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TITLE PAGE
DESIGN AND FABRICATION OF A PEDAL OPERATED HACKSAW

BY

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EE/H2007/01430
DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
SCHOOL OF ENGINEERING
INSTITUTE OF ---

DECEMBER,2018

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APPROVAL PAGE

This is to certify that the research work,"design and fabrication of a pedal operated hacksaw" by ---, Reg. No. EE/H2007/01430 submitted in partial fulfillment of the requirement award of a Higher National Diploma on Electrical and Electronics Engineering has been approved.

By
Engr. ---                                                     Engr. ---
Supervisor                                                  Head of Department.
Signature……………….                           Signature……………….        

……………………………….
 Engr. ---
External Invigilator

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DEDICATION
This project is dedicated to Almighty God for his protection, kindness, strength over my life throughout the period and also to my --- for his financial support and moral care towards me.Also to my mentor --- for her academic advice she often gives to me. May Almighty God shield them from the peril of this world and bless their entire endeavour Amen.

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ACKNOWLEDGEMENT

The successful completion of this project work could not have been a reality without the encouragement of my --- and other people. My immensely appreciation goes to my humble and able supervisor mr. --- for his kindness in supervising this project.
My warmest gratitude goes to my parents for their moral, spiritual and financial support throughout my study in this institution.
My appreciation goes to some of my lecturers among whom are Mr. ---, and Dr. ---. I also recognize the support of some of the staff of --- among whom are: The General Manager, Deputy General manager, the internal Auditor Mr. --- and the ---. Finally, my appreciation goes to my elder sister ---, my lovely friends mercy ---, ---, --- and many others who were quite helpful.

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This project is on the design and construction of a pedal operated hacksaw machine. Pedal Powered Hacksaw Machine is a device which is used for cutting wood, plastic and metals. The basic principle of this machine is slider crank mechanism, which is an inversion of four bar mechanism. The concept of this mechanism is that the rotary motion is converted into reciprocating motion. The mechanism has four links connected to form sliding pair. Thus when one link is moved along the circumference of the circle, the final link will generate the sliding movement for cutting process.

TABLE OF CONTENTS
TITLE PAGE
APPROVAL PAGE
DEDICATION
ACKNOWLEDGEMENT
ABSTRACT
TABLE OF CONTENT
CHAPTER ONE
1.0      INTRODUCTION
1.1      BACKGROUND OF THE PROJECT
1.2      AIM OF THE PROJECT
1.3      OBJECTIVE OF THE PROJECT
1.4      SCOPE OF THE PROJECT
1.5     SIGNIFICANCE OF THE PROJECT
1.6      SCOPE OF THE PROJECT
1.7      LIMITATION OF THE PROJECT
1.7      PURPOSE OF THE PROJECT
1.8          APPLICATION OF THE PROJECT

CHAPTER TWO
2.0     LITERATURE REVIEW
2.1      REVIEW OF THE STUDY
2.2         REVIEW OF THE RELATED WORK
2.3      TYPES OF HACKSAWING
2.4      FEATURES OF MODERN HACKSAW
2.5      DESCRIPTION OF HACKSAW
2.6      REVIEW OF COMPONENTS USED

CHAPTER THREE
3.0     METHODOLOGY
3.1      PROPOSED METHODOLOGY
3.2      COMPONENTS USED AND CALCULATIONS
3.3      DESCRIPTION OF THE HACKSAW MACHINE
3.4 DESCRIPTION OF THE PROJECT SETUP

3.5      WORKING OF THE PROJECT
3.6      DESIGN DIAGRAM

CHAPTER FOUR
RESULT ANALYSIS
4.0      CONSTRUCTION PROCEDURE AND TESTING
4.1      CASING AND PACKAGING
4.2      ASSEMBLING OF SECTIONS
4.3      MOUNTING PROCEDURE
4.4      TESTING OF SYSTEM OPERATION
4.5      RESULT
4.6      COST ANALYSIS

CHAPTER FIVE     
5.0      CONCLUSION, FUTURE SCOPE, AND REFERENCES
5.1      CONCLUSION AND FUTURE SCOPE
5.2      RECOMMENDATION
5.2      REFERENCES

 

CHAPTER ONE
1.0                                                      INTRODUCTION
Pedal power is the transfer 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 hacksaw machining. An individual can generate four times more power (1/4 HP) by pedaling than by hand- cranking. At the rate of ¼ HP, continuous pedaling can be served for only short periods, approximately 10 minutes. However, pedaling 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.
The principle of pedal power hacksaw is to change circulatory motion or cycling motion into translatory motion with the help of metal cutting rod. This is mainly used for cutting metals and plastics. it is manually pedal operated system. If we use dynamo then we can produce electricity which will be help to lighting the work piece area when electricity is not available in mechanical workshop. A hacksaw is a fine- tooth saw with a blade under tension in a frame, used for cutting materials such as metal or plastics. Hand-held hacksaw consist of a  metal arch with a handle, usually a pistol grip, with pins for attaching a narrow disposable blade. A screw or other mechanism is used to used to put the thin blade under tension. It is a fine tooth hand saw with a blade under tension. It is used to cut metals and PVC pipes. It would be useful in many projects discussed on this site which used plastic pipes as materials. Blades of hacksaw are measured in TPI (Tooth per Inch). Different TPI is needed for different jobs of cutting.

1.1                                       BACKGROUND OF THE PROJECT
Generally, a hacksaw is a handheld tool used to cut through materials like plastic tubing and metal pipes. Its cutting mechanism is provided by removable blades which feature sharp teeth along their outer edge. In most cases, a hacksaw consists of a metal frame that resembles a downward- facing. A handle of plastic, wood, or metal is typically affixed to one end of the frame. The frame’s ends feature adjustable pegs that can be tightened to secure a blade in place, and loosened to remove it. Hacksaw blades are long, thin strips of hardened steel that feature a row of teeth along their cutting edge. Each end of the blade is punched with a small hole that fits onto the saw frame’s pegs. Most blades range in length from ten to 12inches (25.4 to 30.48 cm), although six-inch (15.24 cm) blades can be purchased to fit smaller hacksaw models.

1.2                                                 AIM OF THE PROJECT
The aim of this work is to design and construct a pedal driven hacksaw machine that will use a less effort pedaling power to produce uniform cutting of PVC pipes, metals, wood and as the same time serve as an exercising machine for fitness. it is also done to show the performance difference between hand driven and pedal driven hacksaw.

1.3                                              PURPOSE OF THE PROJECT
The main purpose this project is to save man power and time in cutting metals in order to achieve high productivity. It is a cutting machine with teeth on its blade used specially for cutting metals. This machine save man power and time in cutting metals and at the same time achieve high productivity.

1.4                                           OBJECTIVE OF THE PROJECT
The objective of this work is:

• To cater to the issue of competition in mechanical industry the need for automation is assess by all the industry.
• To identify the key policy avenues considered to be appropriate to meet the challenge of sustainable manufacturing and packaging industry for the future.
• To provide alternative for industries aiming toward reducing human effort and improvement in material handling system by implementing automation.
• Sustainable and practical automation solutions for the future industrial environment.

1.4                                         SIGNIFICANCE OF THE PROJECT
A device that applies force, changes the direction of a force, or changes the strength of a force, in order to perform a task, generally involving work done on a load. This machine is often designed to yield a high mechanical advantage to reduce the effort needed to do that work. A simple machines a wheel, a lever or an inclined plane. All other machines can be built using combinations of these simple machines.

• The machine can solve the problem of time consumption.
• Waste of resources in face of labor cost is reduced.
• The machine can be used in the industry where it is manufactured, at the packaging sector.
•  And it is used as hardware in large quantity like in fabrication of machine
• It provide alternative for industries aiming toward reducing human effort
•  It generates sustainable and practical automation solutions for the future industrial development.

1.5                                                 SCOPE OF THE PROJECT

• Working medium adopted is mechanical power.
• The machine works without the help of electricity.
• The rotary motion of the pedalling operation performed to our required on the cutting job.
• The work piece is clamped on the work table using suitable clamp devices like clamp.
• After clamping by pedalling the rotary motion of the pedal is converted into to and fro motion of the cutting tool and cutting operation takes place on the work piece.
• After machining work piece is removed and cleaned

1.6                                      NEED FOR THE PROJECT

The operation of the system is based on the mechanization. Mechanization is the process of doing work with machinery. In an early engineering text a machine is defined as follows:
“Every machine is constructed for the purpose of performing certain mechanical operations, each of which supposes the existence of two other things besides the machine in question, namely, a moving power, and an object subject to the operation, which may be termed the work to be done. Machines, in fact, are interposed between the power and the work, for the purpose of adapting the one to the other.” In some fields, mechanization includes the use of hand tools. In modern usage, such as in engineering or economics, mechanization implies machinery more complex than hand tools and would not include simple devices such as an un- geared horse or donkey mill. Devices that cause speed changes or changes to or from reciprocating to rotary motion, using means such as gears, pulleys or sheaves and belts, shafts, cams and cranks, usually are considered machines. After electrification, when most small machinery was no longer hand powered, mechanization was synonymous with motorized machines
This work is design to overcome the stress attached to hand cutting of engineering materials by turning it into an exercise for body fitness.

1.7                               LIMITATIONS OF THE PROJECT

• Leads to physical stress
• High thick wood cannot be cut
• More amount of human efforts is required.

 

1.8                                          ADVANTAGES OF THE PROJECT

• Pedal powered hacksaw can be used for light duty cutting operations of plywood.
• Pedal powered hacksaw can be used in remote places where electricity is not available.
• It is designed as a portable one which can be used for cutting in various places.
• The ply wood can be cut without any external energy like fuel or current.
• Since Pedal powered hacksaw uses no electric power and fuel, this is very cheap and best.
• Pedal powered hacksaw saw helps to obtain less effort uniform cutting.
• There are fewer losses in power transmission by using pedal powered hacksaw
• As pedalling is done by human it is good exercise and is goo to health.

1.9                                        APPLICATION OF THE PROJECT

• In a furniture making industry at production it is widely used
• It can perform cutting operation in various kinds of industries.
• This     machine        can     be       applied          in carpentry and plumbing works also.

 

1.10                                       PROJECT WORK ORGANISATION
The various stages involved in the development of this project have been properly put into five chapters to enhance comprehensive and concise reading. In this project thesis, the project is organized sequentially as follows:
Chapter one of this work is on the introduction pedal operated hacksaw. In this chapter, the background of pedal operated hacksaw, significance of pedal operated hacksaw, scope of a pedal operated hacksaw, objective of a pedal operated hacksaw, the need for a pedal operated hacksaw(benefit),  limitation and problem of a pedal operated hacksaw, and advantages of pedal operated hacksaw was discussed.
Chapter two is on literature review of the study. In this chapter, all the literature pertaining to this work was reviewed.
Chapter three is on design methodology. In this chapter all the method involved during the design and construction were discussed.
Chapter four is on testing analysis. All testing that result accurate functionality was analyzed.
Chapter five is on conclusion, recommendation and references.

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CHAPTER TWO: The complete chapter two of "design and fabrication of a pedal operated hacksaw"is available. Order full work to download. Chapter two of"design and fabrication of a pedal operated hacksaw" consist of the literature review. In this chapter all the related work on "design and fabrication of a pedal operated hacksaw" was reviewed.

CHAPTER THREE: The complete chapter three of"design and fabrication of a pedal operated hacksaw"is available. Order full work to download. Chapter three of"design and fabrication of a pedal operated hacksaw"consist of the methodology"design and fabrication of a pedal operated hacksaw". In this chapter all the method used in carrying out this work was discussed.

CHAPTER FOUR: The complete chapter four of"design and fabrication of a pedal operated hacksaw" is available. Order full work to download. Chapter four of"design and fabrication of a pedal operated hacksaw"consist of all the test conducted during the work and the result gotten after the whole work

CHAPTER FIVE: The complete chapter five of"design and fabrication of a pedal operated hacksaw" is available. Order full work to download. Chapter five of"design and fabrication of a pedal operated hacksaw"consist of conclusion, recommendation and references of"design and fabrication of a pedal operated hacksaw".

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