This project describes about dual side shaper machine using a scotch yoke mechanism which can
be used in industries for cutting process. A Shaper is a machine used for shaping (metal removal)
operation on the work piece. A usual shaper machine operates by a principle of whit worth quick return
mechanism where materials are processed at one end and other end remains idle. But in a dual side
shaper machine, materials are processed at both ends which become advantageous when compared to
usual shaper. Nowadays, Industries try to achieve high production rate at a minimal amount of time,
cost etc. Usage of dual side shaper machine eliminates most disadvantages faced by a single side shaper.
The main advantage of dual side shaper is that it decreases time as well as production cost. Thereby it
increases productivity. Another advantage is that number of moving parts is less when compared to
usual machine. This model uses a single power source which can be connected to gears for increasing or
decreasing the speed of cut.
CHAPTER I
INTRODUCTION
1.1INTRODUCTION
In this project, it includes the design of a double acting shapping machine. In
industries saving the time and saving the manpower is an important thing all over
the world. To satisfy the needs of the industries, the machine is exclusively
intended for the mass production and they represent a fast and more effective way
to cut the materials. There are numerous types of cutting machines in the
engineering field, which are useful in fulfilling the requirements. This new
machine is used to avoid energy loss and save time. Scotch Yoke [1] Mechanism is
used for this purpose. Increasing productivity is one of the main requirements of
production engineering in any kind of manufacturing industry. Either by reducing
the operation time or by improving the capability of the machine to produce the
components in an increased number at the same time is very essential for an
industry to achieve the same. This project employs the Scotch yoke mechanism in
power hacksaw machine which enables it to cut two components at a time thereby
improving the productivity. In today’s world time a machine should be less time-
consuming. Power hacksaw cut one piece at one time so there was a loss in
production rate. Double acting power hacksaw overcomes this time-consuming
problem. Power hacksaw is a fine-tooth power saw with the blade held under
tension in the frame. Double acting power hacksaw cuts two materials
simultaneously by its scotch yoke mechanism, so the production rate increase
twice than that of power hacksaw. Double acting power hacksaw works under by
the scotch yoke [1] mechanism. The scotch yoke mechanism converts the rotary
motion into the reciprocating motion.
1.2 SCOTCH YOKE MECHANISM
The Scotch Yoke [1] (also known as slotted link mechanism) is a reciprocating
motion mechanism, converting the linear motion of a slider into rotational motion,
or vice versa. The piston or other reciprocating part is directly coupled to a sliding
yoke with a slot that engages a pin on the rotating part. The location of the piston
versus time is a sine wave of constant amplitude, and constant frequency is given a
constant rotational speed. This setup is most commonly used in control valve
actuators in high-pressure oil and gas pipelines. Although not a common
metalworking machine nowadays, crude shapers can use Scotch yokes. Almost all
those use a Whitworth linkage, which gives a slow speed forward cutting stroke
and a faster return. It has been used in various internal combustion engines, such as
the Bourke engine, SyTech engine, and many hot air engines and steam engines.
Fig. 1: Scotch Yoke Mechanism
1.3 HISTORY
This linkage was called by Scotsman in 1869 “a crank and a lot headed rod” but
now it is known as Scotch yoke [1] mechanism because, in America at least, a
scotch was a slotted bar that was slipped under a collar on a string of well drilling
tools to support them while a section was being added. In 1940, Russell Bourke
applied this mechanism to internal combustion engine called Bourke 30 Engine.
While saws for cutting metal had been being used for a long time, noteworthy
upgrades in life span and effectiveness were made in the 1880s by Max Flower-
Nash. Clemson, an author of Clemson Bros., Inc of Middletown, New York,
United States,. Clemson directed tests which included changing the measurements,
states of teeth, styles of set, and variable warmth medications of cutting edges.
Clemson guaranteed tremendous changes to the cutting capacity of edges and
constructed a noteworthy mechanical activity fabricating hacksaw sharp edges sold
under the exchange name Star Hack Saw. In 1898, Clemson was conceded US
Patent 601947, which points of interest different changes in the hacksaw.
1.4 MATERIAL REMOVAL MECHANISM
A. Gravity Feed Machines - In this sort of machine, which is as a rule of light
development for general obligation, the push stack is produced by the gravity feed
of the saw bow. In a large number of these machines the size of the push stack is
settled, albeit a few machines are given flexible masses on the overarm for push
stack change. The push, stack differs all through the slicing stroke because of the
responding relocation of the over arm mass and the activity of the cam worked
liftoff gadget which acts toward the start and the finish of the stroke. This kind of
machine for the most part has a work piece limit between 150 - 200 mm (6 and 8
inches) breadth and is perfect for the little workshop where the cutting prerequisite
is just infrequent and the design of work pieces to be cut extents from mellow steel
level complex formed areas and tubular segments up to 6 inches width. Because of
the light development and gravity feed the applications for this kind of machine are
restricted.
B. Hydraulic Machines - The push drive between the sharp edge and the work
piece in this kind of machine is created by a pressure driven gadget. Weight might
be created in the heap chamber by either a confined reverse framework, or the
weight might be provided from a different pump. In a portion of these machines,
more prominent adaptability of control has been presented by methods for a curve
cutting activity joined with an all-around controlled water powered framework
which permits better execution from the saw sharp edge. The propelled kinds of
uncompromising electro-pressure driven hacksaws have an extensive variety of
task and are accessible in self-loader or completely programmed frame, with
arrangements for programmed sustaining of bar stock, slicing off to foreordained
sizes and emptying and so forth. The component of shut down-feed to the saw bow
consolidated in these machines makes the machine reasonable for cutting the
harder steels and compounds. These machines are the most widely recognized and
create more prominent push loads than machines of other sort and have notoriety
for sawing without issues and requiring least administrator aptitude.
C. Positive Displacement Machines - While these machines are not as prevalent as
the gravity feed or water driven machines, a couple of machines are accessible
where the feed rate of the edge and subsequently, the metal expulsion rate is
straightforwardly controlled by a mechanical screw gadget, giving a positive feed.
This kind of machine can prompt overburdening of the sharp edge giving untimely
edge disappointment especially when the cutting edge is worn. Positive removal
machines are not inclined to variety in push loads amid the cutting stroke-since the
push stacks straightforwardly emerge because of the consistent rate of entrance of
the sharp edge teeth.
1.5 SHAPING MACHINE
A shaper is a type of machine tool that uses linear relative motion between the
workpiece and a single-point cutting tool to machine a linear toolpath. Its cut is
analogous to that of a lathe, except that it is (archetypally) linear instead of helical.
A wood shaper is a similar woodworking tool, typically with a powered rotating
cutting head and manually fed workpiece, usually known simply as a shaper in
North America and spindle moulder in the UK.
A metalworking shaper is somewhat analogous to a metalworking planer, with the
cutter riding a ram that moves relative to a stationary workpiece, rather than the
workpiece moving beneath the cutter. The ram is typically actuated by a
mechanical crank inside the column, though hydraulically actuated shapers are
increasingly used. Adding axes of motion to a shaper can yield helical toolpaths, as
also done in helical planing.
1.6 TYPES OF SHAPING
Shapers are mainly classified as standard, draw-cut, horizontal, universal, vertical,
geared, crank, hydraulic, contour and traveling head,[1] with a horizontal
arrangement most common. Vertical shapers are generally fitted with a rotary table
to enable curved surfaces to be machined (same idea as in helical planing). The
vertical shaper is essentially the same thing as a slotter (slotting machine), although
technically a distinction can be made if one defines a true vertical shaper as a
machine whose slide can be moved from the vertical. A slotter is fixed in the
vertical plane.
1.7 MANUFACTURING PROCESS
The workpiece mounts on a rigid, box-shaped table in front of the machine. The
height of the table can be adjusted to suit this workpiece, and the table can traverse
sideways underneath the reciprocating tool, which is mounted on the ram. Table
motion may be controlled manually, but is usually advanced by an automatic feed
mechanism acting on the feedscrew. The ram slides back and forth above the work.
At the front end of the ram is a vertical tool slide that may be adjusted to either
side of the vertical plane along the stroke axis. This tool-slide holds the clapper
box and tool post, from which the tool can be positioned to cut a straight, flat
surface on the top of the workpiece. The tool-slide permits feeding the tool
downwards to deepen a cut. This adjustability, coupled with the use of specialized
cutters and toolholders, enable the operator to cut internal and external gear tooth
The ram is adjustable for stroke and, due to the geometry of the linkage, it moves
faster on the return (non-cutting) stroke than on the forward, cutting stroke. This
action is via a slotted link (or Whitworth link).
CHAPTER II
LITERATURE SURVEY
2.1 LITERATURE
David Gordon Wilson [1] studied the vast literature to understand the concepts
which effect the performance of the machine The concept of two way hacksaw
cutting machine mainly carried out for production based industries. Zoeb khan [2]
expressed that Industries are essentially implied for generation of valuable
merchandise and enterprises at low creation cost, Machinery cost and low stock
cost. Information about built up a model of a machine reach would be fit for
performing diverse task all the while, and it ought to be monetarily productive.
These machines can be utilized as a part of remote spots where power is
customary. It is planned as a versatile one which can be utilized for cutting in
different spots. It can be utilized for working on materials like thin metals, wood.
A solitary stage vertical electric engine unbendingly set at the focal point of
metallic establishment gave.
Linxu et al. [3] research about the shaft of motor rotates at 90- 100 rpm with the
power 2HP. The circular disc is mounted on the shaft of motor with the help of key
and key slot arrangement. It consists of pedal powered machine setup which has a
simple mechanism operate with chain and sprocket arrangement.
Chaudhary Pravinkumar k [4] learned about the chain is put on the teeth of the
haggle. The pole is mounted on platform direction. To begin with mechanical
linkage is evacuated by expelling nut and screws and v belt drive boring
connection. It is realized that regular power hacksaw machine can be supplanted
with robotized control Hacksaw machine.
S. G. Bahaley et al. [5] expressed that automated power hacksaw machine gives
high efficiency in brief day and age in examination with the ordinary power
hacksaw machines. The real preferred standpoint of this machine is intercession of
work is lessened to greatest level. In this fast developing modern segment the
utilization of intensity Hacksaw machine is wide, time and work assumes a
noteworthy part underway process. The Material choice and testing of hacksaw
sharp edge in light of mechanical properties expressed that the suitable saw edge
must be chosen for better activity and fine cutting by choosing number of teeth per
inch.
Leonel et al. [19] stated that the designers of machines or structures must achieve
acceptable levels of performance and at the same time, assure the part is safe and
durable. Therefore, it is necessary to avoid excess deformation, such as bending,
twisting, or stretching, of the machine’s components. In addition, cracking in
components must be avoided entirely to prevent the crack from progressing to the
point of complete fracture. To avoid structural failure, the stress in a component
must not exceed the strength of the material, where the strength is simply the stress
that causes a deformation or fracture failure.Failures in mechanical structures occur
due to various reasons.
Boyer et al. [11] showed that failures could occur due to mechanisms and
environmental factors. He also suggested that failure analysis of a metal structure
requires identifying the type of failure mode. The failure mode is classified as
either a deformation or fracture.
Layer et al. [18] concluded that the process of identifying a failure mode is
complicated because different techniques can be used to determine the actual cause
of failure.
Linder et al. [20] studied and they are worried about the numerical displaying of
split expanding in weak materials utilizing limited components with installed solid
discontinuities, that is, discontinuities in the relocation field characterizing the
arrangement of the basic limit esteem issue. Specifically, new limited components
are produced in this structure pleasing the distinctive branches of the bifurcating
intermittence in the component inside. The key part of these advancements is the
right portrayal of the kinematics of these designs. This is expert through the
distinguishing proof of the correct partition modes portraying these arrangements
and their fuse in the discrete strain field of the limited component. The subsequent
improved modes are enacted in view of a spreading model contingent upon the
speed of the break tip. The execution of the new components is represented with a
few numerical reproductions including different methodologies for the treatment of
expanding and examinations with accessible trial come about.
Travas et al. [21] investigated the influence of loading rate on the failure mode of
the beam parametric. The numerical results are evaluated, discussed and compared
with test results known from the literature. It is shown that the beam resistance and
failure mode strongly depend on loading rate. For lower loading rates beam fails in
bending (mode-I fracture). However, with increasing loading rate there is a
transition of the failure mechanism from bending to shear. Results are in good
agreement with theoretical and experimental results known from the literature.
2.2 OBJECTIVE
• To take into account the issue of rivalry in mechanical industry the requirement
for computerization is evaluate by all the business.
• To recognize the key arrangement roads thought to be fitting to address the
difficulty of reasonable assembling and bundling industry for what's to come.
• To give other option to ventures pointing toward decreasing human exertion and
change in material taking care of framework by actualizing mechanization.
• Reasonable and down to earth mechanization answers for the future mechanical
condition.
CHAPTER III
FABRICATIONAL SETUP
There are many electrically operated power hack saw machine of different
configuration and different manufactures are available for the use in machine shop.
These machines can cut rods of different material precisely at very fast rate but
they can cut rods of one material at a time which means they can’t able to cut
dissimilar material at a same time. Now in industry, it is necessary to cut metal
bars with very high rate to achieve mass production requirement. So there is need
to move for a new technology which gives us a mass production with less time and
less energy input. It is impossible to depend upon conventional hack saw machine.
By using this two way hack saw machine the two metal bar, pipes or rods can be
cut the simultaneously to achieve high speed cutting rate and mass production for
maximum benefits in manufacturing industries. This machine overcomes the
drawbacks and limitation of single frame hack saw machine. It can be used in a
small workshops and industries as it is available in very low price and its smaller
size and high efficiency.
Figure 3.1 Flow Chart
3.1 REQUIREMENTS OF PARTS
A. Middle Arm - It is used to balance the motor and it is attached to shaft. Its
dimension is (23x9x6.5) inch.
B. Bolt - It is used for the fixing of bench vice for proper alignment of shaft and
flywheel.
C. Nut - It is used in bench vice, connecting rod and shaft for tightening bolts.
D. Base - It is stand on which all parts are mounted like dc motor, shaft
E. Rotating Shaft - It is used here for moving of both arms carrying hacksaws.
F. Shaft - A shaft is a pivoting machine component which is utilized to transmit
control starting with one place then onto the next. The power is conveyed to the
shaft by some unrelated power and the resultant torque (or turning minute) set up
inside the shaft allows the ability to be exchanged to different machines connected
up to the shaft. Keeping in mind the end goal to exchange the power starting with
one shaft then onto the next, the different individuals, for example, pulleys, gears
and so forth., are mounted on it. These individuals alongside the powers applied
upon them makes the shaft bowing. As it were, we may state that a shaft is utilized
for the transmission of torque and bowing minute. The different individuals are
mounted on the shaft by methods for keys or splines.
G. Hacksaw - A hacksaw is a fine-tooth saw with an edge under pressure in a
casing, utilized for cutting materials, for example, metal. Hand-held hacksaws
comprise of a metal edge with a handle, and sticks for joining a thin dispensable
cutting edge. A screw or other system is utilized to put the thin cutting edge under
pressure. A power hacksaw (or electric hacksaw) is a sort of hacksaw that is
controlled by electric engine. Most power hacksaws are stationary machines yet
some helpful models do exist. Stationary models commonly have a framework to
lift up the saw sharp edge on the entry stroke and some have a coolant pump to
keep the saw bleeding edge from overheating.
Figure Cutter Blade
H. DC Motor - A DC motor is an electric motor driven by an immediate current
(DC). The DC motor usually comprises of two essential parts, an outside stationary
stator having loops provided with substituting current to deliver a pivoting
attractive field, and an inside rotor connected to the yield shaft creating a second
turning attractive field. The rotor attractive field might be created by lasting
magnets, hesitance saliency, or DC or AC electrical windings. The responding
movement of the Hacksaw sharp edge, as a result of which the cutting procedure
happens, is delivered with the assistance of a DC motor, which works by a basic
wrench component to change over rotating movement of wrench into responding
movement Hacksaw edge. The DC motor is turned on after the workpiece has been
immovably fit in the pneumatic toss. The Torque of motor is expanded by
transmission of capacity to a pulley by belt transmission.
3.2 ASSEMBLY
For assembly of hacksaw machine first of all on the base plate electric motor is
mount vertically, the hollow disc having internal circle radius is same as the radius
of the shaft of the motor is fit on the shaft and also the disc has an eccentric center,
a metal bar is a weld at the eccentric center. The links one end is connected with
the end of hacksaw frame and the second end is connected with the metal bar of
eccentric centre. The buckle type elements are connected at the end of hacksaw
frame and the link is connected to this buckle, pipe provides support to the
hacksaw frame, the pipe is connected to the base. Vice is also fit on the pipe and
which also connect with the base.
3.3 WORKING
This project focous on presents the manufacture and idea of two way hacksaw
removing machine predominantly conveyed for creation based ventures.
Businesses are fundamentally implied for creation of valuable merchandise and
ventures at low generation cost, Machinery cost and low stock cost. Today in this
world each errand have been made snappier and quick because of innovation
progression yet this headway likewise requests colossal speculation and
consumption, each industry wants to make high efficiency rate keeping up the
quality and standard of the item at low normal cost. We have developed a
prototype model, which is efficient and do multiple cutting operations. These
machines can be utilized as a part of remote spots where power is customary. It is
composed as a convenient one which can be utilized for cutting in different spots.
It can be utilized for working on materials like thin metals, wood.
Figure Proposed Design Model
A hacksaw machine is work on the principle of Scotch Yoke Mechanism in
this rotary motion of the shaft is to be converted into the reciprocating motion of
hacksaw frame. Working principle of hacksaw machine is very simple. First of all,
the hacksaw machine is put on the ground and after that, whatever metal, wood,
PVC, is cut is fixed on vice at required length, after that the electric motor is
connected with electricity. Now start the electric motor so due to that the shaft of
the motor and the hollow disc will be rotated and also rotate the eccentric Centre
and link connect to it. Due to rotation of links the hacksaw frame will be
reciprocated on the metal and cutting of metal is done.
3.4 FEATURES OF HACKSAW MACHINE
i. Power efficiency.
ii. High productivity.
iii. Superb performance.
iv. High operational fluency.
v. Sturdy and robust design.
CHAPTER IV
ADVANTAGES AND APPLICATIONS
4.1 ADVANTAGES
i. The weight of the machine is less.
ii. It reduces the work of labour.
iii. Easy to make because of simple construction.
iv. High production rate.
v. Cost is less.
vi. Easy maintenance and maintenance cost is less.
vii. It resists all atmospheric effects.
4.2 DISADVANTAGES
i. Time consume more.
ii. Speed variation is required for cutting the different metal
4.3 APPLICATIONS
i. In engineering industry.
ii. In construction industry.
iii. In Workshop.
CHAPTER IV
CONCLUSION
As per the above discussion, we concluded that to overcome problems in
conventional hacksaw machines, due to high efficiency, easy to operate and
affordable price the proposed model of multi-way power hacksaw the machine is
helpful and completes all the expectations needed for the mini-industries. Future
scope of proposed research work to increase the production rate cuts the metal bars
easily. It can withstand the vibrations, no hazards from a jerk, no special training
required to operate it. 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 design is possible in practise.
Another hacksaw machine is only cut one part at one time but this machine cut the
four parts at a time, this hacksaw machine has lighter weight compared to another
machine. The cost of the machine is less and easy to operate so it affordable for all
industry.
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