PROJECT REPORT on Pedal Power Hacksaw
ABSTRACT In this Pedal operated hacksaw machine which can be used for industrial applications and Household needs in which no specific input energy or power is needed. This project consists of a crank and slider mechanism. In the mechanism pedal is directly connected co nnected to the hacksaw through crank and slider mechanism for the processing of cutting the wooden blocks, metal bars, pvc materials. The objective of the modal is using the conventional mechanical process which plays a vital role. The main aim is to reduce the human effort for machining various materials such as wooden blocks, steel, PVC etc.
The power hacksaw machine, which runs on human power, works on the principle of the conversion of rotational motion to oscillatory motion. Importance of this project lies in the very fact that it is green project and helps us to reduce our electricity need. Secondly, this cutter can be used and transferred to our working place easily. Moreover, if we want we can generate electricity with our project by connecting it to dynamo, diode d iode and battery.
Page 1
INDEX SR. NO
TOPICS NAME
PAGE NO.
1.
Introduction Of Project
6
2.
Component required
7
3.
Working principle p rinciple
19
4.
Designing Aspects and Parts Details/Drawings Details/Drawings
20
5.
Advantages and Disadvantages
24
6.
Cost estimation
25
7.
Future Modifications M odifications
26
8.
Conclusions
30
9.
References
30
Page 2
LIST OF TABLE 14 LIST OF FIGURE CHAPTER 1
INTRODUCION
6
CHAPTER 2 COMPONENTS REQUIRD 2.1) Pedal power hacksaw
7 7
2.1.1)Selecting A Power Hacksaw blade
9
2.1.2) Mounting a Power Hacksaw blade
11
2.1.3) Selecting a Band Saw Blade
11
2.1.4) Installing a Band Saw Blade
12
2.2) Pedal arrangement 2.2.1) Pedal
13 13
2.3) Stand Setup Parts
14
2.4) Crank And Slider Mechanism
16
2.5) Metal Slab
17
2.6) Bicycle Seat
18
CHAPTER 3
WORKING PRINCIPLE
19
CHAPTER 4
DESIGN
20
4.1 Base Frame
20
4.2 Upright Support
21
4.3 Hacksaw blade
22
Page 3
4.4 Design Consideration
22
CHAPTER 5
ADVANTAGES
24
DIS ADVANTAGES
CHAPTER 6
COST ESTIMATION
CHAPTER 7 FUTURE SCOPE
25
26
CHAPTER 8
CONCLUSION
30
CHAPTER 9
REFERANCES
30
Page 4
LIST OF FIGURE
SR NO
FIGURE NAME
1
Pedal power Hacksaw cutting system
2
Power Hacksaw blade
3
Power Hacksaw blade cutting operation 23
4
Pedal
5
Pedal power attachment
25
6
Bicycle Stand/Carrier
26
7
crank and slider mechanism
8
Metal slab 28
9
Metal slab 28
10
Bicycle sea
11
Working
12
Base Assembly
13
Upright Support Assembly
14
Hacks blade
15
Rice Threshing
16
Winnowing
37
17
Corn Shelling
37
18
Peanut Shelling
19
Operating a Circular Saw 38
20
Water Pumping from a Shallow Well
38
21
Operating a Wood Working Lathe
39
PAGE NO
19
21
24
27
29 30 31 32
33 37
38
Page 5
CHAPTER 1 INTRODUCTION
Pedal power is the transfer of energy from a human source through the use of a foot pedal and crank system. This technology is most commonly used for transportation and has been used to propel bicycles for over a hundred years. Less commonly pedal power is used to power agricultural and hand tools and even to generate electricity. Some applications include pedal powered laptops, pedal powered grinders and pedal powered water wells. Some third world development projects currently transform used bicycles into pedal powered tools for sustainable development. This project concentrates on pedal powered hacksaw machining. An individual can generate four times more power (1/4 HP) by pedaling than by hand-cranking. At the rate of ¼ HP, continuous pedaling can be served for only short periods, approximately 10 minutes. However, pedaling at half this power (1/8 HP) can be sustained for close to 60 minutes but power capability can depend upon age . As a consequence of the brainstorming exercise, it was apparent that the primary function of pedal power one specific product was particularly useful: the bicycle. Many devices can be run right away with mechanical energy. A saw is a tool that uses a hard blade or wire with an abrasive edge to cut through softer materials. The cutting edge of a saw is either a serrated blade or an abrasive. A saw may be worked by hand, or powered by steam, water, electr ic or other power. An abrasive saw uses an a brasive disc or band for cutting, rather than a serrated blade.
Page 6
CHAPTER 2 COMPONENTS REQUIRED I.
Hack saw blade
II.
Pedal arrangement
III.
Stand setup parts
IV.
Crank and slider mechanism
V.
Hack saw assembly
VI.
Metal slab
2.1) PEDAL POWER HACKSAW The principle of pedal power hacksaw is to change circulatory motion or cycling motion into translatory motion with the help of metal cutting rod. This is mainly used for cutting metals and plastics. it is manually pedal operated system. If we use dynamo then we can produce electricity which will be help to lighting the work piece area when electricity is not available in mechanical workshop.
A hacksaw is a fine-tooth saw with a blade under tension in a frame, used for cutting materials such as metal or plastics. Hand-held hacksaw consist of a metal arch with a handle, usually a pistol grip, with pins for attaching a narrow disposable blade. A screw or other mechanism is used to used to put the thin blade under tension. It is a fine tooth hand saw with a blade under tension. It is used to cut metals and PVC pipes. It would be useful in many projects discussed on this s ite which used plastic pipes as materials. Blades of hacksaw are measured in TPI (Tooth Per Inch). Different TPI is needed for different jobs of cutting.
Page 7
There are three types of cutters available in the market: 1. Simple hacksaw which can be used for hand cutting things. 2. Small Electrically Hacksaw for personal uses. 3. Large Cutter Machines used for Industrial Purposes. From the above three, first one will be used for our project
Fig 1-pedal power hexo cutting system
Page 8
A RECIPROCATING POWER HACKSAW It uses a blade that moves back and forth across the work. The blade cuts on the backstroke. There are several types of feeds available. Positive feed-produces an exact depth of cut on each stroke. The pressure on the blade varies with the number of teeth in contact with the work. Definite pressure feed-yields a pressure on the blade that is uniform regardless of the number of teeth in contact with the work. The depth of the cut varies with the number of teeth contacting the work. This condition prevails with gravity feed. Feed can be adjusted to meet varying conditions. For best performance, the blade and feed must be selected to permit high-speed cutting and heavy feed pressure with minimum blade bending and breakage. Standard reciprocating metal cutting saws are available in sizes from 6~ ~ 6~ (150 mm ~ 150 mm) to 24~ ~ 24~ (900 mm ~ 900 mm). The saws can be fitted with many accessor ies, including quickacting vises, power stock feed, power clamping of work, and automatic cycling of the cutting operation. The latter moves the work out the required distance, clamps it, and makes the cut automatically. The cycle is repeated upon completion of the cut. High-speed cutting requires use of a coolant. Coolant reduces friction, increases blade life, and prevents chip-clogged teeth. Cast iron and some brass alloys, unlike most materials, do not require coolant.
2.1.1)
Selecting A Power Hacksaw blade
Proper blade selection is important. Use the three-tooth rule at least three teeth must be in contact with the work. Large sections and soft materials require a coarse-tooth blade. Small or thin work and hard materials require a fine-tooth blade. For best cutting action, apply heavy feed pressure on hard materials and large work. Use light feed pressure on soft materials and work with small cross sections.
Page 9
Blades are made in two principal t ypes: flexible-back and all-hard. The choice depends upon use. i) Flexible-back blades -should be used where safety requirements demand a shatterproof blade.
These blades should also be used for cutting odd-shaped work if there is a possibility of the work coming loose in the vise. ii) All-hard blade -For a majority of cutting jobs, the all-hard blade is best for straight, accurate
cutting under a variety of conditions. When starting a cut with an all-hard blade, be sure the blade does not drop on the work when cutting starts. If it falls, the blade could shatter and flying pieces cause injuries.
Fig 2- Power Hacksaw blade Blades are also made from tungsten and molybdenum steels, and with tungsten carbide teeth on steel alloy backs. The following “rule-of-thumb” can be followed for selecting the correct blade: Use a 4-tooth blade for cutting large sect ions or readily machined metals. Use a 6-tooth blade for cutting harder alloys and miscellaneous cutt ing.
Page 10
Use 10- and 14-tooth blades primarily on light duty machines where work is limited to small sections requiring moderate or light feed pressure.
2.1.2) Mounting a Power Hacksaw blade
The blade must be mounted to cut on the power (back) stroke. The blade must also lie perfectly flat against the mounting plates. If long life and accurate cuts are to be achieved, the blade must be properly tensioned Many techniques have been developed for properly mounting and tensioning blades. Use a torque wrench and consult the manufacturer ’s literature. If the information (proper torque for a given blade on a given machine) is not available, the following methods can be used: Tighten the blade until a low musical ring is heard when t he blade is tapped lightly. A high pitched tone indicates that the blade is too tight. A dull thud means the blade is too loose. The shape of the blade pin hole can serve as an indicator of whether the blade is tensioned properly. When proper tension is achieved, the pin holes will become slightly elongated, The blade will become more firmly seated after the first few cuts and will stretch slightly. The blade will require retensioning (retightening) before further cutting can be done.
2.1.3) Selecting a Band Saw Blade Band saw blades are made with raker teeth or wavy teeth. Most manufacturers a lso make variations of these sets. The rakersetis preferred for general use.
Tooth pattern determines the efficiency of a blade in various materials. The standard tooth blade pattern is best suited for cutting most ferrous metals. A skip tooth blade pattern is preferred for
Page 11
cutting aluminum, magnesium, copper, and soft brasses. The hooktooth blade pattern also is recommended for most nonferrous metallic materials. For best results, consult the blade manufacturer ’s chart or manual for the proper blade characteristics (set, pattern, and number of teeth per inch) for the part icular material being cut.
2.1.4) Installing a Band Saw Blade If the saw is to work at top efficiency, the blade must be installed carefully. Wear heavy leather gloves to protect your hands when installing a band saw blade. Blade guides should be adjusted to provide adequate support, Proper blade support is required to cut true and square with the holding device. Follow the manufacturer ’s instructions for adjusting blade tension. Improper blade tension ruins blades and can cause premature failure of bearings in the drive and idler wheels. Cutting problems encountered with the band saw are similar to t hose of the reciprocating hack saw. Most problems are caused by poor machine condition. They can be kept to a minimum if a maintenance program is followed on a regular basis.This typically includes checking wheel alignment, guide alignment, feed pressure, and hydraulic systems.
Page 12
Fig 3- Power Hacksaw blade cutting operation
2.2) PEDAL ARRANGEMENT A pair of pedals is attached to the stand setup in which the power will be generated manually. A typical Bicycle arrangement is used.
2.2.1) PEDAL A bicycle pedal is the part of a bicycle that the rider pushes with their foot to propel the bicycle. It provides the connection between the cyclist’s foot or shoe and the crank allowing the leg to turn the bottom bracket spindle and propel the bicycle's wheels.
Page 13
Fig 4- pedal Pedals were initially attached to cranks connecting directly to the driven (usually front) wheel. The safety bicycle, as it is known today, came into being when the pedals were att ached to a crank driving a sprocket that transmitted power to the driven wheel by means of a roller chain. Pedals usually consist of a spindle that threads into the end of the crank and a body, on which the foot rests or is attached, that is free to rotate on bearings with respect to the spindle.
2.3) STAND SETUP PARTS Stands are introduced to immobilize the apparatus. Various components used are fixed to this arrangement. The chassis of the bicycle is used as t he stand setup parts . The stand described here is designed to support most bicycles.
Page 14
Fig 6- Bicycle Stand/Carrier 1.
The stand assembly is divided into two parts: the rectangular base frame and two triangular upright supports. Measure and cut the five pieces of 3/4" ( 20mm) angle specif ied for the base frame. Mitre the corners at 45 degrees so they fit together tightly and form square corners.
2.
Weld the rectangle together. Do not weld the center frame member to t he rectangle yet.
3.
Measure and cut as specified the 5 pieces for each upright support.
4.
Carefully assemble the upright support pieces for welding, being sure to leave a 1/8" (3.2mm) gap in the base of each support. This gap will mate with the center frame member of the base frame, allowing the upright supports to slide to accommodate different rear axle widths. Note that the two upright supports are not identical. They are mirror reflections of one another. Weld each upright support assembly together into a secure structure.
5.
Place the upright supports onto the base frame, and position the center frame member so that it mates with the gap in the side supports. Mark its po sition, and weld it in place.
Page 15
2.4) CRANK AND SLIDER MECHANISM This mechanism is used to convert the rotary motion of the crank into the reciprocating motion of hacksaw. The lengths of the crank and connecting rods are made using trial and error method.
Fig 7- crank and slider mechanism
The hack saw is guided by an aluminum plate. The vertical movement of the hacksaw will be guided by to iron rods. The vertical movement will act as a feeding unit.
Page 16
2.5) METAL SLAB He used a guide to control the hacksaw blade which is used to cut the metal. Metal slabs were fitted on the hacksaw blade to ensure pressure on the object to be cut and linear movement of the blade. A clamp, with 360 degree rotation, was fixed to hold the metal pieces while cutting, and to allow them to be cut in any shape and angle.
Fig 8- metal slab
Fig 9- metal slab
Page 17
2.6) BICYCLE SEAT
Fig 10- bicycle seat A bicycle seat, unlike a bicycle saddle, is designed to support the rider's buttocks and back, usually in a semi-reclined position. Arthur Graford is credited with inventing the padded bicycle seat in 1892, and they are now usually found on recumbent bicycles. Bicycle seats come in three main styles; mesh, hard shell and combination
i)
MESH
A typical mesh seat consists of a metal frame with mesh stretched over it and secured with adjustable straps, zip ties, string or shock cord.
ii)HARDSHELL Hard shell seats are normally made of a composite material such as GRP or carbon fiber although metal and wood versions do exist. A hard-shell seat is normally covered with some-form of padding, this is usually closed or open cell foam although some extreme racing machines do not have any padding on the seat to reduce weight and increase efficiency. Hard -shell seats are generally used at more reclined angles than mesh seats.
iii)COMBINATION A combination seat has a padded hard seat base wit h a mesh back.
Page 18
CHAPTER 3 WORKING PRINCIPLE It consists of the pedal arrangement which rotates the crank and through it
slider consists of
oscillating mechanism. The power is transmitted to the crank and slider mechanism. This mechanism is used to rotate the crank disc; the disc which is having an extended rod is connected to the sliding portion of the hacksaw directly by means of a linkage. The hacksaw is passed through the guide ways by means of maintaining the cutting axis. As the user operated the pedal, the hack saw cuts the various materials automatically with less power. The dead weight is for compressive force while the user operated the foot pedal.
Fig 11- working
Page 19
CHAPTER 4 DESIGN 4.1) BASE FRAME Plan view of frame in support position. All pieces 3/4" ( 19mm) steel angle.
Fig 12-Base Assembly
Page 20
4.2) UPRIGHT SUPPORTS Make two pieces of upright supports: one as shown and another one a reflection of the one
shown below. All pieces are made of 3/4" (19mm) steel angle, unless specified otherwise. Weld all joints.
Fig 13-Upright Support Assembly
Page 21
4.3)HACKSAW BLADE LENGTH=15 inch=36 cm WIDTH=1 inch
Fig 14- hacks blade
4.4) DESIGN CONSIDERATIONS When designing our attachment, the following considerations were taken into account 1. The device should be suitable for local manufacturing capabilit ies. 2. The attachment should employ low-cost materials and manufacturing methods. 3. It should be accessible and affordable by low- income groups, and should fulfill their basic need for mechanical power 4. It should be simple to manufacture, operate, maintain and repair. 5. It should be as multi-purpose as possible, providing power for various agricultural implements and for small machines used in rural industry. 6. It should employ locally available materials and skills. Standard steel pieces such as steel plates, iron rods, angle iron, and flat stock that are locally available should be used. Standard tools used in machine shop such as hack saw, files, punches, taps & dies; medium duty welder; drill press; small lathe and milling machine should be adequate to fabricate the parts needed for the dual purpose bicycle.
Page 22
7. It should make use of standard bicycle parts wherever possible. 8. The device should adapt easily to as many different bicycles as possible. No permanent structural modification should be made to the bicycle. 9. Though the device should be easy to take off the bicycle, it is assumed that it would usually remain attached to facilitate readiness and ease of transport from site to site. The device, therefore, should not interfere with the bicycle's t ransportation mode. 10. The broad stand, which provides stability during power production mode, can be flipped upward during the transport mode. This stand/carrier would be a permanent fixture of the dual purpose bicycle. 11. The power take-off mechanism should be as efficient as possible, and should develop relatively high r.p.m. (close to 200) for versatility of application. We had seen designs for devices that take power from the rear tire by means of a friction roller pressed against it, but we had doubts about the efficiency of this arrangement. In order to improve efficiency we used hard bearing surfaces such as roller chains, sprockets and ball bearings. We decided that the most appropriate location for this power take-off mechanism would be at the front of the bike near the fork tube (see photographs). 12. Care must be exercised to insure that the power take-off assembly is far enough forward so as not to interfere with pedaling. Most standard adult bicycle frames have plenty of room for the power take-off mechanism and pulley. Power is supplied to the shaft by means of a chain from the bike's chain wheel (crank) to a ratcheted sprocket on the shaft. During the prime-mover mode, the bike's regular chain is slipped off of the chain-wheel, and the specially sized chain to the power take-off mechanism is slipped on. 13. The device should be able to transmit power to a variety of machines, and changing drive ratios should be as simple as possible. We decided that a V-belt and pulley arrangement would be most appropriate for this. Belts do not require the precise alignment that chains do. Belts can even accommodate pulleys that are slightly skewed with respect to each other. Changing drive ratios is as easy as changing pulleys. Also, belts are reasonably efficient.
Page 23
14. The device should contain a ratcheting mechanism that would let the operator "coast " periodically to rest and conserve energy. A free wheel from any bicycle can be easily adapted for this purpose. 15. Excessive weight should be avoided, as durability is a pr ime consideration.
CHAPTER 5 ADVANTAGES I.
Time saving as compared to simple hacksaw
II.
Power saving as it is manually operated
III.
Easy machinery used
IV.
As it is pedal operated so good for health
V.
Comfortable then ordinary hacksaw
VI.
It is portable
VII.
It could be used wherever metal cutting is done in small scales, including at construction sites and furniture units, or to cut metal for window panes.
DISADVANTAGES I.
Its totally manually operated
II.
Time consuming as compared to electrical power hacksaw
III.
Without human effort its not operated
IV.
Not fit for heavy production
Page 24
CHAPTER-6 Cost Estimation SR.NO.
NAME
OF PIECES
PRICE/PIECE TOTAL
COMPONENT 1
Pedal
2
200
400
2
Stand
1
350
350
3
Base frame
1
750
750
4
Crank& Slider mechanism
1
900
900
5
Clamp
2
130
260
6
Hacksaw
1
550
550
7
Nut & Bolt
7
10
70
Page 25
8
Welding cost
-
380
380
TOTAL
3660
CHAPTER-7 FUTURE SCOPE Following all types of operation can be carried out by the proper pedal attachment as per the requirement. Here are some operation.
Fig 15- Rice Threshing
Fig 16-Winnowing
Page 26
Fig 17-Corn Shelling
Fig 18- Peanut Shelling
Fig 19- Operating a Circular Saw
Page 27
Fig 20-Water Pumping from a Shallow Well
Page 28
Fig 21-Operating a Wood Working Lathe
Page 29
