Bulacan State University

Mechanical Engineering Department

Cutter Slider Support

Antonio, Christian Albert F.

Baje, Lyle B.
Fernandez, Fred Joseph V.
Morales, Shaira Mae DC.
Robles, Engie Allerry L.

Engr. Aldrin C. Bernardo

Adviser
 CHAPTER I

THE PROBLEM AND ITS BACKGROUND

Introduction

Fabrication can be defined as the process of building machines and structures from

raw materials into pre-made shape for assembly use. This process includes cutting, burning,

welding, machining, forming, and assembly to create the final product.

Among these processes involved in fabrication, cutting is the most commonly used.

Cutting is where a material is split into halves, thirds, or smaller sections. It can be done

using tools, from the simplest, like a pair of scissors, blade cutter, or a cutting knife. In

fabrication, cutting tools like sheet metal snips, hacksaw, crosscut saw, and coping saw are

used. Power tools that runs using an electric motor like circular saw, power hacksaw, miter

saw, and angle grinder are also being used.

Angle grinder is a handheld power tool used for cutting, grinding, and polishing. It

is commonly powered by an electric motor that drives a geared head at a right angle. A

cutting disc can be mounted on the geared head with a wide variety of cutting disc to choose

from.

Fabricators and construction workers make use of an angle grinder as one of their

essential tools. Its ability to perform a variety of tasks is due to different accessories that

can be attached to them. One of these tasks is cutting, when fitted with a proper cutting

disc, it can be used to cut tile, metal and even wood. However, this power tool presents a

problem when it comes to usage. As a handheld tool, in order to perform a straight cut, the

user must hold the angle grinder properly and cut the material slowly by following a
straight line. But maintaining its straight course is quite difficult due to several factors like:

the weight of the angle grinder, the vibration caused by the angle grinder, and the firmness

of the hands and arms of the one using the angle grinder. Therefore, using an angle grinder

manually is prone to human error which can lead to inaccurate cuts and imprecise results.

Also, the cutting disc rotates at 10,000 rpm to 15,000 rpm. If the user cuts too fast, the

cutting disc might be jammed with the material being cut, or in worse case, the cutting disc

might shatter and cause an injury to the user, making it quite dangerous to the

inexperienced.

Like any other tool the usefulness of angle grinder highly depends on the user. In

order to improve the usefulness of angle grinder and to minimize accidents related to

cutting, without demanding additional manpower, this study shall introduce the Cutter

Slider Support. Through it, users can have a guide in cutting process through which more

efficient working time can be achieved with less hazard.

Statement of the Problem

The general problem of this study is “How to design, fabricate, and evaluate Cutter

Slider Support for angle grinder to make accurately straight cut on metal, tile, wood, etc.”

Specifically, this research study tried to answer the following questions:

1. What mechanical design is needed in Cutter Slider Support?

2. How to fabricate this cutter slider support?

3. Will the fabricated slider support become acceptable to the end users in terms

of:

3.1. Functionality;

3.2. Reliability;
 3.3. Efficiency and Effectiveness;

3.4. Maintenance and cost;

3.5. Safety; and

3.6. Accuracy?

Significance of the Study

This research study, “Cutter Slider Support” was useful and beneficial to the

following end users:

1. Fabricators – the output of the study will help the fabricators in performing straight cuts

on metal pieces and metal sheets using an angle grinder. This support will speed up

their work without demanding additional manpower. Damages in manual straight

cutting are also prevented.

2. Construction workers – usually the construction workers use an angle grinder manually

to cut tiles when finishing the flooring of a house or structure. By doing so, these

workers are prone to human errors especially when working in a building where a great

number of tiles are needed to be cut.

3. Future Researchers – This project study serves as a related work for other researchers

who might conduct a project study that has the same concept. This study can also be

improved by the researchers who are interested in the same topic focusing on the

glitches in the research findings.

Scope and Limitations

The study was centered in providing a sliding support for angle grinders, to speed

up the cutting process, prevent accident, and minimize human errors which can lead to

inaccurate results. The output of this study was used to cut tiles, metals, and wood.

The feature of this Cutter Slider Support is limited to straight cutting only with an

angle of 90° and 45°, and can only be used to a 4-inches angle grinder or the smallest size

of angle grinder.

The Cutter Slider Support can be used to cut up to 60 centimeters. The materials to

be cut are limited to a maximum thickness of 12 millimeters and maximum width of 15

centimeters for tiles, metal, and woods.

 CHAPTER II

THEORETICAL FRAMEWORK

This chapter presents the relevant theories, related literature, studies, conceptual

framework, hypothesis of the study, definition of terms/variables, and notes.

Relevant Theories

In the fabrication of this project, the researchers have been guided by the

following engineering theories:

I. Machine Design

Machine design is the process of engineering design. A machine is made up of

mechanisms that work together to satisfy the requirements of what the machine needs

to accomplish. Machine design takes into account kinetics and kinematics, which deal

with motion and the forces on an object in motion. Machine design is applied through

a specific process including determining what the machine needs to do, benchmarking

and defining goals and requirements, brainstorming, evaluating and selecting from the

different options, creating an in-depth design, creating and testing a prototype, and

finally manufacturing the machine. The researchers presented the use of machine

design theories in the design of cutter slider support. These theories are the following:

A. Stress

Stress is commonly defined in mechanics as the force applied per unit area.

Simple stress, on the other hand, is the condition under which stress is constant or
uniform. The cutter slider support experience stress caused by the weight of the

angle grinder. This theory guided the researchers in determining the appropriate

size of the angle grinder prior to the design of the cutter slider support.

B. Bearings

Bearings are machine members that support a power transmitting element,

a shaft for example. Its main function is to support the mechanical rotating body,

reducing its coefficient of friction during movement, and to ensure the accuracy of

its rotation. In the case of cutter slider support, bearings are used as a rolling part

of the machine, it helps the slider to travel smoothly along the flat surface of square

tube.

C. Threaded Members

Bolts and screws are cylindrical members with continuous spiral rib, known

as threads and used as fasteners which hold parts of machine member. Threaded

bolts and screws are used to hold the removable heads of cylinders, machine

members that must be built in small units for ease in manufacturing, assembling, or

shipping. The cutter slider support uses bolts and screws to most of its parts for

easier assembly, disassembly, and replacement of parts during maintenance.

 II. Engineering Mechanics

Engineering mechanics deals with the analysis of motion of a body and the force

systems that act upon it. The researchers considered a topic in engineering mechanics

for the design of cutter slider support. This topic is:

A. Friction

Friction may be defined as the contact resistance exerted by one body upon

a second body when the second body moves or tends to move past the first body. It

can also be defined as the force resisting the relative motion of solid surfaces, fluid

layers, and material elements sliding against each other. The cutter slider support

experience friction to its sliding parts when the bearings roll to the square tube. This

friction will cause wear in the path of contact of the bearings and square tube.

III. Engineering Materials

Materials of Engineering refers to selecting the correct materials for the

application in which the engineered part is being used. This selection process includes

choosing the material, paying attention to its specific type or grade based on the

required properties. Engineers will select a particular grade of material based on its

properties such as malleability or tensile strength. Composites comprise two materials,

such as a metallic mesh and a resin, the combination of which also depends on the

properties required. Materials from which the item is to be manufactured are noted on

the engineering drawing using standard material and grade codes. It is important that
manufacturers do not interchange materials because the switch may make the products

susceptible to failures.

This theory helped the researchers in choosing the right kind of material that is

suited to the design of the cutter slider support, as well as the material that was

subjected to testing such as metal, tile, and wood.

A. Ceramic Tile

It is one of the most common types of materials that are used to cover floors

and walls. It is made up of sand, natural products, and clays. It is resistant to

corrosion and it has a color permanence that helps to ensure that it will remain

in pristine condition comparison to other flooring materials.

B. Mild Steel

Mild steel consists of iron alloyed with less than 0.3 percent carbon, most

commonly between 0.1 to 0.25 percent. The building industry frequently uses

mild steel in construction because of its ductility and malleability.

C. Plywood

Plywood is wood veneers bonded together to produce a flat sheet. An extremely

versatile product, plywood is used for a wide range of structural, interior and

exterior applications - from formwork through to internal paneling.

IV. Machine Shop Theory

Machine shop theory is the study of different methods and techniques in

fabricating a part out of given material, commonly in solid form. The fabricator used

the following process in the fabrication of the output of the study:

A. Cutting Process

Cutting is where a material is split into halves, thirds, or smaller sections.

In the fabrication of cutter slider support, cutting process is used to obtain the exact

sizes of the materials needed for the desired output of the project.

B. Grinding Process

Grinding employs an abrasive product, usually a rotating wheel brought into

controlled contact with a work surface. The grinding wheel is composed of abrasive

grains held together in a binder. These abrasive grains act as cutting tools, removing

tiny chips of material from the work. Grinding is done on the excess weld slags on

most parts of the cutter slider support. It is done to improve the surface finish of the

cutter slider support.

C. Welding Process

In arc welding, which is used in welding of most parts of the cutter slider

support, the intense heat needed to melt metal is produced by an electric arc. The

arc is formed between the actual work and an electrode stick that is manually or

mechanically guided along the joint. The electrode can either be a rod with the
purpose of simply carrying the current between the tip and the work. Or, it may be

a specially prepared rod or wire that not only conducts the current but also melts

and supplies filler metal to the joint.

In welding, the arc not only provides the heat needed to melt the electrode

and the base metal, but under certain conditions must also supply the means to

transport the molten metal from the tip of the electrode to the work.

D. Drilling Process

Drilling is the process of cutting holes in metals by using a drilling machine

such as drills. Drilling is done by forcing a rotating drill into stationary job as on a

drilling machine or by forcing stationary drill in a rotating work piece as on a lathe.

In the fabrication of cutter slider support, holes are drilled for insertion of threaded

materials like bolts, screws, and nuts.

E. Mechanical Fastening and Assembly Process

In mechanical fastening and assembly, various different types of hardware

or fasteners (bolts, nuts, screws, etc.) to assemble multiple parts together. This

method is great for an assembly that is not permanent, needs maintenance,

adjustments, and replaceable parts because it allows the flexibility to remove and

reinstall hardware. The cutter slider support is designed for convenience in

replacing worn out parts because it is easy to assemble and disassemble.

Related Literature

An angle grinder (side grinder or disc cutter as they are also sometimes known)

is a hand-held power tool that can be used for a huge variety of different jobs including

grinding, cutting, cleaning and polishing surfaces making it an essential tool to have in

your arsenal.

Figure 2.1: Angle grinder

In general, most manufacturers produce grinders and discs in the following

sizes:

 115mm – 4 1/2 inches

 125mm – 5 inches

 150mm – 6 inches

 180mm – 7 inches

 230mm – 9 inches

Smaller angle grinders tend to operate at faster speeds, upwards and over

10,000rpm whereas larger grinders normally rotate at around 6000 – 6500rpm. Angle

grinder can be powered by an electric motor, petrol engine, or compressed air.

Types of Discs and Attachments for Angle Grinders

 Cut off Discs (metal and stone) –. Metal cut off discs are used for cutting metal

objects and stone cut off disc are for cutting stone or bricks.

(a) (b)

Figure 2.2: (a) metal cut off disc, (b) stone cut off disc

 Diamond Cutting Discs (tiles, mortar raking, slate, marble, granite,

abrasive materials, asphalt) – This type of disc is normally diamond tipped

on its edges so that it can cope with cutting the afforce mentioned hard

materials.

(a) (b)

Figure 2.3: (a) diamond tile blade, (b) diamond mortar raking disc
Related Study

Miter Saw

Figure 2.4: Miter Saw

A power miter saw, also known as a drop saw, is a power tool used to make a

quick, accurate crosscut in a workpiece at a selected angle. Commonly used for cutting

of molding and trim. Most miter saws are relatively small and portable, with common

blade sizes ranging from eight to twelve inches.

The power miter saw makes cuts by pulling a spinning circular saw blade down

onto a workpiece in a short, controlled motion. The workpiece is typically held against

a fence, which provides a precise cutting angle between the plane of the blade and the

plane of the longest workpiece edge. In standard position, this angle is fixed at 90°.

The researchers used the concept of miter saw as the reference for the design of

Cutter Slider Support. The sliding mechanism of miter saw gives an idea to the

researchers in making their own version of sliding mechanism that helps the user in

performing straight and accurate cuts using an angle grinder.

Conceptual Framework

Input Process Output

Infoware: 1. Design of Cutter
Slider Support
 Machine Design 2. Preparation of
 Engineering Tools
Mechanics 3. Measurement of
 Engineering required length
4. Cutting
Materials
5. Drilling
 Machine Shop 6. Welding
Theory 7. Assembling
8. Painting
Technoware: 9. Testing Cutter Slider Support
 Square Tube 10. Evaluation
 Bolts and Nuts
 Drilling
Machine
 Grinder
 Hack Saw or
Metal Cutter
 Welding
Machine

Humanware:
 Machine
Operator
 Welder

Chart 1. Paradigm of the Study

Hypothesis

The Cutter Slider Support was acceptable to the end users considering the following

variables such as functionality, reliability, efficiency, safety, durability, and its price.

And was therefore tested statistically for acceptance or rejection. The researchers

concluded that the cutter slider support was able to reduce the amount of time needed

in performing a straight cut using an angle grinder without sacrificing the accuracy of

the results.

Definition of Terms

1. Cutter Slider Support – a tool used to make straight and accurate cuts using an

angle grinder

2. Electric arc – is an electrical breakdown of a gas that produces an ongoing

electrical discharge.

3. Humanware – usually refers hardware and software that emphasizes user

capability and empowerment and the design of the user interface.

4. Infoware – refers to the recorded documents and facts, such as designs,

specifications and relevant theories that would help enable quick learning.

5. Mechanism – a system of parts working together in a machine

6. Technoware – refers to the objects and facilities that are significant from the

viewpoint of technical concerns, as participative elements in performing tasks.

 CHAPTER III

RESEARCH METHODOLOGY

This chapter presents the method and design, sources of data, data and gathering

procedures, respondents (population and samples), research gathering instrument and

statistic treatment

Research Design and Method

The descriptive type of research was used in this study. Descriptive type of research

refers to the type of research question, design, and data analysis that will be applied to a

given topic. And also describes what exists and may help to uncover new facts and

meaning. The purpose of descriptive research is to observe, describe and document the

aspects of situation as it naturally occurs. This involves the collection of data that will

provide an account or description of individuals, groups or situations.

Conclusive research aims to provide final and conclusive answer to research

questions. There was an identified problem which can be solved by fabricating the Cutter

Slider Support therefore descriptive research and conclusive design were used by the

researchers.

Source of Data

Data sources are broadly classified into primary and secondary data. Primary data

collection uses surveys, experiments or direct observations. This gathering of information

includes by means of the people that will benefit this product and the knowledge of the

researchers about the study.

The researchers used primary data gathered from fabricators in Malolos and

Calumpit, Bulacan in the development of the design of Cutter Slider Support. Secondary

data were collected from internet research, journals, reference books, and previous related

studies.

Data Gathering Procedures

Normative survey is the method used by the researchers to collect data. This is

concerned specifically into observing the commonality of some elements. The said survey

was then formulated by the researchers using suitable questions which are modified from

related research materials. The researchers used questionnaires for data collection, due to

its efficiency in gathering information.

The researchers have used an acceptability test or questionnaire to be answered as

an instrument to collect data. The respondents are those who are familiarized in using an

angle grinder and people who are capable of using this tool.

The researchers have also conducted an interview regarding Cutter Slider Support

to gather consistent and precise information.

Research Instruments

Research instruments included questionnaire, interview, and observation. These are

the fact-finding strategies used for data collection. The collected data should be valid,
reliable, and must be suitable and relevant to the research topic. The gathered data had been

critically examined to check the extent to which is was likely to give the expected results.

Respondents

The research project was evaluated by the owners, customers, and workers of

machine shops located at Malolos, Calumpit, and Hagonoy, Bulacan. It was also evaluated

by mechanical engineering students at Bulacan State University who are familiar and

capable of using an angle grinder. The respondents are given a questionnaire to answer

based on functionality, reliability, efficiency and effectiveness, maintenance and cost,

safety, and accuracy of the project.

Data Processing and Statistical Treatment

The tally of the responses from surveys using questionnaire method were tabulated

and analysed. Numerical values per question given by the respondents were tallied

according to their worded equivalent. The weighted mean is computed in each question to

show the final average that reflect the relative importance of each observation. Standard

deviation is also computed in each question numerically to show how spread out the data

from the average(mean). The rate of the result from the respondents view for each category

have determined that the Cutter Slider Support is acceptable.

 CHAPTER IV

PRESENTATION, ANALYSIS AND INTERPRETATION

This chapter presents the following: labeled isometric view, step by step

fabrication, operating procedures, maintenance/trouble shooting procedures, project

costing, tabular comparison between the project and other related projects; and tabular

summary and interpretation of the acceptability test result.

I. Isometric View

Figure 4.1: Isometric View of Cutter Slider Support

Actual View

Figure 4.2: Actual View of Cutter Slider Support

 Labeled Exploded View

Figure 4.3: Labeled Exploded View of Cutter Slider Support

Table of Parts and Description

Table 4.1: Parts and Description

Part Description Qty Part Description Qty

1 Platform Handle 2 12 Winged Bolt and Nut 1
2 Platform 1 13 Grinder Lock 1
3 Mounting 2 14 Bolts and Nuts M8x70mm 4
4 Bolts and Nuts M10x15mm 2 15 Grinder Holder 1
5 Stainless Square Tube 1 16 Fulcrum 1
6 Clamp 1 17 Bolt M8x10mm 1
7 Stopper 1 18 Galvanized Iron Tube 4
8 Bolts and Nuts M8x70mm 4 19 Allen Bolts and Nuts M8x30mm 8
9 Handle 1 20 Ball Bearing 608zz 16
10 Support Brace 1 21 Bushing 8
11 Slot Adjuster 1 22 Flat Washer M8 40
II. Important Materials Used

1. Ball Bearings – The Cutter Slider Support used ball bearings as the rolling part of

the slider because of its durability and can rotate smoothly without the need of

lubrication.

Figure 4.4: Ball Bearings

2. Stainless Square Tube – This is where the bearings will roll. The Cutter Slider

used stainless square tube rather than galvanized because of its resistance to

corrosion. Corrosions can affect the smoothness of the sliding mechanism of the

machine.

Figure 4.5: Stainless Square Tube

III. Step by Step Fabrication

For Platform:

1. Cut the angle bar 3/16” x 2” x 2” x 20’ into four pieces of which the 2 pieces

measuring 40cm and the other two pieces at 100cm.

2. Weld it together to form a rectangular frame 40cm x 100cm.

3. Cut the mild steel plate 40cm x 100cm and weld it on the top of the frame.

4. Cut four legs measuring 11cm long and weld it on the corners of the frame.

5. Prepare to cut four pieces of 3/16” x 1 ½” x 1 ½” angle bar 9cm long and weld

it together to form two square bracket 4cm x 4cm x 9cm long. Close the top

with a flat bar ¼” x 1 ½” x 1 ½” and the bottom with the same flat bar but longer

¼” x 1 ½” x 9cm.

6. Drill a hole on the top and thread it 10mm. The bottom should be drilled with

two 8mm holes. It will be placed and bolted on the table base.

(a) (b) (c)

Figure 4.6: (a) Setting of marks for drilling (b) Drilling process(c) Drilling result

7. Drill two holes 10mm diameter on both ends of the 38mm x 38mm x 89cm

stainless tube and bolt it on the two square bracket with two M10 x 15mm bolt.
 (Mount it on the table base using four M8 bolts and nuts). Drill four holes 8mm

diameter on the table base corresponding on the length of the two square

brackets. The straightness of the stainless tube must be the same on the edge of

the table base.

Figure 4.7: Slider Holder

8. Measure and cut 3/16” x 1 ½” x 1 ½” angle bar. Drill two holes 8mm in diameter

at both ends and copy the holes on the base table. Bolt it on the base table while

measuring a true 90degree angle. This is the stopper of every material to be cut

by the sliding angle grinder cutter, at 90degree angle after ensuring the

correctness of the angle. Remove the angle bar and, drill two holes again on the

base table but this time you will bolt it at 45degree angle.

For clamp

1. Cut 4.2”x 4.2” in excess steel plate for the body of the clamp.

2. For the brace of the steel plate, make a T-shape by cutting and welding of two

pieces of flat bar by 1 ½” x 4.2”.

3. Fabricate the bushing with outer diameter of 1”, inner diameter of 0.5” and

length of 1”. Weld it at the center of the T-shape.

4. Thread for the bolt of the lock with length of 2.2” and diameter of 0.4”. Weld

the 1” x 2” of flat bar at the bottom of the bolt.

 5. Fabricate another bushing with outer diameter of 1”, inner diameter of 0.5” and

length of 1”. Weld the hexagonal nut with a diameter of 0.5” at the bottom of

the bushing. Weld 0.8” x 2.4” at the top of the bushing.

6. Drill the middle end part of the 60mm angle bar with a diameter of 10mm and

weld a 10mm nut on it.

7. Combined two angle bar and round bar using welding machine.

Figure 4.8: Exploded parts of the clamp

For Slider

1. Prepare 25mm x 25mm square tube. Cut four pieces 19.6cm long drill holes on

all sides 20mm from each edge of the square tube. The holes should be 8mm in

diameter for the M8 Allen bolts to pass through.

2. Fabricate 8 pieces bushing with 8mm holes. Determine the length of the

bushing, because it will serve as spacer for the two 608zz ball bearing on both

sides of each bushing.

Figure 4.9: Turning process for bushing

 3. Assemble the slider, two 608zz ball bearing on each bushing. 16 bearing all in

all. Make sure all the bearing touches the stainless square tube. Adjust the

tightness of the Allen bolt. If the bearing encounter difficulty in rolling. The

slider should run smoothly on the square tube.

Figure 4.10: Slider without bushing and ball bearing

For Angle Grinder Holder

1. Prepare 3/16” x 2” flat bar. Measure the length of the angle grinder. Remove

the handle and bolt the flat bar with M8 bolt x 15mm in the place where the

handle previously attached. On the other end of the 3/16” x 2” flat bar, weld a

3/16” x 1” flat bar with two M8 holes on each side to form a “T”.

2. Fabricate an omega shaped clamp with two holes on each side that corresponds

on the hole of the “T”. Bolt the grinder by the clamp with two M8 x 20mm

bolts. Check if the grinder is secure and the attachment fits perfectly underneath

the attachment.

3. Weld a solid bar 14mm in diameter; weld it on the place where the balance of

the grinder’s weight is located.

4. Cut two pieces ¼” x 1” x 1” flat bar and drill each hole 14mm in diameter. Weld

it on the bottom of the slider on the 25mm x 25mm square tube.

 5. Insert the grinder’s attachment and determine the distance, the grinder should

be free to move up and down on the other end of the solid bar drill and thread

it with M6 hand tap. Put an M6 bolt with washer. The purpose of this is to

prevent the grinder attachment to fall off.

6. On a steel plate 5mm in thickness cut a semicircle slotted hole 10mm in

diameter and weld it on the grinder attachment. It will serve as the feeding

mechanism for the angle grinder then weld a ¼” x 1” flat bar on the top of the

slider directly proportional on the slotted attachment.

7. Drill a hole of 10mm in diameter and secure a 10mm bolt with nut and washer

as a tightener.

(a) (b) (c)

Figure 4.11: (a) Angle grinder holder (b) Fulcrum (c) Slider Mechanism

Finishing and Assembly

1. Scrub all parts of the Cutter Slider Support using a sand paper to smoothen all

the surfaces.

2. Paint all parts except the bearings, washers, and bolts. Put a gray primer first

before applying the black and yellow paint.

3. Combine the assembled slider to the stainless square tube. Make sure the all the

bearings touch the square tube.

4. Attach the two mounting on the both end of the square tube and fasten it.

5. Fasten the mounting on the platform.

6. Insert the angle grinder holder on the slider and fasten it using screw. Put the

stopper and clamp on the platform.

Figure 4.12: Finishing

Figure 4.13: Assembly

Figure 4.14: Final Output

IV. Procedure on How to Operate the Project

1. Make sure you are wearing a personal protective equipment (safety glass,

protective clothing, gloves, earmuffs, safety shoes) and the working area is free

from hindrances and hazards.

2. Check the angle grinder if its properly secured on the grinder holder. Make

sure that the cutting disc is appropriate for the material that you will cut and

the angle grinder has a safety guard. Check the power cord for damages and

make sure that the angle grinder is turned off before plugging in the power

cord.

3. Place the material that you will cut on the platform and make sure it has a full

contact to the stopper to get an accurate result. Stick out the excess part that

you need to cut. Use the clamp to secure the material’s position and to prevent

it from moving.

4. Lower the angle grinder using the slot adjuster depending on your desired

cutting depth and tighten the winged bolt to fix its position. When cutting

metals, the cutting disc is consumed therefore it not advisable to fix its position

so you can adjust the cutting depth while the disc is being consumed.

5. Turn on the angle grinder and start cutting by sliding the handle. Your position

must be behind the safety guard of the angle grinder to protect you from

possible accidents that can happen.

6. After the cutting process, turn off the angle grinder and return it to its original

position. Unclamp the material and check if you got your desired measurement.

7. Unplug the angle grinder and clean your working area.

 V. Testing

The Cutter Slider Support was subjected to actual testing in order to measure its

cutting capacity and efficiency. The actual testing was done at a residence located at

Hagonoy, Bulacan.

Note: The actual testing was done by professional users of angle grinder.

Table 4.2: Testing

Cutting
Cutting
Duration
Duration
Type of (without
Test No. Dimension (with cutter Remarks
Material cutter
slider
slider
support)
support)
The machine
was able to cut
Length: with ease and
110mm was faster than
Mild Steel 1min 1min
1st Test manual cutting.
Plate 19secs 53secs
Thickness: It also produced
5mm a smoother
finish than the
other.
The machine
Length:
was able to cut
600mm 1 minute
nd up to its
2 Test Wood 21 seconds and 9
maximum
Thickness: seconds
capacity of 60
8mm
centimeters.
The machine
was able cut
faster than
manual cutting
Length: even when it has
290mm 2 minute lapses when
rd Ceramic
3 Test 31 seconds and adjusting the
Tiles
Thickness: 2seconds cutting depth of
5mm the angle
grinder. It also
produced a
smooth finish to
the tiles.
 Length:
70.5mm
The machine
Ceramic Thickness: was able to cut
4th Test 22 seconds -
Tiles 5mm with an angle of
45°.
Orientation:
45°

Based from the table shown above, the researchers found the results of different

test the Cutter Slider Support was subjected to, and it was shown that within the first test

until the third test, the machine was able to produce a faster and better finish than manual

cutting using the angle grinder. It was also shown that the machine can be used up to its

maximum capacity of 60 centimeters. On the fourth test, the researchers tested a feature of

Cutter Slider Support that can cut with an angle of 45° and it was shown that the result was

good and accurate.

VI. Maintenance Procedures

1. You should inspect the Cutter Slider Support for damage, wear, broken or

missing parts and that all components function before use.

2. Check all the bolts and screws if it is properly fastened.

3. Use a clean rag to wipe all the dust that is produced when using the machine.

4. Remove the rust on the bearings using a sand paper to maintain its smooth

movement.

5. Put lubrication on the moving parts of the machine if necessary.

VII. Project Costing

Table 4.3: Project Costing (Actual Cost)

Cutter Slider Support

Materials Dimension Quantity Unit Price Price (Php)

Mild Steel Plate 5mm x 46cm x 1m 18kg ₱24/kg ₱900.00

Angle Bar 3/16” x 2” x 2” x 20’ 12kg ₱25/kg ₱300.00

Flat Bar 3/16” x 2’ x 10’ 1kg ₱30kg ₱30.00

Stainless Tube 38mm x 38mm x 1m 1pc ₱250/pc ₱250.00

Galvanized Iron 25mm x 25mm x 1pc ₱120/pc ₱120.00

Tube 60mm
Bolt and Nuts M8 Stainless 70mm 8pcs ₱5/pc ₱40.00

M8 Hexagonal x 8pcs ₱50/pc ₱400.00

30mm

M8 Hexagonal x 1pc ₱5/pc ₱5.00

10mm

M10 x 15mm 2pcs ₱5/pc ₱10.00

M10 x 50mm 1pc ₱5/pc ₱5.00

M12 x 70mm 1pc ₱10/pc ₱10.00

Flat Washer M8 40pcs ₱2/pc ₱80.00

Flat Bar 1/4” x 1 1/2” x 4’’ 1kg ₱37/kg ₱37.00

Flat Bar 1/8” x 8” 1kg ₱32/kg ₱32.00

Black Iron Pipe 3/4” x 5” 1kg ₱32/kg ₱32.00

3/4” x 11cm
 Ball Bearing 608zz 16pcs ₱45/pc ₱670.00

Round Bar 10mm x 40cm 2kg ₱30/kg ₱60.00

25mm x 50mm 1kg ₱30/kg ₱30.00

Motor Cycle - 1pc ₱30/pc ₱30.00

Plastic Handle
Bosny Spray Paint Primer Gray, 3pc ₱100/pc ₱300.00
Black, Yellow
Labor ₱5,000.00

Total ₱ 8,341.00

Fabrication can be reduced by 25.09% if it will be mass produced by 10 units.

VIII. Acceptability Test

A total of 50 respondents were selected fourth year Mechanical

Engineering students of Bulacan State University, fabricators and construction

workers in Malolos, Hagonoy, and Calumpit, Bulacan. The acceptability test was

evaluated in terms of functionality, reliability, efficiency and effectiveness,

maintenance and cost, safety, and accuracy. The weighted mean for the criteria of

the output being evaluated was computed and analyzed. The interpretation of

weighted mean was based on the following scale:

1.0 – 1.49 ---------- Strongly Disagree

1.5 – 2.49 ---------- Disagree

2.5 – 3.49 ---------- Moderately Agree

3.5 – 4.49 ---------- Agree

 4.5 – 5.00 ---------- Strongly Agree

Weighted mean was used to measure the general response of the survey

samples.

The formula in computing weighted mean as is follows:

Where;

X – Mean

f – Weighted given to each respondent

x – Number of respondents

n – Total number of respondents

Mean Standard Deviation

𝚺𝐟𝐱 𝚺𝐟𝐱 (𝐱−𝐱)𝟐

𝐗= 𝐒𝐃 = √
𝐧 𝐧

Table 4.4: Functionality Test

Functionality

Variable 5 4 3 2 1 𝐱 SD VD

1. The materials (woods, ceramic, metals and 31 16 3 0 0 4.56 0.61 SA

etc.) can be straightly cut with the use of CSS.
20 20 10 0 0 4.2 0.76 A
2. The CSS is durable and lasting.
3. The CSS is convenient to use and easy to 30 18 2 0 0 4.56 0.58 SA
operate.
 Over-all Functionality Mean 4.44 0.65 A

Interpretation

In terms of functionality of the project, the tabular result gives an over-all

functionality mean of 4.44 which means that the respondents have agreed that the Cutter

Slider Support served its intended purpose of making straight and accurate cuts. The

standard deviation of 0.65 indicates that the majority of the respondents agreed on the same

perspective according to its functionality.

Table 4.5: Reliability Test

Reliability

Variable 5 4 3 2 1 𝐱 SD VD

1. The CSS can be used for straight cutting up to 31 15 4 0 0 4.54 0.65 SA

60cm.
23 22 5 0 0 4.36 0.66 A
2. The CSS can satisfy the user’s needed output.
3. The CSS is reliable in terms of strength and 29 17 4 0 0 4.5 0.65 SA
capacity to cut material in a straight manner.
Over-all Reliability Mean 4.47 0.65 A

Interpretation

In terms of reliability of the project, the tabular result gives an over-all reliability

mean of 4.47 which means that the respondents have agreed that the Cutter Slider Support

can satisfy the user’s needed output and that it is indeed reliable in terms of strength and
capacity. The standard deviation of 0.65 indicates that the majority of the respondents

agreed on the same perspective according to its reliability.

Table 4.6: Efficiency and Effectiveness Test

Efficiency and Effectiveness

Variable 5 4 3 2 1 𝐱 SD VD

1. The CSS meets the user’s objectives and 29 18 3 0 0 4.52 0.61 SA

requirements.
2. The CSS can be used to its intended job 30 16 4 0 0 4.52 0.65 SA
capacity if the right cutting disc is used.
31 17 2 0 0 4.58 0.58 SA
3. The CSS operates efficiently and effectively
Over-all Efficiency and Effectiveness Mean 4.54 0.61 SA

Interpretation

In terms of efficiency and effectiveness of the project, the tabular result gives an

over-all efficiency and effectiveness mean of 4.54 which means that the respondents have

strongly agreed that the Cutter Slider Support is efficient and effective and had met the

user’s objective and requirement. The standard deviation of 0.61 indicates that the majority

of the respondents agreed on the same perspective according to its efficiency and

effectiveness.

Table 4.7: Maintenance and Cost Test

Maintenance and Cost

 Variable 5 4 3 2 1 𝐱 SD VD

29 18 3 0 0 4.52 0.61 SA
1. The CSS is easy to maintain.
27 16 7 0 0 4.4 0.73 A
2. The CSS is inexpensive to maintain.
3. The CSS parts are easy to replace when 32 14 4 0 0 4.56 0.64 SA
damaged.
Over-all Maintenance and Cost Mean 4.49 0.66 A

Interpretation

In terms of maintenance and cost of the project, the tabular result gives an over-all

maintenance and cost mean of 4.49 which means that the respondents have agreed that the

Cutter Slider Support is easy and inexpensive to maintain. The standard deviation of 0.66

indicates that the majority of the respondents agreed on the same perspective according to

its maintenance and cost.

Table 4.8: Safety Test

Safety

Variable 5 4 3 2 1 𝐱 SD VD

1. The CSS is safe to the end users because of its 27 18 5 0 0 4.44 0.68 A
sturdiness.
2. The CSS has a proper and secured holder of 30 13 7 0 0 4.46 0.73 A
grinder.
3. The CSS has a clamp on the platform to 32 14 4 0 0 4.56 0.64 SA
prevent the metals, tiles and wood from slipping.
Over-all Safety Mean 4.49 0.68 A

Interpretation
 In terms of safety of the project, the tabular result gives an over-all safety mean of

4.49 which means that the respondents have agreed that the Cutter Slider Support has safety

features and is safe to the end users. The standard deviation of 0.68 indicates that the

majority of the respondents agreed on the same perspective according to its safety.

Table 4.9: Accuracy Test

Accuracy

Variable 5 4 3 2 1 𝐱 SD VD

1. The CSS can be used with minimal 30 16 4 0 0 4.52 0.65 SA

maintenance.
2. The CSS can adapt to changes in its working 29 15 6 0 0 4.46 0.71 A
condition.
3. The CSS can guide the user to cut straight line 37 10 3 0 0 4.68 0.59 SA
with minimal effort.
Over-all Accuracy Mean 4.55 0.65 SA

Interpretation

In terms of accuracy of the project, the tabular result gives an over-all accuracy

mean of 4.55 which means that the respondents strongly agreed that the Cutter Slider

Support is accurate in terms of it needing minimal maintenance and that it could adapt to

changes in its working conditions. The standard deviation of 0.65 indicates that the

majority of the respondents agreed on the same perspective according to its accuracy.
Interpretation of the Acceptability Test Data

The researchers concluded that in terms of efficiency and effectiveness, and

accuracy, the respondents assessed this variable and arrived with the rate of “strongly

agree”. In terms of functionality, reliability, maintenance and cost, and safety, the

respondents assessed those variables and arrived with the same rate of “agree”. This means

that the Cutter Slider Support was acceptable to the end users and they were satisfied on

its uses. Also, some of the respondents participated to test the machine and offered some

suggestions and recommendations. With these interpretations in mind, the researchers took

into consideration to further improve the Cutter Slider Support.

 CHAPTER V

SUMMARY, FINDINGS, CONCLUSION AND RECOMMENDATION

This chapter presents the summary of the research findings, conclusions and

recommendations.

Summary

The Cutter Slider Support has the capability to help the user in performing a straight

and accurate cut with an angle grinder. A slider which holds the angle grinder, has bearings

attached to it, these bearings roll along the flat surface of the square tube and provide the

sliding mechanism of the machine. This sliding mechanism is what makes an easier straight

cutting possible to the end users.

The general problem of this study is “How to design, fabricate, and evaluate Cutter

Slider Support for angle grinder to make accurately straight cut on metal, tile, wood, etc.”

Specifically, the study sought to answer the following questions:

1. What mechanical design is needed in Cutter Slider Support?

2. How to fabricate the Cutter Slider Support?

3. Will the fabricated slider support become acceptable to the end users in terms

of:

3.1 Functionality;

3.2 Reliability;

3.3 Efficiency and effectiveness;

3.4 Maintenance and cost;

3.5 Safety and;

 3.6 Accuracy

Surveys and interviews were conducted to the selected fourth year Mechanical

Engineering students of Bulacan State University, fabricators and construction workers in

Malolos, Hagonoy, and Calumpit, Bulacan. These respondents have answered the

following questionnaire according to the capacity, limitation, and convenience of the

proponent’s project.

Findings:

Strengths

1. The Cutter Slider Support served its intended purpose specifically on making

straight and accurate cuts with an angle grinder up to its maximum capacity of

60 centimeters.

2. Most parts of the Cutter Slider Support are fastened by bolts and screws.

Therefore, the assembly, disassembly, maintenance, and replacement of worn

out parts are convenient to the end user.

3. The machine was easy to use and significantly reduced the amount of time

needed when cutting metals, tiles, and wood using an angle grinder.

Weaknesses

1. The machine was heavy to lift and carry when transferring from a working place

to another. It also consumes much space therefore it cannot be used to small or

tight working areas.

Conclusion:

1. The steel plate used in the platform of the Cutter Slider Support was thick therefore

it contributes a lot in the weight of the machine. It also lacks in mobility so it needs

to be carried by two people.

Recommendation:

1. The researchers recommend to use lighter materials in the platform so that the

machine can be carried around easily. Caster wheels can also be used improve the

mobility of the machine so it can be transferred to a different location without

exerting too much effort.

Notes in Chapter 1

Continelli, A. (2016, November 3). What is metal fabrication and where is the industry
headed? Retrieved November 16, 2018, from The fabricator:
https://www.thefabricator.com/article/shopmanagement/what-is-metal-
fabrication-and-where-is-the-industry-headed-

What Are the Most Common Metal Fabrication Processes and What Are the Applications?
(2018, March 28). Retrieved November 16, 2018, from tuckey:
https://www.tuckey.com/blog/common-metal-fabrication-processes-applications/

Metal Fabrication Cutting Tools - Making Sparks. (2015, March 03). Retrieved November
16, 2018, from fourwheeler: http://www.fourwheeler.com/how-to/tech-qa/1504-
metal-fabrication-cutting-tools-making-sparks/

Angle grinder. (2018, August 17). Retrieved November 16, 2018, from wikipedia:
https://en.wikipedia.org/wiki/Angle_grinder

https://hubpages.com/technology/How-to-cut-a-straight-cut-in-steel-with-an-angle-
grinder
https://www.chegg.com/homework-help/definitions/machine-design-5

Pytel, A., & Singer, F. L. (1987). Simple Stress. In A. Pytel, & F. L. Singer, Strength of

Materials, 4th ed. (pp. 5-8). New York: Harper Collins Publishers, Inc

https://engineeringinsider.org/bearings-types/

Bautista, A. J. (2011). Threaded Members. In A. J. Bautista, Fundamentals of Machine

Design, Reviewer - Text (p. 135). Manila: Booklore Publishing Corporation.

Singer, F. L. (1954). Friction. In F. L. Singer, Engineering Mechanics (p. 114). New

York: Harper & Row, Ltd.

https://en.wikipedia.org/wiki/Friction
https://www.chegg.com/homework-help/definitions/materials-of-engineering-5

https://en.wikipedia.org/wiki/Arc_welding
http://www.lincolnelectric.com/en-us/support/process-and-theory/pages/arc-welding-
detail.aspx
https://manufacturing.stanford.edu/processes/Grinding.pdf
https://www.slideshare.net/Mohamed-Abu-Elhamayel/drilling-machines-and-operations
https://www.diydoctor.org.uk/projects/using_an_angle_grinder.htm

https://en.wikipedia.org/wiki/Miter_saw

https://www.slideshare.net/ludymae/chapter-9methods-of-data-collection
https://www.statisticshowto.datasciencecentral.com/statistical-treatment/
https://www.slideshare.net/DarylTabogoc/statistical-treatment
https://wwhttps://www.surveymonkey.com/mp/likert-
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