PNEUMATIC HACKSAW

ACKNOWLEDGMENT

We forward our gratitude to the SRI D.PHANEENDHRA PRASAD,

MTECH, principal, Govt polytechnic, Visakhapatnam, for extending the
official support for the progress of the project.

We avail ourselves of this opportunity to express our sense of

gratitude to SRI Dr.R.BHASKARA RAO, PH.D, Head of mechanical
engineering section, for undertaking the initiative of providing the necessary
infrastructure and for being the stepping stone of our project work and also
for the encouragement and appreciation he always gives us.

We wish to express our profound gratitude to our beloved guide

SRI.U.RAVINDRANATH, M.E, Senior lecturer, mechanical department,
who has been a great source of inspiration and encouragement. We are
indebted to our guide for his valuable suggestions, impeccable advises and
for his indefatigable zeal towards us from all kind of difficulties. We
profusely thank our guide for his guidance for completing this project work
successfully.

Our utmost sincere and grateful acknowledgement to our Govt

polytechnic, Visakhapatnam for giving us a chance to fulfil our aspirations.

We are thankful to the teaching and non teaching staff of our staff
that helped us directly or indirectly in completion of this project.

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CONTENTS

1. ABSTRACT

2. INTRODUCTION

3. WHAT IS TO BE ACHIEVED

4. BASIC CONCEPTS OF PNEUMATICS

4.1 Introduction to Pneumatics

4.2 Advantages And Limitations of Pneumatics
4.3 Pneumatic Components with symbols
4.4 Pneumatic Actuators

5. PROJECT DETAILS

5.1Project Description
5.2 Components Used
5.3 Estimation
5.4 Circuit Diagram
5.5 Advantages & Limitations of Pneumatic Hacksaw

6. CALCULATION OF CUTTING FORCE

7. BREAK EVEN ANALYSIS

8. FUTURE SCOPE

9. CONCLUSION

10. BIBLIOGRAPHY

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INDEX OF FIGURES:

S.NO FIG.NO NAME PG.NO

1 4.1 Basic components of pneumatic systems 11
2 4.2 Air compressor 14
3 4.3 Pneumatic filter 15
4 4.4 Lubricator 16
5 4.5 Pneumatic accumulator 17
6 4.6 Pressure reducing valve 18
7 4.7 Pressure relief valve 19
8 4.8 Sequence valve 20
9 4.9 Counterbalance valve 21
10 4.10 Unloading valve 22
11 4.11 Check valve 23
12 4.12 Pressure gauge 24
13 4.13 Temperature gauge 26
14 4.14 3/2 DCV 27
15 4.15 4/2 DCV 28
16 4.16 5/2 valve 29
17 4.17 Pneumatic actuator 30
18 4.18 Linear actuator 31
19 4.19 Rotary actuator 32
20 4.20 Diaphragm cylinder 33
21 4.21 Rolling diaphragm cylinder 34
22 4.22 Gravity return single acting cylinder 35
23 4.23 Spring return single acting cylinder 35
24 4.24 Telescopic cylinder 37
25 4.25 Tandem cylinder 38
26 4.26 Cable cylinder 39
27 4.27 Sealing band cylinder with slotted 40
cylinder barrel
28 4.28 Cylinder with magnetically coupled slide 40
29 4.29 Impact cylinder 41
30 4.30 Duplex cylinder 42
31 5.1 Representation of 5/2 double pilot 44
operated DCV
32 5.1.1 5/2 double pilot operated DCV 45
33 5.2 3/2 roller operated DCV 45
34 5.3 Double acting cylinder with single piston 46
rod

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35 5.4 Pressure relief valve 48

36 5.5 Control unit/ regulator 48
37 5.6 Hoses 49
38 5.7 Hacksaw 50
39 5.8 Elbow fitting 51
40 5.9 T connector 52
41 5.10 Cross fitting 52
42 5.11 Flow control valve 53
43 5.12 Compressor 53
44 5.13 Circuit diagram 56
45 5.14 Pneumatic hacksaw machine 57
46 5.15 Illustration of cutting by hacksaw 59
50 5.16 Break even analysis 61
51 5.17 Break even chart of pneumatic hacksaw 64

INDEX OF TABLES

S.NO TABLE NAME PG.NO

NO
1 5.1 ESTIMATION 55
2 5.2 FORCE OBTAINED FROM PNEUMATIC 60
CYLINDER

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1. ABSTRACT:

Hacksaw is a cutting tool which is widely used in workshops. Industries

and has many applications. In large scale applications, power hacksaw is
generally used. However there are some cases, where power hacksaw
use is not recommended. In small and medium scale industries may not
be able to use costly conventional power hacksaw. Also in case of
refineries, food processing industries, chemical industries can have a
chance of fire accidents due to electricity usage.

In above cases, pneumatic hacksaw is more suitable to use as it

is safe and cheaper than the power hacksaw. It is automated one. Using
of pneumatics enable us to use different cutting speeds and feeds.
Control of the system is very easy and accurate.

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2. INTRODUCTION

In present conditions many pneumatically operated power hacksaw

machines of different companies with different specifications are
available for the use in shop floor. These machines are to precise that
they can cut metal bars with minimum time made up of different
materials but they have one and major disadvantage that they can cut a
single piece at a time. The pneumatic hacksaw with overload protection
is compact and is reliable for small scale industries. This machine can
cut materials like metal pipes, rods, plastic and wood.

A hacksaw is a multipoint cutting tool, its cutting mechanism is provided

by removable blades with feature sharp teeth along their outer edge. In
most cases, a hack saw consists of a metal frame that resembles a
downward facing. A handle of plastic, wood, or metal is typically affixed
to one end of the frame. The frame's ends feature adjustable pegs that
can be tightened to secure a blade in a place, and loosened to remove it.
Hacksaw blades are long, thin strips of hardened steel that feature a row
of teeth along their cutting edge. Machines are often designed to yield a
high mechanical advantage to reduce the effort needed to do that work.
A simple machine pneumatic hacksaw with overload protection can be
built by using combination of these simple components.

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3. WHAT IS TO BE ACHIEVED

OBJECTIVE:
 To design and fabricate a pneumatic hacksaw machine with
overload protection.
 To make hacksaw machine affordable for small workshops.
 To utilise pneumatic systems for cutting operations on bars.
 To design a pneumatic circuit for operation of hacksaw.
 To provide safe working conditions by using compressed air.

PROBLEM DEFINITION:

 The cost of conventional power hacksaw is about Rs.60,000/-

 It is not suitable to work in conditions prone to fire hazard and short
circuits.
 Variable cutting force and speeds cannot be obtained.
 Variable cutting strokes cannot be obtained in conventional power
hacksaw.

PROBLEM SOLUTION:

 Pneumatic Hacksaw costs about 15000-20000/-

 Pneumatics provides high safety in operation.
 Variable cutting force and speeds can be obtained by controlling air
pressure and flow rate.
 Variable cutting strokes can be obtained by adjusting the position
of 3/2 Roller valves.

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PROCEDURE FOLLOWED:

 Data Collection of different types of hacksaw machines present.

 Data collection of various Pneumatic Components
 Design of Pneumatic circuit for the operation of Hacksaw.
 Selection of the materials required for different parts of the
pneumatic components for the fabrication of the hacksaw.
 Calculation of force required for cutting different materials.
 Purchasing the standard components.
 Selection of fabrication process.
 Assembling of all the parts of the pneumatic hacksaw.
 Calculation of various types of parameters which is subjected to
optimization process.

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4. BASIC CONCEPTS OF PNEUMATICS

4.1 INTRODUCTION TO PNEUMATICS

Pneumatics: It is defined as the branch of fluid power technology that
deals with generation, transmission, and control of power using
pressurised air.

The word pneuma means air or breath

In pneumatic control, compressed air is used as the working

medium, normally at a pressure from 2 bars to 8 bars.

A pneumatic circuit is a system consisting of various pneumatic

components; such as cylinders, directional control valves, flow control
valves, etc. to complete a task.

ADVANTAGES &DISADVANTAGES OF COMPRESSED AIR

ADVANTAGES:

• Compressed air can be conveyed through pipelines even over

longer distances.

• Compressed air can be strong.

• Compressed air need not be returned. It can be vented to

atmosphere after it has performed work.

• Speeds and forces of the pneumatic elements can be infinitely

adjusted.

• Compressed air is clean. It can be used in food, Pharma, textile,

beverage industries.

• Operating elements for compressed air operation are of simple and

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inexpensive construction.

• Compressed air is fast. Thus, high operational speed can be

attained.

• Tools and operating elements are overload proof. Straight line

movement can be produced directly.

DISADVANTAGES:

• Compressed air is relatively expensive means of conveying

energy.

• Compressed air requires good air conditioning. Dirt and dust leads
to wear on tools and equipment.

• It is not possible to achieve uniform and constant piston speeds (air

is compressible).

• Compressed air is economical only up to certain force limits.

• The exhaust is loud.

• The oil mist mixed with the air for lubricating the equipment
escapes with the exhaust to atmosphere.

• Air due to its low conductivity, cannot dissipate heat as compared

to hydraulic fluid.

• Air is not a good lubricating medium unlike hydraulic fluid.

APPLICATIONS OF PNEUMATIC SYSTEMS:

• Operation of heavy or hot doors.

• Crop spraying and operation of other tractor equipment.

• Spray painting.

• Holding in jigs and fixtures in assembly machinery and m/c tools.

• Forming operations of bending, drawing and flattening.

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• Spot welding machines.

• Riveting.

• Bottling and filling machines.

• Test rigs.

• Machine tool, work or tool feeding.

• Component and material conveyor transfer.

• Pneumatic robots.

BASIC COMPONENTS OF PNEUMATIC SYSTEMS:

Fig 4.1
 Compressor transforms mechanical energy into pneumatic
energy. Air taken in at atmospheric pressure is compressed and
delivered at a higher pressure to the pneumatic system.

 Electric motor supplies the mechanical power to the compressor.

 Pressure switch controls the electric motor by sensing the

pressure in the tank. It is set to maximum pressure at which it
stops the motor, and a minimum pressure at which it restarts it.

 Check valve allows the compressed air from the compressor into
the talk and prevents the reverse flow.

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 Tank Stores the compressed air from the compressor into the tank
and prevents the reverse flow.

 Pressure gauge indicates the pressure of the system.

 Auto drain drains all the water condensing in the tank without
supervision.

 Safety valve blows compressed air off if the pressure in the tank
should rise above the allowed pressure.

 Refrigerated air dryer cools the compressed air to a few degrees

above freezing point and condenses most of the air humidity. This
avoids having water in the downstream system.

 Line filter being in the main pipe, this filter must have a minimal
pressure drop and the capability of oil mist removal. It helps to
keep the line free from dust, water and oil.

 Air filters are used to filter out the contaminants from the air.

 Air coolers during compression operation, air temperature

increases. Therefore coolers are used to reduce the temperature of
the compressed air.

 Control valves are used to regulate, control, and monitor for the
control of direction of flow, rate of flow, pressure etc.

 Air cylinders and motors are used to obtain the re

 Required movements of mechanical elements of pneumatic

system.

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4.2 ADVANTAGES AND DISADVANTAGES OF

PNEUMATICS

ADVANTAGES:

• Low inertia effect of pneumatic components due to low density of air.

• Pneumatic systems are light in weight.
• Operating elements are cheaper and easy to operate.
• Power losses are less due to low viscosity of air.
• High output to weight ratio.
• Pneumatic systems offer a safe source in explosive environment.
• Leakage is less and does not influence the systems.
Moreover, leakage is not harmful.

DISADVANTAGES:

• Suitable only for low pressure and hence low force

applications.
• Compressed air actuators are economical up to 50 KN only.
• Generation of the compressed air is expensive compared to
electricity.
• Exhaust air noise is unpleasant.
• Rigidity of the system is poor.
• Weight to pressure ratio is large.
• Less precise. It is not possible to achieve uniform speed
due to compressibility of air.
• Pneumatic system is vulnerable to dirt and contamination

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4.3 PNEUMATIC COMPONENTS WITH SYMBOLS:

1. AIR COMPRESSOR

ACTUAL EQUIPMENT

GRAPHICAL SYMBOL

Fig 4.2

An air compressor is a device that converts power (using an

electric motor, diesel or gasoline engine, etc.) into potential
energy stored in pressurized air (i.e., compressed air). By one of several
methods, an air compressor forces more and more air into a storage
tank, increasing the pressure. When tank pressure reaches its
engineered upper limit the air compressor shuts off. The compressed air,
then, is held in the tank until called into use. The energy contained in the
compressed air can be used for a variety of applications, utilizing the
kinetic energy of the air as it is released and the tank depressurizes.

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When tank pressure reaches its lower limit, the air compressor turns on
again and re-pressurizes the tank.
An air compressor must be differentiated from an air pump which
merely pumps air from one context (often the surrounding environment)
into another (such as an inflatable mattress, an aquarium, etc.).Air
pumps do not contain an air tank for storing pressurized air and are
generally much slower, quieter, and less expensive to own and operate
than an air compressor.

2. PNEUMATIC FILTER

ACTUAL EQUIPMENT

Filter Filter Filter

(Automatic Drain) (Manual Drain)
Fig 4.3

GRAPHICAL SYMBOLS

A pneumatic filter is a device which removes contaminants from

a compressed air stream. This can be done using a number of different
techniques, from using a "media" type that traps particulates, but allows
air to pass through to a venturi, to a membrane that only allows air to
pass through.

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USAGE:
It is now common to have various stages of filtration employed in a filter-
regulator-lubricator form factor, usually with the different filter housings
connected. Air filtration applications are diverse and include end-user
sectors such as clean rooms, environments, biomedical, analytical
instrumentation, food processing, marine and aviation, agriculture,
manufacturing, food and beverage packaging and a host of other uses.

3.LUBRICATOR

ACTUAL EQUIPMENT

GRAPHICAL SYMBOL
Fig 4.4

A pneumatic lubricator injects an aerosolized stream of oil into an

airline to provide lubrication to the internal working parts
of pneumatic tools, and to other devices such as actuating
cylinders, valves and motors.
Compressed air enters the inlet port and passes over a needle valve
orifice attached to a pick-up tube. This tube - often equipped with a
sintered bronze filter - is submerged into a reservoir bowl filled with light
machine oil. Oil is pulled up by the venturi effect, and emitted as an

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aerosol at the outlet port. The needle valve is typically situated within a
clear polycarbonate or nylon housing to aid in oil flow rate adjustment.
Some compressor oils and external chemicals can cause polycarbonate
and/or nylon sight glass to be degraded and create a safety hazard
A lubricator should always be the last element in an FRL (Filter-
Regulator-Lubricator) unit. If an FRL is connected "backwards" with
incoming air connected to the lubricator, oil-laden air interferes with
pressure regulator operation, oil is separated from the air stream and
drained by the filter, and very little or none is delivered to connected
equipment.

4.PNEUMATIC ACCUMULATOR

ACTUAL EQUIPMENT

GRAPHICAL SYMBOLS
Fig 4.5
In the pneumatic accumulators. gas and oil occupy the same container.
When the oil pressure rises, incoming oil compresses the gas. When oil
pressure drops, the gas expands, forcing oil out.
Accumulators also can act as surge or pulsation absorbers, much as an
air dome is used on pulsating piston or rotary pumps. Accumulators will
cushion hydraulic hammer, reducing shocks caused by rapid operation
or sudden starting and stopping of power cylinders in a hydraulic circuit.

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There are four principal types of accumulators: the weight-loaded piston

type, diaphragm (or bladder) type, spring type, and the hydro-pneumatic
piston type. The weight-loaded type was the first used, but is much larger
and heavier for its capacity than the modern piston and bladder types.
Both weighted and spring types are infrequently found today. Hydro-
pneumatic accumulators, Figure 1, are the type most commonly used in
industry.

5.PRESSURE REDUCING VALVE

ACTUAL EQUIPMENT

GRAPHICAL SYMBOL
Fig 4.6

A pressure regulator is a control valve that reduces the input pressure of

a fluid to a desired value at its output. Regulators are used for gases and
liquids, and can be an integral device with an output pressure setting, a

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restrictor and a sensor all in the one body, or consist of a separate

pressure sensor, controller and flow valve.
A pressure regulator includes a restricting element, a loading element,
and a measuring element:

 The restricting element is a valve that can provide a variable restriction

to the flow, such as a globe valve, butterfly valve, poppet valve, etc.
 The loading element is a part that can apply the needed force to the
restricting element. This loading can be provided by a weight, a spring,
a piston actuator, or the diaphragm actuator in combination with a
spring.
 The measuring element functions to determine when the inlet flow is
equal to the outlet flow. The diaphragm itself is often used as a
measuring element; it can serve as a combined element.

6.PRESSURE RELIEF VALVE

ACTUAL EQUIPMENT

GRAPHICAL SYMBOL
Fig 4.7
A relief valve or pressure relief valve (PRV) is a type of safety valve used
to control or limit the pressure in a system; pressure might otherwise
build up and create a process upset, instrument or equipment failure, or

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fire. The pressure is relieved by allowing the pressurised fluid to flow

from an auxiliary passage out of the system. The relief valve is designed
or set to open at a predetermined set pressure to protect pressure
vessels and other equipment from being subjected to pressures that
exceed their design limits. When the set pressure is exceeded, the relief
valve becomes the "path of least resistance" as the valve is forced open
and a portion of the fluid is diverted through the auxiliary route. The
diverted fluid (liquid, gas or liquid–gas mixture) is usually routed through
a piping system known as a flare header or relief header to a central,
elevated gas flare where it is usually burned and the resulting
combustion gases are released to the atmosphere.[1] As the fluid is
diverted, the pressure inside the vessel will stop rising. Once it reaches
the valve's reseating pressure, the valve will close. The blowdown is
usually stated as a percentage of set pressure and refers to how much
the pressure needs to drop before the valve reseats. The blowdown can
vary from roughly 2–20%, and some valves have adjustable blowdowns.

7.SEQUENCE VALVE:

ACTUAL EQUIPMENT

GRAPHICAL SYMBOL
Fig 4.8
There are times when two or more cylinders need to stroke in a planned
Sequence. With two or more cylinders controlled by a single directional

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valve, the cylinder with the lowest resistance always strokes first. If the
actuator with the least resistance is first in the sequence, the circuit runs
smoothly without other valving.

When the cylinder that must move first has the highest resistance, a
single directional control will not work. A separate directional valve for
each cylinder is one way to sequence such a circuit. Energizing one
solenoid extends the first cylinder. When the first cylinder contacts a limit
switch, it energizes a second solenoid, causing the next cylinder to
stroke. With this type of sequencing circuit, the first cylinder may lose
holding power when the second directional valve shifts. It may require
other valves to make sure the first cylinder generates and maintains the
force required both before and during the second cylinder stroke.

Another way to force fluid to take the path of greatest resistance is to use
a pressure-control valve called a sequence valve.

8. COUNTERBALANCE VALVE

ACTUAL EQUIPMENT

GRAPHICAL SYMBOL

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Fig 4.9
The Counterbalance Valve is used to maintain control over a vertical
cylinder so that it will not fall freely because of gravity.
Counter balance Valve is a combination of a pressure relief valve
and a check valve. The left side port is connected to the port of the
Cylinder or Actuator and the right side port is connected to the
Directional control valve. Check valve allows free flow in one direction
(during extension stroke) and offers resistance to flow in another
direction (during retraction stroke). During retraction stroke, the flow is
allowed through Pressure relief valve until a certain pressure is reached.
A Counterbalance Valve is used in some hydraulically operated fork
lifts. It offers resistance to flow from an actuating cylinder when a fork is
lowered.

9.UNLOADING VALVE

ACTUAL EQUIPMENT

GRAPHICAL SYMBOL
Fig 4.10

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Unloading valve consists of a control chamber, spring spool, screw, two

ports. One port is connected to the tank and another is connected to the
pump or compressor. It has a separate drain passage from control
chamber to the tank.
It is used in high-low pump circuits where two pumps move an
Actuator at a high speed and low pressure. Normally the flow from the
pump or compressor is diverted to the circuit. When the system pressure
increase to spring setting value, the pilot pressure moves the spool and
the spool and the fluid bypasses to atmosphere.

10.CHECK VALVE

ACTUAL EQUIPMENT

GRAPHICAL SYMBOL
Fig 4.11
A check valve, clack valve, non-return valve, reflux valve, retention
valve or one-way valve is a valve that normally allows fluid (liquid or gas)
to flow through it in only one direction.
Check valves are two-port valves, meaning they have two openings in
the body, one for fluid to enter and the other for fluid to leave. There are

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various types of check valves used in a wide variety of applications.

Check valves are often part of common household items. Although they
are available in a wide range of sizes and costs, check valves generally
are very small, simple, or inexpensive. Check valves work automatically
and most are not controlled by a person or any external control;
accordingly, most do not have any valve handle or stem. The bodies
(external shells) of most check valves are made of plastic or metal.
An important concept in check valves is the cracking pressure which is
the minimum upstream pressure at which the valve will operate.
Typically, the check valve is designed for and can therefore be specified
for a specific cracking pressure.

11.PRESSURE GAUGE

ACTUAL EQUIPMENT

GRAPHICAL SYMBOL
Fig 4.12

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Pressure measurement is the analysis of an applied force by

a fluid (liquid or gas) on a surface. Pressure is typically measured in units
of force per unit of surface area. Many techniques have been developed
for the measurement of pressure and vacuum. Instruments used to
measure and display pressure in an integral unit are called pressure
gauges or vacuum gauges. A manometer is a good example as it uses a
column of liquid to both measure and indicate pressure. Likewise the
widely used Bourdon gauge is a mechanical device which both
measures and indicates and is probably the best known type of gauge.
A vacuum gauge is a pressure gauge used to measure pressures lower
than the ambient atmospheric pressure, which is set as the zero point, in
negative values (e.g.: -15 psi or -760 mmHg equals total vacuum). Most
gauges measure pressure relative to atmospheric pressure as the zero
point, so this form of reading is simply referred to as "gauge pressure".
However, anything greater than total vacuum is technically a form of
pressure. For very accurate readings, especially at very low pressures, a
gauge that uses total vacuum as the zero point may be used, giving
pressure readings in an absolute scale.

12.TEMPERATURE GAUGE :

ACTUAL EQUIPMENT

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GRAPHICAL SYMBOL
Fig 4.13
A temperature gauge is a device used to indicate the temperature of an
item being monitored. The display can be an analogue dial, an analogue
range or a digital readout. Common methods of measuring temperature
include bimetallic strip (the bending of which increases with temperature)
and the thermocouple which produces an electronic voltage that
depends on the temperature.

Temperature gauges measure the thermal state of a homogeneous

substance. The measuring system must be brought as closely together
as possible with the body to be measured. The most widely used
measuring methods rely on temperature-dependent physical and
material characteristics.

 Bimetal temperature gauge

 Expansion temperature gauge
 Gas-actuated temperature gauge
 Machine glass temperature gauge

13. DIRECTIONAL CONTROL VALVES:

3/2 DC VALVE

ACTUAL EQUIPMENT

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GRAPHICAL SYMBOL
Fig 4.14

A 3/2 way solenoid valve has three ports and two switching states. In
each switching state, two of the three ports are connected. By activating
the solenoid, the valve switches state and a different connection between
the valve ports is established. The drawing below shows a direct
operated 3/2 way valve. The port on the left side is the input port (P). In
the de-energized state, the medium can flow from the port on the left
side to the top port (exhaust port). In the energized state, the medium
can flow from the right port to the left port. This is a called a normally
closed 3/2-way valve.
The 3-Way Directional Valve block represents a directional control valve
with three ports and two positions, or flow paths. The ports connect to
what in a typical model are a hydraulic pump (port P), a storage tank
(port T), and a single-acting actuator (port A). Fluid can flow from the
pump to the actuator via path P-A and from the actuator to the tank via
path A-T.

In the default configuration, one valve position corresponds to the P-A

flow path maximally—though not necessarily fully—open and the A-T
flow path maximally closed (position I in the figure). The second valve
position corresponds to the A-T flow path maximally open and the P-A
flow path maximally closed (position II in the figure). A translating spool
serves as the valve control member and determines the position that the
valve is in—I, II, or in between.

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4/2 VALVE

ACTUAL EQUIPMENT

GRAPHICAL SYMBOL
Fig 4.15
4-way solenoid valves are generally used to operate double-acting
cylinders or actuators. They have four or five pipe connections,
commonly called ports. One pressure inlet. Two cylinder ports providing
pressure to the double-acting cylinder or actuator. One or two outlets to
exhaust pressure from the cylinders. In a de-energized position, pressure
is connected to one cylinder port; the other port is connected to the
exhaust. In an energized position, pressure and exhaust are reversed. In
a de-energized position, pressure is connected to one cylinder port; the
other port is connected to the exhaust. In an energized position, pressure
and exhaust are reversed. Four ports means less piping is required. With
five ports, independent speed controls can be mounted in each port.

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5/2 VALVE

ACTUAL EQUIPMENT

GRAPHICAL SYMBOL
Fig 4.16
The 5/2 DCV contains 5 ports with 2 positions as the name suggests.
Out of these 5 ports one port is connected to pump and known as
pressure port (here port1). There are two working ports (2 and 4) and
two vents/exhaust (3 and 5) connected to the reservoir.

5/2 DCV has a spool on which 3 lands lie. These lands restrict or allows
the flow of fluid from one port to other as per the position of spool.

As mentioned earlier it has two positions, which means spool can be

made to be only in two positions. One of the position is shown in the
picture.

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4.4 PNEUMATIC ACTUATORS

Pneumatic actuators are the devices used for converting pressure

energy of compressed air into the mechanical energy to perform useful
task.

Fig 4.17

Cylinders are the 'muscles' of pneumatic systems as they are used

to move, hold and lift objects.

TYPES OF PNEUMATIC ACTUATORS

Pneumatic actuators can be used to get linear, rotary and oscillatory
motion.
There are three types-
• Linear actuators or pneumatic cylinders.
• Rotary actuator or air motors.
• Limited angle actuators.

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[A] LINEAR ACTUATOR OR PNEUMATIC CYLINDERS

Fig 4.18
Pneumatic cylinders are the devices used for converting the air
pressure into linear motion and force.

These are used for single purpose application such as clamping,

stamping, bending, turning, etc.

CLASSIFICATION OF PNEUMATIC CYLINDERS

1. Based on application of air cylinders
o Light duty air cylinders
o Medium duty air cylinders
o Heavy duty air cylinders
2. Based on the cylinder action
o Single acting cylinder
o Double acting cylinder
o Single rod type double acting cylinder
o Double rod type double acting cylinder
3. Based on cylinder's movement
o Rotating type air cylinder
o Non rotating type air cylinder
4. Based on the cylinder's design
o Telescopic cylinder
o Tandem cylinder
o Rodless cylinder

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o Impact cylinder
o Duplex cylinders
o Cylinders with sensors.

[B] ROTARY ACTUATORS

Rotary Actuators are used to achieve angular motion. Rotary actuators
are devices which produce high torque output and have a limited rotary
movement. Standard rotations are 90°, 180°, and 270°.

Fig 4.19

Rotary actuators are mainly available in three designs-

1. Limited rotation motors
o Vane type limited rotation motors
o Single vane rotation motor
o Double vane rotation motor
o Rotary actuator of rack and pinion type
o Helix spine rotary actuator
2. Full rotation motors
o Gear motors
o Vane motors

APPLICATIONS OF AIR MOTORS

o Electric motor coil winding.
o Oil pipeline inspection equipment.
o Under sea camera manipulation.
o Jumbo Jet maintenance Jacks.
o Milling and sawing applications.

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o Dynamite blast hole pump drive.

o Automatic clamping.
o Textile washing agitators.
o Orange peeling machines.
o Fan drives.
o Diamond wheel dresser.
o Drill and tap machine tool.
o Chicken processing machinery.
o Conveyor drives.

TYPES OF PNEUMATIC CYLINDERS:

(a) Single acting cylinders -

o Diaphragm cylinder
o Rolling diaphragm cylinder
o Gravity return single acting cylinder
o Spring return single acting cylinder

DIAPHRAGM CYLINDER

In a diaphragm cylinder, a built-in-diaphragm replaces the function of the

piston. Diaphragm is made of rubber, plastic or metal and the stem which
serves as a piston rod is attached to the centre of the diaphragm as
shown in the fig. Only short operating strokes upto 50mm can be
executed by a diaphragm cylinder.

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ROLLING DIAPHRAGM CYLINDER

Fig 4.21

The advent of the long stroke rolling diaphragm as a means of low-

friction dynamic sealing has led to the development of the Control Air
Diaphragm Air Cylinder. These cylinders provide virtually frictionless
conversion of pneumatic pressure to linear force, and offer such
operating features as:

• Super Sensitivity

• Absolutely No Lubrication Required

• Low Hysteresis

• No Blow-By Leakage

• Wide Temperature Variations.

The rolling diaphragm creates the perfect seal for friction free cylinders. It
is a durable, flexible membrane shaped like a top hat with the peak of the
hat fastened to the end of the piston and the “brim” clamped to the

cylinder cap. Inside of the cylinder this forms a long lasting frictionless
seal between the piston head and cylinder wall. The fabric reinforced

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elastomer rolling diaphragms are produced utilizing a microprocessor

controlled process that is recognized as the leading edge mode of
production. Custom diaphragm material design allows for operation of
the cylinders at temperatures from -75°F to 400°F.

GRAVITY RETURN SINGLE ACTING CYLINDER

Fig 4.22

Push Type the pressure is sent through the pressure port situated at the
blank end of the cylinder. When the pressure is released, the spring
automatically returns the cylinder to the fully retracted position. The vent
port is open to atmosphere so that air can flow freely in and out of the
rod end of the cylinder.

Pull Type the cylinder retracts when the pressure port is connected to
the pump flow and extends whenever the pressure port is connected to
the tank. Here the pressure port is situated at the rod end of the cylinder.

SPRING RETURN SINGLE ACTING CYLINDER

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Fig 4.23
Almost any text on cylinders begins with single-acting, spring-return
models and implies that these are the simplest form of cylinder. While it
is true that mechanical spring cylinders have been around the fluid power
industry almost as long as the industry itself, their correct application still
involves some thoughtful design decisions. Springs in conjunction with
cylinders provide the force to move a load to a predetermined point
(normally considered its fail-safe point). Mechanical spring cylinders
either use a spring to extend (so the cylinder will stroke to the fully
extended position when pressure pneumatic or hydraulic- is removed
from the rod-end port), or retract, (so the cylinder will stroke to the fully
retracted position when pressure is removed from the cap-end port).
Thus, mechanical spring cylinders can be used in any application where
it is required, for any reason, that the cylinder either extend or retract if
input pressure is removed by the control or lost by accident. In most
cases, a mechanical spring is the only device that can be coupled to a
cylinder to consistently deliver a specific design force when input
pressure is lost- and retain that force for as long as the cylinder
assembly integrity is maintained. Depending on application factors such
as space, force required, operating pressure, and cylinder configuration,
the spring may be installed inside the cylinder, mounted externally on the
cylinder body, or adapted to a linkage connected to the cylinder.

(b)Double acting cylinders –

o Telescopic cylinder
o Tandem cylinder
o Rodless cylinder
i.Cable cylinder
ii.Sealing band cylinder with slotted cylinder barrel
iii.Cylinder with magnetically coupled slide
o Impact cylinder
o Duplex cylinder

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TELESCOPIC CYLINDER

Fig 4.24

Telescopic cylinders are a special design of a hydraulic cylinder or

pneumatic cylinder as well as pulley system which provide an
exceptionally long output travel from a very compact retracted length.
Typically the collapsed length of a telescopic cylinder is 20 to 40% of the
fully extended length depending on the number of stages. Some
pneumatic telescoping units are manufactured with retracted lengths of
under 15% of overall extended unit length. This feature is very attractive
to machine design engineers when a conventional single stage rod style
actuator will not fit in an application to produce the required output
stroke.

Heavy duty telescopic cylinders are usually powered by oil hydraulics,

whereas some lighter duty units could also be powered by compressed
air.

Telescopic cylinders are also referred to as telescoping cylinders and

multi-stage telescopic cylinders.

An application for telescopic cylinders commonly seen is that of the

dump body on a dump truck used in a construction site. In order to empty
the load of gravel completely, the dump body must be raised to an angle
of about 60 degrees. To accomplish this long travel with a conventional
hydraulic cylinder is very difficult considering that the collapsed length of
a single stage rod cylinder is approximately 110% of its output stroke. It
would be very challenging for the design engineer to fit the single stage

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cylinder into the chassis of the dump truck with the dump body in the
horizontal rest position. This task is easily accomplished, however, using
a telescopic style multi-stage cylinder.

TANDEM CYLINDER

Fig 4.25

Master cylinder can be rightly named as heart of the hydraulic braking

system. There are two main chambers viz. the fluid reservoir &
compression chamber in which the piston operates(Fig:5.1). The fluid in
the reservoir compensates for any change In the fluid volume in the
pipelines due to temperature variations & to some extent due to leakage.
To prevent leakage there are rubber seals on both ends of the piston in
the compression chamber. The reduced diameter region of the piston is
always surrounded by the fluid. A rubber boot covers the pushrod end of
the master cylinder to prevent the dirt from entering inside towards the
brake lines side of the compression chamber, there is a fluid check value
with a rubber cup inside. It serves to retain the residual pressure in the
brake lines even when the brakes are released.

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CABLE CYLINDER

Fig 4.26

The cable cylinders work in a linear translation systems, they are very
compact and can be used where a normal cylinder with a rigid rod is too
cumbersome. The main characteristic of the cable cylinders is the
absence of the rod which, in coming out of the end plate at the end of the
stroke, doubles the total overall dimension of the cylinder.

In a double acting cylinder, a cable is attached to each side of the piston

and guided over rollers. When the compressed air enters the cylinder,
the piston moves from end-to-end, and the cable extend out the ends of
the cylinder move as well.

Depending on the direction of the piston the carriage and anything on

the carriage moves towards one end or the other end of the air cylinder.

They are used in small-sized units producing large stroke lengths. They
are also used for door operations.

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SEALING BAND CYLINDER WITH SLOTTED CYLINDER BARREL

Fig 4.27

In sealing band cylinder with slotted cylinder barrel, the piston is

connected to the carriage by suitable mechanism in a similar way as that
of cable cylinder.

CYLINDER WITH MAGNETICALLY COUPLED SLIDE

Fig 4.28

Magnetic coupling cylinders are rodless cylinders that use the magnetic
force of permanent magnets to strongly link the outside slide to the inside
one. Both of them slide onto a stainless steel tube with two end caps.

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The high magnetic coupling force due to the use of special permanent
magnets allows to move heavy loads

The piston inside the cylinder has a powerful magnet. It bonds with
carriage outside that also contain powerful magnet. The magnetic
cylinders can operate at a speed of 180 m/min. In this type of cylinders
there is no leakage and also wear is less because there is no direct
contact of moving elements.

IMPACT CYLINDER

Fig 4.29

In impact cylinder piston rod is designed to withstand high impact force.

The cylinder can work at high velocity so that impact energy could be
utilised for deformation of metals. They are used for press working
operation such as stamping, punching, embossing, etc.

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DUPLEX CYLINDER

Fig 4.30

A unit comprised of two cylinders with independent control, mechanically

connected on a common axis to provide three or four positions
depending on the method of application.

Duplex cylinder or multiposition cylinder consists of two or more double

acting cylinders. Duplex cylinder with two double acting cylinders is
shown in the figure.

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5.PROJECT DETAILS

5.1 PROJECT DESCRIPTION:

In present conditions many pneumatically operated power hacksaw

machines of different companies with different specifications are
available for the use in shop floor. These machines are to precise that
they can cut metal bars with minimum time made up of different
materials but they have one and major disadvantage that they can cut a
single piece at a time. The pneumatic hacksaw with overload protection
is compact and is reliable for small scale industries. This machine can
cut materials like metal pipes, rods, plastic and wood.
A hacksaw is a multipoint cutting tool, its cutting mechanism is provided
by removable blades with feature sharp teeth along their outer edge. In
most cases, a hack saw consists of a metal frame that resembles a down
ward facing. A handle of plastic, wood, or metal is typically affixed to one
end of the frame. The frame's ends feature adjustable pegs that can be
tightened to secure a blade in a place, and loosened to remove it.
Hacksaw blades are long, thin strips of hardened steel that feature a row
of teeth along their cutting edge. Machines are often designed to yield a
high mechanical advantage to reduce the effort needed to do that work.
A simple machine pneumatic hacksaw with over load protection can be
built by using combination of these simple components.

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5.2COMPONENTS USED:

1.5/2 DOUBLE PILOT OPERATED DCV

2.3/2 ROLLER OPERATED DCV
3. DOUBLE ACTING CYLINDER WITH SINGLE PISTON ROD
4. PRESSURE RELIEF VALVE
5. CONTROL UNIT/REGULATOR
6. HOSES WITH 6mm DIAMETER
7. BENCH VICE
8. HACK SAW
9. CYLINDER CONNECTOR
10.'T'- CONNECTOR
11. FLOW CONTROL VALVES

1.5/2 DOUBLE PILOT OPERATED DCV:

Fig 5.1

A 5/2 way directional valve from the name itself has 5 ports equally
spaced and 2 flow positions. It can be used to isolate and simultaneously
bypass a passageway for the fluid which for example should retract or
extend a double-acting cylinder. There are variety of ways to have this
valve actuated. A pilot operated dcv is used in our project. 1-pressure
port; 2,4-outletports; 3,5-ventports; 12,14-pilot ports when the pilot signal
is from port-14 then the actuator moves towards right and when the
signal from port-12 the actuator moves left.in this way the 5/2 pilot
operated dcv is controlled.

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Fig 5.1.1

PRESSURE RANGE: 2-10 bar

COMPANY : JANATICS
MODEL NO : DS 255 EE 61
SIZE : ¼"

2.LIMIT SWITCH 3/2 ROLLER OPERATED DCV: whenever the

limit switch is pressed by the hacksaw, the 3/2 valve is actuated .The
name itself says it has three ports and 2 positions. It has three ports-a
pressure port, an outlet port and exhaust port. In actuated position, the
pressure port is connected to outlet port and the exhaust port is blocked.

Fig 5.2

PRESSURE RANGE : 2-10 bar

SIZE : ¼"
3.DOUBLE ACTING CYLINDER WITH SINGLE PISTON ROD: The
constructional features of double acting cylinder is shown in figure
below. It is provided with two working ports. One port is situated on
piston side and other on rod side. In double acting cylinder, compressed
air is applied to either side of piston and force exerted by compressed air
moves the piston in two directions. There are two types of designs for
double acting cylinders.

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1. Double acting cylinder with piston rod on one side

2. Double acting cylinder with piston rod on both sides.
In our project, we are using double acting cylinder with piston rod on one
side.

Fig 5.3

4.PRESSURE RELIEF VALVES: A relief valve or pressure relief valve

(PRV) is a type of safety valve used to control or limit the pressure in a
system; pressure might otherwise build up and create a process upset,
instrument or equipment failure, or fire. The pressure is relieved by
allowing the pressurised fluid to flow from an auxiliary passage out of the
system. The relief valve is designed or set to open at a predetermined
set pressure to protect pressure vessels and other equipment from being
subjected to pressures that exceed their design limits. When the set
pressure is exceeded, the relief valve becomes the path of least
resistance as the valve is forced open and a portion of the fluid is
diverted through the auxiliary route. The diverted fluid (liquid, gas or

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liquid–gas mixture) is usually routed through a piping system known as a

flare header or relief header to a central, elevated gas flare where it is
usually burned and the resulting combustion gases are released to the
atmosphere. Theblowdown is usually stated as a percentage of set
pressure and refers to how much the pressure needs to drop before the
valve reseats. The blowdown can vary from roughly 2–20%, and some
valves have adjustable blowdowns.
In high-pressure gas systems, it is recommended that the outlet of the
relief valve is in the open air. In systems where the outlet is connected to
piping, the opening of a relief valve will give a pressure build up in the
piping system downstream of the relief valve. This often means that the
relief valve will not re-seat once the set pressure is reached. For these
systems often so called "differential" relief valves are used. This means
that the pressure is only working on an area that is much smaller than
the openings area of the valve. If the valve is opened the pressure has to
decrease enormously before the valve closes and also the outlet
pressure of the valve can easily keep the valve open. Another
consideration is that if other relief valves are connected to the outlet pipe
system, they may open as the pressure in exhaust pipe system
increases. This may cause undesired operation.
In some cases, a so-called bypass valve acts as a relief valve by being
used to return all or part of the fluid discharged by a pump or gas
compressor back to either a storage reservoir or the inlet of the pump or
gas compressor. This is done to protect the pump or gas compressor
and any associated equipment from excessive pressure. The bypass
valve and bypass path can be internal (an integral part of the pump or
compressor) or external (installed as a component in the fluid path).
Many fire engines have such relief valves to prevent the over
pressurization of fire hoses.
In other cases, equipment must be protected against being subjected to
an internal vacuum (i.e., low pressure) that is lower than the equipment
can withstand. In such cases,vacuum relief valves are used to open at a
predetermined low pressure limit and to admit air or an inert gas into the
equipment so as control the amount of vacuum.

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Fig 5.4

5.CONTROL UNIT/REGULATOR:
A regulator is a device for controlling the rate of working of machinery or
for controlling fluid flow in a particular system. It is used for maintaining a
constant pressure.

Fig 5.5

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6. HOSES:

Fig 5.6

● A hose is a flexible hollow tube designed to carry fluids from one

location to another. Hoses are also sometimes called pipes, or
more generally tubing. The shape of a hose is usually
cylindrical.

● Made of heat-, oil-, and abrasion-resistant synthetic rubber, with

an RMA Class B cover and Class A tube, this nonconductive
hose offers easy-fitting installation with no clamps, ferrules, or
crimping required. It's suitable for low-pressure hydraulic and
pneumatic systems and can handle many solvents. The MSHA-
approved cover provides great fitting retention. The safety factor
is 4:1.
● PRESSURE RANGE: upto 10bar
● MATERIAL: Rubber (PU tube )

7.HACK SAW: Hack saw blades both hand and power hacksaw) are
generally made up of carbon steel or high speed steel. A hacksaw is a
fine-toothed saw, originally and principally for cutting metal. They can
also cut various other materials, such as plastic and wood for example,
plumbers and electricians often cut plastic pipe and plastic conduit with
them. There are hand saw versions and powered versions (power hack
saw). Most hacksaws are hand saws with a C-shaped frame that holds
a blade under tension. Such hacksaws have a handle, usually a pistol
grip, with pins for attaching a narrow disposal blade. The frames may

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also be adjustable to accommodate blades of different sizes. A screw or

other mechanism is used to put the thin blade under tension. Panel
hacksaws forgo the frame and instead have a sheet metal body; they
can cut into a sheet metal panel further than a frame would allow. These
saws are no longer commonly available, but hacksaw blade holders
enable standard hacksaw blades to be used similarly to a keyhole saw or
pad saw.

Fig 5.7

8.PNEUMATIC FITTINGS INFORMATION:

Pneumatic fittings are parts used to connect sections of pipe, tube, and
hose in pneumatic (pressurized gas) systems. Compared to hydraulic
fittings, pneumatic fittings are typically characterized by tighter seals and
lower pressure requirements. They are frequently used in pneumatic
logic control systems and instrumentation.
It is important to distinguish what type of vessels are being connected in
the system to determine what fittings are appropriate.
● Hoses are flexible vessels that are constructed of multiple

layers of different materials. Fittings for hoses are often not

permanent, since the hose itself is often replaced in time due to
wear.
● Pipes are rigid vessels constructed of one solid material.

Generally, pipes are defined by their inner diameter dimension.

● Tubes are fairly rigid vessels constructed of one solid material.

Generally, tubes are defined by their outside diameter

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dimension.

● Cylinder and valve connectors specifications:

Size :6mm
Max. Pressure : 10 bar
Temperature :0-100 degree
Fluid Media : air

TYPES OF FITTINGS:

1.ELBOW:

Changes the direction of flow to various angles. The most common

angles are 45°and 90° but 22.5°elbow can also be available.

Fig 5.8

2.TEE:

Connects three flow sections in aT-shaped intersection. This allows fluid

flow to be coming or split apart.

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Fig 5.9

3. CROSS:

4-way connections providing one inlet Port and three outlet ports or vice
versa.

Fig 5.10

9. FLOW CONTROL VALVES: Flow control valves controls the quantity

of fluid that passes a given point in the circuit. The purpose of flow
control in a pneumatic system is to regulate the speed of pneumatic
cylinders and motors.
The flow rate also determines the rate of energy transfer at a given
pressure. The work done by actuator on the load is equal to force

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exerted by an actuator multiplied by the distance through which it moves

(strokes). The energy transferred by a fluid must also equal to the work
done. Actuator speed determines the rate of energy transfer and speed
is thus function of flow rate. Simple flow control valve restrict the fluid
flow with either fixed or variable orifice. The pressure range upto 1.5 to 8
bar.

Fig 5.11

10.COMPRESSOR
● A compressor a mechanical device that compresses the air.

● A compressor consists of two components: the power source

and the compressing mechanism (piston, vane, etc.). In the

case of an air compressor, the compressing mechanism is in
fact compressing the atmosphere air.

Fig 5.12

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The air compressor works in the following way:

● Air enters the piston or vane, and it is compressed by increasing

its pressure and at the same time decreasing its volume. As

soon as the pressure reaches a maximum set by the operator or
the manufacturer, a switch mechanism prevents any further air
intake in the compressor. The compressed air is used and
pressure levels decrease. As soon as the pressure reaches a
minimum, also set by the operator or the manufacturer, the
switch allows air to enter the compressor. This procedure is
repeated as long as the compressor is being used.

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5.3 ESTIMATION:

ESTIMATED
COMPONENTS QUANTITY COST
5/2 Double pilot operated DCV- 1 1300/-
1/4”
3/2 Roller operated DCV 2 1300/-

Pressure Relief valve 1 300/-

DA cylinder with single piston rod 1 1800/-

63x200mm
Compressor 1 10000/-

6mm Hoses 6mts 120/-

Bench vice 1 500/-

Hack saw 1 350/-

Cylinder Connectors 14 220/-

Tee connector 4 80/-

Flow Control Valve 2 250/-

Other Fittings & Table Cost _ 2500/-

TOTAL COST 18720/-

Table 5.1

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5.4 CIRCUITDIAGRAM:

1. PRESSURE RELIEF VALVE

2. FLOW CONTROL VALVE
3. 5/2 DOUBLE PILOT OPERATED D.C.V.
4. PNEUMATIC DOUBLE ACTING CYLINDER
5. METAL FRAMED HACKSAW
6,7. ROLLER OPERATED 3/2 D.C.V.
C - COMPRESSOR

Fig 5.13

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WORKING:

The compressed air is used to produce the power with the help of air
cylinder. Air from compressor enters into cylinder through 5/2 DCV which
is operated by pilot signal from 3/2 roller DC's. 3/2 DCV are operated by

the hack saw itself, at the end of strokes, pilot signals operate DCV and
control the direction of working fluid.
Flow control valves are used to control the speed of the piston.
Control unit is used to on and off the supply of compressed air.

Fig 5.14

OVERLOAD PROTECTION:

When the pressure in cylinder increases due to stoppage of hacksaw

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because of cutting hard material or being obstructed for any cause, the
pressure relief valve opens and compressed air from Pressure relief
valve pilots the DCV and piston is retracted back to initial position. Thus
the system is protected from high pressure.
5.5 ADVANTAGES:

● Light weight equipment

● No return lines for the used fluid
● Infinite control of speed and pressure
● Safeguards the circuit
● Easy installation of lines at any desired angle
● Cost of equipment is low
● Economically efficient for small scale industries

DISADVANTAGES:

 Cannot cut hard materials due to compressibility of air.

 Require compressor.
 Cannot produce high cutting forces.

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6.CALCULATION OF CUTTING FORCE:

Hacksaw is a multi point cutting tool and the cutting force is obtained by
first law of cutting forces

● From the modified first law of cutting forces, cutting force

required to cut is given by the following formula.

Fig 5.15

Fc = (po/ am)×a × b × zc
= ks × a × b × z c
Where,
Ks = specific cutting pressure, kg/mm^2
a = rise per tooth, mm
Zc=no of teeth
b=width of the hacksaw blade,mm

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From standard conditions and calculations

Cutting force required to cut mild steel,
FC = 170.609 =1671.88 N

FORCE OBTAINED FROM PNEUMATIC CYLINDER :

Bore diameter, d = 63 mm
Stroke, l = 200 mm
Piston rod diameter, dp=20 mm
Piston area, Ap= 3117.24 mm2
Piston rod area, Ar = 314.159 mm2
Force, f = P × A newton
P= pressure, N/mm2
A = piston area, mm2

S.NO PRESSURE CUTTING FORCE FORCE IN RETURN

(BAR) (N) STROKE (N)
1. 3 935.173 840.925
2. 4 1246.89 1121.23
3. 5 1558.62 1401.54
4. 5.5 1714.48 1541.69
5. 6 1870.34 1681.8

Hence, The force obtained from Pneumatic cylinder is sufficient to cut

Mild steel bar if air is pressurised to 6 bar.

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7.BREAK EVEN ANALYSIS:

Fig 5.16

The break-even point (BEP) in economics, business and specifically cost

accounting is the point at which total cost and total revenue are equal.
There is no net loss or gain, and one has "broken even," though
opportunity costs have been paid and capital has received the risk-
adjusted, expected return. In short, all costs that must be paid are paid,
and there is neither profit nor loss.

The break-even point (BEP) or break-even level represents the sales

amount-in either unit (quantity) or revenue (sales) terms-that is required
to cover total costs, consisting of both fixed and variable costs to the
company. Total profit at the break-even point is zero. It is only possible
for a firm to Break-even, if the dollar value of sales is higher than the
variable cost per unit. This means that the selling price of the good must
be higher than what the company paid for the good or its components for
them to cover the initial price they paid (variable costs). Once they
surpass the break-even price, the company can start making a profit.

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The break-even point is one of the most commonly used concepts of

financial analysis, and is not only limited to economic use, but can also
be used by entrepreneurs, accountants, financial planners, managers
and event marketers. Break-even points can be useful to all avenues of a
business, as it allows employees to identify required outputs and work
towards meeting these.

At break even point, profit=0

Total cost of sales =total cost of production
Q×S=F+ (V×Q)
Q(S-V) =F
Q=F/(S-V)

Where,
F = Fixed Cost,
V = variable cost,
S = Selling Price,
Q = Quantity of production.

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BREAK EVEN ANALYSIS ON PNEUMATIC

HACKSAW MACHINE
Breakeven analysis is very vital in the size of production in an industry.
The break even analysis for a pneumatic hacksaw manufacturing unit for
duration of one month is presented below:

FIXED COST:
1. Factory cost - 12000
2. Machines cost - 1350
3. Office Salaries - 36000
4. Depreciation - 1000
5. Rent of showroom - 2500
6. Maintenance - 2000
TOTAL - 54850

VARIABLE COST (PER UNIT):

1. Material cost - 8000
2. Labour cost -1500
3. Salaries of sales department - 535
4. Electricity -16
5. Others - 50
TOTAL - 10100

SELLING PRICE (PER UNIT) -13000

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BREAK EVEN CHART:

Cost of production vs Quantity of production for one month

Fig 5.17

BREAK EVEN POINT

Q= F/(S-V)
= 54850/(13000-10100 )

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= 18.9 units
= 19 units

8.FUTURE SCOPE
In our project, the depth of cut is given by keeping dead weight on
hacksaw frame. Comparing to the power hacksaw it is compact and less
weight And highly portable.
Due to following reasons pneumatic hacksaw gains good demand in
future

1) Less power consumption compared to power hacksaw

2) Can be easily assembled and dissembled
3) The stroke of the hacksaw machine can be adjusted as per the
requirements
4) Variable cutting forces and speeds obtained from pneumatic
hacksaw makes it suitable to cut wide variety of materials
5) Avoids the breakage of blade with the help of overload protection
6) Can be operated by the less intervention of the operator

The main advantage in this hacksaw is the various types of

attachments can be done without disturbing any construction of the
structure and other parts.

Its overload protection gives a high end safety in the operation by not
allowing the sudden breakage of the blade and the pressure is
bypassed into the circuit and the operation is stopped automatically.

Automation is possible in the circuit by using the roller values. Even

microcontroller can be used for the automation incase of solenoid
valve.

This hacksaw can be used in CNC, DNC, and can also be used in
flexible manufacturing by making required attachment to the circuit
and there is a great flexibility in the operation.

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9.CONCLUSION

We have learnt a lot from this project about different types of tools,
machines and how are they used in mechanical workshops in industry,
some basic techniques like cutting, planning, welding etc. In addition to
this we have also learn about how to manage our work in every aspect of
our project and also learn about painting and more over this project gave
us a good experience of purchasing material from market and increased
our surveying capabilities.

10.BIBLIOGRAPHY

 Metal cutting theory and practice by A. BHATTACHARYA-Pg. 288-

294
 Simple power hacksaw popular magazine.
 FESTO Pneumatics private limited.
 Pneumatics cylinders and double pilot DCV from product manual of
janatics LTD.
 Standard blade size used in power hacksaw machines from the link
https://www.planomillers.com.
 Pneumatic circuit reference from the link
http://nptel.ac.in/courses/112103174/pdf/mod6.pdf

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