SLIDER CRANK MECHANISM USING HACKSAW

SYNOPSIS

Here we are fabricating the hacksaw machine based on crank slider mechanism without

any electronics intervention. In this project, no electricity is needed for the operation of the wiper

while raining. As the name implies, it is a fully mechanical based project. This project consists of

the following parts Handle, Cam, Hacksaw frame and Metal rods.

INTRODUCTION

The hacksaw is a metal cutting machine tool designed to cut multiple metals simultaneously by
applying cam mechanism. The machine is exclusively intended for mass production and they
represent the faster and more efficient way to cut a metal. Hacksaws are used to cut thin and soft
metals. The operation of the unit is simplified to a few simple operations involving a motor and a
cam mechanism. There are numerous types of cutting machines in Engineering field, which are
used to fulfil the requirements. We are interested to introduce multiple hacksaw cutting operation
in Hacksaw machine. The main function of this hacksaw machine is to cut thin and soft metals
by motor power. This is an era of automation where it is broadly defined as replacement of
manual effort by mechanical power in all degrees of automation. The operation remains an
essential part of the system although with changing demands on physical input as the degree of
mechanization is increased. Degrees of automation are of two types, viz. Full automation.
Semi automation. In semi automation a combination of manual effort and mechanical power is
required whereas in full automation human participation is very negligible.
ARECIPROCATING POWER HACKSAW
Ituses a blade that moves back and forth across the work. The blade cuts on the backstroke.
There are several types of feeds available.
Positive feed-produces an exact depth of cut on each stroke. The pressure on the blade varies
with the number of teeth in contact with the work. Definite pressure feed-yields a pressure on the
blade that is uniform regardless of the number of teeth in contact with the work. The depth of the
cut varies with the number of teeth contacting the work. This condition prevails with gravity
feed. Feed can be adjusted to meet varying conditions. For best performance, the blade and feed
must be selected to permit high-speed cutting and heavy feed pressure with minimum blade
bending and breakage. Standard reciprocating metal cutting saws are available in sizes from 6~ ~
6~ (150 mm ~ 150 mm) to 24~ ~ 24~ (900 mm ~ 900 mm). The saws can be fitted with many
accessories, including quick-acting vises, power stock feed, power clamping of work, and
automatic cycling of the cutting operation. The latter moves the work out the required distance,
clamps it, and makes the cut automatically. The cycle is repeated upon completion of the cut.
High-speed cutting requires use of a coolant. Coolant reduces friction, increases blade life, and
prevents chip-clogged teeth. Cast iron and some brass alloys, unlike most materials, do not
require coolant. 2.1.1) Selecting A Power Hacksaw blade Proper blade selection is important.
Use the three-tooth ruleatleast three teeth must be in con-tact with the work. Large sections and
soft materialsrequire a coarse-tooth blade. Small or thin work and hard materials require a fine-
tooth blade. For best cutting action, apply heavy feed pressure on hard materials and large work.
Use light feed pressure on soft materials and work with small cross sections. Blades are made in
two principal types: flexible-back and all-hard. The choice depends upon use. i) Flexible-back
blades -should be used where safety requirements demand a shatterproof blade. These blades
should also be used for cutting odd-shaped work if there is a possibility of the work coming
loose in the vise. ii) All-hard blade -For a majority of cutting jobs, theall-hard bladeis best for
straight, accurate cutting under a variety of conditions.
When starting a cut with an all-hard blade, be sure the blade does not drop on the work when
cutting starts. If it falls, the blade could shatter and flying pieces cause injuries.
Blades are also made from tungsten and molybdenum steels, and with tungsten carbide teeth on
steel alloy backs. The following rule-of-thumb can be followed for selecting the correct blade:
Use a 4-tooth blade for cutting large sections or readily machined metals. Use a 6-tooth blade for
cutting harder alloys and miscellaneous cutting. Use 10- and 14-tooth blades primarily on light
duty machines where work is limited to small sections requiring moderate or light feed pressure.
Mounting a Power Hacksaw blade The blade must be mounted to cut on the power (back) stroke.
The blade must also lie perfectly flat against the mounting plates. If long lifeand accurate cuts
are to be achieved, the blade must be properly tensioned Many techniques have been developed
for properly mounting and tensioning blades. Use a torque wrench and consult the manufacturer
s literature. If the information (proper torque for a given blade on a given machine) is not
available, the following methods can be used: Tighten the blade until a low musical ring is heard
when the blade is tapped lightly. A highpitched tone indicates that the blade is too tight. A dull
thud means the blade is too loose. The shape of the blade pin hole can serve as an indicator of
whether the blade is tensioned properly. When proper tension is achieved, the pin holes will
become slightly elongated, The blade will become more firmly seated afterthe first few cuts and
will stretch slightly. The blade will require retensioning(retightening) before further cutting can
be done. 2.1.3) Selecting a Band Saw Blade Band saw blades are made with raker teeth or wavy
teeth. Most manufacturers also make variations of these sets. The rakersetis preferred for general
use. Tooth pattern determines the efficiency of a blade in various materials. The standard tooth
blade pattern is best suited for cutting most ferrous metals. A skip tooth blade pattern is preferred
for cutting aluminum, magnesium, copper, and soft brasses. The hooktooth blade pattern also is
recommended for most nonferrous metallic materials. For best results, consult the blade
manufacturer s chart or manual for the proper blade characteristics (set, pattern, and number of
teeth per inch) for the particular material being cut.
Installing a Band Saw Blade If the saw is to work at top efficiency, the blade must be installed
carefully. Wear heavy leather gloves to protect your hands when installing a band saw blade.
Blade guides should be adjusted to provide adequate support, Proper blade support is required to
cut true and square with the holding device. Follow the manufacturer s instructions for adjusting
blade tension. Improper blade tension ruins blades and can cause premature failure of bearings in
the drive and idler wheels. Cutting problems encountered with the band saw are similar to those
of the reciprocating hack saw. Most problems are caused by poor machine condition. They can
be kept to a minimum if a maintenance program is followed on a regular basis. This typically
includes checking wheel alignment, guide alignment, feed pressure, and hydraulic systems.

CRANK AND SLIDER MECHANISM

This mechanism is used to convert the rotary motion of the crank into the reciprocating motion
of hacksaw. The lengths of the crank and connecting rods are made using trial and error method.
The hack saw is guided by an aluminum plate. The vertical movement of the hacksaw will be
guided by to iron rods. The vertical movement will act as a feeding unit. METAL SLAB He used
a guide to control the hacksaw blade which is used to cut the metal. Metal slabs were fitted on
the hacksaw blade to ensure pressure on the object to be cut and linear movement of the blade. A
clamp, with 360 degree rotation, was fixed to hold the metal pieces while cutting, and to allow
them to be cut in any shape and angle.
MESH
A typical mesh seat consists of a metal frame with mesh stretched over it and secured with
adjustable straps, zip ties, string or shock cord
ii)HARDSHELL Hard shell seats are normally made of a composite material such as GRP or
carbon fiber although metal and wood versions do exist. A hard-shell seat is normally covered
with some-form of padding, this is usually closed or open cell foam although some extreme
racing machines do not have any padding on the seat to reduce weight and increase efficiency.
Hard-shell seats are generally used at more reclined angles than mesh seats.
iii)COMBINATION A combination seat has a padded hard seat base with a mesh back.

When designing our attachment, the following considerations were taken into account
1. The device should be suitable for local manufacturing capabilities.
2. The attachment should employ low-cost materials and manufacturing methods.
3. It should be accessible and affordable by low-income groups, and should fulfill their basic
need for mechanical power
4. It should be simple to manufacture, operate, maintain and repair.
5. It should be as multi-purpose as possible, providing power for various agricultural implements
and for small machines used in rural industry.
6. It should employ locally available materials and skills. Standard steel pieces such as steel
plates, iron rods, angle iron, and flat stock that are locally available should be used. Standard
tools used in machine shop such as hack saw, files, punches, taps & dies; medium duty welder;
drill press; small lathe and milling machine should be adequate to fabricate the parts needed for
the dual-purpose bicycle.
 LITERATURE SURVEY

The process of tube bending involves using mechanical force to push stock material
pipe or tubing against a die, forcing the pipe or tube to conform to the shape of the
die. Often, stock tubing is held firmly in place while the end is rotated and rolled
around the die. Other forms of processing including pushing stock through rollers
that bend it into a simple curve. For some tube bending processing, a mandrel is
placed inside the tube to prevent collapsing. The tube is also held in tension by a
wiper die to prevent any creasing during stress (Kalpakjian, 1997 and Acherkan,
1973). A wiper die is usually made of a softer alloy i.e. aluminium, brass to avoid
scratching or damaging the material being bent. Much of the tooling is made of
hardened steel or tooled steel to maintain and prolong the tools life. However
wherever there is a concern of scratching or gouging the work piece, a softer
material such as aluminium or bronze is utilized. For example, the clamping block,
rotating form block and pressure die are often formed from the hardened steel
because the tubing is not moving past these parts of the machine. On the other
hand, the pressure die and the wiping die are formed from aluminium or bronze to
maintain the shape and surface of the work piece as it slides by. Pipe bending
machines are typically human powered, pneumatic powered, hydraulic assisted,
hydraulic driven or electric servomotor. Hydraulic machines are machinery and tools
that use liquid fluid power to do simple work. Heavy equipment is a common
example .In this type of machine, hydraulic fluid is transmitted throughout the
machine to various hydraulic motors and hydraulic cylinders and which becomes
pressurised according to the resistance present. The fluid is controlled directly or
automatically by control valves and distributed through hoses and tubes. The
popularity of hydraulic machinery is due to the very large amount of power that can
be transferred through small tubes and flexible hoses, and the high power density
and wide array of actuators that can make use of this power Hydraulic machinery is
operated by the use of hydraulics, where a liquid is the powering medium (Beer and
Johnston, 1992 and Dagwa and Ibhadode, 2005).
The horizontal press brake was first introduced by SIMASV in 1957, are particularly
distinguished by their flexibility and versatility. User-friendly and easy to maintain,
the horizontal press brakes can be fitted with countless tools. The horizontal
bending press fits any small to medium-sized industry when machinery for large-
scale production must necessarily make way for machinery with distinctly lower
production costs. The hydraulic pipe bending consists of two series of horizontal
press brakes, the standard series and the super series. Both series have gone
through decades of improvements which is why no other bending press offers as
much value for the investment. One of our biggest improvements was placing the
Hydraulic Jack below the table. After years of producing machines with the cylinder
above the table (which we still produce today upon request) we standardized on
machines with the cylinder below, offering the greatest working environment, and
the most bend accuracy due to less deflection in the table. The horizontal machine
has the following features:

Cylinder under work table allowing for better accuracy and more work surface;

User performs operation in front of the machine instead of the side of the machine
making it easier to produce quality products, and frontal position on our press
brakes is protected and practical position for the operator;

Our patented conical pins with lock-on bayonet fittings eliminate all mechanical
slack as far as tolerance is concerned, providing maximum rigidity with minimal
flexing of work table. This patented feature is why no other horizontal bending press
is as accurate;

Our super series stroke control is by means of hydraulically controlled stroke end
devices that allows for greater accuracy (compared to limit switch stroke end
control) allowing for continuous movement under pressure, achieving maximum
accuracy and repeatability in position; and much more.
WORKING PRINCIPLE
The handle is fixed to the cam by means of a shaft by which it rotates. The cam converts

the rotational motion into to and fro motion by means of crank slider mechanism. The slider rod

moves into the bearing. A hacksaw frame is coupled with the end of slider. When we rotate the

cam here rotary motion is converted in to linear motion, so the hacksaw moves forward and

reverse. Here we have achieved the required operation.

DESCRIPTION

Manufacturing processes are the steps through which raw materials are transformed into a final

product. The manufacturing process begins with the creation of the materials from which the

design is made. These materials are then modified through manufacturing processes to become

the required part. Manufacturing processes can include treating (such as heat treating or coating),

machining, or reshaping the material. The manufacturing process also includes tests and checks

for quality assurance during or after the manufacturing, and planning the production process

prior to manufacturing. Metal Cutting: Metal cutting or machining is the process of by removing

unwanted material from a block of metal in the form of chips. Cutting processes work by causing

fracture of the material that is processed. Usually, the portion that is fractured away is in small

sized pieces, called chips. Common cutting processes include sawing, shaping (or planning),

broaching, drilling, grinding, turning and milling. Although the actual machines, tools and

processes for cutting look very different from each other, the basic mechanism for causing the

fracture can be understood by just a simple model called for orthogonal cutting. In all machining

processes, the work piece is a shape that can entirely cover the final part shape. The objective is

to cut away the excess material and obtain the final part. This cutting usually requires to be

completed in several steps in each step, the part is held in a fixture, and the exposed portion

can be accessed by the tool to machine in that portion. Common fixtures include vise, clamps, 3-
jaw or 4-jaw chucks, etc. Each position of holding the part is called a setup. One or more cutting

operation may be performed, using one or more cutting tools, in each setup. To switch from one

setup to the next, we must release the part from the previous fixture, change the fixture on the

machine, clamp the part in the new position on the new fixture, set the coordinates of the

machine tool with respect to the new location of the part, and finally start the machining

operations for this setup.

Therefore, setup changes are time-consuming and expensive, and so we should try to do the

entire cutting process in a minimum number of setups; the task of determining the sequence of

the individual operations, grouping them into (a minimum number of) setups, and determination

of the fixture used for each setup, is called process planning. These notes will be organized in

three sections: (i) Introduction to the processes, (ii) The orthogonal cutting model and tool life

optimization and (iii) Process planning and machining planning for milling. Sawing: Cold saws

are saws that make use of a circular saw blade to cut through various types of metal, including

sheet metal. The name of the saw has to do with the action that takes place during the cutting

process, which manages to keep both the metal and the blade from becoming too hot. A cold saw

is powered with electricity and is usually a stationary type of saw machine rather than a portable

type of saw.

The circular saw blades used with a cold saw are often constructed of high speed steel. Steel

blades of this type are resistant to wear even under daily usage. The end result is that it is

possible to complete a number of cutting projects before there is a need to replace the blade.

High speed steel blades are especially useful when the saws are used for cutting through thicker

sections of metal. Along with the high speed steel blades, a cold saw may also be equipped with

a blade that is tipped with tungsten carbide. This type of blade construction also helps to resist
wear and tear. One major difference is that tungsten tipped blades can be re-sharpened from time

to time, extending the life of the blade. This type of blade is a good fit for use with sheet metal

and other metallic components that are relatively thin in design. Welding: Welding is a process

for joining similar metals. Welding joins metals by melting and fusing 1, the base metals being

joined and 2, the filler metal applied. Welding employs pinpointed, localized heat input. Most

welding involves ferrous-based metals such as steel and stainless steel.Weld joints are usually

stronger than or as strong as the base metals being joined.

Welding is used for making permanent joints. It is used in the manufacture of automobile bodies,

aircraft frames, railway wagons, machine frames, structural works, tanks, furniture, boilers,

general repair work and ship building.

Carbon steel is steel in which the main interstitial alloying constituent is carbon in the range of
0.122.0%. The American Iron and Steel Institute (AISI) definition says:

Steel is considered to be carbon steel

when no minimum content is specified or required

for chromium, cobalt, molybdenum, nickel, niobium, titanium, tungsten,vanad
ium or zirconium, or any other element to be added to obtain a desired
alloying effect;
when the specified minimum for copper does not exceed 0.40 percent;
or when the maximum content specified for any of the following elements
does not exceed the percentages
noted:manganese 1.65, silicon 0.60, copper 0.60.[1]

The term "carbon steel" may also be used in reference to steel which is not stainless steel; in
this use carbon steel may include alloy steels.
 As the carbon percentage content rises, steel has the ability to
become harder and stronger through heat treating; however, it becomes less ductile.
Regardless of the heat treatment, a higher carbon content reduces weldability. In carbon
steels, the higher carbon content lowers the melting point.[2]

Mild and low-carbon steel[edit]

Mild steel[definition needed], also known as plain-carbon steel, is now the most common form of steel
because its price is relatively low while it provides material properties that are acceptable for
many applications. Low-carbon steel contains approximately 0.050.25% carbon[1] making it
malleable and ductile. Mild steel has a relatively low tensile strength, but it is cheap and easy to
form; surface hardness can be increased through carburizing.[3]

It is often used when large quantities of steel are needed, for example as structural steel. The
density of mild steel is approximately 7.85 g/cm3 (7850 kg/m3 or 0.284 lb/in3)[4] and the Young's
modulus is 210 GPa (30,000,000 psi).[5]

Low-carbon steels suffer from yield-point runout where the material has two yield points. The
first yield point (or upper yield point) is higher than the second and the yield drops dramatically
after the upper yield point. If a low-carbon steel is only stressed to some point between the upper
and lower yield point then the surface may develop Lder bands.[6]Low-carbon steels contain less
carbon than other steels and are easier to cold-form, making them easier to handle.[7]

Higher-carbon steels[edit]

Carbon steels which can successfully undergo heat-treatment have a carbon content in the range
of 0.301.70% by weight. Trace impurities of various other elements can have a significant effect
on the quality of the resulting steel. Trace amounts of sulfur in particular make the steel red-
short, that is, brittle and crumbly at working temperatures. Low-alloy carbon steel, such
as A36 grade, contains about 0.05% sulfur and melts around 1,4261,538 C (2,5992,800 F).
[8]
Manganese is often added to improve the hardenability of low-carbon steels. These additions
turn the material into a low-alloy steel by some definitions, but AISI's definition of carbon steel
allows up to 1.65% manganese by weight.
 CHAPTER VI

BILL OF MATERIAL

SL NO. NAME OF THE COMPONENT MATERIAL

01 Base Mild steel, Tyre

02 Shaft Mild steel

03 L angle Mild steel Harden

04 Rod Steel

05 Spring Steel

06 Fabrication Material Mild Steel

 COST ESTIMATION

S.NO NAME OF THE COMPONENT QUANTITY RATE

01 MS steel 1 500
02 Worm gear 16 T 2 650

03 Worm gear 10 T 2 600

05 Base 2 400
06 Fabrication Material - 1500
07 Fabrication Cost - 1750
08 Paint - 150

ADVANTAGES
 Initial cost is low
Easy to Operate
No need of battery power
Operation is fast

DRAWING FOR MECHANICAL WIPER BASED ON CRANK SLIDER

MECHANISM

ADVANTAGES

Simple in construction.

Easy to fabricate.

The components used for the fabrication of the are easily available.

Repairing and replacing is not a difficult task.

Multiple work pieces can be cut simultaneously.

The time taken for cutting operation is less.

 Increased productivity.

DISADVANTAGES

More number of moving parts.

Must be handled with care.

The loading and unloading of the work pieces must be done manually.

CONCLUSION

Thus a low cost and simple design of slider mechanism using hacksaw
machine is fabricated. This machine reduces the human effort and hence we
dont need two persons to cut the wooden logs. This simple design of
conventional design which can enhance day today household needs and daily
day to day purposes and it can be also used in for industrial applications
during power shut down scenarios. By using this method we can do any
operation as per our requirement without the use of electricity. so we can
save the electrical power.

BIBLIOGRAPHY

[1] Rastogi, N. (2004). Design of composite drive shafts for automotive applications. Visteon
Corporation, SAE technical paper series.

[2] 73332270 Design and Analysis of a Propeller Shaft of a Toyota Qualis by Syed Hasan.

[3] A.M.Ummuhaani and Dr.P.Sadagopan Design, Fabrication and Stress Analysis of a

Composite Propeller Shaft, 2011-28-0013.

[4] Anup A. Bijagare, P.G. Mehar and V.N. Mujbaile Design Optimization & Analysis of Drive
Shaft, Vol. 2 (6), 2012, 210-215.
[5] Rangaswamy, T.; Vijayrangan, S. (2005). Optimal sizing and stacking sequence of composite
drive shafts. Materials science, Vol. 11 No 2., India.

[6] Rastogi, N. (2004). Design of composite drive shafts for automotive applications. Visteon
Corporation, SAE technical paper series.

[7] R. P. Kumar Rompicharla1, Dr. K. Rambabu2 Sep-Oct. 2012 Design and Optimization of
Drive Shaft with Composite Materials International Journal of Modern Engineering Research
(IJMER) www.ijmer.com Vol.2, Issue.5, pp-3422-3428 ISSN: 2249-6645.

WEBSITE REFERENCES
1. www.google.in

2. Dynamic bicycles.com

3. www.engineeringtoolbox.com

4. Makeitform.com

5. Convertunits.com

6. Webbicycle.netpaths.net/technology.ph p