A

PROJECT
SYNOPSIS
ON

SOLAR POWERED MECHANICAL HACKSAW

Submitted to:
DR. A.P.J. ABDUL KALAM TECHNICAL UNIVERSITY,
LUCKNOW
In partial fulfillment of the requirements for the
degree of
Mechanical Engineering
Session 2016-17

Submitted by:
SANDEEP KUMAR RAWAT (1342340064)
PRAVIN KUMAR PANDEY (1342340046)
RADHESHYAM YADAV (1342340048)
RAHUL KUMAR SINGH (1342340051)
YASH KUMAR SINGH (1342340081)
SAURABH RAI (1342340066)

Under the supervision of:

MR. ANOOP KUMAR SINGH
ABSTRACT
The objective of our work is to automate the conventional power hacksaw machine in
order to achieve high productivity of work-pieces than the power hacksaw machine using
solar energy. The automated machine acquires two inputs from the user namely the number
of pieces to be cut and the length of each piece that is required to be cut. The inputs are
given by the user with the help of a keypad and an LCD display, which will help the user to
verify the data given by him. The operator need not measure the length of the work-piece
that is to be cut and to load and unload the work-piece from the chuck each time after a
piece has been cut. After acquiring the two inputs from the user, the machine automatically
feeds the given length of work-piece in to a chuck and starts to cut till the given number of
work-pieces has been cut. The machine feeds the work-piece with the help of a conveyor,
which is driven by a DC motor and an IR sensor ensures that the feeding stops when the
specified length has been reached. A pneumatic cylinder is used for holding the work-piece
when cutting operation is done. An AC motor is used to bring about the reciprocating
motion required for cutting the work-pieces. There is a self-weight attached with the
reciprocating mechanism to provide the necessary downward force required for penetration
of hacksaw blade in to the work-piece. When a single piece has been cut, a limit switch
will get triggered by the self-weight mechanism, which is sensed by the microcontroller to
start the cyclic operation again provided if the specified number of work-pieces has not
been cut.

INTRODUCTION OF SOLAR ENERGY

Solar energy applies energy from the sun in the form of solar radiation for heat or to generate electricity.
Solar powered electricity generation uses either photo voltaic or heat engines (concentrated solar power).
A partial list of other solar applications includes space heating and cooling through solar architecture, day
lighting, solar hot water, solar cooking, and high temperature process heat for industrial purposes. Solar
technologies are broadly characterized as either passive solar or active solar depending on the way they
capture, convert and distribute solar energy.
Active solar techniques include the use of photovoltaic panels and solar thermal collectors to harness the
energy. Passive solar techniques include orienting a building to the Sun, selecting materials with favorable
thermal mass or light dispersing properties, and designing spaces that naturally circulate air.

India is densely populated and has high solar insulation, an ideal combination for using solar power in
India. Much of the country does not have an electrical grid, so one of the first applications of solar power
has been for water pumping, to begin replacing India's four to five million diesel powered water pumps,
each consuming about 3.5 kilowatts, and off-grid lighting.
Some large projects have been proposed, and a 35,000 km area of the That Desert has been set aside
for solar power projects, sufficient to generate 700 to 2,100 gigawatts.
The Indian Solar Loan Programme, supported by the United Nations Environment Programme has won
the prestigious Energy Globe World award for Sustainability for helping to establish a consumer financing
program for solar home power systems.
Over the span of three years more than 16,000 solar home systems have been financed through 2,000
bank branches, particularly in rural areas of South India where the electricity grid does not yet extend.

Solar energy doesnt cause pollution.

Solar energy is free

Solar energy will never run out.

However, there are some problems: You can only get solar power during the day (and there

is less on cloudy days).

 Solar equipment is very expensive.

Expensive batteries are needed to store solar energy for cars to be able to run at night.

Solar cells are not very efficient, and the collector areas are too big for consumer cars.

INTRODUCTION OF MECHANICAL HACKSAW

A hacksaw is a fine-toothed saw, originally and principally for cutting metal. They
can also cut various other materials, such as plastic and wood; for
example, plumbers and electricians often cut plastic pipe and plastic conduit with them.
There are hand saw versions and powered versions (power hacksaws). Most hacksaws are
hand saws with a C-shaped frame that holds a blade under tension. Such hacksaws have a
handle, usually a pistol grip, with pins for attaching a narrow disposable blade. The frames
may also be adjustable to accommodate blades of different sizes. A screw or other
mechanism is used to put the thin blade under tension. Panel hacksaws forgo the frame and
instead have a sheet metal body; they can cut into a sheet metal panel further than a frame
would allow. These saws are no longer commonly available, but hacksaw blade holders
enable standard hacksaw blades to be used similarly to a keyhole saw or pad saw. Power
tools including nibblers, jigsaws, and angle grinders fitted with metal-cutting blades and
discs are now used for longer cuts in sheet metals.

On hacksaws, as with most frame saws, the blade can be mounted with the teeth
facing toward or away from the handle, resulting in cutting action on either the push or pull
stroke. In normal use, cutting vertically downwards with work held in a bench vice,
hacksaw blades should be set to be facing forwards. Some frame saws, including Fret Saws
and Piercing Saws, have their blades set to be facing the handle because they are used to
cut by being pulled down against a horizontal surface.

A hacksaw is a fine-tooth saw with a blade under tension in a frame, used for
cutting materials such as metal. Hand-held hacksaws consist of a metal frame with a
handle, and pins for attaching a narrow disposable blade. A screw or other mechanism is
used to put the thin blade under tension. A power hacksaw (or electric hacksaw) is a type of
hacksaw that is powered by electric motor. Most power hacksaws are stationary machines
but some portable models do exist. Stationary models usually have a mechanism to lift up
the saw blade on the return stroke and some have a coolant pump to prevent the saw blade
from overheating

Power hacksaws are used to cut large sections of metal or plastic shafts and rods.
Cutting of solid shafts or rods of diameters more than fifteen millimeters is a very hard
work with a normal hand held hacksaw. Therefore power hacksaw machine was invented
during 1920s in the United States to carry out the difficult and time consuming work. This
power hacksaw machine shown in figure 1 is considered as an automatic machine because
the operator need not be there to provide the reciprocating motion and downward force on
the work-piece in order to cut it. Once the operator has fed the work-piece till the required
length in to the machine and starts the machine, then the machine will cut until the work-
piece has been completely cut in to two pieces. Fig 1.Power Hacksaw Machine The fact
that the operator has to feed the work-piece to the required length in to the vice is one
aspect that motivated us to automate the feeding of work-piece automatically. Another one
aspect is that after a shaft has been cut for one time, the operator has to unload the work-
piece and advance the rest of the work-piece to the required length again and again till the
end of the work-piece is reached. The Power hacksaw machine though being able to cut the
shaft or rod without requiring any human effort to cut, it does require a human intervention
to feed the work-piece many times with measurements being taken each time before
feeding. Therein, arose a need to completely automate the process of cutting, and here we
are with a proposal which will aid in eliminate the effort of the people associated with it.
Problem Identification

The power hacksaw machines, which are operated by human operators as aforementioned,
have the demerit of unloading and loading the work-piece many times. In industries
manufacturing pumps, these machines are used to cut the motor shafts to the required
lengths. It will be difficult for the operator if he has been assigned to cut a huge quantity of
motor shafts and he has to measure the lengths each time for cutting. Since humans are not
as versatile as machines, there is a possibility that there may be inaccuracies. Besides, if
there is a slight time delay in between every cycle of cutting a piece, the cumulative delay
in time will be found to have a considerable magnitude, which might have been utilized
properly if the proposed machine were in use there.

Proposed Methodology

The demerit of power hacksaw machine is the automatic feeding of work-piece is

eliminated by feeding of work-piece with the help of a conveyor, which directs the work-
piece in to the chuck. The conveyor motor is stopped when it has fed the specified length
in to the chuck with the help of a microcontroller and IR sensor. After this, a pneumatic
cylinder is extended to hold the work-piece firmly to arrest the movement of work-pieces
when being cut. This is achieved by a solenoid operated DCV, controlled by a
microcontroller. Then the self-weight attached to the blade, which would be previously in a
lifted position by means of another pneumatic cylinder will be lowered so that the hacksaw
blade will contact the work-piece at the point where the cutting is to be done. This is
achieved by retracting the weight-lifting cylinder operated by the same solenoid DCV. The
cutting motor then gets turned on by the microcontroller, so that the blade is set to
reciprocate on the work-piece to cut. After a piece has been cut, the cycle begins again
from automatic feeding without any human intervention and proceeds till the specified
number of pieces is cut.
 HISTORY OF SAWS

While saws for cutting metal had been in used for many years, significant improvements in
longevity and efficiency were made in the 1880s by George N. Clemson, a founder
ofClemson Bros., Inc of Middletown, New York, USA,. Clemson conducted tests which
involved changing the dimensions, shapes of teeth, styles of set, and variable heat
treatments of blades. Clemson claimed enormous improvements to the cutting ability of
blades and built a major industrial operation manufacturing hacksaw blades sold under the
trade name Star Hack Saw.[1] In 1898, Clemson was granted US Patent 601947, which
details various improvements in the hacksaw.

Blades

Blades are available in standardized lengths, usually 10 or 12 inches for a standard hand
hacksaw. "Junior" hacksaws are typically 150mm long. Powered hacksaws may use large
blades in a range of sizes, or small machines may use the same hand blades.

The pitch of the teeth can be anywhere from fourteen to thirty-two teeth per inch (tpi) for a
hand blade, with as few as three tpi for a large power hacksaw blade. The blade chosen is
based on the thickness of the material being cut, with a minimum of three teeth in the
material. As hacksaw teeth are so small, they are set in a "wave" set. As for other saws they
are set from side to side to provide a kerf or clearance when sawing, but the set of a
hacksaw changes gradually from tooth to tooth in a smooth curve, rather than alternate
teeth set left and right.

Hacksaw blades are normally quite brittle, so care needs to be taken to prevent brittle
fracture of the blade. Early blades were of carbon steel, now termed 'low alloy' blades, and
were relatively soft and flexible. They avoided breakage, but also wore out rapidly. Except
where cost is a particular concern, this type is now obsolete. 'Low alloy' blades are still the
only type available for the Junior hacksaw, which limits the usefulness of this otherwise
popular saw.
For several decades now, hacksaw blades have used high speed steel for their teeth, giving
greatly improved cutting and tooth life. These blades were first available in the 'All-hard'
form which cut accurately but were extremely brittle. This limited their practical use to
benchwork on a workpiece that was firmly clamped in a vice. A softer form of high speed
steel blade was also available, which wore well and resisted breakage, but was less stiff
and so less accurate for precise sawing. Since the 1980s, bi-metal blades have been used to
give the advantages of both forms, without risk of breakage. A strip of high speed steel
along the tooth edge is electron beam welded to a softer spine. As the price of these has
dropped to be comparable with the older blades, their use is now almost universal.

Hacksaw blade specifications: The most common blade is the 12 inch or 300 mm length.
Hacksaw blades have two holes near the ends for mounting them in the saw frame and the
12 inch / 300 mm dimension refers to the center to center distance between these mounting
holes.

The principle of motor power hacksaw is to change circulatory motion or rotary motion
into translator motion with the help of metal cutting rod. This is mainly used for cutting
metals and plastics. it is auto 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 use 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 site 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.

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

ARECIPROCATING POWER HACKSAW

ADVANTAGES
I. Time saving as compared to simple hacksaw
II. Money saving as it operated by Solar Energy
III. Easy machinery used
IV. Comfortable then ordinary hacksaw
V. It is portable
VI. It could be used wherever metal cutting is done in small scales, including at
construction sites and furniture units
DISADVANTAGES
I. Without human effort its not operated
II. Work only on Sunny Days only
III. Not fit for heavy production

Mechanical Power Hacksaw