FABRICATION OF DOUBLE HACKSAW MACHINE USING SCOTCH YOKE

MECHANISM

CHAPTER I
SYNOPSIS

This work was mainly carried for manufacturing and fabrication industries. The
machine which is used to produce the product with high accuracy and quality and
produce the goods in an economical manner. It makes the inventory cost less. The
multipurpose machine has performed different operations simultaneously with high
possibility. The scotch yoke mechanism which is attached with the main drive shaft
directly attached then it is used for different operation. Number of operations has been
performed by a single drive system. The main focus of the work is to reduce power
usage and increase the productivity reduced floor space. Portability is an important
quality in any machine in today’s world; every field of science and engineering has got
portability as one of its most important advancements. Therefore, the machine we have
designed satisfies this principle with respect to the manufacturing industry.
INTRODUCTION
 CHAPTER II

INTRODUCTION

Multi-operation machine as a research area is motivated by questions that arise in

industrial manufacturing, production planning, and computer control. Consider a large
automotive garage with specialized shops. A car may require the following work,
replace exhaust system, align wheels, and tune up. These three tasks may be carried out
in any order. However, since the exhaust system, alignment, and tune-up shops are in
different buildings, it is impossible to perform two tasks for a car simultaneously. When
there are many cars requiring services at the three shops, it is desirable to construct a
service schedule that takes the least amount of total time.

1.1 Scotch Yoke Mechanism

The Scotch yoke is a mechanism for 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 shape of the
motion of the piston is a pure sine wave over time given a constant rotational speed.

Figure 1.1 Sectional view of Scotch yoke mechanism

 Figure 1.2 Front view of Scotch Yoke Mechanism

1.2 Construction
The scotch yoke mechanism is constructed with iron bars. Here the crank
is made in some length and the yoke is also made using the same material. It is noted
that the minimum length of the yoke should be double the length of the crank. The crank
and yoke is connected with a pin. Iron bars are welded to both sides of the yoke to get
the reciprocating motion.  The yoke with the iron bars is fixed on the display board with
the help of c clamp. Now the crank is welded to the end of the shaft of the motor. Now
the pin on the crank is connected to the yoke. The pin used to connect yoke and crank is
a bolt.
LITERATURE SURVEY
 CHAPTER III

LITERATURE SURVEY

Before starting our work we have undergone through many research papers which
indicates that for a production based industries machine installation is a tricky task as
many factor being associated with it such as power consumption (electricity bill per
machine), maintenance cost, no of units produced per machine i.e. capacity of machine,
time consumption and many more.

A. Heinrich ARNOLDL (2011) Rather long re-investment cycles of about 15

years have created the notion that innovation in the machine tool industry happens
incrementally. But looking at its recent history, the integration of digital controls
technology and computers into machine tools has hit the industry in three waves of
technology shocks. Most companies underestimated the impact of this new technology.
This article gives an overview of the history of the machine tool industry since
numerical controls were invented and introduced and analyses the disruptive character of
this new technology on the market. About 100 interviews were conducted with decision-
makers and industry experts who witnessed the development of the industry over the last
forty years. The study establishes a connection between radical technological change,
industry structure, and competitive environment. It reveals a number of important
occurrences and interrelations that have so far gone unnoticed.

B. Dr. Toshimichi Moriwaki(2006) Recent trends in the machine tool

technologies are surveyed from the viewpoints of high speed and high performance
machine tools, combined multifunctional machine tools, ultra precision machine tools
and advanced and intelligent control technologies.

C. Frankfrut-Am Main, (2011) Machine tools nowadays have to be veritable “jack

of all trades”, able to handle all kinds of materials, to manage without any process
materials as far as possible, and be capable of adapting to new job profiles with
maximized flexibility. Two highly respected experts on machining and forming from
Dortmund and Chemnitz report on what’s in store for machine tool manufacturers and
users.
COMPONENT
DESCRIPTION
 CHAPTER III

COMPONENT DESCRIPTION

3.1 Scotch yoke mechanism

Scotch yoke is a mechanism for 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 shape of the
motion of the piston is a pure sine wave over time given a constant rotational speed. The
Scotch yoke (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 given a constant rotational speed.
Machines are mechanical devices used to accomplish work.

A mechanism is a heart of a machine. It is the mechanical portion of the machine

that has the function of transferring motion and forces from a power source to an output.
Mechanism is a system of rigid elements (linkages) arranged and connected to transmit
motion in a predetermined fashion. 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, SY
Tech engine, and many hot air engines and steam engines. The term scotch yoke
continues to be used when the slot in the yoke is shorter than the diameter of the circle
made by the crank pin. For example, the side rods of a locomotive may have scotch
yokes to permit vertical motion of intermediate driving axles.
3.2 Hacksaw Blade

A hacksaw is a fine-tooth hand saw with a blade held under tension in a frame,

used for cutting materials such as metal or plastics. Hand-held hacksaws consist of a
metal arch with a handle, usually a pistol grip, with pins for attaching a narrow
disposable blade. A screw or other mechanism is used to put the thin blade under
tension.

The blade can be mounted with the teeth facing toward or away from the handle,
resulting in cutting action on either the push or pull stroke. On the push stroke, the arch
will flex slightly, decreasing the tension on the blade, often resulting in an increased
tendency of the blade to buckle and crack. Cutting on the pull stroke increases the blade
tension and will result in greater control of the cut and longer blade life.

Banco Hacksaw

A hacksaw is a fine-tooth saw with a blade under tension in a frame, used for
cutting materials Such as metal. Hand-held hacksaws consist of a metal frame with a
handle, and pins for attaching a narrow disposable blade. A screw or other mechanism is
used to put the thin blade under tension. A power hacksaw (or electric hacksaw) is a type
of hacksaw that is powered by electric motor. Most power hacksaws are stationary
machines but some portable models do exist. Stationary models usually have a
mechanism to lift up the saw blade on the return stroke and some have a coolant pump to
prevent the saw blade from overheating.

Market Potential

The demand of hacksaw blade is considerably increasing day by day with the growth of
Industrialization, engineering sector, real estate, and automobile sector etc. It is used in
almost every Sector for cutting of materials like angle, channel, flat plates, rods and such
other things. It is Also required in auto repairing shops, general repairing workshops,
fitting shops, welding shops And technical institutes. Govt. Department like Railway,
Defence, PWD, Postal & Telegraph and Others are one of the main users of it. In India
large nos. of small enterprises are engaged in its manufacturing. By considering its
demand, new production unit has great prospect.

Basis and Presumptions

The information supplied is based on a standard type of manufacturing activity

utilizing Conventional techniques of production and optimum level of performance.75%
of the envisaged capacity is taken as efficiency on single working shift of 8 hrs & 300
working days in a year. Labor and wages are required as per present circumstances.

The cost in respect of land & building, machine & equipment, raw material &
selling price of finished product etc are those generally obtained at the time of
preparation of project profile and may vary depending upon the location, make and for
variety of reasons. The interest on total capital has been assumed @ 14% p.a

Technical Aspects and Design

Blades are available in standardized lengths, and with anywhere from three to thirty-two
teeth/inch (tpi). The blade used is based on the thickness of the material being cut, with a
Minimum of three teeth in the material. Hacksaw blades are normally quite brittle, so
care needs to be taken to prevent brittle fracture of the blade. Bi-metal blades are meant
to minimize this risk.

Recommended Teeth per 25mm (tpi) for each material type

Blades 

Blades are available in standardized lengths, usually 10 or 12 inches for a standard hand
hacksaw. "junior" hacksaws are half this size. Powered hacksaws may use large blades
in a range of sizes, or small machines may use the same hand blades.

The pitch of the teeth can be anywhere from fourteen to thirty-two teeth per inch (tpi) for
a hand blade, with as few as three tpi for a large power hacksaw blade. The blade chosen
is based on the thickness of the material being cut, with a minimum of three teeth in the
material. As hacksaw teeth are so small, they are set in a "wave" set. As for other saws
they are set from side to side to provide a kerfs or clearance when sawing, but the set of
a hacksaw changes gradually from tooth to tooth in a smooth curve, rather than alternate
teeth set left and right.

Hacksaw blades are normally quite brittle, so care needs to be taken to prevent brittle

fracture of the blade. Early blades were of carbon steel, now termed 'low alloy' blades,
and were relatively soft and flexible. They avoided breakage, but also wore out rapidly.
Except where cost is a particular concern, this type is now obsolete. 'Low alloy' blades
are still the only type available for the junior hacksaw, which limits the usefulness of this
otherwise popular saw.

For several decades now, hacksaw blades have used high speed steel for their teeth,
giving greatly improved cutting and tooth life. These blades were first available in the
'All-hard' form which cut accurately but were extremely brittle. This limited their
practical use to bench work on a work piece that was firmly clamped in a vice. A softer
form of high speed steel blade was also available, which wore well and resisted
breakage, but was less stiff and so less accurate for precise sawing. Since the 1980s, bi-
metal blades have been used to give the advantages of both forms, without risk of
breakage. A strip of high speed steel along the tooth edge is electron beam welded to a
softer spine. As the price of these has dropped to be comparable with the older blades,
their use is now almost universal.

Hacksaw blade specifications 

The most common blade is the 12 inch or 300 mm length. Hacksaw blades have two
holes near the ends for mounting them in the saw frame and the 12 inch / 300 mm
dimension refers to the center to center distance between these mounting holes.

12 Inch Blade

Hole to Hole: 11 7/8 inches / 300 mm

Overall blade length: 12 3/8 inches / 315 mm (not tightly controlled)

Mounting Hole diameter: 9/64 to 5/32 inch / 3.5 to 4 mm (not tightly

controlled)

Blade Width: 7/16 to 33/64 inch / 11 to 13 mm (not tightly

controlled)

Blade Thickness: 0.020 to 0.027 inches / 0.5 to 0.70 mm

The kerf produced by the blades is somewhat wider than the blade thickness due to the
set of the teeth. It commonly varies between 0.030 and 0.063 inches / 0.75 and 1.6 mm
depending on the pitch and set of the teeth. The 10 inch blade is also fairly common and
all the above dimensions apply except for the following:

Hole to Hole: 9 7/8 inches / 250 mm

Overall blade length: 10 3/8 inches / 265 mm (not tightly controlled)

A panel hacksaw eliminates the frame, so that the saw can cut into panels of sheet
metal without the length of cut being restricted by the frame. Junior hacksaws are the
small variant, while larger mechanical hacksaws are used to cut working pieces from
bulk metal.

A power hacksaw (or electric hacksaw) is a type of hacksaw that is powered either by its

own electric motor or connected to a stationary engine. Most power hacksaws are
stationary machines but some portable models do exist. Stationary models usually have a
mechanism to lift up the saw blade on the return stroke and some have a coolant pump to
prevent the saw blade from overheating.

While stationary electric hacksaws are reasonably uncommon they are still produced but
saws powered by stationary engines have gone out of fashion. The reason for using one
is that they provide a cleaner cut than an angle grinder or other types of saw. Large,
power hacksaws are sometimes used in place of a band saw for cutting metal stock to
length.

Types of Hacksaw Machine

(1) Light duty hacksaw machine.

(2) Hydraulic hacksaw machine.

(3) Power hacksaw machine.

(4) Circular band hacksaw machine.

(5) Horizontal swing type band saw machine.

(6) Band hacksaw machine.

(7) Jigsaw machine.

(8) Universal type circular hacksaw machine.

(9) Double column band saw machine.

(10) Chain saw circular machine.

A hacksaw machine is work on principle of SCOTCH YOKE MECHANISM in

this rotary motion of shaft is to be convert into the reciprocating motion of hacksaw
frame. Working principle of hacksaw machine is very simple. First of all the hacksaw
machine is put on ground and after that whatever metal, wood, pvc, is cut is fixed on
vice at required length, after that the electric motor is connect with electricity. Now start
the electric motor so due to that the shaft of motor and hollow disc will be rotate and
also rotate the eccentric Centre and link connect to it. Due to rotation of links the
hacksaw frame will be reciprocate on the metal and cutting of metal is done.
WORKING PRINCIPLE
 CHAPTER IV
WORKING PRINCIPLE

The rotation of the crank and the sliding of the pin inside the yoke and also
moves the yoke forward. The rotation of the crank in a clockwise direction results in the
yoke getting displaced in a forward direction. The maximum quantum of displacement
will be equal to the length of the crank. As soon as the crank completes the rotation of
the yoke will come back to its initial position. At the next rotation, the yoke will move in
the reverse direction. On completion of a full rotation by the crank, the yoke will move
back to its original position. The yoke moves across a length are equivalent to double the
crank for a complete rotation. To change the crank length, displacement of yoke only
need be changed.

This project employs the Scotch yoke mechanism in multi operational machine
which enables it to perform cutting as well as shaping at the same time thereby
improving the productivity. This machine performs cutting Operation on Both Sides of
material simultaneously with its scotch yoke mechanism, to increase production rate
twice then that of conventional machine. This mechanism is used to translate the
reciprocating motion from a rotary motion.
DRAWING
CHAPTER V
DRAWING
COST ESTIMATION
 CHAPTER VI
COST ESTIMATION

S.NO Component Qty Price

1 Frame Rs.600

2 Crank plate 1 Rs.200

3 Hacksaw 2 Rs.225

5 Labour charge Rs.1500

Total Rs.2725

LABOUR COST

 welding

 Grinding

 Power hacksaw

OVERHEAD CHARGES:

The overhead charges are arrived by ”manufacturing cost”

Manufacturing Cost =Material Cost +Labour Cost

= 2725

= Rs. 2725/-

Overhead Charges = 20%of the manufacturing cost

= Rs.545 /-

TOTAL COST

Total cost = Material Cost +Labour Cost +Overhead Charges

= 2725+545

= 3270/-

Total cost for this project = 3270/-

FEATURES
 CHAPTER VII
FEATURES
7.1 Advantages

 Weight of machine is less.

 It reduces the work of labor.
 Easy to make because of simple construction.
 High production rate.
 Cost is less.
 Easy maintenance and maintenance cost is less.
 It resists all atmospheric effects.

7.2 Applications

 In engineering industry.
 In construction industry.
 In Workshop.
CONCLUSION
 CHAPTER VIII
CONCLUSION

The scotch yoke mechanism is made and its advantages and disadvantages are
discussed. Its motion characteristics are studied. It is concluded that this mechanism is a
good choice to convert rotating motion into reciprocating motion because of fewer
moving parts and smoother operation. It can be used in direct injection engines like
diesel engines, hot air engines.

In this project report we provide an overview of the issues concerning different

aspects of multipurpose machine using scotch yoke mechanism .The project report focus
on the principle of scotch yoke mechanism, type of tooling and machining parameters
and process performance measure, which include cutting speed, depth of cut,material
removal rate with different type of equipments which can be run simultaneously and
fabricate the work piece In multipurpose machine has been presented . the presented
results can help to plan the machining of work piece with expected tolerance. 

The following major conclusions may be drawn from the present project report.

 Multipurpose machine is derived from turning lathe which has been a well
established industrial processes offering attractive capabilities for handling work
piece of various length to be used at micro level.

 We have presented the development of multipurpose machine in various modes by

which it can be actively adopted.

 We have explained the various parts and components of multipurpose machine

using scotch yoke mechanism.
  Different types of attachments and tools which can be implemented on
multipurpose machine has been discussed

 We have discussed the entire time line and working chart .

The vital need for the fabrication of a multipurpose machine is significant in the
much delay and time as well as energy wasted in using simple hand tools to carry out
jobs. Moreover, the cost of a lathe machine is too high for an average user. Also,
multipurpose machine will helps to reduce the cost and consequently increase the rate of
production and craftsman’s skill.

The general purpose for any project is to find solutions on a certain problems. It’s
also gives main idea how the project to be completed. For this project, the problems that
need to be solved are:-
1) Any manufacturer wants to reduce cost and time taken to complete a product but
gives better quality products and increases the outputs.
2) Manufacturer tends to upgrade their machines to compete with the new machine
with new technology.
3) Lathe machine cutting tool can easily break and needs to enhance its tool life.

The continuous quest to have the problems of man and his growing needs solved has
led to the establishment of factories and other industries, which necessitates an
intermediate technology. However, simple hand tools that were in use before are no
longer efficient for mass production. Then, there comes the need for urgent attention to
better and useful multipurpose machines.
REFERENCES
 CHAPTER IX
REFERENCES

[1] Mack. R., Mueller, R., Crotts, J., & Broderick, A. (2000). Perceptions,
corrections and defections: implications for Scotch yoke mechanism,
10(6), 339-346.
[2] Mattila, A.S. (2001). The effectiveness of service recovery in a multi-
industry setting. The Journal of Services Marketing, 15(7), 596-583.
[3] McDougall, G.H.G., & Levesque, T.J. (1999). Waiting for service: the
effectiveness of recovery strategies. International Journal of
Contemporary mechanism 11(1), 6-15.
[4] Michel, S. (2001). Analyzing service failures and recoveries a process
approach. International Journal of kinematic links, 12(1), 20-33.
[5] Miller, J.L., Craighead, C.W., & Karwan, K.R. (2000). Service recovery:
a framework and empirical Investigation. Journal of links Management,
18(4), 387-400.
[6] Six types of service scotch-Yoke mechanism and rack and pinion
mechanism (Chase and Stewart, 1994)
[7] http://ezinearticles.com/?Using-Your- multipurpose machines –Way &
id=4352151

CHAPTER X
PHOTOGRAPHS