This document provides details on the design and fabrication of a hacksaw machine project. It includes an introduction describing the objective to automate a conventional power hacksaw machine to achieve higher productivity. It then covers the various chapters that will be included in the project report such as literature review, description of equipment like AC motors and pulleys, design and working principles. The last few chapters will cover the merits, applications, materials list, cost estimation and conclusion.

1. “DESIGN AND FABRICATION OF HACKSAW
MACHINE
PROJECT REPORT 2017-2018
Submitted by:
(Team name)
Guided by:
Submitted in partial fulfillment of the requirement for the
Award of Diploma in -----------------------------------------
By the State Board of Technical Education Government of
Tamilnadu, Chennai.
Department:
College name:
Place:
COLLEGE LOGO

2. COLLEGE NAME
COIMBATORE
DEPARTMENT OF MECHANICAL ENGINEERING
PROJECT REPORT-2017-2018
This Report is certified to be the Bonafide work done by
Selvan/Selvi ---------------- Reg.No. ------------ Of VI
Semester class of this college.
Guide Head of the Department
Submitter for the Practical Examinations of the board of
Examinations,State Board of Technical Education,Chennai,
TamilNadu.On --------------(date) held at the ------------
(college name),Coimbatore
Internal Examiner External Examiner

3. DEDICATED TO OUR BELOVED
PARENTS

4. ACKNOWLEDGEMENT

5. ACKNOWLEDGEMENT
At this pleasing moment of having successfully completed
our project, we wish to convey our sincere thanks and gratitude
to the management of our college and our beloved
chairman------------------------.who provided all the facilities to us.
We would like to express our sincere thanks to our
principal ------------------for forwarding us to do our project and
offering adequate duration in completing our project.
We are also grateful to the Head of Department
prof…………., for her/him constructive suggestions
&encouragement during our project.
With deep sense of gratitude, we extend our earnest
&sincere thanks to our guide --------------------, Department of
Mechanical for her/him kind guidance and encouragement
during this project we also express our indebt thanks to our
TEACHING staff of MECHANICAL ENGINEERING
DEPARTMENT, ---------- (college Name).

6. “DESIGN AND FABRICATION OF HACKSAW MACHINE

7. CONTENTS

8. CONTENTS
CHAPTER NO TITLE
SYNOPSIS
LIST OF FIGURES
1 Introduction
2 Literature review
3 Description of equipments
3.1 Ac Motor
3.2 Belt
3.3 Pulley
4 Design and drawing
4.1 Components and Specification
4.2 Block diagram
4.3 Overall diagram
5 Working principle
6 Merits and demerits
7 applications
8 List of materials
9 Cost Estimation
10 Conclusion
Bibliography
photography

9. LIST OF FIGURES

10. LIST OF FIGURES
Figure
Number Title
1 Block diagram
2 Overall Diagram

11. SYNOSPSIS

12. SYNOPSIS
The objective of this work is to automate the conventional power hacksaw
machine in order to achieve high productivity of work-pieces than the power
hacksaw machine using Double hacksaw blade. The operator need not
measure the length of the work-piece that is to be cut. The machine feeds the
work-piece with the help of a shaft, which is driven by a DC motor . An DC
motor is used to bring about the reciprocating motion required for cutting the
work-pieces. With the help of this multi-way power hacksaw machine the
four metal bars can be cut simultaneously to get high speed cutting rate and
to achieve mass production for maximum profit in related companies. This
project is very much useful and easy to install by user. The reference number
should be shown in square bracket

13. CHAPTER -1
INTRODUCTION

14. CHAPTER -1
INTRODUCTION
In present condition many electrically operated power hacksaw machines of different
companies with different specifications are available for the use in shop floor. These
machines are so precise that they can cut metal bars with minimum time made up of
different materials but they have one and major disadvantage that those are able to cut
single piece of bar at a time. For industries to achieve the mass production, it is necessary
to cut metal bars with high rate. So it is impossible to depend upon conventional single
frame power hacksaw machines and need the improvement in technology and design of
such machines. With the help of this multi-way power hacksaw machine the four metal
bars can be cut simultaneously to get high speed cutting rate and to achieve mass
production for maximum profit in related companies. As this machine overcomes all the
limitations and drawbacks of conventional hacksaw machines, it is also helpful for small
scale industries due to its simple working and operating conditions along with its
compatibility, efficiency and affordable price. This project is about cutting the wood,
metal, pipe, angle, channel, flat plates, rods and such other things. This project is very
much useful and easy to install by user. The reference number should be shown in square
bracket [1]. However the authors name can be used along with the reference number in
the running text. The order of reference in the running text should match with the list of
references at the end of the paper.

15. CHAPTER -2
LITRATURE SURVEY

16. CHAPTER -2
LITRATURE SURVEY
Saw:
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, electric or other power.
In a modern serrated saw, each tooth is bent to a precise angle
called its "set". The set of the teeth is determined by the kind of cut
the saw is intended to make. For example, a "rip saw" has a tooth set
that is similar to the angle used on a chisel. The idea is to have the
teeth rip or tear the material apart. Some teeth are usually splayed
slightly to each side the blade, so that the cut width (kerf) is wider
than the blade itself and the blade does not bind in the cut.
An abrasive saw uses an abrasive disc or band for cutting,
rather than a serrated blade.
According to Chinese tradition, the saw was invented by Lu
Ban. In Greek mythology, Talos, the nephew of Daedalos, invented

17. the saw. In fact, saws date back to prehistory, and likely evolved from
Neolithic tools or bone tools. The early ancestors of man, in the
Pleistocene era, likely first used a jaw bone of a bovid animal as a
saw.
TYPES OF SAW BLADES AND THE CUTS THEY
MAKE
BLADE TEETH ARE OF TWO GENERAL TYPES:
Tool steel or carbide. Carbide is harder and holds a sharp edge much
longer.
CROSSCUT:
In woodworking, a cut made at (or near) a right angle to the
direction of the grain of the work piece. A crosscut saw is used
to make this type of cut.
RIP CUT:
In woodworking, a cut made parallel to the direction of the grain
of the work piece. A rip saw is used to make this type of cut.

18. PLY TOOTH:
A circular saw blade with many small teeth designed for cutting
plywood with minimal splintering.
MATERIALS USED FOR SAWS
THERE ARE SEVERAL MATERIALS USED IN SAWS, WITH EACH
OF ITS OWN SPECIFICATIONS.
BRASS:
Mostly used in back saws because of its low price, its flow
characteristics that make the material relatively easy to cast,
and unlike other types of saw, the forces that take place in back
saws are relatively low because of the pulling motion used.
STEEL:

19. Used in almost every existing kind of saw. Because steel is
cheap, easy to shape, and very strong, it has the right
properties for most kind of saws.
DIAMOND:
Used only in saws for the really heavy cutting. It is very
expensive and comes in two shapes: ropes and circular saws.
Mostly used for cutting concrete and other materials with rock-
like structures or in softer materials, such as wood, where the
precision and high volume of work justifies the expense of
diamond-edged cutting tools. Diamond saws are made by
combining powder metal with diamond crystals, which are then
heated and pressed into a molding to form the diamond
segments.

20. USES:
• Saws are most commonly used for cutting hard materials. They
are used extensively in forestry, construction, demolition,
medicine, and hunting.
• Some saws are used as instruments to make music.
• Chainsaw carving is a flourishing modern art form. Special
saws have been developed for this purpose.
HACKSAW:
A hacksaw is a fine-tooth saw with a blade under tension in a
frame, used for cutting materials such as metal or bone. Some have
pistol grips which keep the hacksaw firm and easy to grip.
A power hacksaw is a type of hacksaw that is powered either
by its own electric motor (also known as electric hacksaw) or
connected to a stationary engine. 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

21. return stroke and some have a coolant pump to prevent the saw
blade from overheating.
While stationary electric hacksaws are reasonably uncommon
they are still produced but saws powered by a stationary engines
have gone out of fashion. The reason for using one is that they
provide a cleaner cut than an angle grinder or other types of saw.
CUTTING:
Cutting sheet metal can be done in various ways from hand
tools called tin snips up to very large powered shears. With the
advances in technology, sheet metal cutting has turned to computers
for precise cutting.
Cutting is the separation of a physical object, or a portion of a
physical object, into two portions, through the application of an
acutely directed force. An implement commonly used for cutting is the
knife or in medical cases the scalpel. However, any sufficiently sharp
object is capable of cutting if it has a hardness sufficiently larger than
the object being cut, and if it is applied with sufficient force. Cutting

22. also describes the action of a saw which removes material in the
process of cutting.
Cutting is a compressive and shearing phenomenon, and
occurs only when the total stress generated by the cutting implement
exceeds the ultimate strength of the material of the object being cut.
The simplest applicable equation is stress = force/area: The stress
generated by a cutting implement is directly proportional to the force
with which it is applied, and inversely proportional to the area of
contact. Hence, the smaller the area (i.e., the sharper the cutting
implement), the less force is needed to cut something.
When referring to propagating plants, cutting is one of the
methods that can be used. It involves cutting a part of the plant
typically a healthy shoot, with sharp and sterile scissors or any other
cutting device, and then placing the removed part in water. Some
cuttings do not require water. Certain shoots when cut are able to
grow when placed in vermiculite or potting soil. However, the former
is the easiest to do as most shoots when cut from the main plant
need time to grow roots, and then they are able to be transferred to
potting soil.

23. ULTIMATE AIM
The “Design and Fabrication of Hacksaw Machine machine is low cost
automation equipment which can be widely used in small scale
industries and automobile maintenance shops. Pressing speed is
high. The manpower requirement is reduced also reducing the
machining time.

24. CHAPTER-3
DESCRIPTION OF EQUAPMENTS

25. CHAPTER-3
DESCRIPTION OF EQUIPMENTS
3.1 AC MOTOR (IM)
An induction motor (IM) is a type of alternating current motor
where power is supplied to the rotating device by means of
electromagnetic induction. It is also called asynchronous motor.
An electric motor converts electrical power to mechanical power
in its rotor (rotating part). There are several ways to supply power to
the rotor. In a DC motor this power is supplied to the armature directly

26. from a DC source, while in an induction motor this power is induced
in the rotating device. An induction motor is sometimes called a
rotating transformer because the stator (stationary part) is essentially
the primary side of the transformer and the rotor (rotating part) is the
secondary side. Induction motors are widely used, especially
polyphase induction motors, which are frequently used in industrial
drives.
Induction motors are now the preferred choice for industrial
motors due to their rugged construction, absence of brushes (which
are required in most DC motors) and — thanks to modern power
electronics — the ability to control the speed of the motor.
PRINCIPLE OF OPERATION AND COMPARISON TO
SYNCHRONOUS MOTORS
The basic difference between an induction motor and a
synchronous AC motor is that in the latter a current is supplied onto
the rotor. This then creates a magnetic field which, through magnetic
interaction, links to the rotating magnetic field in the stator which in
turn causes the rotor to turn. It is called synchronous because at
steady state the speed of the rotor is the same as the speed of the
rotating magnetic field in the stator.

27. By way of contrast, the induction motor does not have any
direct supply onto the rotor; instead, a secondary current is induced in
the rotor. To achieve this, stator windings are arranged around the
rotor so that when energised with a polyphase supply they create a
rotating magnetic field pattern which sweeps past the rotor. This
changing magnetic field pattern induces current in the rotor
conductors. These currents interact with the rotating magnetic field
created by the stator and in effect causes a rotational motion on the
rotor.
However, for these currents to be induced, the speed of the
physical rotor and the speed of the rotating magnetic field in the
stator must be different, or else the magnetic field will not be moving
relative to the rotor conductors and no currents will be induced. If by
some chance this happens, the rotor typically slows slightly until a
current is re-induced and then the rotor continues as before. This
difference between the speed of the rotor and speed of the rotating
magnetic field in the stator is called slip. It is unitless and is the ratio
between the relative speed of the magnetic field as seen by the rotor
(the slip speed) to the speed of the rotating stator field. Due to this an

28. induction motor is sometimes referred to as an asynchronous
machine.
CONSTRUCTION
The stator consists of wound 'poles' that carry the supply
current to induce a magnetic field that penetrates the rotor. In a very
simple motor, there would be a single projecting piece of the stator (a
salient pole) for each pole, with windings around it; in fact, to optimize
the distribution of the magnetic field, the windings are distributed in
many slots located around the stator, but the magnetic field still has
the same number of north-south alternations. The number of 'poles'
can vary between motor types but the poles are always in pairs (i.e.
2, 4, 6, etc.).
Induction motors are most commonly built to run on single-
phase or three-phase power, but two-phase motors also exist. In
theory, two-phase and more than three phase induction motors are
possible; many single-phase motors having two windings and
requiring a capacitor can actually be viewed as two-phase motors,
since the capacitor generates a second power phase 90 degrees
from the single-phase supply and feeds it to a separate motor
winding. Single-phase power is more widely available in residential

29. buildings, but cannot produce a rotating field in the motor (the field
merely oscillates back and forth), so single-phase induction motors
must incorporate some kind of starting mechanism to produce a
rotating field. They would, using the simplified analogy of salient
poles, have one salient pole per pole number; a four-pole motor
would have four salient poles. Three-phase motors have three salient
poles per pole number, so a four-pole motor would have twelve
salient poles. This allows the motor to produce a rotating field,
allowing the motor to start with no extra equipment and run more
efficiently than a similar single-phase motor.
THERE ARE THREE TYPES OF ROTOR
 SQUIRREL-CAGE ROTOR
The most common rotor is a squirrel-cage rotor. It is made up of
bars of either solid copper (most common) or aluminum that span the
length of the rotor, and are connected through a ring at each end.
The rotor bars in squirrel-cage induction motors are not straight, but
have some skew to reduce noise and harmonics.
 SLIP RING ROTOR
A slip ring rotor replaces the bars of the squirrel-cage rotor with
windings that are connected to slip rings. When these slip rings are

30. shorted, the rotor behaves similarly to a squirrel-cage rotor; they can
also be connected to resistors to produce a high-resistance rotor
circuit, which can be beneficial in starting
 SOLID CORE ROTOR
A rotor can be made from solid mild steel. The induced current
causes the rotation.
3.2 PULLEY
A pulley is a wheel with a groove along its edge, also called a
sheave, for holding a rope or cable. Pulleys are usually used in sets
designed to reduce the amount of force needed to lift a load. The
same amount of work is necessary for the load to reach the same
height as it would without the pulleys. The magnitude of the force is
reduced, but it must act through a longer distance. The effort needed
to pull a load up is roughly the weight of the load divided by the
number of wheels. The more wheels there are, the less efficient a
system is, because of more friction between the rope and the wheels.
The pulleys and lines are weightless, and that there is no
energy loss due to friction. It is also assumed that the lines do not
stretch. With this assumption, it follows that, in equilibrium, the total
force on the pulley must be zero. This means that the force on the

31. axle of the pulley is shared equally by the two lines looping through
the pulley. The lines are not parallel, the tensions in each line are still
equal, but now the vector sum of all forces is zero.
A second basic equation for the pulley follows from the
conservation of energy the product of the weight lifted times the
distance it is moved is equal to the product of the lifting force times
the distance the lifting line is moved. The weight lifted divided by the
lifting force is defined as the advantage of the pulley system. It is
important to notice that the amount of work done in an ideal pulley is
always the same. The work is given by the effort times the distance
moved. The pulley simply allows trading effort for distance.
3.3 BELT
Belts are used to mechanically link two or more rotating items.
They may be used as a source of motion, to transmit power at up to
98% efficiency between two points, or to track relative movement.

32. As a source of motion, a conveyor belt is one application where
the belt is adapted to continually carry a load between two points. A
belt may also be looped between two points so that the direction of
rotation is reversed at the other point. Power transmission is achieved
by specially designed belts and pulleys. The demands on a belt drive
transmission system.
Belts normally transmit power only on the tension side of the
loop. Designs for continuously variable transmissions exist that use
belts that are a series of solid metal blocks, linked together as in a
chain, transmitting power on the compression side of the loop.

33. CHAPTER-4
DESIGN AND DRAWING

34. CHAPTER-IV
DESIGN OF EQUIPMENT AND DRAWING
4.1 COMPONENTS AND ITS SPECIFICATION
The cutting machine consists of the following components to full
fill the requirements of complete operation of the machine.
1. AC MOTOR
2. HACKSAW
3. BELT
4. PULLEY

35. DRAWING

36. 4.2 DRAWING FOR PNEUMATIC HIGH SPEED
HACK SAW MACHINE

37. CHAPTER -5
WORKING PRINCIPLE

38. CHAPTER-V
WORKING PRINCIPLE
A hacksaw machine is work on principle of QUICK RETURN
MECHANISUM in this rotary motion of shaft is to be convert into the
reciprocating motion of hacksaw frame. Working principle of hacksaw
machine is very simple. First of all the hacksaw machine is put on ground
and after that whatever metal, wood, pvc, is cut is fixed on vice at required
length, after that the electric motor is connect with electricity. Now start the
electric motor so due to that the shaft of motor and hollow disc will be rotate
and also rotate the eccentric Centre and link connect to it. Due to rotation of
links the hacksaw frame will be reciprocate on the metal and cutting of metal
is done.

39. CHAPTER -6
MERITS AND DEMERITS

40. CHAPTER -6
MERITS AND DEMERITS
MERITS:
 Weight of machine is less.
 It reduces the work of labor.
 Easy to make because of simple construction.
 High production rate.
 Cost is less.
 Easy maintenance and maintenance cost is less.
 It resists all atmospheric effects.
DEMERITS:
 Time consume more.
 Speed variation is required for cutting the different metal

41. CHAPTER-7
APPLICATIONS

42. CHAPTER-VII
APPLICATIONS
• This machine is very useful for small scale industries
• These machines used to cut the roller sheet metal
• All industrial application

43. CHAPTER-8
LIST OF MATERIALS

44. CHAPTER-VIII
LIST OF MATERIALS
FACTORS DETERMINING THE CHOICE OF MATERIALS
The various factors which determine the choice of material are
discussed below.
1. Properties:
The material selected must posses the necessary properties for
the proposed application. The various requirements to be satisfied
Can be weight, surface finish, rigidity, ability to withstand
environmental attack from chemicals, service life, reliability etc.
The following four types of principle properties of materials
decisively affect their selection
a. Physical
b. Mechanical
c. From manufacturing point of view
d. Chemical
The various physical properties concerned are melting point, thermal
Conductivity, specific heat, coefficient of thermal expansion, specific
gravity, electrical conductivity, magnetic purposes etc.

45. The various Mechanical properties Concerned are strength in tensile,
Compressive shear, bending, torsional and buckling load, fatigue
resistance, impact resistance, eleastic limit, endurance limit, and
modulus of elasticity, hardness, wear resistance and sliding
properties.
The various properties concerned from the manufacturing point
of view are,
 Cast ability
 Weld ability
 Forge ability
 Surface properties
 Shrinkage
 Deep drawing etc.
2. Manufacturing case:
Sometimes the demand for lowest possible manufacturing cost or
surface qualities obtainable by the application of suitable coating
substances may demand the use of special materials.
3. Quality Required:
This generally affects the manufacturing process and ultimately
the material. For example, it would never be desirable to go casting of

46. a less number of components which can be fabricated much more
economically by welding or hand forging the steel.
4. Availability of Material:
Some materials may be scarce or in short supply. It then
becomes obligatory for the designer to use some other material which
though may not be a perfect substitute for the material designed. the
delivery of materials and the delivery date of product should also be
kept in mind.
5. Space consideration:
Sometimes high strength materials have to be selected because the
forces involved are high and space limitations are there.
6. Cost:
As in any other problem, in selection of material the cost of
material plays an important part and should not be ignored.
Some times factors like scrap utilization, appearance, and non-
maintenance of the designed part are involved in the selection of
proper materials.

47. CHAPTER-9
COST ESTIMATION

48. CHAPTER-IX
COST ESTIMATION
1. MATERIAL COST:
2. LABOUR COST:
Lathe, drilling, welding, grinding, power hacksaw, gas cutting cost
3. OVERGHEAD CHARGES:
The overhead charges are arrived by ”manufacturing cost”
Manufacturing Cost =Material Cost +Labour Cost
=
=
Overhead Charges =20%of the manufacturing cost
=
4. TOTAL COST:
Total cost = Material Cost +Labour Cost +Overhead Charges
=
=
Total cost for this project =

49. CHAPTER-10
CONCLUSION

50. CHAPTER-X
CONCLUSION
The project carried out by us made an impressing task in the
field of small scale industries and automobile maintenance shops. It
is very useful for the workers work in the lath and small scale
industries.
This project will reduce the cost involved in the concern. Project
has been designed to perform the entire requirement task at the
shortest time available.

51. BIBLIOGRAPHY

52. BIBLIOGRAPHY
1. Design data book -P.S.G.Tech.
2. Pneumatic handbook -R.H.warrning
3. Machine tool design handbook –Central machine tool
Institute, Bangalore.
4. Strength of Materials -R.S.Kurmi
5. Manufacturing Technology -M.Haslehurst.
6. Design of machine elements- R.s.Kurumi

53. PHOTOGRAPHY