DESIGN AND FABRICATION PEDAL OPERATED

DRILLING MACHINE
 Contents

Chapter Page No

1 Abstract 5

2 Introduction 6

3 Future scope of the Project 7

4 Subjects Discussed 10

5 Sketch of Pedal Operated Drilling Machine 16

6 Main Components of Pedal Operated Drilling Machine 17

7 Working Principle 36

8 Advantages and Disadvantages 37

9 Calculations 38

10 References 41
ABSTRACT :-

Pedal powered drilling machine is a machine which can be used for industrial
applications and Household needs in which no specific input energy or power is
needed. This project consists of a crank and slider mechanism. In the mechanism pedal
is directly connected to the drilling through crank and slider mechanism for the
processing of cutting the wooden blocks, metal bars, PVC materials. The objective of
the modal is using the conventional mechanical process which plays a vital role. The
main aim is to reduce the human effort for machining various materials such as
wooden blocks, steel, PVC etc.

The power drilling machine, which runs on human power, works on the principle of
the conversion of rotational motion to oscillatory motion. Importance of this project
lies in the very fact that it is green project and helps us to reduce our electricity need.
Secondly, this cutter can be used and transferred to our working place easily.
Moreover, if we want we can generate electricity with our project by connecting it to
dynamo, diode and battery.

CHAPTER 1
 INTRODUCTION :-

Pedal power is the tr.ansfer of energy from a human source through the use of a foot
pedal and crank system. This technology is most commonly used for transportation
and has been used to propel bicycles for over a hundred years. Less commonly pedal
power is used to power agricultural and hand tools and even to generate electricity.
Some applications include pedal powered laptops, pedal powered grinders and pedal
powered water wells. Some third world development projects currently transform used
bicycles into pedal powered tools for sustainable development.

This project concentrates on pedal powered drilling machining. An individual can

generate four times more power (1/4 HP) by pedalling than by hand-cranking. At the
rate of HP, continuous pedalling can be served for only short periods, approximately
10 minutes. However, pedalling at half this power (1/8 HP) can be sustained for close
to 60 minutes but power capability can depend upon age. As a consequence of the
brainstorming exercise, it was apparent that the primary function of pedal power one
specific product was particularly useful: the bicycle. Many devices can be run right
away with mechanical energy. 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. An abrasive saw uses an abrasive disc or band for
cutting, rather than a serrated blade.
Future Scope of Pedal Powered Drilling Machine:-

Rice Threshing Peanut shelling

Winnoving
 Corn Shelling

Operating a wood working lathe

SUBJECTS DISCUSSED :-

1. Stirling Engine :

A stirling engine is a heat engine that operates by cyclic compression and expansion
of air or other gas (the working fluid) at different temperatures, such that there is a net
conversion of heat energy to mechanical work. More specifically, the Stirling engine is
a closed-cycle regenerative heat engine with a permanently gaseous working fluid.
Closed cycle , in this context, means a thermodynamic in which the working fluid is
permanently contained within the system, and regenerative describes the use of a
specific type of internal heat exchanger and thermal store, known as the regenerator.
The inclusion of a regenerator differentiates the Stirling engine from other closed
cycle hot air engines.

Originally conceived in 1816 as an industrial prime mover to rival the steam engine,
its practical use was largely confined to low-power domestic applications for over a
century.

The Stirling engine is noted for high efficiency compared to steam engines, quiet
operation, and its ability to use almost any heat source. The heat energy source is
generated external to the Stirling engine rather than by internal combustion as with
the Otto cycle or Diesel cycle engines. Because the Stirling engine is compatible with
alternative and renewable energy sources it could become increasingly significant as
the price of conventional fuels rises, and also in light of concerns such as peak
oil and climate change. This engine is currently exciting interest as the core
component of micro combined heat and power (CHP) units, in which it is more
efficient and safer than a comparable steam engine. However, it has a low power-to-
weight ratio rendering it more suitable for use in static installations where space and
weight are not at a premium.
The energy crisis is increasing day by day, so we have to find more ways to get useful
energy. Energy saved is energy produced. Many industries use furnaces for production
processes, in which most of the heat is lost. We can use this excess heat to run the
sterling engine and hence produce electricity.

But as the cost of the project is very high, so we decided to reject it.
2.Electricity Generation Using Speed Breaker :-

In this model we show that how we can generate electricity from the busy traffic.
Conversion of the mechanical energy into electrical energy is widely used concept. It
is a mechanism to generate power by converting the potential energy generated by a
vehicle going up on a speed breaker into rotational energy.

We can use this simple concept to the project. We can connect one mechanical rod
with the dynamo and fit this rod on the surface of the road .When any vehicle moves
from this roller then due to friction, vehicle rotate the rod or roller and roller then
move the dynamo. When dynamo move, then it generates a voltage and this voltage
now connects to the bulbs. In actual practice with the help of this voltage we can
charge the battery and then we can use this voltage to light the small bulb. If we install
this unit to the any small flyover then with the help of this mechanism, we can
generate voltage, and with the help of this voltage we can light the bulb.

The second part of the project is the efficient use of energy by using simple
electronics. We always see that road lights continuously glow whether vehicles are on
the road or not. We can introduce a concept to avoid this wastage of light. We can use
two sensors between some distances. When vehicle pass through first sensor it sends
the signal to the microcontroller that the vehicle is passing along that particular
distance then light will glow for that particular time and when vehicle goes out from
the second sensor.

Then the second sensor sends a signal to a microcontroller that vehicle has been
passed through that particular path then light gets off automatically. Different types of
basic electronics components has been used to get the desired output like capacitor,
resister etc.

We have also used a light diode resistance(LDR) when LDR senses a light around it
all the road lights gets off and when LDR senses there is a dark around it then LDR
sends a signal to microcontroller then all the road lights gets on. By using a LDR we
can avoid a waste of light that glow in a day time. The two sensors are made from the
concept of electronics. These sensors are called an infrared sensor which is made from
photo diode and light emitting diode each. When any vehicle pass from first sensor
then first sensor becomes on, for that time the road lights gets on and when it pass
from second sensor the second sensor become on and the first sensor gets off then the
road light gets off.

It gives low and non-uniform voltage. Also, it is difficult to achieve proper

balance between speed and torque, hence we decided against it.
3.Modification In Local Trains Compartment :-

1.For ventilation in local compartments, we use fans which needs electricity. Sufficient
energy loss takes place in ventilation. we can make easy and eco-friendly ventilation
system in the compartments using natural air flowing around the compartment due to
movement of train.
We can attach hollow structures on the roof of compartment as shown in figure which
forces the air to come inside and flows through the windows and doors.

2.If we reduce one seat from the row of three seats which is close to door, it will help
people for comfortable boarding and alighting.

Since we cannot use this modification in rainy seasons, hence we decided to reject
it.

4. Crop Cutter:-

India is an agricultural country. The economy of our nation is mostly dependent on

agriculture. So for the development of our country, the agricultural sector of our
economy should be developed.

There are many steps in agriculture field like Ploughing, Sowing, Harvesting etc.
Harvesting is the operation of cutting, picking, plucking and digging or a combination
of these operations for removing the crop from under the ground or above the ground
or removing the useful part or fruits from plants.Harvesting action can be done by four
ways:

Slicing action with a sharp tool.

Tearing action with a rough serrated edge
High velocity single element impact with sharp edge.
Two elements scissors type action.

In India harvesting is done by sickle which is time consuming process. By using crop
cutter, it speeds up the harvesting process. Since, trials of this project are not
possible in urban cities like Mumbai, hence we decided to reject it.

Chapter 2
 Main component

Main Components of Pedal Powered Drilling Machine :-

1. Pedal

2. Sprocket

3. Chain

4. Crank

5. Connecting Rod

6. Flywheel

8. Bearing Blocks

9. Brake

10. Drilling
1. Pedal :-

A bicycle pedal is the part of a bicycle that the rider pushes with their foot to propel
the bicycle. It provides the connection between the cyclists foot or shoe and the crank
allowing the leg to turn the bottom bracket spindle and propel the bicycle's wheels.

Pedals were initially attached to cranks connecting directly to the driven (usually
front) wheel. The safety bicycle, as it is known today, came into being when the pedals
were attached to a crank driving a sprocket that transmitted power to the driven wheel
by means of a roller chain. Pedals usually consist of a spindle that threads into the end
of the crank and a body, on which the foot rests or is attached, that is free to rotate on
bearings with respect to the spindle.

Pedal will be used to transfer our muscular energy to the large sprocket.
2. Sprocket:-

A sprocket or sprocket-wheel is a profiled wheel with teeth, cogs, or even

sprockets that mesh with a chain,track or other perforated or indented material. The
name 'sprocket' applies generally to any wheel upon which radial projections engage a
chain passing over it. It is distinguished from a gear in that sprockets are never meshed
together directly, and differs from a pulley in that sprockets have teeth and pulleys are
smooth.

Sprockets are used in bicycles, motorcycles, cars, tracked vehicles, and

other machinery either to transmit rotary motion between two shafts where gears are
unsuitable or to impart linear motion to a track, tape etc. Perhaps the most common
form of sprocket may be found in the bicycle, in which the pedal shaft carries a large
sprocket-wheel, which drives a chain, which, in turn, drives a small sprocket on the
axle of the rear wheel . Early automobiles were also largely driven by sprocket and
chain mechanism, a practice largely copied from bicycles.

Sprockets are of various designs, a maximum of efficiency being claimed for each by
its originator. Sprockets typically do not have aflange. Some sprockets used
with timing belts have flanges to keep the timing belt centered. Sprockets and chains
are also used for power transmission from one shaft to another where slippage is not
admissible, sprocket chains being used instead of belts or ropes and sprocket-wheels
instead of pulleys. They can be run at high speed and some forms of chain are so
constructed as to be noiseless even at high speed.

Larger sprocket will take the energy from pedal and transfer it to the smaller
sprocket which will further transmit it to the shaft.

3. Sprocket chain :-

Sprocket Chain:

Roller chain or bush roller chain is the type of chain drive most commonly used for
transmission A sprocket or sprocket-wheel is a profiled wheel with teeth, cogs, or
even sprockets that mesh with a chain, track or other perforated or indented
material. The name 'sprocket' applies generally to any wheel upon which radial
projections engage a chain passing over it. It is distinguished from a gear in that
sprockets are never meshed together directly, and differs from a pulley in that
sprockets have teeth and pulleys are smooth.

It consists of a series of short cylindrical rollers held together by side links. It is driven
by a toothed wheel called a sprocket. It is a simple, reliable, and efficient means of
power transmission.

Construction of the Chain:

There are actually two types of links alternating in the bush roller chain. The first type
is inner links, having two inner plates held together by two sleeves or bushings upon
which rotate two rollers. Inner links alternate with the second type, the outer links,
consisting of two outer plates held together by pins passing through the bushings of
the inner links. The "bushingless" roller chain is similar in operation though not in
construction; instead of separate bushings or sleeves holding the inner plates together,
the plate has a tube stamped into it protruding from the hole which serves the same
purpose. This has the advantage of removing one step in assembly of the chain.

The roller chain design reduces friction compared to simpler designs, resulting in
higher efficiency and less wear. The original power transmission chain varieties lacked
rollers and bushings, with both the inner and outer plates held by pins which directly
contacted the sprocket teeth; however this configuration exhibited extremely rapid
wear of both the sprocket teeth, and the plates where they pivoted on the pins. This
problem was partially solved by the development of bushed chains, with the pins
holding the outer plates passing through bushings or sleeves connecting the inner
plates. This distributed the wear over a greater area; however the teeth of the sprockets
still wore more rapidly than is desirable, from the sliding friction against the bushings.
The addition of rollers surrounding the bushing sleeves of the chain and provided
rolling contact with the teeth of the sprockets resulting in excellent resistance to wear
of both sprockets and chain as well. There is even very low friction, as long as the
chain is sufficiently lubricated. Continuous, clean, lubrication of roller chains is of
primary importance for efficient operation as well as correct tensioning.

Sprocket chain will transfer motion from the large sprocket to the small sprocket.

4. Crank :-

A crank is a mechanical part able to perform a conversion between reciprocating

motion and rotational motion. In a reciprocating engine, it translates reciprocating
motion of the piston into rotational motion; whereas in a reciprocating compressor, it
converts the rotational motion into reciprocating motion. In order to do the conversion
between two motions, the crankshaft has "crank throws" or "crankpins", additional
bearing surfaces whose axis is offset from that of the crank, to which the "big ends" of
the connecting rods from each cylinder attach.

It is typically connected to a flywheel to reduce the pulsation characteristic of the four-

stroke cycle, and sometimes a torsional or vibrational damper at the opposite end, to
reduce the torsional vibrations often caused along the length of the crankshaft by the
cylinders farthest from the output end acting on the torsional elasticity of the metal.
Crank will convert rotary motion of shaft into the reciprocating motion which
will further transmit to the hack saw assembly.

5. Connecting Rod :-

The connecting rod connects the piston to the crank or crankshaft. Together with the
crank, they form a simple mechanism that converts reciprocating motion into rotating
motion.
Connecting rods may also convert rotating motion into reciprocating motion.
Historically, before the development of engines, they were first used in this way.

As a connecting rod is rigid, it may transmit either a push or a pull and so the rod may
rotate the crank through both halves of a revolution, i.e. piston pushing and piston
pulling. Earlier mechanisms, such as chains, could only pull. In a few two-stroke
engines, the connecting rod is only required to push.

Today, connecting rods are best known through their use in internal combustion piston
engines, such as automotive engines. These are of a distinctly different design from
earlier forms of connecting rods, used in steam engines and steam locomotives.

We are using the connecting rod to convert the rotary motion of crank into
reciprocating motion and supplied it to the hack saw assembly.

6.Flywheel:
A flywheel is a rotating mechanical device that is used to store rotational energy.
Flywheels have an inertia called the moment of inertia and thus resist changes in
rotational speed. The amount of energy stored in a flywheel is proportional to the
square of its rotational speed. Energy is transferred to a flywheel by the application of
a torque to it, thereby increasing its rotational speed, and hence its stored energy.
Conversely, a flywheel releases stored energy by applying torque to a mechanical load,
thereby decreasing the flywheel's rotational speed.

Common uses of a flywheel include:

Providing continuous energy when the energy source is discontinuous. For

example, flywheels are used in reciprocating engines because the energy source,
torque from the engine, is intermittent.
 Delivering energy at rates beyond the ability of a continuous energy source.
This is achieved by collecting energy in the flywheel over time and then releasing
the energy quickly, at rates that exceed the abilities of the energy source.

Controlling the orientation of a mechanical system. In such applications,

the angular momentum of a flywheel is purposely transferred as a torque to the
attaching mechanical system when energy is transferred to or from the flywheel,
thereby causing the attaching system to rotate into some desired position.

Flywheels are typically made of steel and rotate on conventional bearings; these are
generally limited to a revolution rate of a few thousand RPM. Some modern flywheels
are made of carbon fibre materials and employ magnetic bearings, enabling them to
revolve at speeds up to 60,000 RPM.

Carbon-composite flywheel batteries have recently been manufactured and are proving
to be viable in real-world tests on mainstream cars. Additionally, their disposal is more
eco-friendly.

As our drilling assembly is inclined, we have to provide more energy to lift up the
hack saw assembly. Flywheel will store the energy during downward stroke and
supply the stored energy during upward stroke to lift up the hack saw assembly.
8. Bearing Blocks :-

A bearing is a machine element that constrains relative motion to only the desired
motion, and reduces friction between moving parts. The design of the bearing may, for
example, provide for free linear movement of the moving part or for free rotation
around a fixed axis; or, it may prevent a motion by controlling the vectors of normal
forces that bear on the moving parts. Many bearings also facilitate the desired motion
as much as possible, such as by minimizing friction. Bearings are classified broadly
according to the type of operation, the motions allowed, or to the directions of the
loads (forces) applied to the parts.

The term "bearing" is derived from the verb "to bear"; a bearing being a machine
element that allows one part to bear (i.e., to support) another. The simplest bearings
are bearing surfaces, cut or formed into a part, with varying degrees of control over the
form, size, roughness and location of the surface. Other bearings are separate devices
installed into a machine or machine part. The most sophisticated bearings for the most
demanding applications are very precise devices; their manufacture requires some of
the highest standards of current technology.

Bearing blocks will be used to provide support to the rotating shaft on which
flywheel, crank, clutch, brakes, and sprocket are mounted.
9. Brake :-

A brake is a mechanical device that inhibits motion, slowing or stopping a moving

object or preventing its motion.

Most brakes commonly use friction between two surfaces pressed together to convert
the kinetic energy of the moving object into heat, though other methods of energy
conversion may be employed. For example, regenerative braking converts much of the
energy to electrical energy, which may be stored for later use. Other methods
convert kinetic energy into potential energy in such stored forms as pressurized air or
pressurized oil. Eddy current brakes use magnetic fields to convert kinetic energy into
electric current in the brake disc, fin, or rail, which is converted into heat. Still other
braking methods even transform kinetic energy into different forms, for example by
transferring the energy to a rotating flywheel.

Brakes are generally applied to rotating axles or wheels, but may also take other forms
such as the surface of a moving fluid (flaps deployed into water or air). Some vehicles
use a combination of braking mechanisms, such as drag racing cars with both wheel
brakes and a parachute, or airplanes with both wheel brakes and drag flaps raised into
the air during landing.

Magnetic brake system:

Disclosed is a magnetic brake system for a vehicle, comprising: a plurality of brake

disk solenoids for generating the magnetic force; a plurality of brake pad solenoids for
generating the magnetic force; a braking sensor for detecting whether a brake pedal is
applied; a wheel speed sensor for detecting wheel speed; a magnetic polarity sensor
for detecting magnetic polarity of the brake disk solenoids; and a control unit for
controlling the brake pad solenoids using signals from the braking sensor, the wheel
speed sensor and the magnetic polarity sensor.

Sometimes, if we have to stop the machine in case of emergency, then we will

press the brake lever so that it will decrease the speed of the hack saw assembly.
10. Drilling :-

A drilling is a fine-toothed saw, originally and principally for cutting metal. They can
also cut various other materials, such as plastic and wood; for
example, plumbers and electricians often cut plastic pipe and plastic conduit with
them. There are hand saw versions and powered versions (power drillings). Most
drillings are hand saws with a C-shaped frame that holds a blade under tension. Such
drillings have a handle, usually a pistol grip, with pins for attaching a narrow
disposable blade. The frames may also be adjustable to accommodate blades of
different sizes. A screw or other mechanism is used to put the thin blade under
tension. Panel drillings forgo the frame and instead have a sheet metal body; they can
cut into a sheet metal panel further than a frame would allow. These saws are no
longer commonly available, but drilling blade holders enable standard drilling blades
to be used similarly to a keyhole saw or pad saw. Power tools including nibblers,
jigsaws, and angle grinders fitted with metal-cutting blades and discs are now used for
longer cuts in sheet metals.

On drillings, as with most frame saws, the blade can be mounted with the teeth facing
toward or away from the handle, resulting in cutting action on either the push or pull
stroke. In normal use, cutting vertically downwards with work held in a bench vice,
drilling blades should be set to be facing forwards. Some frame saws, including Fret
Saws and Piercing Saws, have their blades set to be facing the handle because they are
used to cut by being pulled down against a horizontal surface.
 Chapter 3

WORKING PRINCIPLE

It consists of the pedal arrangement which rotates the crank and through it slider
consists of oscillating mechanism. The power is transmitted to the crank and slider
mechanism. This mechanism is used to rotate the crank disc; the disc which is having
an extended rod is connected to the sliding portion of the drilling directly by means of
a linkage. The drilling is passed through the guide ways by means of maintaining the
cdrilling axis. As the user operated the pedal, the drilling machice is drill the various
materials automatically with less power. The dead weight is for compressive force
while the user operated the foot pedal.
 Chapter 4

ADVANTAGES:-

I. Time saving as compared to simple drilling

II. Power saving as it is manually operated

III. Easy machinery used

IV. As it is pedal operated so good for health

V. Comfortable then ordinary drilling

VI. It is portable

VII. It could be used wherever metal cutting is done in small scales, including at
construction sites and furniture units, or to cut metal for window panes.
 CHAPTER 5

Calculations:-

Chain Driver Sprocket

Driven Sprocket

Radius of Driver Sprocket = R1

Radius of Driven Sprocket = R2

No. of teeths on Driver Sprocket = T1

No. of teeths on Driven Sprocket = T2

Pitch of the Chain = P

Teeth Ratio = T1/T2

Velocity Ratio = (T1/T2 = N2/N1)

R1 = P/2 cosec ( 180 / T1 )

R2 = P/2 cosec ( 180 / T2 )

Length of the chain = (R1 + R2) + 2x + (R1 R2)2/x

input Power = 2 N T / 60

where, N = Sprocket speed in rpm

T = Torque applied by human in Nm

T=Fxr

where, F = Force applied by human in N

r = Length of pedal arm

Now, we can increase the torque by increasing the length of pedal from its centre.

The cutting force required = x D x t x s

where D = Diameter of workpiece

t = Cutting Depth

s = Shear strength of material

In case of rectangular workpiece,

Fmax = 2 x (B+L) x t x s

where, B = Breadth of workpiece

L = Length of workpiece

Maximum power required = Fmax x V

where, V = velocity of blade

SHEAR STRENGTH OF VARIOUS MATERIALS

Metal s N/mm2
Carbon steel
0.10% C 245 to 310
0.20% C 308 to 385
0.30% C 364 to 469
High strength low alloy steel 315 to 446
Silicon Steel 420 to 490
Stainless steel 399 to 903
Aluminium alloys 49 to 322
 Copper and Bronze 154 to 490
Lead alloys 12.8 to 41
Magnesium alloys 119 to 203
Nickel alloys 245 to 812
Tin alloys 20.5 to 77.5
Titanium alloys 420 to 490
Zinc alloys 98 to 266

CHAPTER 6
CONCLUSION

In the coming days, as demand of electricity is increasing every moment, it will

prove a great boon to the world, since it will save a lot of electricity. Pedal operated
drilling machine brings hope for recycling the wasted energy.

With improvement of technology, Pedal power drilling machine may become

one of promising trends of vehicle industry. This project can also be modified by using
crank shaft and chain system instead of gears which we have used in our project which
will reduce the complexities and difficulties faced during the project.
 CHAPTER 7

REFERENCES:

1. Theory of Machines By R.S. Khurmi and J.K Gupta,1st multicolour edition .

2. A Textbook of Production Engineering by P.C.Sharma