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Beam Engine Hack Saw
Beam Engine Hack Saw
PROJECT TITTLE
Abstract :
In this project, the output of a Beam Engine is used to drive a reciprocating saw to cut timber.
Here, instead of the rotating fly wheel, it is intended to have a rotating reciprocating saw. This
rotating reciprocating saw is used to cut timber. Reciprocating saws driven with electric power
are a common feature. But in places where electricity is scarce, or absent, it is difficult
to operate these equipments. But since the Beam Engine powered saw runs on fuel, it can be
operated even in places where electricity is totally absent. A beam engine is a design of
stationary steam engine [1]. A stationary engine is an engine whose framework does not move
[2]. Usually, a stationary engine is used not to propel a vehicle but to drive a piece of immobile
equipment such as a pump or power tools [4]. In a beam engine, the piston is mounted
vertically, and the piston rod does not connect directly to the connecting rod, but instead to
a rocker or beam above both the piston and flywheel. The beam is pivoted in the middle, with the
cylinder on one side and the flywheel, which incorporates the crank, on the other. The
connecting rod connects to the opposite end of the beam to the piston rod, and then to the
flywheel [1].
BEAM ENGINE POWERED HACKSAW
INTRODUCTION:
A beam engine is a type of steam engine where a pivoted overhead beam is used to apply the
force from a vertical piston to a vertical connecting rod. This configuration, with the engine
directly driving a pump, was first used by Thomas Newcomen around 1705 to remove water
from mines in Cornwall . The efficiency of the engines was improved by engineers
including James Watt who added a separate condenser, Jonathan Hornblower and Arthur
Woolf who compounded the cylinders, and William McNaught (Glasgow) who devised a
method of compounding an existing engine. Beam engines were first used to pump water out of
mines or into canals, but could be used to pump water to supplement the flow for a waterwheel
powering a mill .
The rotative beam engine is a later design of beam engine where the connecting rod drives
a flywheel , by means of a crank (or, historically, by means of a sun and planet gear ). These
beam engines could be used to directly power the line-shafting in a mill . They also could be
used to power steam ships .
BEAM ENGINE POWERED HACKSAW
As mentioned earlier the motivation for this project being the course ME 637, the course
required each student to submit a project using the Pro-E modeling tool and the instructor
emphasized that the project should be creative and something new. This made me think about
something new and finally I arrived at the Beam Engine idea. The word “power tools” caught my
attention and I just started to think why not I use a beam engine to drive a circular saw to cut
timber. While electric powered saws are a common feature as also diesel and gasoline powered
saws, a saw that works on the principle of a beam engine is something that I thought of. This
saw, which can run either on diesel or gasoline, can be used in places where electricity is sparse
or absent.
BEAM ENGINE POWERED HACKSAW
1. Idea generation.
2. Idea screening.
3. Concept development & testing.
4. Market strategy development.
5. Business Analysis.
6. Test Marketing.
7. Commercialization
People always welcome change and new product development is an opportunity for the firms to
meet the changes in consumer demands.
They are a source of competitive advantage. Your new product may infuse a fresh lease of life to
your sagging profits.
BEAM ENGINE POWERED HACKSAW
New products may turn out to be the star performers of your firm and provide long term financial
return on your investment.
Some firms take the smart strategic choice of using the idle capacity of their plant for
manufacture of a new product that may utilize the existing production and operation resources to
an optimum level.
They capitalize on research and development. Products that create a wave are a result of research
on market trend and consumer preference. Firms can make it, if their research is customer-centric
rather than product-centric.
BEAM ENGINE POWERED HACKSAW
METHODOLOGY
DESIGN OF MACHINE:-
In our attempt to design a special purpose machine we have adopted a very a very careful
approach, the total design work has been divided into two parts mainly;
System design
Mechanical design
System design mainly concerns with the various physical constraints and ergonomics,
space requirements, arrangement of various components on the main frame of machine no
of controls position of these controls ease of maintenance scope of further improvement;
height of m/c from ground etc.
Design parts
Parts to be purchased.
For design parts detail design is done and dimensions thus obtained are compared to next
highest dimension which are readily available in market this simplifies the assembly as well
as post production servicing work.The various tolerances on work pieces are specified in the
manufacturing drawings. The process charts are prepared & passed on to the manufacturing stage
.The parts are to be purchased directly are specified &selected from standard catalogues.
Methodology can properly refer to the theoretical analysis of the methods appropriate to a field
of study or to the body of methods and principles particular to a branch of knowledge. In this
chapter, it talks about the methods use to gather information in order to finish the research. It was
involve the process flow of every step in archive the objective of this project. There are many
methods use in this project such as internet references, interviewing lecturers and technicians and
the most important is group discussion.
BEAM ENGINE POWERED HACKSAW
DIAGRAM : 1 METHODOLOGY
BEAM ENGINE POWERED HACKSAW
conceptual model
The mechanical properties of the metals are those, which are associated with the ability of the
material to resist mechanical forces and load. We shall now discuss these properties as follows:
A. Strength B. Elasticity
C. Stress D. Plasticity
E. Stress F. Ductility
G. Brittleness H. Malleability
I. Toughness J. Resilience
When a part is subjected to a constant stress at high temperature for long period Of time, it will
undergo a slow and permanent deformation called creep. This property is considered in
designing internal combustion engines, boilers and turbines.
BEAM ENGINE POWERED HACKSAW
Hardness
It is a very important property of the metals and has a wide verity of meanings. It embraces
many different properties such as resistance to wear scratching, deformation and mach inability
etc. It also means the ability of the metal to cut another metal. The
hardness is usually expressed in numbers, which are dependent on the method of making the test.
In engineering practice, the machine parts are subjected to various forces, which may be due to
either one or more of the following.
1. Energy transmitted
2. Weight of machine
3. Fictional resistance
5. Change of temperature
The selection of the materials depends upon the various types of stresses that are set up during
operation. The material selected should with stand it. Another criterion for selection of metal
depends upon the type of load because a machine part resist load more easily than a live load and
live load more easily than a shock load.
BEAM ENGINE POWERED HACKSAW
Selection of the material depends upon factor of safety, which in turn depends upon the
following factors.
1. Reliabilities of properties
A parameter study is done to evaluate the most crucial parameters for FE analysis of axial ball
bearings. The parameters that are evaluated are mesh density, contact stiffness, osculation, load
level, geometrical nonlinearity and material nonlinearity. The studies are performed by means of
the FE software Ansys. The accuracy of finite element analysis depends on different parameters
such as element type, boundary condition and how the loads are applied etc. Therefore the FE
model is nothing else but an approximate realization of the reality. The parameter study can be
done by physical tests. However it will increase the cost, time and resources consumed and
therefore FE analysis is more suitable choice, at least for parameter evaluation.
In this study the finite element method is adopted using Pro Engineer and Ansys as a commercial
CAD and FE program. The following chapter contains some fundamentals of the applied theories
provided that the reader has an initial knowledge of basic structural mechanics, machine
components, and fundamentals of the finite element method.
Finite element method (FEM) is a method for approximate solutions of partial differential
equations. The domain of interest is divided into finite elements on which the solution is
approximated by piecewise-polynomials. The finer the partition (Mesh) is, the more accurate the
solution.
Nonlinear analysis is used when a structure behaves nonlinear when loaded i.e. the deformation
and the stress state does not have a linear relation to the applied load. The three main sources to
BEAM ENGINE POWERED HACKSAW
nonlinear behaviors are: contact, geometric nonlinearities and material nonlinearities. In order to
manage such calculations with a linear process the Newton Raphson method can be used
Newton-Raphson is an iterative method for finding solution to nonlinear equations and equation
systems . In FE calculations the method is used for non-linear problems and the relations
between force and displacement is shown in Figure 2.1 for one degree of freedom. The
procedure for Newton-Raphson method is as follows: The load is applied and the displacements
are calculated. From the displacements new conditions are calculated and the displacements are
recalculated. This procedure is repeated until the solution is converged i.e. reach a certain value
or level.
Material nonlinearities
4.8 Ansys
Ansys is a commercial, general purpose FE software which has been on the market since 1971.
It can be used in several applications for example to study the thermal heat flow, fluid flow,
magnetic fields, acoustics/vibrations and last but not least structural mechanical problems.
A handful of ways to handle contact are available in Ansys. However, the one described here is
penalty based contact since it provides short calculation times and therefore is used.
When a penalty-based contact is used, Ansys adds a spring coefficient (k factor) when two
surfaces come in contact with each other, in order to prevent penetration and to transfer load.
(Figure 2.7) However penetration will occur in order to transfer force, which is not the case in
reality. Therefore the penalty-based methods are sensitive to the choice of the spring coefficient.
The spring coefficient Ansys uses during calculations is the product between the “normal
stiffness factor” specified by the user and a reference factor calculated by the program. An
additional aspect (apart from the accuracy) to consider when selecting the “normal stiffness
factor” is the convergence behaviour. A stiffer contact will result in more calculation iterations,
since bouncing might occur.
A contact condition can be either symmetric or asymmetric. When the contact condition is
symmetric none of the surfaces can penetrate each other, while when the contact is specified as
being asymmetric only one of the surfaces is prevented from penetrating the other i.e. the contact
surface can not penetrate the target surface but the opposite is possible. Figure 2.8 illustrates the
importance of selecting the correct contact pair.
In context of the license version used, Ansys tender a bilinear approximation of the stress-strain
relationship as in figure 2.9. The bilinear stress-strain curve requires two input values, yield
strength and tangent modulus. The yield strength is the value when plastics straining occurs and
the tangent modulus is the slope of the stress-strain curve after yielding.
BEAM ENGINE POWERED HACKSAW
Fig.10 Relationship Between Stress & strain, Bilinear curve in Red & True Material Relation in
blue
Ansys offers several tools to control the meshing procedure. The mesh densities of the whole
model can be controlled by global settings for relevance centre in three steps: coarse, medium or
fine.
4.14 Method
Method is a meshing control that provides the possibility to select different elements shapes.
The different elements that are available are: tetrahedron or quadrilateral. Tetrahedron elements
are triangular pyramid like elements with 10 or 4 nodes and quadrilateral elements are cube
elements with 20 or 8 nodes.
BEAM ENGINE POWERED HACKSAW
4.15 Sizing
Sizing is a meshing control that provides the possibility to mesh with different mesh densities at
selected regions. By meshing fine in the area of interest and using coarse mesh in the remaining
parts one is able to reduce CPU time and memory usage. There are a couple of ways to select
the region of a sizing control available in Ansys. The region can be a surface. This will produce a
fine mesh (or actually a mesh with the size specified) on the surface only. The region can also be
an entire body which will produce a fine mesh all over the body. If a contact region is to be
analysed, Ansys offers the possibility to specify the mesh size in the contact region. And to
capture a local behaviour it is possible to specify a so called sphere of influence which makes it
possible to set the element size (mesh size) within the volume of a sphere. The sphere of
influence can be used to enclose both faces and bodies.
BEAM ENGINE POWERED HACKSAW
In our attempt to design a special purpose machine we have adopted a very a very careful
approach, the total design work has been divided into two parts mainly;
System design
Mechanical design
System design mainly concerns with the various physical constraints and ergonomics , space
requirements, arrangement of various components on the main frame of machine no of controls
position of these controls ease of maintenance scope of further improvement ; weight of m/c
from ground etc.
Design parts
Parts to be purchased.
For design parts detail design is done and dimensions thus obtained are compared to next
highest dimension which are readily available in market this simplifies the assembly as well as
post production servicing work.
The various tolerance on work are specified in the manufacturing drawings the process charts
are prepared & passed on to the manufacturing stage .The parts are to be purchased directly
are specified &selected from standard catalogues.
BEAM ENGINE POWERED HACKSAW
While selecting any m/c it must be checked whether it is going to be used in large scale or
small scale industry in our care it is to be used in small scale industry so space is a major
constrain .The system is to be very compact it can be adjusted to corner of a room. The
mechanical design has direct norms with the system design hence the foremost job is to
control the physical parameters so that the distinction obtained after mechanical design can be
well fitted into that.
Keeping into view the space restriction the components should be laid such that their easy
removal or servicing is possible moreover every component should be easily seen & none
should be hidden every possible space is utilized in component arrangement.
The friendliness of m/c with the operation is an important criterion of design. It is application
of anatomical
The losses incurred by owner in case of failure of a component are important criteria of design.
Factor of safety while doing the mechanical design is kept high so that there are less chances of
failure there over periodic maintenance is required to keep the m/c trouble free.
The layout of components should be such that easy servicing is possible especially those
components which required frequent servicing can be easily disassembled.
The total weight of m/c depends upon the selection of material components as well as
dimension of components. A higher weighted m/c is difficult for transportation & in case of
major break down it becomes difficult to repair.
Mechanical design phase is very important from the view of designer as whole success of the
project depends on the correct deign analysis of the problem.
Many preliminary alternatives are eliminated during this phase. Designer should have
adequate knowledge above physical properties of material, loads stresses, deformation, and
failure. Theories and wear analysis, He should identify the external and internal forces acting
on the machine parts
BEAM ENGINE POWERED HACKSAW
b) Friction forces
c) Inertia forces
d) Centrifugal forces
Designer should estimate these forces very accurately by using design equations .If he does not
have sufficient information to estimate them he should make certain practical assumptions
based on similar conditions which will almost satisfy the functional needs. Assumptions
must always be on the safer side.
BEAM ENGINE POWERED HACKSAW
WORKING PRINCIPLE
When the piston in the cylinder reciprocates, it imparts an oscillating motion to the rocker arms,
as shown in figure 1 on page 2. This oscillating motion of the rocker arm is converted
into rotary motion by the crankshaft. The crankshaft, which is connected to the circular saw,
makes the circular saw rotate. This rotary action of the circular wood saw is used to saw timber
or wood blocks. There is a small table attachment for supporting the wooden block. The wooden
block is placed on the table and pushed towards the rotating wood saw, which results in the
sawing action. The main advantage of this machine is that it can be used in places where
electricity is not economical or in places where electricity is absent.
EXPERIMENTAL SETUP :
A beam engine mechanism is one where we use an overhead beam to create motion. Here we use
a beam engine motion based assembly in order to achieve hack saw cutting motion using a
circular cutting disc. Our system uses a motorized disc to drive a connector which is in turn
connected to an overhead beam. The overhead bean has a connecting rod in turn connected to a
mini hacksaw blade. When the motorized disc below is turned on the connecting arm starts
reciprocating the overhead beam. This beam now heals achieve a back and forth cutting motion
as required by the hacksaw blade.
We construct a small bed in order to rest the work piece to achieve desired cutting. Thus we
study the design and fabrication of mini hacksaw using beam engine mechanism.
BEAM ENGINE POWERED HACKSAW
The objective of this work is to automate the conventional power hacksaw machine in
order to achieve high productivity of work-pieces than the power hacksaw machine using
pneumatic power. Pneumatic is a huge topic of science and engineering dealing with the
mechanical properties of air. In our project we take this pneumatic and a hacksaw for
cutting purpose, The pneumatic reciprocating high- speed hacksaw machine has an
advantage of working in high pressure , the hacksaw used in this is reciprocate such that
required shape can be cutted according to the requirement. The hacksaw is the metal
cutting machine tool designed to cut metal by applying pneumatic pressure. Hacksaws are
used to cut thin and soft metals the operation of the unit is simplified to a few simple operations
involving a cylinder block and piston arrangement. There are numerous systems in hacksaw
machine.
The hacksaw is the metal cutting machine tool designed to cut metal by applying
pneumatic pressure. The machine exclusively intended for mass production and they
represent fasten and more efficient way to cut a metal. Hacksaws are used to cut thin and
soft metals the operation of the unit is simplified to a few simple operations involving a
cylinder block and piston arrangement. There are numerous systems in hacksaw machine
.The main function of pneumatic hacksaw is to cut thin and soft metals by pneumatic power.
BEAM ENGINE POWERED HACKSAW
System Drawings
BEAM ENGINE POWERED HACKSAW
BEAM ENGINE POWERED HACKSAW
Bill of material
ADVANTAGES
1. The cutting speed can be varied according to our needs by adjusting the timer.
2. It is portable.
5. It is compact one.
6. Less maintenance.
BEAM ENGINE POWERED HACKSAW
LIMITATION
APPLICATION
2. It useful when materials need to be cut in hazardous areas such as oil & gas refineries,
chemical factories or oil rigs as well as dusty and wet environments where electric tools
fiberglass workshops, because they will last longer than electric tools.
BEAM ENGINE POWERED HACKSAW
CONCLUSIONS
This being a creative project, there are no particular instances of this type of machine
being available in the commercial market. But the aim of this project is to show that
this type of machine too is an option for wood working industry in remote places in the
absence of electricity. Further improvements include using reduction gears, to vary the speed of
the circular saw, having an adjustable bed with slots for adjusting the table length, so that even
large sizes of timber can be sawed by varying the distance of the table and the size of the circular
saw.
BEAM ENGINE POWERED HACKSAW
REFERENCES
[1] http://en.wikipedia.org/wiki/Beam_engine
[2] http://www.answers.com/topic/stationary-engine
[3] http://www.keveney.com/unkbeam.html
[4] http://en.wikipedia.org/wiki/Stationary_engine