CHAPTER 1

INTRODUCTION

Increasing the productivity is one of the main requirements of

production engineering in any kind of manufacturing industry. Either by
reducing the operation time or by improving the capability of the machine to
produce the components in an increased number at the same time is very
essential for an industry to achieve the same. This project employs the
Scotch yoke mechanism in power hacksaw machine which enables it to cut
two components at a time thereby improving the productivity. Thus the
productivity is increases.

The scotch yoke mechanism is used for converting ratary motion into a
reciprocating motion. The inversion is obtained by fixing either the link 1 or
link 3. Link 1 is fixed.in this mechanism, when the link 2 rotates B as centre,the
link 4 reciprocates. The fixed link 1 guides the frame.

1
 CHAPTER 2
LITERATURE REVIEW
X Wang et al. 1 have studied about the Scotch Yoke crank mechanism
whose application could be used in a reciprocating internal combustion engine
which will reduce the engines size and weight in-turn generates sinusoidal
piston motion that allowsfor complete balance of the engine. C. Gopal et al. 2
have reviewed the research developments with Renewable Energy Source Water
Pumping Systems (RESWPSs). Alireza Rezae et al. 3 have studied about the
technical and financial aspects of photovoltaic water pumping system for
irrigation purpose in the GORGANs farm fields (one of Northern Province of
Iran) with the RET Screen software tools. Abdeen Mustafa Omer4 has reviewed
the means of using wind energy for water pumping in rural areas in Sudan.
Ahmed Mohammedi et al. 5 has designed a model which will express about the
water flow output (Q) that will be directly a function of the electrical power
input (P) to the motor-pump, for various total heads. Arif Hepbasli et al.6 has
given review on HPWH systems in terms of energetic and exergetic aspects in
which the technology along with its historical development was briefed and a
comprehensive review of studies were subsequently conducted over them and
hence they were classified and presented in the form of tables. P. Amrutesh et
al.7 has made a study to change the existing setup so that an unskilled operator
could operate and maintain the lawn very fine and attain a uniform surface look
with an application easier and also at reduced cost where they finally achieved
in pollution control too. M. Sermaraj8 have made a study about the foot pedal
pump which is powered by our legs instead of arms to lift the water from a
depth range of seven meters. In the past human energy has generally been
applied through the use of the arms, hands, and back. Rizgar Baker Weli et al.9
has made experimental investigation on a rig which is specially designed to
perform the study at residential area in city of Erbil that is used to find out the
amount of water which could be lifted from the ground floor to a static head of
8 meters over the roof using two modules of 50 W photovoltaic solar modules,
the system contains AC centrifugal pump, inverter, charging control and a 88
Ah battery for energy saving in addition to photovoltaic panels. The electricity
generation has many difficulties in our area and it is about 900 W.h/m2 .day for
PV module positioned toward south at a tilt angle of 360. Oghogho
Ikponmwosa et al.10 has made a system that could be used for elimination of
the cost and inefficiency of human interference that could be associated with

2
monitoring and controlling the pump by increasing the performance and life
span of the electric water pump. The aim of this work is to design the dual side
water pumping system for increased discharge and efficiency also analyse and
fabricate the dual side water pumping system which works on Scotch yoke
mechanism which is a mechanism used for converting the linear motion of a
slider into rotational motion or vice-versa. This system is inexpensive, easy to
operate and build in a small-scale size.

3
 CHAPTER 3
PARTS OF THE PROJECT

A.C MOTOR

BOLT AND NUT

PULLEY

SHAFT

HACKSAW

V-BELT

O TYPE CLAMP

4
3.1 A.C MOTOR

OPERATION OF AC MOTOR

In any electric motor, operation is based on simple electromagnetism. A

current-carrying conductor generates a magnetic field; when this is then placed
in an external magnetic field, it will experience a force proportional to the
current in the conductor, and to the strength of the external magnetic field. As
you are well aware of from playing with magnets as a kid, opposite (North and
South) polarities attract, while like polarities (North and North, South and
South) repel. The internal configuration of a AC motor is designed to harness
the magnetic interaction between a current-carrying conductor and an external
magnetic field to generate rotational motion. Let's start by looking at a simple 2-
pole AC electric motor (here red represents a magnet or winding with a "North"
polarization, while green represents a magnet or winding with a "South"
polarization).

SECTIONAL VIEW OF A.C MOTOR

Fig. Sectional view of AC Motor.

5
 Every AC motor has six basic parts: axle, rotor (armature), stator,
commutator , field magnet(s), and brushes. In most common AC motors (and all
that Beamers will see), the external magnetic field is produced by high-strength
permanent magnets. The stator is the stationary part of the motor; this includes
the motor casing, as well as two or more permanent magnet pole pieces. The
rotors (together with the axle and attached commutator) rotate with respect to
the stator. The rotor consists of windings (generally on a core), the windings
being electrically connected to the commutator The above diagram shows a
common motor layout with the rotor inside the stator (field) magnets.

Brushed Motor

This type of motor produces a magnetic field in a wound rotor

(the part that rotates) by passing an electrical current through a commutator and
carbon brush assembly , hence the term "Brushed". The stators (the stationary
part) magnetic field is produced by using either a wound stator field winding or
by permanent magnets. Generally brushed AC motors are cheap, small and
easily controlled.

Brushless Motor

This type of motor produce a magnetic field in the rotor by using

permanent magnets attached to it and commutation is achieved electronically.
They are generally smaller but more expensive than conventional brushed type
AC motors because they use "Hall effect" switches in the stator to produce
the required stator field rotational sequence but they have better torque/ speed
characteristics, are more efficient and have a longer operating life than
equivalent brushed types.

6
Servo Motor

This type of motor is basically a brushed DC motor with some form

of positional feedback control connected to the rotor shaft. They are connected
to and controlled by a PWM type controller and are mainly used in positional
control systems and radio controlled models. Normal AC motors have almost
linear characteristics with their speed of rotation beingdetermined by the applied
AC voltage and their output torque.

7
3.2 BOLT AND NUT

Fig. Bolt and Nut.

A bolt is a form of threaded fastener with an external male thread. Bolts

are thus closely related to, and often confused with, screws.

BOLT HEADS

Bolts use a wide variety of head designs, as do screws. These are

designed to engage with the tool used to tighten them. Some bolt heads instead
lock the bolt in place, so that it does not move and a tool is only needed for the
nut end.

The first bolts had square heads, formed by forging. These are still found,
although much more common today is the hexagonal head. These are held and
turned by a spanner or wrench, of which there are many forms. Most are held
from the side, some from in-line with the bolt. Other bolts have T-heads and
slotted heads.

Many screws use a screwdriver head fitting, rather than an external

wrench. Screwdrivers are applied in-line with the fastener, rather than from the
side. These are smaller than most wrench heads and cannot usually apply the

8
same amount of torque. It is sometimes assumed that screwdriver heads imply a
screw and wrenches imply a bolt, although this is incorrect. Coach screws are
large square-headed screws with a tapered wood screw thread, used for
attaching ironwork to timber.

Head designs that overlap both are the Allen or Torx heads; hexagonal or
splined sockets. These modern designs span a large range of sizes and can carry
a considerable torque.

9
3.3 PULLEY

Fig. Pulley.

A belt and pulley system is characterised by two or more pulleys in

common to a belt. This allows for mechanical power, torque, and speed to be
transmitted across axles. If the pulleys are of differing diameters, a mechanical
advantage is realised.

A belt drive is analogous to that of a chain drive, however a belt sheave

may be smooth (devoid of discrete interlocking members as would be found on
a chain sprocket, spur gear, or timing belt) so that the mechanical advantage is
approximately given by the ratio of the pitch diameter of the sheaves only, not
fixed exactly by the ratio of teeth as with gears and sprockets.

In the case of a drum-style pulley, without a groove or flanges, the pulley

often is slightly convex to keep the flat belt centered. It is sometimes referred to
as a crowned pulley. Though once widely used on factory line shafts, this type

10
of pulley is still found driving the rotating brush in upright vacuum cleaners,
in belt sanders and band saws. Agricultural tractors built up to the early 1950s
generally had a belt pulley for a flat belt (which is what Belt Pulley magazine
was named after). It has been replaced by other mechanisms with more
flexibility in methods of use, such as power take-off and hydraulics.

Just as the diameters of gears (and, correspondingly, their number of

teeth) determine a gear ratio and thus the speed increases or reductions and
the mechanical advantage that they can deliver, the diameters of pulleys
determine those same factors. Cone pulleys and step pulleys (which operate on
the same principle, although the names tend to be applied to flat belt versions
and V belt versions, respectively) are a way to provide multiple drive ratios in a
belt-and-pulley system that can be shifted as needed, just as
a transmission provides this function with a gear train that can be shifted. V belt
step pulleys are the most common way that drill presses deliver a range of
spindle speeds.

11
3.4 SHAFT

Fig. 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. The various
members such as pulleys and gears are mounted on it.

12
3.5 HACKSAW

Fig. HackSaw.

A hacksaw is a fine-toothed saw, originally and principally made 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
hacksaws). Most hacksaws are hand saws with a C-shaped frame that holds
a blade under tension. Such hacksaws 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 hacksaws forgo the frame and instead
have a sheet metal body; they can cut into a sheet metal panel further than a
13
frame would allow. These saws are no longer commonly available, but hacksaw
blade holders enable standard hacksaw 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 hacksaws, 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, hacksaw 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.

14
3.6 V-BELT

Fig .V-belt.

V belts solved the slippage and alignment problem. It is now the basic
belt for power transmission. They provide the best combination of traction,
speed of movement, load of the bearings, and long service life. They are
generally endless, and their general cross-section shape is
roughly trapezoidal (hence the name "V"). The "V" shape of the belt tracks in a
mating groove in the pulley (or sheave), with the result that the belt cannot slip
off. The belt also tends to wedge into the groove as the load increases the
greater the load, the great the wedging action improving torque transmission
and making the V-belt an effective solution, needing less width and tension than
flat belts. V-belts trump flat belts with their small center distances and high
reduction ratios. The preferred center distance is larger than the largest pulley
diameter, but less than three times the sum of both pulleys. Optimal speed range

15
is 1,0007,000 ft/min (3002,130 m/min). V-belts need larger pulleys for their
thicker cross-section than flat belts.

For high-power requirements, two or more V-belts can be joined side-by-

side in an arrangement called a multi-V, running on matching multi-groove
sheaves. This is known as a multiple-V-belt drive (or sometimes a "classical V-
belt drive").

V-belts may be homogeneously rubber or polymer throughout, or there

may be fibers embedded in the rubber or polymer for strength and
reinforcement. The fibers may be of textile materials such as
cotton, polyamide (such as Nylon) or polyester or, for greatest strength, of steel
or aramid (such as Twaron or Kevlar).

When an endless belt does not fit the need, jointed and link V-belts may
be employed. Most models offer the same power and speed ratings as
equivalently-sized endless belts and do not require special pulleys to operate. A
link v-belt is a number of polyurethane/polyester composite links held together,
either by themselves, such as Fenner Drives' Power Twist, or Nu-T-Link (with
metal studs). These provide easy installation and superior environmental
resistance compared to rubber belts and is length-adjustable by disassembling
and removing links when needed.

16
3.7 O-TYPE CLAMP

Fig O-Clamp.

A clamp is a fastening device used to hold or secure objects tightly together to

prevent movement or separation through the application of inward pressure. In
the United Kingdom and Australia, the term cramp is often used instead when
the tool is for temporary use for positioning components during construction
and wood working; thus a G cramp or a sash cramp but a wheel clamp or a
surgical clamp.

17
There are many types of clamps available for many different purposes. Some
are temporary, as used to position components while fixing them together,
others are intended to be permanent. In the field of animal husbandry, using a
clamp to attach an animal to a stationary object is known as "rounded
clamping." A physical clamp of this type is also used to refer to an obscure
investment banking term; notably "fund clamps." Anything that performs the
action of clamping may be called a clamp, so this gives rise to a wide variety of
terms across many fields.

18
 CHAPTER 4

SCOTCH YOKE MECHANISM

This project is worked under by the

scotch yoke mechanism.
The scotch yoke mechanism convert the
rotary motion into the reciprocating motion.
Fig. scotch yoke mechanism
The machine has the prime mover at the bottom of the machine.
The pulley is attached to the body at the top and the end of the side
portion.
The pulley is connected with the disc type plate.
The pulley and the disc has separate connection with the one small
metal rod through the bearing.
The motor and pulley is connected with one V-type belt.
The clamp Is fixed with the disc. The clamp is fixed with the two shaft
at the two end.
The each shaft is act the reciprocating motion through the each shaft.
The hack saw connected to the each shaft at the end.
If the motor is turned on the pulley is getting rotating motion that rotation
motion Is convert Into the reciprocating motion and the cutting operation
takes place.

19
 CHAPTER 5

LAYOUT

Layout of double acting hachsaw using scotch yoke mechanism.

20
 CHAPTER 6

WORKING

In this project one electric motor is used to drive the system. Fly wheels
and two belt driven wheel is used in this project.

Belt driven wheels are connected with electrical motor to drive the
system. These wheels also used to give reduced and comet speed to fly wheel
mechanism. The fly wheel mechanism will give operating force to the
hacksaws.

Electrical motor is directly connected with belt driven wheel. The fly
wheel is mounted with belt driven wheel. This fly wheel is connected with
hacksaw through some mechanical arrangement. Electrical motor is used to
transfer the rotational force to flywheel through the belt. Flywheel mechanism
will give the front and back horizontal movement to hacksaw through
mechanical arrangements. This movement of hacksaw is used to cut the
workpieces.

21
 CHAPTER 7

DESIGN CALCULATION

= (1 cos )

Where - Angle between crank & connecting rod

R- Radius of crank 8.5cm 85mm

X- Displacement

I N1/N2 D2/D1 260/60 4.33

N1/N2 4.33 1300/N2 4.33

N2300rpm

Where N1- speed of pinion 1300rpm

N2- speed of pulley 300rpm

D1- dia of pinion 260mm

D2- dia of pulley 60mm

Angular velocity of crank 2N2/60

2300/60

31.4 rad/sec

22
Velocity of the frame,

For 10, X 1.29mm V ( 2 ) ( 2 )

V 31.4(852 ) (1.292 )

2668mm/s

2.66m/s

Acceleration of the frame a 2 x

31.42 1.29

1271.88mm/ 2

1.271mm/ 2

Power P 2NT/60

150 21300T/60

T 1.10Nm

23
 = ( ())
0 0
30 11.38
60 42.5
90 85
120 127.5
150 158.61
180 170
210 158.61
240 127.5
270 85
300 42.5
330 11.38
360 0

24
 CHAPTER 8

ADVANTAGES

Direct conversion of rotary motion into reciprocating motion.

Easy construction & operation.

Can perform various operations such as cutting, slotting etc.

Process can be automated.

DISADVANTAGES

High wearing rate due to mechanical contact.

Less application in real life.
Guide ways are necessary for proper reciprocating motion of arms.

APPLICATION

This setup is most commonly used in control valve actuators in high-

pressure oil and gas pipelines.
It is used in making double hack saw. It is used in reciprocating pumps
to convert rotational motion into reciprocating motion required for
piston movement.
It is used in beam engine pumps to convert rotational motion into
reciprocating motion.

25
 CHAPTER 9

COST ESTIMATION

SI No PARTS COST
1 MOTOR 300
2 PULLEY 100
3 BELT 80
4 HACKSAW FRAME 300
5 MATERIAL 1200
6 HACKSAW BLADE 30
7 VICE 40
8 PAINT 150
TOTAL 2200

26
 CHAPTER 10

CONCLUSION

In this project we designed a double acting hacksaw machine. This

machine is used to save time and man power in industries. This machine is used
for mass production and more effective to cut a work piece. This machine is
used to avoid energy loss. Scotch Yoke mechanism is used in this project

27
 CHAPTER 11

PHOTOGRAPHS

CHAPTER 12

CAD DIAGRAM

28
 CHAPTER 13

REFERENCE

29
1. Mack. R., Mueller, R., Crotts, J., & Broderick, A. (2000). Perceptions,
corrections and defections: implications for Scotch yoke mechanism, 10(6),
339-346.
2. Mattila, A.S. (2001). The effectiveness of service recovery in a multi-industry
setting. The Journal of Services Marketing, 15(7), 596-583.
3. McDougall, G.H.G., & Levesque, T.J. (1999).Waiting for service: the
effectiveness of recovery strategies. International Journal of Contemporary
mechanism 11(1), 6-15.
4. Michel, S. (2001). Analyzing service failures and recoveries a process
approach. International Journal of kinematic links,
5. Miller, J.L., Craighead, C.W., &Karwan, K.R. (2000). Service recovery: a
frame work and empirical Investigation. Journal of links Management, 18(4),
387-400.
6.Six types of service scotch-Yoke mechanism and rack and pinion mechanism
(Chase and Stewart, 1994)
7. Amrutesh P, Sagar B, Venu B. Solar grass cutter with linear blades by using
scotch yoke mechanism. Int Journal of Engineering Research and Applications.
2014 Sep; 4(9):1021.
8. Sermaraj M. Design and Fabrication of Pedal Operator Reciprocating Water
Pump. IOSR Journal of Mechanical and Civil Engineering.
9. Weli RB, Ibraheem RR, Abdulla KA. Water pumping using solar energy.
Journal of Science and Engineering. 2013; 3(1):3543.
10. Ikponmwosa O, Charles A. Development of an electric water pump
controller and level indicator. International Journal of Engineering and Applied
Sciences.

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