This project deals with the design and fabrication of a pedal-powered hacksaw machine. The machine aims to provide a more affordable option for cutting wood and plastic materials that is powered by human pedaling rather than electricity. It works by converting the circular motion of pedaling into a translational motion that drives the hacksaw blade. The design considerations focused on using locally available materials and standard bicycle parts to create a simple and durable machine that could be manufactured and operated at low cost. The pedal-powered hacksaw has applications in furniture making industries and other workshops for basic cutting needs.

1. SUMIT PRAJAPATI 1HM07ME105
FUZAIL SHAIKH 1HM09ME114
MD. FAZAL ALAM 1HM09ME051
PRESENTED BY

2. INTRODUCTION
This project deals with the design and fabrication of pedal powered hacksaw
setup. The aim of our project work is to develop a modernized operation for cutting
wood and plastic materials. It is very useful for cutting PVC materials. It can be used
widely in lathe and in furniture making industries.
Since the manual effort by cutting through pedaling a wheel is much lower than
cutting by hand. Hence this project is very useful in our day to day life.
The maximum power output from a human being occurs in a rowing action
because most muscle groups in the body are used. However, these outputs are closely
approached by those obtained from the legs applied to moving pedals. The use of cranks
gives a fairly smooth rotary motion at speeds of 60- 80rpm. The power output to be
expected from normal peddlers is around 0.1HP. This output can be maintained for 60
min or more.

3. CONCEPT GENERATION
Project team sit together and conducted a brain storming session for
reducing the cost of hacksaw machining. During the brain storming session
several concepts were generated. Nowadays the existing hacksaw machine are
too expensive for a middle or low class entrepreneur to afford and to be installed
in a company or shop. By considering all the parameters to reduce the cost of
hacksaw machine we have a new model; pedal powered hacksaw machine (less
expensive).
In this project we are using only one operation that is cutting of metals and
wood. This mechanism can also be used for various purpose in rural areas like

4. WORKING PRINCIPLE
The principle of pedal power hacksaw is to change circulatory motion or
cycling motion into translatory motion with the help of metal connecting rod. If
we use dynamo then we can produce electricity which will be help to lighting
the work piece area when electricity is not available in mechanical workshop.
 The working medium adopted is Mechanical power.
 The machine work without the help of electricity.
 The Rotary motion of pedaling operation performed to our required on cutting
the job.
 The work piece is clamped on the work table using suitable clamping device like
vice.
 After clamping, by pedaling the cutting operation takes place on the work piece.
 After machining the work piece is removed and cleaned.

6. DESIGN CONSIDERATIONS
 The device should be suitable for local manufacturing capabilities.
 The attachment should employ low-cost materials and manufacturing
methods.
 It should be simple to manufacture, operate, maintain and repair.
 It should be accessible and affordable by low-income groups, and should
fulfill their basic need for mechanical power.
 It should make use of standard bicycle parts wherever possible.
 Excessive weight should be avoided, as durability is a prime
consideration
 The power take off mechanism should be as efficient as possible, and
should develop relatively high r.p.m. (close to 200) for versatility of
application

7. FABRICATION OF MACHINE
Machining Operations: In this project it is used to cut the raw material such as plates, rod.
This done by arc cutting machine.
Drilling: Drilling is used to produce holes in objects. In this project the square type pipe
required the holes for making rake assembly. These holes are done by vertical type
drilling machine.
Fine Grinding: It is nothing but a grinding process, which is done as smooth with fine
grains. It is done by convention grinding machine.
Welding: It is the process, which is used to join two, is more similar materials as well as
dissimilar materials. This is done by gas welding process.
Turning: It is used in this project to make the groove on the both sides of top cover plate.
This is done by conventional lathe.
Further Operations
Cleaning: It is the operation to clean the all machined parts without burrs, dust and chip
formals. By meaning the parts they are brightened and good looking.
Assembling: It is the operation, its deals with the assembling of various parts produced by
above operations.

8. APPLICATIONS
1) In a furniture making industry at production department it is widely used.
2) Cutting performs in all types of industries.
3) This machine applied in carpentry shops and plumbing works.

9. ADVANTAGES & LIMITATIONS
ADVANTAGES
 No need electricity.
 More efficient
 Power can be easily transmission.
 Less loss in transmission.
 Time saving as compared to simple hacksaw
 Power saving as it is manually operated
 Easy machinery used.
 As it is pedal operated so good for health.
 Comfortable then ordinary hacksaw.
LIMITATIONS
 Leads to physical ill.
 High thick wood cannot be cut.
 Its totally manually operated.
 Time consuming as compared to electrical power hacksaw
 Without human effort it’s not operated.
 Not fit for heavy production.

10. CONCLUSION
Thus this project work might be useful in all industries. For practical applications
this is fabricated for light duty operation. Its height, weight and other mechanical designs
are may be not suitable for any other heavy operation or work on hardened material.
We are proud that we have completed the work with the limited time successfully.
The PEDAL POWERED HACKSAW works with satisfactory conditions. We are able to
understand the difficulties in maintaining the tolerances and also quality. We have done to
our ability and skill making maximum use of available facilities.
In conclusion remarks of our project work, let us add a few more lines about our
impression on project work. Thus we have developed a “PEDAL POWERED
HACKSAW” which helps to know how to achieve simple cycling mechanism.
The application of this machine is comparatively wide with respect to the cost of the
machine.

11. REFERENCES
 P. B. Khope: Development and Performance Evaluation Of A Human Powered Flywheel
Motor Operated Forge Cutter. INTERNATIONAL JOURNAL OF SCIENTIFIC &
TECHNOLOGY RESEARCH VOLUME 2, ISSUE 3, MARCH 2013.
 Zakiuddin Syed Kazi: Design and Development of the Human Energized Chaff Cutter,
New York Science Journal, 2010.
 S.K. Hajra Choudury and A.K. Hajra Choudury, Workshop Technology (VOL II).
 W.A. Chapman, Workshop Technology.
 Raghuvanshi, Workshop Technology.
 R.S. Khurmi & J.K.Gupta, Machine Design.
 R.S. Khurmi & J.K. Gupta, Theory of Machine.
 K.R. Gopalakrishnan, Machine Drawing.
 Anderson & Tatro, Shop Theory.
 Gerling, All About machines.

12. GALLERY