JOURNAL OF INFORMATION, KNOWLEDGE AND RESEARCH IN
MECHANICAL ENGINEERING
ISSN 0975 – 668X| NOV 16 TO OCT 17 , VOLUME –04, ISSUE – 02
DESIGN AND DEVELOPMENT OF PNEUMATIC POWERED
HACKSAW MACHINE
1
BHISE MACHINDRA R ,2DHAYGUDE GANESH D, 3SUTAR ANIKET M, 4KONDE MANGESH B,
5
PROF. BANKAR M. B.
1,2,3,4,5
Department of Mechanical Engineering, Assistant Professor
Rajgad technical campus, SavitribaiPhule Pune University,
Pune, Dhangwadi-412205, Maharashtra, India.
ABSTRACT:-
The objective of this work is to automate the conventional power hacksaw machine in order achieve high
productivity of work pieces than the power hacksaw machine using pneumatic power. Pneumatic is a huge
topic of science and engineering dealing with the mechanical properties of air. In our project we take this
pneumatic and a hacksaw for cutting purpose, The pneumatic reciprocating high-speed hacksaw machine
has an advantage of working in high pressure, the hacksaw used in this is reciprocate such that required
shape can be cut according to the requirement. The hacksaw is the metal cutting machine tool designed to
cut metal by applying pneumatic pressure. Hacksaws are used to cut thin and soft metals the operation of
the unit is simplified to a few simple operations involving a cylinder block and piston arrangement.
KEYWORDS:Power hacksaw, Pneumatic cylinder, Compressor, Testing.
1. INTRODUCTION
The hacksaw is the metal cutting machine tool
designed to cut metal by applying pneumatic
pressure. Hacksaws are used cut thin and soft metal
the operation of the unit is simplified to a few
simple operation involving a cylinder block and
arrangement. The hacksaw is the metal cutting
machine tool designed to cut metal by applying
pneumatic pressure. The machine exclusively
intended for mass production and they represent
fasten and more efficient way to cut a metal. Fig 1.Power Hacksaw Machine
Hacksaws are used to cut thin and soft metals the
operation of the unit is simplified to a few simple Air at Intake conditions namely at atmosphere
operations involving a cylinder block and piston pressure and normal ambient temperature.
arrangement. There are numerous systems in Materials Use :
hacksaw machine .The main function of pneumatic 1. Control unit
hacksaw is to cut thin and soft metals by pneumatic 2.Solenoidal valve
power. 3. Pneumatic cylinder
The hacksaw is the metal cutting machine tool 4. Hack saw
designed to cut metal by applying pneumatic 5. Air compressor
pressure. The machine exclusively intended for 6. Handle
mass production and they represent fasten and 7. Pressure Regulator
more efficient way to cut a metal. Hacksaws are 8. Connecting ports
used to cut thin and soft metals the operation of the 9. Houses
unit is simplified to a few simple operations 10. Actuator
involving a cylinder block and piston arrangement.
There are numerous systems in hacksaw machine 1. 1. Element of the Pneumatic System:
.The main function of pneumatic hacksaw is to cut i)Compressor: A pump which compresses air,
thin and soft metals by pneumatic power. raising it to a higher pressure, and delivers it to the
pneumatic system (sometimes, can also be used to
generate a vacuum).
Control valve: one-way valve that allows
pressurized air to enter the pneumatic system, but
prevents backflow (and loss of pressure) into the
compressor when it is stopped. Solenoid value:
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JOURNAL OF INFORMATION, KNOWLEDGE AND RESEARCH IN
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ISSN 0975 – 668X| NOV 16 TO OCT 17 , VOLUME –04, ISSUE – 02
controls the flow of pressurized air from the source ii)Piston Rod :The piston rod is circular in cross
to the selected port. Some valves permit free section. It connects piston with piston of other
exhaust from the port not selected. These valves cylinder. The piston rod is made of mild steel
can be actuated either manually or electrically (the ground and polished. A high finish is essential on
valves typically provided in the FIRST kits use the outer rod surface to minimize wear on the rod
dual solenoids to change the direction of the valve, seals. Thepiston rod is connected to the piston by
based on input signals from the control system). mechanical fastening. The piston and the piston rod
can be separated if necessary.One end of the piston
rod is connected to the bottom of thepiston. The
other end of the piston rod is connected to theother
piston rod by means of coupling. The piston
transmits the working force to the oil cylinder
through the piston rod. The piston rod is designed
to withstand the highCompressive force.
iii)Cylinder Cover Plates:
The cylinder should be enclosed to get the applied
pressure from the compressor and act on the pinion.
Fig. 2:Pneumatic Compressor The cylinder is thus closed by the cover plates on
both the ends such that there is no leakage of air.
ii)Actuator: Converts energy stored in the An inlet port is provided on the top cover plate and
compressed air into mechanical motion. A Linear an outlet ports on the bottom cover plate. There is
piston is shown. Alternate tools include rotary also a hole drilled for the movement of the piston.
actuators, air tools, expanding bladders, etc. control The cylinder cover plate protects the cylinder from
unit: It is used control the solenoid by ON and OFF dust and other particle and maintains the same
valve. To the requirement of air flow in further way pressure that is taken from the compressor. The
to in and out for the working of pneumatic flange has to hold the piston in both of its extreme
cylinder. positions. The piston hits the top plate during the
return stroke and hits the bottom plate during end
1.2Parts Of Pneumatic Cylinder: of forward stroke. So the cover plates must be
i)Piston:The piston is a cylindrical member of strong enough to withstand the load.
certain length which reciprocates inside the
cylinder. The diameter of the piston is slightly less 2.DESCRIPTION OF EQUIPMENTS
than that of the cylinder bore diameter and it is
fitted to the top of the piston rod. It is one of 2.1.Pneumatic Cylinder
theimportant parts which convert the pressure
energy into mechanical power.The piston is Cylinder Technical Data
equipped with a ring suitably proportioned and it is i)Piston Rod:M.S. hard Chrome plated
relatively soft rubber which is capable of providing ii)Seals:Nitrile (Buna – N) Elastomer
good sealing with low friction at the operating iii)End Covers:Cast iron graded fine grained from
pressure. The purpose of piston is to provide means 25mm to 300mm
of conveying the pressure of air inside the cylinder iv)Piston:Aluminium
to the piston of the oil cylinder. Generally piston is v)Media: Air
made up of-Aluminums alloy-light and medium vi)TemperatureRange: 0oc to 85oc
work. Brass or bronze or CI-Heavy duty
The piston moves forward when the high-pressure The piston is a cylindrical member of certain length
air is turned from the right side of cylinder. The which reciprocates inside the cylinder. The
piston moves backward when the solenoid valve is diameter of the piston is slightly less than that of
in OFF condition. The piston should be as strong the cylinder bore diameter and it is fitted to the top
and rigid as possible. The efficiency and economy of the piston rod. It is one of the important parts
of the machine primarily depends on the working which convert the pressure energy into mechanical
of the piston. It must operate in the cylinder with a power
minimum of friction and should be able to Generally piston is made up of
withstand the high compressor force developed in 1.Aluminium alloy-light and medium work.
the cylinder and also the shock load during 2.Brass or bronze or CI-Heavy duty.
operation.
Noise.
It should be frictionless.
It should withstand high pressure.
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JOURNAL OF INFORMATION, KNOWLEDGE AND RESEARCH IN
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ISSN 0975 – 668X| NOV 16 TO OCT 17 , VOLUME –04, ISSUE – 02
hits the bottom plate during end of forward stroke.
So the cover plates must be strong enough to
withstand the load.
2.2 Working
A pneumatic system is one in which power is
transmitted from one place to another place through
the medium of an compressible air. Usually
pneumatic system have found versatile application
in machine tool engineering .power transmission,
by using an air as medium is called by a name
Figure No3: Pneumatic cylinder
pneumatic.it is more compact and eliminates the
mechanical complicated linkages like gears, came
The piston is single acting spring returned type.
and levers .It does not require any lubrication as
The piston moves forward when the high-pressure
aresult wear and tear of the moving components are
air is turned from the right side of cylinder. The
considerably reduced .
piston moves backward when the solenoid valve is
The Pneumatic system components are connected
in OFF condition. The piston should be as strong
by pipe lines .It provides flexibility in locating the
and rigid as possible. The efficiency and economy
components at any desired place .by varying. The
of the machine primarily depends on the working
quantity of air flow by means of a value any
of the piston. It must operate in the cylinder with a
amount of step less speed can easily be obtained
minimum of friction and should be able to
The air used in system, provides cushioning effect
withstand the high compressor force developed in
for the shock loads. The life of the component is
the cylinder and also the shock load during
increased. Very large forces can easily be obtained
operation.
and force multiplication is also possible with the
minimum changes and losses. Whenever the
Piston Rod :-The piston rod is circular in cross
pneumatic systems are over loaded the pressure’s
section. It connects piston with piston of other
immediately relieved. Thus the system components
cylinder. The piston rod is made of mild steel
are protected against the breakages and overstrain.
ground and polished. A high finish is essential on
The pneumatic air is compressible the system is
the outer rod surface to minimize wear on the rod
very sensitive for instant operations. Thus
seals. The piston rod is connected to the piston by
backlashes in mechanical system will exist in
mechanical fastening. The piston and the piston
pneumatic system. This system requires very
rod can be separated if necessary.One end of the
simple maintence cares. The heat generated in the
piston rod is connected to the bottom of the piston.
bearings and moving parts are carried away by the
The other end of the piston rod is connected to the
air itself. Thus the system does not require any
other piston rod by means of coupling. The piston
cooling arrangements. The system provides quick
transmits the working force to the oil cylinder
return motion of the components with the simple
through the piston rod. The piston rod is designed
arrangements. Thus idle times of machining
to withstand the high compressive force. It should
operations are reduced. The pneumatic system
avoid bending and withstand.Shock loads caused
provides very high degree of dependability.
by the cutting force. The piston moves inside the
rod seal fixed in the bottom cover plate of the
2.3Solenoid Valve
cylinder. The sealing arrangements prevent the
leakage of air from the bottom of the cylinder while
Technical Data:
the rod reciprocates through it.
Size : 5/2”
Pressure : 0 to 10 kg / cm2
Cylinder Cover Plates:-The cylinder should be
Media : Air
enclosed to get the applied pressure from the
Purpose:This valve is used to speed up the piston
compressor and act on the pinion. The cylinder is
movement and also it acts as a one – way
thus closed by the cover plates on both the ends
restriction valve which means that the air can pass
such that there is no leakage of air. An inlet port is
through only one way and it can’t return back. By
provided on the top cover plate and an outlet ports
using this valve the time consumption is reduced
on the bottom cover plate. There is also a hole
because of the faster movement of the piston.The
drilled for the movement of the piston.The cylinder
directional valve is one of the important parts of a
cover plate protects the cylinder from dust and
pneumatic system commonly known as DCV. This
other particle and maintains the same pressure that
value is used to control the direction of air flow in
is taken from the compressor. The flange has to
the pneumatic system; the directional valve does
hold the piston in both of its extreme positions. he
this by changing the position of its internal
piston hits the top plat during the return stroke and
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ISSN 0975 – 668X| NOV 16 TO OCT 17 , VOLUME –04, ISSUE – 02
movable parts. His value was selected for speeedy entire valve. It protects the solenoid from dirt and
operation and to reduce the manual effort and also other foreign matter, and protects the actuator also.
for the modification of the machine into automobile 4. Connectors, Reducer And Hosecollar:In our
machine by means of using a solenoid valueA pneumatic system there are two types of connectors
solenoid is an electrical device that converts used; one is the hose connector and the other is the
electrical energy into straight line motion and reducer. Hose connectors normally comprise an
force. These are also used to operate a mechanical adapter (connector) hose nipple and cap nut. These
operation which in turn operates the valve types of connectors are made up of brass or
mechanism. Solenoid is one which the plunger is Aluminium or hardened steel. Reducers are used to
pulled when the solenoid is energized.The name of provide inter connection between two pipes or
the parts of the solenoid should be learned so that hoses of different sizes. They may be fitted
they can be recognized when called upon to make straight “L” or other configuration.
repairs, to do service work or to install them.
TechnicalData
1. Solenoid Valve
2. Pressure- 0-8 x 10 ⁵N/m²
3. Media: Air
4. Port size - 0.635 x 10 ² m
5.Connectors
Maxworking pressure :-10 x 10 ⁵N/m²
Temperature:-0-100 º
Fluid media :-Air
Figure no.4:-5/2 Solenoid Valve
6.Hoses
Parts Of A Solenoid Valve: Maxpressure 10 x 10 ⁵N/m²
1. Coil:-The solenoid coil is made of copper wire. Outerdiameter:-6 mm = 6 x 10 ˉ ³m
The layers of wire are seprated by insulating Innerdiameter:-3.5 mm = 3.5 x 10 ˉ ³m
layer.The entire solenoid coil is covered with a
varnish that is not affected by solenoid moisture.
Cutting oil or often fluids.coils are rated in various 3.DESIGN AND DRAWING:-
voltages such as 115 volts AC, 230volts AC,
460volts AC,575volts AC. 6volts DC,12volts
DC,24 volts DC,115volts DC & 230 volts DC.
They are designed for such frequencies as 50Hz to
60 Hz.
2. Frame:-The Solenoid Frames Serves several
purposes. Since it is made of laminated sheets, it
magnetized when the current passes through the
coil. The magnetized coils attract the metal plunger
to move. The frame has provisions for attaching the
mounting they are usually bolted or welded to the
frame. The frame has provisions for receviers the
Figure No: 8Drawing For Pneumatic Reciprocating
plunger. The wear strips are mounted to the
Highspeed Hacksaw Machine
solenoid frame. And are made of materials such as
metal or imaginated less fiber cloth.
Working Principle-
The compressed air from the compressor reaches
3. Solenoid Plunger:-The solenoid plunger is the
the solenoid valve. The solenoid valve changes the
mover mechanism of the solenoid. The plunger is
direction of flow according to the signals from the
made of steel laminations which are riveted
timing device. The compressed air passes through
together under high pressure, so that there will be
the solenoid valve and it is admitted into the front
no movement of the lamination with respect to one
end of the cylinder block.The air pushes the piston
another. At the top of the plunger a pin hole is
for the cutting stroke. At the end of the cutting
placed for making a connection to some device.
stroke air from the solenoid valve reaches the rear
The solenoid plunger is moved by a magnetic force
end of the cylinder block.The pressure remains the
in one direction and it’s usually returned by spring
same but the area is less due to the presence of
action.Solenoid operated valves are usually
piston rod. This exerts greater pressure on the
provided with cover either the solenoid or the
piston, pushing it at a faster rate thus enabling
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JOURNAL OF INFORMATION, KNOWLEDGE AND RESEARCH IN
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ISSN 0975 – 668X| NOV 16 TO OCT 17 , VOLUME –04, ISSUE – 02
faster return stroke. The weight attached at the end 5] S.G. Bahaley, Dr. Awate A.V, ”Performance
of the hacksaw frame gives constant loads which Analysis Of Pedal Powered Multipurpose
lower the hacksaw to enable continuous cutting of Machine”, IJERT, Volume-1, Issue-5, July-
the work. The stroke length of the piston can be (2012).
changed by making suitable adjustment in the 6] T. Mohanraj, V. Siddhartha, ”Design And
timer. Fabrication Of Automated Hacksaw Machine”,
IJIRSET, Volume-3, Issue-2, April-(2014).
4. ADVANTAGES 7] Analysis Of Multipurpose Hacksaw
1. This new developed pneumatic cutting Machine”,IJRAT,Volume-3,April-(2015)
machine is useful in small &large scale 8] Stephen Tambari, AyejahVictor.”Study On
industries instead of manual cutting machine The Design And Construction of Pedal Power
Hacksaw Machine”, IISN:-2320-334X,
for reducing effort of Human
Volume-12, July-August-(2015)
2. It is portable & is compact one
3. This machine has Less maintenance.
5. APPLICATION
1. It is used in small scale industries and large
scale industries.
2. It is useful when material need to cut in
hazardous area such as oil& gas refineries.
3. It is used to cut small sized pipes or rods.
6. CONCLUSION:
Today, buyers are demanding quiet machines
because of their concern about meeting in dusty’s
noise limits. Vickers is helping to meet this demand
by supplying quiet pneumatic components. Sound
levels of some pumps today, for example, there are
fifty percentage of lower than the same model
pumps of a few years ago. In the pneumatic the one
major problem is leakage. In future we can avoid
this leakage by taking proper activities.
7. REFERENCES
1] K.Sathishkumar1, N.Ugesh2, K.Vignesh3 and
P.B.SanjeevaPrasath, “Pneumatic
Reciprocating Hacksaw Machine” ,
International Conference on Breakthrough in
Engineering, Science & Technology– 2016,6-
10
2] John et al.” Design and Fabrication of
Automated Hacksaw Machine” Second
National Conference on Trends in Automotive
Parts Systems and Applications (TAPSA-
2014) 261-269
3] RathodNayan J, “Discussed an identification
of external structural load by measuring
harmonic responses.” Division of Solid
Mechanics, Chalmers University of
Technology.
4] Nagraj M harihar“Inverse finite element
approach to determine the static and dynamic
forces acting on vehicle model” Mtech project
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