & Discussions

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 Chapter 5
Results & Discussions

6.1 Result and Discussions

Thus a low cost and simple design operated wood working machine is fabricated.
This machine reduces the human effort to cut the wooden logs. This simple design
of conventional design which can enhance day-to-day household needs and day-
to-day purposes and it can be also used in for industrial applications during
power shut down scenarios.

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 Chapter 6
Conclusion and Future Scope

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 Chapter 6
Conclusion and Future Scope

7.1 Conclusion
The machine is proposed by keeping in mind the two most crucial
factors of manufacturing, the accuracy and the cost. The machine is good wood
cutting instrument with cost effectiveness. It is made for cutting a variety of
wooden work pieces with varying length and dimensions. Proper evaluation of the
design will be performed and created something even better instead of electrically
operated operations. Finally we conclude that this machine is better option to use
for Carpenter. By using this method we can do Cutting operation without the use
of electricity. So we can save the electrical power. The ply wood can be cut without
any external energy like fuel or current. The manually operated wood working
machine is easy to use hence does not require any skilled person.

7.2 Future Scope

1. Arm can be made to fabricate to revolve in 360degrees in order to cut
material in different angles.
2. Heavy motor and battery can be used for cutting large components and long
life of machine.
3. Solar panel can be used instead of battery.
4. To utilize the full potential, safety mechanism should be retrofitted to all
circular saw machines (table saw, panel saw and bench saw machine)

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Reference

1. Engineering and Operations Management Detroit, Michigan,

USA, September 23-25,
2. Prof. Zoeb khan, Mr.SushilDopekar “Design and Fabrication of
Human Powered Wood Cutting machine” International Journal
on Recent and Innovation Trends in Computing and Proceedings
of the 2016 International Conference on Industrial
Communication. (ISSN: 2321-8169)
3. https://ujcontent.uj.ac.za/vital/access/services/Download/uj:2
1614/SOURCE1
4. https://nevonprojects.com/mini-bench-saw-machine-project/
5. https://www.alce.vt.edu/content/dam/alce_vt_edu/teacher-
resources/lab-safety-resources/tablesaw.pdf
6. https://en.wikipedia.org/wiki/Welding
7. http://www.rsisinternational.org/IJRSI/Issue42/49-56.pdf
8. https://en.wikipedia.org/wiki/Table_saw

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