29-09-2016, 11:53 AM
1456759396-paperid34201521.pdf (Size: 60.81 KB / Downloads: 13)
Abstract- There are many industrial applications where round bar or square bars are required to be operated on
different machines to make machine components such as Shafts, Bolts, Screws etc. This needs more and more
number of pieces to be cut for mass production of those components. To achieve this goal the Multi-way power
hacksaw machine is developed. This paper proposes the model of multi-way hacksaw machine which is able to
cut four pieces simultaneously without any jerk and minimum vibrations. The model implies conversion of
rotary motion into the reciprocating motion for proper working of hacksaw. This model overcomes the
limitations of conventional hacksaw machines which can cut single piece at a time. It is able to cut metal bars of
different materials at same time and will be helpful in many industries due its compatibility, reliability and
efficiency.
INTRODUCTION
In present condition many electrically operated power
hacksaw machines of different companies with
different specifications are available for the use in
shop floor. These machines are so precise that they
can cut metal bars with minimum time made up of
different materials but they have one and major
disadvantage that those are able to cut single piece of
bar at a time. For industries to achieve the mass
production, it is necessary to cut metal bars with high
rate. So it is impossible to depend upon conventional
single frame power hacksaw machines and need the
improvement in technology and design of such
machines. With the help of this multi-way power
hacksaw machine the four metal bars can be cut
simultaneously to get high speed cutting rate and to
achieve mass production for maximum profit in
related companies. As this machine overcomes all the
limitations and drawbacks of conventional hacksaw
machines, it is also helpful for small scale industries
due to its simple working and operating conditions
along with its compatibility, efficiency and affordable
price.
2. PROJECT IDEATION
Current scenario of industry focuses on the high
production rate with less consumption of resources.
To achieve this we need to minimize idle time and
machine time per unit. The multi-way power hacksaw improves those factors by reducing time per unit to
increase the production.
2.1. Problem Definition
To cut different metal bar pieces with high rate and
accuracy to minimize an idle time.
2.1.1 Present method and problems associated
In present situation electrical as well as hydraulic
operated machines are used but the output from them
is not satisfactory as it has low cutting rate.
REVIEW OF LITERATURE
The vast review of literature will help to understand
the concepts, theorems and different factors affecting
the performance of machine. R.S.Khurmi, J.K.Gupta
in their book “Theory of machines” (Velocities in
mechanisms) helps to find Velocity diagrams of slider
crank mechanism.[06]
Prof. Nitinchandra R. Patel, Ravi Thakkar,
Miteshkumar Rathwa in his research paper “Material
selection and testing of hacksaw blade based on
mechanical properties” stated that the appropiate saw
blade must be selected for better operation and fine
cutting by selecting number of teeth per inch.[02]
There are four types of blades based on material
namely High Carbon steel, Alloy Steel, Bi-metallic
strip and High speed steel blades.[10] Out of these
four the best suitable for cutting hard materials like
Mild steel bar and Aluminium is Bi-metallic blade on
the basis of Properties of materials, Wear resistance
and Cutting performance.
D.V.Sabarinanda, V.Siddhartha, T.Mohanraj in their
paper “Design and Fabrication of Automated
Hacksaw Machine” (April 2014) gives an idea about
the various components required for fabrication of the
proposed model [01],[07],[08]. These components
will help to get smooth working condition and future
automation of different mechanical actions as well as
linkages.
O.Cakir, A. Yardimen, T. Ozben in the paper
“Selection of cutting fluids in machining processes”
gives directions about selection of proper cutting
fluids [03]. The suitable cutting fluid is required to
select for the purpose of cooling, to avoid friction and
making smooth operation and removal of burr.
3.1. Conventional Hacksaw Machine
All the conventional power hacksaw machines contain
main four components are Base, Frame, Vise and
Speed change mechanism etc. The conventional
machine contains complex design and working. The
processes like frame reciprocation, lifting up of frame
after cutting stroke etc.
4. PROPOSED METHODOLOGY
This project consists of single phase vertical electric
motor rigidly placed at the center of metallic
foundation provided. The shaft of motor rotates at 90-
100 rpm with the power 2HP. The circular disc is
mounted on the shaft of motor with the help of key
and key slot arrangement. The eccentric point on the
plane of disc is provided such that the desired cutting
stroke is achieved (around 4-5 inches). One end of
each connecting rod is pivoted at this eccentric point
by the use of suitable bearing. Another end of each
rod is connected to the hacksaw blade fame with the help of universal joint to get vertical and horizontal
Degree of Freedom of rotation for the proper cutting
operation. The hacksaw frame slides on the guide
ways provided. When motor is ON and disc starts
rotating, due to the reciprocating motion of hacksaw
frame the metal rod is cut which is firmly fixed in
vise. The automatic feeding of coolant is provided to
reduce heat generated due to friction which also
avoids the jerk.