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Submitted by
Saleem FA14-BME-060
Supervisor
Assistant Professor
FACULTY OF ENGINEERING
SAHIWAL CAMPUS
JUNE, 2018
DESIGN AND FABRICATION OF HUMAN POWERED
Supervisor
Assistant Professor
FACULTY OF ENGINEERING
SAHIWAL CAMPUS
1
JUNE, 2018
Abstract
Human powered metal-wood cutting machine can be used for cutting wood and metal without
the power of electricity as there is a huge shortage of electricity in Pakistan, since most of the
time during working hours electric power is not available for work due to high rate of load
shedding. It can also be helpful in reducing human efforts. The machine consist of chain and
sprocket mechanism, slider crank mechanism, blade assembly and work bench for cutting
2
Acknowledgements
We are heartedly very much thankful to Almighty ALLAH, Who gave us the courage and power
My appreciation goes to the innumerable people who contributed to the success of this project.
We owe Special debt of gratitude to Dr. Muhammad Akram for his kind support and direction.
His sincerity, perseverance and sense of transparency have been an inspiration for us. Big
Thankful to my brothers, Parents, friends and countless others who lent their support in diverse
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TABLE OF CONTENT
Contents
Abstract………………………………………………………………………………………2
Acknowledgement…………………………………………………………………………..3
Table of contents……………………………………………………………………………4
List of figures………………………………………………………………………………..6
List of tables………………………………………………………………………………...7
CHAPTER 1 INTRODUCTION………………………………………………………...8
1.1 Background………………………………………………………………………...…8
2.1 History………………………………………………………………………………..12
4
3.1.1 Design parameters…………………………………………………………….…19
3.3 Drawing………………………………………………………………………………23
CHAPTER 4 EXPERIMENTATIONS OR SIMULATIONS……….………………26
RECOMMENDATION………………………………………………………...…………31
6.1 Conclusion…………………………………………………………...……………….31
CHAPTER 7 REFERENCES…………………………………………………………..34
LIST OF FIGURES
5
Figure 8 Connecting rod……………………………………………………………………..25
Table 2 Number of strokes and time taken to completely cut a metal rod…………..............29
Table 3 Cutting depth and the time taken to cut the various wood pieces…………………...29
6
CHAPTER 1
INTRODUCTION:
1.1 Background
• Egyptians illustrations from about 1500BC onward show the saw being used to rip
boards, timber being lashed to a vertical post set into the ground.
• Iron saws started to be produces in the mid-7th century BC. The Romans, added many
• While saws for cutting metal had been in used for many years, significant
• In 1898, Clemson was granted US patent 601947, which details various improvements
in the hacksaw.
Pedal power is a source of energy in which human energy is transferred into useful work.
As human eat food which produces chemical energy in their bodies. This chemical energy
is used for the movement of body parts to produce mechanical energy. The mechanical
energy produced by pedal has been a source of transportation for a long time. More than
billion bicycles are present around the world. Now pedal power is used in agriculture and
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also to generate electricity. Some application includes pedal powered water wells and
grinders. We are going to use pedal power for metal and wood cutting through hacksaw
assembly.
Power can be produced by hand motion but research shows that a person can produce power
by his foots four times more than the power produced by the hand. With this rate if a man
completes an action by pedaling in ten minutes then same action will be completed in 40
minutes by his hand action. Because of brainstorming, it was apparent that pedal power
was particularly useful. Many devices can be run right away with mechanical energy.
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The project is the designing and fabrication of human powered metal and wood cutting
machine. Pedal power metal and wood cutting machine performs the cutting action by shearing
force between piece to be cut and teeth of the blade. This is achieved by pedal action which
rotates the crank disc, and by means of connecting rod rotatory motion of crank disc is converted
The first step was to design the components and the assembly. For that purpose, we used PROE
to generate 3-D views of components and finally assembled them. After the completion of the
modal the analysis of the parts was done. Then the dimensions of the parts were calculated.
After these steps we manufactured each part separately and finally assembled them.
This is a learning project in which we applied our designing skills to design the components
and assembly and theoretical knowledge to perform the calculations. Finally, we manufactured
Another advantage of pedal powered metal and wood cutting machine is to facilitate the people
in small industries and students in the university workshops who cut metal or wood pieces by
hands in the absence of electricity which takes more time and energy. By using this cutting
machine, they will be able to do exercise, avoid electricity bills, save their time and energy.
Firstly, it is more efficient and secondly it is safe as compared to performed cutting by hands.
Several organizations also have shown their interest in pedal powered technology. It is
affordable, environment friendly, alternative to devices which consume electricity or fossil fuel.
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components are easily available in market. We hope that this design will be produced where
most creative and unlimited source available is the kinetic energy produced from human
The aim of the proposed system is to use the mechanical energy produced during exercising
to obtain useful work. This project will help one develop engineering skills while learning about
the utility of pure mechanical powered machines. The system leads a way to preserve our
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CHAPTER 2:
LITERATURE REVIEW
Human power has been instrumental in taking care of issues since long time. For instance, all
instruments used in ancient times have truly been human powered. It is trusted that the primary
human powered device to produce rotating movement was the potter's wheel, around 3,500
B.C. Afterward, devices, for example, Archimedes‟ screw permitted effective exchange of
water starting with one level then onto the next. The Chinese, after 200 C.E., were found to
utilize hand cranks to help in material assembling, metallurgy and horticulture. After the
midfifteenth century, the strategy of fusing flywheels to deliver smooth movement multiplied,
permitting devices for example, the turning wheel to pick up prominence in Europe. Hand
cranks and pedal power ended up a standout amongst the most proficient methods for coupling
human power to applications. In the nineteenth century, the bike's utilization of pedals permitted
an effective method for self-transportation. In parallel with the innovation of the electric
dynamo in the nineteenth century, it is theorized that pedal power was utilized to create electric
power as right on time as at that point. Nonetheless, with the prospering of the modern
transformation in the nineteenth century and forward, human culture discovered different
methods for powering their built applications. Especially, the accessibility of shoddy and
copious power, powerful engines and expendable batteries can be ascribed to the lessening in
ubiquity of utilizing human quality. Moreover, the moral ramifications of having humans
deliver vitality as discipline, as found in some jail processes additionally decreased the notoriety
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of human sourced power. It would take until the point when the last 50% of the twentieth
Today, Human power is used in applications like water pumping, honey extracting, water
filtration, air compressing, exercise equipment for power generation, concrete mixing, grinding
machines, clothes washing, juice making, wood cutting, metal cutting and hundreds of many
more applications in daily life. Presently human power has made kind of a rebound with
numerous applications where it can be useful and the motivation to explore is elective vitality.
A novel sentiment empowerment is perceived when individuals can get things done for which
they needed to depend on machines already. To such an extent, that powering exclusively from
human vitality exists as a specialized test. For instance, the American Society of Mechanical
Engineers (ASME) holds the Human Powered Vehicle Challenge (HPVC) rivalry every year
for urging advanced education understudies to develop and contend with single-driver models
power by the driver alone. Further, the Royal Aeronautical Society has different difficulties for
the Kremer's prizes in human powered flight. Human power has additionally been observed to
At the point when the energy in of humans is considered, a vast potential appears to be evident.
Considering the standard 2000kcal of daily food utilization (97W of power in, overall), humans
take in around 8.368MJ or 2324Wh of energy each and every day. This is roughly a similar
measure of energy stored in the normal auto battery (2400Wh). This energy can be utilized
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2.4 Pedal Power Cutting Machine:
In this project, we are going to design and fabricate a metal-wood cutting machine which is
operated with the help of human assistance, in other words our objective is to construct a human
powered metal-wood cutting machine. This arises question in our minds that in this era of
technology in which machines are being automated and being relieved of human intervention
why we have taken a step backward and made a machine which operates or functions with the
help of human power. The answer to this question is that in a country like
Pakistan which is classified as a third world country is suffering from severe power shortages.
Around 30 million people in different areas of Pakistan are living without electricity and their
electrification may take several years, the people associated with the program say. The goal
“Electricity for All” was to be achieved by 2007 by electrifying all the villages in Pakistan, but
the financial and power supply shortages are the major reasons behind the non-achievement of
this goal. A data reads that out of 125,000 villages in Pakistan, around 95,000 have been
electrified and some 30,000 villages are still to be electrified. By determining average
population of a village as 1,000, the number of persons living without power in Pakistan in 21st
century is touching 30 million. Lack of electricity in the areas means the people are living
without televisions, fridges, mobile phones and other necessities of life in the 21st century.
Regions in Pakistan even lack the basic facility of electricity due to which people living there
are unable to get advantage from the latest appliances which work on electricity. In these
regions cutting of metal by using hands which take large time for the habitants. To provide them
facility of a cutting machine which doesn’t required electricity. Our cutting machine provides
solution to the people living in remote areas of Pakistan which are deprived of basic facility of
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life i.e. electricity. In short words, this cutting machine is a blessing in the disguise for the poor
people.
Secondly the reason for designing and fabrication of this type of machine was that it was
earlier told in the paragraph that we live in a third world country which is deprived of basic
facilities so people are generally illiterate and have less knowledge of operating machines so
this kind of cutting machine which only operates with the help of human power is of great
Third reason for designing and fabricating this kind of cutting machine is that it provides
opportunity for people to exercise. In this modern or fast world people have limited time to
exercise which is leading to increase in weight of the people. Lack of exercise is the source of
many diseases in the human body. This kind of cutting machine provides great source for
exercise which burns the calories and prevents lot of diseases. Exercise keeps a person healthy
and fit, cutting machine is of great advantage for the people. Burning of calories by doing
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Table 1 calories burning chart by doing different activities
These all reasons contribute for the design and fabrication of such cutting machine which is of
great use for humanity. As explained earlier the cutting machine is machine which targets
people living in the third world countries such as Pakistan in which remote areas lack basic
facilities such as electricity and people here are generally illiterate who have less knowledge of
operating machines which are highly automated and difficult to use for such people. It also
generally targets people of middle and lower middle-class families who are not capable of
buying such expensive machines. The cost of the human powered cutting machine is
approximately 6-8 thousand which is in limit of such families as compared to the modern power
hacksaw which are highly expensive and are in 35-70 thousand range which cannot be bought
by everyone. Another advantage of these kind of machine as explained earlier is that they
provide source of exercise for people who are deeply involved in their work throughout the day
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and don’t have enough amount of time for exercise. [18] Exercise is really essential for human
life. These all factors contribute in our idea for designing and fabricating such kind of cutting
machine.
This machine will easily cut wood piece of 30-40 mm diameter within 10-20 sec, and metal
piece of 26mm approximately in 7 min. Quality of machine is that it provides very smooth and
aligned cut.
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CHAPTER 3 DESIGN
METHODOLOGY
Machine Sub-Systems
The major functions of the machine fall into three sub units: the energy unit, the transmission
unit, and the cutting unit. Energy unit is composed of pedal crank assembly used to manually
power the machine. The transmission unit is made up of chain drive transmission arrangements
which involve the chain running over a pair of sprockets as front & Rear sprockets. This unit
also has the crank disc directly attached to a rear sprocket, connecting rod and slider assembly.
The cutting unit contains of hacksaw frame, blade and the vice.
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3.1.1 Design parameters:
• It should be available and inexpensive by low income groups, and should accomplish
• Care must be taken up to assure that the power take-off assembly is far enough ahead
so as not to obstruct with pedaling. Most typical bicycle frames have ample of room for
a) Pedal Crank
Two pedals are set to form a couple through a pedal shaft. In action, the pedals and their shaft
are stressed out due to burden of the worker as he uses his feet and leg to turn around the pedal
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about the crank axel. Therefore, in sort to protect against breakdown, the diameter of shaft is
determined from
Where, dp is the pedal shaft diameter, F is the maximum force preferred which worker may use
b) Sprocket Design
The number of teeth on both front & rear sprockets were measured, based on the transmission
ratio required between the front and rare sprocket, using a below Equation
Where, i=1.2 is the transmission ratio, z1 is the number of teeth on driven sprocket/ and z2 is
c) Chain Design
Chain drive full length was resolute by using the design equation (Jayakumar 2012, 40) as:
where, LCD is the length of chain, an is the inside separation between tomahawks of greater
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d) Bearing Selection
The pedal shafts at the greater sprocket and the pinion gone through heading at the two finishes
of each pole amid activity of the machine. The fundamental load evaluations were resolved
where, Cb is the essential dynamic load rating, We is the equal load, Ld is the plan life of
bearing to fill machine need (Khurmi and Gupta 2008), z is a steady for all course and Nd is
e) Hacksaw-Blade Selection
The hacksaw sharp edge which plays out the cutting amid machine activity is relied upon to
slice through work piece between 10-30 mm thick. Consequently, a rapid steel hex cutting edge
The partner shaft is one a player in the machine which ensures that rotational development of
the turning circle is gotten as reacting development by the hacksaw in a torque and slider
instrument. The bar is subjected to compressive power in the midst of assignment of the
machine. The power yielded in the forward advancement of the hacksaw against the workpiece
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may tend to catch the bar with its fair-minded center point. Likewise, remembering the ultimate
objective to shield against catching, the cross-sectional domain, an is settled from condition:
where, Wbk is the clasping load following up on associating bar, k is the range of gyration
between the turning circle and the pivoted end of the pole, σc is the devastating worry of gentle
steel material, an is the Rankine's consistent and Lh is the length of interfacing pole., g)
The rotating plate is the part controlled by methods for the pinion shaft from the transformation
of the pinion at the opposite side of the circle. It is the torque which changes over this
development to a reacting development required by the hacksaw. The thickness of the plate
measures up to that of the interfacing bar with a separation crosswise over of 210 mm.
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3.3 Drawing:
22
Figure 5 Base Frame
23
Figure 7 Crank disc
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CHAPTER 4
EXPERIMENTATIONS OR SIMULATIONS
It involves the pedal game-plan which turns the torque and through it slider contains influencing
instrument. The power is transmitted to the torque and slider segment. This framework is used
to turn the torque plate; the circle which is having an extended bar is related with the sliding
piece of the hacksaw clearly by techniques for a linkage. The hacksaw is experienced the guide
courses by strategies for keeping up the cutting turn. As the customer worked the pedal, the
hack saw cuts the distinctive materials therefore with less power. The dead weight is for
25
Figure 9 Frame design
26
Figure 10 Large sprocket
27
Figure 12 Crank disc
Table 2 Number of strokes and time taken to completely cut a metal rod
Table 3 Cutting depth and the time taken to cut the various wood pieces
28
29
CHAPTER 5
6.1 Conclusion:
The advancement of the pedal controlled hacksaw has been effectively finished and its goals
completely accomplished. It is vital to take note of that plan and improvement of the pedal
fueled hacksaw was based on the materials locally accessible. The result of the venture was
effective, as it requires little upkeep what's more, the machine can be worked helpfully by
individuals of various statures since both the seat and handle are customizable, hence making
it ergonomically compelling. All the more thus, the machine can be utilized when there is
control blackout and in remote territories and there is simplicity of task which makes it simple
for any individual to work independent of his/her instruction foundation as it doesn't require a
preparation permit. The pedal controlled hacksaw isn't costly or not too substantial yet has the
required quality and ability to work with little vibration and the machine can cut materials
Hence with a minimal effort and straightforward outline pedal worked human powered hack
saw machine is manufactured. This machine lessens the human exertion and henceforth we
require one person to cut the wooden as well as metals. This basic plan which can upgrade day
today family unit needs and day by day everyday purposes and it can be additionally utilized as
a part of for mechanical applications amid control close down situations. By utilizing this
strategy we can do any activity according to our necessity without the utilization of power. So
Followings are the different types of a operation that can be carried out by the proper Human
31
Figure 15 human powered compost chipper
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CHAPTER 7
REFERENCES
1. Dr. S. S. Umale, Apurva Walke, Ashwini Ganacharya, Saurabh Thapliyal, Design,
2. Dhanasegaran, Dhilip Kumar, Dinesh Kumar, Gopi Kumar and S.Gokul, Design and
3. Zoeb khan , “ Design and Fabrication of Human Powered Wood Cutting machine”
Boulevard USA.
5. Linxu, Weinan Bai, Jingyu Ru,Qiang Li, “Design and Implementaion of the
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Research (Vol.282-283 (2011) pp 735-738 .
6. S.G.Bahaley,Dr.A.U.Awate, S.V.Saharkar, “Performance Analysis of Pedal Powered
ISSN: 2321-9637
International Journal of Engineering And Science Vol.4, Issue 7 (July 2014), PP 01-05
does not require electricity for several operations like cutting, grinding”, International
(2013).
10. M. Khaja Gulam Hussain, T. John babu,” Fabrication of pedal powered hacksaw
machine”, International Journal of Scientific Development and Research, ISSN:
24552631.
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