42 3.9.7 WELDING MACHINE Figure 41: Welding Equipment Welding is a fabrication process where by two or more parts are fused together by means of heat, pressure or both forming a join as the parts cool. Welding is usually used on metals but can also be used on aluminums to. The completed welded joint may be referred to as a weldment. Some materials require the use of specific processes and techniques. A number are considered 'unwieldable,' a term not usually found in dictionaries but useful and descriptive in engineering. The parts that are joined are known as a parent material. The material added to help form the join is called filler or consumable. The form of these materials may see them referred to as parent plate or pipe, filler wire, consumable electrode (for arc welding), etc. Consumables are usually chosen to be similar in composition to the parent material, thus forming a homogenous weld, but there are occasions, such as when welding brittle cast irons, when filler with a very different composition and, therefore, properties is used. These welds are called heterogeneous. The completed welded joint may be referred to as a weldment.
43 3.10 EQUIPMENT AND HARDWARE 3.10.1 CRAFTING TOOLS Table 4:- Equipment Used The full list of crafting tools we used are: No Equipment Description 1 File Used for deburr the edge or corner of a component or work piece. 2 Hand Saw Used to cut metal to a certain size and also the parts of a thin metal represents the excess of the marked. 3 Allen key Used when making adjustment, open or tighten the nut. 4 Spanner Used to make adjustment, open or tighten bolts and nut. 5 Mallet A long-handled wooden stick with a head like a hammer, used for hitting croquet and not dented surface 6 Hand Tap To make screw holes that allow screw to insert 7 Parallel Bar Use to put under the part for parallel
44 3.11 COMPUTER SOFTWARE Computer software is used to design and manufacture prototypes, finished products, and production runs. An integrated CAD/CAM system offers one complete solution for design through manufacturing. We have used this software: i. Microsoft Word 2010 - Microsoft Word 2010 is use to write the report. ii. CREO Parametric 5.0 - CREO Parametric 5.0(CAD) is use to draw a design for our project. Here also we draw our jig before we do a toolpath in Esprit CAM. iii. Esprit CAM - Esprit CAM, we use to do a toolpath for our jig. 3.12 MEASURING TOLLS Table 5:- Measuring Equipment Measurement Equipment Functions Vernier Caliper Used to measure the thickness and length of the work piece, internal depth with limitation, height of stairs, distance between the diameter hole, slot holes and high measuring work piece. Dial Indicator Used to indicate vice or surface flatness of the work piece Measuring Taps Measuring roughly work piece in a large scale. Steel Ruler Measuring roughly work piece small distance.
45 3.13 QUALITY CONTROL Quality control is a procedure or set of procedures intended to ensure that a manufactured product or performed service adheres to a defined set of quality criteria. 3.14 MEASURING TOOLS The table 6 below shows the measurement tools that we use to check the dimension. Table 6 :- Measuring Tools Measuring Tool Name Description Vernier Calipers Use to measure the thickness and length of the work piece, internal depth, Distance between the diameter hole and high measuring work piece. Measuring Tape Check when machine on optional stop. Profile Projector To check the hole accurate location to clamp the stopper. Steel Ruler Easy to check dimension long material.
46 3.15 ASSEMBLY CONCEPT 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 42: – Drawing Automatic Hacksaw
47 3.16 COSTING The process of calculating how much a product will cost, that include direct labor, direct materials, consumable production supplies, and factory overhead. 3.17 TOTAL MANUFACTURE TIME CALCULATION Following table shows the total machining duration. Table 7:- Total Manufacture Time Calculation NO. PART AND PROCESS TIME (MIN) 1. Pulley 50 MINUTES 2. Pulley Connecter 30 MINUTES 3. Motor L Support 30 MINUTES 4. Motor Sec Support 30 MINUTES 5. Full Welding 2 HOURS 6. Full Square Bars Cutting Follow the Dimensions 1 Hours 15 MINUTES TOTAL 335 MINUTES/ 5 HOURS 35 MINUTES
48 3.18 RAW MATERIAL COST Table 8:- Shown the Raw Material Cost No. Description Material type Quantity Total cost (MYR) 1. Wanshsin 90yt 120w 1ph/240v Motor with Fan Motor 1 RM 400.00 2. Flat Bar 4.5mm x 25mm x 1025 OFFC Stainless Steel 304 1 Rm 14.00 3. Pipe Stainless Steel 304 1 RM 15.00 4. Pipe 3/8 x 2/8 x 660mm OFFC Stainless Steel 304 1 RM 6.00 5. Mild Steel Square Hollow Section Mild Steel 1 RM 15.00 6. Square Hollow Section 1 Stainless Steel 304 1 Rm 32.00 Total price RM 482.00
49 3.19 STANDARD PARTS Standard parts are the parts that we purchase. Below the table 9: has shown the parts details and prices. Table 9:- Standard Parts No. Description Material Type Quantity Total Cost (MYR) 1. Wanshsin 120w 1ph /240v Panel Speed Controller Speed Controller 1 RM40.00 2. Complete Bracket Motor Seat Motor Bracket 1 RM50.00 3. Drill Hole and Fitting Saw Bracket Complete Bracket 1 RM 94.34 4. M6 x 25 HEX Bolt Nut & 2 Washer Nut & Washer 4 RM2.00 5. Stanly Hacksaw Blade Blade 1 RM 25.00 6. 4” Sinowolf Cutting Dics Dics 2 RM 3.60
50 7. 2m Core Cable 3 Core Cable 1 RM 7.00 8. Enclosure Box Wire Cover Box 1 RM 12.00 9. Gear Head Head 1 RM 20.00 10. Female Terminal Thread 4 RM1.20 Total Price RM 255.14 Materials Cost + Standard Parts Cost = Product Cost Total Price RM82.00 + RM655.14 = RM 737.14
51 CHAPTER 4 DISCOVERY AND ANALYSIS 4.1 INTRODUCTION This chapter presents the result of the power hacksaw machine product and research findings of the data that we collected from the case study samples. We have discussion with our supervisor, En. Nor Azman Bin Samsuri and gave us more information about our product to improve the power hacksaw machine. 4.2 RESULT For the confirmation of experimental test for sustain in real life action in our project. Based on the experimental tests we have performed on our project, the following are the result that we have obtained: i. Saving man power energy and time. ii. Can cut through various materials easily. iii. Worker or Student easily can use it. 4.3 DISCUSSION In our project, we have discussion with our supervisor En. Nor Azman Bin Samsuri. We have few ideas to improve our Final year Project such as: i. Install high power ac motor ii. Install limit switch iii. Install emergency stop
52 4.4 SAFETY 4.4.1 SAFETY ASPECTS In the workshop or engineering laboratory, they must be discipline and safety precautions to avoid accident .We have listed safety aspects such as: i. Wear safety goggles to avoid getting injured. ii. Keep Tools and Equipment Sharp. iii. Keep Your Workshop Clean. iv. No Drugs, Alcohol or Other Impairments Please. v. Keep Tools and Equipment Sharp. vi. Avoid Unnecessary Distractions. vii. Use Safety Tools To Assist You. viii. If you see unsafe conditions, let a supervisor know. ix. Follow procedure, don't take shortcuts. x. Use tools and machines properly. 4.4.2 SAFETY IN WORKSHOP There are three types of safety in workshop i. You are responsible for your own safety ii. Make sure workshop floor is clean and tidy iii. Report any spillages or any equipment is brake or broken 4.4.3 INDIVIDUAL SAFETY The student must always avoid from getting injuries while working in workshop. If they don’t follow rules and regulation they might get injured. So, we are listed individual safety while working in workshop such as: i. Always wear eye protection and safety shoes ii. Wear gloves and ear buds while operating machine iii. Wear apron while operating machine
53 4.4.4 SAFETY WHILE USING TOOL IN WORKSHOP In the workshop, the student must make sure safety by using tool in workshop or might be injured. The safety of using tools is highly recommended that accident may occur anytime. So, they are following tips by avoiding getting injured such as: i. Inspect regularly your tools to make sure that they are in good condition. ii. Keep them clean and dry iii. Carry with care iv. Always be aware of the people around you when using tools v. Only operate tools according to manufacturer’s instructions 4.4.5 CLEANLINESS IN THE WORKSHOP Maintaining cleanliness in the workplace not only creates a healthier environment for employees but also tends to help companies become more efficient and productive. The worker can work peacefully at good environment and work can be done smooth flow. At the same times, worker must follow the rules and regulation by cleaning the workplace area and keep the tools at toolbox or origin place before going home. 4.5 ADJUSTMENT First of all, the raw material has to clamp on the vise. Then, release the hacksaw handle bar and put on the raw material for cut. When cutting the raw material, the handle bar is shacking. So, we are discussing about the problem with our team. The solution is we have decided to weld the handle supporter from the base because we don’t want the handle bar to shaking while cutting the raw materials. It will give a good result by cutting the raw material with straight and clean.
54 4.6 DATA ANALYSIS According to the data analysis, the handsaw will take more time to cut down raw material. The usage of handsaw will make worker more tired. We have found out a new project is Hacksaw Machine that can cut raw material very fast and take less time. The result of using handsaw and hacksaw machine has been shown in chart 2.0 below. Graph Chart 2.0:- Summary Result Graph Chart 2.0 Difference between Handsaw, Hacksaw Machine and Bandsaw. In Graph Chart 2.0 above shown that comparison between hacksaw machines is very faster than using handsaw. The hacksaw machine can cut raw material faster because of using high power ac motor. The advantage of using hacksaw machine is the time taken to cut raw material is less than using handsaw. 0 5 10 15 20 25 30 MANUAL HANDSAW AUTOMATIC HACKSAW BANDSAW MACHINE Summary of Result 1. Time of Manual Handsaw = 25.4 mins 2. Time of Automatic Hacksaw = 10.59 mins 3. Time of Bandsaw Machine = 18.69 mins 4. Time Difference = 15.21 mins
55 4.7 SUMMARY ANALYSIS According due to the summary analysis above, we have found out that difference between handsaw and hacksaw machine. The handsaw will take more time to cut down raw material. The handsaw could not make a clean and straight cut using a handsaw is much more difficult. We have found out new way to cut raw material is Hacksaw machine.The operation of power hacksaw is simple. The power hacksaw can cut the materials very fast even though the thickness or diameter is more. This type of machine tool can be operated at high speeds and even at low speeds. The power hacksaw machine blades are easy to remove and fix so, we use the different types of blades according to the strength for different types of materials. Figure 43 & 44: Summary Analysis
56 4.8 TROUBLESHOOT On this project, they are some troubleshooting that we found out after finishing our project. We like to explain the problem and give the solution to get over it. The problem that we face such as: Table 10:- Problem of Project NO PROBLEM SOLUTION REMARKS 1. The blade getting stuck while cutting the material. We bought a new high quality Stanley blade for cutting material easily. SOLVED 2. The motor is still running even the material cut. We install limitation switch that motor will stop automatically after cutting the material. SOLVED Based on table 4.8.1 above, we have listed the problem and given the solution to solve the problem. We find out that our project work well
57 4.9 CONCEPT AND FUNCTIONING Table 11:- Shown the Steps Step 1 Check the hacksaw machine condition before turn on Example : on & off switch, limit switch, emergency stop and etc. Step 2 Switch on the main switch Step 3 Clamp the raw material on vise
58 Step 4 Release hacksaw handle bar on raw material Step 5 Turn on the speed controller Step 6 Increase the suitable speed for the raw material and wait until material is cut Step 7 The hacksaw handle bar will automatically stop by touching limit switch
59 Step 8 Then, raise the hacksaw handle bar after cutting process. Step 9 Loosen up the vise and remove the raw material Step 10 Switch off the main switch
60 CHAPTER 5 CONCLUSION AND SUGGESTION 5.1 DISCUSSION Automatic Hacksaw Machine is more convenient to use in industry or college. It will be easy to control the hacksaw machine, the operator must learn to operate and follow the step to control the hacksaw. The vise will be placed near the blade and easy to cut the material. It can improve and reduce the time and manpower energy by cutting the material by using manual hack Based on the testing that had done on the project, we have obtained the following results: i) Material will be easily cut and clean ii) Reduce Manpower Energy iii) Proses of cutting is faster
61 5.2 PROBLEMS AND SOLUTIONS This chapter we discuss about problem that we face about before and after development of this project. The solutions for the problem are: Table 12: Problem and Solution NO PROBLEM SOLUTION 1 Screw and nut missing while working Put all the screw in a container box so that might not lost while working 2 Blade getting stuck while cutting the material Apply Wd-40 or oil while cutting the material so it will give smooth cutting 5.3 RECOMMENDATION FOR IMPROVEMENTS After discussion with my Supervisor En. Nor Azman Bin Samsuri the objective of our project is to cut material so that worker or student can easily use it. We also found some information that can improve our F.Y.P project such as: 1. We need to install coolant for extra smooth cutting so that the material won’t be dented.
62 5.4 CONCLUSION As per the above discussion of finishing our final year project, we concluded to a conclusion of making Hacksaw Machine. According to our research and data we collected of our project is: i. Easy to operate ii. Cuts the material easily iii. No need special training required to operate it iv. The time taken for cutting operation is less v. Repairing and replacement is not difficult task The machine is affordable price the proposed model of Development Hacksaw Machine the machine is helpful and completes all the expectations needed for the mini-industries. It can withstand the vibrations, no hazards from a jerk. After studying this report, we have to know that how the A hacksaw machine will work and knowing the construction and how mechanism work in the machine. We learnt how the theoretical. Based on this project, the machine can cutting various types of material that cut easily and various cost of the machine is less. 5.5 SUGGESTION After finishing our finishing project, we still realized that can improve our project that even better in in terms of quality, efficiency and productivity. We have listed the improvement that we can make: i. We can install coolant to cut material even better. ii. We can install automatic handle bar going up and down. iii. Additional Storage for blade that we can change easily.
63 5.6 REFFERENCE 1. https://journal.ump.edu.my/ijets/article/download/2476/395/7740 2. https://www.researchgate.net/publication/334163342_Design_of_Auto matic_Cooling_Power_Hacksaw_Machine_for_Multipurpose_Applicatio ns 3. https://www.ijert.org/research/automated-double-hacksaw-cutterIJERTV7IS070028.pdf 4. https://nevonprojects.com/automated-double-hacksaw-project/ 5. http://www.ijirset.com/upload/2014/special/tapsa/44_TAPSA_MECH_0 06.pdf 6. https://www.slideshare.net/mechvignesan/double-hacksaw 7. https://www.scribd.com/document/400225288/Double-Acting-HacksawPDF 8. https://www.ijert.org/research/automated-double-hacksaw-cutterIJERTV7IS070028.pdf 9. https://www.slideshare.net/ParikshitSharma16/double-hex-sawmachine-final 10.https://qdoc.tips/double-acting-hacksaw-using-scotch-yokemechanism-4-pdf-free.html
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