Pneumatic hack sawmachine (doc)

PNEUMATIC HIGH SPEED HACK
SAW MACHINE

CONTENTS
CHAPTER NO TITLE
SYNOPSIS
LIST OF FIGURES
NOMENCLATURE
1 Introduction
2 Literature review
3 Description of equipments
3.1 Pneumatic control components
3.2 Valves
3.3 Hose
3.4 Pressure gauge
3.5 Vice
3.6 Filing
3.7 Control unit
4 Design and drawing
4.1 Machine component
4.2 Design calculation
5 Fabrication
6 Working principle
7 Merits and demerits
8 Applications
9 List of materials
10 Cost Estimation
11 Conclusion
Bibliography
photography

LIST OF FIGURES
LIST OF FIGURES
Figure
Number Title
1 Piston Rod
2 piston
3 Double acting pneumatic cylinder
4 Hose
5 Solenoid valve
6 Base
7 Base up plate

8 Center plate
9 Moving cutter
10 Overall Diagram
NOMENCLATURE

NOMENCLATURE
 A =Area of cylinder(m2
)
 D=Diameter of Piston (m)
 F =Force exerted on the piston (N)
 H=Height (m)
 L=Length(m)
 P=Pressure (N/m2
)
 V=Volume (m3
)

SYNOPSIS
The pneumatic hack saw cutting and filing is a metal cutting and filing
machine tool designed to cut/filing metal by applying pneumatic pressure.
The machine is exclusively intended for mass production and they represent
the fast and more efficient way to cut a metal. The slow speed operation is
occurs in a grinding operation. This machine is a multipurpose machine.
Hacksaw is used to cut thin and soft metals. The grinding shaft I used
to grinding operation by replacing the hacksaw frame. The operation of the
unit is simplified to a few simple operations involving a cylinder block and
piston arrangement. There are numerous types of cutting machine in
engineering field, which are used to full fill the requirements. We are
interested to introduce pneumatic system in especially in cutting machine and
also filling operation. The main function of pneumatic cutting is to cut thin and
soft metals by pneumatic power.

CHAPTER -1
INTRODUCTION
CHAPTER -1
INTRODUCTION

A hacksaw is a fine-tooth saw with a blade under tension in a frame,
used for cutting materials such as metal or bone. Some have pistol grips
which keep the hacksaw firm and easy to grip.
Small hand-held hacksaws consist of a metal arch with a handle that fits
around a narrow, rigid blade. One edge of the blade has many small saw
teeth along almost its entire length. The blade can either be attached such
that the teeth face away from the handle, resulting in sawing action when
pushing, or be attached such that the teeth face toward the handle, resulting
in sawing action when pulling. On the push stroke, the arch will bend a little,
releasing the tension on the blade. The blade is normally quite brittle, so care
needs to be taken to prevent brittle fracture of the blade.
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.Large, power hacksaws are sometimes
used to replace a band saw in machine shops.
Nowadays almost all the manufacturing process is being atomized in order to
deliver the products at a faster rate. The manufacturing operation is being
atomized for the following reasons.
 To achieve mass production
 To reduce man power

 To reduce the work load
 To reduce the fatigue of workers
 To achieve good product quality
 Less maintenance

CHAPTER -2
LITRATURE SURVEY
CHAPTER -2
LITRATURE SURVEY
Saw:
A saw is a tool that uses a hard blade or wire with an abrasive edge to cut
through softer materials. The cutting edge of a saw is either a serrated blade
or an abrasive. A saw may be worked by hand, or powered by steam, water,
electric or other power.
In a modern serrated saw, each tooth is bent to a precise angle called its
"set". The set of the teeth is determined by the kind of cut the saw is intended
to make. For example, a "rip saw" has a tooth set that is similar to the angle
used on a chisel. The idea is to have the teeth rip or tear the material apart.
Some teeth are usually splayed slightly to each side the blade, so that the cut

width (kerf) is wider than the blade itself and the blade does not bind in the
cut.
An abrasive saw uses an abrasive disc or band for cutting, rather than a
serrated blade.
According to Chinese tradition, the saw was invented by Lu Ban. In Greek
mythology, Talos, the nephew of Daedalos, invented the saw. In fact, saws
date back to prehistory, and likely evolved from Neolithic tools or bone tools.
The early ancestors of man, in the Pleistocene era, likely first used a jaw
bone of a bovid animal as a saw.
TYPES OF SAW BLADES AND THE CUTS THEY MAKE
BLADE TEETH ARE OF TWO GENERAL TYPES:
Tool steel or carbide. Carbide is harder and holds a sharp edge much
longer.
CROSSCUT:
In woodworking, a cut made at (or near) a right angle to the direction of
the grain of the work piece. A crosscut saw is used to make this type of
cut.
RIP CUT:
In woodworking, a cut made parallel to the direction of the grain of the
work piece. A rip saw is used to make this type of cut.

PLY TOOTH:
A circular saw blade with many small teeth designed for cutting
plywood with minimal splintering.
MATERIALS USED FOR SAWS
THERE ARE SEVERAL MATERIALS USED IN SAWS, WITH EACH OF ITS
OWN SPECIFICATIONS.
BRASS:
Mostly used in back saws because of its low price, its flow
characteristics that make the material relatively easy to cast, and unlike
other types of saw, the forces that take place in back saws are
relatively low because of the pulling motion used.
STEEL:
Used in almost every existing kind of saw. Because steel is cheap,
easy to shape, and very strong, it has the right properties for most kind
of saws.
DIAMOND:
Used only in saws for the really heavy cutting. It is very expensive and
comes in two shapes: ropes and circular saws. Mostly used for cutting
concrete and other materials with rock-like structures or in softer

materials, such as wood, where the precision and high volume of work
justifies the expense of diamond-edged cutting tools. Diamond saws
are made by combining powder metal with diamond crystals, which are
then heated and pressed into a molding to form the diamond segments.
USES:
• Saws are most commonly used for cutting hard materials. They are
used extensively in forestry, construction, demolition, medicine, and
hunting.
• Some saws are used as instruments to make music.
• Chainsaw carving is a flourishing modern art form. Special saws have
been developed for this purpose.
HACKSAW:
A hacksaw is a fine-tooth saw with a blade under tension in a frame, used for
cutting materials such as metal or bone. Some have pistol grips which keep
the hacksaw firm and easy to grip.
A power hacksaw is a type of hacksaw that is powered either by its own
electric motor (also known as electric hacksaw) 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 a 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.
CUTTING:
Cutting sheet metal can be done in various ways from hand tools called
tin snips up to very large powered shears. With the advances in technology,
sheet metal cutting has turned to computers for precise cutting.
Cutting is the separation of a physical object, or a portion of a physical object,
into two portions, through the application of an acutely directed force. An
implement commonly used for cutting is the knife or in medical cases the
scalpel. However, any sufficiently sharp object is capable of cutting if it has a
hardness sufficiently larger than the object being cut, and if it is applied with
sufficient force. Cutting also describes the action of a saw which removes
material in the process of cutting.
Cutting is a compressive and shearing phenomenon, and occurs only when
the total stress generated by the cutting implement exceeds the ultimate

strength of the material of the object being cut. The simplest applicable
equation is stress = force/area: The stress generated by a cutting implement
is directly proportional to the force with which it is applied, and inversely
proportional to the area of contact. Hence, the smaller the area (i.e., the
sharper the cutting implement), the less force is needed to cut something.
When referring to propagating plants, cutting is one of the methods that can
be used. It involves cutting a part of the plant typically a healthy shoot, with
sharp and sterile scissors or any other cutting device, and then placing the
removed part in water. Some cuttings do not require water. Certain shoots
when cut are able to grow when placed in vermiculite or potting soil.
However, the former is the easiest to do as most shoots when cut from the
main plant need time to grow roots, and then they are able to be transferred
to potting soil.
PNEUMATICS:
The word ‘pneuma’ comes from Greek and means wind. The word
pneumatics is the study of air movement and its phenomena is derived from
the word pneuma. Today pneumatics is mainly understood to means the
application of air as a working medium in industry especially the driving and
controlling of machines and equipment.
Pneumatics has for some considerable time between used for carrying
out the simplest mechanical tasks in more recent times has

Played a more important role in the development of pneumatic technology for
automation.
Pneumatic systems operate on a supply of compressed air which must
be made available in sufficient quantity and at a pressure to suit the capacity
of the system. When the pneumatic system is being adopted for the first time,
however it wills indeed the necessary to deal with the question of
compressed air supply.
The key part of any facility for supply of compressed air is by means
using reciprocating compressor. A compressor is a machine that takes in air,
gas at a certain pressure and delivered the air at a high pressure.
Compressor capacity is the actual quantity of air compressed and
delivered and the volume expressed is that of that of the air at intake
conditions namely at atmosphere pressure and normal ambient temperature.
The compressibility of the air was first investigated by Robot Boyle in
1962 and that found that the product of pressure and volumes of particular
quantity of gas.
The usual written as
PV =C (or) PiVi =P2V2
In this equation the pressure is the absolute pressured which for free is
about 14.7Psi and is of courage capable of maintaining a column of mercury,

nearly 30 inches high in an ordinary barometer. Any gas can be used in
pneumatic system but air is the mostly used system now a days.
SELECTION OF PNEUMATICS:
Mechanization is broadly defined as the replacement of manual effort
by mechanical power. Pneumatic is an attractive medium for low Cost
mechanization particularly for sequential (or) repetitive operations. Many
factories and plants already have a compressed air system, which is capable
of providing the power (or) energy requirements and control system (although
equally pneumatic control systems may be economic and can be
advantageously applied to other forms of power).
The main advantages of an all pneumatic system are usually Economic
and simplicity the latter reducing maintenance to a low level. It can have out
standing advantages in terms of safety.
PNEUMATIC POWER:
Pneumatic systems use pressurized gases to transmit and control
power. Pneumatic systems typically use air as the fluid medium because air
is safe, low cost and readily available.

THE ADVANTAGES OF PNEUMATICS:
1. Air used in pneumatic systems can be directly exhausted back
In to the surrounding environment and hence the need of special
reservoirs and no-leak system designs are eliminated.
2. Pneumatic systems are simple and economical
3. Control of pneumatic systems is easier
THE DISADVANTAGES OF PNEUMATICS:
1. Pneumatic systems exhibit spongy characteristics due to compressibility of
air.
2. Pneumatic pressures are quite low due to compressor design
limitations(less that 250 psi).
PRODUCTION OF COMPRESSED AIR
Pneumatic systems operate on a supply of compressed air, which must be
made available. In sufficient quantity and at a pressure to suit the capacity of
the system. When pneumatic system is being adopted for the first time,
however it wills indeed the necessary to deal with the question of
compressed air supply.

The key part of any facility for supply of compressed air is by means using
reciprocating compressor. A compressor is a machine that takes in air, gas at
a certain pressure and delivered the air at a high pressure. Compressor
capacity is the actual quantity of air compressed and delivered and the
volume expressed is that of the air
At intake conditions namely at atmosphere pressure and normal ambient
temperature.
Clean condition of the suction air is one of the factors, which decides
the life of a compressor. Warm and moist suction air will result increased
precipitation of condense from the compressed air.
COMPRESSOR MAY BE CLASSIFIED IN TWO GENERAL TYPES.
1. Positive displacement compressor
2. Turbo compressor
Positive displacement compressors are most frequently employed for
Compressed air plant and have proved highly successful and supply air for
pneumatic control application.
The types of positive compressor
1. Reciprocating type compressor
2. Rotary type compressor

Turbo compressors are employed where large of air required at low
discharge pressures. They cannot attain pressure necessary for pneumatic
control application unless built in multistage designs and are seldom
encountered in pneumatic service.
RECIPROCATING COMPRESSORS:
Built for either stationary (or) portable service the reciprocating
compressor is by far the most common type. Reciprocating compressors lap
be had is sizes from the smallest capacities to deliver more than
500m3
/min.In single stage compressor, the air pressure may be of 6 bar
machines discharge of pressure is up to 15bars.Discharge pressure in the
range of 250bars can be obtained with high pressure reciprocating
compressors that of three & four stages. Single stage and 1200 stage models
are particularly suitable
For applications, with preference going to the two stage design as soon as
the discharge pressure exceeds 6 bars, because it in capable of matching the
performance of single stage machine at lower costs per driving powers in the
range.
ULTIMATE AIM
The pneumatic hacksaw cutting and filing machine is low cost
automation equipment which can be widely used in small scale industries and

automobile maintenance shops. Pressing speed is high. The manpower
requirement is reduced also reducing the machining time.
CHAPTER-3
DESCRIPTION OF EQUAPMENTS
3.1 PNEUMATIC CONTROL COMPONENT
3.1.1 Pneumatic cylinder:
An air cylinder is an operative device in which the state input energy of
compressed air i.e.penuamtic power is converted into mechanical Output
power, by reducing the pressure of the air to that of the atmosphere.

3.1.1a) single acting cylinder:
Single acting cylinder is only capable of performing an operating
medium in only one direction. Single acting cylinders equipped with one inlet
for the operating air pressure, can be production in several fundamentally
different designs. Single cylinders Develop power in one direction only.
Therefore no heavy control equipment should be attached to them,
which requires to be moved on the piston return stroke single action cylinder
requires only about half the air volume consumed by a double acting for one
operating cycle.
3.1.1 B) Double acting Cylinders:
A double acting cylinder is employed in control systems with the full
pneumatic cushioning and it is essential when the cylinder itself is required to
retard heavy messes. This can only be done at the end positions of the
piston stroke. In all intermediate position a separate externally mounted
cushioning derive most be provided with the damping feature.
The normal escape of air is out off by a cushioning piston before the
end of the stroke is required. As a result the sit in the cushioning chamber is
again compressed since it cannot escape but slowly according to the setting
made on reverses. The air freely enters the cylinder and the piston strokes in
the other direction at full
Force and velocity.

3.2 VALVES
SOLENOID VALVE
The directional valve is one of the important parts of a pneumatic system.
Commonly known as DCV; this valve is used to control the direction of air
flow in the pneumatic system. The directional valve does this by changing the
position of its internal movable parts.
This valve was selected for speedy operation and to reduce the manual effort
and also for the modification of the machine into automatic machine by
means of using a solenoid valve.
A solenoid is an electrical device that converts electrical energy into
straight line motion and force. These are also used to operate a mechanical
operation which in turn operates the valve mechanism. Solenoid is one is
which the plunger is pulled when the solenoid is energized.
The name of the parts of the solenoid should be learned so that they
can be recognized when called upon to make repairs,to do service work or to
install them.

PARTS OF A SOLENOID VALVE
1. Coil
The solenoid coil is made of copper wire. The layers of wire are
separated by insulating layer. The entire solenoid coil is covered with a
varnish that is not affected by solvents, moisture, cutting oil or often fluids.
Coils are rated in various voltages such as 115 volts AC,230volts
AC,460volts Ac,575 Volts AC.6Volts DC,12Volts DC,
24 Volts DC,115 Volts DC &230Volts DC.they are designed for such
Frequencies as 50Hz to 60Hz.
2. Frame

The solenoid frame serves several purposes. Since it is made of
laminated sheets, it is 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 receivers, the plunger. The wear
strips are mounted to the solenoid frame, and are made of materials such as
metal or impregnated less Fiber cloth.
3. Solenoid plunger
The solenoid plunger is the mover mechanism of the solenoid. The
plunger is made of steel laminations which are riveted together under high
pressure, so that there will be no movement of the lamination with respect
to one another. At the top of the plunger a pin hole is placed for making a
connection to some device. The solenoid plunger is moved by a magnetic
force in one direction and is usually returned by spring action.
Solenoid operated valves are usually provided with cover either the
solenoid or the entire valve. This protects the solenoid from dirt and other
foreign matter, and protects the actuator. In many applications it is
necessary to use explosion proof solenoids.
WORKING OF SOLENOID VALVE:

The solenoid valve has 5 openings. These ensure easy exhausting of
5/2Valve.the spool of the 5/2 valve slide inside the main bore according to
spool position: the ports get connected and disconnected.
The working principle is as follows.
Position-1
When the spool is actuated towards outer direction port ‘P’ gets
Connected to ‘B’ and ‘S’ remains closed while ‘A’gets connected to ‘R’.
Position-2
When the spool is pushed in the inner direction port ‘P’ and ‘A’
Gets connected to each other and ‘B’ to ‘S’ while port ‘R’remains closed.
SOLINOID VALVE (OR) CUT OFF VALVE:
The control valve is used to control the flow direction is called cut off valve or
solenoid valve. This solenoid cutoff valve is controlled by the electronic
control unit.
In our project separate solenoid valve is used for flow direction of vice
cylinder. It is used to flow the air from compressor to the single acting
cylinder.
3.2.2 Flow control valve:
In any fluid power circuit, flow control valve is used to control the speed
of actuator. The flow control can be achieved by varying the area of flow
through which the air in passing.

When area is increased, more quantity of air will be sent to actuator as
a result its speed will increase. If the quantity of air entering into the actuator
is reduced, the speed of the actuator is reduced.
3.2.3 Pressure control valve:
The main function of the pressure control valve is to limit (or)
Control the pressure required in a pneumatic circuit.
Depending upon the method of controlling they are classified as
1. Pressure relief valve
2. Pressure reducing valve
PNEUMATIC HACKSAW:
Pneumatic hacksaw machine is consists of a cutter. It is made up of
mild steel. The work piece is placed from the bottom of the table. The cutter
is moved with the help of pneumatic power, to cut the work piece firmly
against the fixed cutter.
3.3. Hoses:
Hoses used in this pneumatic system are made up of polyurethane.
These hose can with stand at a maximum pressure level of 10 x105
N/m2.
Connectors
In our system there are two type of connectors used. One is the

Hose connector and the other is the reducer. Hose connectors normally
comprise an adopt hose nipple and cap nut. These types of connectors are
made up of brass (or) aluminum (or) hardened pneumatic steel.
3.4 PRESSURE GAUGE:
Pressure gauges are usually fitted with the regulators. So the air
Pressure adjusted in the regulator is indicated in the pressure Gauge, is the
line pressure of the air taken to the cylinder.
3.4 VICE:
A vise or vice (see under miscellaneous spelling differences) is a mechanical
screw apparatus used for holding or clamping a work piece to allow work to
be performed on it with tools such as saws, planes, drills, mills, screwdrivers,
sandpaper, etc. Vises usually have one fixed jaw and another, parallel, jaw
which is moved towards or away from the fixed jaw by the screw.
Metalworkers' vises:
For metalworking, the jaws are made of metal which may be hardened
steel with a coarse gripping finish. Quick change removable soft jaws are
being used more frequently to accommodate fast change-over on set-ups.
They are also kept for use where appropriate, to protect the work from
damage.

Metalworking bench vises, known as engineers' or fitters' vises, are bolted
onto the top surface of the bench with the face of the fixed jaws just forward
of the front edge of the bench. The bench height should be such that the top
of the vise jaws is at or just below the elbow height of the user when standing
upright. Where several people use the one vise, this is a counsel of
perfection but is still a good guide.
The nut in which the screw turns may be split so that, by means of a lever, it
can be removed from the screw and the screw and moveable jaw quickly slid
into a suitable position at which point the nut is again closed onto the screw.
Many fitters prefer to use the greater precision available from a plain screw
vise. The vise may include other features such as a small anvil on the back of
its body but it is in general, better to separate the functions of the various
tools.
Vise screws are usually either of an Acme thread form or a buttress thread.
Those with a quick-release nut use a buttress thread.
The word 'vise' comes ultimately, from the Latin word vitis (vine), referring to
the helical tendrils of the vine. The more direct source is the French vis,
screw.
Metalworking vises in Machine Shops
In high production machine work, work must be held in the same
location with great accuracy so CNC machines may perform operations on an

array of vises. To assist this, there are several machine-shop specific vises
and vise accessories.
Hard and soft machine jaws have a very important difference between other
metalworking vise jaws. The jaws are precision ground to a very flat and
smooth surface for accuracy. These rely on mechanical pressure for gripping,
instead of a rough surface. An unskilled operator has the tendency to over-
tighten jaws, leading to part deformation and error in the finished work piece.
The jaws themselves come in a variety of hard and soft jaw profiles, for
various work needs. One can purchase machinable soft jaws, and mill the
profile of the part into them to speed part set-up and eliminate measurement.
This is most commonly done in gang operations, discussed below. For
rectangular parts being worked at 45 degree angles, prismatic hard jaws exist
with V grooves cut into them to hold the part. Some vises have a hydraulic or
pneumatic screw, making setup not only faster, but more accurate as human
error is reduced.
For large parts, an array of regular machine vises may be set up to hold a
part that is too long for one vise to hold. The vises' fixed jaws are aligned by
means of a dial indicator so that there is a common reference plane for the
CNC machine.
For multiple parts, several options exist, and all machine vise manufacturers
have lines of vises available for high production work.

• The first step is a two clamp vise, where the fixed jaw is in the center of
the vise and movable jaws ride on the same screw to the outside.
• The next step up is the modular vise. Modular vises can be arranged
and bolted together in a grid, with no space between them. This allows
the greatest density of vises on a given work surface. This style vise
also comes in a two clamp variety.
• Tower vises are vertical vises used in horizontal machining centers.
They have one vise per side, and come in single or dual clamping
station varieties. A dual clamping tower vise, for example, will hold
eight relatively large parts without the need for a tool change.
• Tombstone fixtures follow the same theory as a tower vise.
Tombstones allow four surfaces of vises to be worked on one rotary
table pallet. A tombstone is a large, accurate, hardened block of metal
that is bolted to the CNC pallet. The surface of the tombstone has holes
to accommodate modular vises across all four faces on a pallet that
can rotate to expose those faces to the machine spindle.
• New work holding fixtures are becoming available for five-axis
machining centers. These specialty vises allow the machine to work on
surfaces that would normally be obscured when mounted in a
traditional or tombstone vise setup.
3.6 FILING:

A file (or hand-file) is a hand tool used to shape material by cutting. A
file typically takes the form of a hardened steel bar, mostly covered with a
series of sharp, parallel ridges or teeth. Most files have a narrow, pointed
tang at one end to which a handle can be fitted. The rasp is a related tool
which is generally larger and has raised, pointed teeth on its surface rather
than straight ridges.
Files come in a wide variety of sizes, shapes, and tooth configurations. The
cross-section of a file can be flat, round, half-round, triangular, square, knife
edge or of a more specialized shape. There is no unitary international
standard for file nomenclature; however, there are many generally accepted
names for certain kinds of files.
A file's teeth can range from rough, coarse and bastard (meaning
intermediate) to second-cut, smooth and dead smooth. A single-cut or mill file
has one set of parallel teeth, while a cross-cut or double-cut file has a second
set at an angle to the first. In Swiss-pattern files the teeth are cut at a
shallower angle, and are graded by number, with a number 1 file being
coarser than a number 2, etc. Most files have teeth on all faces, but some
specialty flat files have teeth only on the face or only on the edge, so that the
user can come right up to another edge without damaging the finish on it.
Some of the common shapes and their uses:

• Hand files are parallel in width and tapered in thickness; they are used
for general work.
• Joint round edge files are parallel in width and thickness, with
rounded edges. The flats are safe (no teeth) and cut on the rounded
edges only. Used for making joints and hinges.
• Half round ring files taper in width and thickness, coming to a point,
and are narrower than a standard half round. Used for filing inside of
rings.
• Barrette files are tapered in width and thickness, coming to a rounded
point at the end. Only the flat side is cut, and the other sides are all
safe. For doing flat work.
• Checkering files are parallel in width and gently tapered in thickness.
They have teeth cut in a precise grid pattern, and are used for making
serrations and doing checkering work, as on gunstocks.
• Crossing files are half round on two sides with one side having a
larger radius than the other. Tapered in width and thickness. For filing
interior curved surfaces. The double radius makes possible filing at the
junction of two curved surfaces or a straight and curved surface.
• Crochet files are tapered in width and gradually tapered in thickness,
with two flats and radiused edges, cut all around. Used in filing
junctions between flat and curved surface, and slots with rounded
edges.

• Knife files are tapered in width and thickness, but the knife edge has
the same thickness the whole length, with the knife edge having an arc
to it. Used for slotting or wedging operations.
• Pippin files are tapered in width and thickness, generally of a teardrop
cross section and having the edge of a knife file. Used for filing the
junction of two curved surfaces and making V-shaped slots.
• Square files are gradually tapered and cut on all four sides. Used for a
wide variety of things.
• Triangle files, also called three square files, are gradually tapered
and come to a point. Used for many things, cutting angles less than 90
degrees, etc. It has been pointed out that there's no such thing as a
"three square". Triangle files are 60 degree angles, and "square" is 90
degrees. All this is true, but triangle files are often called the term
simply as a matter of slang.
• Round files, also called rat-tail files, are gradually tapered and are
used for many tasks that require a round tool, such as enlarging round
holes or cutting a scalloped edge.
• Round parallel files are similar to round files, except that they do not
taper. Shaped like a toothed cylinder.
• Equaling files are parallel in width and thickness. Used for filing slots
and corners.
• Slitting files are parallel in width with a diamond shaped cross section.
Thinner than knife files and use for filing slots.

• Pillar files are parallel in width and tapered in thickness for perfectly
flat filing. Double cut top and bottom with both sides safe; these are
long, narrow files for precision work.
• Warding files are parallel in thickness, tapered in width, and thin. Like
a hand or flat file that comes to a point on the end. Used for flat work
and slotting.
• Dreadnought (curved teeth) and millenicut (straight teeth) files both
have heavily undercut, sharp but coarse teeth. Both can be used for
rapidly removing large quantities of material from thick aluminum alloy,
copper or brass. Today, the millenicut and dreadnought have found a
new use in removing plastic filler materials such as two-part epoxies or
styrenes such as those commonly used in automobile body repairs.
Files have forward-facing cutting teeth, and cuts most effectively when
pushed over the workpiece. Drawfiling involves laying the file sideways on
the work, and carefully pushing or pulling it across the work. This catches the
teeth of the file sideways instead of head on, and a very fine shaving action is
produced. There are also varying strokes that produce a combination of the
straight ahead stroke and the drawfiling stroke, and very fine work can be
attained in this fashion. Using a combination of strokes, and progressively
finer files, a skilled operator can attain a surface that is perfectly flat and near
mirror finish. The grooves in a file may became clogged during use, causing

the file to lose its cutting ability and trapped shavings can scratch the work
surface. A file card can be used to clean the file.
3.7 CONTROL UNIT:
The pneumatic high speed hacksaw machine. Air-operated device used for
many small operations. It is a portable one. Compressed air is the source of
energy for this device. The compressed air is allowed. Here the compressed
air from the compressor firstly enters the Control unit. In the control unit the
pressure of the air is controlled.

CHAPTER-IV
DESIGN OF EQUIPMENT AND DRAWING
4.1 MACHINE COMPONENTS
The pneumatic hack saw cutting and filing machine consists of the
following components to full fill the requirements of complete operation of the
machine.
1. Double acting pneumatic cylinder
2. Solenoid vale
3. Flow control valve
4. Connectors
5. Hoses
6. Saw frame
1. Double acting pneumatic cylinder:
Technical Data
Stroke length: cylinder stroke length 100mm =0.1m
Piston rod : 10mm =10 X10-3
m
Quantity : 1
Seals : Nitride (Buna-N) Eastover

End cones : Cast iron
Piston : EN-8
Media : Air
Temperature: 0-80°C
Pressure Range: 8N/m2
2. Solenoid Valve
Technical data
Size : 0.635x10-2
m
Part size : G0.635x10-2
m
Maximum pressure: 0-10 x10 5
N/m2
Range
Quantity: 1
3. Flow control valve:
Technical data
Port size: 0.635 x 10-2
m
Pressure: 0-8 x105
N/m2
Media : Air
Quantity: 1
4. Connectors

Technical data
Max working pressure : 10 x105
N/m2
Temperature : 0-100°C
Fluid media :Air
Material :Brass
5. Hoses
Technical data
Max pressure : 10 x105
N/m
2
Outer diameter : 6mm =6 x 10-3
m
Inner diameter : 3.5mm =3.5 x10-3
m
Pneumatic unit
Type of cylinder : Double acting cylinder
Type of valve : flow control valve &solenoid valve
Max air pressure : 8 x105
N/m2
4.2 DESIGN CALCULATION
Max pressure applied in the cylinder (p) : 8N/m2
Area of cylinder (A) : (3.14/4*(D2
)
: 80.38cm2

: 80.38 X 10-4
m2
Force exerted in the piston (F) : Pressures applied X area
Of cylinder.
DRAWING

PNEUMATIC HACKSAW CUTTING AND FILING MACHINE

CHAPTER-V
FABRICATION
METHOD OF FABRICATION:
The pneumatic cylinder mounded on the supporting horizontal
column.in this pneumatic piston rod is threaded to the cutter, with the help of
nut. The cutter is placed in side of the pneumatic stand; witch is placed
above the base of the machine. And the work piece is placed at the bottom of
the table,the base and it is welded part, and the cutter is placed were the
moving(reciprocating motion) direction.
Then the two hoses are connected from solenoid valve to the cylinder.
The air goes through the tubes. The tubes are also connected by the nozzle
head. The supporting stands are placed in the base side by means of
welding. Finally the unit is connected to the compressor.
Chapter -6

WORKING PRINCIPLE
CHAPTER-VI
WORKING PRINCIPLE
The compressed air from the compressor reaches the solenoid valve.
The solenoid valve changes the direction of flow according to the signals
from the timing device. The compressed air passes through the solenoid
valve and it is admitted into the front end of the cylinder block. The air pushes
the piston for the cutting stroke. At the end of the cutting stroke air from the
solenoid valve reaches the rear end of the cylinder block.

The pressure remains the same but the area is less due to the
presence of piston rod. This exerts greater pressure on the piston, pushing it
at a faster rate thus enabling faster return stroke. The weight attached at the
end of the hacksaw frame gives constant loads which lower the hacksaw to
enable continuous cutting of the work. The stroke length of the piston can be
changed by making suitable adjustment in the timer. Cutting hack saw frame
is removed in the case of grinding operation. The above same procedure is
occurring operation.
CHAPTER -7
MERITS AND DEMERITS

CHAPTER-VII
MERITS AND DEMERITS
MERITS:
• There is no need of giving feed during every cut due to the presence of
weight.
• The cutting /filing speed can be varied according to our needs by
adjusting the timer
• It is portable
• It does not have any prime mover, like electric motor related to the unit.
• As the air is freely available, we can utilize the air to cut metal and
hence it is economical.
• Simple in construction than mechanical hacksaw
DEMERITS:

• Only smaller size and soft metal can be cut
• It is costlier than the mechanical hacksaw because of compressor unit.
• Less efficiency when compressed to mechanical device.
• Leakage of air affects the working of the unit.
Chapter-8
APPLICATIONS

CHAPTER-VIII
APPLICATIONS
1. Agriculture
Crop forming
Stock breeding
Animal food industries
Foresting
2. Utilities:
Power station
Nuclear engineering
Water supply
3. Mining
4. Chemical industry
5. Plastics and rubber industries
6. Stone, ceramic and glass industries
7. Metal industries:
Iron and steel
Non-ferrous metals
Foundries

Scrap and recycled metals
8. Leather industry
9. Textile industry
10. Paper and printing industry
11. Filing industries

CHAPTER-9
LIST OF MATERIALS
CHAPTER-IX
LIST OF MATERIALS
FACTORS DETERMINING THE CHOICE OF MATERIALS
The various factors which determine the choice of material are
discussed below.
1. Properties:

The material selected must posses the necessary properties for the
proposed application. The various requirements to be satisfied
Can be weight, surface finish, rigidity, ability to withstand environmental
attack from chemicals, service life, reliability etc.
The following four types of principle properties of materials decisively
affect their selection
a. Physical
b. Mechanical
c. From manufacturing point of view
d. Chemical
The various physical properties concerned are melting point, thermal
Conductivity, specific heat, coefficient of thermal expansion, specific gravity,
electrical conductivity, magnetic purposes etc.
The various Mechanical properties Concerned are strength in tensile,
Compressive shear, bending, torsional and buckling load, fatigue resistance,
impact resistance, eleastic limit, endurance limit, and modulus of elasticity,
hardness, wear resistance and sliding properties.
The various properties concerned from the manufacturing point of view
are,
 Cast ability
 Weld ability

 Forge ability
 Surface properties
 Shrinkage
 Deep drawing etc.
2. Manufacturing case:
Sometimes the demand for lowest possible manufacturing cost or surface
qualities obtainable by the application of suitable coating substances may
demand the use of special materials.
3. Quality Required:
This generally affects the manufacturing process and ultimately the
material. For example, it would never be desirable to go casting of a less
number of components which can be fabricated much more economically by
welding or hand forging the steel.
4. Availability of Material:
Some materials may be scarce or in short supply. It then becomes
obligatory for the designer to use some other material which though may not
be a perfect substitute for the material designed. the delivery of materials and
the delivery date of product should also be kept in mind.
5. Space consideration:
Sometimes high strength materials have to be selected because the forces
involved are high and space limitations are there.
6. Cost:

As in any other problem, in selection of material the cost of material
plays an important part and should not be ignored.
Some times factors like scrap utilization, appearance, and non-
maintenance of the designed part are involved in the selection of proper
materials.
S.No DESCIRPTION QTY Material
1 Double acting
pneumatic cylinder
1 aluminum
2 Solenoid Valve 1 aluminum
3 Flow control valve 1 aluminum
4 hacksaw 1 M.S
5 Control unit 1 Electronic
6 PU tubes 5meter polyurethane
7 Base 1 M.S
8 Base up plate 1 M.S
9 Center plate 1 M.S
10 Filing tool 1 --

Chapter-x
COST ESTIMATION
1. MATERIAL COST.
S.No DESCRIPTION QTY MATERIAL AMOUNT
(Rs)
1 Double acting
pneumatic Cylinder
1 aluminum
2 Solenoid Valve 1 Aluminum
3 Flow Control Valve 1 Aluminum
4 hacksaw 1 M.S
5 Control unit 1 Electronic
6 PU Tubes 5 meter Polyurethane
7 Base 1 M.S
8 Base up plate 1 M.S
9 Center plate 1 M.S
10 Filing tool 1 --
2. LABOUR COST:
Lathe, drilling, welding, grinding, power hacksaw, gas cutting cost
3. OVERGHEAD CHARGES:
The overhead charges are arrived by”manufacturing cost”
Manufaturing Cost =Material Cost +Labour Cost
=
=
Overhead Charges =20%of the manufacturing cost
=

4. TOTAL COST:
Total cost = Material Cost +Labour Cost +Overhead Charges
=
=
Total cost for this project =
Chapter-11

CONCLUSION
CHAPTER-XI
CONCLUSION
The project carried out by us made an impressing task in the field of
small scale industries and automobile maintenance shops. It is very useful for
the workers work in the lath and small scale industries.
This project will reduce the cost involved in the concern. Project has
been designed to perform the entire requirement task at the shortest time
available.

BIBLIGRAPHY
1. Design data book -P.S.G.Tech.
2. Pneumatic handbook -R.H.warrning
3. Machine tool design handbook –Central machine tool Institute,
Bangalore.
4. Strength of Materials -R.S.Kurmi
5. Manufacturing Technology -M.Haslehurst.
6. Design of machine elements- R.s.Kurumi

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