i DEVELOPMENT OF AN AUTOMATIC HACKSAW MACHINE BY : THARMARAJA A/L WILLIAM DARMILAN A/L KARTHIGEYAN Supervisor : EN. NOR AZMAN BIN SAMSURI DMU 34 FINAL YEAR PROJECT INDUSTRIAL MAINTENANCE DEVELOPMENT OF AUTOMATIC HACKSAW FOR DIPLOMA SKILLS MALAYSIA INSTITUT KEMAHIRAN TINGGI BELIA NEGARA BUKIT MERTAJAM, JALAN BERAPIT, 14000 BUKIT MERTAJAM, PULAU PINANG SESI 2/2021
ii APPRECIATION I would like to express my deepest appreciation to all those who provided me the possibility to complete this report. A special gratitude I give to our class teacher, Pn. Nor Rumaizah Binti Azmi whose contribution in stimulating suggestions and encouragement, helped me to coordinate my project especially in writing this report. Furthermore, we also want to express my gratitude to the IKTBN BM primarily to be Department of Mechanical Industrial because it provides all the equipment and items that we need throughout this project. Especially the tools at the workshop. Last but not least, many thank our project supervisor, En.Nor Azman Bin Samsuri whose have invested his full effort in guiding us in achieving the goal. I also would like to express my appreciation to everybody that are involved whether direct or indirect for their suggestions and assistance during the preparation of final project and all class mate for their help and meaningful contributions to this final project. Finally, very special thanks to my family and friends for their encouragement and support.
iii THIS REPORT BEEN SUBMITTED TO MECHANICAL DEPARTMENT IKTBN (BM) AS ONE OF THE REQUIREMENT IN DIPLOMA MECHANICAL TECHNOLOGY 2023 APPLIED MECHANICAL DEPARTMENT FINAL YEAR PROJECT REPORT VALIDATION With the approval for this report has fulfilled one of the requirements to obtain Diploma Mechanical Technology. Supervisor ’s Signature : ( EN. NOR AZMAN BIN SAMSURI ) Coordinator ’s Signature : ( PN. NOR RUMAIZAH BINTI AZMI )
iv APPLIED MECHANICAL DEPARTMENT IKTBN (BM) FINAL YEAR PROJECT REPORT CERTIFICATION We hereby prove this report is made by us except and summaries that have been explain from the resources. Signature : Student’s Name : DARMILAN A/L KARTHIGEYAN Student’s Number : 023256 Signature : Student’s Name : THARMARAJA A/L WILLIAM Student’s Number : 023298
v ABSTRACT As we were given the project to choose from different topics we have decide to pick this Automatic Hacksaw. We felt there is a need for this type of Hacksaw machine as it will be used in the factories, workshop, and home use. While the manual hacksaw as a simple hand tool for cutting metals and nonmetals cannot be overemphasized the manual labour. This may have led to the idea of applying power to the principle of saws originally designed for executing various cutting operation that requires the use of simple hand tools. However, power hacksaw is a type of hacksaws that is powered by electric motor with low speed, and sometimes requires reduction from the normal motor speed to a moderately low speed that is suitable enough to drive the sewing machine parts. Power hacksaws are widely applicable in operations that require cutting large dimension materials such as metals, wood, plastics, glasses etc. Technicians and craftsmen would agree to the fact that cutting of solid shafts or rods with diameters exceeding 15mm thickness is a very difficult task to be achieved with normal hand held hacksaw which is where the power hacksaw machine comes into play. The power hacksaw machine is a piece of equipment that is designed to cut material to desired length and contours, there by simplifying the cutting process for the machine operator by essentially saving time, energy and material wastage. In other words, power hacksaw machine is faster, easier and more accurate in terms of precision cutting than hand sawing and is mainly used in producing accurate angular cutting as well as square or metered cutting on a workpiece. The operation principles of power hacksaw and the bandsaw which are the two commonly used sawing machines involve running a blade with series of teeth on its edge through a given workpiece to cut a narrow opening into a workpiece.
vi ABSTRAK Kami telah diberi projek untuk memilih dari topik yang luas, kami telah memutuskan untuk memilih Hacksaw Automatik ini. Kami merasakan terdapat keperluan untuk mesin Hacksaw automatik kerana ia akan digunakan di kilang, bengkel, dan penggunaan rumah. Walaupun gergaji manual sebagai alat tangan mudah untuk memotong logam dan bukan logam tidak boleh terlalu ditekankan buruh manual. Ini mungkin membawa kepada idea untuk menggunakan kuasa kepada prinsip gergaji yang pada asalnya direka untuk melaksanakan pelbagai operasi pemotongan yang memerlukan penggunaan alat tangan mudah. Walau bagaimanapun, gergaji kuasa adalah sejenis gergaji hack yang dikuasakan oleh motor elektrik dengan kelajuan rendah, dan kadang-kadang memerlukan pengurangan dari kelajuan motor biasa ke kelajuan sederhana rendah yang cukup sesuai untuk memacu bahagian mesin jahit. Power hacksaws digunakan secara meluas dalam operasi yang memerlukan pemotongan bahan dimensi besar seperti logam, kayu, plastik, cermin mata dan lain-lain. Juruteknik dan tukang akan bersetuju dengan hakikat bahawa pemotongan aci pepejal atau rod dengan diameter melebihi ketebalan 15mm adalah tugas yang sangat sukar untuk dicapai dengan tangan biasa dipegang hacksaw iaitu di mana mesin hacksaw kuasa dimainkan. Mesin gergaji kuasa adalah sekeping peralatan yang direka untuk memotong bahan kepada panjang dan kontur yang dikehendaki, di sana dengan memudahkan proses pemotongan untuk pengendali mesin dengan pada dasarnya menjimatkan masa, tenaga dan pembaziran bahan. Dalam erti kata lain, mesin gergaji kuasa lebih cepat, lebih mudah dan lebih tepat dari segi pemotongan ketepatan daripada gergaji tangan dan terutamanya digunakan dalam menghasilkan pemotongan sudut yang tepat serta pemotongan persegi atau meter pada bahan kerja. Prinsip operasi gergaji kuasa dan bandsaw yang merupakan dua mesin gergaji yang biasa digunakan melibatkan menjalankan bilah dengan siri gigi di pinggirnya melalui bahan kerja yang diberikan untuk memotong pembukaan sempit ke dalam bahan kerja.
vii INDEKS CHAPTER SUBJECT PAGE TITLE I. APPRECIATION II. REPORT VALIDATION III. REPORT CERTIFICATION IV. ABSTRACT / ABSTRAK V – VI INDEKS VII, VIII, IX CHAP 1 INTRODUCTIONS 1.1 PROJECT INTRODUCTION 1 1.2 PROBLEM STATEMENT 2 1.3 PROJECT OBJECTIVE 3 1.4 PROJECT LIMITATION 3 1.5 PRODUCT SPECIFICATION 4 1.6 PROJECT BENEFITS 5 CHAP 2 LITERATURE REVIEW 2.1 RISK STUDY 6 2.2 LITERATURE SURVEY 6 2.3 COMPARING 7 2.4 DOCUMENTATION 8 2.5 INSTALLATION 8
viii 2.6 LIFE EXPECTANCY 8 2.7 DESCRIPTION OF USING CAD/CAM 9 2.8 CAD MODEL FOR DESIGN 9 2.9 MAIN COMPONENTS USED IN AUTOMATIC HACKSAW 10 – 21 2.10 SURROUNDINGS 22 2.11 QUALITY AND PERFORMANCE 22 CHAP 3 METHODOLOGY 3.1 INTRODUCTION 23 3.2 PLANNING AND PROJECT IMPLEMENTATION 24 3.3 GANTT CHART 25 3.4 DESIGN 26 – 29 3.4 ASSEMBLY DRAWING 30 – 32 3.5 BILL OF MATERIALS 33 3.6 WORK PART 33 3.7 WORK STEP 34 – 35 3.8 USED METHOD 36 – 42 3.9 EQUIPMENT AND HARDWARE 43 3.10 COMPUTER SOFTWARE 44 3.11 MEASURING TOLLS 44 3.12 QUALITY CONTROL 45 3.13 MEASURING TOOLS 45 3.14 ASSEMBLY CONCEPT 46
ix 3.15 COSTING 47 3.16 TOTAL MANUFACTURE TIME CALCULATION 47 3.17 RAW MATERIAL COST 48 3.18 STANDARD PARTS 49 – 50 CHAP 4 DISCOVERY AND ANALYSIS 4.1 INTRODUCTION 51 4.2 RESULT 51 4.3 DISCUSSION 51 4.4 SAFETY 52 – 53 4.5 ADJUSTMENT 53 4.6 DATA ANALYSIS 54 4.7 SUMMARY ANALYSIS 55 4.8 TROUBLESHOOT 56 4.9 CONCEPT AND FUNCTIONING 57 – 59 CHAP 5 CONCLUSION AND SUGGESTION 5.1 DISCUSSION 60 5.2 PROBLEMS AND SOLUTIONS 61 5.3 RECOMMENDATION FOR IMPROVEMENTS 61 5.4 CONCLUSION 62 5.5 SUGGESTION 62 5.6 REFFERENCE 63
1 CHAPTER 1 INTRODUCTION 1.1 PROJECT INTRODUCTION In present condition many electrically operated hacksaw machines of different companies with different specifications are available for the use in the shop floor. The automatic hacksaw is considered as an automatic machine because the operator need not be there to provide the reciprocating motion and downward force on the work-piece in order to cut it. Once the operator has fed the work-piece till the required length in to the machine and starts the machine, then the machine will cut until the work-piece has been completely cut in to two pieces. These machines are so precise that they can cut the materials with minimum time made up of different dimensions. The Power hacksaw machine though being able to cut the material or rod without requiring any human effort to cut, it does require a human intervention to feed the work-piece many times with measurements being taken each time before feeding. There in, arose a need to completely automate the process of cutting, and here we are with a proposal which will aid in eliminate the effort of the people associated with it. It is designed to simplify the cutting process and cut the material in desired contours and length thus helps in saving energy and material wastage. As this machine overcomes all the limitations and drawbacks of conventional hacksaw machines, it is also helpful for big-scale industries due to its simple working and operating conditions along with its compatibility, efficiency and affordable price. In small machine shops, mostly there is a need to cut a small workpiece and a power hacksaw qualifies the best for the job because of its low power consumption, portability, ability to cut with accurate. Automatic hacksaws are also extremely reliable due to their compatibility, affordability, and efficiency. Hacksaw’s cutting action is different from other cutting tools like milling, turning, etc. Because the blades operate normally and it’s cutting-edge radius is more than the depth of cut. This project is about cutting the metal, wood, pipe, flat plates, rods and such other things. This project is very much useful and easy to install and operate by the user.
2 1.2 PROBLEM STATEMENT As we were given the project to choose from different topics we have decide to pick this Development Automatic Hacksaw. We felt there is a need this type of hacksaw machine in industries. The manual hacksaw was a simple hand tool but the problem is when operator using handsaw to cut the material it will not straight. It was more difficult than using a hacksaw machine. If Workers force too hard on manual hacksaw they will get tied. The second problem is industry worker mostly using bandsaw machine for cutting small workpiece also. It may take time using bandsaw machine for cut the small part. If the bandsaw is broken, they need to replace the new parts and the price of the part is more expensive. When bandsaw was in maintenance, the production time will be delay. Therefore, we list the following problems: i. The students has difficulty in making straight cut by using a handsaw. ii. Cutting with a hacksaw machine is more tiring. iii. The Bandsaw machine in industry were more expensive and costlier to maintain.
3 1.3 PROJECT OBJECTIVE Project objectives are what we plan to achieve by our final year project was making Automatic Hacksaw Machine to help IKTBN (BM) student to use it easily and safely. Furthermore, we created a budget hacksaw machine to help industries to cut small workpiece accurate and steady. It also can cut work pieces simultaneously. We can save more production time. Then using our automatic hacksaw the user can save from injury because in our machine we have installed an emergency stop switch. If any think happen the user can press the emergency stop button. Our hacksaw machine repairing and replacement is not difficult task and the part of our project is not expensive. In other words, our Automatic hacksaw machine is faster, easier and more accurate then manual handsaw. In addition, we have other functionality for this product as well. We list 3 main objectives of this product : i. To design a machine saw which it easily to operate. ii. To reduce the cost of maintaining our hacksaw machine. iii. To reduces time compare to manual cutting using handsaw 1.4 PROJECT LIMITATION For limitation is the most important thing we should know about the project so that we can use it well. Then, limitation is something a project cannot do. It causes a project to break down when this limitation is not used. There are 5 limitations to this project: i. This machine can able to cut maximum 30 mm only. ii. Our machine can clamp maximum 100mm width only. iii. Our machine cannot cut sheet metal plates. iv. This machine cannot apply too much pressure on the blade.
4 1.5 PRODUCT SPECIFICATION Figure 1: Automatic Hacksaw Table 1:- Project Specification NAME PROJECT SPECIFICATION PROJECT Automatic Hacksaw SIZE 760x 380x430 WEIGHT 30Kg FUNCTION To cut Raw Materials. MATERIAL Aluminum , Steel & Metal
5 1.6 PROJECT BENEFITS The benefit from this project is type of Automatic Machine Tool whereas the whole purpose is cutting the materials metal or non-metal that consists less and high thickness material. The Hacksaw is a simple cutting tool operated manually that requires more effort. Moreover, we have listed the 5 benefits that come from this product: 1. The operation of power hacksaw is simple. 2. This type of machine tool can be operated at high speeds and even at low speeds. 3. The automatic hacksaw machine blades are easy to remove and fix. We use the different types of blades (according to the strength) for different types of materials. 4. This automatic hacksaw repairing and replacement is not difficult task to the user.
6 CHAPTER 2 LITERATURE REVIEW 2.1 RISK STUDY General After the study of many literatures about design, construction and working of automatic power hacksaw machine, some of them describe the methodology of automatic power hacksaw. Lots of factor have been consider for the design, construction and working of automatic power hacksaw machine such as cutting speed, cutting material, cutting time ,power ,efficiency etc. So, lots of literatures have been found which gives the relevance information and methodology of constructing an automatic power hacksaw machine. 2.2 LITERATURE SURVEY METHOD OF PRODUCE AUTOMATIC HACKSAW. We did some research about the equipment that we will use for our project. It is often required to machine a round and square rod on different machines to make various products like shaft, screws, bolts etc. In our research that the appropriate saw blade must be selected for better operation and fine cutting by selecting number of teeth per inch in “Material selection and testing of hacksaw blade based on mechanical properties” which is his research paper. There are four types of blades namely High Carbon steel, Alloy Steel, Bimetallic strip and High speed steel blades. Based on the properties of materials, Bi-metal 24TPI/10D is best suitable blade for cutting hard materials like Mild steel bar and Aluminum.
7 2.3 COMPARING The comparison between market product and own product has a lot of differences. Our product is lightweight than market product. The part is very expensive than our product because our part is cheaper and can replace easily. Although, the market product is expensive than our product. Figure 2- Market Price RM12,900.00 Figure 3:- Automatic Hacksaw RM800.00
8 2.4 DOCUMENTATION Hacksaw Machines offered by us are used for metal cutting ranging from transportable model to giant size machine. Owing to smooth & speedy functioning abilities, these hacks machines operations spontaneously for aiding the worker in consistently carrying his work with ultimate competence. A sewing machine is a machine tool designed to cut material to a desired length or contour. It functions by drawing a blade containing cutting teeth through the workpiece. The sewing machine is faster and easier than a hand saw and is used principally to produce an accurate square or mired cut on the workpiece. 2.5 INSTALLATION i. Installation explains and guides the users how the product is installed, so it does not require personnel to guide and explain the installation method for the product. ii. As for our product, the installation can be done by our personnel or by customer himself/herself as it is easy to install it. 2.6 LIFE EXPECTANCY Lifespan represents the lifespan of the product. It can be categorize in two ways which is Service Life and Product Life. i. As for our product, we will ensure that our product will be able to function in for as long as two to three years after purchase. ii. Other than that, is also known as a marketing strategy in the business. iii. Our product comes with warranty as well, which it can give information how the product is used so that we can review and improve the product to a newer product that can competes with other in the marketing by following the request by the customer in the industries.
9 2.7 DESCRIPTION OF USING CAD/CAM CAD/CAM technology is the result of decades of efforts by numerous people in the name of production automation. It is the vision of innovators and inventors, mathematicians and machinist, who are all working to build the future and drive production with technology. A lot of people use the term “CAD-CAM” when they talk about the software that is used to make things with a CNC machine. CAD stand for Computer-Aided Design and CAM stands for Computer-Aided manufacturing, both of which are used to make things. CAD/CAM software is used to design and manufacture prototypes, finished products, and production runs of product. At IKTBM (BM), they have the facilities for the CAD/CAM software. They have provided the best facilities for the students here. For the diploma course, CAD/CAM is one of the subjects that need to be learned. It is an important subject for mechanical course. For the CAM software, they are using the ESPRIT CAM software and for the CAD software, they are using CREO parametric. This software is very useful for us to manufacture our project. We can design the project by using the CREO parametric. By using this software, we can adjust the size of the project base on our desire. We are also able to assemble the part by using the feature that this software has. We can view the part that being assembled perfectly. For the machining process, we are using the ESPRIT CAM. It is able to simulate the machining process. We can view how the cutter is move and how the material is being cut. After that, we generate the program from this software and load the program in the CNC milling machine. 2.8 CAD MODEL FOR DESIGN A CAD model allows us to see a part in three dimensions, including any intricate features that would be difficult to depict in a two dimensional drawing. CAD files are useful in that they can be incorporated with other software such CAM software.
10 We have utilized the facilities that IKTBN (BM) have for the CAD software. We have used the CREO parametric 5.0 to design our project. It enables us to design the project base on the dimension and shape that we needed. From this software, we are able to assemble the part from the features that this software has. It enables us to view this project after being assembled. After we have done by designing the project, we are able to generate the drawing. The drawing that has been generated will be inserted in this report. 2.9 MAIN COMPONENTS USED IN AUTOMATIC HACK SAW i. Ac gear motor ii. Pulley iii. Hacksaw iv. Hacksaw Blade v. Limit switch vi. Wires vii. Base viii. Vice 2.9.1 AC Gear Motor "Ac gear motor" refers to a combination of a motor plus a reduction geartrain. These are often conveniently packaged together in one unit. The gear reduction (gear train) reduces the speed of the motor, with a corresponding increase in torque. A small ratio can be accomplished with a single gear pair, while a large ratio requires a series of gear reduction steps and thus more gears. There are a lot of different kinds of gear reduction. An AC motor is an electric motor driven by an alternating current (AC). The AC motor commonly consists of two basic parts, an outside stationary stator having coils supplied with alternating current to produce a rotating magnetic field, and an inside rotor attached to the output shaft producing a
11 second rotating magnetic field. The rotor magnetic field may be produced by permanent magnets, reluctance saliency, or DC or AC electrical windings. Less commonly, linear AC motors operate on similar principles as rotating motors but have their stationary and moving parts arranged in a straight line configuration, producing linear motion instead of rotation. In the case of a small transmission ratio N, the unit may be back drivable, meaning you can turn the output shaft, perhaps by hand, at angular velocity w and cause the motor to rotate at angular velocity Nw. A larger transmission ratio N may make the unit non-back drivable. Each has advantages for different circumstances. Back drivability depends not just on N, but on many other factors. For large N, often the maximum output torque is limited by the strength of the final gears, rather than by N times the motor's torque. Figure 4:- AC Gear Motor What Is a Gear Motor? Simply put, a gear motor is any electric motor coupled with a gear train. Gear motors use either AC (Alternating Current) or DC (Direct Current) power. In most cases, the gear reducer is intended to multiply the available output torque without increasing the power consumption of the motor while maintaining a compact size. The tradeoff for torque multiplication is a proportional reduction in the speed of the output shaft, and reduced overall efficiency. By utilizing the proper gear technology and ratio for specific applications, the optimal output and speed profiles can be obtained along with the perfect mechanical fit to unlock the maximum value of your OEM equipment.
12 Figure 5:- Gearbox What is a gearbox? The term 'Geared motor' or 'Motor Gearbox' refers to a combination of a motor plus a reduction gear train. These are often conveniently packaged together in one unit. The gear reduction (gear train) reduces the speed of the motor, with a corresponding increase in torque. A small ratio can be accomplished with a single gear pair, while a large ratio requires a series of gear reduction steps and thus more gears. There are a lot of different kinds of gear reduction, some of which we have described a little below. Most standard motors are only available in set speeds, these limit the functionality of the motor in certain applications, it also means that the output torque is 'set'. If you require larger amounts of torque but do not have space for a larger motor, a motor-gearbox unit can be used. If you would like even better control or a range of speed but with the additional torque, you may also like to add an Inverter to the mix. This will give you full control of the application and almost limitless options with regards output speeds and torque requirements.
13 Gearboxes & Speed For motor-only applications, the slower the motor speed, the larger the motor needs to be. Large motors can be expensive and may not fit within the allowable envelope space of an application. Using a gearbox with a smaller motor enables the unit to operate at lower speeds. In order to understand the importance of using a gearbox to decrease motor speed, consider this scenario. You have a pastry conveyor that adds cherry filling as the pastries go by. Because this is a fairly light load, you would not want the conveyor running at 5000 rpm. If it was, there would be pastries and cherry filling everywhere! Figure 6 & 7:- Pulley A pulley is a wheel on an axle or shaft that is designed to support movement and change of direction of a taut cable or belt, or transfer of power between the shaft and cable or belt. In the case of a pulley supported by a frame or shell that does not transfer power to a shaft, but is used to guide the cable or exert a force, the supporting shell is called a block, and the pulley may be called a sheave.
14 Figure 8:- Connecting Rod The connecting rod is used to connect the main screw and handle of hack saw. The metal is made tempered steel, which is hardened. The connecting rod undergoes fatigue and tensile load. So the steel has to be hardened. Figure 9:- Hack saw A hacksaw is a fine-toothed saw, originally and mainly made for cutting metal. The equivalent saw for cutting wood is usually called a bow saw. Most hacksaws are hand saws with a C-shaped walking frame that holds a blade under tension. Such hacksaws have a handle, usually a pistol grip, with pins for attaching a narrow disposable blade. The frames may also be adjustable to accommodate blades of different sizes. It is sometimes called an adjustable hacksaw because the length of the frame can be altered to hold blades of different sizes. Blades are supplied in two lengths, 250mm and 300mm. A screw or other mechanism is used to put the thin blade under tension. On hacksaws, as with most frame saws, the blade can be mounted with the teeth facing toward or away from the handle, resulting in cutting action on either the push or pull stroke. In normal use, cutting vertically downwards with work held in a bench vise, hacksaw blades are set to be facing forwards.
15 Figure 10:- Limit switch In electrical engineering, a limit switch is a switch operated by the motion of a machine part or the presence of an object. A limit switch can be used for controlling machinery as part of a control system, as a safety interlock, or as a counter enumerating objects passing a point. Limit switches are used in a variety of applications and environments because of their ruggedness, ease of installation, and reliability of operation. They can determine the presence, passing, positioning, and end of travel of an object. They were first used to define the limit of travel of an object, hence the name "limit switch" Standardized limit switches are industrial control components manufactured with a variety of operator types, including lever, roller plunger, and whisker type. Limit switches may be directly mechanically operated by the motion of the operating lever. A reed switch may be used to indicate proximity of a magnet mounted on some moving part. Proximity switches operate by the disturbance of an electromagnetic field, by capacitance, or by sensing a magnetic field.
16 Figure 11:- Symbol of Limit Switches Features and Benefits of Limit Switches 1) Can be used in almost any industrial environment 2) Very precise in terms of accuracy and repeatability 3) Consume little electrical energy 4) Can switch loads with high inductance 5) Can control multiple loads Limit Switch Terminology I. Pre travel — the distance or angle that the actuator must go through to trip the contacts. II. Operating Point — position of the actuator at which the contacts snap to the operated position. III. Release Point — the position of the actuator at which the contacts return to their original state. IV. Differential — distance (degrees) between contacts trip and contacts reset. V. Over travel — movement of the actuator beyond the contacts trip point. VI. Initial Position — position of actuator when no external forces applied to the actuator.
17 VII. Operating force (torque) — force required to move the actuating element. VIII. Minimum return force (torque) — minimum force required to return actuator to its initial position. IX. Total Travel — the maximum allowable distance the actuating element can travel. X. Repeat Accuracy — ability of a switch to repeat its characteristics precisely from one operation to the next operation. Figure 12:- 3 Core Electric Circuit What is use for green (earth) wire? In every circuit, one wire is connected to the earth; the main function of the earth wire is to protect the sudden damage of the electrical appliances or the electrical instruments due to the sudden voltage increase or the leakage of the current. Earth wire is also used for the safety measures. What is use for red (live) wire? The live is the wire that has a high potential. It means it carries the high voltage and delivers it to the appliance. It is also called hot wire or phase wire. For a complete circuit, the live conductor requires a neutral conductor to carry the current back to the power source.
18 What is use for black (neutral) wire? Neutral wire carries the circuit back to the original power source. More specifically, neutral wire brings the circuit to a ground or bus bar usually connected at the electrical panel. This gives currents circulation through your electrical system, which allows electricity to be fully utilized. Figure 13:- Base Frame The frame is made of mild steel material. The cross section of mild steel is square. Square tube material is used because it is hard, withstands tensile and compressive loads. The cost is comparatively less to other materials. The frame carries motor, pulley, connecting rod, hacksaw, vice and the work piece.
19 Figure 14:- Sheet Metal Plate Sheet metal is metal formed by an industrial process into thin, flat pieces. Sheet metal is one of the fundamental forms used in metalworking, and it can be cut and bent into a variety of shapes. Countless everyday objects are fabricated from sheet metal. Thicknesses can vary significantly; extremely thin sheets are considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are considered plate steel or "structural steel".
20 Figure 15:- Vice The vice is made from high quality cast iron and is quickly adjustable to enable the operator to change from one size of material to another in a matter of seconds. A vise is a mechanical apparatus used to secure an object to allow work to be performed on it. Vises have two parallel jaws, one fixed and the other movable, threaded in and out by a screw and lever. Classification of the hacksaw blades The hacksaw blade is classified by: 1. Teeth pitch which is the number of teeth per 25 mm. 2. Blade length which is the length between the centers of its pin holes as Figure 16:- Hacksaw Blade A simple rule to follow when choosing Used is explained by. At least two or three teeth should be cutting all the time.
21 Figure 17 & 18:- Blade a) Thin sections more teeth (b) Thick sections less teeth The teeth are set that the blade makes a cut wider than itself. This helps to prevent the blade from jamming becoming blocked and provides for good chip clearance when cutting the metal. The most common types of sets used are: Figure 19:- How To Install the Blade 1. Install the teeth point away from the handle of the hacksaw as shown in Figure 14. 2. Tighten the wing nut until the blade is definitely under tension. This helps make straight cuts.
22 2.10 SURROUNDINGS Undoubtedly, the environment also plays an important role in testing the durability and suitability of the product designed and keeping users comfortable. In addition, to ensure the product is resistant to: I. Our project can be cut straight without oblique. II. Our project after cutting can stop on its own. 2.11 QUALITY AND PERFORMANCE Quality of a product is so important to ensure it is function well. A quality product able to satisfied the user or customer. The products need to be tested to view the capabilities and functionality of each part and components. A quality product also needs to meets the intended function. It is supposed to solve the problem that arises. To identify the quality of our product, we need to test the functionality and capabilities of the product. On our project can be cut straight and easy to operate.
23 CHAPTER 3 METHODOLOGY 3.1 INTRODUCTION General This project is about cutting the metal, pipes, angles, channel, flat plates, rods, wood and such other things. It is very simple mechanism but very useful to produce many typed of components in less time. A Hacksaw is a fine tooth saw with a blade under tension in frame used for cutting material such as metal. The Demand of hacksaw blade is considerably increasing day by day with the growth of industrialization, engineering sector, real estate, automobile sector etc. It is used in almost every sector for cutting of material l like flat plate, rods and such other things, it is also required in auto repairing shop, general repairing workshops, fitting shops, we lading shops and technical institutes. Hand held hacksaw consist of a metal frame with a handle and pin for attaching a narrow disposal blade, a screw or other mechanism issued to put the thin blade under tension. Hacksaw blade cutting is a conventional machining process where harder material which is tooth of the blades cuts the relatively softer materials per need. In present condition many electrically operated power hacksaw machines of different specifications are available for the use in shop floor. These machines are so precise that they can cut metal bars with minimum times made up of different materials. For industries to achieve the mass production, it is necessary to cut metals bars with high rate.
24 3.2 PLANNING AND PROJECT IMPLEMENTATION This chapter is talk about our process time for create the product, and the part of the design, it was including Gantt chart, drawing of part, step to assembly, and total cost of our project. 1.0 FLOW CHART Start Briefing Title selection AUTOMATIC HACKSAW Design And Drawing Machining CNC Milling Assembly Test Run Report Present End No No Modification Discuss with group members Ask our supervisor for advice Start run machine Yes Yes Supervisor Wiring (DC)
25 3.3 GANTT CHART Chart : 1.1 & 1.2 YEAR MONTH WEEK 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 PLANNING ACTUAL PROJECT TITLE AND SCOPE OF PROJECT 2021 LITERATURE REVIEW LIBRARY REVIEW VISIT THE WORKSHOP AREA DESIGN THE PRODUCT METHOD APR DISCUSSION AND MEETING WITH THE SUPERVISOR ACTIVITIES NOV DEC JAN FEB PLAN MAR PROJECT OBJECTIVE OCT 2022 DO SEM 5 MANUFACTURE THE PROJECT PREPARE RAW MATERIAL MACHINING PROCESS PROJECT ASSEMBLY YEAR MONTH WEEK 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 PLANNING ACTUAL SEM 6 METHOD DO CHECK ACTION ACTIVITIES PROJECT MEASUREMENT 2022 2023 AUG SEP OCT NOV DEC JAN ANALYZE AND DISCUSSION QUALITY CONTROL PRODUCT TEST RUN TROUBLE SHOOTING MEETING WITH THE SUPERVISOR IN CHARGE PROJECT REPORT PROJECT PRESENTATION
26 3.4 DESIGN Below is the 3D model part for machining that been design using CREO parametric 5.0 software. i. Base (Figure : 20) Material that used mild steel. Figure 20:- Design of Project (CAD)-Base ii. Base 3mm Plate (Figure : 21) Material that used Mild steel Figure 21:- Design of Project (CAD) - Base 3mm Plate
27 iii. L connector movement (Figure : 22) Material that used stainless steel Figure 22: - Design of Project (CAD) - L connector movement iv. Movable Plate (Figure : 23) Material that used Stainless Steel Figure 23: - Design of Project (CAD) - Movable Plate
28 v. Motor L Support 1 (Figure : 24) Material that used Mild Steel Figure 24: - Design of Project (CAD) - Motor L Support vi. Motor Support 2 (Figure : 25) Material that used Mill Steel Figure 25: - Design of Project (CAD) - Motor Support 2
29 vii. Pulley (Figure: 26) Material that used Mill Steel Figure 26: - Design of Project (CAD) – Pulley viii. Pulley Connector (Figure : 27) Material that used Mill Steel Figure 27: - Design of Project (CAD) - Pulley Connector
30 3.5: ASSEMBLY DRAWING Figure 28: – Automatic Hacksaw Assembly drawings can be used to represent items that consist of more than one component. Assembly drawings may include instructions, list of the component parts reference numbers and reference numbers and references to detail drawings. Figure 1 is the complete assembly drawing.
31 3.5.1 DETAIL DRAWING The figure below will show the detail of the drawing Figure 29: Motor Support L Figure 30: Motor Support 2
32 Figure 31: Pulley Connector Figure 32: Pulley
33 3.6 BILL OF MATERIALS The table 2 below shows the item that we use for this project. The entire item is shown on the table below: Table 2: -Bill of materials No Item Size (mm) Qty Remark 1. Square bar 30x120x30 2 Mild Steel 2. Sheet Metal 30x60x30 1 Mild Steel 3. Solid Metal Sheet 762x3x381 1 Mild Steel 4. Hand Hacksaw 250MM 1 Carbon Steel 5. Gear Motor N/A 1 N/A 6. Square Bar 25x70x25 1 Stainless Steel 7. Vise N/A 1 Mild Steel 8. Screw M6 4 N/A 9. Mild Steel Plate 6MM 1 Mild Steel 10. Sheet Metal Band Plate N/A 1 Mild Steel 11. L Bracket N/A 2 Mild Steel 12. Screw M8 4 Stainless Steel 3.7 WORK PART Machining is any of various processes in which a piece of raw material is cut into a desired final shape and size by a controlled material removal process. The processes that have this common theme, controlled material removal, collectively known as subtractive manufacturing, in distinction from processes of controlled material addition, which are known as additive manufacturing. Below are the work steps and machining process;
34 3.8 WORK STEP : Automatic Hacksaw Machine Table 3: -Work step to assembly Automatic Hacksaw Machine Work Step Work Detail • Step 1 – cut the square bar into dimension of 15 inch x 30 inch • Step 2 – using the square bar that have been cut welding the base with rectangular shape. • Step 3 – use the Makita polish little bit the top the welding that we did the step 2. • Step 4 – welding this 3mm plate top of the base that we welding. • Step 5 – then assemble all the parts like vise, motor more then. • Step 6 – test the machine all was okay.
35 • Step 7 – then open the vise, motor and spray black color at the base. • Step 8 – then assemble all the part that we done.
36 3.9 USED METHOD To produce the Automatic Hacksaw, the machines that we used are ‘Band saw machine’, ‘Manual Drilling Machine’, ‘Conventional Lathe Machine’, ‘Conventional Milling Machine’ and ‘CNC Milling Machine’, ‘Makita’ and ‘Welding Machine’. Descriptions of a machine with a diagram are: 3.9.1 BAND SAW MACHINE Figure 34: Band Saw Machine A band saw machine is a power saw with a long, sharp blade consisting of a continuous band of toothed metal stretched between two or more wheels to cut material. They are used principally in metalworking, woodworking and lumbering, but may cut a variety of materials. Advantages include uniform cutting action as a result of an evenly distributed tooth load, and the ability to cut irregular or curved shapes like a jigsaw. [1] The minimum radius of a curve is determined by the width of the band and its kerf. Most band saws have two wheels rotating in the same plane, one of which is powered, although some may have three or four to distribute the load. The blade itself can come in a variety of sizes and tooth pitches (teeth per inch, or TPI), which enables the machine to be highly versatile and able to cut a wide variety of materials including wood, metal and plastic.
37 3.9.2 CNC MILLING MACHINE Figure 35: CNC milling machine CNC Milling Machines are machine operated cutting tools that are programmed and managed by Computer Numerical Control (CNC) systems to accurately remove materials from a workpiece. The end result of the machining process is a specific part or product that is created using Computer Aided Design (CAD) software. These machine tools are normally equipped with a main spindle and three-linear-axes to position or move the part to be machined. Depending on the material used for the part, as well as the complexity of the machined part, varying axes, cutting head speeds, and feed rates may be applied. Milling is normally used to machine parts that are not symmetrical from an axial perspective. These parts may have unique curvatures or surface contours, which may require a combination of drilling & tapping, grooves, slots, recesses, pockets and holes to work on them. They may also form parts of the tooling for other manufacturing processes – for example in the fabrication of 3D moulds.
38 3.9.3 CONVENTIONAL LATHE MACHINE Figure 36: Conventional Lathe Machine Conventional lathe machine is used to do simple turning process that does not required advanced machine such as facing the surface, drilling. A lathe machine is a machine tool that rotates a workpiece about an axis of rotation to perform various Operations Such as cutting, sanding, knurling, drilling, deformation, facing, and turning, with tools that are applied to the workpiece to create an object with symmetry about that axis. Lathes are used in woodturning, metalworking, metal spinning, thermal spraying, parts reclamation, and more.
39 3.9.4 CONVENTIONAL MILLING MACHINE Figure 37: Conventional Milling Machine Conventional Milling Machine is used for the cutting of flat surface, side cut, drilling and other manual process at the material. The material is clamped tight and does the simple changing in the machining process. Milling is the process of machining using rotary cutters to remove material by advancing a cutter into a workpiece. This may be done varying direction on one or several axes, cutter head speed, and pressure.[3] Milling covers a wide variety of different operations and machines, on scales from small individual parts to large, heavy-duty gang milling operations. It is one of the most commonly used processes for machining custom parts to precise tolerances. Milling can be done with a wide range of machine tools. The original class of machine tools for milling was the milling machine (often called a mill).
40 3.9.5 BENCH DRILLING MACHINE Figure 38: Bench Drilling Machine Bench drilling machine is device for producing holes in hard substances. The drill is held in a rotating spindle and is fed into the workpiece, which is usually clamped in a vise resting on a table. The drill may be gripped in a chuck with three jaws that move radially in unison, or it may have a tapered shank that fits into a tapered hole in the spindle. Means are always provided for varying the spindle speed and on some machines for automatically feeding the drill into the workpiece. . This machine can also be used for doing other processes such as Counter Sunk, Counter Bore, Reamer, Chamfering and Pilot Hole. Drill presses for occasional use in general-purpose machine shops usually have only one spindle. For drilling several holes successively or simultaneously in a workpiece, machines with multiple spindles are available. When large quantities of identical mechanical components are required, special-purpose drilling machines, with spindles arranged in a variety of positions relative to the workpiece, can be constructed. Although drill presses are used mainly for drilling holes, they can also be used for enlarging holes with a boring tool or finishing holes with a reamer. With the aid of a special tapping attachment and a tap, they can produce threads in a hole.
41 3.9.6 HAND GRINDER Figure 39 & 40: Hand Grinder In the field of power tools, Hand grinder offers classic tools (drilling and stemming hammers, drills, planers, saws, cutting and angle grinders), gardening equipment (electric lawnmowers, high-pressure cleaners, blowers), and measuring tools (rangefinders, rotating lasers). Hand grinder is excellent tools for polishing, cutting and even sanding. They are serious tools, though, that work at high speeds and are potentially dangerous.