DESIGN AND FABRICATION OF HUMAN POWERED

METAL-WOOD CUTTING MACHINE

Submitted by

M. Zain ul Abideen FA14-BME-094 Abubakar

Saleem FA14-BME-060

Supervisor

Dr. Muhammad Akram

Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

FACULTY OF ENGINEERING

COMSATS UNIVERSITY ISLAMABAD,

SAHIWAL CAMPUS

JUNE, 2018
DESIGN AND FABRICATION OF HUMAN POWERED

METAL-WOOD CUTTING MACHINE

M. Zain ul Abideen FA14-BME-094

Abubakar Saleem FA14-BME-060

Supervisor

Dr. Muhammad Akram

Assistant Professor

External Examiner 1 Signature: _________________________

External Examiner 2 Signature: _________________________

Thesis Supervisor Signature: _________________________

DEPARTMENT OF MECHANICAL ENGINEERING

FACULTY OF ENGINEERING

COMSATS UNIVERSITY ISLAMABAD,

SAHIWAL CAMPUS
1
 JUNE, 2018
Abstract

Human powered metal-wood cutting machine can be used for cutting wood and metal without

the power of electricity as there is a huge shortage of electricity in Pakistan, since most of the

time during working hours electric power is not available for work due to high rate of load

shedding. It can also be helpful in reducing human efforts. The machine consist of chain and

sprocket mechanism, slider crank mechanism, blade assembly and work bench for cutting

various materials such as metal, wood and plastic rods etc.

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 Acknowledgements

We are heartedly very much thankful to Almighty ALLAH, Who gave us the courage and power

all the way to complete this project.

My appreciation goes to the innumerable people who contributed to the success of this project.

We owe Special debt of gratitude to Dr. Muhammad Akram for his kind support and direction.

His sincerity, perseverance and sense of transparency have been an inspiration for us. Big

thanks to the Academics and other staff of department of Mechanical Engineering. I am

Thankful to my brothers, Parents, friends and countless others who lent their support in diverse

ways when the going was tough. Thank you.

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 TABLE OF CONTENT

Contents

Abstract………………………………………………………………………………………2

Acknowledgement…………………………………………………………………………..3

Table of contents……………………………………………………………………………4

List of figures………………………………………………………………………………..6

List of tables………………………………………………………………………………...7

CHAPTER 1 INTRODUCTION………………………………………………………...8

1.1 Background………………………………………………………………………...…8

1.2 Problem definition……………………………………………………………………..8

1.3 Project Scope…………………………………………………………………………10

1.4 Need Assessment……………………………………………………………………11

CHAPTER 2 LITERATURE REVIEW……………………………………………….12

2.1 History………………………………………………………………………………..12

2.2 Modern application of human power………………………………………………...13

2.3 The potential of human power………………………………….……………………13

2.4 Pedal power cutting machine………………………………………………………...14

CHAPTER 3 DESIGN METHODOLOGY…………………………………………...18

3.1 Design description……………………………………………………………………18

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 3.1.1 Design parameters…………………………………………………………….…19

3.2 Material selection…………………………………………………………………….19

3.3 Drawing………………………………………………………………………………23
CHAPTER 4 EXPERIMENTATIONS OR SIMULATIONS……….………………26

4.1 Experimental procedure……………………………………………………………..26

4.1.1 Working methodology……………………………………………………..........26

CHAPTER 5 RESULT & ANALYSIS………………………………...……………....30

CHAPTER 6 CONCLUSION AND FUTURE

RECOMMENDATION………………………………………………………...…………31

6.1 Conclusion…………………………………………………………...……………….31

6.2 Future recommendation………………………………………………….....…………32

CHAPTER 7 REFERENCES…………………………………………………………..34
LIST OF FIGURES

Figure 1 Pedal power wood cutting machine ………………………………………………....9

Figure 2 Human power machine………………………………………………………………9

Figure 3 Blade fitting support………………………………………………………………..23

Figure 4 Slider support……………………………………………………………………….23

Figure 5 Base frame………………………………………………………………………….24

Figure 6 Pedal shaft………………………………………………………………………….24

Figure 7 Crank disc…………………………………………………………………………..25

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Figure 8 Connecting rod……………………………………………………………………..25

Figure 9 Frame design ………………………………………………………………………27

Figure 10 Large sprocket………………………………………………………………….....27

Figure 11 Small sprocket……………………………………………………………….……28

Figure 12 Crank disc………………………………………………………………………....28

LIST OF TABLES

Table 1 Calories burning chart……………………………………………………………….16

Table 2 Number of strokes and time taken to completely cut a metal rod…………..............29

Table 3 Cutting depth and the time taken to cut the various wood pieces…………………...29

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 CHAPTER 1

INTRODUCTION:

1.1 Background

• Egyptians illustrations from about 1500BC onward show the saw being used to rip

boards, timber being lashed to a vertical post set into the ground.

• Iron saws started to be produces in the mid-7th century BC. The Romans, added many

improvements to simple says which made them easier to work with.

• While saws for cutting metal had been in used for many years, significant

improvements in longevity and efficiency were made in 1800s by George N. Clemson.

• In 1898, Clemson was granted US patent 601947, which details various improvements

in the hacksaw.

1.2 Problem Definition

Pedal power is a source of energy in which human energy is transferred into useful work.

As human eat food which produces chemical energy in their bodies. This chemical energy

is used for the movement of body parts to produce mechanical energy. The mechanical

energy produced by pedal has been a source of transportation for a long time. More than

billion bicycles are present around the world. Now pedal power is used in agriculture and

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also to generate electricity. Some application includes pedal powered water wells and

grinders. We are going to use pedal power for metal and wood cutting through hacksaw

assembly.

Figure 1 Pedal power wood cutting machine

Power can be produced by hand motion but research shows that a person can produce power

by his foots four times more than the power produced by the hand. With this rate if a man

completes an action by pedaling in ten minutes then same action will be completed in 40

minutes by his hand action. Because of brainstorming, it was apparent that pedal power

was particularly useful. Many devices can be run right away with mechanical energy.

Figure 2 Human powered machine

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 The project is the designing and fabrication of human powered metal and wood cutting

machine. Pedal power metal and wood cutting machine performs the cutting action by shearing

force between piece to be cut and teeth of the blade. This is achieved by pedal action which

rotates the crank disc, and by means of connecting rod rotatory motion of crank disc is converted

into translator motion (to and fro motion) of blade assembly.

The first step was to design the components and the assembly. For that purpose, we used PROE

to generate 3-D views of components and finally assembled them. After the completion of the

modal the analysis of the parts was done. Then the dimensions of the parts were calculated.

After these steps we manufactured each part separately and finally assembled them.

1.3 Project Scope:

This is a learning project in which we applied our designing skills to design the components

and assembly and theoretical knowledge to perform the calculations. Finally, we manufactured

it to enhance our practical skills.

Another advantage of pedal powered metal and wood cutting machine is to facilitate the people

in small industries and students in the university workshops who cut metal or wood pieces by

hands in the absence of electricity which takes more time and energy. By using this cutting

machine, they will be able to do exercise, avoid electricity bills, save their time and energy.

Firstly, it is more efficient and secondly it is safe as compared to performed cutting by hands.

Several organizations also have shown their interest in pedal powered technology. It is

affordable, environment friendly, alternative to devices which consume electricity or fossil fuel.

As it is based on simple bicycle technology so it’s manufacturing, maintenance is easy and

9
components are easily available in market. We hope that this design will be produced where

bicycle technology is available to bring appropriate technology and opportunities to develop

nation across the world.

1.4 Need Assessment:

In underdevelopment countries specially in Pakistan, in the absence of electricity one of the

most creative and unlimited source available is the kinetic energy produced from human

exercise, delivered to pedal powered hacksaw to perform cutting operations.

The aim of the proposed system is to use the mechanical energy produced during exercising

to obtain useful work. This project will help one develop engineering skills while learning about

the utility of pure mechanical powered machines. The system leads a way to preserve our

environment and reduce pollution.

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 CHAPTER 2:

LITERATURE REVIEW

2.1 A Brief History of Human Powered Machines:

Human power has been instrumental in taking care of issues since long time. For instance, all

instruments used in ancient times have truly been human powered. It is trusted that the primary

human powered device to produce rotating movement was the potter's wheel, around 3,500

B.C. Afterward, devices, for example, Archimedes‟ screw permitted effective exchange of

water starting with one level then onto the next. The Chinese, after 200 C.E., were found to

utilize hand cranks to help in material assembling, metallurgy and horticulture. After the

midfifteenth century, the strategy of fusing flywheels to deliver smooth movement multiplied,

permitting devices for example, the turning wheel to pick up prominence in Europe. Hand

cranks and pedal power ended up a standout amongst the most proficient methods for coupling

human power to applications. In the nineteenth century, the bike's utilization of pedals permitted

an effective method for self-transportation. In parallel with the innovation of the electric

dynamo in the nineteenth century, it is theorized that pedal power was utilized to create electric

power as right on time as at that point. Nonetheless, with the prospering of the modern

transformation in the nineteenth century and forward, human culture discovered different

methods for powering their built applications. Especially, the accessibility of shoddy and

copious power, powerful engines and expendable batteries can be ascribed to the lessening in

ubiquity of utilizing human quality. Moreover, the moral ramifications of having humans

deliver vitality as discipline, as found in some jail processes additionally decreased the notoriety
11
of human sourced power. It would take until the point when the last 50% of the twentieth

century for science to truly reexamine this source.

2.2 Modern Applications of Human Power:

Today, Human power is used in applications like water pumping, honey extracting, water

filtration, air compressing, exercise equipment for power generation, concrete mixing, grinding

machines, clothes washing, juice making, wood cutting, metal cutting and hundreds of many

more applications in daily life. Presently human power has made kind of a rebound with

numerous applications where it can be useful and the motivation to explore is elective vitality.

A novel sentiment empowerment is perceived when individuals can get things done for which

they needed to depend on machines already. To such an extent, that powering exclusively from

human vitality exists as a specialized test. For instance, the American Society of Mechanical

Engineers (ASME) holds the Human Powered Vehicle Challenge (HPVC) rivalry every year

for urging advanced education understudies to develop and contend with single-driver models

power by the driver alone. Further, the Royal Aeronautical Society has different difficulties for

the Kremer's prizes in human powered flight. Human power has additionally been observed to

be particularly great at giving vitality age in segregated circumstances.

2.3 The Potential of Human Power:

At the point when the energy in of humans is considered, a vast potential appears to be evident.

Considering the standard 2000kcal of daily food utilization (97W of power in, overall), humans

take in around 8.368MJ or 2324Wh of energy each and every day. This is roughly a similar

measure of energy stored in the normal auto battery (2400Wh). This energy can be utilized

using human powered devices.

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2.4 Pedal Power Cutting Machine:

In this project, we are going to design and fabricate a metal-wood cutting machine which is

operated with the help of human assistance, in other words our objective is to construct a human

powered metal-wood cutting machine. This arises question in our minds that in this era of

technology in which machines are being automated and being relieved of human intervention

why we have taken a step backward and made a machine which operates or functions with the

help of human power. The answer to this question is that in a country like

Pakistan which is classified as a third world country is suffering from severe power shortages.

Around 30 million people in different areas of Pakistan are living without electricity and their

electrification may take several years, the people associated with the program say. The goal

“Electricity for All” was to be achieved by 2007 by electrifying all the villages in Pakistan, but

the financial and power supply shortages are the major reasons behind the non-achievement of

this goal. A data reads that out of 125,000 villages in Pakistan, around 95,000 have been

electrified and some 30,000 villages are still to be electrified. By determining average

population of a village as 1,000, the number of persons living without power in Pakistan in 21st

century is touching 30 million. Lack of electricity in the areas means the people are living

without televisions, fridges, mobile phones and other necessities of life in the 21st century.

Regions in Pakistan even lack the basic facility of electricity due to which people living there

are unable to get advantage from the latest appliances which work on electricity. In these

regions cutting of metal by using hands which take large time for the habitants. To provide them

facility of a cutting machine which doesn’t required electricity. Our cutting machine provides

solution to the people living in remote areas of Pakistan which are deprived of basic facility of

13
life i.e. electricity. In short words, this cutting machine is a blessing in the disguise for the poor

people.

Secondly the reason for designing and fabrication of this type of machine was that it was

earlier told in the paragraph that we live in a third world country which is deprived of basic

facilities so people are generally illiterate and have less knowledge of operating machines so

this kind of cutting machine which only operates with the help of human power is of great

benefit for such people.

Third reason for designing and fabricating this kind of cutting machine is that it provides

opportunity for people to exercise. In this modern or fast world people have limited time to

exercise which is leading to increase in weight of the people. Lack of exercise is the source of

many diseases in the human body. This kind of cutting machine provides great source for

exercise which burns the calories and prevents lot of diseases. Exercise keeps a person healthy

and fit, cutting machine is of great advantage for the people. Burning of calories by doing

different activities is shown in table:

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 Table 1 calories burning chart by doing different activities

These all reasons contribute for the design and fabrication of such cutting machine which is of

great use for humanity. As explained earlier the cutting machine is machine which targets

people living in the third world countries such as Pakistan in which remote areas lack basic

facilities such as electricity and people here are generally illiterate who have less knowledge of

operating machines which are highly automated and difficult to use for such people. It also

generally targets people of middle and lower middle-class families who are not capable of

buying such expensive machines. The cost of the human powered cutting machine is

approximately 6-8 thousand which is in limit of such families as compared to the modern power

hacksaw which are highly expensive and are in 35-70 thousand range which cannot be bought

by everyone. Another advantage of these kind of machine as explained earlier is that they

provide source of exercise for people who are deeply involved in their work throughout the day
15
and don’t have enough amount of time for exercise. [18] Exercise is really essential for human

life. These all factors contribute in our idea for designing and fabricating such kind of cutting

machine.

This machine will easily cut wood piece of 30-40 mm diameter within 10-20 sec, and metal

piece of 26mm approximately in 7 min. Quality of machine is that it provides very smooth and

aligned cut.

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 CHAPTER 3 DESIGN

METHODOLOGY

3.1 Design decription:

Machine Sub-Systems

Energy Unit Transmission Unit Cutting unit

The major functions of the machine fall into three sub units: the energy unit, the transmission

unit, and the cutting unit. Energy unit is composed of pedal crank assembly used to manually

power the machine. The transmission unit is made up of chain drive transmission arrangements

which involve the chain running over a pair of sprockets as front & Rear sprockets. This unit

also has the crank disc directly attached to a rear sprocket, connecting rod and slider assembly.

The cutting unit contains of hacksaw frame, blade and the vice.

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3.1.1 Design parameters:

• The machine should be right for general manufacturing capabilities.

• The accessory should take up low-cost materials and manufacturing Processes.

• It should be available and inexpensive by low income groups, and should accomplish

their basic requirement of mechanical power.

• It should be simple to assemble, function, retain and restore.

• It should be as multi-function, providing power for a variety of operations used in

workshops and for small machines used in rural trade.

• It should make use of typical bicycle parts everywhere possible.

• Care must be taken up to assure that the power take-off assembly is far enough ahead

so as not to obstruct with pedaling. Most typical bicycle frames have ample of room for

the power take-off system and pulley.

• Too much load should be avoided, as strength is a main consideration.

3.2 Material selection:

a) Pedal Crank

Two pedals are set to form a couple through a pedal shaft. In action, the pedals and their shaft

are stressed out due to burden of the worker as he uses his feet and leg to turn around the pedal

18
about the crank axel. Therefore, in sort to protect against breakdown, the diameter of shaft is

determined from

Where, dp is the pedal shaft diameter, F is the maximum force preferred which worker may use

in pedaling, and τ is the torsional shear.

b) Sprocket Design

The number of teeth on both front & rear sprockets were measured, based on the transmission

ratio required between the front and rare sprocket, using a below Equation

Where, i=1.2 is the transmission ratio, z1 is the number of teeth on driven sprocket/ and z2 is

the number of teeth on driving sprocket sprocket

c) Chain Design

Chain drive full length was resolute by using the design equation (Jayakumar 2012, 40) as:

where, LCD is the length of chain, an is the inside separation between tomahawks of greater

sprocket and pinion and ‘a’ is the chain pitch

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 d) Bearing Selection
The pedal shafts at the greater sprocket and the pinion gone through heading at the two finishes

of each pole amid activity of the machine. The fundamental load evaluations were resolved

utilizing the condition,

where, Cb is the essential dynamic load rating, We is the equal load, Ld is the plan life of

bearing to fill machine need (Khurmi and Gupta 2008), z is a steady for all course and Nd is

unrest every moment of shaft..

e) Hacksaw-Blade Selection

The hacksaw sharp edge which plays out the cutting amid machine activity is relied upon to

slice through work piece between 10-30 mm thick. Consequently, a rapid steel hex cutting edge

of measurement 350 mm × 25 mm × 1.25 mm×2.5mm was chosen. The aggregate length of

hacksaw outline did not surpass 350 mm

f) Connecting Rod Design

The partner shaft is one a player in the machine which ensures that rotational development of

the turning circle is gotten as reacting development by the hacksaw in a torque and slider

instrument. The bar is subjected to compressive power in the midst of assignment of the

machine. The power yielded in the forward advancement of the hacksaw against the workpiece
20
may tend to catch the bar with its fair-minded center point. Likewise, remembering the ultimate

objective to shield against catching, the cross-sectional domain, an is settled from condition:

where, Wbk is the clasping load following up on associating bar, k is the range of gyration

between the turning circle and the pivoted end of the pole, σc is the devastating worry of gentle

steel material, an is the Rankine's consistent and Lh is the length of interfacing pole., g)

Rotating Disc Design

The rotating plate is the part controlled by methods for the pinion shaft from the transformation

of the pinion at the opposite side of the circle. It is the torque which changes over this

development to a reacting development required by the hacksaw. The thickness of the plate

measures up to that of the interfacing bar with a separation crosswise over of 210 mm.

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3.3 Drawing:

Figure 3 Blade fitting support

Figure 4 Slider support

22
Figure 5 Base Frame

Figure 6 Pedal shafts

23
 Figure 7 Crank disc

Figure 8 Connecting rod

24
 CHAPTER 4

EXPERIMENTATIONS OR SIMULATIONS

4.1 Experimental procedure:

It involves the pedal game-plan which turns the torque and through it slider contains influencing

instrument. The power is transmitted to the torque and slider segment. This framework is used

to turn the torque plate; the circle which is having an extended bar is related with the sliding

piece of the hacksaw clearly by techniques for a linkage. The hacksaw is experienced the guide

courses by strategies for keeping up the cutting turn. As the customer worked the pedal, the

hack saw cuts the distinctive materials therefore with less power. The dead weight is for

compressive power while the customer worked the foot pedal.

4.1.1 Working Methodology:

25
Figure 9 Frame design

26
Figure 10 Large sprocket

Figure 11 Small sprocket

27
 Figure 12 Crank disc

Table 2 Number of strokes and time taken to completely cut a metal rod

Table 3 Cutting depth and the time taken to cut the various wood pieces

28
29
 CHAPTER 5

RESULTS AND FINDINGS CHAPTER 6

CONCLUSIONS & FUTURE RECOMMENDATION

6.1 Conclusion:

The advancement of the pedal controlled hacksaw has been effectively finished and its goals

completely accomplished. It is vital to take note of that plan and improvement of the pedal

fueled hacksaw was based on the materials locally accessible. The result of the venture was

effective, as it requires little upkeep what's more, the machine can be worked helpfully by

individuals of various statures since both the seat and handle are customizable, hence making

it ergonomically compelling. All the more thus, the machine can be utilized when there is

control blackout and in remote territories and there is simplicity of task which makes it simple

for any individual to work independent of his/her instruction foundation as it doesn't require a

preparation permit. The pedal controlled hacksaw isn't costly or not too substantial yet has the

required quality and ability to work with little vibration and the machine can cut materials

quicker than when hand is utilized for cutting.

Hence with a minimal effort and straightforward outline pedal worked human powered hack

saw machine is manufactured. This machine lessens the human exertion and henceforth we

require one person to cut the wooden as well as metals. This basic plan which can upgrade day

today family unit needs and day by day everyday purposes and it can be additionally utilized as

a part of for mechanical applications amid control close down situations. By utilizing this

strategy we can do any activity according to our necessity without the utilization of power. So

we can spare the electrical control.

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6.2 Future recommendation:

Followings are the different types of a operation that can be carried out by the proper Human

powered attachment as per the requirement including.

Figure 13 Human powered bands saw

Figure 14 Human powered apple grinde

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Figure 15 human powered compost chipper

Figure 16 Human powered Thresher

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 CHAPTER 7
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Fabrication of Pedal Powered Circular Saw for Wood Working Applications,

International Journal of Current Engineering and Technology, 16 April 2016, Vol.6,

ISSN 2277 – 4106

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