Beam Engine Hack Saw

BEAM ENGINE POWERED HACKSAW

PROJECT TITTLE

Design & fabrication of Beam Engine powered reciprocating saw Abstract :

In this project, the output of a Beam Engine is used to drive a reciprocating saw to cut timber. Here, instead of the rotating fly wheel, it is intende d to have a rotating reciprocating saw. This rotating reciprocating saw is used to cut timber. Reciprocating Reciprocating saws driven with electric electric power are a common feature. But in places where electricity is scarce, or absent, it is difficult to operate these equipments. But since the Beam Engine Engine powered saw runs runs on fuel, it can be operated even in places where electricity is totally absent. A beam engine is a design of stationary steam engine [1]. A stationary engine is an engine whose framework does not move [2]. Usually, a stationary engine is used not to propel a vehicle but to drive a piece of immobile equipment such as a pump or power tools [4]. In a beam engine, the piston is mounted vertically, and the piston rod does not connect directly to the connecting rod, but instead to a rocker or beam above both the piston and flywheel. The beam is pivoted in the middle, with the cylinder on one side and the flywheel, which incorporates the crank, on the other. The connecting rod connects to the opposite end of the beam to the piston rod, and then to the flywheel [1].


INTRODUCTION:

A beam engine is a type of steam engine where a pivoted overhead beam is used to apply the force from a vertical piston to a vertical connecting rod. This configuration, with the en gine directly driving a pump, was first used by Thomas Newcomen around 1705 to remove water from mines in Cornwall . The efficiency of the engines was improved by engineers including James Watt who added a separate separate condenser, Jonathan Hornblower and Arthur Arthur Woolf who compounded the c ylinders, and William McNaught (Glasgow) who devised a method of compounding an existing engine. Beam engines were first used to pump water out of mines or into canals, but could be used to pump water to supplement supp lement the flow for a waterwheel powering a mill .

The rotative beam engine is a later design of beam engine en gine where the connecting rod drives a flywheel , by means of a crank (or, historically, by means of a sun and planet gear ). These beam engines could be used to directly power the line-shafting in a mill . They also could be used to power steam ships .


DEVELOPMENT OF IDEA, DISCUSSION AND SIGNIFICANCE

As mentioned earlier the motivation for this project being the course ME 637, the course required each student to submit a project using the Pro-E modeling tool and the instructor emphasized that the project should be creative and something new. This made me think about something new and finally I arrived at the Beam Engine idea. The word “power tools” caught my attention and I just started to think why wh y not I use a beam engine to drive a circular saw to cut timber. While electric powered saws are a common feature as also diesel and gasoline powered po wered saws, a saw that works on the principle of a beam engine is something that I thought of. This saw, which can run either on diesel or gasoline, can be used u sed in places where electricity is sparse or absent.


STAGES IN NEW PRODUCT DEVELOPMENT

1. Idea generation. 2. Idea screening. 3. Concept development & testing. 4. Market strategy development. 5. Business Analysis. 6. Test Marketing. 7. Commercialization

Fig. Product development flow chart Need for new product development:

People always welcome change and new product development is an opportunity f or the firms to meet the changes in consumer demands. They are a source of competitive advantage. Your new product may infuse a fresh lease of life to your sagging profits.


New products may turn out to be the star performers of your firm and provide long term financial return on your investment. Some firms take the smart strategic choice of using the idle capacity of their plant for manufacture of a new product that may utilize the existing production and operation resources to an optimum level. They capitalize on research and development. Products that create a wave are a result of research on market trend and consumer preference. Firms can make it, if their research is customer-centric rather than product-centric.


METHODOLOGY

DESIGN OF MACHINE:In our attempt to design a special purpose machine we have adopted a very a very careful approach, the total design work has been divided into two parts mainly; 

System design



Mechanical design

System design mainly concerns with the various physical constraints and ergonomics, space requirements, arrangement of various components on the main frame of machine no of controls position of these controls ease of maintenance scope of further improvement; height of m/c from ground etc.

In Mechanical design the components are categoriesed in two parts. 

Design parts



Parts to be purchased.

For design parts detail design is done and dimensions thus obtained are compared to next highest dimension which are readily available in market this simplifies the assembly as well as post production servicing work.The various tolerances on work pieces are specified in the manufacturing drawings. The process charts are prepared & passed on to the manufacturing stage .The parts are to be purchased directly are specified &selected from standard catalogues.

Methodology can properly refer to the theoretical analysis of the methods appropriate to a field of study or to the body of methods and principles particular to a branch of knowledge. In this chapter, it talks about the methods use to gather information in order to finish the research. It was involve the process flow of every step in archive the objective of this project. There are many methods use in this project such as internet references, interviewing lecturers and technicians and the most important is group discussion.


DIAGRAM : 1 METHODOLOGY


METHODOLOGY OF WORKING PROCESS

Study of different Research papers

Framing of project setup (Line diagram of t he Model)

Dimensioning of frame, Specification of the com onent for settin u a conce tual model

Assembling Of different components

Results & disscusion about the error in the conce tual model

Fig. 5 Flow Chart For Working Process


MATERIAL SELECTION & METHODOLOGY.

1.1 Material Selection The proper selection of material for the different part of a machine is the main objective. In the fabrication of machine. For a design engineer it is must that he be familiar with the effect, which the manufacturing process and heat treatment have on the properties of materials. The Choice of material for engineering purposes depends upon the following factors: 1. Availability of the materials. 2. Suitability of materials for the working condition in service. 3. The cost of materials. 4. Physical and chemical properties of material. 5. Mechanical properties of material.

The mechanical properties of the metals are those, which are associated with the ability of the material to resist mechanical forces and load. We shall now discuss these properties as follows: A. Strength

B. Elasticity

C. Stress

D. Plasticity

E. Stress

F. Ductility

G. Brittleness

H. Malleability

I.

J. Resilience

Toughness

When a part is subjected to a constant stress at high temperature for long period Of time, it will undergo a slow and permanent deformation called creep. This property is considered in designing internal combustion engines, boilers and turbines.


Hardness

It is a very important property of the metals and has a wide verity of meanings. It embraces many different properties such as resistance to wear scratching, deformation and mach inability etc. It also means the ability of the metal to cut another metal. The hardness is usually expressed in numbers, which are dependent on the method of making the test. The hardness of a metal may be determined by the following test. 1. Brinell hardness test 2. Rockwell hardness test 3. Vickers hardness (also called diamond pyramid) test and 4. Share scaler o scope.

In engineering practice, the machine parts are subjected to various forces, which may be due to either one or more of the following. 1. Energy transmitted 2. Weight of machine 3. Fictional resistance 4. Inertia of reciprocating parts 5. Change of temperature 6. Lack of balance of moving parts

The selection of the materials depends upon the various types of stresses that are set up during operation. The material selected should with stand it. Another criterion for selection of metal depends upon the type of load because a machine part resist load more easily than a live load and live load more easily than a shock load.


Selection of the material depends upon factor of safety, which in turn depends upon the following factors. 1. Reliabilities of properties 2. Reliability of applied load 3. The certainty as to exact mode of failure 4. The extent of simplifying assumptions 5. The extent of localized 6. The extent of initial stresses set up during manufacturing 7. The extent loss of life if failure occurs 8. The extent of loss of property if failure occu rs


4.4 Methodology of Design & Analysis

A parameter study is done to evaluate the most crucial parameters for FE analysis of axial ball bearings. The parameters that are evaluated are mesh density, contact stiffness, osculation, load level, geometrical nonlinearity and material nonlinearity. The studies are performed by means of the FE software Ansys. The accuracy of finite element analysis depends on different parameters such as element type, boundary condition and how the loads are applied etc. Therefore the FE model is nothing else but an approximate realization of the reality. The parameter study can be done by physical tests. However it will increase the cost, time and resources consumed and therefore FE analysis is more suitable choice, at least for parameter evalua tion.

4.5 Theoretical aspects of the work

In this study the finite element method is adopted using Pro Engineer and Ansys as a commercial CAD and FE program. The following chapter contains some fundamentals of the applied theories provided that the reader has an initial knowledge of basic structural mechanics, machine components, and fundamentals of the finite element method.

4.6 Finite element method

Finite element method (FEM) is a method for approximate solutions of partial differential equations. The domain of interest is divided into finite elements on which the solution is approximated by piecewise-polynomials. The finer the partition (Mesh) is, the more accurate the solution.

4.7 Nonlinear Analysis

Nonlinear analysis is used when a structure behaves nonlinear when loaded i.e. the deformation and the stress state does not have a linear relation to the applied load. The three main sources to


nonlinear behaviors are: contact, geometric nonlinearities and material nonlinearities. In order to manage such calculations with a linear process the Newton Raphson method can be used 4.7.1 Newton-Raphson method

Newton-Raphson is an iterative method for finding solution to nonlinear equations and equation systems . In FE calculations the method is used for non-linear problems and the relations between force and displacement is shown in Figure 2.1 for one degree of freedom.

The

procedure for Newton-Raphson method is as follows: The load is applied and the displacements are calculated. From the displacements new conditions are calculated and the displacements are recalculated. This procedure is repeated until the solution is converged i.e. reach a certain value or level. The iterative procedure is as follows: Material nonlinearities

A nonlinear stress-strain relationship results in a nonlinear behavior. Plasticity is a nonlinear stress-strain relationship as shown in Figure 2.4. Definition of Plasticity according Ansys (2007) is: “When a ductile material experiences stresses beyond the elastic limit, it will yield, acquiring large permanent deformations.”

Fig.6 Relationship Between Stress & Strain


4.8 Ansys

Ansys is a commercial, general purpose FE software which has been on the market since 1971. It can be used in several applications for example to study the thermal heat flow, fluid flow, magnetic fields, acoustics/vibrations and last but not least structural mechanical problems. 4.9 Contact in Ansys

A handful of ways to handle contact are available in Ansys. However, the one described here is penalty based contact since it provides short calculation times and therefore is used. 4.10 Penalty based contact

When a penalty-based contact is used, Ansys adds a spring coefficient (k factor) when two surfaces come in contact with each other, in order to prevent penetration and to transfer load. (Figure 2.7) However penetration will occur in order to transfer force, which is not the case in reality. Therefore the penalty-based methods are sensitive to the choice of the spring coefficient. The spring coefficient Ansys uses during calculations is the product between the “normal stiffness factor” specified by the user and a reference factor calculated by the program. An additional aspect (apart from the accuracy) to consider when selecting the “normal stiffness factor” is the convergence behaviour. A stiffer contact will result in more calculation iterations, since bouncing might occur.

Fig.7 Contact Stiffness


4.11 Asymmetric behaviour

A contact condition can be either symmetric or asymmetric. When the contact condition is symmetric none of the surfaces can penetrate each other, while when the contact is specified as being asymmetric only one of the surfaces is prevented from penetrating the other i.e. the contact surface can not penetrate the target surface but the opposite is possible. Figure 2.8 illustrates the importance of selecting the correct contact pair.

Fig.8 Asymmetric behaviour 4.12 Bilinear stress-strain curve

In context of the license version used, Ansys tender a bilinear approximation of the stress-strain relationship as in figure 2.9. The bilinear stress-strain curve requires two input values, yield strength and tangent modulus. The yield strength is the value when plastics straining occurs and the tangent modulus is the slope of the stress-strain curve after yielding.


Fig.10 Relationship Between Stress & strain, Bilinear curve in Red & True Material Relation in blue 4.13 Meshing controls

Ansys offers several tools to control the meshing procedure. The mesh densities of the whole model can be controlled by global settings for relevance centre in three steps: coarse, medium or fine. 4.14 Method

Method is a meshing control that provides the possibility to select different elements shapes. The different elements that are available are: tetrahedron or quadrilateral. Tetrahedron elements are triangular pyramid like elements with 10 or 4 nodes and quadrilateral elements are cube elements with 20 or 8 nodes.


4.15 Sizing

Sizing is a meshing control that provides the possibility to mesh with different mesh densities at selected regions. By meshing fine in the area of interest and using coarse mesh in the remaining parts one is able to reduce CPU time and memory usage.

There are a couple of ways to select

the region of a sizing control available in Ansys. The region can be a surface. This will produce a fine mesh (or actually a mesh with the size specified) on the surface only. The region can also be an entire body which will produce a fine mesh all over the body. If a contact region is to be analysed, Ansys offers the possibility to specify the mesh size in the contact region. And to capture a local behaviour it is possible to specify a so called sphere of influence which makes it possible to set the element size (mesh size) within the volume of a sphere. The sphere of influence can be used to enclose both faces and bodies.


SYSTEM DESIGN & COMPONENT

In our attempt to design a special purpose machine we have adopted a very a very careful approach, the total design work has been divided into two parts mainly; System design Mechanical design

System design mainly concerns with the various physical constraints and ergonomics , space requirements, arrangement of various components on the main frame of machine no of controls position of these controls ease of maintenance scope of further improvement ; weight of m/c from ground etc.

In Mechanical design the component in two categories. Design parts Parts to be purchased.

For design parts detail design is done and dimensions thus obtained are compared to next highest dimension which are readily available in market this simplifies the assembly as well as post production servicing work.

The various tolerance on work are specified in the manufacturing drawings the process charts are prepared & passed on to the manufacturing stage .The parts are to be purchased directly are specified &selected from standard catalogues.


3.1

System Design

In system design we mainly concentrate on the following parameter

3.1.1 System selection based on physical constraints

While selecting any m/c it must be checked whether it is going to be used in large scale or small scale industry in our care it is to be used in small scale industry so space is a major constrain .The system is to be very compact it can be adjusted to corner of a room. The mechanical design has direct norms with the system design hence the foremost job is to control the physical parameters so that the distinction obtained after mechanical design can be well fitted into that. 3.1.2 Arrangement of various component

Keeping into view the space restriction the components should be laid such that their easy removal or servicing is possible moreover every component should be easily seen & none should be hidden every possible space is utilized in component arrangement.

3.1.3 Components of system

As already stated system should be compact enough so that it can be accommodated at a corner of a room. All the moving parts should be well closed & compact A compact system gives a better look & structure.

3.1.4 Man – m/c Interaction

The friendliness of m/c with the operation is an important criterion of design. It is application of anatomical Following are some e.g. of this section


Design of machine height Energy expenditure in hand operation Lighting condition of m/c

3.1.5 Chances of failure

The losses incurred by owner in case of failure of a component are important criteria of design. Factor of safety while doing the mechanical design is kept high so that there are less chances of failure there over periodic maintenance is required to keep the m/c trouble free. 3.1.6 Servicing facility

The layout of components should be such that easy servicing is possible especially those components which required frequent servicing can be easily disassembled. 3.1.7 Weight of machine

The total weight of m/c depends upon the selection of material components as well as dimension of components. A higher weighted m/c is difficult for transportation & in case of major break down it becomes difficult to repair. 3.2 Mechanical Design

Mechanical design phase is very important from the view of designer as whole success of the project depends on the correct deign analysis of the problem. Many preliminary alternatives

are eliminated during this

phase. Designer should have

adequate knowledge above physical properties of material, loads stresses, deformation, and failure. Theories and wear analysis, He should identify the external and internal forces acting on the machine parts


These forces may be classified as;

a) Dead weight forces b) Friction forces c) Inertia forces d) Centrifugal forces e)

Forces generated during power transmission etc

Designer should estimate these forces very accurately by using design equations .If he does not have sufficient information to estimate them he should make certain practical assumptions based on similar conditions which will almost satisfy the functional needs. Assumptions must always be on the safer side.


WORKING PRINCIPLE

When the piston in the cylinder reciprocates, it i mparts an oscillating motion to the rocker arms, as shown in figure 1 on page 2. This oscillating motion of the rocker arm is converted into rotary motion by the crankshaft. The crankshaft, which is connected to the circular saw, makes the circular saw rotate. This rotary action of the circular wood saw is used to saw timber or wood blocks. There is a small table attachment for supporting the wooden block. The wooden block is placed on the table and pushed towards the rotating wood saw, which results in the sawing action. The main advantage of this machine is that it can be used in places where electricity is not economical or in places where electricity is absent.

Fig. Working Model of Beam Engine


Fig. Linkage line diagram for beam engine.


EXPERIMENTAL SETUP :

A beam engine mechanism is one where we use an overhead beam to create motion. Here we use a beam engine motion based assembly in order to achieve hack saw cutting motion using a circular cutting disc. Our system uses a motorized disc to drive a connector which is in turn connected to an overhead beam. The overhead bean has a connecting rod in turn connected to a mini hacksaw blade. When the motorized disc below is turned on the connecting arm starts reciprocating the overhead beam. This beam now heals achieve a back and forth cutting motion as required by the hacksaw blade.

Fig. CAD Model of project using CATIA V 5R20

We construct a small bed in order to rest the work piece to achieve desired cutting. Thus we study the design and fabrication of mini hacksaw using beam engine mechanism.


WORKING OF RECIPROCATING HACKSAW

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 pneumatic power. Pneumatic is a huge topic of science and engineering dealing with the mechanical properties of air. In our project we take this pneumatic and a hacksaw for cutting purpose,

The

pneumatic

reciprocating high- speed

hacksaw

machine

has

an

advantage of working in high pressure , the hacksaw used in this is reciprocate such that required shape can be cutted according to the requirement. The hacksaw is the metal cutting machine tool designed to cut metal by applying pneumatic pressure. Hacksaws are used to cut thin and soft metals the operation of the unit is simplified to a few simple operations involving a cylinder block and piston arrangement. There are numerous systems in hacksaw machine. The hacksaw is the metal cutting machine tool designed to cut metal by applying pneumatic pressure. The machine exclusively intended for mass production and they represent fasten and more efficient way to cut a metal. Hacksaws are used to cut thin and soft metals the operation of the unit is simplified to a few simple operations involving a cylinder block and piston arrangement. There are numerous systems in hacksaw machine .The main function of pneumatic hacksaw is to cut thin and soft metals by pneumatic power.


System Drawings



Bill of material

SR. NO

DESCRIPTION

QUANTITY COST

1

Square Tube M.S

3mtr

600

2

Shaft 100 mm Od 10long

01

50

3

Handle

01

100

4

Hacksaw

01

50

5

Guide way

01

70

6

M6 Bolts

05

35

7

Ms flat 12*12*1000

01

150

8

Hinge MS

01

25


ADVANTAGES

1. The cutting speed can be varied according to our needs by adjusting the timer. 2. It is portable. 3. It does not have any prime mover like electric motor. 4. Simple in construction than mechanical hacksaw. 5. It is compact one. 6. Less maintenance.


LIMITATION

1. Only smaller size and soft metal can be cut. 2. It is costlier than the mechanical hacksaw because of compressor unit. 3. Less efficiency when compressor to mechanical device. 4. Leakage of air affects the working of the unit.


APPLICATION

1. It is used in small scale industries and in large scale industries. 2. It useful when materials need to be cut in hazardous areas such as oil & gas refineries, chemical factories or oil rigs as well as dusty and wet environments where electric tools are not effective. 3. It is valuable tools in production environments such as pallet repair, shipbuilding or fiberglass workshops, because they will last longer than electric tools.


CONCLUSIONS

This being a creative project, there are no particular instances of this type of machine being available in the commercial market. But the aim of this project is to show that this type of machine too is an option for wood working industry in remote places in the absence of electricity. Further improvements include using reduction gears, to vary the speed of the circular saw, having an adjustable bed with slots for adjusting the table length, so that even large sizes of timber can be sawed b y varying the distance of the table and the size of the circular saw.

Beam Engine Hack Saw

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