DESIGN AND FABRICATION OF AUTOMATIC FEEDING

MECHANISM FOR POWER HACKSAW MACHINE

A MINI PROJECT REPORT

Submitted by

ARAVINTH CHANDRA KUMAR R 310815114010

AROCKIA ALEX FRANKIN X 310815114012

ASHWIN RAJU R 310815114019

GOPINATH S 310815114042

In partial fulfillment for the award of the degree

Of

BACHELOR OF ENGINEERING

In

MECHANICAL ENGINEERING

JEPPIAAR ENGINEERING COLLEGE

CHENNAI -119

ANNA UNIVERSITY: CHENNAI –25

APRIL – 2018
 ANNA UNIVERSITY: CHENNAI-600025

JEPPIAAR ENGINEERING COLLEGE

DEPARTMENT OF MECHANICAL ENGINEERING

Jeppiaar Nagar, Rajiv Gandhi Salai, Chennai –119

BONAFIDE CERTIFICATE

Certified that this project report “DESIGN AND FABRICATION OF AUTOMATIC

FEEDING MECHANISM FOR POWER HACKSAW MACHINE” is the bonafide
work of “ARAVINTH CHANDRA KUMAR R (310815114010), AROCKIA ALEX
FRANKIN X (310815114012), ASHWIN RAJU R (310815114019), GOPINATH S
(310815114042)” who carried out the project under my supervision. Submitted for the
examination held on __________

SIGNATURE SIGNATURE
Dr. V. Natarajan., M.E., Ph.D., Mr.K.JAGATHEESHAN, M.E.,(Ph.D).,
HEAD OF THE DEPARTMENT SUPERVISOR
PROFESSOR ASSISTENT PROFESSOR
Dept. of Mechanical Engineering, Dept. of Mechanical Engineering,
Jeppiaar Engineering College, Jeppiaar Engineering College,
Chennai-600119. Chennai-600119.

INTERNAL EXAMINER EXTERNAL EXAMINER

 ACKNOWLEDGEMENT

We would like to take this opportunity to express our heartest gratitude to the
following people for their invaluable help rendered durng our project period at
JEPPIAAR ENGINEERING COLLEGE.

We express our sincere thanks to our Hon’ble Colonel Dr.JEPPIAAR,M.A.,

B.L, Ph.D., (Late), our Chairman and Managing Director Dr. M. REGEENA
JEPPIAAR, B. Tech., M.B.A., Ph.D., for their constant support and
encouragement in studies.

We express our gratitude to our Principal Dr. J.VENU GOPALAKRISHNAN,

M.Tech., F.I.E., Ph.D., for his indispensable help,amenities provided to carry
out our project work.

We would like to express our heartful thanks to Prof. Dr. V. Natarajan., M.E.,
Ph.D., Head of the Department of Mechanical Engineering for his support and
encouragement towards the project work.

We would like to express our best and sincere thanks to our project guide
Mr.K.JAGATHEESHAN, M.E.,(Ph.D)., for giving valuable suggestions for
making this project a grand success.

We also thank the teaching and non teaching staff members of the department
of MECHANICAL ENGINEERING for their constant support.

i
 ABSTRACT

Nowadays, automation in the industries plays an important role.

Almost all the machines are atomized. The electronic switches and AC motors
are used for doing this automation process. This is one of the automation
processes by using the torque motor. The “AUTOMATIC FEEDING
MECHANISM FOR POWER HACKSAW MACHINE” is our project,
which is fixed with the motor and with the electronic automations.The motor
controls the bar in the mechanism automatically by using the electronic
automations. The bar can be moved in the mechanism with the regular time
interval. This results ease in the process of feeding the workpiece in power
hacksaw .

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 TABLE OF CONTENTS

CHAPTER TITLE PAGE

NO. NO.

ABSTRACT ii

LIST OF FIGURES vi

LIST OF TABLES vii

1 INTRODUCTION 1

1.1 GENERAL 1

1.2 NEED FOR AUTOMATION 1

1.3 DEVELOPMENT OF AUTOMATION 2

1.4 PROBLEM DEFINITON FOR 2

MANUAL FEEDING

2 COMPONENTS USED 4

2.1 AC MOTOR 4

2.2 BEARING 6

2.3 PULLEY AND ROPE 7

2.4 PUSH BUTTON 7

2.5 SQUARE PLATE 8

2.6 SHAFT 9

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CHAPTER TITLE PAGE

NO. NO.

3 SPECIFICATION 9

3.1 AC MOTOR 9

3.2 BEARING 9

4 AUTOMATIC BAR FEEDING 10

MECHANISM

4.1 WORKING 10

4.2 CONTROL OF MOTOR SPEED 11

4.3 CONTROL OF PUSH BUTTON 12

5 CATIA V5 3D MODELING 12

5.1 ISOMETERIC VIEW 12

5.2 FRONT VIEW 12

5.3 TOP VIEW 13

5.4 RIGHT SIDE VIEW 13

6 MATERIALS USED 14

7 FABRICATION PROCESS 15

7.1 TURNING 15

7.2 FACING 16

7.3 DRILLING 16

7.4 ARC WELDING 17

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CHAPTER TITLE PAGE

NO. NO.

8 WORKING 18

8.1 BLOCK DIAGRAM 18

9 DESIGN CALCULATION 19

10 BENEFITS 20

10.1 ADVANTAGES 20

10.2 LIMITATION 20

10.3 APPLICATION 21

11 COST ESTIMATION 22

12 CONCLUSION 23

13 PHOTOGRAPHY 24

14 FUTURE IMPROVEMENTS AND 26

INNOVATION

15 REFERENCE 27

v
 LIST OF FIGURES

FIGURE TITLE PAGE

NO NO

1.4 MANUAL FEEDING 2

2.1.1 AC MOTOR 4

2.2 BEARING 6

2.3 PULLEY 7

2.4 PUSH BUTTON 7

2.5 SQUARE PLATE 8

2.6 SHAFT 8

7.1 TURNING 15

7.2 FACING 16

7.3 DRILLING 16

7.4 ARC WELDING 17

vi
 LIST OF TABLES

TABLE TITLE PAGE

NO NO.

6.1 MATERIALS USED 14

11.1 COST ESTIMATION 22

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 CHAPTER-1

INTRODUCTION

Automation or automatic control, is the use of various control

systems for operating equipment such as machinery, processes in factories,
boilers and heat treating ovens, switching on telephone networks, steering and
stabilization of ships, aircraft and other applications and vehicles with minimal
or reduced human intervention. Some processes have been completely
automated.The biggest benefit of automation is that it saves labor; however, it is
also used to save energy and materials and to improve quality, accuracy and
precision.

1.1 GENERAL:

The term automation, inspired by the earlier word automatic (coming

from automaton), was not widely used before 1947, when Ford established an
automation department. It was during this time that industry was rapidly
adopting feedback controllers, which were introduced in the 1930s.

1.2 NEED FOR AUTOMATION:

During observation it was found that the bar which is to be cut was
feeded by using manual.There are no proper equipments to fed the bar in the
machine , the bar is rest on the hand which we can see in the picture due to
which sometimes the bar is being cut in wrong dimensions

To overcome this problems automation was needed for cutting the

bar in accuracy as well to reduce human efforts and to reduce wastage of raw
material.Therefore by using stands and mechanized motion the problem is
solved .

1
1.3 DEVELOPMENT OF AUTOMATION:

Automation has been achieved by various means including

mechanical, hydraulic, pneumatic, electrical, electronic devices and computers,
usually in combination. Complicated systems, such as modern factories,
airplanes and ships typically use all these combined technique. Nowadays
almost all the manufacturing process is being atomized in order to deliver the
products at a faster rate.

1.4 PROBLEMS DEFINITION FOR MANUAL FEEDING:

 Length or size variations.

 Improper cutting.
 Wastage of raw materials.
 More time required to adjust required length.

2
 FIGURE 1.4 MANUAL FEEDING

1.5 ADVANTAGAES FOR AUTOMATIC FEEDING MECHANISM:

 Reducing man power

 Simple in construction.
 It can used for solid as well as hollow materials.
 Accuracy and precision.
 More productivity.

3
 CHAPTER-2

COMPONENTS USED

The prototype was created using following parts:

AC MOTOR : used to drive entire shaft setup

BEARING : used to rotated the driving shaft

PULLEY AND ROPE : used to transmitted the power

PUSH BUTTON : used to cut off/on the power

SQUARE PLATE : used to constructing the frame

SHAFT : used to transmit the power

2.1 AC MOTOR:

An AC motor is an electric motor driven by an alternating current (AC).

The AC motor commonly consists of two basic parts, an outside
stationary stator having coils supplied with alternating current to produce a
rotating magnetic field, and an inside rotor attached to the output shaft
producing a second rotating magnetic field. The rotor magnetic field may be
produced by permanent magnets, reluctance saliency, or DC or AC electrical
windings.

Less commonly, linear AC motors operate on similar principles as

rotating motors but have their stationary and moving parts arranged in a straight
line configuration, producing linear motion instead of rotation.

4
2.1.1 OPERATING PRINCIPLE:

When an AC motor is in steady-state rotation (motion), the magnetic

fields of the rotor and stator rotate (move) with little or no slippage (near
synchrony). The magnetic forces (repulsive and attractive) between the rotor
and stator poles create average torque, capable of driving a load at rated speed.

The speed of the stator rotating magnetic field and the speed of the rotor
rotating magnetic field, relative to the speed of the mechanical shaft, must
maintain synchronism for average torque production by satisfying the
synchronous speed relation. Otherwise, asynchronously rotating magnetic fields
would produce pulsating or non-average torque.

The two main types of AC motors are classified as induction and

synchronous. The induction motor (or asynchronous motor) always relies on a
small difference in speed between the stator rotating magnetic field and the
rotor shaft speed called slip to induce rotor current in the rotor AC winding. As
a result, the induction motor cannot produce torque near synchronous speed
where induction (or slip) is irrelevant or ceases to exist. In contrast, the
synchronous motor does not rely on slip-induction for operation and uses either
permanent magnets, salient poles (having projecting magnetic poles), or an
independently excited rotor winding. The synchronous motor produces its rated
torque at exactly synchronous speed. The brushless wound-rotor doubly fed
synchronous motor system has an independently excited rotor winding that does
not rely on the principles of slip-induction of current. The brushless wound-
rotor doubly fed motor is a synchronous motor that can function exactly at the
supply frequency or sub to super multiple of the supply frequency.

5
 Other types of motors include eddy current motors, and also AC/DC
mechanically commutated machines in which speed is dependent on voltage and
winding connection.

FIGURE 2.1.1 AC MOTOR

2.2 BEARING:

A ball bearing is a type of rolling element bearing that uses to

maintain the separation between the bearing races. The purpose of ball bearing
is used to reduce rational friction and support radial and axial load.

FIGURE 2.2 BALL BEARING

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2.3 PULLEY AND ROPE:

V-belt Pulley image V-belt pulleys (also called v belt sheaves) are
devices which transmit power between axles by the use of a v-belt, a
mechanical linkage with a trapezoidal cross-section. Together these devices
offer a high-speed power transmission solution that is resistant to slipping and
misalignment.

Typically, v-belt drives operate between 1,500 to 6,000 ft/min, with

4,500 ft/min the ideal capacity for standard belts. Some narrow v-belts can
operate at speeds of up to 10,000 ft./min, but these pulleys must be dynamically
stabilized.

FIGURE 2.3 PULLEY

2.4 PUSH BUTTON:

The main function of the push button in our project is to cut off the
power to the motor as soon as the bar touches the button to avoid over feeding
of bar and to get the exact dimensions of bar . This push button is located on the
end side of the machine.

7
 FIGURE 2.4 PUSH BUTTON

2.5 SQUARE PLATE:

The Square tubing of MS 1.5 inches is used for construction of frame

which can withstand the load of heavy bar.

FIGURE 2.5 SQUARE PLATE

2.6 SHAFT:

A shaft is a rotating machine element, usually circular in cross

section, which is used to transmit power from one part to another, or from a
machine which produces power to a machine which absorbs power.

FIGURE 2.6 SHAFT

8
 CHAPTER-3

SPECIFICATION

3.1 AC MOTOR:

Motor Weight : 3.5KG

Motor Speed : 1440 RPM
Motor HP : 5 HP
Motor Type : AC Motor
Motor Amps : 3.6/1.8 Ω
Motor volts : 220/110

3.2 BEARING:

Diameter : 25 mm
Rpm : 3000 rpm ( 50 Hz )
Life span : 1 million rotation
Material : chrome steel-SAE 52100
Dynamic load : 1100kgf
Static load : 710kgf

9
 CHAPTER- 4

AUTOMATIC FEEDING MECHANISM

4.1 WORKING:

The work piece which is to be machined is placed in the rotary bar.

When the motor is switched ON motor will be rotated, the pulley will rotate due
to the friction due to the rope placed between the motor and pulley so that the
bar is moving from initial position to the determined position.Length adjusting
unit with push button is used to determine the bar dimension to be cut.When rod
reaches and touches the push button electric supply stops and motor stops
rotating.Hence the rod stops moving. And further clamping the vice,the rod
cutting process will starts.

What is Feed Mechanism?

The Feeding mechanism is a metal cutting machine tool

designed to feed the metal. The machine is exclusively intended for mass
production and they represent fasten and more efficient way to feed a metal.

How Feed Mechanism works?

In feed mechanisms which have been proposed and used

include shaft feeding the bar through the machine by rotation of the shaft. It is
the objective of this invention to provide a feed mechanism for a power
hacksaw in a form which minimizes damage both to the bar stock and to the bar
contacting shaft surfaces.

10
4.2 CONTROL OF MOTOR SPEED :

This push-button operated AC motor speed controller uses

Phase Angle Regulation (PAR) and a triac output and allows you to adjust the
speed of 230Vac 50Hz single-phase "universal" motors as used in power drills,
vacuum cleaners, etc and an operating load of up to 750 Watts.

4.3 CONTROL OF PUSH BUTTON:

A push-button (also spelled pushbutton) or simply button is a

simple switch mechanism for controlling some aspect of a machine or a process.
Buttons are typically made out of hard material, usually plastic or metal. The
surface is usually flat or shaped to accommodate the human finger or hand, so
as to be easily depressed or pushed. Buttons are most often biased switches,
although many un-biased buttons (due to their physical nature) still require a
spring to return to their un-pushed state. Terms for the "pushing" of a button
include pressing, depressing, mashing, hitting, and punching.

11
 CHAPTER-5

CATIAV5 3D MODELING

5.1 ISOMETERIC VIEW:

5.2 FRONT VIEW:

12
5.3 TOP VIEW:

5.4 RIGHT SIDE VIEW:

13
 CHAPTER-6

MATERIALS

COMPONENTS MATERIALS DIMENSIONS

Inner Diameter : 25mm

BEARING Low carbon alloy Outer Diameter: 31mm

Diameter : 25mm
SHAFT Mild steel Length : 110cm

FRAME Mild steel (110x45) Rectangular

Frame

AC MOTOR Speed : 1440rpm

Length : 35cm
ADJUSTING Aluminium steel Breath : 15cm
STOPPER Hole : 10mm

ROLLER DRIVE Rubber Material Diameter : 25mm

Diameter : 25mm
PULLEY AND ROPE Mild steel & Rubber Height : 95mm
material Thickness : 1.5mm
TABLE 6.1 : MATERIALS USED

14
 CHAPTER-7

FABRICATION PROCESSES

Fabrication
process

Frame Shaft
Welding Turning
Drilling facing

7.1 TURNING:
This operation is one of the most basic machining processes. That is,
the part is rotated while a single point cutting tool is moved parallel to the axis
of rotation. Turning can be done on the external surface of the part as well as
internally (boring). The starting material is generally a work piece generated by
other processes such as casting, forging, extrusion, or drawing.

FIGURE 7.1: TURNING

15
7.2 FACING:

Facing in the context of turning work involves moving the cutting tool
at right angles to the axis of rotation of the rotating work piece. This can be
performed by the operation of the cross-slide, if one is fitted, as distinct from
the longitudinal feed (turning). It is frequently the first operation performed in
the production of the work piece, and often the last—hence the phrase "ending
up".

FIGURE 7.2: FACING

7.3 DRILLING:

Drilling is a cutting process that uses a drill bit to cut a hole of

circular cross-section in solid materials. The drill bit is usually a rotary cutting
tool, often multipoint. The bit is pressed against the work piece and rotated at
rates from hundreds to thousands of revolutions per minute. This forces the
cutting edge against the work piece, cutting off chips (swarf) from the hole as it
is drilled. In rock drilling, the hole is usually not made through a circular cutting
motion, though the bit is usually rotated. Instead, the hole is usually made by
hammering a drill bit into the hole with quickly repeated short movements. The
hammering action can be performed from outside of the hole (top-hammer drill)
or within the hole (down-the-hole drill, DTH). Drills used for horizontal drilling
are called drifter drills.

16
 In rare cases, specially-shaped bits are used to cut holes of non-circular
cross-section; a square cross-section is possible.

FIGURE 7.3: DRILLING

7.4 ARC WELDING:

Arc welding is a process that is used to join metal to metal by using

electricity to create enough heat to melt metal, and the melted metals when cool
result in a binding of the metals. It is a type of welding that uses a welding
power supply to create an electric arc between an electrode and the base
material to melt the metals at the welding point.

FIGURE 7.4: ARC WELDING

17
 CHAPTER-8

WORKING

The work piece which is to be machined is placed in the rotary bar. When
the motor is switched ON motor will be rotated, the pulley will rotate due to the
friction due to the rope placed between the motor and pulley so that the bar is
moving from initial position to the determined position.

Length adjusting unit with push button is used to determine the bar
dimension to be cut. When rod reaches and touches the push button electric
supply stops and motor stops rotating.

Hence the rod stops moving and further clamping the vice,the rod cutting
process will starts.

8.1 BLOCK DIAGRAM:

MOTOR PULLEY BEARING

FEEDING
WORKPECE

18
 CHAPTER-9

DESIGN CALCULATION

MOTOR INTIAL SPEED WITHOUT LOAD : 1500rpm

MOTOR INTIAL SPEED WITH LOAD : 1480rpm

TRIALS : Dimension ɸ25x100mm

MANUAL AUTO

1hr = 15 rod 1hr = 18 rod

8hrs = 120 rods 8hrs = 144 rods

By using “AUTOMATIC FEEDING MECHANISM FOR POWER

HACKSAW MACHINE” we can save 2 hrs/day, 24 pieces increases per
shift.

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 CHAPTER-10

BENEFITS.

10.1 ADVANTAGES:

 Reducing man power

 Simple in construction.

 It can used for solid as well as hollow materials.

 Accuracy and precision.

 More productivity.

10.2 LIMITATIONS:

 Limited weight material only used

 Inital amount is high.

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10.3 APPLICATION:

 Small and Medium scale industries Application

 Metal Cutting Industries and Work Shops

 Pipe cutting

 Splendor rod cutting

 Round, Square, Oval, Hexagonal, etc shape materials can also feed by

using this mechanism.

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 CHAPTER-11

COST ESTIMATION

COMPONENTS NO’S COST

MOTOR 1 1500
WELDING & DRILLING 700

SQUARE PLATE 12KG 500

STEEL PLATE 2 300

BALL BEARING 2 240

PULLEY 2 200

CUTTING TOOL 1 140

NUTS AND BOLTS 10 50

ROPE 1 40

TOTAL 3670

TABLE 11.1 COST ESTIMATION

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 CHAPTER-12

CONCLUSION

The “AUTOMATIC FEEDING MECHANISM FOR POWER

HACKSAW MACHINE” is working with satisfactory conditions.

While concluding this report, we feel quite fulfill in having

completed the project assignment well on time, we had enormous practical
experience on fulfillment of the manufacturing schedules of the working project
model. We are therefore, happy to state that the in calculation of mechanical
aptitude proved to be a very useful purpose.

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 CHAPTER-13

PHOTOGRAPHY

FRONT VIEW:

24
TOP VIEW:

25
 CHAPTER-14

FUTURE IMPROVEMENTS AND INNOVATIONS

The paper included very simple type of Machine parts requiring

very less component than conventional machinery. As work was successful
studying & completing the results of this automatic feeding mechanism for
hacksaw with solving other types of conventional feeding problems associated
with machine that can be implemented from higher to lower units cost. Its lower
most requirement of maintenance can again be beneficial for keeping cost
down. This automation can surely reduce the loss thereby increasing the
productivity by investing small capital less equipments. As per Indian content is
concern this machine can be very beneficial for virtually all type of power
hacksaw machines as it has very low capital investment. This machine may
form a simple solution for feeding of bar in the future. This automation also can
be controlled by computer programs.

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 CHAPTER-15

REFERENCES

1. Khurmi and Gupta “Theory of Machine” Edition Reprint 2007.

2. Khurmi and Gupta “Machine Design” Edition 2005.

3. Workshop Technology, Hajara Chaudhari.

4. Production Technology, R.K. Jain.

5. PSG Design Data Book.

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