ABSTRACT

This project is used to identify and evaluate the design of circular saw cutting machine which is
one of the cutting method and aid of production mechanism by using V-Belt. A circular saw
blade includes, generally circular blade portion and a plurality of spaced a part teeth attached to
the circular blade portion. Each tooth extends outwardly and upwardly from the circular blade
portion. Designing of circular saw cutting machine is the best metal cutting tool that used to
achieve the cutting speed by satisfying the root users (customers).

This cutting machine indicates how to reduce the time and human power consumption in the
design project of circular saw cutting machine. Circular saw cutting machine is a mechanical
mass-production method or system that cuts the ferrous metals by their dimensions of the work
piece as the customer or root users needed. In order to satisfy the customers it should be
increasing the quantity and quality of the working process during cutting operations.

Keywords: design, circular saw, cutting, machine

 ACKNOWLEDGMENT
First of all Our deep gratitude goes to the almighty GOD for everything he done to us in all the
way we path through, then after for our advisor Professor Chandra.R and mechanical engineering
department staff members for their continues and progressive support, advice and guides us to do
better work and gave us a reference materials and initiated us for our work and project. In
addition, we would like to thank also other local companies like KOSPI, employees for their
respect, familiarity, their advice and support. In addition, we would like to thank our classmates
and friends for sharing their ideas and materials to us. Finally, we would like to thank our
families for understanding and helping us with all our needs.
 CHAPTER ONE
INTRODUCTION
1.1 background
A circular saw is the best machine for cutting ferrous and non-ferrous materials. For ferrous
materials, this unique type of cutting turns the blade at a low rpm, similar to a milling process,
giving a fast, precise, burr-free cut without heat or sparks. A circular saw is a tool for cutting
many materials such as wood, masonry, plastic or metals and may be hand-held or mounted to a
machine. Circular saw blades are specially designed for each particular material. They are
intended to cut and in cutting metal are specially for making rip-cuts, cross cuts, or combination
of both. This machine is commonly powered by electricity, but may be powered by a gasoline
engine or a hydraulic motor which allows it to be fastened to heavy equipment, eliminating the
need for a separate energy source. A circular saw is a power saw using a toothed or abrasive disc
or blade to cut different materials using a rotary motion spinning around an arbor. Saw mills first
used smaller diameter circular saw to re saw dimension lumber such as lathe and wall studs for
edging boards. As the technology advanced large diameter saw blades began to be used for the
head saws and to cut clamp boards. To choose the appropriate number of teeth, saw blade type,
cutting speed, all of these variables are based on the type and size of material being cut. Cold
saws are capable of machining most ferrous and non-ferrous allows. These saws are intended to
be used with a flood coolant system to keep the saw blade teeth cooled and lubricated. A cold
saw cut produces minimal burr, no sparks, no discoloration and no dust. Working principle of the
machine is typically, the material to be cut is securely clamped or held in a vise at a desired
angle, and the saw is advanced slowly across it. As each tooth in the blade strikes the material, it
makes a small chip. Then the coolant or cutting fluid flows around work piece and blade to
prevent its overheating, transferring the heat produced by the work piece and blade that use or
dissipate. The teeth guide the chip out of the work piece, preventing it from binding the blade.
Work pieces are clamped in a vise or fixture, one or more pieces at a time. The circular blade is
mounted on a power driven arbor and rotated through the cut. The cold saw leaves as a smooth,
accurate surface finish similar to milling and provides a fast method for cut off. High production
can be obtained with this machine. [1]
1.2 Problem statement
The problem that initiates us to design circular saw cutting machine is that there is no developed
process to cut metals in accurate dimension. Due to this problem it has been identified that there
is defect which affects the excellence of designing in the market which intern affects the income
of one country. And also currently power hacksaw, hacksaw and other machines used to cut
metals, but these machines have their own limitations. Among those the blades are easily twisted
or bent and broken down of the saw, low mass production, low accuracy and shorter tool life.
Due to these limitations it is better to design circular saw cutting machine because of the
machine has many duties rather than power hacksaw and other machines in metal industries and
workshops. Hence, the machine has the following merits such as it increases mass production,
reduces working time, wastage of metals and the operation is safe. The popularity of cold saw
blades are increasing due to technological advancements in cold saw machine. Why because it is
applicable for heavy duty and high production requirements are needed. This machine
consistently produces the lowest cost per cut among all sawing methods.

1.3. Objective of the project

1.3.1. Main objective of the project
The general objective of this project is designing circular saw cutting machine for mild steel with
optimum cost and basic features.

1.3.2. Specific objective of the project

 To understand the working mechanism of the machine
 To analyze geometry of the machine
 To design each components of circular saw cutting machine
 To analyze assembly of circular saw cutting machine

Generally, the specific objective of this project is needed to do, to achieve the overall objective.
 CHAPTER TWO
LITRATURE REVIEW

2.1. Background of circular saw cutting machine

The circular saw was invented around the end of the18th century as a rip-saw to convert logs in
to timber in saw mills and various claims have been made as to who invented the circular saw.
The rotary nature of the circular requires more power to operate but cuts faster because the teeth
are in constant motion. The sound of the circular saw is different from the sound of up-and-down
saw and earned it the neck of buzz-saw.

Saw mills first used smaller diameter circular saw to re saw dimension lumber such as lathe and
mill studs and for edging boards. As the technology advanced large diameter saw blades began to
be used for the head saws and to cut clapboards.

A circular saw is a power saw a toothed or abrasive disc or blades to cut different materials using
a rotary motion spinning around an arbor. A hole-saw and a ring saw also uses a rotary motion
but are different from circular saw.

Circular saw cutting machine is machine is a machine that cuts the parts of the required material
in order to get the required result. These machines are extremely fast compared to the convention
as double column band saw machine and are designed to cut ferrous and non-ferrous metals.
These are production machines used for cutting channels, solid bars, hollows, squares, angles
and other section of ferrous and non-ferrous metals. It is a high productive, accurate and compact
machine and has a high rate of production at comparatively low investment with good surface
finish.

A circular saw is a tool for cutting many materials such as wood, masonry, plastic, or metal and
may be hand held or mounted to a machine. Circular saw blades are specially designed for each
particular material they are intended to cut and in cutting metal are specially designed for ripcuts,
cross cuts, or combination of both. Circular saws are commonly powered by electricity, but may
be powered by a gasoline engine or a hydraulic motor which allows it to be fastened to heavy
equipment, eliminating the need for a separate energy source. [1]
2.2. Types of sawing machines
There are many types of sawing machines. Among these commonly used saws are listed below.

1) Hacksaw
2) Power hacksaw
3) Abrasive saw
4) Panel saw
5) Cold saw

2.2.1. Hacksaw
A hacksaw is a fine-toothed saw with a blade under tension in a frame, used for cutting materials
such as metal. Hand held hacksaw consist of a metal frame with a handle, and pins for attaching
a narrow disposal blade. A screw or other mechanism is used to put the thin blade under tension.
The demand of hacksaw blade is considerably increasing day by day with growth of
industrialization, engineering sector, real-estate, automobile sector etc. It is used in almost every
sector for materials like channel, flat plates, rods and such other things, also required in auto
requiring shops, general repairing workshops, fitting shops, welding shops and technical
institutes.

In technical institutes the failure rates of blades are increased because of lack of experience,
knowledge and improper selection of material. The failure rate of blade can be controlled by
proper selection of material. The improper selection of materials may result in loss of
productivity and efficiency. The selection of material should not be restricted to technical aspects
only but focus should be made on environmental considerations also.

And also a hacksaw is a fine-toothed saw originally and principally for cutting metal. They can
also cut various other materials, such as plastic and wood. Most hacksaws are hand saws with a
c-shaped frame that holds a blade under tension. Such hacksaws have a handle, usually a piston
grip, with pins for attaching a narrow disposable blade. The frame may also be adjustable to
accommodate blades of different sizes. A screw or other mechanism is used to put the thin blade
under tension. Panel hacksaws far go the frame and instead have a sheet metal body, they can cut
into a sheet metal panel further than a frame further than a frame would allow. These saws are no
longer commonly available, but hacksaw blade holders enable standard hacksaw blades to be
used similarly to a keyhole saw or pad saw. Power tools including nibblers, jig saws and angle
grinder fitted with a metal-cutting blade and discs are now used for longer cuts in sheet metals.

On hacksaws, as with most frame saws, the blade can be mounted with the teeth facing toward or
away from the handle, resulting in cutting action on either the push or the pull stroke. In normal
use cutting vertically downwards with work held in bench vise, hacksaw blades should be set to
be facing forwards. Some frame saws, including fret saws and piercing saws, have their blades
set to be facing the handle because they are used to cut by being pulled down against a horizontal
surface.

Working principle

To avoid broken tools, wasted material, and injury hacksaw users should follow a few basic
operating or working principles. First, all body parts should be kept away from the saw’s blade
while in use. Further the item being sawed should be firmly secured into place to prevent it from
slipping and potentially striking or cutting the user. Finally, to prevent breakage, saw blades
should be oiled before use and thoroughly cleaned afterward. When cutting with hacksaw, the
user should first select an appropriate blade and using the blade pegs faster it onto the saw’s
frame. The object to be cut should be secured in place, ideally with a vise similar device.

Limitation of hacksaw

 The main limitation of a hand held hacksaw is the depth that cut
 It requires strength to operate
 It can only perform small jobs
 It is much slower than electric alternatives [2]

2.2.2. Power hacksaw

A power hacksaw (electric hacksaw) is a type of hacksaw that is powered either by its own
electric motor or connected a stationary engine. Most power hacksaws are stationary machines
but some portable models do exit; the latter (with frames) have been displaced to some extent by
reciprocating saws which accept blade with hacksaw teeth. Stationary models usually have a
mechanism to lift up the saw blade on the on the return stroke and some have a coolant pump to
prevent the saw blade from overheating.
Power hacksaws are not a commonly used in the metal working industries as they once were
band saws and cold saws have mostly displaced them while stationary electric hacksaws are not
very common, they are still produced. Power hacksaws of the type powered by stationary
engines and line shafts, like other line shaft powered machines are now rare.

Working principle

Working principle of power hacksaw have of a saw edge a method for reciprocate saw with
edge, a work table and vise a supporting base by a reason of power. In method the machine
drives a blade back and forth during a work piece, critical down on the cutting stroke and
releases pressure on the revisit. Downward supply force on table perhaps obtains as of gravity or
spring keeping pace by a ratchet mechanism, a positive feed screw or as of a hydraulic drive.

Stock to be cut is held among the clamping saws. Some pieces of bar stock can be clamped
jointly and cut at the similar time. Importance of sawing is single of mainly essential cutting off
process perform in a developed plant. Metal cutting is mainly worried with cutting bar stock to a
convenient length or size for machining. A man first process in any shop is the sawing of
materials and bar stock for consequent machining process.

Limitation of power hacksaw

A major disadvantage of power hacksaw machines is that they are a slower than other sawing
machines. The cutting action is non continuous and only half of each reciprocating stroke is
productive. The reciprocating action prohibits the use of blades supports close to the area of
cutting, therefore, hacksaw blades are thicker than the hands used on band sawing machines, thus
requiring more power and producing more chips. Power hack sawing is essentially a roughing
operation and at least 0.05mm should be left on cut surfaces for finishing. [3]

2.2.3. Abrasive saw

An abrasive saw, also known as a cut-off saw or metal chop saw, is a power tool which is
typically used to cut hard materials, such as metals. The cutting action is performed by an
abrasive disk, similar to a thin grinding wheel. Technically speaking this is not saw, as it does
not use regularly shape edges or teeth for cutting. The abrasive saw generally has a built-in vise
or other clamping arrangement, and has the cutting wheel and motor mounted on a pivoting arm
attached to a fixed base plate.
They typically use composite friction disk blades to abrasively cut through the steel. The disks
are consumable items as they wear throughout the cut. The abrasive disk for the circular saw
cutting machine is typically 360mm in diameter and 2.8mm thick. Larger saws use 410mm
diameter blades. Disks are available for steel and stainless steel.

Since their introduction, portable metal cut-off saws have made many building site jobs easier.
With these saws, light weight steel fabrication previously performed in workshops using
stationary power or cold saws can be done on-site. Abrasive saws have replaced more expensive
and hazardous acetylene torches in many applications.

Working principle

The immediate cutting area must extend the full width of the saw movement. Where the blade
does not meet this, an extension table should be fitted. It is good practice to mark the immediate
cutting area of the blade with a colored prohibition area. This should ideally be 300mm either
side of the saw cut. The operators hand should not enter this area. Small components and /or
offcuts should be removed using a push-stick. Also, reaching across the saw line should be
avoided.

Limitation of abrasive saw

Abrasive saw is a basic, manual method of cutting-to-length product to the customer’s

specification in any allow. An abrasive saw operates with a circular abrasive blade or
resincomposition wheel-either wet or dry that grinds through the product.

An abrasive saw is easy to use and requires little or no setup time. It cannot provide a square cut,
because the process use cutting or burning action is not efficient for thick walled material. It also
might leave a heat affected zone that can affect secondary processing.

Generally an abrasive saw is a type of saw that has cutting with much faster speed this may cause
for broken of the blade or teeth. And also an abrasive saw could over heat the carbide to the point
where the teeth fall off. These are limitations of an abrasive saw. [4]

2.2.4. Panel saw

A panel saw is any type of sawing machine with a sliding table that cuts sheets into sized parts.
A sliding panel saw was invented by Wilhelm Elmendorf in 1906 in Germany. Its invention set a
new standard in woodworking, with dramatic differences from traditional machines. Up to that
time, a conventional table saw had no mechanism for edging. Meaning that for the first and
second longitudinal cut on untreated massive wood, the lumber always had to be fed manually
through the saw blade. The new system accomplished the task more elegantly by allowing the
work piece to be fed through the saw blade while lying on a sliding table. Thus cutting becomes
faster, accurate and effortless.

Panel saws are used by cabinet shops to easily cut panels, profiles, solid-wood, plywood, MDF,
laminates, plastic sheets and melamine sheets into sizes or cabinet components. They are also
used by sign shops to cut sheets of aluminum, plastic and wood for their sign blanks. Some
higher end panel saws feature computer controls that move the blade and fence systems to preset
values. Other lower end machines offer simplicity and ease of use, including full scale hobbyist
level panel saws at a mere fraction of the cost. While the entry level machines are designed for
light duty usage, they offer home Dyers a cheap alternative for infrequent cutting when accuracy
and clean cuts are not required.

Panel saws can have one main saw blade, or a scoring along with a main saw blade. Scoring is
used to create a groove, especially in double side laminate before the main saw rips the piece
apart, to avoid chipping. The scoring saw rotates in an opposite direction, as the main saw to
avoid chipping.

Working principle

 Position the saw motor in the cross cutting with the blade oriented vertically
 Using the two adjusting knobs located above and below the saw motor to adjust the
spring loaded saw foot of the panel.
 Loosen the carriage lock and move the carriage to the top of the guides.
 Place the work piece on the top of the rollers. Be careful not to drop the material on the
rollers.
 Slide the work piece to the desired position using the cross cut rulers or optional
gauging systems as measures.

Limitation of panel saw

 Panel saw is designed mainly for cutting woods and aluminum metals so previously it is
not designed for cutting hardened materials.
  Routers are not recommended for work piece that are smaller than the carriage.
 Do not cut pieces that are so small that the hand must behind the carriage to hold the
piece in place. [5]

2.2.5. Cold saw

A cold saw is a machine that uses a circular saw blade to cut metal. The name "cold saw" comes
from the cutting process they employ. These sawing machines transfer the heat generated by
cutting to the chips created by the saw blade. Therefore, the blade and material being cut remain
cold, unlike an abrasive saw, which abrades the metal and creates a great deal of heat in the
metal and cutting blade. Cold saws use either a solid high speed steel (HSS) or tungsten
carbidetipped (TCT), resharpenable circular saw blade. They are equipped with an electric
motor. A cold saw cut produces minimal burr, no sparks, no discoloration and no dust. The
material being cut must be mechanically clamped to prevent movement during the cutting
process. Cold saws are capable of machining most ferrous and non-ferrous alloys. Cold saws are
intended to be used with a flood coolant system to keep the saw blade teeth cooled and
lubricated.

Cold saw blades are circular metal cutting saw blades categorized into two types: solid HSS or
tungsten carbide-tipped (TCT). Both types of blades are resharpenable and may be used many
times before being discarded. Cold saw blades are used to cut metal using a relatively slow
rotational speed, usually less than 5000 surface feet per minute (SFM) (25m/s). They are called
"cold saw blades" because they transfer all the energy and heat created during the cutting process
to the chip. This enables the blade and the work material to remain cold.

The first type of cold saw blade, solid HSS, may be made from either M2 tool steel or M35 tool
steel, alloyed with additional cobalt. Solid HSS saw blades are heat treated and hardened to
64/65 HRC for ferrous cutting applications and 58/60 HRC for non-ferrous cutting applications.
This high hardness gives the cutting edges of the teeth a high resistance to heat and wear.
However, this increased hardness also makes the blades brittle and not very resistant to shock. In
order to produce a high quality HSS cold saw blade, you must start with very flat and properly
tensioned raw material. The blades must be press quenched after hardening to prevent them from
being warped. Solid HSS cold saw blades may be used for cutting many different shapes. These
blades may also be coated with special wear resistant coatings such as titanium nitride (TiN) or
titanium aluminum nitride (TiAlN).

The second type of cold saw blade, tungsten carbide-tipped (TCT) are made with an alloy steel
body and tungsten carbide inserts brazed to the tips of the teeth. These tips are ground on all
surfaces to create tangential and radial clearance and provide the proper cutting and clearance
angles on the teeth. The alloy body is generally made from a wear resistant material such as a
chrome vanadium steel, heat treated to 38/42 HRC. The tungsten carbide tips are capable of
operating at much higher temperatures than solid HSS, therefore, TCT saw blades are usually run
at much higher surface speeds. This allows carbide-tipped blades to cut at faster rates and still
maintain an acceptable chip load per tooth. These blades are commonly used for cutting
nonferrous alloys.

Generally, cold sawing has several advantages over band saws and abrasive saws. Besides the
mill quality cut, cold saws have the ability to generate faster cutoff times than band saws. There
are no sparks and excessive noises that are associated with abrasive cutoff saws.

Advantages of cold saw blades;

 Accuracy of cut
 Good surface finish
 Increased tool life
 Shorter cutting time or more productive in cutting

Cold saws also offer the advantage of blades that can be re-sharpened until the diameter of the
blade will no longer cut through the material. [6]

2.3. Components of circular or cold saw machine

 Ac motor
 Shaft
 Pulley
 Blade or cutter
 V-belt
 Key
 Spring
 Disc
 Bearing
 Table
 Vise
 Bolt and nut
 Safety guard
 Handle
 Coolant pump
 CHAPTER THREE
3. DESIGN ANALYSIS OF CIRCULAR SAW CUTTING MACHINE
3.1. Design procedure
Any design procedure has to follow the essentials of the design process. The design procedure
describes, in steps, the evolution of a design. The following sequence is often followed:

 Recognition: it is the complete description of the problem .i.e. the machined to be

designed and its purpose is recognized.
 Synthesis: in the second step of a mechanism or a group of mechanisms are selected to
result in to desired motion or group of motion.
 Analysis: each element of selected mechanism will transmitted some energy and this will
be subjected to some force. At this stage the energy to be transmitted by and the force
acting on each element of the mechanism are determined or estimated.
 Selection of material: the material for each member is selected on the basis of its
function.
 Calculation: the permissible stresses are immediately known once the material is selected.
Based up on this and forces coming up on each member the size of the element is
calculated. Sometimes the permissible deflection or deformations may have to be used as
criterion or size calculation.
 Revision and modification: the size of each member has to be examined in context of
previous experience code or standards. This may be followed by revision &modification
of the sizes. Such revision may many times involve use of empirical formula based up on
experimental results. Modification may also be necessitated by consideration of
manufacturing to reduce overall cost. This step emphasis that design is an integrative
process and as such feedback from every possible source is utilized at this stage. This
stage includes, experience, code standards and regulation, experiment, cost,
manufacturing process, and human factor.
 Report: finally, the complete detail drawing of machine has to be made. Such drawing
includes all details of materials and specifications of manufacturing process.
3.2 Specifications for the design project
During the collection of data we collect the relevant data from the beneficiaries. Then select the
material to be cut or done is mild steel.

Mild steel is a type of steel alloy which is the most common high volume steel in production. It
is now the most common form of steel because of its price is relatively low while it provides
material properties that are acceptable for many applications. It contains small amount of carbon
making it malleable and ductile. Mild steel has a relatively low tensile strength, but it is cheap
and easy to form. It is quite soft and malleable so can be bent and forged into different shapes
with minimal heat treatment.

Unlike other grades of carbon steel, which tend to be brittle, mild steel is very hard, yet
malleable, making it the perfect choice for construction materials and many other every day
products. It can be easy to shape and machine because it is flexible and hardened by a heat
treatment process called carburizing. It is a suitable material for producing a variety of products
in the consumer industry. Due to these reasons most metal industries, workshops and garages
used mild steel for many applications. Now from this evidence we select mild steel to be cut by
our machine.

Then these are the specifications;

 Material to be cut mild steel

 Maximum diameter of work piece to be done= 100mm (round)
 Maximum length of work piece to be done=100mm  Maximum thickness of work piece
to be done=5mm
 Type of saw blade=HSS(High speed steel)
 Blade diameter=250mm
 Blade bore diameter=40mm(32,40 and50mm are most common in ferrous cutting saw
blades)
 Blade thickness=2.5mm
 Blade tooth style=C (Heller or Cochrane teeth) most common tooth style of blade for
cutting ferrous metals.

Then taking maximum diameter, length and thickness of the work from the beneficiaries; this is
due to determine power requirement. And also blade diameters are available in many dimensions
.To match the cutter diameter with the work piece dimensions selecting the specified number is
important.
 CHAPTER FOUR
BUDGET
No Budget category Unit cost Multiplying Total Cost
Factor
1 Personnel
1.1 Salary for assistance
1.2 Salary and expenses for sub-contracted
professional data collectors
1.3 Salary and expenses for researcher
Total Personnel Expense
2 Material and Supply Expenses
2.1 Supplies required throughout the research
like pen, paper, erasers, voice recorder etc.
Total Material and Supply Expense
3 Travel expense
3.1 Domestic travels required for interviewing
project managers of agricultural sectors at
regional and national level
Total Travel Expense
4 Publication/Documentation/
Dissemination
4.1 Expenses required for documentation and
Dissemination such as printing, copying,
computer service etc
Total
Publication/Documentation/Dissemination
Expense
5 Recreational Expenses
5.1 Break time expenses such as tea, coffee etc.
Total Recreational Expense
6 Other Expenses (Miscellaneous)
Total Miscellaneous Expense
Expense Grand Total
 o
NActivity

March

April

May

June
WORK PLAN
CHAPTER FIVE

July

August

Septemb
er