DESIGN AND ANALYSIS OF CROP CUTTER

CHAPTER-01

INTRODUCTION

INTRODUCTION

In the country like India where the main source of income is agriculture. Needs to concentrate in
some aspects like how to increase productivity and profit, how to reduce cost and how to solve
and ease the problems of workers. To overcome this a new manually operated cutter is fabricated
for cutting of multiple types of crop during harvesting and named as Multi Crop Cutter. It
possesses four criterion ease in manufacturing, ease in handling, low cost and light weight. There
are some procedures involved in fabrication of this device such as fabricating prototypes,
material & component selection, etc. Today, India ranks second among other countries across the
globe in farm output. Agriculture and allied sectors like forestry and fisheries accounted for
13.7% of the GDP in 2013, about 50% of the workforce. The economic contribution of
agriculture to India's GDP is steadily decreasing with the country's broad-based economic
growth. Still, agriculture is a demographically broad economic sector and plays a important role
in the overall socio-economic fabric of India. According to WHO, Slow agricultural growth is a
interest for policymakers as two-thirds of Indias people depend on rural employment for a
living. The agricultural practices which are currently employed are neither economically nor
environmentally sustainable and India's yields for many agricultural material are comparatively
low. Improperly maintained irrigation systems and almost universal lack of good extension
services are among the factors responsible. Farmers' access to markets is hampered by poor
roads, rudimentary market infrastructure, and excessive regulation.

1.1.NEED FOR INVENTION

Crop cutting machine is more important for the maintenance of farms. The power source of
riding movers for example are powered by engine (gasoline) and are ridden and steered by the
operator. It is designed in such a way that the operator pushes the machine from behind and
typically run on gasoline or electricity. Modern gas and electric powered lawn movers cuts grass
with a single blade rotating at a high speed parallel to the ground. Mulch movers suspends
clippings and other debris near the blade shredding them before blowing them straight down in
the lawn where they serve for lawn growth. Koori, (2010) designed a operated engine powered
crop cutter. The machine is fitted with horizontal blade attached to a vertical shaft. The machine
was tested ,the efficiency and average effective field capacity were 88.4% and 0.127 ha/hr
respectively. Jeremy, In 2005 designed and fabricated solar charged cutter machine. The
machine was dependent on weather since the battery would be charged using solar panel. The
common drawback was that the engine runs slowly and the production cost was high for an
average individual to purchase. Until engines were small enough and powerful enough to run the
blades at a high speed ,rotary movers were not developed. people experimented with rotary
blades in the late 1930s and early 1940s, and Power Specialties Ltd. introduced a gasoline
powered rotary mover. His concept was the use of a toothed circular saw blade mounted
horizontally on a vertical shaft, which would be suspended at a height of 2 inches (50 mm) and
moved across a lawn to cut grass and other lawn at a uniform height. The power for his
experimental mower was an electric motor. The success of Stacy's design was limited by two
factors: the relatively small diameter of the saw blades he used for his experiments, which were
about 8 inches (200mm); and the fact that toothed circular saw blades are not an ideal tool for
cutting freestanding grass and other plants. Stacy did not come up with any idea for a cutter
similar to modern rotary mower straight blades, and soon dropped his experiments with rotary
mowing. Ballads developed this into what he called the "Weed Eater", since it eaten up the grass
and weeds around trees. Victor and Verns, (2003) designed and developed a power operated
rotary weedier for wet land paddy. The complex nature of the machine makes its maintenance
and operation difficult for the peasant farmers. Generally, in India, the conventional methods of
crop cutting involved the use of cutlasses which satisfies to max. More so, it is complicated, time
and labour intensive. In world the usage of agriculture equipment is increasing. In the usage of
agriculture tools, India contributes only 16% as Conducted survey in year 2011.two types of
cutting methods generally available are 1.Manual method 2. Mechanized type of harvesting In
Manual Harvesting to cut one acre of crop With reference to literature available there are many
types of crop, bushcutters and lawn tractors are exist in the market, which may not fulfill the
capital andoperational cost criteria. The top concentration of our design is the cost and
operational ease in case small form units it is very costly, so we decide to develop the
newharvesting machine to reduce the cost of harvesting. We start research on the cuttingmethods
and machines. In the development of ultraportable crop cutter we utilize the pastdata and
techniques. Therefore, there is the need to develop a locally, fabricated Multiple CropCutter.

1.2.CROP CUTTER

To overcome all issues a new manually handled and engine operated cutter is fabricated
for cutting of multiple types of crop like paddy, wheat, oil seeds, and pulses etc. named as
Multiple Crop CuttingMachine. There is two types of blades are used according to need
of crops

1.2.1.PADDY CUTTER

The small paddy reaper machine is used for harvesting rice, wheat, soybean, forage grass and
other simple Individual plants. ... Our Paddy Cutter can be also used for cuttingsmall kind of
other crop and weeds.

1.2.2.WHEAT CUTTER

Wheat Crop Cutting Machine offered provides for flawless functional support and can be used
for harvesting/cutting of different types of corps. ... We offer best quality Crop cuttingmachine
which is very useful for crop harvesting like Rice (Dhaan), Wheat, Grass, Khar-Patwar, soybean,
weeds, etc

1.2.3. BRUSH CUTTER

You use a brush cutter for clearing grass, small bushes and undergrowth. ... With the right
accessories, you can use the same machine for trimming grass, clearing undergrowth and shrubs
as well as thinning out smaller trees. The brush cutter is fitted with a longer shaft to increase its
working range.
1.3. MATERIALS USED FOR SAWS

For the drive shaft we choose the EN8 (medium carbon steel) material, it is economical and
having the required strength for the equipment. The Multi crop cutter is
designed, fabricated and tested. ... This is new type of machine which is different to the
other cutting machine which are used for harvesting purpose till now.

There are several materials used in cutter, with each of its own specifications. The material used
are determine by what the blade is used for. There are certain materials that are commonly used
to make blade. They are explained below.

1.3.1Brass

Mostly used in back saws because of its low price, its flow characteristics that make the
material relatively easy to cast, and unlike other types of saw, the forces that take place in back
saws are relatively low because of the pulling motion used.

1.3.2Steel

Used in almost every existing kind of saw. Because steel is cheap, easy to shape, and
very strong, it has the right properties for most kind of saws.

1.4CROP CUTTER

In the country like India where the main source of income is agriculture. Needs to concentrate in
some aspects like how to increase productivity and profit, how to reduce cost and how to solve
and ease the problems of workers. To overcome this a new manually operated cutter is fabricated
for cutting of multiple types of crop during harvesting and named as Multi Crop Cutter. It
possesses four criterion ease in manufacturing, ease in handling, low cost and light weight. There
are some procedures involved in fabrication of this device such as fabricating prototypes,
material & component selection, etc. Today, India ranks second among other countries across the
globe in farm output. Agriculture and allied sectors like forestry and fisheries accounted for
13.7% of the GDP in 2013, about 50% of the workforce. The economic contribution of
agriculture to India's GDP is steadily decreasing with the country's broad-based economic
growth. Still, agriculture is a demographically broad economic sector and plays a important role
in the overall socio-economic fabric of India.

1.5 CUTTING

Cutting sheet metal can be done in various ways from hand tools called tin snips up to
very large powered shears. With the advances in technology, sheet metal cutting has turned to
computers for precise cutting.

Cutting is the separation of a physical object, or a portion of a physical object, into two
portions, through the application of an acutely directed force. An implement commonly used for
cutting is the knife or in medical cases the scalpel. However, any sufficiently sharp object is
capable of cutting if it has a hardness sufficiently larger than the object being cut, and if it is
applied with sufficient force. Cutting also describes the action of a saw which removes material
in the process of cutting.

Cutting is a compressive and shearing phenomenon, and occurs only when the total stress
generated by the cutting implement exceeds the ultimate strength of the material of the object
being cut. The simplest applicable equation is stress = force/area: The stress generated by a
cutting implementis directly proportional to the force with which it is applied, and inversely
proportional to the area of contact. Hence, the smaller the area (i.e., the sharper the cutting
implement), the less force is needed to cut something.

When referring to propagating plants, cutting is one of the methods that can be used. It
involves cutting a part of the plant typically a healthy shoot, with sharp and sterile scissors or any
other cutting device, and then placing the removed part in water. Some cuttings do not require
water. Certain shoots when cut are able to grow when placed in vermiculite or potting soil.
However, the former is the easiest to do as most shoots when cut from the main plant need time
to grow roots, and then they are able to be transferred to potting.
1.6 VICE

It is a device consisting of two parallel jaws for holding a work piece; one of the jaws is fixed
and the other movable by a screw, a lever, or a cam. When used for holding a work piece during
hand operations, such as filing, hammering, or sawing, the vise may be permanently bolted to a
bench. In vises designed to hold metallic work pieces.

The active faces of the jaws are hardened steel plates, often removable, with serrations that
grip the work piece to prevent damage to soft parts; the permanent jaws can be covered with
temporary jaws made from sheet copper or leather. Pipe vises have double V-shaped jaws that
grip in four places instead of only two. Woodworking vises have smooth jaws, often of wood,
and rely on friction alone rather than on serrations.

1.7 SPRING

The automobile chassis is mounted on the axles not direct but through some form of
springs. This is done to isolate the vehicle body from the road shocks which may be in the form
of bounce, pitch, roll or sway. These tendencies give rise to an uncomfortable ride and also cause
additional stress in the automobile frame and body. All the parts which perform the function of
isolating the automobile from the road shocks are collectively.

1.8 CAM PLATE

A cam plate is a projecting part of a rotating wheel or shaft that strikes a lever at one or
more points on its circular path. The cam plate can be a simple tooth, as is used to deliver pulses
of power to a steam hammer, for example, or an eccentric disc or other shape that produces a
smooth reciprocating (back and forth) motion in the follower which is a lever making contact
with the cam.

The reason the cam acts as a lever is because the hole is not directly in the centre,
therefore moving the cam rather than just spinning. On the other hand, some cams are made with
a hole exactly in the centre and their sides act as cams to move the levers touching them to
move up and down or to go back and forth.
1.9 BEARING

A bearing is a device to permit constrained relative motion between two parts, typically
rotation or linear movement. Bearings may be classified broadly according to the motions they
allow and according to their principle of operation. Low friction bearings are often important for
efficiency, to reduce wear and to facilitate high speeds. Essentially, a bearing can reduce friction
by virtue of its shape, by its material, or by introducing and containing a fluid between surfaces.
By shape, gains advantage usually by using spheres or rollers. By material, exploits the nature of
the bearing material used. The Sliding bearings, usually called bushes bushings journal bearings
sleeve bearings rifle bearings or plain bearings. Rolling-element bearings such as ball bearings
and roller bearings.

The Jewel with bearings, in which the load is carried by rolling the axle slightly off-
center. fluid bearings, in which the load is carried by a gas or liquid magnetic bearings, in which
the load is carried by a magnetic field Flexure bearings, in which the motion is supported by a
load element which bends. Bearings vary greatly over the forces and speeds that they can
support. Forces can be radial, axial (thrust bearings) or moments perpendicular to the main axis.

A linear-motion bearing or linear slide is a bearing designed to provide free motion in

one dimension. There are many different types of linear motion bearings and this family of
products is generally broken down into two sub-categories: rolling-element and plane.

Motorized linear slides such as machine slides, roller tables and some dovetail slides are
bearings moved by drive mechanisms. Not all linear slides are motorized and non-motorized
dovetail slides, ball bearing slides and roller slides provide low-friction linear movement for
equipment powered by inertia or by hand.

All linear slides provide linear motion based on bearings, whether they are ball bearings,
dovetail bearings or linear bearings. Linear stages, machine slides and other advanced slides use
linear motion bearings to provide movement.
1.9.1 Friction

Reducing friction in bearings is often important for efficiency, to reduce wear and to
facilitate extended use at high speeds and to avoid overheating and premature failure of the
bearing. Essentially, a bearing can reduce friction by virtue of its shape, by its material, or by
introducing and containing a fluid between surfaces or by separating the surfaces with an
electromagnetic field. By shape, gains advantage usually by using spheres or rollers, or by
forming flexure bearings. By material, exploits the nature of the bearing material used. (An
example would be using plastics that have low surface friction.)

By fluid, exploits the low viscosity of a layer of fluid, such as a lubricant or as a

pressurized medium to keep the two solid parts from touching, or by reducing the normal force
between them. By fields, exploits electromagnetic fields, such as magnetic fields, to keep
solid parts from touching. Combinations of these can even be employed within the same bearing.
An example of this is where the cage is made of plastic, and it separates the rollers/balls, which
reduce friction by their shape and finish.

1.9.2 Stiffness

A second source of motion is elasticity in the bearing itself. For example, the balls in a
ball bearing are like stiff rubber, and under load deform from round to a slightly flattened shape.
The race is also elastic and develops a slight dent where the ball presses on it.

The stiffness of a bearing is how the distance between the parts which are separated by
the bearing varies with applied load. With rolling element bearings this is due to the strain of the
ball and race. With fluid bearings it is due to how the pressure of the fluid varies with the gap
(when correctly loaded, fluid bearings are typically stiffer than rolling element bearings).

1.9.3 Rolling Element Bearings

Rolling element bearing life is determined by load, temperature, maintenance,

lubrication, material defects, contamination, handling, installation and other factors. These
factors can all have a significant effect on bearing life. For example, the service life of
bearings in one application was extended dramatically by changing how the bearings were stored
before installation and use, as vibrations during storage caused lubricant failure even when the
only load on the bearing was its own weight; the resulting damage is often false brandling.
Bearing life is statistical: several samples of a given bearing will often exhibit a bell curve of
service life, with a few samples showing significantly better or worse life. Bearing life varies
because microscopic structure and contamination vary greatly even where macroscopically they
seem identical.

1.9.4 Plain Bearings

For plain bearings some materials give much longer life than others. Some of the John
Harrison clocks still operate after hundreds of years because of the lignum vitae wood employed
in their construction, whereas his metal clocks are seldom run due to potential wear.

1.9.5 Flexure Bearings

Flexure bearings rely on elastic properties of material. Flexure bearings bend a piece of
material repeatedly. Some materials fail after repeated bending, even at low loads, but careful
material selection and bearing design can make flexure bearing life indefinite. Bearing life is
statistical: several samples ofa given bearing will often exhibit a bell curve of service life, with a
few samples showing significantly better or worse life.

1.9.6 Short-life Bearings

Although long bearing life is often desirable, it is sometimes not necessary. Tedric, Harris
describes a bearing for a rocket motor oxygen pump that gave several hours life, far in excess of
the several tens of minutes life needed.
1.9.7 Maintenance and Lubrication

Many bearings require periodic maintenance to prevent premature failure, but many
others require little maintenance. The latter include various kinds of fluid and magnetic bearings,
as well as rolling-element bearings that are described with terms including sealed bearing and
sealed for life. These contain seals to keep the dirt out and the grease in. They work
successfully in many applications providing maintenance-free operation. Some applications
cannot use them effectively.

No sealed bearings often have a grease fitting, for periodic lubrication with a grease gun,
or an oil cup for periodic filling with oil. Before the 1970s, sealed bearings were not encountered
on most machinery, and oiling and greasing were a more common activity than they are today.
For example, automotive chassis used to require "lube jobs" nearly as often as engine oil
changes, but today's car chassis are mostly sealed for life. From the late 1700s through mid
1900s, industry relied on many workers called oilers to lubricate machinery frequently with oil
cans.

1.9.8 Splash Lubrication

Some machines contain a pool of lubricant in the bottom, with gears partially immersed
in the liquid or crank rods that can swing down into the pool as the device operates. The spinning
wheels fling oil into the air around them, while the crank rods slap at the surface of the oil,
splashing it randomly on the interior surfaces of the engine. Some small internal
combustion engines specifically contain special plastic flinger wheels which randomly scatter oil
around the interior of the mechanism.

1.9.9 Pressure Lubrication

For high speed and high power machines, a loss of lubricant can result in rapid bearing
heating and damage due to friction. Also in dirty environments the oil can become contaminated
with dust or debris that increases friction. In these applications, a fresh supply of lubricant can be
continuously supplied to the bearing and all other contact surfaces, and the excess can be
collected for filtration, cooling, and possibly reuse. Pressure oiling is commonly used in large
and complex internal combustion engine in parts of the engine where directly splashed oil cannot
reach, such as assemblies.

1.10.Multi crop cutter

Agriculture is the backbone of India. In India agriculture has facing serious challenges like
scarcity of agricultural labour, in peak working seasons but also in normal time. This is mainly
for increased nonfarm job opportunities having higher wage, migration of labour force to cities
and low status of agricultural labours in the society. In India two type of crop cutting like as
manual method (conventional method) and mechanized type of crop cutter. The crop cutting is
important stage in agriculture field

The machine is used for cutting stems of the cereal crops. The machine is operated with help of
the manual power The speed of cutter is varying with the help of speed of the cutter machine
(Pushing speed) for which handle provided on the Chassis. After cutting of stems they are taken
by worker and are separated from the field. So our machine is fully manual due to that we can
adjust the cutting feed of the machine manually.
 CHAPTER-02

LITERATURE SERVEY

horizontally on a vertical shaft, which would be suspended at a height of 2 inches (50 mm) and
moved across a lawn to cut grass and other lawn at a uniform height. The power for his
experimental mower was an electric motor. The success of Stacy's design was limited by two
factors: the relatively small diameter of the saw blades he used for his experiments, which were
about 8 inches (200mm); and the fact that toothed circular saw blades are not an ideal tool for
cutting freestanding grass and other plants. Stacy did not come up with any idea for a cutter
similar to modern rotary mower straight blades, and soon dropped his experiments with rotary
mowing. Ballads developed this into what he called the "Weed Eater", since it eaten up the grass
and weeds around trees. Victor and Verns, (2003) designed and developed a power operated
rotary weedier for wet land paddy. The complex nature of the machine makes its maintenance
and operation difficult for the peasant farmers. Generally, in India, the conventional methods of
crop cutting involved the use of cutlasses which satisfies to max. More so, it is complicated, time
and labour intensive. In world the usage of agriculture equipment is increasing. In the usage of
agriculture tools, India contributes only 16% as Conducted survey in year 2011.two types of
cutting methods generally available are 1.Manual method 2. Mechanized type of harvesting In
Manual Harvesting to cut one acre of crop With reference to literature available there are many
types of crop, bushcutters and lawn tractors are exist in the market, which may not fulfill the
capital andoperational cost criteria. The top concentration of our design is the cost and
operational ease in case small form units it is very costly, so we decide to develop the
newharvesting machine to reduce the cost of harvesting. We start research on the cuttingmethods
and machines. In the development of ultraportable crop cutter we utilize the pastdata and
techniques. Therefore, there is the need to develop a locally, fabricated Multiple CropCutter.

The above three sections of this project can easily describe the project function. The input is
given to the pushing force of labour to the handling .The output of 1st section is then given to the
input of power transmission section which includes 1st shaft having sprocket. Then the output of
the power to the 2nd shaft having freewheel and a cycle wheel transfer power to the 3rd shaft
having metal wheel, two bevel gear arrangement is attached to the end of 3rd shaft and which is
power transmit to the cutter mechanism
 CHAPTER-03

DESCRIPTION OF EQUIPMENTS

3.1 VICE

FigureNo.3.1 Bench Vice

It is a device consisting of two parallel jaws for holding a work piece; one of the jaws is
fixed and the other movable by a screw, a lever, or a cam. When used for holding a work piece
during hand operations, such as filing, hammering, or sawing, the vise may be permanently
bolted to a bench. In vises designed to hold metallic work pieces, the active faces of the jaws are
hardened steel plates, often removable, with serrations that grip the work piece to prevent
damage to soft parts, the permanent jaws can be covered with temporary jaws made from sheet
copper or leather. Pipe vises havedoubleV-shaped jaws that grip in four places instead of only
two. Woodworking vises have smooth jaws, often of wood, and rely on friction alone rather than
on serrations.

For holding work pieces on the tables of machine tools, vises with smooth hardened-steel
jaws and flat bases are used. These machine vises are portable but may be clamped to the
machine table when in use means may also be provided for swiveling the active part of the vice
so that the work piece can be held in a variety of positions relative to the base. For holding parts
that cannot be clamped with flat jaws, special jaws can be provided. Traditional workbench vises
are commonly either face vises, attached to the front of the workbench, near the left end (for a
right-handed worker) or end vises, attached to or forming part of the right end of the bench.

3.2 Types of Vice

3.2.1 Woodworking Vice

Figure No.3.2.1 Woodworking Vice

Woodworking vises are attached to a workbench, typically flush with its work surface.
Their jaws are made of plywood or metal but mostly metal, the latter usually faced with wood,
called cheeks, to avoid marring the work. The movable jaw may include a retractable dog to hold
work against a bench dog."Quick-release" vises employ a split nut that allows the screw to
engage or disengage with a half turn of the handle. When disengaged the movable jaw may be
moved in or out throughout its entire range of motion, vastly speeding up the process of
adjustment. Common thread types are Acme and buttress. Traditional workbench vises are
commonly either face vises, attached to the front of the workbench, near the left end (for a right-
handed worker) or end vises, attached to or forming part of the right end of the bench.

One common variety of face vises is the leg vise, which has a long extension down to the
floor, with a provision to adjust the spacing of the bottom of the leg, to keep the clamping
surfaces of the jaws approximately parallel, even though the work to be clamped may be of
various thicknesses.

These vises are portable but may be clamped to the machine table when in use means
may also be provided for swiveling the active part of the vice so that the work piece can be held
in a variety of positions relative to the base. For holding parts that cannot be clamped with flat
jaws, special jaws can be provided the vice. When used for holding a work piece during hand
operations, such as filing, hammering, or sawing, the vise may be permanently bolted to a bench.
In vises designed to hold metallic work pieces, the active faces of the jaws are hardened steel
plates, often removable, with serrations that grip the work piece to prevent damage to soft parts,
the permanent a bench.

3.2.2 Machine Vice

Figure No.3.2.2 Machine Vice

Machine vise an also known as a metalworking vise or fitter's vise, is used to clamp metal
instead of wood. It is typically made of cast steel or malleable cast iron. Cheaper vises may be
made of brittle cast iron. The jaws are often separate and replaceable, usually engraved with
serrated or diamond teeth. Soft jaw covers made of aluminum, lead, or plastic may be used to
protect delicate work. An engineer's vise is bolted onto the top surface of a workbench, with the
face of the fixed jaws just forward of its front edge. The vise may include other features such as
a small anvil on the back of its body. For holding work pieces on the tables of machine tools,
vises with smooth hardened-steel jaws and flat bases are used. These machine vises are portable
but may be clamped to the machine table when in use means may also be provided for swiveling
the active part of the vice so that the work piece can be fixing to vice.

3.3 LINKAGE

Linkage is made-up of mild steel. It is connect to cam shaft and rack. Linkages are an
essential part of many mechanisms. They can be used to change direction, alter speed and change
the timing of moving parts. In this example two linked linkages are used to convert the small
linear movementof the drive shaft (bottom left) into first a rotational body movement and
secondly a fast hammer movement. Compare the speed of the hammer with the speed of the
drive shaft.

Linear motion is the most basic of all motions. Uninterrupted objects will continue to
move in a straight line indefinitely. Under every day circumstances gravity and friction
conspire to bring objects to rest. Linear motion is measured in two parts. Together these make up
the velocity. Linear motion is not often used as a starting point for mechanisms.

3.4SAW

Figure No.3.6 saw

 A saw is a fine-tooth saw with a blade under tension in a frame, used for cutting materials
such as metal or bone. Hand-held hacksaws 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
put thethin blade under tension. The blade can mounted with the teeth facing toward or away
from the handle, resulting in cutting action on either the push or pull stroke. On the push stroke,
the arch will flex slightly, decreasing the tension on the blade.

Blades are available in standardized lengths, and with anywhere from three to thirty-two
teeth per inch. The blade used is based on the thickness of the material being cut, with a
minimum of three teeth in the material. Hacksaw blades are normally quite brittle, so care needs
to be taken to prevent brittle fracture of the blade. Bi-metal blades are meant to minimize this
risk, by fusing a strip of harder metal along the tooth edge to a softer spine.

A panel hacksaw eliminates the frame, so that the saw can cut into panels of sheet metal
without the length of cut being restricted by the frame. Junior hacksaws are the small variant,
while larger mechanical hacksaws are used to cut working pieces from bulk metal.

Hacksaw blades are normally quite brittle, so care needs to be taken to prevent brittle
fracture of the blade. Early blades were of carbon steel, now termed 'low alloy' blades, and were
relatively soft and flexible. They avoided breakage, but also wore out rapidly. Except where cost
is a particular concern, this type is now obsolete. 'Low alloy' blades are still the only type
available for the junior hacksaw, which limits the usefulness of this otherwise popular saw.

For several decades now, hacksaw blades have used high speed steel for their teeth,
giving greatly improved cutting and tooth life. These blades were first available in the 'All-hard'
form which cut accurately but were extremely brittle.

This limited their practical use to benchwork on a work piece that was firmly clamped in
a vice. A softer form of high speed steel blade was also available, which wore well and resisted
breakage, but was less stiff and so less accurate for precise sawing. Since the 1980s, bimetal
blades have been used to give the advantages of both forms, without risk of breakage.
 A strip of high speed steel along the tooth edge is electron beam welded to a softer spine.
As the price of these has dropped to be comparable with the older blades, their use is now almost
universal.

Hacksaw blade specifications: 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
inchper 300 mm dimension refers to the center to center distance between these mounting holes.

The12 Inch Blade dimensions apply except for the following;

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 kerfs produced by the blades aresomewhat wider than the blade thickness due to the set
of the teeth. It commonly varies between 0.030 and 0.063 inches / 0.75 and 1.6 mm depending
on the pitch and set of the teeth.

The 10 inch blade is also fairly common and all the above dimensions apply except for the
following:

Hole to Hole: 9 7/8 inches / 250 mm

Overall blade length: 10 3/8 inches / 265 mm (not tightly controlled)
3.5Types of saw

3.5.1 Panel Hacksaw

Figure No.3.5.1 Panel Hacksaw

A panel hacksaw has a frame made of a deep, thin sheet aligned behind the blade's kerfs,
so that the saw could cut into panels of sheet metal without the length of cut being restricted by
the frame. The frame follows the blade down the kerfs into the panel. Junior hacksaws are a
small version with a half size blade. Like coping saws, the blade has pins that are held by notches
in the frame. Although potentially a useful tool for a toolbox or in confined spaces, the quality of
blades in the junior size is restricted and they are only made in the simple low alloy steels this
restricts their usefulness.

The Low alloy blades are still the only type available for the junior hacksaw which limits
the usefulness of this otherwise popular saw. For several decades now, hacksaw blades have
used high speed steel for their teeth, giving greatly improved cutting and tooth life. These blades
were first available in the 'All-hard' form which cut accurately but were extremely brittle. This
limited their practical use to bench work on a work piece that was firmly clamped in a vice.

A softer form of high speed steel blade was also available, which wore well and resisted
breakage, but was less stiff and so less accurate for precise sawing. Since the 1980s, bi-
metal blades have been used to give the advantages of both forms, without risk of breakage. A
strip of high speed steel along the tooth edge is electron beam welded to a softer spine. As the
price of these has dropped to be comparable with the older blades, their use is now almost
universal. Panel hacksaws 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 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.

3.6Circular saw

A circular saw is a power-saw using a toothed or abrasive disc or blade to cut different
materials using a rotary motion spinning around an arbor. A hole saw and ring saw also use a
rotary motion but are different from a circular saw. Circular saws may also be loosely used for
the blade itself. Circular saws were invented in the late 18th century and were in common use
in sawmills in the United States by the middle of the 19th century.

A circular saw is a tool for cutting many materials such as wood, masonry, plastic,
or metal and may be hand-held or mounted to a machine. In woodworking the term "circular
saw" refers specifically to the hand-held type and the table saw and chop saw are other common
forms of circular saws. "Skil saw" has become a generic trademark for conventional hand-held
circular saws. Circular saw blades are specially designed for each particular material they are
intended to cut and in cutting wood are specifically designed for making rip-cuts, cross-cuts, or a
combination of both. Circular saws are commonly powered by electricity, but may be powered
by a gasoline engine or a hydraulic motorwhich allows it to be fastened to heavy equipment,
eliminating the need for a separate energy source.

3.7.1 Power Hacksaw

Figure No.3.7.1Power Hacksaw

A power hacksaw (or electric hacksaw) is a type of hacksaw that is powered either by its
own electric motor or connected to a stationary engine. Most power hacksaws are stationary
machines but some portable models do exist; the latter (with frames) have been displaced to
some extent by reciprocating saws such as the Sewall, which accept blades with hacksaw teeth.
Stationary models usually have a mechanism to lift up the saw blade on the return stroke and
some have a coolant pump to prevent the saw blade from overheating.

Power hacksaws are not as commonly used in the metalworking industries as they once
were. Band saws and cold saws have mostly displaced them. While stationary electric hacksaws
are not very common, they are still produced. Power hacksaws of the type powered by stationary
engines and line shafts, like other line-shaft-powered machines, are now rare museums and
antique-tool hobbyists still preserve a few of them.
 Ray electric hacksaws are not very common, they are still produced. Power hacksaws of
the type powered by stationary engines and line shafts, like other line-shaft-powered machines,
are now rare museums and antique-tool hobbyists still preserve a few of them. Hacksaw blades
are normally quite brittle, so care needs to be taken to prevent brittle fracture of the blade.

Early blades were of carbon steel, now termed 'low alloy' blades, and were relatively soft
and flexible. They avoided breakage, but also wore out rapidly. Except where cost is a particular
concern this type is now obsolete.

3.8SPRING

Figure No.3.8Spring

The automobile chassis is mounted on the axles not direct but through some form of
springs. This is done to isolate the vehicle body from the road shocks which may be in the form
of bounce, pitch, roll or sway. These tendencies give rise to an uncomfortable ride and also cause
additional stress in the automobile frame and body. All the parts which perform the function of
isolating the automobile from the road shocks are collectively.
 A Springing device must be a compromise between flexibility and stiffness. If it is more
rigid,it will not absorb road shocks efficiently and if it is more flexible it will continue to vibrate
even after the bump has passed so we must have sufficient damping of the spring to prevent
excessive flexing.

3.8.1 Return Spring

A spring is a flexible elastic object used to store mechanical energy. Springs are usually
made out of hardened steel. Small springs can be wound from pre-hardened stock, while larger
ones. A spring is a mechanical device, which is typically used to store energy and subsequently
release it, to absorb shock, or to maintain a force between contacting surfaces. They are made of
an elastic material formed into the shape of a helix which returns to its natural length when
unloaded this is called return spring. Springs are placed between the road wheels and the vehicle
body. When the wheel comes across a bump on the road, it rises and deflects the spring, thereby
storing energy therein. On releasing, due to the elasticity of the spring, material, it rebounds
thereby expending the stored energy.

In this way the spring starts vibrating, with amplitude decreasing gradually on internal
friction of the spring material and friction of the suspension joints till vibrations die down.

3.9 Types of Spring

3.9.1 Compression Spring

Figure No.3.9.1 Compression Spring

 A spring is an elastic object used to store mechanical energy. Springs are usually made
out of spring steel. There are a large number of spring designs in everyday usage the term often
refers to coil springs. Small springs can be wound from pre-hardened stock, while larger ones are
made from annealed steel and hardened after fabrication. Some non-ferrous metals are also used
including bronze and titanium for parts requiring corrosion resistance and beryllium
copper for springs carrying electrical current (because of its low electrical resistance).

A Springing device must be a compromise between flexibility and stiffness. If it is more

rigid, it will not absorb road shocks efficiently and if it is more flexible it will continue to
vibrate even after the bump has passed so we must have sufficient damping of the spring to
prevent excessive flexible.

They are made of an elastic material formed into the shape of a helix which returns to its
natural length when unloaded this is called return spring. Springs are placed between the road
wheels and the vehicle body. They are made of an elastic material formed into the shape of a
helix which returns to its natural length when unloaded this is called return spring. Springs are
placed between the road wheels and the vehicle body. When the wheel comes across a bump on
the road, it rises and deflects the spring, thereby storing energy spring.
3.9.2 Extension Spring

Figure No.3.9.2Extension Spring

When a Heavy duty spring is compressed or stretched slightly from rest, the force it
exerts is approximately proportional to its change in length (this approximation breaks down for
larger deflections). The rate or spring constant of a spring is the change in the force it exerts,
divided by the change in deflection of the spring. That is, it is the gradient of the force versus
deflection curve. An extension or compression spring has units of force divided by distance, for
example. Torsion springs have units of torque divided by angle, such as degree.

The inverse of spring rate is compliance that is if a spring has a rate of 10 N/mm it has a
compliance of 0.1 mm. The stiffness (or rate) of springs in parallel is additive, as is the
compliance of springs in series.

Depending on the design and required operating environment, any material can be used to
construct a spring, so long as the material has the required combination of rigidity and elasticity
technically, a wooden bow is a form of spring. Springs are usually made out of hardened steel.
Small springs can be wound from pre-hardened stock, while larger ones. A spring is a
mechanical device, which is typically used to store energy and subsequently release it, to absorb
shock, or to maintaina force between contacting surfaces.
3.10CAM PLATE

Figure No. 3.10 Cam Plate

A cam plate is a projecting part of a rotating wheel or shaft that strikes a lever at one or
more points on its circular path. The cam plate can be a simple tooth, as is used to deliver pulses
of power toa steam hammer, for example, or an eccentric disc or other shape that produces a
smooth reciprocating (back and forth) motion in the follower which is a lever making contact
with the cam.

The reason the cam acts as a lever is because the hole is not directly in the centre,
therefore moving the cam rather than just spinning. On the other hand, some cams are made with
a hole exactly in the centre and their sides act as cams to move the levers touching them to move
up and down or to go back and forth.
3.10.1 Overview

The cam plate can be seen as a device that rotates from circular to reciprocatingmotion.A
common example is the camshaft of an automobile, which takes the rotary motion of the engine
and translates it into the reciprocating motion necessary to operate the intake and exhaust valves
of the cylinders.

3.10.2 Displacement diagram

Figure No. 3.10.2 Displacement Diagram

Certain cams can be characterized by their displacement diagrams, which reflect the
changing Position a roller follower.Would make as the cam rotates about an axis. These
diagrams relate regular position, usually in degrees, to the radial displacement experienced at
that position. Displacement diagrams are traditionally presented as graphs with non-negative
values.

A simple displacement diagram illustrates the follower motion at a constant velocity rise
followed by a similar return with a dwell In between as depicted. The rise is the motion of the
follower away from the cam center; dwell is the motion where the follower is at rest, and return
is the motion of the follower toward the cam

However, the most common type is in the valve actuators in internal combustion engines.
Here, the cam profile is commonly symmetric and at rotational speeds generally met with, very
high acceleration forces develop. Ideally, a convex curve between the onset and maximum
position of lifterreduces acceleration, but this requires impractically large shaft diameters relative
to lift. Thus, in practice, the points at which lift begins and ends mean that a tangent to the base
circle appears on the profile.
 This is continuous with a tangent to the tip circle. In designing the cam, the lift and the
dwell angle are given. If the profile is treated as a large base circle and a small tip circle, joined
by a common tangent, giving lift,the relationship can be calculated.Rotational speeds generally
with, very acceleration forces developed.

The cam plate can be a simple tooth, as is used to deliver pulses of power to a steam
hammer, for example, or an eccentric disc or other shape that produces a smooth reciprocating
back and forth motion.

3.11BEARING

Figure No. 3.11 Bearing

A bearing is a device to permit constrained relative motion between two parts, typically
rotation or linear movement. Bearings may be classified broadly according to the motions they
allow and according to their principle of operation. Low friction bearings are often important for
efficiency,to reduce wear and to facilitate high speeds. Essentially, a bearing can reduce friction
by virtue of its shape, by its material, or by introducing and containing a fluid between surfaces.
By shape, gains advantage usually by using spheres or rollers. By material, exploits the nature of
the bearing material used. Sliding bearings, usually called bushes bushings journal bearings
sleeve bearings rifle bearings or plain bearings.
 Rolling-element bearings such as ball bearings and roller bearings. Jewel with bearings,
in which the load is carried by rolling the axle slightly off-center. fluid bearings, in which the
load is carried by a gas or liquid magnetic bearings, in which the load is carried by a magnetic
field Flexure bearings, in which the motion is supported by a load element which bends.
Bearings vary greatly over the forces and speeds that they can support. Forces can be radial, axial
(thrust bearings) or moments perpendicular to the main axis.

The earliest recovered example of a rolling element bearing is a wooden ball

bearing supporting a rotating table from the remains of the in Lake Noemi, Italy. The wrecks
were dated to Leonardo day Vinci incorporated drawings of ball bearings Bearings very typically
involve some degree of relative movement between surfaces, and different types have limits as to
the maximum relative surface speeds they can handle, and this can be specified as a speed in m/s.

3.12Types of Bearing

3.12.1Linear Bearing

Figure No. 3.12.1 Linear Bearing

A linear-motion bearing or linear slide is a bearing designed to provide free motion in

one dimension. There are many different types of linear motion bearings and this family of
products is generally broken down into two sub-categories: rolling-element and plane.
 Motorized linear slides such as machine slides, roller tables and some dovetail slides are
bearings moved by drive mechanisms. Not all linear slides are motorized and non-motorized
dovetail slides, ball bearing slides and roller slides provide low-friction linear movement for
equipment powered by inertia or by hand.

All linear slides provide linear motion based on bearings, whether they are ball bearings,
dovetail bearings or linear bearings. Linear stages, machine slides and other advanced slides use
linear motion bearings to provide movement.

Bearings may be classified broadly according to the motions they allow and according to
their principle of operation. Low friction bearings are often important for efficiency, to reduce
wear and to facilitate high speeds. Essentially, a bearing can reduce friction by virtue of its
shape, by its material, or by introducing and containing a fluid between surfaces.

They are depicted in their own drawings in the tomb of as moving massive stone blocks
on sledges with the runners lubricated with a liquid which would constitute a plain bearing.
There are also Egyptian drawings of bearings used with hand drills.

3.12.2Ball Bearings
 Figure No. 3.12.2 Ball Bearing

Ball bearings, as shown to the left, are the most common type by far. They are found in
everything from skate boards to washing machines to PC hard drives. These bearings are capable
of taking both radial and thrust loads, and are usually found in applications where the load is
light to medium andis constant in nature (i.e. not shock loading). The bearing shown here has the
outer ring cut away revealing the balls and ball retainer.

3.12.3 Thrust Ball Bearings

Figure No. 3.12.3 Thrust Ball Bearing

Ball thrust bearings like the one shown to the left are mostly used for low-speed non
precision applications. They cannot take much radial load and are usually found in lazy Susan
turntables and low precision farm equipment.
3.12.4Roller Bearings

Figure No. 3.12.4Roller Bearing

Roller bearings like the one shown to the left are normally used in heavy duty
applications suchas conveyer belt rollers, where they must hold heavy radial loads. In these
bearings the roller isa cylinder, so the contact between the inner and outer race is not a point
(like the ball bearing above) but a line. This spreads the load out over a larger area, allowing the
roller bearing to handle much greater loads than a ball bearing. However, this type of bearing
cannot handle thrust loads to any significant degree

3.12.5Roller Thrust Bearing

Figure No: 3.12.5 Roller Thrust Bearing

Roller thrust bearings like the one illustrated to the left can support very large thrust loads. They
are often found in gear sets like car transmissions between gear sprockets, and between the
housing and the rotating shafts. The helical gears used in most transmissions have angled teeth
this can causesa high thrust load that must be supported by this type of bearing.

3.12.6 Taper Roller Bearing

Figure No. 3.12.6 Tapper Roller Bearing

Tapered roller bearings are designed to support large radial and large thrust loads. These
loads can take the form of constant loads or shock loads. Tapered roller bearings are used in
many car hubs, where they are usually mounted in pairs facing opposite directions. This gives
them the ability to take thrust loads in both directions. The cutaway taper roller on the left shows
the specially designed tapered rollers and demonstrates their angular mounting which gives their
dual load ability. The invention of the rolling bearing, in the form of wooden rollers supporting,
or bearing, an object being moved is of great antiquity, and may predate the invention of
the wheel. Though it is often claimed that the Egyptians used roller bearings in the form of tree
trunks under sleds, this is modern speculation. They are depicted in their own drawings in the
tomb of as moving massive stone blocks on sledges with the runners lubricated with a liquid
which would constitute a plain bearing. There are also Egyptian drawings of bearings used
with hand drills. The earliest recovered example of a rolling element bearing is a wooden ball
bearing supporting a rotating table from the remains of the in Lake Noemi, Italy. The wrecks
were dated to Leonardo day Vinci incorporated drawings of ball bearings in his design for a
helicopter around the year 1500. This is the first recorded use of bearings in an aerospace design.
However, Ramelli is the first to have published sketches of roller and thrust bearings. An issue
with ball and roller bearings is that the balls or rollers rub against each other causing additional
friction which can be prevented by enclosing the balls or rollers in a cage. The captured, or
caged, ball bearing was originally described by Galileo in the 17th century.

3.13 Principles& Operation of Bearing

Figure No. 3.13Bearing

Animation of ball bearing (without a cage). The inner ring rotates and the outer ring is stationary.

There are at least 6 common principles of operation:

Plain bearing, also known by the specific styles bushing, journal bearing, sleeve bearing,
rifle bearing
Rolling-element bearing such as ball bearings and roller bearings
Jewel bearing, in which the load is carried by rolling the axle slightly off-center
Fluid bearing, in which the load is carried by a gas or liquid
Magnetic bearing, in which the load is carried by a magnetic field
Flexure bearingin which the motion is supported by a load element which bends.
3.13.1 Friction

Reducing friction in bearings is often important for efficiency, to reduce wear and to
facilitate extended use at high speeds and to avoid overheating and premature failure of the
bearing. Essentially, abearing can reduce friction by virtue of its shape, by its material, or by
introducing and containinga fluid between surfaces or by separating the surfaces with an
electromagnetic field. By shape, gains advantage usually by using spheres or rollers, or by
forming flexure bearings. By material, exploits the nature of the bearing material used. (An
example would be using plastics that have low surface friction.)

By fluid, exploits the low viscosity of a layer of fluid, such as a lubricant or as a

pressurized medium to keep the two solid parts from touching, or by reducing the normal force
between them.By fields, exploits electromagnetic fields, such as magnetic fields, to keep solid
parts from touching.

Combinations of these can even be employed within the same bearing. An example of
this is where the cage is made of plastic, and it separates the rollers/balls, which reduce friction
by their shape and finish.

3.13.2Stiffness

A second source of motion is elasticity in the bearing itself. For example, the balls in a
ball bearing are like stiff rubber, and under load deform from round to a slightly flattened shape.
The race is also elastic and develops a slight dent where the ball presses on it.

The stiffness of a bearing is how the distance between the parts which are separated by
the bearing varies with applied load. With rolling element bearings this is due to the strain of the
ball and race. With fluid bearings it is due to how the pressure of the fluid varies with the gap
(when correctly loaded, fluid bearings are typically stiffer than rolling element bearings).

3.13.3 Rolling Element Bearings

Rolling element bearing life is determined by load, temperature, maintenance,

lubrication, material defects, contamination, handling, installation and other factors. These
factors can all have a significant effect on bearing life. For example, the service life of
bearings in one application was extended dramatically by changing how the bearings were stored
before installation and use, as vibrations during storage caused lubricant failure even when the
only load on the bearing was its own weight; the resulting damage is often false brandling.
Bearing life is statistical: several samples ofa given bearing will often exhibit a bell curveof
service life, with a few samples showing significantly better or worse life. Bearing life varies
because microscopic structure and contamination vary greatly even where macroscopically they
seem identical.

3.13.4Plain Bearings

For plain bearings some materials give much longer life than others. Some of the John
Harrison clocks still operate after hundreds of years because of the lignum vitae wood employed
in their construction, whereas his metal clocks are seldom run due to potential wear.

3.13.5 Flexure Bearings

Flexure bearings rely on elastic properties of material. Flexure bearings bend a piece of material
repeatedly. Some materials fail after repeated bending, even at low loads, but careful material
selection and bearing design can make flexure bearing life indefinite.

3.13.6 Short-life Bearings

Although long bearing life is often desirable, it is sometimes not necessary. Tedric,
Harrisdescribes a bearing for a rocket motor oxygen pump that gave several hours life, far in
excess of the several tens of minutes life needed.

3.13.7 Maintenance and Lubrication

Many bearings require periodic maintenance to prevent premature failure, but many
others require little maintenance. The latter include various kinds of fluid and magnetic bearings,
as wellas rolling-element bearings that are described with terms including sealed bearing and
sealed for life. These contain seals to keep the dirt out and the grease in. They work successfully
in many applications, providing maintenance-free operation. Some applications cannot use them
effectively.
 No sealed bearings often have a grease fitting, for periodic lubrication with a grease gun,
or an oil cup for periodic filling with oil. Before the 1970s, sealed bearings were not encountered
on most machinery, and oiling and greasing were a more common activity than they are today.
For example,automotive chassis used to require "lube jobs" nearly as often as engine oil changes,
but today's car chassis are mostly sealed for life. From the late 1700s through mid 1900s,
industry relied on many workers called oilers to lubricate machinery frequently with oil cans.

3.13.8Rolling Element Bearing Outer Race Fault Detection

The Rolling Element Bearing is widely used in the Industries today and hence
maintenance of these bearings becomes an important task for the maintenance professionals. The
Rolling Element bearings wear out easily due to metal to metal contact which creates faults in
the outer race, inner raceand ball. It is also however the most vulnerable component of a
machine because it is often under high load and high running speed conditions. Regular
diagnostics of rolling element bearing faults is critical for industrial safety and operations of the
machines along with reducing the maintenance costs or avoiding shutdown time. Among the
outer race, inner race and ball, the outer race tends to be more vulnerable to faults and defects.

There is still a room for discussion if the rolling element excites the natural frequencies
of bearing component when it passes the fault on the outer race. Hence we need to identify the
bearing outer race natural frequency and its harmonics. The bearing faults create impulses and
results in strong harmonics of the fault frequencies in the spectrum of vibration signals.

These fault frequencies are sometimes masked by adjacent frequencies in the spectra due
to their little energy. Hence, a very highspectral resolution is often needed to identify these
frequencies during an analysis.

3.13.9 Packing

Some bearings use thick grease for lubrication, which is pushed into the gaps between the
bearing surfaces, also known as packing. The grease is held in place by a plastic, leather, or
rubber gasket (also called a gland) that covers the inside and outside edges of the bearing race to
keep the grease from escaping.
 Bearings may also be packed with other materials. Historically, the wheels on railroad
cars used sleeve bearings packed with waste or loose scraps of cotton or wool fiber soaked in oil,
and then later used solid pads of cotton.

3.13.10 Ring Oiler

For more details on this topic, see Ring oiler. Bearings can be lubricated by a metal ring
that rides loosely on the central rotating shaft of the bearing. The ring hangs down into a
chamber containing lubricating oil. As the bearing rotates, viscous adhesion draws oil up the ring
and onto the shaft, where the oil migrates into the bearing to lubricate it. Excess oil is flung off
and collects in the pool again.

3.13.11Splash Lubrication

Some machines contain a pool of lubricant in the bottom, with gears partially immersed
in the liquid or crank rods that can swing down into the pool as the device operates. The spinning
wheels fling oil into the air around them, while the crank rods slap at the surface of the oil,
splashing it randomly on the interior surfaces of the engine. Some small internal
combustion engines specifically containspecial plastic flinger wheels which randomly scatter oil
around the interior of the mechanism.

3.13.12Pressure Lubrication

For high speed and high power machines, a loss of lubricant can result in rapid bearing
heating and damage due to friction. Also in dirty environments the oil can become contaminated
with dust or debris that increases friction. In these applications, a fresh supply of lubricant can be
continuously supplied to the bearing and all other contact surfaces, and the excess can be
collected for filtration, cooling,and possibly reuse. Pressure oiling is commonly used in large and
complex internal combustion engine in parts of the engine where directly splashed oil cannot
reach, such as assemblies.
 CHAPTER-04

SUMMERYOF EQUIPMENT AND DRAWING

4.1 COMPONENTS

The pedal power hacksaw consists of the following components to full fill the
requirements of complete operation of the machine.

1. Cam Plate

2. Motor

3. Vice

4. saw

5. Bearing

4.1.1 Specification

Vice : Bench Vice

Spring : Return Spring (Extension Spring)

Spring Diameter :10mm

Length : 160mm

Cam Plate Diameter : 190mm

Thickness : 3mm

Blade : Wave Teeth Type

Length : 320mm
4.2 SUMMERY OF EQUIPMENT

4.2.1 List of Materials

Factors Determining the Choice of Materials

The various factors which determine the choice of material are discussed below.

1. Properties
The material selected must possess the necessary properties for the proposed application. The
various requirements to be satisfied can be weight, surface finish, rigidity, ability to withstand
environmental attack from chemicals, service life, reliability etc.

The following four types of principle properties of materials decisively affect their
selection

Physical
Mechanical
From manufacturing point of view
Chemical
The various physical properties concerned are melting point, thermal
Conductivity, specific heat, coefficient of thermal expansion, specific gravity, electrical
conductivity, magnetic purposes etc.

The various Mechanical properties Concerned are strength in tensile, Compressive shear
bending, torsion and buckling load, fatigue resistance, impact resistance, elastic limit, endurance
limit, and modulus of elasticity, hardness, wear resistance and sliding properties.

The various properties concerned from the manufacturing point of view are,

Cast ability
Weld ability
Surface properties
Shrinkage
Deep drawing etc.
2. Manufacturing Case

Sometimes the demand for lowest possible manufacturing cost or surface qualities
obtainable by the application of suitable coating substances may demand the use of special
materials.

3. Quality Required

This generally affects the manufacturing process and ultimately the material. For
example, it would never be desirable to go casting of a less number of components which can be
fabricated much more economically by welding or hand forging the steel.

4. Availability of Material

Some materials may be scarce or in short supply, it then becomes obligatory for the
designer to use some other material which though may not be a perfect substitute for the material
designed. The delivery of materials and the delivery date of product should also be kept in mind.

5. Space Consideration

Sometimes high strength materials have to be selected because the forces involved are
high and space limitations are there.

6. Cost

As in any other problem, in selection of material the cost of material plays an important
part and should not be ignored.

Some Times factors like scrap utilization, appearance, and non-maintenance of the designed part
are involved in the selection of proper materials.
Drawing

When the worker will push machine with the handle then wheels starts rotating. This rotation of
wheels is transmitted to the shaft. On this shaft the sprocket is mounted having chain drive with
2nd shaft having freewheel and cycle wheel which transfer the rotation to the 3rd shaft .On this
shaft the bevel gear is attached to both the ends then with the help of bevel gears this rotation is
transmitted to vertical shaft having cutter at the end. Due to the teeth ratio of bevel gears,
rotation is maintain and power is obtained for cutting purpose.

Fabrication is the process of making the machine or structure by using the various machining
methods and fabrication techniques. Turning is used to reduce the radius of the work piece,
usually to a specified dimension, and to produce a smooth finish on the metal. Milling can be
done with a broad range of machine tools. The original class of machine tools for milling was the
milling machine (often called a mill). Grinding is used to finish work pieces that must show high
surface quality (e.g., low surface roughness) and high accuracy of shape and dimension. Drilling
is machining method is used to produce the circular holes in the machining component, to
produce the holes in jobs various drill bits are used. A machine tool with a vertically
reciprocating planning tool used for making a mortise or shaping the sides of an aperture.
Welding is a fabrication or sculptural process that joins materials, usually metals. There are also
special-purpose closing devices, nuts and bolts. For the drive shaft we choose the EN8 (medium
carbon steel) material, it is economical and having the required strength for the equipment.

4.5 COST ESTIMATION

4.5.1 LABOUR COST

Lathe = Rs 300

Drilling = Rs 250

Welding = Rs 500

Gas cutting cost = Rs450

TOTAL LABOUR COST = Rs 1500/-

4.5.2 MATERIAL COST

S. No. MATERIAL COST

(Rs.)
1 Hacksaw Blade 20
2 Spring 40
3 Hacksaw Frame 140
4 Cam Plate 300
5 Bearing 350
6 Bench Vice 1200
7 Linkages 1120
TOTAL Rs.3170

Table No.4.5.2 Material Cost

4.5.3 OVERHEAD CHARGES

The overhead charges are arrived by manufacturing cost

Manufacturing Cost = Material Cost + Labour Cost

= 3170 + 1500

= Rs 4670/-

Overhead Charges = 20%of the manufacturing cost

= Rs 930/-

4.5.4 TOTAL COST

Total cost = Material Cost +Labor Cost +Overhead Charges

= 3170 + 1500 + 930

= Rs 560/-

\
5.1 METHODOLOGY

STUDY OF PEDAL POWERED HACKSAW MACHINES

FINDING DEMERITS OF OLDER PROCESS

FINDING THE SOLUTION FOR PROBLEMS

FGGGGS

IMAGINARY PLAN

COLLECTING THE MATERIAL

FABRICATION OF PEDAL POWERED HACK SAW MACHINE

WORKING & ANALYSING THE CUTTING OF WORK PIECE

RESULT AND SCOPE OF FUTURE WORK

Table No.5.1 Methodology

5.2 APPLICATIONS

Can be useful while power shut down & in urgent situations.

In a furniture making industry at production department it is widely used
Can be used for all carpenters who make the work easier.

5.3MERITS

Low Installation cost.

Easy Maintenance
No need of Electricity.
No need of two persons for cutting a wooden log.
Easily operating System
Maintenance cost is low

5.4 FABRICATION

5.4.1 Vice

It is a device consisting of two parallel jaws for holding a work piece; one of the jaws is
fixed and the other movable by a screw, a lever, or a cam. When used for holding a work piece
during hand operations, such as filing, hammering, or sawing, the vise may be permanently
bolted to a bench. In vises designed to hold metallic work pieces, the active faces of the jaws are
hardened steel plates, often removable,

5.4.2 Motor

An electric motor is an electrical machine that converts electrical energy into mechanical energy.
The reverse of this is the conversion of mechanical energy into electrical energy and is done by
an electric generator, and generators and motors have much in common.

Most electric motors operate through the interaction between an electric motor's magnetic
field and winding currents to generate force. In certain applications, such as in regenerative
braking with traction motors in the transportation industry, electric motors can also be used in
reverse as generators to convert mechanical energy into electric power.

Found in applications as diverse as industrial fans, blowers and pumps, machine tools, household
appliances, power tools, and disk drives, electric motors can be powered by direct current (DC)
sources, such as from batteries, motor vehicles or rectifiers, or by alternating current(AC)
sources, such as from the power grid, inverters or generators. Small motors may be found in
electric watches. General-purpose motors with highly standardized dimensions and
characteristics provide convenient mechanical power for industrial use.

5.4.3 Spring

A Springing device must be a compromise between flexibility and stiffness. If it is more

rigid, it will not absorb road shocks efficiently and if it is more flexible it will continue to vibrate
even after the bump has passed so we must have sufficient damping of the spring to prevent
excessive flexing.

5.4.4 Saw

A saw is a tool consisting of a tough blade, wire, or chain with a hard toothed edge. It is used
to cut through material, very often wood. The cut is made by placing the toothed edge against the
material and moving it forcefully forth and less forcefully back or continuously forward. This
force may be applied by hand, or powered by steam, water, electricity or other power source.
An abrasive saw has a powered circular blade designed to cut through metal.

5.4.5Cam Plate

A cam is a projecting part of a rotating wheel or shaft that strikes a lever at one or more
points on its circular path. The cam can be a simple tooth, as is used to deliver pulses of power to
a steam hammer, for example, or an eccentric disc or other shape that produces a smooth
reciprocating (back and forth) motion in the follower which is a lever making contact with the
cam.
 CHAPTER-06

CONCLUSION

6.1 Conclusion

The Multi crop cutter is designed, fabricated and tested. This machine does not employees any
use of power equipments such as DC motors and it is fully human operated . The use of this
machine makes the harvesting process faster hence reduce most of the cutting time and labour
required to operate the machine is also less. This machine is helpful for small as well as big
firms. This human powered machine will help to improve an economical condition. This is new
type of machine which is different to the other cutting machine which are used for harvesting
purpose till now.

6.2 Scope for future work

The objective of this project is to design and fabricate a low cost multi crop cutting
machine based on the need of farmers.
To minimize time of harvesting
To minimize the human effort.