International Journal of Advances in Engineering and Management (IJAEM)

Volume 6, Issue 05 May 2024, pp: 1059-1065 www.ijaem.net ISSN: 2395-5252

Design and Fabrication of a Pedal Driven

Hacksaw Machine
1
Lawal A. S1
Department of Mechanical Engineering, Ekiti State University Ado Ekiti, Nigeria,
----------------------------------------------------------------------------------------------------------------------------- ---------
Date of Submission: 18-05-2024 Date of Acceptance: 28-05-2024
----------------------------------------------------------------------------------------------------------------------------- ---------
ABSTRACT of the outcomes included an array of new drilling
Metal fabrication is a value added process that machines, but their heydays were over fast. These
involves the construction of machines and human-powered tools were not only a vast
structures from various raw materials. This study improvement over those that came before them;
involved a larger sprocket which rotates with help they also had many advantages in comparison to
of human powered pedal. The smaller sprocket is the power drills that we use today (Khope et.al.,
connected to the plane which is mutually 2013).Human powered tools and machines have
perpendicular to the axis of the larger sprocket is been viewed as an obsolete technology ever since
made to rotated by using chain drive. The smaller the arrival of fossil fuels and electricity. This
sprocket is rigidly supported by means of shaft and makes it easy to forget that there has been a great
bearing support. The circular frame is mounted on deal of progress in their design, largely improving
the same shaft where the smaller sprocket is their productivity.
mounted. When the pedal is operated, circular The most efficient mechanism to harvest
frame rotated which in turn cuts the mild steel, human energy appeared in the late 19th century:
copper and Poly Vinyl Chloride material. The main pedaling. Stationary pedal powered machines went
aim is to reduce the human effort for machining through a boom at the turn of the 20th century, but
various materials such as mild steel, copper and the arrival of cheap electricity and fossil fuels
Poly Vinyl Chloride etc. The pedal powered abruptly stopped all further development (Gite
machine which runs on human power, works on the et.al., 2011).The cleverest innovation in applying
principle of the conversion of rotational motion in a human power to rotary motion only appeared in the
mutually perpendicular axis (Crank and Slider 1870s. Some of us still use it as a means of
Mechanism). The Pedal operated hacksaw machine transportation, but it is rarely applied to stationary
was successfully tested after development for the machines anymore: pedal power. Initially, pedals
speed of 50, 70 and 90 rpm and its shows cutting and cranks were connected directly to the front (or
time of 70% less than that of human time. The sometimes rear) wheel. With the arrival of the
machine is cost effective compared to electrically 'safety bicycle' shortly afterwards, this direct power
powered hacksaw machine. Also, the machine transmission was replaced by a chain drive and
consumes no electricity at all, which is a major plus sprockets still the basics of most present day
and it has simple design, reliable, and can be used bicycles. Pedal power did not come out of the blue
where electric supply is not available, particularly because some of the first bicycles were equipped
in rural areas. The machine operates with the with treadles, which could be considered the
mechanical efficiency of 72.9% and mechanical predecessor of the pedal.
advantage of 0.47. Pedal power is the transfer of energy from
Keywords: machine, sprocket, pedal, hacksaw, a human source through the use of a foot pedal and
mechanical efficiency, mechanical advantage. crank system. This technology is most commonly
used for transportation and has been used to propel
I. INTRODUCTION bicycles for over a hundred years. Less commonly
Hand-powered devices have been used for pedal power is used to power agricultural and hand
millennia, but during the last quarter of the 19th tools and even to generate electricity. Some
century a radically improved generation of tools applications including pedal powered laptops,
appeared, taking advantage of modern mass pedal powered grinders and pedal powered water
production machinery and processes (like wells. Some third world development projects
interchangeable parts) and an increased availability currently transform used bicycles into pedal
in superior material (metal instead of wood). One powered tools for sustainable development
DOI: 10.35629/5252-060510591065 |Impact Factorvalue 6.18| ISO 9001: 2008 Certified Journal Page 1059
 International Journal of Advances in Engineering and Management (IJAEM)
Volume 6, Issue 05 May 2024, pp: 1059-1065 www.ijaem.net ISSN: 2395-5252

(Chaudhary et.al., 1986).On their own, pedals and The Pedal driven hacksaw works on slider
cranks did not offer a better mechanical advantage crank mechanism. The Pedal driven hacksaw is
than the hand crank, let alone the capstan or the used to cut ply wood in small scales. Pedal driven
tread wheel. What made pedal power so hacksaw helps to obtain a less effort uniform
revolutionary was that it offered the possibility to cutting. It can be used in places where electricity is
use the stronger leg muscles in a continuous motion not available. It is designed as a portable one which
while at the same time offering a much more can be used for cutting in various places. The main
compact mechanism than the capstan or the tread parts of Pedal driven hacksaw are hack saw,
wheel. Moreover, using the appropriate gear ratio a reciprocating rod welded to the pedal of a bicycle,
mechanical advantage similar to that of a capstan or flywheel, sprocket and chain drive. The hack saw is
a tread wheel could be achieved by multiplying connected with the reciprocating rod. By pedaling
torque at the expense of speed or vice versa. This the bicycle the reciprocating rod moves to and fro,
made pedal power suitable for a much larger the hack saw will be moving with the rod. The
variety of applications. plywood to be cut is placed under the hack saw on
In the world of pedal-power devices, most a work piece holder. Thus the plywood can be cut
devices fall into two categories: Electrical devices without any external energy like fuel or current.
and mechanical devices. Electrical devices often Since this uses no electric power and fuel, this is
have limited input current tolerance. Consequently very cheap and best.
Electrical elements (such as diodes and inverters -
available to purchase at a local electronic store or II. METHODOLOGY
online) are necessary to convert the current created The study entails selecting of some
into a current that your device can use. If these suitable fabrication materials such as round
elements are left out there is a good chance that you galvanized iron pipe and mild steel and also
will damage your device. The other consequence is developed a concept design of the structure.
that this configuration loses more energy in Analysis of the design (design calculations) was
translation than a mechanical device, especially if a carried out, after which the production and
battery is needed between the generator that creates fabrication process commences. Finally, the
your energy and your device. In other words, these machine was tested and overall performance
systems are less efficient as pedal-power devices evaluations were also performed.
than mechanical devices. Mechanical devices
typically have to be modified, possibly to the point Design and Fabrication Procedure
that it may be impossible to return it to its original The design and fabrication procedures followed in
condition. These devices include blenders, drills, this project are structured as below:
washing machines, etc. All of the energy put into
pedaling is translated directly into the action the
device's motor would have performed.

Source: Khurmi,2014.
Figure 1: Design and Fabrication Procedure

DOI: 10.35629/5252-060510591065 |Impact Factorvalue 6.18| ISO 9001: 2008 Certified Journal Page 1060
 International Journal of Advances in Engineering and Management (IJAEM)
Volume 6, Issue 05 May 2024, pp: 1059-1065 www.ijaem.net ISSN: 2395-5252

Step1: Calculation of Speed ratio


The block diagram representation of speed ratio(i) = 0.7  10 4
of the system.
A  7 10 5m 2
 2  1
Chain Velocity V  P  Z1  N1 / 60
Speed ratio i = Maximum Speed/Minimum Speed
(Khurmi, 2014)
i  N1 / N 2 
= 15.875  10 3  25  3000 / 60
 3000 / 1500 V = 19.84 m/s
i2 Service Factor KS 
Step2: Calculation of Number of Teeth K1  K 2  K 3  K 4  K 5  K 6
Z1  14 (Khurmi, 2014)
Z 2  42 Constant Load K 1  1.0
Fixed Centre Distance
Step3: Calculation of Pitch Value P K 2  1.25
A  30  P (Kalaikathir,
a p  30 to50 P
2014)
560  30  P K3  1
Position up to 60
Pitch P = 18.67 mm
A  50  P
K4  1
560  50  P Drop Lubrication
Pitch P = 11.2 mm K 5  1 .0
Ranges from 11.2 to 18.67 Single Shift K6 = 1.0
K s  1.25
Step4: Selection of Chain
Based on Pitch Value we selected ‘R50’ Power N =
  
(Kalaikathir, 2014) (18 .56  10 6)  (7  10 5)  19 .84 / 10 2  1.25
Step5: Calculation of Total Load Power N = 988 kW
Total Load  P  Pt  Pc  Ps 
Tangential Force Pt  10 2  988 / 19 .84
(Kalaikathir, 2014) = 5079.43 kgf
Tangential Force Pt  10  2  N / V Pt = 49.82 kN
Tension due to Sagging of Chain
Power N = AV / 10 2  KS

Ps  K  W  a
(Kalaikathir, 2014)
 Coefficient of Sag K= 6 (Kalaikathir,
Stress = 1.85  9.81/ 10 6

2014)
Stress = 18.15  10 6 N / mm
2
Weight per meter W= 1.01 kgf
Bearing Area A  0.7cm
2 (Kalaikathir, 2014)
(Kalaikathir, 2014) W = 9.91 N

DOI: 10.35629/5252-060510591065 |Impact Factorvalue 6.18| ISO 9001: 2008 Certified Journal Page 1061
 International Journal of Advances in Engineering and Management (IJAEM)
Volume 6, Issue 05 May 2024, pp: 1059-1065 www.ijaem.net ISSN: 2395-5252

Tension due to Sagging e = 70.55 mm

Ps  6  9.91  0.56 m = (Z2-Z1/2Л) 2
= (50-25/2Л) 2
= 33.29 kgf m = 15.83
Ps= 326.64 N Centre Distance
Centrifugal Tension
Pc  W  V 2 / g a  70.55  [ 70.55  (8 15.85) ] 15.875 / 4
2

= 9.91  19.84 / 9.81

2
a = 557.93 mm
= 397.63 kgf
Pc = 3.9 kN Step10: Calculation of Sprocket Diameter
Total Load  P  Pt  Ps  Pc d1  P / sin(180 / Z1 ) (Khurmi, 2014)
 
= (49 .82  10 3)  326 .64  (3.9  10 3) = 15.875 / sin(180 / 25)
ΣP= 54.05 kN d1 = 126.66 mm
d 01  d1  0.8d r
Step6: Calculation of Design Load
P  K
(Khurmi, 2014)
Design Load = s = 126.66  (0.8  10.16)

= (54 .05  10 3)  1.25 d01= 134.78 mm
Design load = 67.56 kN
d 2  P /(180 / Z 2 )
Step7: Calculation of Factor of Safety FSw = 15.875 / sin(180 / 50)
FSw = Breaking Load/Design Load d2 = 252.82 mm
Breaking Load d 02  d 2  0.8d r
Q = 2220 kgf (Kalaikathir, 2014) = 252.82  (0.8  10.16)
= 2220*9.81
= 21.77 kN d02=260.94 mm
FSw = 21.77/67.56
FSw = 0.32
3.2.3.2 Design of Ball Bearing
Step8: Calculation of Chain Length
Length of Chain = l p  P Axial Load Fa = 1000 N

(Kalaikathir, 2014) Radial Load Fr = 1500 N

Length of Continuous Chain in Multiple of Pitches Speed N = 1500 rpm
l p  2a p  ( Z 1  Z 2 / 2)  [( Z 2  Z 1 / 2 JI )2 / a p ] Life in hours = 15000 hrs
(Kalaikathir, 2014)
Calculation of Radial and Axial Force
Approximate Centre Distance
Step1: Axial Load Fa = 1000 N
a p  a / P
(Kalaikathir, 2014) Radial Load Fr = 1500 N
= 560/15.875 Step2: Calculation of Fa / Fr
ap = 35.27
Axial Load/Radial Load
lp= (2*35.27) + (25+50/2) + [(50-25/2Л)2/35.27]
lp = 108.05 mm = Fa / Fr
Length of Chain L = 108.05*15.875 = 1000/1500
L = 1.72  m = 0.667
Step3: Selection of Bearing
Step9: Exact Centre Distance Speed N = 1500 rpm (Kalaikathir,
2014)
Centre Distance a  [e  (e 2  8m)  P / 4] Bearing of Basic Dimension, „SKF 6236‟
e  l p  (Z1  Z 2 ) / 2
= 108.05-(25+50)/2
DOI: 10.35629/5252-060510591065 |Impact Factorvalue 6.18| ISO 9001: 2008 Certified Journal Page 1062
 International Journal of Advances in Engineering and Management (IJAEM)
Volume 6, Issue 05 May 2024, pp: 1059-1065 www.ijaem.net ISSN: 2395-5252

Step4: Calculation of Static and Dynamic Load

Carrying Capacity Ideal Mechanical Advantage (I.M.A.) of the
For „SKF 6236‟ machine
Static Load Rating = 204000 N
(Kalaikathir, 2014)

Dynamic Load Rating C = 76000 N
(Kalaikathir, 2014)  in

= out
Step5: Calculation of Fa / C ratio
Axial Load /Static Load Rating So, using N in  120 rpm (Stephen et al., 2015)
= Fa/C* 2N in
= 1000/204000  in 
= 0.0049 60
2  3.142  120
Step6: Selection of e Value
e = 0.22 (Kalaikathir, 2014)
in 
60
Step7: Selection of Radial Load Factor and Thrust = 12.568rad/s
Load Factor
Radial Load Factor X = 0.56
 in
(Kalaikathir, 2014) I.M.A = 
out
Thrust Load FactorY = 2
in
(Kalaikathir, 2014)   out 
Step8: Selection of Service Factor IMA
Rotatory Machine with No Impact 70
(Kalaikathir, 2014) IMA=  0.47
Service Factor S = 1.5 150
Step9: Calculation of Equivalent Load P 12.568
Load P = [( X  F )  (Y  F )]S
out   26.74rad / s
0.47
(Kalaikathir, 2014) The output rotational speed of the
= [(0.56*1500) + (2*1000)] 1.5 flywheel=26.74rad/s
Load P = 4260 N The Power output, P = Fc  V
Step10: Selection of C/Pratio
C/P = 11.5(Kalaikathir, 2014) Where Fc =centrifugal force on the flywheel
C = 11.5  P V=linear velocity
= 11.5  4260 ButV =  out x r
C = 48990 N
Step11: Check for Selected Bearing Where r = radius of flywheel.
Calculated C Value= 48990N So, using the weight of an average man say 60-
Standard C Value = 176000N 75kg and 15kg mass of flywheel
Selected Bearing „SKF 6236‟ D3
Design is Safe But flywheel radius(r) =
2  1000
Step12: Calculated of Expected Life in hours
 160
Expected Life L  (60 nLn ) / 10 6 = =0.08m
2  1000
= (60  1500  15000)/10  6
V  26.74  0.08
L = 1350 million revolution
V  2.14m / s
And Fc  m r
2
3.2.3.3 Torque and Power Calculations
Design Data: Human energy expended say 70kg
= 15  26.74  0.08
2

person: for cycling at 15km/ hr (

=858.03N
16  24km/ hr ) = 1.62kJ / kg , the average
 The Power, P  Fc  V
cycling speed = 15.5km/ hr (Stephen et al., 2015)
the cycling speed in rpm = 120rpm (Stephen et  858.03  2.14  1836.19W
al., 2015).  The Torque, T  Fc  r
DOI: 10.35629/5252-060510591065 |Impact Factorvalue 6.18| ISO 9001: 2008 Certified Journal Page 1063
 International Journal of Advances in Engineering and Management (IJAEM)
Volume 6, Issue 05 May 2024, pp: 1059-1065 www.ijaem.net ISSN: 2395-5252

 858.03  0.08  68.64Nm 100

=
3.2.3.4 Efficiency
155
V.R= 0.645
Ideal Mechanical Advantage (I.M.A.) of the
The Mechanical Efficiency of the machine=
machine =
IMA
 100%
V .R
=
0.47
 100%
70 0.645
=
150 = 72.9%
I.M.A. =0.47
Performance Evaluation
The machine was tested for three different
materials (mild steel pipes, wood and PVC pipes).
The ideal mechanical advantage of 0.47, power
output of 1836.19W and efficiency of 72.9% makes
it very adequate and efficient as a useful machine
for exercise and as a cutting machined compared to
the existing ones.

Table 4.1: Comparison of cutting time of different materials of 16mm diameter shaft
Speed(rpm) Time(in seconds)
Mild Steel Wood PVC Pipe
50 76 57 46
70 62 43 33
90 53 38 25

Mild Steel: Density; Hardness= 120 BHN

3
PVC pipe: 1467 kg / m ; Hardness= 80 BHN

Graph of speed(r.p.m) versus Time(seconds)

80
70
60
Time(in seconds)

50
40 Mild Steel
30 Wood
20 PVC Pipe
10
0
50 70 90

Speed(in r.p.m)
Figure 2: the graph of speed versus Time

DOI: 10.35629/5252-060510591065 |Impact Factorvalue 6.18| ISO 9001: 2008 Certified Journal Page 1064
 International Journal of Advances in Engineering and Management (IJAEM)
Volume 6, Issue 05 May 2024, pp: 1059-1065 www.ijaem.net ISSN: 2395-5252

It can be observed from the graph that as [7]. Kalaikathir, A. (2014). Design Data, Data
the speed (in r.p.m) increases from 50 r.p.m to 70 book of Engineers, (ISBN 978-81-
r.p.m the cutting time decreases (fig 2).This is 927355-0-4, Compiled by PSG College of
because as the hardness of the material increases Engineering and Published in Coimbatore,
the time required to cut the work piece increases. India).
The time required to cut the same work piece with [8]. Khope, P.B. andModak J.P. (2013).
hacksaw machine is less than half of that time “Development and Performance
required to cut directly by hacksaw Evaluation of a Human Powered Flywheel
Motor Operated Forge Cutter.”
III. CONCLUSIONS international journal of scientific &
The Pedal operated hacksaw machine was technology research (volume 2, issue 3,
successfully tested for the speed of 50,70 and 90 March).
rpm and shows cutting time 70% less than that of [9]. Khurmi, R.S. and Gupta J.K. (2004).
human time. The machine is cost effective Machine Design, 4th Edition.
compared to electrically powered hacksaw [10]. Khurmi, R.S. (2014). “Design of Machine
machine. Also, the machine consumes no Elements”, (Eurasnia publishing house 3
electricity at all, which is a major plus point. The Pvt Ltd, 14th revised edition).
machine is simple in design, reliable, and can be [11]. 111
used where electric supply is not available, [12]. Kirthikumar,D.C. (2013). “A Research on
particularly in rural areas. The machine operates Multi-Purpose Machine”, International
with the mechanical efficiency of 72.9% and Journal for Technological Research in
mechanical advantage of 0.47. Engineering (Vol.1, Issue.1, ISSN: 2347-
4718).
REFERENCES [13]. Linxu, W., Jingyu R., and Qiang L.(2011).
[1]. Adarsh, R., Kushagra, S. and Sudeep, M. “Design and Implementaion of the
(2014).”Design and construction of a Reciprocating Pedal Powered Electricity
Pedal Powered Washing Machine Generating Device”, Advanced Materials
(PPWM)”, International Journal of Research (Vol.282-283 pp 735-738).
Scientific & Technology Research [14]. Prasad, A., Hatwalne, Sushil T.,
(Volume 3, Issue 11 ISSN 2277-8616). Ambadkar, Vivek R. and Wankhade,
[2]. Amos, W. (2015). “Design of A Bicycle A.M.(2011). “Design and development of
Peddle Operated Grain Mill”. Pedal operated flour mill.” New York
[3]. Bahaley,S.G., Awate,A.U. Science Journal.
andSaharkar,S.V. (2012). “Performance [15]. Stephen, Tambari, Dan O.G., Ruene W.
Analysis of Pedal Powered Multipurpose and Ayejah V. (2015).IOSR Journal of
Machine”, International Journal of Mechanical and Civil Engineering (IOSR-
Engineering Research and Development JMCE) e-ISSN: 2278-1684 P -ISSN:
(IJERD) (Vol.1, Issue.5, e-ISSN: 2278- 2320-334X, Volume 12, Issue 4, PP 48-52
0181). www.iosrjournals.org.
[4]. Carlos, M., Henry G. and Maya, P. [16]. Vishal, G., Neelesh K. and Gautam Y.
(2010).“Design & Realisation of a pedal (2013). “An Experimental Setup and
powered mill”. Design of Pedal Powered Water Pump”,
[5]. Chaudhary,P. (1986). “Understanding International Journal of Engineering
pedal power” ISBN: 0-86619268-9 [C], Research and Technology (Vol.2, Issue.1).
Volunteers in Technical Assistance
Technical paper 51 VITA 1600 Wilson
Boulevard USA.
[6]. Gite, L.P., Pandey, M.M., Shrivastav,
A.K. and Tiwari, P.S. (2011). “Pedal
power for occupational activities: Effect
of power output &pedaling rate on
physiological responses”. International
journal of Industrial Ergonomics; pp. 261-
267.

DOI: 10.35629/5252-060510591065 |Impact Factorvalue 6.18| ISO 9001: 2008 Certified Journal Page 1065