project report on pedal operated hack saw machine

7/25/2019 Project Report on Pedal Operated Hack Saw Machine

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PROJECT REPORT ON

TITLE OF THE PROJECT

Submitted

For The Partial fulfillment of

Diploma In

Mechanical Engineering

Submitted by

Ajinkya S. hedekar ! "#$""%%%"&aj '. Patel ! "#$""%%%(

Pra)ad *. +hada)hi ! "#$""%%",

'ikram -. Mane ! "#$""%%(

Year 2015-2016

/nder The +uidance of

Prof. K.P.Kudalkar

EER!"T" JIJ"#"I TECHNOLO$IC"L IN%TIT&TE

!"T&N$"' !&!#"I-(0001)

"CKNO*LE+$E!ENT

Pedal Powered Hacksaw Machine Page 1


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0Project1 i) a 2ery crucial part of e2ery engineering )tudent. To think of )omething

ne3 and different and bringing that imagination into practical i) a 2ery tediou) job.

It 3a) not that ea)y for u) too. 4ut it 3a) due to the kind co5operation 6 2aluable

guidance rendered to u) by the people 3e 3ould like to mention7 it became ea)ier

for u) to complete our project )ucce))fully.

8e take the great plea)ure to pre)ent thi) project report on 0Pedal Po3ered

-ack)a3 Machine1. 8e ha2e taken great care that the information pro2ided by i)

)ati)factorialy enough and correct9 but e2en then 3e 3elcome any correction.

8ritten 3ord) ha2e an unfortunate tendency to degenerate genuine gratitude into a

formality. -o3e2er9 it i) the only 3ay to record one:) feeling) permanently. -ence

3e take thi) opportunity to e;pre)) our heartfelt thank) to all tho)e 3ho ha2e been

a))ociated 3ith our project.

Fir)t of all9 8e are thankful to our project guide Prof. .P.udalkar 3ho)e con)tant

encouragement9 pre)iou) guidance and full5fiedge co operation ha) lead to the

)ucce)) of thi) project.

8e 3ould like to thank each other for acti2ely participating and making thi)

project 3hat it i) today. It 3a) a full5blooded effort of our 3hole team 3ithout

3hom our project 3ould ha2e not been fruitful. 8e 3ould like to thank almighty

for making our project a full5fledged )ucce)).

8e 3ould like to e;pre)) our )pecial thank) to our Department.

CERTIFIC"TE



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Thi) i) to certify that all the )tudent) of thi) group a) mentioned

earlier ha2e )ucce))fully completed project report on 0Pedal Po3ered

-ack)a3 Machine19 i) found to be )ati)factory and appro2ed for the

partial fulfillment of Diploma in Mechanical Engg. under the

guidance of Prof..P.udalkar during the academic year


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Coe/

Caer Pae No

" Ab)tract =

< Introduction

# Future )cope of the Project (

$ Subject) Di)cu))ed "%

= Sketch of Pedal ?perated -ack)a3 Machine "

Main *omponent) of Pedal ?perated -ack)a3

Machine

"(

( 8orking Principle #

, Ad2antage) and Di)ad2antage) #(

@ *alculation) #,

"% &eference) $"



5/45

A4ST&A*T !5

Pedal po3ered hack)a3 machine i) a machine 3hich can be u)ed for

indu)trial application) and -ou)ehold need) in 3hich no )pecific

input energy or po3er i) needed. Thi) project con)i)t) of a crank and)lider mechani)m. In the mechani)m pedal i) directly connected to the

hack)a3 through crank and )lider mechani)m for the proce))ing of

cutting the 3ooden block)9 metal bar)9 P'* material). The objecti2e

of the modal i) u)ing the con2entional mechanical proce)) 3hich

play) a 2ital role. The main aim i) to reduce the human effort for

machining 2ariou) material) )uch a) 3ooden block)9 )teel9 P'* etc.

The po3er hack)a3 machine9 3hich run) on human po3er9 3ork) onthe principle of the con2er)ion of rotational motion to o)cillatory

motion. Importance of thi) project lie) in the 2ery fact that it i) green

project and help) u) to reduce our electricity need. Secondly9 thi)

cutter can be u)ed and tran)ferred to our 3orking place ea)ily.

Moreo2er9 if 3e 3ant 3e can generate electricity 3ith our project by

connecting it to dynamo9 diode and battery.



6/45

IT&?D/*TI? !5

Pedal po3er i) the tr.an)fer of energy from a human )ource through

the u)e of a foot pedal and crank )y)tem. Thi) technology i) mo)t

commonly u)ed for tran)portation and ha) been u)ed to propelbicycle) for o2er a hundred year). Be)) commonly pedal po3er i)

u)ed to po3er agricultural and hand tool) and e2en to generate

electricity. Some application) include pedal po3ered laptop)9 pedal

po3ered grinder) and pedal po3ered 3ater 3ell). Some third 3orld

de2elopment project) currently tran)form u)ed bicycle) into pedal

po3ered tool) for )u)tainable de2elopment.

Thi) project concentrate) on pedal po3ered hack)a3 machining. Anindi2idual can generate four time) more po3er C"$ -P by pedalling

than by hand5cranking. At the rate of -P9 continuou) pedalling can

be )er2ed for only )hort period)9 appro;imately "% minute). -o3e2er9

pedalling at half thi) po3er C", -P can be )u)tained for clo)e to %

minute) but po3er capability can depend upon age. A) a con)eGuence

of the brain)torming e;erci)e9 it 3a) apparent that the primary

function of pedal po3er one )pecific product 3a) particularly u)eful!

the bicycle. Many de2ice) can be run right a3ay 3ith mechanical

energy. A )a3 i) a tool that u)e) a hard blade or 3ire 3ith an abra)i2e

edge to cut through )ofter material). The cutting edge of a )a3 i)

either a )errated blade or an abra)i2e. A )a3 may be 3orked by hand9

or po3ered by )team9 3ater9 electric or other po3er. An abra)i2e )a3

u)e) an abra)i2e di)c or band for cutting9 rather than a )errated blade.



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Future Scope of Pedal Po3ered -ack)a3 Machine!5

&ice Thre)hing Peanut )helling



8/45

8inno2ing

*orn Shelling



9/45

?perating a 3ood 3orking lathe



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S/4>E*TS DIS*/SSED !5

". Stirling Engine !

" /3rl3 e3ei) a heat engine that operate) by cyclic compre))ion

and e;pan)ion of air or other ga) Cthe 3orking fluid at different

temperature)9 )uch that there i) a net con2er)ion of heat energy to

mechanical 3ork. More )pecifically9 the Stirling engine i) a clo)ed5

cycle regenerati2e heat engine 3ith a permanently ga)eou) 3orking

fluid. *lo)ed cycle 9 in thi) conte;t9 mean) a thermodynamic in 3hich

the 3orking fluid i) permanently contained 3ithin the )y)tem9

and regenerati2e de)cribe) the u)e of a )pecific type of internal heat

e;changerand thermal )tore9 kno3n a) the regenerator. The inclu)ion

of a regenerator differentiate) the Stirling engine from other clo)ed

cycle hot air engine).

?riginally concei2ed in "," a) an indu)trial prime mo2er to ri2al

the )team engine9 it) practical u)e 3a) largely confined to lo35po3er

dome)tic application) for o2er a century.

The Stirling engine i) noted for high efficiency compared to )team

engine)9 Guiet operation9 and it) ability to u)e almo)t any heat )ource.

The heat energy )ource i) generated e;ternal to the Stirling engine

rather than by internal combu)tion a) 3ith the ?tto cycleor Die)el

cycleengine). 4ecau)e the Stirling engine i) compatible 3ith

alternati2e and rene3able energy )ource) it could become

increa)ingly )ignificant a) the price of con2entional fuel) ri)e)9 andal)o in light of concern) )uch a)peak oiland climate change. Thi)

engine i) currently e;citing intere)t a) the core component of micro

combined heat and po3erC*-P unit)9 in 3hich it i) more efficient

and )afer than a comparable )team engine. -o3e2er9 it ha) a

lo3po3er5to53eight ratiorendering it more )uitable for u)e in )tatic

in)tallation) 3here )pace and 3eight are not at a premium.

https://en.wikipedia.org/wiki/Heat_exchangerhttps://en.wikipedia.org/wiki/Heat_exchangerhttps://en.wikipedia.org/wiki/Regenerative_heat_exchangerhttps://en.wikipedia.org/wiki/Hot_air_engineshttps://en.wikipedia.org/wiki/Steam_enginehttps://en.wikipedia.org/wiki/Otto_cyclehttps://en.wikipedia.org/wiki/Diesel_cyclehttps://en.wikipedia.org/wiki/Diesel_cyclehttps://en.wikipedia.org/wiki/Peak_oilhttps://en.wikipedia.org/wiki/Climate_changehttps://en.wikipedia.org/wiki/Micro_combined_heat_and_powerhttps://en.wikipedia.org/wiki/Micro_combined_heat_and_powerhttps://en.wikipedia.org/wiki/Power-to-weight_ratiohttps://en.wikipedia.org/wiki/Regenerative_heat_exchangerhttps://en.wikipedia.org/wiki/Hot_air_engineshttps://en.wikipedia.org/wiki/Steam_enginehttps://en.wikipedia.org/wiki/Otto_cyclehttps://en.wikipedia.org/wiki/Diesel_cyclehttps://en.wikipedia.org/wiki/Diesel_cyclehttps://en.wikipedia.org/wiki/Peak_oilhttps://en.wikipedia.org/wiki/Climate_changehttps://en.wikipedia.org/wiki/Micro_combined_heat_and_powerhttps://en.wikipedia.org/wiki/Micro_combined_heat_and_powerhttps://en.wikipedia.org/wiki/Power-to-weight_ratiohttps://en.wikipedia.org/wiki/Heat_exchangerhttps://en.wikipedia.org/wiki/Heat_exchanger


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The energy cri)i) i) increa)ing day by day9 )o 3e ha2e to find more

3ay) to get u)eful energy. Energy )a2ed i) energy produced. Many

indu)trie) u)e furnace) for production proce))e)9 in 3hich mo)t of the

heat i) lo)t. 8e can u)e thi) e;ce)) heat to run the )terling engine and

hence produce electricity.

#u a/ e 4o/ of e roe4 3/ er7 3' /o 8e de43ded o ree4

3.



12/45


13/45

8e ha2e al)o u)ed a light diode re)i)tanceCBD& 3hen BD& )en)e) a

light around it all the road light) get) off and 3hen BD& )en)e) there

i) a dark around it then BD& )end) a )ignal to microcontroller then all

the road light) get) on. 4y u)ing a BD& 3e can a2oid a 3a)te of lightthat glo3 in a day time. The t3o )en)or) are made from the concept of

electronic). The)e )en)or) are called an infrared )en)or 3hich i) made

from photo diode and light emitting diode each. 8hen any 2ehicle

pa)) from fir)t )en)or then fir)t )en)or become) on9 for that time the

road light) get) on and 3hen it pa)) from )econd )en)or the )econd

)en)or become on and the fir)t )en)or get) off then the road light get)

off.

I 3e/ lo8 ad o-u3for9 olae. "l/o' 3 3/ d3ff34ul o a43ee

roer :ala4e :e8ee /eed ad or;ue' e4e 8e de43ded

aa3/ 3.



14/45

#.Modification In Bocal Train:) *ompartment !5

".For 2entilation in local compartment)9 3e u)e fan) 3hich need)

electricity. Sufficient energy lo)) take) place in 2entilation. 3e can

make ea)y and eco5friendly 2entilation )y)tem in the compartment)

u)ing natural air flo3ing around the compartment due to mo2ement of

train.

8e can attach hollo3 )tructure) on the roof of compartment a) )ho3n

in figure 3hich force) the air to come in)ide and flo3) through the

3indo3) and door).


15/45

$. *rop *utter!5

India i) an agricultural country. The economy of our nation i) mo)tly

dependent on agriculture. So for the de2elopment of our country9 the

agricultural )ector of our economy )hould be de2eloped.

There are many )tep) in agriculture field like Ploughing9 So3ing9

-ar2e)ting etc.

-ar2e)ting i) the operation of cutting9 picking9 plucking and digging

or a combination of the)e operation) for remo2ing the crop from

under the ground or abo2e the ground or remo2ing the u)eful part or

fruit) from plant).-ar2e)ting action can be done by four 3ay)!

Slicing action 3ith a )harp tool.

Tearing action 3ith a rough )errated edge

-igh 2elocity )ingle element impact 3ith )harp edge.

T3o element) )ci))or) type action.

In India har2e)ting i) done by )ickle 3hich i) time con)uming

proce)). 4y u)ing crop cutter9 it )peed) up the har2e)ting proce)).%34e' r3al/ of 3/ roe4 are o o//3:le 3 ur:a 433e/ l3ke

!u9:a3' e4e 8e de43ded o ree4 3.



16/45

=. Pedal Po3ered -ack)a3 Machine !5



17/45

Main *omponent) of Pedal Po3ered -ack)a3 Machine !5

". Pedal


18/45

". Pedal !5

A bicycle pedal i) the part of a bicycle that the rider pu)he) 3ith theirfoot to propel the bicycle. It pro2ide) the connection bet3een the

cycli)t:) foot or )hoe and the crank allo3ing the leg to turn the bottom

bracket )pindle and propel the bicycleH) 3heel).

Pedal) 3ere initially attached to crank) connecting directly to the

dri2en Cu)ually front 3heel. The )afety bicycle9 a) it i) kno3n today9

came into being 3hen the pedal) 3ere attached to a crank dri2ing a

)procket that tran)mitted po3er to the dri2en 3heel by mean) of a

roller chain. Pedal) u)ually con)i)t of a )pindle that thread) into the

end of the crank and a body9 on 3hich the foot re)t) or i) attached9

that i) free to rotate on bearing) 3ith re)pect to the )pindle.

Pedal 83ll :e u/ed o ra/fer our 9u/4ular eer7 o e lare

/ro4ke.



19/45


20/45

#. Sprocket chain !5

Sprocket *hain!

Roller 4a3or :u/ roller 4a3 i) the type of chain dri2emo)t

commonly u)ed for tran)mi))ion A /ro4ke or /ro4ke-8eeli) a

profiled 3heel3ith teeth9 cog)9 or e2en )procket) that me)h 3ith

a chain9 trackor other perforated or indented material. The name

H)procketH applie) generally to any 3heel upon 3hich radial

projection) engage a chain pa))ing o2er it. It i) di)tingui)hed from

a gearin that )procket) are ne2er me)hed together directly9 and differ)from apulleyin that )procket) ha2e teeth and pulley) are )mooth.

It con)i)t) of a )erie) of )hort cylindrical roller) held together by )ide

link). It i) dri2en by a toothed 3heel called a )procket. It i) a )imple9

reliable9 and efficient mean) of po3er tran)mi))ion.

*on)truction of the *hain!

There are actually t3o type) of link)alternating in thebu)hroller

chain. The fir)t type i) inner link)9 ha2ing t3o inner plate) held

together by t3o )lee2e) or bu)hing) upon 3hich rotate t3o roller).

Inner link) alternate 3ith the )econd type9 the outer link)9 con)i)ting

of t3o outer plate) held together by pin) pa))ing through the bu)hing)

of the inner link). The bu)hingle)) roller chain i) )imilar in

operation though not in con)truction7 in)tead of )eparate bu)hing) or)lee2e) holding the inner plate) together9 the plate ha) a tube )tamped

https://en.wikipedia.org/wiki/Chain_drivehttps://en.wikipedia.org/wiki/Wheelhttps://en.wikipedia.org/wiki/Roller_chainhttps://en.wikipedia.org/wiki/Caterpillar_trackhttps://en.wikipedia.org/wiki/Gearhttps://en.wikipedia.org/wiki/Pulleyhttps://en.wikipedia.org/wiki/Sprockethttps://en.wikipedia.org/wiki/Link_(chain)https://en.wikipedia.org/wiki/Bushing_(bearing)https://en.wikipedia.org/wiki/Chain_drivehttps://en.wikipedia.org/wiki/Wheelhttps://en.wikipedia.org/wiki/Roller_chainhttps://en.wikipedia.org/wiki/Caterpillar_trackhttps://en.wikipedia.org/wiki/Gearhttps://en.wikipedia.org/wiki/Pulleyhttps://en.wikipedia.org/wiki/Sprockethttps://en.wikipedia.org/wiki/Link_(chain)https://en.wikipedia.org/wiki/Bushing_(bearing)


21/45

into it protruding from the hole 3hich )er2e) the )ame purpo)e. Thi)

ha) the ad2antage of remo2ing one )tep in a))embly of the chain.

The roller chain de)ign reduce) friction compared to )impler de)ign)9

re)ulting in higher efficiency and le)) 3ear. The original po3ertran)mi))ion chain 2arietie) lacked roller) and bu)hing)9 3ith both the

inner and outer plate) held by pin) 3hich directly contacted

the )procketteeth7 ho3e2er thi) configuration e;hibited e;tremely

rapid 3ear of both the )procket teeth9 and the plate) 3here they

pi2oted on the pin). Thi) problem 3a) partially )ol2ed by the

de2elopment of bu)hed chain)9 3ith the pin) holding the outer plate)

pa))ing through bu)hing) or )lee2e) connecting the inner plate). Thi)

di)tributed the 3ear o2er a greater area7 ho3e2er the teeth of the)procket) )till 3ore more rapidly than i) de)irable9 from the )liding

friction again)t the bu)hing). The addition of roller) )urrounding the

bu)hing )lee2e) of the chain and pro2ided rolling contact 3ith the

teeth of the )procket) re)ulting in e;cellent re)i)tance to 3ear of both

)procket) and chain a) 3ell. There i) e2en 2ery lo3 friction9 a) long

a) the chain i) )ufficiently lubricated. *ontinuou)9 clean9 lubrication

of roller chain) i) of primary importance for efficient operation a)

3ell a) correct ten)ioning.

%ro4ke 4a3 83ll ra/fer 9o3o fro9 e lare /ro4ke o e

/9all /ro4ke.

$. *rank !5

A crank i) a mechanical part able to perform a con2er)ion

bet3een reciprocating motionand rotational motion. Ina reciprocating engine9 it tran)late) reciprocating motionof

https://en.wikipedia.org/wiki/Sprockethttps://en.wikipedia.org/wiki/Reciprocating_motionhttps://en.wikipedia.org/wiki/Rotational_motionhttps://en.wikipedia.org/wiki/Reciprocating_enginehttps://en.wikipedia.org/wiki/Reciprocating_motionhttps://en.wikipedia.org/wiki/Sprockethttps://en.wikipedia.org/wiki/Reciprocating_motionhttps://en.wikipedia.org/wiki/Rotational_motionhttps://en.wikipedia.org/wiki/Reciprocating_enginehttps://en.wikipedia.org/wiki/Reciprocating_motion


22/45

thepi)toninto rotational motion7 3herea) in a reciprocating

compre))or9 it con2ert) the rotational motion into reciprocating

motion. In order to do the con2er)ion bet3een t3o motion)9 the

crank)haft ha) crank thro3) or crankpin)9 additional bearing

)urface) 3ho)e a;i) i) off)et from that of the crank9 to 3hich the big

end) of the connecting rod)from each cylinder attach.

It i) typically connected to a fly3heelto reduce the pul)ation

characteri)tic of the four5)troke cycle9 and )ometime) a tor)ional or

2ibrational damper at the oppo)ite end9 to reduce the tor)ional

2ibration)often cau)ed along the length of the crank)haft by the

cylinder) farthe)t from the output end acting on the tor)ional ela)ticity

of the metal.

Crak 83ll 4oer roar7 9o3o of /af 3o e re43ro4a3

9o3o 834 83ll furer ra/93 o e a4k /a8 a//e9:l7.

https://en.wikipedia.org/wiki/Pistonhttps://en.wikipedia.org/wiki/Reciprocating_compressorhttps://en.wikipedia.org/wiki/Reciprocating_compressorhttps://en.wikipedia.org/wiki/Crankpinhttps://en.wikipedia.org/wiki/Connecting_rodhttps://en.wikipedia.org/wiki/Flywheelhttps://en.wikipedia.org/wiki/Four-stroke_cyclehttps://en.wikipedia.org/wiki/Torsional_vibrationhttps://en.wikipedia.org/wiki/Torsional_vibrationhttps://en.wikipedia.org/wiki/Pistonhttps://en.wikipedia.org/wiki/Reciprocating_compressorhttps://en.wikipedia.org/wiki/Reciprocating_compressorhttps://en.wikipedia.org/wiki/Crankpinhttps://en.wikipedia.org/wiki/Connecting_rodhttps://en.wikipedia.org/wiki/Flywheelhttps://en.wikipedia.org/wiki/Four-stroke_cyclehttps://en.wikipedia.org/wiki/Torsional_vibrationhttps://en.wikipedia.org/wiki/Torsional_vibration


23/45

=. *onnecting &od !5

The 4oe43 rodconnect) thepi)tonto the crankor crank)haft.

Together 3ith the crank9 they form a )imple mechani)m that con2ert)

reciprocating motion into rotating motion.

*onnecting rod) may al)o con2ert rotating motion into reciprocating

motion. -i)torically9 before the de2elopment of engine)9 they 3ere

fir)t u)ed in thi) 3ay.

A) a connecting rod i) rigid9 it may tran)mit either a pu)h or a pull

and )o the rod may rotate the crank through both hal2e) of a

re2olution9 i.e. pi)ton pu)hing and pi)ton pulling. Earlier mechani)m)9

https://en.wikipedia.org/wiki/Pistonhttps://en.wikipedia.org/wiki/Crank_(mechanism)https://en.wikipedia.org/wiki/Crankshafthttps://en.wikipedia.org/wiki/Pistonhttps://en.wikipedia.org/wiki/Crank_(mechanism)https://en.wikipedia.org/wiki/Crankshaft


24/45

)uch a) chain)9 could only pull. In a fe3 t3o5)troke engine)9 the

connecting rod i) only reGuired to pu)h.

Today9 connecting rod) are be)t kno3n through their u)e in internal

combu)tion pi)ton engine)9 )uch a) automoti2e engine). The)e are ofa di)tinctly different de)ign from earlier form) of connecting rod)9

u)ed in )team engine) and )team locomoti2e).

*e are u/3 e 4oe43 rod o 4oer e roar7 9o3o of

4rak 3o re43ro4a3 9o3o ad /ul3ed 3 o e a4k /a8

a//e9:l7.

.Fly3heel!A fl78eeli) a rotating mechanical de2ice that i) u)ed to

)tore rotational energy. Fly3heel) ha2e an inertia called the moment

of inertiaand thu) re)i)t change) in rotational )peed. The amount of

energy )tored in a fly3heel i) proportional to the )Guare of

it) rotational )peed. Energy i) tran)ferred to a fly3heel by the

application of a torGueto it9 thereby increa)ing it) rotational )peed9

and hence it) )tored energy. *on2er)ely9 a fly3heel relea)e) )tored

https://en.wikipedia.org/wiki/Automotive_enginehttps://en.wikipedia.org/wiki/Rotational_energyhttps://en.wikipedia.org/wiki/Moment_of_inertiahttps://en.wikipedia.org/wiki/Moment_of_inertiahttps://en.wikipedia.org/wiki/Rotational_speedhttps://en.wikipedia.org/wiki/Torquehttps://en.wikipedia.org/wiki/Automotive_enginehttps://en.wikipedia.org/wiki/Rotational_energyhttps://en.wikipedia.org/wiki/Moment_of_inertiahttps://en.wikipedia.org/wiki/Moment_of_inertiahttps://en.wikipedia.org/wiki/Rotational_speedhttps://en.wikipedia.org/wiki/Torque


25/45

energy by applying torGue to a mechanical load9 thereby decrea)ing

the fly3heelH) rotational )peed.

*ommon u)e) of a fly3heel include!

Pro2iding continuou) energy 3hen the energy )ource i)

di)continuou). For e;ample9 fly3heel) are u)ed in reciprocating

engine)becau)e the energy )ource9 torGue from the engine9 i)intermittent.

Deli2ering energy at rate) beyond the ability of a continuou)

energy )ource. Thi) i) achie2ed by collecting energy in the

fly3heel o2er time and then relea)ing the energy Guickly9 at rate)

that e;ceed the abilitie) of the energy )ource.

*ontrolling the orientation of a mechanical )y)tem. In )uch

application)9 the angular momentumof a fly3heel i) purpo)ely

https://en.wikipedia.org/wiki/Reciprocating_enginehttps://en.wikipedia.org/wiki/Reciprocating_enginehttps://en.wikipedia.org/wiki/Angular_momentumhttps://en.wikipedia.org/wiki/Reciprocating_enginehttps://en.wikipedia.org/wiki/Reciprocating_enginehttps://en.wikipedia.org/wiki/Angular_momentum


26/45

tran)ferred a) a torGue to the attaching mechanical )y)tem 3hen

energy i) tran)ferred to or from the fly3heel9 thereby cau)ing the

attaching )y)tem to rotate into )ome de)ired po)ition.

Fly3heel) are typically made of )teel and rotate on con2entional

bearing)7 the)e are generally limited to a re2olution rate of a fe3

thou)and &PM. Some modern fly3heel) are made of carbon fibre

material) and employ magnetic bearing)9 enabling them to re2ol2e at

)peed) up to %9%%% &PM.

*arbon5compo)ite fly3heel batterie) ha2e recently beenmanufactured and are pro2ing to be 2iable in real53orld te)t) on

main)tream car). Additionally9 their di)po)al i) more eco5friendly.

"/ our a4k /a8 a//e9:l7 3/ 34l3ed' 8e ae o ro3de 9ore

eer7 o l3f u e a4k /a8 a//e9:l7. Fl78eel 83ll /ore e

eer7 dur3 do88ard /roke ad /ul7 e /ored eer7

dur3 u8ard /roke o l3f u e a4k /a8 a//e9:l7.

https://en.wikipedia.org/wiki/Magnetic_bearinghttps://en.wikipedia.org/wiki/Magnetic_bearing


27/45

(.*lutch!

A 4lu4i) a mechanical de2ice that engage) and di)engage) the

po3er tran)mi))ion9 e)pecially from dri2ing )haftto dri2en )haft.

*lutche) are u)ed 3hene2er the tran)mi))ion of po3er or motion mu)t

be controlled either in amount or o2er time Ce.g.9 electric )cre3dri2er)

limit ho3 much torGue i) tran)mitted through u)e of a clutch7 clutche)

control 3hether automobile) tran)mit engine po3er to the 3heel).

In the )imple)t application9 clutche) connect and di)connect t3o

rotating )haft) Cdri2e )haft)or line )haft). In the)e de2ice)9 one )hafti) typically attached to an engine or other po3er unit Cthe dri2ing

member 3hile the other )haft Cthe dri2en member pro2ide) output

po3er for 3ork. 8hile typically the motion) in2ol2ed are rotary9

linear clutche) are al)o po))ible.

In a torGue5controlled drill9 for in)tance9 one )haft i) dri2en by a

motor and the other dri2e) a drill chuck. The clutch connect) the t3o

)haft) )o they may be locked together and )pin at the )ame )peed

Cengaged9 locked together but )pinning at different )peed) C)lipping9

or unlocked and )pinning at different )peed) Cdi)engaged.

*e 8e 83ll /ar e 9a43e' 8e 83ll re// e 4lu4 leer /o

a 4lu4 83ll e d3/eaed ad ree e 4oe43o of

fl78eel ad 4rak. "/ e /eed of e fl78eel 34rea/e/' 8e 83ll

relea/e e 4lu4 /o a 3 83ll e eaed ad 83ll 4oe4 e

fl78eel ad 4rak.

https://en.wikipedia.org/wiki/Transmission_(mechanics)https://en.wikipedia.org/wiki/Driving_shafthttps://en.wikipedia.org/wiki/Drive_shafthttps://en.wikipedia.org/wiki/Line_shafthttps://en.wikipedia.org/wiki/Drillhttps://en.wikipedia.org/wiki/Transmission_(mechanics)https://en.wikipedia.org/wiki/Driving_shafthttps://en.wikipedia.org/wiki/Drive_shafthttps://en.wikipedia.org/wiki/Line_shafthttps://en.wikipedia.org/wiki/Drill


28/45

Friction clutche)!

The 2a)t majority of clutche) ultimately rely on frictional force) for

their operation. The purpo)e of friction clutche) i) to connect a

mo2ing member to another that i) mo2ing at a different )peed or

)tationary9 often to )ynchroniJe the )peed)9 andor to tran)mit po3er./)ually9 a) little )lippage Cdifference in )peed) a) po))ible bet3een

the t3o member) i) de)ired.



29/45

,. 4earing 4lock) !5

A :ear3i) a machine elementthat con)train) relati2e motion to

only the de)ired motion9 and reduce) friction bet3een mo2ing part).

The de)ign of the bearing may9 for e;ample9 pro2ide for

free linearmo2ement of the mo2ing part or for free rotation around a

fi;ed a;i)7 or9 it may pre2ent a motion by controlling

the 2ector)of normal force)that bear on the mo2ing part). Many

bearing) al)o facilitate the de)ired motion a) much a) po))ible9 )uch

a) by minimiJing friction. 4earing) are cla))ified broadly according

to the type of operation9 the motion) allo3ed9 or to the direction) of

the load) Cforce) applied to the part).

The term bearing i) deri2ed from the 2erb to bear7 a bearing being

a machine element that allo3) one part to bear Ci.e.9 to )upport

another. The )imple)t bearing) arebearing )urface)9 cut or formed into

a part9 3ith 2arying degree) of control o2er the form9

)iJe9 roughne))and location of the )urface. ?ther bearing) are

)eparate de2ice) in)talled into a machine or machine part. The mo)t

)ophi)ticated bearing) for the mo)t demanding application) are

2erypreci)ede2ice)7 their manufacture reGuire) )ome of the highe)t)tandard) of current technology.

#ear3 :lo4k/ 83ll :e u/ed o ro3de /uor o e roa3

/af o 834 fl78eel' 4rak' 4lu4' :rake/' ad /ro4ke are

9oued.

https://en.wikipedia.org/wiki/Machine_elementhttps://en.wikipedia.org/wiki/Moving_partshttps://en.wikipedia.org/wiki/Line_(geometry)https://en.wikipedia.org/wiki/Rotation_around_a_fixed_axishttps://en.wikipedia.org/wiki/Rotation_around_a_fixed_axishttps://en.wikipedia.org/wiki/Vector_(mathematics_and_physics)https://en.wikipedia.org/wiki/Normal_forcehttps://en.wiktionary.org/wiki/bear#Verbhttps://en.wikipedia.org/wiki/Bearing_surfacehttps://en.wikipedia.org/wiki/Surface_roughnesshttps://en.wikipedia.org/wiki/Accuracy_and_precisionhttps://en.wikipedia.org/wiki/High_techhttps://en.wikipedia.org/wiki/High_techhttps://en.wikipedia.org/wiki/Machine_elementhttps://en.wikipedia.org/wiki/Moving_partshttps://en.wikipedia.org/wiki/Line_(geometry)https://en.wikipedia.org/wiki/Rotation_around_a_fixed_axishttps://en.wikipedia.org/wiki/Rotation_around_a_fixed_axishttps://en.wikipedia.org/wiki/Vector_(mathematics_and_physics)https://en.wikipedia.org/wiki/Normal_forcehttps://en.wiktionary.org/wiki/bear#Verbhttps://en.wikipedia.org/wiki/Bearing_surfacehttps://en.wikipedia.org/wiki/Surface_roughnesshttps://en.wikipedia.org/wiki/Accuracy_and_precisionhttps://en.wikipedia.org/wiki/High_tech


30/45

@. 4rake !5

A :rakei) a mechanical de2icethat inhibit) motion9 )lo3ing or

)topping a mo2ing object or pre2enting it) motion.

Mo)t brake) commonly u)e frictionbet3een t3o )urface) pre))ed

together to con2ert the kinetic energyof the mo2ing object into heat9though other method) of energy con2er)ion may be employed. For

e;ample9 regenerati2e brakingcon2ert) much of the energy

to electrical energy9 3hich may be )tored for later u)e. ?ther method)

con2ert kinetic energyintopotential energyin )uch )tored form)

a)pre))uriJed airor pre))uriJed oil. Eddy current brake)u)e magnetic

field) to con2ert kinetic energy into electric current in the brake di)c9

fin9 or rail9 3hich i) con2erted into heat. Still other braking method)

e2en tran)form kinetic energyinto different form)9 for e;ample bytran)ferring the energy to a rotating fly3heel.

4rake) are generally applied to rotating a;le) or 3heel)9 but may al)o

take other form) )uch a) the )urface of a mo2ing fluid Cflap) deployed

into 3ater or air. Some 2ehicle) u)e a combination of braking

mechani)m)9 )uch a) drag racing car) 3ith both 3heel brake) and a

parachute9 or airplane) 3ith both 3heel brake) and drag flap) rai)ed

into the air during landing.

https://en.wikipedia.org/wiki/Machinehttps://en.wikipedia.org/wiki/Frictionhttps://en.wikipedia.org/wiki/Kinetic_energyhttps://en.wikipedia.org/wiki/Heathttps://en.wikipedia.org/wiki/Regenerative_brakinghttps://en.wikipedia.org/wiki/Electrical_energyhttps://en.wikipedia.org/wiki/Kinetic_energyhttps://en.wikipedia.org/wiki/Potential_energyhttps://en.wikipedia.org/wiki/Compressed_air_energy_storagehttps://en.wikipedia.org/wiki/Eddy_current_brakeshttps://en.wikipedia.org/wiki/Kinetic_energyhttps://en.wikipedia.org/wiki/Machinehttps://en.wikipedia.org/wiki/Frictionhttps://en.wikipedia.org/wiki/Kinetic_energyhttps://en.wikipedia.org/wiki/Heathttps://en.wikipedia.org/wiki/Regenerative_brakinghttps://en.wikipedia.org/wiki/Electrical_energyhttps://en.wikipedia.org/wiki/Kinetic_energyhttps://en.wikipedia.org/wiki/Potential_energyhttps://en.wikipedia.org/wiki/Compressed_air_energy_storagehttps://en.wikipedia.org/wiki/Eddy_current_brakeshttps://en.wikipedia.org/wiki/Kinetic_energy


31/45

Magnetic brake )y)tem:

Di)clo)ed i) a magnetic brake )y)tem for a 2ehicle9 compri)ing! a

plurality of brake di)k )olenoid) for generating the magnetic force7 a

plurality of brake pad )olenoid) for generating the magnetic force7 a

braking )en)or for detecting 3hether a brake pedal i) applied7 a 3heel

)peed )en)or for detecting 3heel )peed7 a magnetic polarity )en)or fordetecting magnetic polarity of the brake di)k )olenoid)7 and a control

unit for controlling the brake pad )olenoid) u)ing )ignal) from the

braking )en)or9 the 3heel )peed )en)or and the magnetic polarity

)en)or.

%o9e39e/' 3f 8e ae o /o e 9a43e 3 4a/e of e9ere47'

e 8e 83ll re// e :rake leer /o a 3 83ll de4rea/e e /eed

of e a4k /a8 a//e9:l7.



32/45

"%. -ackSa3 !5

A a4k/a8i) a fine5toothed )a39 originally and principally for

cutting metal. They can al)o cut 2ariou) other material)9 )uch a)

pla)tic and 3ood7 for e;ample9plumber)and electrician)often

cutpla)tic pipeandpla)tic conduit3ith them. There are hand

)a32er)ion) and po3ered 2er)ion) Cpo3er hack)a3). Mo)t

hack)a3) are hand )a3) 3ith a *5)haped frame that hold)

https://en.wikipedia.org/wiki/Sawhttps://en.wikipedia.org/wiki/Metalhttps://en.wikipedia.org/wiki/Plumberhttps://en.wikipedia.org/wiki/Electricianhttps://en.wikipedia.org/wiki/Plastic_pipeworkhttps://en.wikipedia.org/wiki/Electrical_conduithttps://en.wikipedia.org/wiki/Hand_sawhttps://en.wikipedia.org/wiki/Hand_sawhttps://en.wikipedia.org/wiki/Sawhttps://en.wikipedia.org/wiki/Metalhttps://en.wikipedia.org/wiki/Plumberhttps://en.wikipedia.org/wiki/Electricianhttps://en.wikipedia.org/wiki/Plastic_pipeworkhttps://en.wikipedia.org/wiki/Electrical_conduithttps://en.wikipedia.org/wiki/Hand_sawhttps://en.wikipedia.org/wiki/Hand_saw


33/45

abladeunder ten)ion. Such hack)a3) ha2e a handle9 u)ually api)tol

grip9 3ith pin) for attaching a narro3 di)po)able blade. The frame)

may al)o be adju)table to accommodate blade) of different )iJe). A

)cre3 or other mechani)m i) u)ed to put the thin blade under

ten)ion. Panel hack)a3) forgo the frame and in)tead ha2e a )heet

metalbody7 they can cut into a )heet metal panel further than a frame

3ould allo3. The)e )a3) are no longer commonly a2ailable9 but

hack)a3 blade holder) enable )tandard hack)a3 blade) to be u)ed

)imilarly to a keyhole )a3 or pad )a3. Po3er tool) including nibbler)9

jig)a3)9 and angle grinder) fitted 3ith metal5cutting blade) and di)c)

are no3 u)ed for longer cut) in )heet metal).

?n hack)a3)9 a) 3ith mo)t frame )a3)9 the blade can be mounted3ith the teeth facing to3ard or a3ay from the handle9 re)ulting in

cutting action on either the pu)h or pull )troke. In normal u)e9 cutting

2ertically do3n3ard) 3ith 3ork held in a bench 2ice9 hack)a3 blade)

)hould be )et to be facing for3ard). Some frame )a3)9 including Fret

Sa3) and Piercing Sa3)9 ha2e their blade) )et to be facing the handle

becau)e they are u)ed to cut by being pulled do3n again)t a

horiJontal )urface.

https://en.wikipedia.org/wiki/Bladehttps://en.wikipedia.org/wiki/Tension_(physics)https://en.wikipedia.org/wiki/Pistol_griphttps://en.wikipedia.org/wiki/Pistol_griphttps://en.wikipedia.org/wiki/Sheet_metalhttps://en.wikipedia.org/wiki/Sheet_metalhttps://en.wikipedia.org/wiki/Bladehttps://en.wikipedia.org/wiki/Tension_(physics)https://en.wikipedia.org/wiki/Pistol_griphttps://en.wikipedia.org/wiki/Pistol_griphttps://en.wikipedia.org/wiki/Sheet_metalhttps://en.wikipedia.org/wiki/Sheet_metal


34/45

"". 4lade !5

4lade) are a2ailable in )tandardiJed length)9 u)ually "% or "< inche)

for a )tandard hand hack)a3. junior hack)a3) are typically "=%mm

long. Po3ered hack)a3) may u)e large blade) in a range of )iJe)9 or

)mall machine) may u)e the )ame hand blade).

The pitch of the teeth can be any3here from fourteen to thirty5t3o

teeth per inch Ctpi for a hand blade9 3ith a) fe3 a) three tpi for a

large po3er hack)a3 blade. The blade cho)en i) ba)ed on the

thickne)) of the material being cut9 3ith a minimum of three teeth in

the material. A) hack)a3 teeth are )o )mall9 they are )etin a 3a2e

)et. A) for other )a3) they are )et from )ide to )ide to pro2ide

https://en.wikipedia.org/wiki/Saw_sethttps://en.wikipedia.org/wiki/Saw_set


35/45

a kerfor clearance 3hen )a3ing9 but the )et of a hack)a3 change)

gradually from tooth to tooth in a )mooth cur2e9 rather than alternate

teeth )et left and right.

Hacksaw blades are normall !"i#e bri##le$ so careneeds #o be #aken #o %re&en# bri##le 'rac#"reo' #heblade( )arl blades were o' carbon s#eel$ now #ermed*low allo* blades$ and were rela#i&el so'# and +e,ible(

-he a&oided breakage$ b"# also wore o"# ra%idl(),ce%# where cos# is a %ar#ic"lar concern$ #his #%e isnow obsole#e( *.ow allo* blades are s#ill #he onl #%ea&ailable 'or #he /"nior hacksaw$ which limi#s #he

"se'"lness o' #his o#herwise %o%"lar saw(

For )e2eral decade) no39 hack)a3 blade) ha2e u)ed high )peed

)teelfor their teeth9 gi2ing greatly impro2ed cutting and tooth life.

The)e blade) 3ere fir)t a2ailable in the HAll5hardH form 3hich cut

accurately but 3ere e;tremely brittle. Thi) limited their practical u)e

to bench3ork on a 3orkpiece that 3a) firmly clamped in a 2ice. A

)ofter form of high )peed )teel blade 3a) al)o a2ailable9 3hich 3ore

3ell and re)i)ted breakage9 but 3a) le)) )tiff and )o le)) accurate forpreci)e )a3ing. Since the "@,%)9bi5metalblade) ha2e been u)ed to

gi2e the ad2antage) of both form)9 3ithout ri)k of breakage. A )trip of

high )peed )teel along the tooth edge i) electron beam 3eldedto a

)ofter )pine. A) the price of the)e ha) dropped to be comparable 3ith

the older blade)9 their u)e i) no3 almo)t uni2er)al.

https://en.wiktionary.org/wiki/kerfhttps://en.wikipedia.org/wiki/Brittlenesshttps://en.wikipedia.org/wiki/Fracture#Brittle_fracturehttps://en.wikipedia.org/wiki/High_speed_steelhttps://en.wikipedia.org/wiki/High_speed_steelhttps://en.wikipedia.org/wiki/Visehttps://en.wikipedia.org/wiki/Bi-metalhttps://en.wikipedia.org/wiki/Electron_beam_weldinghttps://en.wiktionary.org/wiki/kerfhttps://en.wikipedia.org/wiki/Brittlenesshttps://en.wikipedia.org/wiki/Fracture#Brittle_fracturehttps://en.wikipedia.org/wiki/High_speed_steelhttps://en.wikipedia.org/wiki/High_speed_steelhttps://en.wikipedia.org/wiki/Visehttps://en.wikipedia.org/wiki/Bi-metalhttps://en.wikipedia.org/wiki/Electron_beam_welding


36/45

Selection of blade!5

Proper blade )election i) important. /)e the three5tooth rule at lea)t

three teeth mu)t be in con5tact 3ith the 3ork. Barge )ection) and )oft

material) reGuire a coar)e5tooth blade. Small or thin 3ork and hard

material) reGuire a fine5tooth blade.For be)t cutting action9 apply hea2y feed pre))ure on hard material)

and large 3ork. /)e light feed pre))ure on )oft material) and 3ork

3ith )mall cro)) )ection).

4lade) are made in t3o principal type)! fle;ible5back and all5hard.

The choice depend) upon u)e.

i Fle;ible5back blade) 5)hould be u)ed 3here )afety reGuirement)

demand a )hatterproof blade. The)e blade) )hould al)o be u)ed for

cutting odd5)haped 3ork if there i) a po))ibility of the 3ork coming

loo)e in the 2i)e.

ii All5hard blade 5For a majority of cutting job)9 theall5hard bladei)

be)t for )traight9 accurate cutting under a 2ariety of condition).

8hen )tarting a cut 3ith an all5hard blade9 be )ure the blade doe) not

drop on the 3ork 3hen cutting )tart). If it fall)9 the blade could )hatter

and flying piece) cau)e injurie).

Po3er -ack)a3 blade !5

4lade) are al)o made from tung)ten and molybdenum )teel)9 and 3ith

tung)ten carbide teeth on )teel alloy back). The follo3ing 0rule5of5

thumb1 can be follo3ed for )electing the correct blade!

/)e a $5tooth blade for cutting large )ection) or readily machined

metal).



37/45

/)e a 5tooth blade for cutting harder alloy) and mi)cellaneou)

cutting.

/)e "%5 and "$5tooth blade) primarily on light duty machine) 3here

3ork i) limited to )mall )ection) reGuiring moderate or light feedpre))ure.

Mounting a Po3er -ack)a3 blade!5

The blade mu)t be mounted to cut on the po3er Cback )troke. The

blade mu)t al)o lie perfectly flat again)t the mounting plate). If long

life and accurate cut) are to be achie2ed9 the blade mu)t be properly

ten)ioned.

Many techniGue) ha2e been de2eloped for properly mounting andten)ioning blade). /)e a torGue 3rench and con)ult the

manufacturer:) literature. If the information Cproper torGue for a gi2en

blade on a gi2en machine i) not a2ailable9 the follo3ing method) can

be u)ed!

Tighten the blade until a lo3 mu)ical ring i) heard 3hen the blade i)

tapped lightly. A high pitched tone indicate) that the blade i) too tight.

A dull thud mean) the blade i) too loo)e. The )hape of the blade pinhole can )er2e a) an indicator of 3hether the blade i) ten)ioned



38/45

properly. 8hen proper ten)ion i) achie2ed9 the pin hole) 3ill become

)lightly elongated9

The blade 3ill become more firmly )eated after the fir)t fe3 cut) and

3ill )tretch )lightly. The blade 3ill reGuire re5ten)ioningCretightening before further cutting can be done.

8?&I+ P&I*IPBE

It con)i)t) of the pedal arrangement 3hich rotate) the crank and

through it )lider con)i)t) of o)cillating mechani)m. The po3er i)

tran)mitted to the crank and )lider mechani)m. Thi) mechani)m i)

u)ed to rotate the crank di)c7 the di)c 3hich i) ha2ing an e;tended rod

i) connected to the )liding portion of the hack)a3 directly by mean)

of a linkage. The hack)a3 i) pa))ed through the guide 3ay) by mean)

of maintaining the cutting a;i). A) the u)er operated the pedal9 the

hack )a3 cut) the 2ariou) material) automatically 3ith le)) po3er.

The dead 3eight i) for compre))i2e force 3hile the u)er operated the

foot pedal.



39/45

AD'ATA+ES!5

I. Time )a2ing a) compared to )imple hack)a3

II. Po3er )a2ing a) it i) manually operated

III. Ea)y machinery u)ed

I'. A) it i) pedal operated )o good for health

'. *omfortable then ordinary hack)a3

'I. It i) portable

'II. It could be u)ed 3here2er metal cutting i) done in )mall )cale)9

including at con)truction )ite) and furniture unit)9 or to cut metal for

3indo3 pane).

DISAD'ATA+ES!5

I. It:) totally manually operated

II. Time con)uming a) compared to electrical po3er hack)a3

III. 8ithout human effort it:) not operated

I'. ot fit for hea2y production



40/45

*alculation)!5

*hain Dri2er Sprocket

K

Dri2en Sprocket

&adiu) of Dri2er Sprocket L &"

&adiu) of Dri2en Sprocket L &. +upta9")t

multicolour edition .


45/45

project report on pedal operated hack saw machine

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