International Journal of Research in Advent Technology, Vol.3, No.

4, April 2015
E-ISSN: 2321-9637

Theoretical Analysis of Multi-Way Power Hacksaw

Machine
Prof. Kshirsagar Prashant R.1, Rathod Nayan J2, Rahate Prashant P3, Halaye Prashant P4 ,
Surve Sachin S5
Assistant Professor1, Final Year Students2,3,4,5 ,Department of Mechanical Engineering, RMCET,Ambav
(Devrukh),Ratnagiri Maharashtra,India.
Email: ksprashant007@gmail.com1

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.

Index Terms- Multi-way hacksaw machine, teeth per inch, power hacksaw

1. INTRODUCTION
In present condition many electrically operated power improves those factors by reducing time per unit to
hacksaw machines of different companies with increase the production.
different specifications are available for the use in
shop floor. These machines are so precise that they 2.1. Problem Definition
can cut metal bars with minimum time made up of
different materials but they have one and major To cut different metal bar pieces with high rate and
disadvantage that those are able to cut single piece of accuracy to minimize an idle time.
bar at a time. For industries to achieve the mass
production, it is necessary to cut metal bars with high 2.1.1 Present method and problems associated
rate. So it is impossible to depend upon conventional
single frame power hacksaw machines and need the In present situation electrical as well as hydraulic
improvement in technology and design of such operated machines are used but the output from them
machines. With the help of this multi-way power is not satisfactory as it has low cutting rate.
hacksaw machine the four metal bars can be cut
simultaneously to get high speed cutting rate and to 2.2. List of components with materials[6],[7],[8]
achieve mass production for maximum profit in
related companies. As this machine overcomes all the Following are the important parts of hacksaw
limitations and drawbacks of conventional hacksaw machines.
machines, it is also helpful for small scale industries
due to its simple working and operating conditions No. Components Material
along with its compatibility, efficiency and affordable 1 Single phase electric motor -
price. 2 Disc MS
3 Hacksaw Blade Bi-metallic
2. PROJECT IDEATION 4 Hacksaw Frame MS
5 Guide ways MS
Current scenario of industry focuses on the high 6 Universal joints Alloy steel
production rate with less consumption of resources. 7 Connecting rods MS
To achieve this we need to minimize idle time and 8 Bearings High C-Cr steel
machine time per unit. The multi-way power hacksaw 9 Cooling pumps -
10 Material holding vise MS
11 Base MS
Table no. 1

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3. REVIEW OF LITERATURE help of universal joint to get vertical and horizontal
The vast review of literature will help to understand Degree of Freedom of rotation for the proper cutting
the concepts, theorems and different factors affecting operation. The hacksaw frame slides on the guide
the performance of machine. R.S.Khurmi, J.K.Gupta ways provided. When motor is ON and disc starts
in their book “Theory of machines” (Velocities in rotating, due to the reciprocating motion of hacksaw
mechanisms) helps to find Velocity diagrams of slider frame the metal rod is cut which is firmly fixed in
crank mechanism.[06] vise. The automatic feeding of coolant is provided to
Prof. Nitinchandra R. Patel, Ravi Thakkar, reduce heat generated due to friction which also
Miteshkumar Rathwa in his research paper “Material avoids the jerk.
selection and testing of hacksaw blade based on
mechanical properties” stated that the appropiate saw 5. CAD Model of machine [9],[11]
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 Fig.1 Proposed model of Multi-way power hacksaw
making smooth operation and removal of burr. machine

3.1. Conventional Hacksaw Machine

6. DESIGN CALCULATIONS
All the conventional power hacksaw machines contain
main four components are Base, Frame, Vise and B
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.
P
4. PROPOSED METHODOLOGY
This project consists of single phase vertical electric
A C
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
D
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 Fig.2 Top view of the power hacksaw machine
rod is connected to the hacksaw blade fame with the

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6.1 Torque Calculations:[4],[5] So,
𝑇0 × 9.42 = 850 𝑁𝑚/𝑠e𝑐
From Velocity Diagram, 𝑇0 = 90.23 𝑁𝑚
Considering cutting stroke length 5i𝑛𝑐ℎe𝑠 = 125𝑚𝑚 Available Torque
𝑃 = 2𝜋𝑁𝑇 / 60
(Value taken by referring hacksaw manufacturer’s Wℎe𝑟e 𝑁 = 90 𝑟𝑝𝑚
catalogue) 𝑃 = 2𝐻𝑃 = 1492 W 𝑎𝑠 1𝐻𝑃 = 746 W𝑎𝑡𝑡
As we know 𝑙 = 2𝑟; where 𝑟 =crank radius 𝑇 = 158.30 𝑁 − 𝑚
Therefore 𝑟 = 2.5i𝑛𝑐ℎ = 62.5𝑚𝑚
The length of connecting rod = 300𝑚𝑚 7. FURTHER SUGGESTED WORK AND
Speed= 𝑁 = 90𝑟𝑝𝑚 (as per catalogue) CONCLUSION
2𝜋𝑁
So angular velocity 𝜔 = = 9.424 𝑟𝑎𝑑/𝑠e𝑐
60 7.1 Future work
Here 𝑂𝑃 = 𝑐𝑟𝑎𝑛𝑘 𝑟𝑎𝑑i𝑢𝑠
𝑂𝐴 = 𝑂𝐵 = 𝑂𝐶 = 𝑂𝐷 = 𝑐o𝑛𝑛e𝑐𝑡i𝑛𝑔 𝑟o𝑑𝑠  The maximum size of Round or Square bar
𝜔𝑝o = 9.42 𝑟𝑎𝑑/𝑠e𝑐 can be increased by increasing the
since op=0.0625m motor power and dimensions of different
so velocity of p wrt o parts.
𝑉𝑝o = 𝑉𝑝 = 9.42 × 0.0625 = 0.588𝑚/𝑠e𝑐  Automatic feeding mechanism for material
can be introduced by using limit switches or
sensors.
b 𝑉𝑏  Automatic lifting up mechanism for frame
p when cutting operation is finished to
Vd introduce next portion of bar for cutting.
d
7.2 Conclusion
As per the above discussion we concluded that to
overcome problems in conventional hacksaw
Vp Vc Va machines, due to high efficiency, easy to operate and
affordable price the proposed model of multi-way
power hacksaw machine is helpful and completes all
the expectations needed in the mini industries.
Future scope of proposed research work to increase
the production rate, cuts the metal bars easily. It can
o c a withstand the vibrations, no hazards from jerk, no
special training required to operate it.
Fig.3 Velocity Diagram (Scale 0.588𝑚/𝑠e𝑐=50mm)
REFERENCES
From velocity diagram, we get velocities of slider [1] D.V.Sabarinanda, V.Siddhartha, B. Sushil
𝑉𝑎𝑝 = 4.4𝑐𝑚/𝑠e𝑐 = 0.44𝑚/𝑠e𝑐 Krishnana, T.Mohanraj , “Design and Fabrication
𝑉𝑏𝑝 = 4.1𝑐𝑚/𝑠e𝑐 = 0.41𝑚/𝑠e𝑐 of Automated Hacksaw Machine”, International
𝑉𝑐𝑝 = 4.4𝑐𝑚/𝑠e𝑐 = 0.44𝑚/𝑠e𝑐 Journal of Innovative Research in Science,
𝑉𝑑𝑝 = 4.1𝑐𝑚/𝑠e𝑐 = 0.41𝑚/𝑠e𝑐 Engineering and Technology, ISSN (Online):
2319-8753, volume 3, April 2014.
[2] Prof. Nitinchandra R. Patel, Mohammad A.
Required Torque Vasanwala, Balkrushna B. Jani, Ravi Thakkar,
Miteshkumar D. Rathwa, ”Material selection and
We know forces at A, B, C,D testing of hacksaw blade based on mechanical
𝐹𝐴 = 𝐹𝐵 = 𝐹𝐶 = 𝐹𝐷 = 500𝑁 properties”, International Journal of Innovative
𝑃owe𝑟 o𝑢𝑡𝑝𝑢𝑡 = 𝑇o × 𝜔𝑝o Research in Science, Engineering and
= 𝑇o × 9.42 𝑁𝑚/𝑠e𝑐 Technology, ISSN: 2319-8753, volume 2, Issue
6, June 2013.
𝑃owe𝑟 i𝑛𝑝𝑢𝑡 = (𝐹Æ × 𝑉Æ) + (𝐹𝐵 × 𝑉𝐵 ) [3] O.Cakir, A. Yardimen, T. Ozben, “Selection of
+ (𝐹𝐶 × 𝑉𝐶 ) + (𝐹𝐷 × 𝑉𝐷 ) cutting fluids in machining processes”, Journal of
= (500 × 0.44) + (500 × 0.41) Achievements in Materials and Manufacturing
Engineering, volume 25, Issue 2, December
+(500 × 0.44) + (500 × 0.41)
2007.
= 850 𝑁𝑚 /𝑠e𝑐
[4] R. Subhash, C.M. Meenakshi, K. Samuel
Neglecting losses power input is equal to power
Jayakaran, C. Venkateswaran, R. Sasidharan,
output
“Fabrication pedal powered hacksaw using dual

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2015
chain drive”, International Journal of Engineering
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[5] Dr. V.P. Singh, (2007)”Mechanical Vibration”,
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machines”, Page no. 143-168
[7] PSG College of Technology, (2007) “Design
Data Book”, Page no. 1.4-1.37
[8] V.B.Bhandari, Design of machine elements, Year
2007, Page no. 5-7 & 20-39
[9] Walter E. Burton, (1964), “Homemade Power
hacksaw for less than $20”, Popular science, Feb
1964.
[10] Micro, Small and Medium Enterprises
Development Institute, ”Project profile on
hacksaw blade manufacturing”, NIC code: 28939,
ASICC code: 71303, 2010-11.
[11] Bradford Dittmer,” Build a power hacksaw from
washing machine parts”.