A Study

on

FABRICATION OF
PEDAL POWERED CHOP SAW AND
GRINDER

(Submitted in partial fulfillment of the requirements for the award of degree of Bachelor of
Engineering in Mechanical Engineering of Gauhati University)

Submitted by
Syed Sadique ul Zakariah (11-108)

Under the guidance of

Dr. Satyajit Paul
Associate Professor
MECHANICAL ENGINEERING DEPARTMENT
ASSAM ENGINEERING COLLEGE
JALUKBARI, GUWAHATI 781013
2014-2015
 ABSTRACT

Metal rod cutting is a primary operation in many industry and construction site. The

convention methods for cutting the same are electrically operated hacksaw/chop saw and

manually operated hacksaw. The present study aims to develop a manual system to cut and grind

metal rods for industrial applications and household needs. The fabricated machine not only

saves power but also be used as a rural technology or used in places where there are frequent

power outages. In this machine no electric power is required as the tools, i.e. the cutting wheel

and grinder is rotated by pedaling operation performed on a bicycle frame. The power is

transmitted with the help of chain drive. Thus, the use of this machine is universal as simple

machinery and mechanisms are used. Finally, the prime advantages of the machine are to reduce

human effort, more time saving as compared to simple hand operated hacksaw and power saving

as it is manually operated.
 CHAPTER-1

INTRODUCTION

1.1 Conventional chop saw and grinder

A chop saw, also known as a cut-off saw, is a power tool which is typically used to cut
hard materials, such as metals. An abrasive disc called cutting wheel, similar to a
thin grinding wheel, performs the cutting action. It does not use regularly shaped edges
(teeth) for cutting. The chop saw generally has a built-in vise or other clamping arrangement,
and has the cutting wheel and motor mounted on a pivoting arm attached to a fixed base
plate. The motor imparts rotational motion to the cutting blade. A chop saw has been shown
in fig 1.1.1.

A chop saw typically uses composite friction disk blades to abrasively cut through the
steel. The abrasive disks for these saws are typically 360 mm (14 in) in diameter and 2.8 mm
thick. Larger saws use 410 mm (16 in) diameter blades. Disks are available for steel and
stainless steel.

Since their introduction, portable metal chop saws have made many building site jobs
easier. With these saws, lightweight steel fabrication previously performed in workshops
using stationary power bandsaws or cold saws can be done on-site.

Figure 1.1.1: A conventional chop saw

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 A grinding machine or a grinder uses an abrasive wheel as a cutting tool to shape or
change the dimensions of a hard material. The type of materials that need grinding are usually
metallic items such as tools and rods. These machines generally work by reducing the material
through abrasion. Generally, the grain of the abrasive wheel chips away at the material, changing
its shape or dimension. The basic parts that a user works with are typically the grinding
machine's power driven wheel, the work-bed where the material is placed, and a fixture which
guides and holds the material. The wheels, which can vary in size, are generally made from a
manufactured abrasive such as silicon carbide or aluminum oxide.

Figure 1.1.2: A conventional bench grinder

1.2 Background of project

Fabrication of a pedal powered chop saw and grinder will help achieve a cost effective
mechanism to have the same functions as that of an electric powered chop saw and grinder. It
will be cost effective because a pedal powered chop saw and grinder will use manual power
to drive the cutting blade instead of electricity. In addition, use of simpler part for fabrication
will impart easy portability to the fabrication for use in on-site purpose. The project will
therefore help provide an alternative to motor powered chop saw wherever possible.

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1.2 Fabrication objectives
The objectives for fabrication of pedal powered chop saw and ginder are:
It will cut metal rods.
It will grind metal rods and sharpen tools.
It will use manual power.
It will reduce human effort.
It will provide a suitable alternative to power driven hacksaw in places where there is no
electricity.

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 CHAPTER-2
ANALYSIS OF THE MACHINE

2.1 Principle of operation

The various working principles employed in the fabricated machine are:

The pedaling operation performed on a bicycle frame rotates a sprocket.
The sprocket then actuates the motion of the chain drive.
The chain drive transmits the motion to a shaft with the help of a freewheel.
The rotation of the shaft imparts rotary motion to the tools mounted on it.
The rotating cutting wheel and grinding wheel is then used to cut and grind metal rods
respectively.
The work piece is suitably held in position on top of a platform.
The feed to the cutting blade is provided manually.

2.2 Advantages
The advantages of pedal powered chop saw and grinder may be enlisted as follows:
Faster performance as compared to simple hand operated hacksaw.
Power saving as it is manually operated.
Simple machinery used, so its use may be universal.
It is a rural technology.
It can be used in sites where there is frequent power outage.
The grinding wheel can also be used to sharpen certain tools like punch, chisel, etc.
The fabrication has been completed at a cost under Rs.5000. A motor driven chop saw is
prices between Rs.8000 and Rs.20000 depending on features available and quality. The price
of motor driven bench grinder is between Rs.3000 and Rs. 5000. Thus, we see that the
combined cost of motor driven chop saw and grinder will be well above the fabricated chop
saw and grinder. Hence, it is cost effective.

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 CHAPTER-3

COMPONENTS REQUIRED

The components required in the fabrication of pedal powered chop saw and grinder are:

1. Bicycle frame
2. Bicycle pedals
3. Sprocket
4. Freewheel
5. Chain
6. Angle beams, flat beams
7. Metal plates and cylindrical metal rod
8. Bearing along with bearing cover
9. Cutting wheel
10. Grinding wheel
11. Counter weight
12. Nut and bolts
13. Washer

Details of the fabricated parts have been provided in the subsequent chapters.

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 CHAPTER-4

SHAFT FOR POWER TRANSMISSION

The fabricated shaft, which will act as arbor for the cutting blade, has been shown in fig 4.1

Figure 4.1: Shaft for power transmission

The steps involved in fabrication of the shaft are as follows:

1. Firstly, a cylindrical section of length 457 mm is cut out from a longer cylindrical rod
using a power hacksaw.
2. Then by using a lathe, the rod is turned to have an outer diameter of 30 mm so that the
bearings and freewheel can be provided a push fit on the rod.
3. At both ends of the rod, screw threads of length 38 mm is made using a lathe.
4. Using a radial drilling machine and a drill bit of size 3 mm a hole is made at each end of
the rod for providing a locking mechanism for the nut.
5. Finally, two ball bearings and one freewheel is push fitted on the shaft as shown in the
figure above.

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 CHAPTER-5

TOOL HOLDER

The tool holder, which will support the arbor and the cutting blade, is shown below in fig 5.1

Figure 5.1: Tool holder

The steps involved in fabrication of the tool holder are as follows:

1. Firstly, the surface of a square plate of dimension 177 x 177 mm is made smooth using
emery paper. Then its edges have been grinded and rounded with the help of a grinding
machine.

2. Then a rectangular shaped opening is made on the base plate; first by making holes
along the desired surface required to be removed using a radial drilling machine and 10
mm drill bit and then remaining material along the edges of the holes removed using
hacksaw blade and file. This rectangular opening is provided so as to allow the chain of
the chain drive to pass through it.

3. Two angle beams of length 300 mm are cut using a shearing machine whose edges are
then smoothened using a grinding machine.

4. Now, at a distance of about 25 mm from one end, a hole of length 25mm is made on
both the beams using plasma welding. This opening is made so that the bearing covers

7
 can be bolted on the angle beams. Then from the end of the hole, at a distance measured
by using the bearing cover, another hole is made of length 25 mm. The inner edges of
the holes are then smoothened using a file.

5. Finally, the angle beams have been welded at the two corners of the square plate using
arc welding.

8
 CHAPTER-6

SUPPORTING FRAME

The supporting frame of the fabrication is shown below in fig 6.1. The supporting frame is a
bicycle frame along with the pedal arrangements. The supporting frame will bear the weight of
the operator and other components attached the frame.

Figure 6.1: Supporting frame

The various steps in fabrication of the supporting frame are as follows:

1. Four angle beams, two each of length 660 mm and 457 mm are cut using shearing machine.
2. The angle beams of length 457 mm are obliquely arc welded at the rear end of the bicycle
frame as shown in the figure above.
3. The angle beams of length 660 mm are welded at the front of the bicycle frame, as shown
in the figure above, using arc welding.
4. The welding has been done precisely so that the bicycle frame stands perpendicularly to the
floor.
5. In order to provide further rigidity to the four legs of the supporting frame, steel beams
have been welded horizontally joining any two adjacent legs as shown in the figure above.

9
 CHAPTER7
CLAMPING THE TOOL HOLDER ON SUPPORTING FRAME

The various steps in clamping the tool holder on the supporting frame are as follows:

1. The front section of the bicycle frame is cut out.

2. A metal plate of dimensions of length 250 mm and breadth 60 mm is welded in the cut
out part of the bicycle frame. [figure 7.1]

Figure 7.1: Adjustment of the bicycle frame

3. On this metal plate, the tool holder is attached using nut and bolt arrangement and two
rectangular flat metal plates. [figure 7.2]

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 NUT AND BOLT
ARRANGEMENT

RECTANGULAR
METAL PLATE

Figure 7.2: Clamping of tool holder

4. Two flat bars (inclined) are welded below the two angles and one flat bar (horizontal) is
welded on middle section on the front of the tool holder so as to provide rigidity and
support to the system. [figure: 7.3]

FLAT BEAMS

Figure 7.3: Welded flat beams

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 CHAPTER-8
MOUNTING OF SHAFT ON TOOL HOLDER

FREEWHEEL
BEARING WITH
BEARING COVER

NUT AND BOLT

ARRANGEMENT

Figure 8.1 Shaft mounted on the tool holder

The various operations in mounting the shaft on the tool holder are as follows:

1. The power transmitting shaft is mounted on the angles on the tool holder using two ball
bearings and bearing covers with nut and bolt arrangement.

2. The freewheel is also fitted on the power transmitting shaft.

3. The chain is connected between this freewheel and the driver sprocket so as to facilitate the
pedaling operation.

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 CHAPTER-9
TOOLS MOUNTED ON SHAFT

The figure 9.1 below shows the various tools and elements mounted on the shaft. The
shaft acts as the power transmitting element from freewheel to the tools mounted on it. The
rotational motion of the shaft is thus transferred to the tools and elements mounted on it.

NUT
GRINDING WHEEL
DIAMETER: 120 mm WASHER

COUNTER WEIGHT
MASS: 1KG

CUTTING WHEEL
DIAMETER: 177 mm

Figure 9.1: Tools and elements mounted on the shaft

The various tools mounted on the shaft are:-

1. Cutting wheel
2. Grinding wheel

9.1 CUTTING WHEEL

A cutting wheel of diameter 177 mm is mounted on the shaft [figure: 9.1.1]. In order to
properly mount the cutting wheel rubber packing and metal washers are used. These are tighten

13
and held in position by using a nut whose threads mesh with the threads made at the end of the
shaft. A second nut is introduced in the shaft for locking purpose.

Figure 9.1.1: Cutting wheel mounted on shaft

9.2 GRINDING WHEEL

A grinding wheel of diameter 120 mm is also mounted on the shaft [figure: 9.2.1]. In
order to mount the grinding wheel on the shaft plastic packing and nut is used. A safety pin is
introduced into the shaft to keep the nut in a locked position.

Figure 9.2.1: Grinding wheel mounted on shaft

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9.3 COUNTER WEIGHT

A cast iron counter weight of mass 1 kg and diameter 140 mm is arc welded on the shaft
which acts as a flywheel and thereby helps maintain the rotational speed of the cutting wheel.

15
 CHAPTER-10

CHAIN DRIVE

In order to transmit power from the pedaling operation to the shaft carrying the tools a
chain drive is used. The chain passes over a sprocket at the position of the bicycle pedal and over
a freewheel placed at the mid section of the shaft. The intricate details are mentioned below.

10.1 Freewheel

A freewheel with 16 number of teeth is placed at a appropriate position at the mid section
of the shaft in order act as the driven and transmit rotary motion to the shaft and therefore to the tools
mounted on it. The freewheel is clamped on to the shaft with the help of nut present circumferential
all around the freewheel. This arrangement is shown in figure 10.1.1 below. The chain passes over
this freewheel and reaches the sprocket through the opening made on the base plate of the tool holder.

FREEWHHEL
NUMBER OF
TEETH: 16

CHAIN PASSING
THROUGH TOOL
HOLDER

Figure 10.1.1: Chain passing over freewheel

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10.2 SPROCKET

From the freewheel the chain passes over the sprocket. The sprocket used in the assembly
has 48 number of teeth. Rotary motion to the sprocket is given with the help of bicycle pedal.
This motion is transferred to the chain which indeed moves the freewheel. Thus, the sprocket
will act as the deriver. This arrangement is shown below in figure 10.2.1

SPROCKET
NUMBER OF
TEETH: 48

Figure 10.2.1: Chain passing over the sprocket

10.3 Derailleur

In order to increase the tension on the chain so that the chain does not fall off the sprocket
a derailleur is introduced in the chain drive. Derailleur is a variable-ratio transmission system
commonly used on bicycles, consisting of multiple sprockets of different sizes, and a mechanism
to move the chain from one sprocket to another. In the assembly the derailleur used as two
sprockets one having 14 teeth and the having 12 teeth. The derailleur arrangement of the
assembly is shown in figure 10.3.1

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BICYCLE FRAME

CHAIN

ALUMINIUM
SHEET

DERAILLEUR
NUT AND BOLT

ANGLE BEAM

Figure 10.3.1: Derailleur arrangement

The steps involved in attaching the derailleur to the bicycle frame are:

1. An angle beam is welded on the bicycle frame.

2. Placing the derailleur on the welded beam an aluminium sheet is wrapped around the
derailleur.
3. The aluminium sheet is tighten and held in position with the help of nut and bolt
arrangement.

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 CHAPTER-11

PLATFORM

A platform is fitted at the front section of the assembly above the tool holder to provide a
surface on which the cutting operation can be performed. The platform is shown below in figure
11.1. The platform contains appropriate openings to accommodate the mounting of the various
tools on the shaft.

JOB

CUTTING PLATFORM

Figure 11.1: Platform

The steps involved in mounting the platform on the tool holder are:

1. A metal plate is welded vertically at one end of the platform. [figure: 11.2]. At the other
end of this vertical plate two small L shaped metal plates are welded. This L shaped
plates acts as hooks and these hooks are inserted on the tool holder. Thus one end of the
platform is supported.

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VERTICAL PLATE

Figure 11.2: Supporting the platform with a vertical plate

2. At the other end of the platform, holes are drilled to make provision for nut and bolt
arrangement [figure: 11.3]. The ends of these bolts are inserted in nuts welded on the tool
holder.
NUT AND BOLT
ARRANGEMENT

WELDED NUTS

Figure 11.3: Supporting platform with nut and bolt arrangement

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 Chapter-12
PAINTING

Painting is the method of protecting metal components from attack by the local
environment. It is the most widely used system of corrosion protection. The machine has been
painted in order to increase its aesthetic appeal and to provide protection against corrosion that
may result due to the various environmental conditions in which the machine has to operate.

The various steps involved in painting of the fabrication are:

1. The rust from metal parts of the fabrication is removed by use of sand paper and the
surface is cleaned and made free from grease or oil.

2. Red oxide primer is applied on the surface to be painted and then it is allowed to dry.

3. Finally, enamel paint is applied on the required surface and is allowed to dry.

The figure 12.1 below shows the painted fabrication

Figure 12.1: Painted fabrication

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 CHAPTER-13

TESTING THE ASSEMBLY

The fabricated model was tested to check its performance. Solid cylindrical metal rod of
diameter 8 mm and hollow rod having square cross section and thickness of about 2 mm was
used as job. In both the metal cutting operations, the machine performed satisfactorily. The
sheared section of the cylindrical rod was grinded successfully using the mounted grinding
wheel.

Figure 13.1: Man performing a metal cutting operation

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Figure 13.2: Cutting operation on a cylindrical rod of diameter 8 mm

Figure 13.3: The cutting operation performed successfully

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 CHAPTER-14

SPECIFICATIONS

Different parameters of the fabricated machine are stated below in table 14.1

Sl. No. Parameter Dimension (mm)

1 Height up to seating position 950
2 Length of machine 1035
3 Width of machine 585
4 Length of platform 350
5 Width of platform 390
6 Total length of chain 2032
7 Diameter of shaft 30
8 Inner diameter of bearing 30
9 Diameter of cutting blade 177
10 Thickness of cutting blade 3
11 Diameter of grinding wheel 120
12 Thickness of grinding wheel 20
13 Diameter of counter weight 140

Table 14.1: Dimension of various parts

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 CHAPTER-15
CALCULATIONS
The calculations below give us an approximate idea of the cutting wheel speed that can be
generated in the machine.

Number of teeth on the sprocket (driver) = 48

Number of teeth on freewheel (driven) = 16

We know,

Number of teeth on sprocket = Speed of freewheel (rpm)

Number of teeth on freewheel Speed of sprocket (rpm)

48 = Speed of freewheel
16 Speed of sprocket

Therefore, we have

Speed of freewheel = 3 Speed of sprocket

Now, if we consider that a man can rotate the pedal approximately 60 times per minute, i.e. the
sprocket can have 60 rpm on an average.

Speed of freewheel = 3 60 rpm

Speed of freewheel = 180 rpm

Since, the freewheel rotates the shaft which indeed rotates the cutting wheel and grinding wheel,
as result we can say that the tools mounted on the shaft will a have on an approximate speed of
180 rpm.

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 CHAPTER-16
COST INVOVED IN FABRICATION
The cost incurred in fabricating the pedal powered chop saw and grinder has been detailed below
in table 16.1

Sl. No. Particulars Rate (Rs.) Quantity Amount (Rs.)

1. Material (Angles, Flat Bars, 600

Round bars, etc)

2. Cutting wheel 150 1 150

3. Grinding Wheel 100 1 100

4. Bicycle Frame, Chain & Seat 1000

5. Sprocket Gear 190 1 190

6. Freewheel 50 1 50

7. Welding cost 200 200

8. Bearings (With Cover) 150

9. Painting 400

10. Labour Cost 1500

GRAND TOTAL 4340

Table 16.1: Cost incurred

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 CHAPTER-17
SCOPE FOR FURTHER IMPROVEMENT
Although the fabricated machine performs satisfactorily, there is room for many improvements.
Some of the proposed improvements are:

Increasing the speed of cutting wheel: By decreasing the size of freewheel and increasing
the size of sprocket the speed of the cutting wheel can be increased. With increase in
cutting speed, faster performance can be achieved and heavier jobs performed.
Mounting a protective shield on the platform: The shield will provide for protection
against any potential physical harm caused by chip particles to the operator. Also, in case
the cutting wheel suffers any damage, the shield will offer adequate protection to the
operator
Better grip on the job: A system for better gripping the job on the platform can be
introduced. It will provide ease of operation to the operator and hence improve
performance.
Introducing wheels: Introducing wheels at the base of the supporting frame can make the
machine mobile.

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 CHAPTER-18

CONCLUSION

With the gradual depletion of oil reserve and ever-increasing pollution level, it is high
time for developing devices and instruments which are manually driven and/or use alternative
energy sources. With the help of this study, a low cost and simple design pedal operated chop
saw has been fabricated. This machine is a rural technology and can be implemented in various
small-scale rural industries. Even in urban sites, this machine will be a boon during power
outages.

In order that community adopts this technology, the machine must be inexpensive and
easy to build. Recognizing this need, the machine has been fabricated from the start bearing low
cost in mind. The machine contains bicycle parts that are readily available in the market. This
eliminates the need to order or import components for its fabrication. The pedal-powered chop
saw and grinder is quite different from the communitys current method of cutting metal.

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BIBLIOGRAPHY

1. A Course in Workshop Technology (Vol. 1 and 2) by B.S. Raghuwanshi.

2. Elements of Workshop Technology (Vol. 1 and 2) by S.K. Hajra Choudhury,
A.K. Hajra Choudhury and Nirjhar Roy.
3. Design of Machine Elements by V.B. Bhandari.

WEBSITE REFERENES

1. http://en.wikipedia.org/wiki/Abrasive_saw
2. http://www.dewalt.com/tool-categories/Metal-Working.aspx
3. https://en.wikipedia.org/wiki/Derailleur_gears
4. http://www.wisegeek.com/what-is-a-grinding-machine.htm

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