Professional Documents
Culture Documents
Submitted in partial fulfillment for the requirements for the award of the degree of the
BACHELOR OF TECHNOLOGY
(MECHANICAL ENGINEERING)
By
K.BALAJI 081131201026
K.BASKARAN 081131201038
V.DHANASEKAR 081131201054
R.DHIVAKAR 081131201057
Dr.M.G.R EDUCATIONAL AND RESEARCH INSTITUTE
(Dr .M.G.R DEEMED UNIVERSITY)
MADURAVOYAL,CHENNAI-600 095.
NAME :
REG. NO. :.
SEC : .
Dr. M.G.R. Educational and Research Institute
DEPARTMENT : .
(Dr. M. G. R. University)
Maduravoyal, Chennai 600 095.
November 2015.
Dr. M.G.R. EDUCATIONAL AND RESEARCH INSTITUTE
Dr. M.G.R. UNIVERSITY
DEPARTMENT OF MECHANICAL ENGINEERING
CHENNAI 600 095.
Dr.M.G.R EDUCATIONAL AND RESEARCH INSTITUTE
(Dr .M.G.R DEEMED UNIVERSITY)
MADURAVOYAL,CHENNAI-600 095.
NAME :
BONAFIDE CERTIFICATE
REG. NO. :.
SEC : .
DEPARTMENT : .
We wish to expand our sincere thanks and our whole-hearted gratitude to the
following persons. At the outset, we would like to convey our grateful thanks to our
Chairman Mr. A.C. Shanmugam, our Pro-Chancellor Mr. A.C.S.Arun Kumar, our
implications, without which our project would not have been sculpted successfully.
OBJECTIVE
The most important objective function is to minimize the cost and overcome problems
(1) The main objective of this project is to reduce the human effort for machining
various materials.
(2) The basic principles of power driven hacksaw or two way hacksaw is Scotch Yoke
Mechanism.
(3) The objective of this project is to save man power and time in cutting materials in
order to achieve high productivity.
(4) By using scotch yoke Mechanism we can operate four hacksaw at same time.
Literature Review:-
Literature Review:-
The vast review of literature will help to understand the concepts, theorems and
different factors affecting the performance of machine:-
3.1 Dharwa Chaitanya Kirtikumar:-
In this paper we study about the designed and developed a multipurpose machine
which does not require electricity for several operations like cutting, grinding, etc. this
is a human powered machine runs on chain drives mainly with human efforts. But if
you wanted to operate this machine by electric power this machine can also does that.
It has some special attachment so use both human power as well as electric power.
The design is idle for use in the developing world because it doesnt require electricity
and can be built using metal base, chain, pulley, rubber belt, foot pedal electric motor,
chain socket.
3.2 R. Subash, K Samuel Jayakaran (2014) :-
In this paper author has designed pedal operated hacksaw machine which can be used
for industrial applications and households needs in which no specific input energy or
power is needed. This project consist of sprocket arrangement, crank and slider
mechanism, and chain drive. In the mechanism, chain derive is directly connected to
the hacksaw for the processing of cutting the wooden blocks. The objective of the
paper 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.
3.3 Prof. Nitinchandra, R. Patel, Ravi Thakkar:-
In his paper Material Selection And Testing Of hacksaw Blade Based On
Mechanical Properties stated that the appropriate saw blade must be selected for
better operation and fine cutting by selecting number of teeth per inch. There are four
blades based on materials namely listed below:-
High Carbon Steel
Alloy Steel
Bi-Metallic Strip
Out of this four best suitable for cutting hard materials like mild steel bar and
aluminum is bi-metallic blade on the basis of properties of materials, wear resistance
and cutting performance.
ABSTRACT
ABSTRACT
This project proposes the model of two way hacksaw machine which is
able to cut two pieces (may be of same or different material) simultaneously with a
very less time consumption. The model using DC motor for its operation. Conversion
of rotary motion of dc motor into reciprocating motion is obtained by using scotch
yoke mechanism . This model can perform a cutting operation on two different
components of different material simultaneously. It becomes very useful in industry
due to its efficiency, reliability and compatibility.
WHAT IS OPTIZATION ???
History
at an angular velocity .
If r is the radius of the crank then,
x-axis
Tangential velocity, v= r.
u = v.sin
Advantage of SHM
means employed to
transmit and modify
motion in a machine or any
assemblage of mechanical
parts. The chief
characteristic of the
mechanism of a machine is
that ALL
CONSTRUCTION
CONSTRUCTION
This unit consists of following parts ;
1. 24VDC motor with built in gear box
2. 24 VDC power supply
3. Two numbers of hacksaw with blade
4. Crank disc with motor coupler
5. Yoke
6. M.S. Fabricated stand
1. 24VDC MOTOR WITH BUILT IN GEAR BOX;
This DC motor is shunt type 24V DC motor. This motor is having built in type speed
reduction gear box unit. It has high torque and low speed capacity. The electrical
supply to the motor is from 24V DC power supply. The DC Motor drives the Crank
wheel mechanism.
rectifier diodes. .This voltage is used for supply for the DC motor.
STEP DOWN TRANSFORMER:
circuit the transformer of 230V/12-0-12V is used to perform the step down operation
where a 230V AC appears as 24V AC across the secondary winding. Apart from
stepping down voltages, it gives isolation between the power source and power supply
circuitries.
RECTIFIER UNIT:
In the power supply unit, rectification is normally achieved using a solid state
diode. Diode has the property that will let the electron flow easily in one direction at
proper biasing condition. As AC is applied to the diode, electrons only flow when the
anode and cathode is negative. Reversing the polarity of voltage will not permit
electron flow. A commonly used circuit for supplying large amounts of DCpower is
the bridge rectifier. A bridge rectifier of four diodes (4 x IN4007) are used to achieve
full wave rectification. Two diodes will conduct during the negative cycle and the
other two will conduct during the positive half cycle, and only one diode conducts. At
the same time one of the other two diodes conducts for the negative voltage that is
applied from the bottom winding due to the forward bias for that diode. In this circuit
due to positive half cycle D1 & D2 will conduct to give 0.8V pulsating DC. The DC
output has a ripple frequency of 100Hz. Since each alteration produces a resulting
output pulse, frequency = 2 x 50 Hz. The output obtained is not a pure DC and
The DC voltage appearing across the output terminals of the bridge rectifier will
be somewhat less than 90% of the applied rms value. Normally one alteration of the
input voltage will reverse the polarities. Opposite ends of the transformer will
therefore always be 180 degree out of phase with each other. For a positive cycle, two
FILTERING CIRCUIT:
Filter circuits which is usually capacitor acting as a surge arrester always follow
the rectifier unit. This capacitor is also called as a decoupling capacitor
3. Two numbers of hacksaw with blade
The sawing machine is a machine tool designed to cut material to a desired length or
contour. It functions by drawing a blade containing cutting teeth through the work piece. The sawing
machine is faster and easier than hand sawing and is used principally to produce an accurate square
or mitered cut on the work piece.
The power hacksaw and the handsaw are two common types of sawing machines used to cut metal in
the machine shop .The power hacksaw uses a reciprocating (back and forth) cutting action similar to
the one used in a hand hacksaw. The power hacksaw is used for square or angle cutting of stock, The
band saw uses a continuous band blade. A drive wheel and an idler wheel support and drive the
blade.
Fig 11 Hacksaw
HACKSAW BLADE
The selections of the blade depend upon the materials which have to cut by the
hacksaw. These blades are ideal to use when the work is held securely and the blade is not subjected
to bending and twisting stresses. They hold the edge when cutting hard to machine Alloys,
maintaining straightness of the cut. The blades are uniformly hardened throughout.
The most common blade is the 12 inch or 300 mm length. Hacksaw blades have two
holes near the ends for mounting them in the saw frame and the 12 inch / 300 mm dimension refers
to the center to center distance between these mounting holes.
12 Inch Blade
Hole to Hole: 11 7/8 inches / 300 mm
Overall blade length: 12 3/8 inches / 315 mm (not tightly controlled)
Mounting Hole diameter: 9/64 to 5/32 inch / 3.5 to 4 mm (not tightly controlled)
Blade Width: 7/16 to 33/64 inch / 11 to 13 mm (not tightly controlled)
Blade Thickness: 0.020 to 0.027 inches / 0.5 to 0.70 mm (varies with tooth pitch and other factors)
The hacksaw is used to cut steel and other metals. It can also be used to cut plastics,
although it is not normally used to cut Woods. It is sometimes called an adjustable hacksaw because
the length of the frame can be altered to hold blades of Different sizes. Blades are supplied in two
lengths, 250mm and 300mm. If the adjusting screw is unscrewed, the frame can Be pushed into the
handle so that the smaller blades fit the hacksaw. Blades are also described by the number of teeth
per inch (TPI). Blades very fine.
M.S.FABRICATED STAND
yoke
Crank disc
WORKING PRINCIPLE
WORKING PRINCIPLE
When the power is supplied to the 24v Dc motor, shaft and crank attached to
the shaft start rotating. As the crank rotates the pin slides inside the yoke and also
moves the yoke forward. When the crank rotates through in clockwise direction the
yoke will get a displacement in the forward direction. The maximum displacement
will be equal to the length of the crank. When the crank completes the next of rotation
the yoke comes back to its initial position. For the next of rotation, yoke moves in the
backward direction. When the crank completes a full rotation the yoke moves back to
the initial position..
The yoke is connected to reciprocating rod with hacksaw frame on both sides. Two
hacksaw frames are reciprocated to cut the PVC tube which is screwed in the table.
ADVANTAGES AND
DISADVANTAGES
ADVANTAGES AND DISADVANTAGES
At a single point of time it can able to cut more than one job of any required
size.
It is easily portable.
Rapid wear of the slot in the yoke caused by sliding friction and
high contact pressures.
Lesser percentage of the time spent at bottom dead centre
reducing blow down time for two stroke engines.
The shape of the motion of the piston is a pure sine wave over time
given a constant rotational speed.
Applications:
1. Cutting of two metal piece at the same time.
2. Cutting of wooden workpieces.
3. Cutting of plastic materials and PVC pipes.
RESOURCES USED
Materials Dimensions
Mild steel plates 1. 25 mmX25mm x 3 mm
L angle
2. 50 mm x 2.5 mm
M.S.flat
EQUIPMENT USED
1. Lathe Machine
2. Drilling machine
3. Grinding machine
4. Power tools
5. Power Hacksaw
Good science project does not stop with building a motor. It is very important to
measure different electrical and mechanical parameters of your motor and calculate
unknown values using the following helpful formulas.
We will use the International System of Units (SI). This is modern metric system that
is officially accepted in electrical engineering in the USA.
One of the most important laws of physics is the fundamental Ohms Law. It states
that current through the conductor is directly proportional to applied voltage and is
expressed as:
I=V/R
where I current, measured in amperes (A);
V applied voltage, measured in volts (V);
R resistance, measured in ohms ().
This formula could be used in many cases. You may calculate the resistance of your
motor by measuring the consumed current and applied voltage. For any given
resistance (in the motors it is basically the resistance of the coil) this formula explains
that the current can be controlled by applied voltage.
The consumed electrical power of the motor is defined by the following formula:
Pin = I * V
where Pin input power, measured in watts (W);
I current, measured in amperes (A);
V applied voltage, measured in volts (V).
Motors supposed to do some work and two important values define how powerful the
motor is. It is motor speed and torque the turning force of the motor. Output
mechanical power of the motor could be calculated by using the following formula:
Pout = *
where Pout output power, measured in watts (W);
torque, measured in Newton meters (Nm);
angular speed, measured in radians per second (rad/s).
It is easy to calculate angular speed if you know rotational speed of the motor in rpm:
= rpm * 2 / 60
where angular speed, measured in radians per second (rad/s);
rpm rotational speed in revolutions per minute;
mathematical constant pi (3.14).
60 number of seconds in a minute.
If the motor has 100% efficiency all electrical power is converted to mechanical
energy. However such motors do not exist. Even precision made small industrial
motors such as one we use as a generator in generator kit have maximum efficiency of
50-60%. Motors built from our kits usually have maximum efficiency of about 15%
(see Experiments section on how we estimated this).
Dont be disappointed with 15% maximum efficiency. All our kits are intended for
education and not designed for real applications. This efficiency is not bad at all it is
actually much better than most of other self made designs on Internet can provide. The
motors have enough torque and speed to do all kinds of experiments and calculations.
Measuring the torque of the motor is a challenging task. It requires special expensive
equipment. Therefore we suggest calculating it.
Efficiency of the motor is calculated as mechanical output power divided by electrical
input power:
E = Pout / Pin
therefore
Pout = Pin * E
after substitution we get
*=I*V*E
* rpm * 2 / 60 = I * V * E
and the formula for calculating torque will be
= (I * V * E *60) / (rpm * 2)
Connect the motor to the load. Using the motor from generator kit is the best way to
do it. Why do you need to connect the motor to the load? Well, if there is no load
there is no torque.
Measure current, voltage and rpm. Now you can calculate the torque for this load at
this speed assuming that you know efficiency of the motor.
Our estimated 15% efficiency represents maximum efficiency of the motor which
occurs only at a certain speed. Efficiency may be anywhere between zero and the
maximum; in our example below 1000 rpm may not be the optimal speed so the for
the sake of calculations you may use 10% efficiency (E = 0.1).
Example: speed is 1000 rpm, voltage is 6 Volts, and current is 220 mA (0.22 A):
In our example input electrical power of the motor is 0.22 A x 6 V = 1.32 W, output
mechanical power is 1000 rpm x 2 x 3.14 x 0.00126 Nm /60 = 0.132 W.
Motor torque changes with the speed. At no load you have maximum speed and zero
torque. Load adds mechanical resistance. The motor starts to consume more current to
overcome this resistance and the speed decreases. If you increase the load at some
point motor stops (this is called stall). When it occurs the torque is at maximum and it
is called stall torque. While it is hard to measure stall torque without special tools you
can find this value by plotting speed-torque graph. You need to take at least two
measurements with different loads to find the stall torque.
How accurate is the torque calculation? While voltage, current and speed could be
accurately measured, efficiency of the motor may not be correct. It depends on the
accuracy of your assembly, sensor position, friction, alignment of the motor and
generator axles etc. If you want to get meaningful numbers you might use a second
generator kit as explained in Torque and Efficiency Calculation section.
Speed, torque, power and efficiency of the motors are not constant values. Usually the
manufacturer provides the following data in a table like this one (sample data from
one of the motors used in generator kit):
Also the manufacturers usually provide power curves for the motor at nominal
voltage:
These curves are generated by plotting motor speed, consumed current, and efficiency
as functions of the motor torque. Sometimes there might be also a curve representing
mechanical output power.
As you can see from the graph speed and current are linear functions of torque so you
might need only two measurements to draw these graphs. Efficiency and power will
need more data. Usually for small motors maximum power is at 50% of stall torque
(approximately 50% of no load speed). Maximum efficiency may be 10-30% of motor
stall torque (70-90% of no load speed).
While it is technically better to follow the same format and create similar curves for
your motor it is not absolutely necessary for a good science project. You may take all
measurements, calculate unknown values and plot the graphs where for example speed
and torque are represented as functions of applied voltage or current etc.
THEORY
The Scotch yoke is a mechanism for converting the linear motion of a slider into
rotational motion or vice-versa. The piston or other
reciprocating part is directly coupled to a sliding
yoke with a slot that
FIGURE 1.1
engages a pin on the
rotating part. The shape of the motion of the piston
is a pure sine wave over time given a constant
rotational speed.fig 1.1 illustrates a simple scotch
yolk mechanism
The advantages compared to a standard crankshaft and connecting rod setup are:
Applications
This setup is most commonly used in control valve actuators in high pressure oil
and gas pipelines.
It has been used in various internal combustion engines, such as the Bourke
engine, SyTech engine, stirling,and many hot air engines and steam engines.
Refer to fig 1.2
Experiments have shown that extended dwell time will not work well with
constant volume combustion (Otto, Bourke or similar) cycles.Gains might be
more apparent using a stratified direct injection (diesel or similar) cycle to
reduce heat losses.
DESCRIPTION OF HACKSAW
MACHINE
3.1 Types of Hacksaw Machine
Your quest for finest quality hydraulic hacksaw machine ends with us. We are
recognized as one of the chief power hacksaw machine manufacturers of India. The
hacksaw machine manufactured by us is used at length in number of industries.
(2) Corrosion-resistance.
Supreme efficiency and long term durability are blended in Circular Band
SawMachine provided by us. Being durable and rendering unparalleled service, band
saw machine manufactured by us is gaining lot of popularity in appreciation of
customer's requirement. We offer circular band saw machines in varied sizes ranging
from 10' to 14'.
Horizontal swing type band saw is manufactured by us in integral front and rear
bed design. The entire assortment of these machines has large cross section of swing
frame and ensures high speed productivity. All these horizontal swing type band saw
machines are widely demanded in engineering industries for various cutting
applications.
Very useful for preparing specimen of big size in anatomy and meat
departments. Fitted with large moving table and extension table operated on four ball-
bearing rollers.
Used extensively in the meat packing, and wholesale fish industry, for handling
swordfish and large halbutes etc.
The top maker of jig saws is Skill, A jig saw is both versatile and very safe to
use. Ajigsaw combines the functions of band saw, a router, circular saw, and a scroll
saw into one portable tool.
There are both corded jig saws and cordless jig saws - each offering its
advantagesand disadvantages.
The corded jig saws are extremely convenient in remote areas and are best
suited to cut wood and wood products. They are available from 12 to 18 volts and
higher voltage equates to a battery that lasts longer.
Universal Type Circular Saw machines which are used for paneling, cutting or ripping
lumber.
This wonderful circular saw machine is available in two different ways which
are automatic circular saw and semi-automatic circular saw.
Double Column Band Saw Machine is equipped with rigid chrome plated
double column, separate electrical panel, infinitely variable feed with flow control
valves and power driven wire brush.
The range of band saw machine is hydraulically operated dual clamping system.
Its application is used in engineering industry and construction industry.
Chain Saw Machines is specially designed for square hole in wood for doors
and windows. This machine is used for mass production of square hole operation.
Hacksaw Machines offered by us are used for metal cutting ranging from
transportable model to giant size machine. Owing to smooth & speedy functioning
abilities, these hacksaw machines operations spontaneously for aiding the worker in
consistently carrying his work with ultimate competence.
(a) Bed: -The bed is available as a single piece casting. It has wide rigid casting for
the collection of coolant, swarf and also houses the V-belt device.
(b) Saw Frame: - The rigid saw frame ensures a square & parallel cut & the cut takes
place on the backward pull stroke. To prevent the wear of the blade, it is hydraulically
lifted out of contact with work place on the forward stroke up.
There are two type of saw frame:
Solid frame
Adjustable frame
(1) Solid Frame: - In this type, only one particular standard length of blade can be
used with this frame.
(2) Adjustable Frame: - In this type different standard lengths of blades can be fitted
to this frame.
Fig 3.2.2 Adjustable frame
(c) The Drive: - The drive is attached through V-Pulleys with provision to adjust the
complete tension of the V-Belts. The shafts are fitted with ball bearings and taper and
ball bearings to eliminate friction.
(d) Speed: - Specific speeds have been provided for different kind of metals in order
to make it suitable. High speed for metals like mild steel, brass, copper etc. and low
speed for cast iron.
(e) Feed saw: - Two levers are provided to hydraulically control the Feed Saw at the
dash-pot. One controls the rate of feed and the other enables the bow slide to be raised
or lowered and after the completion of the cut, the motor gets automatically switched
off.
(f) Vice: - The vice is rigid construction. It has two jaws, one jaw remains fixed and
the other is adjusted according to the size of the material to be cut.
(g) Coolant: - A coolant tank is enclosed within the base of machines with constant
speed to supply continuous cooling to the saw blade.
(h) Electricals: - A Push button starter is fitted with an adjustable trip mechanism that
helps in stopping the machine soon when the blade is clear from the work at extra cost.
Fig 3.3.1 Teeth pitch
(2) Blade length which is the length between the centers of its pin holes.
CONCLUSION AND
FUTURE RESEARCH
CONCLUSION AND FUTURE RESEARCH
From above discussion we conclude that model of two way hack saw is helpful to
overcome the problems of conventional hack saw with high efficiency its easy to
operate and simple in construction.
By increasing the motor power and dimensions of eccentric cam the size of material to
be cut can be increased.
By using limit switches or sensors Automatic feeding mechanism for material can be
introduced.
Automatic lifting up mechanism for frame when cutting operation can be by using
hydraulic piston and cylinder.
CONCLUSION
CONCLUSION
The scotch yoke mechanism is made and its advantages and disadvantages are
discussed. Its motion characteristics are studied. It is concluded that this mechanism is
a good choice to convert rotating motion into reciprocating motion because of fewer
moving parts and smoother operation. It can be used in direct injection engines like
diesel engines, hot air engines.
(4) Prof. Nitinchandra R. Patel, Mohammad A.Vasanwala, Balkrushna B. Jani, Ravi Thakkar,