MIZAN-TEPI UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

DESING AND MODELING OF VERTICAL METAL CUTTING BAND

SAW MACHINE

A Bachelor thesis submitted to the Department of Mechanical Engineering Mizan-Tepi

University in partial fulfillment of the requirements for the degree of Bachelor of Science in
Mechanical Engineering.

By:

NAME ID No.
1. Melese Yibeltal RU/00292/10
2. Weredaw Gebru RU/00381/10
3. Maru Mulaw RU/00277/10
4. Belayinesh Ayalew RU/00148/10

June 2022 G.C

Tepi, Ethiopia
 MIZAN-TEPI UNIVERSITY
COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

Design and modeling of vertical metal cutting band saw machine

NAME ID No.

1. Melese Yibeltal………………………………………..RU/00292/10
2. Weredaw Gebru……………………………………….RU/00381/10
3. Maru Mulaw…………………………………………..RU/00277/10
4. Belayinesh Ayalew…………………………………....RU/00148/10

Advisors

1. Mr. Tesfahun M.
2. Mr. Girma W.
Approval sheet

Approved by:-

Advisors Signature Date

1. Mr. Tesfahun M.
2. Mr. Girma W.

Examiners:

Name Signature Date

1.

2.

Department head:

1. Mr. Assefa belay

 Declaration
We declare that this Bachelor thesis entitled” design and modeling of vertical metal cutting band
saw machine” submitted to Mizan-Tepi University, College of engineering and technology
department of mechanical engineering, is our original work and has not been presented in any
other university for the of degree.

Name Signature Date

1. Melese Yibeltal

2. Weredaw Gebru

3. Maru Mulaw

4. Belayinesh Ayalew

This bachelor thesis has been submitted to Mizan-Tepi University, Department of Mechanical
Engineering with our approval as the University Advisors.

Advisors:

Name Signature

1. Mr. Tesfahun M.

2. Mr. Girma W.
 Abstract
In our country the metal materials need to be cut to get desired shape and length. The cutting
system can be manually, semi-manually and non-manually. Material cutting equipment’s are
designed such that facilitate easy, fast, cheap, free damage with least human interference. A band
saw machine is a machine tool designed to cut off bar stock, tubing pipe or any metal stock
within its capacity or to cut sheet stock to desired contours. In the mechanism the gear is directly
connected to the lower pulley which used to transmitted power to the upper pulley by means of
blade. The main aim is to cut metals in curve, contour and straight shapes. There are so many
types of factors for the selection and design of a band saw machine. Hence band saw machine
can be designed for easy cutting of materials beyond human capacity such as weight, strength
and height. The thesis shows the design and modeling of vertical band saw machine in our
country to cut the metals.

Mathematical analysis is applied based on size, capacity, speed, type and arrangement of the
band saw and driving unit. Short and clear cost analysis for the different components is also
performed.

Keyword: Band saw, Blade, Pulley, Blade guide.

 Table of content
Contents page
Declaration.................................................................................................................................................II
Abstract.....................................................................................................................................................III
Table of content........................................................................................................................................IV
List of figure.............................................................................................................................................IV
List of table................................................................................................................................................V
CHAPTER ONE........................................................................................................................................1
1. INTRODUCTION.................................................................................................................................1
1.1 BACKGROUND OF BAND SAW.................................................................................................1
1.2 STATEMENT OF THE PROBLEM.............................................................................................2
1.3 OBJECTIVE OF THE STUDY......................................................................................................2
1.3.1 GENERAL OBJECTIVE.........................................................................................................2
1.3.2 SPECIFIC OBJECTIVE..........................................................................................................2
1.4 SCOPE OF THE PROJECT...........................................................................................................2
1.5 SIGNIFICANCE OF THE PROJECT...........................................................................................3
CHAPTER TWO.......................................................................................................................................4
2. LITERATURE REVIEW.....................................................................................................................4
2.1 previous work related to the project..............................................................................................4
2.2 Gap of project..................................................................................................................................5
2.4 TYPES OF BAND SAW MACHINE................................................................................................5
2.5 COMPONENTS OF VERTICAL BAND SAW MACHINE............................................................6
Chapter three.............................................................................................................................................8
3. Methodology..........................................................................................................................................8
3.1 DESIGN ANALYSIS..........................................................................................................................10
3.1.1 Design consideration....................................................................................................................10
3.1.2 Selection of Electric Motor.........................................................................................................10
Reference..................................................................................................................................................10

List of figure
Figure 1 Flow diagram of the project..........................................................................................................7

List of table
Table 1 Time schedule.................................................................................................................................9
Table 2 cost of components.......................................................................................................................10
 CHAPTER ONE

1. INTRODUCTION
A band saw machine is a machine tool designed to cut off bar stock, tubing pipe or any metal
stock within its capacity or to cut sheet stock to desired contours. A band saw machine consists
of two pulleys (sometimes referred to drums) with an endless blade that rotates about them. One
of the pulley is powered, rotating the blade and the material to the blade forward. The powered
pulley is the drive pulley and the unpowered pulley is the idler pulley.

Band sawing like circular sawing, is a continuous cutting operation. An endless blade (properly
called a band) is tensioned between two shrouded, rotating wheels, and a portion of it is exposed
to do the cutting. [1]

Band saw is one of the common types of material cutting machine. It is designed such that
facilitate easy, fast and safely cutting with less human interference and due to this reason the
design can be ergonomically factor should be considered which is human capability in terms of
safety of operations weight and height.

This project consider with the design and modeling of band saw machine in our country for the
cutting of metals because of the metals cuts in our country is manually and there is no enough
band saw machine and other types of metal cutting.

1.1 BACKGROUND OF BAND SAW

In 1808 Englishman William Newberry patented the band saw. This was the first mechanical
arrangement to use a saw band that cut in one direction continuously. The band saw was 're-
invented' by Lemuel Hedge, an American in 1849 and in 1855, by a Frenchman named Perin.

Leighton A. Wilkie invented the first practical metal cutting contour band saw. Wilkie thought
of the increased productivity and reduced cost that would result if he could develop a band saw
capable of cutting contours in metal with the same efficiency his wood cutting band saw cut
timber. He adapted a wood saw so that it became more rigid and supplied more power, and built
a brazer into the saw frame so he could join the saw blade into, a band after passing it through a

1
starting hole in the work piece when making internal cuts. [2]

1.2 STATEMENT OF THE PROBLEM

In our country human use different types of cutting tools and equipment that are manually
operated like saw that operated by human hand work. This kind of manual cutting method is not
effective for industries and workshop even for our country, because manual cutting method is
less productive and it takes much time and energy.
In our country, all tools for cutting materials are operates manually to gate desired shape because
of lack of machine for cutting wood and metals. This leads to a negative feed backs such as; need
of high effort, time consumption, inefficient shape/undesired counters, damage of cutting tools
and injury of workers.
Therefore, this problem is avoided by designing and modeling of metal cutting band saw
machine in order to reduce time consumption. So that the design and modeling of band saw
machine in our country is mandatory, in order to solve the above problems.

1.3 OBJECTIVE OF THE STUDY

1.3.1 GENERAL OBJECTIVE
The main objective of this project is to design and modeling of vertical metal cutting band
saw machines that used to cut metal.

1.3.2 SPECIFIC OBJECTIVE

The specific objective of this project is as follows;

 Design of band saw components.

 Select the proper materials for band saw

 To develop model of each part and assembly drawing of the machine using solid work

 To analysis the distribution of force and stress of components

 To estimate the cost analysis

1.4 SCOPE OF THE PROJECT

The scope of this project is to design and modeling of vertical band saw machine for
industries and workshops. The design of band saw machine project is performed in industries
and workshops for the purpose of cutting metals and woods to desired contours.

Beneficiaries;

 Industries and workshops

 Other communities can be use

1.5 SIGNIFICANCE OF THE PROJECT

The thesis primarily helps to upgrade our design approach and practical knowledge in extreme
manner. And also the machine has the following significance:

 It will helps to minimize the problem of Industries and workshops by designing and
manufacturing the machine.
 It will helps to reduce work load of employs
 It will to reduce time consumption
 It will help to avoidance of injury of workers
 It will help to keep the cutting material from undesired shape.
 CHAPTER TWO

2. LITERATURE REVIEW
A great deal of research has been conducted in order to design and modeling band saw machine,
which would optimize productivity of manufacturing. This research has played a major role in
promoting design and modeling of band saw machine. This chapter tries to summarize some key
background references and their contributions to the design and modeling of band saw machine.

2.1 previous work related to the project

A literature review is a comprehensive summery of previous research on a topic. The literature
review surveys articles, books, and other resource relevant to a particular area of research. We
review the following scholar papers that are related to our thesis.

X, xu, y. yu (2005): this thesis investigated sawing performance of diamond with alloy coatings,
and the coating can raise the TRS performance. [8]

I.S. Buyuksehir (2007): investigated specific wear ratio and obtained specific energy under up-
cutting modes, and determined the optimal performance between process parameters, cutting
depth and work piece moved velocity. Besides, wire-saw is another important machining
application for natural stones and architecture. [11]

R. Okai et. al (2006): this thesis used saw-blade analyzed to investigate the effects of cutting
velocity and cutting force, however, the cutting tool caused wear because of cutting heat and
local stress concentrated. [10]

T. Thaler et. al (2014): studied the stability diagrams and chatter avoidance in horizontal band
sawing, and the experimental results the analysis of chatter avoidance is better than unstable
cutting force signals. To raise the cutting efficiency and cutting velocity, the cutting stratray is to
reduce chatter occurred. [12]

Some modified things from above works

In the previous work they use only one side of the blade rotation but we use the machine can be
work in both side of the blade rotation.
2.2 Gap of project
In our countries, people were used deferent types of cutting tools that used for cut plastic, wood,
metal and other materials. From these tools which are used for cutting materials are stone, faxes,
and saw etc. These cutting tools consumed more time, not give desired shape, take more energy
and become causes for waste of materials.

Due to the above reason human forced to design and manufactured another cutting tools or
machines and also the expansion of work shop and Industries in the world are another cause for
forced human to design and manufactured another cutting tools or machines which used for
eliminate the waste of time, energy, money and materials in work place. From these new
machines which used for cutting materials includes, pedal hacksaw, power hacksaw, cold saw
and others. These machines also have their limitations. Such as they cut simply straight line,
mostly they designed for wood, have no different speed for cutting different materials and the
blade moves backward and forward direction. Generally these machines cannot give desired
shape. To avoid the above problems we designed vertical band saw machine which used for
minimize waste of time, energy, materials etc. and to get required shape.

2.4 TYPES OF BAND SAW MACHINE

Horizontal band saw: Horizontal band saws hold the work piece stationary while the blade
swings down through the cut. This configuration is used to cut long materials such as pipe or bar
stock to length. Thus it is an important part of the facilities in most machine shops. The
horizontal design is not useful for cutting curves or complicated shapes. Small horizontal band
saws typically employ a gravity feed alone, retarded to an adjustable degree by a coil spring; on
industrial models, the rate of descent is usually controlled by a hydraulic cylinder bleeding
through an adjustable valve. When the saw is set up for a cut, the operator raises the saw,
positions the material to be cut underneath the blade, and then turns on the saw. The blade slowly
descends into the material, cutting it as the band blade moves. When the cut is complete, a switch
is tripped and the saw automatically turns off. More sophisticated versions of this type of saw are
partially or entirely for high-volume cutting of machining blanks. Such machines provide a
stream of cutting fluid recirculated from a sump, in the same manner that a machining centre
does.
Vertical band saw: A vertical band saw, also called a contour saw, keeps the blade's path
stationary while the work piece is moved across it. This type of saw can be used to cut out
complex shapes and angles. The part may be fed into the blade manually or with a power assist
mechanism. This type of metalcutting band saw is often equipped with a built-in blade welder.
This not only allows the operator to repair broken blades or fabricate new blades quickly, but
also allows for the blade to be purposely cut, routed through the center of a part, and re-welded
in order to make interior cuts. These saws are often fitted with a built-in air blower to cool the
blade and to blow chips away from the cut area giving the operator a clear view of the work. This
type of saw is also built in a woodworking version. The woodworking type is generally of much
lighter construction and does not incorporate a power feed mechanism, coolant, or welder.

Therefore, our project is based on vertical band saw machine.

2.5 COMPONENTS OF VERTICAL BAND SAW MACHINE

1. Blade: a band saw blade is basically a long, thin strip metal with a serrated edge for cutting
through wood and other materials, including metal. The strength of the blade and the tooth
determines the types of material it can cut. The cut is made by placing the toothed edge against
the material and moving it force fully.

Blade is the main parts of the band saw machine. In band saw machine materials are cut by the
blade.

2. Pulleys: There are different pulleys performing specific functions on the band saw. For
instance, a drive pulley is mounted on the motor, and its function is to move the drive belt, which
controls the speed at which the blade cuts.

3. Motor: This part pretty much runs the blades. It provides power to the cutting blades,
depending on how strong it is. Before you purchase a band saw, make sure you check its motor
power. This is the backbone of the machine; the band saw won’t work if the motor fails, so it is
worth putting the effort into the research process.

4. Frame: it is horizontal, vertical and inclined hardest structure used to supports and maintains
the alignments of the idlers and pulleys and support the driving machinery.

5. Shaft: is a rotating machine element, usually circular in cross section, which is used to
transmit power from one part to another, or from a machine which produces power to a machine
which absorbs power. Here one shaft is used to transfer the motor rotation to the pulley and
another one is used to transfer pulley rotation to the band saw blade.

6. Table: This is the worktop of the band saw, where all of the magic will take place! It is
located at the middle of the band saw and can come in many different widths and lengths.

7. Blade guides: These are the parts that essentially keep the band saw cutting blade in place,
directing the cutting path. Setting the blade guides both above and below the table helps to keep
the blade in place and also helps to reduce vibrations that may result from cutting. As with any
tool, fewer vibrations guarantee a good quality cut. The blade guide material greatly determines
the rate of wear and tear, which is due to the friction that results when the blade is reciprocating.

8. Gear: A mechanical drives defined as mechanize, which is intended to transmit mechanical

power over a certain distance, usually involving a change in speed and torque.

9. Bearing: is a machine element that constrains relative motion to only the desired motion, and
reduces friction between moving parts. Allows the relative motion of shaft and idlers.
 Chapter three
3. Methodology
The project must be following a series of methods and work flows. The flow starts from problem
identification and justification. This is done by observing problem of cutting system in metal and
wood materials. To analyzing detail design of all components collecting data is important. The
data can be collect by two methods. These are;

a. Primary data collection using

 Visual observation in the local area
 By interviewing to the workers
b. Secondary data collection
 By referring different books, documentations which are related to the
study
 By using different websites

During the design process the material selection for components is selecting using material
property text book to prepare any machine part, the type of material should be properly selected,
considering design safety. After selecting the material design of the component analytically
(dynamic and static) and identifying part components which are needed for the machine is the
next step. After design the components the machine is modeling using software. By the data and
result of the above procedures the modeling of the part and assembly drawing of band saw
machine is done using solid software. The cost analysis of the machine can be done using direct
method by considering material costs. Finally the conclusion and recommendation of the
machine is done.

Generally the methodology of this project is summarized using the following simple diagram.
 Problem identification

Data collection

Literature review

Design assumption

Material selection

Design analysis

No
Is it safe?

Yes
Result and discussion

3D modeling using soft ware

(Solid work, auto cad)

Conclusion &
recommendation

Figure 1 Flow diagram of the project

3.1 DESIGN ANALYSIS
3.1.1 Design consideration
Selection of materials

It is the especially that the most important factor that the designer should have knowledge of the
properties of design materials and cutting materials under working condition, some of the
important behaviors of design materials are, strength, durability, flexibility, costly, corrosiveness,
wear, reliability, utility and weight to cost ratio etc.

Durability of machine

To design one machine or equipment the services life of the machine is taken in to account.

Safety operation

The operation of vertical band saw machine is an extremely high degree of safety. Fewer
personnel are required for operation they are exposed low hazards than with other means of
cutting system.

Cost consideration

Cost is the most important consideration including in design. The aim of this design is under all
considerations should be to reduce the cutters cost.

3.1.2 Design specification

 The material being cut by this band saw machine is carbon steel
 The maximum thickness being cut by this band saw machine is 20mm.
 The cutting speed recommendation fore carbon steel is 60-108m/min
 Materials used for band saw blade is high speed steel(HSS)
 Table will be tilt 10 to the left and 10 to right
 Work table length 76cm
 Work table width 76cm
 Over all height of band saw machine is 176cm
 Overall length of band saw machine is 116cm
 Over all width of band saw machine is 100cm
 Depth of throat is 66cm
 Length of work piece is 75cm
 Width of work piece is 60cm
 The working height is 50cm
 The distance from center of lower pulley to upper pulley 100cm

3.1.3 Selection of Electric Motor

The different types of motors basically classified into two, DC and AC motor. These motors
have a sub classifications. DC motors classified into brushes and brush loss. The AC motor
classified into synchronous and induction. The induction motor divide into one phase and three
phase.

AC (alternative current) motors are highly flexible in many features including speed control and
have a much larger installed base compared to DC (direct current) motors, some of the key
advantages are: low power demand on start, controlled acceleration, adjustable operational
speed, controlled starting current, adjustable torque limit, reduced power line disturbances. So
because of the stated reasons AC motor is selected.

Three phase AC motor are generally used as source of power in machine tools. The power rating
of electric motor in generally purpose machine tool is calculated by the formula;

Nc
Nm= Kw
η

Where,

Nm=power rating of the electric motor (kW )

Nc=Total power required for removing of metal

η=Coefficient of the efficiency of the drives .90 % for gear drive

m
Nc=Fc ×V
s

Where,

Fc=Cutting force

V =cutting speed
From above equation the cutting force will be;

Fc=Ks ×f × d ( 1+ Kr + Kw ) , where

Ks=The specific cutting resistance for the working materials

d=depthof cutting mm/rev

f =feed rate mm/rev

Kr and Kw are the allowable the rake angle and wear resistance respectively

So we calculate cutting force (Fc) as follow;

Fc=Ks ×f × d ( 1+ Kr + Kw ) ,
2
Ks=For carbon steel=500 N /mm

f =1 mm/ rev

d=1mm /rev

Kr=0.1

Kw=0.15
2
Fc=500 N / mm × 1mm /rev ×1 mm/rev (1+0.1+0.15)

Fc=625 N

Then from the above equation;

Fc × V
Nc= KW ,Vc=60 m/min
6120

625 N ×60 m/min

Nc= =6.127 KW
6120

Nc
Nm= , η=90 %
η

6.127 KW
Nm= =6.8 KW
0.90

The motor power=6.8kw and the cutting power=6.127kw.

3.1.4 Motor Speed

The speed of a motor is the number of revolutions in a given time frame, typically revolutions
per minute (RPM). The speed of an AC motor depends on the frequency of the input power and
the number of poles for which the motor is wound. The synchronous speed in RPM is given by
the following equation, where the frequency is in hertz or cycles per second:

120× Frequency
Synchronous Speed ( RPM )=
No . of poles

Indian motors have synchronous speeds like 3000 / 1500 / 1000 / 750 / 600 / 500 / 375 RPM
corresponding to no. of poles being 2, 4, 6, 8, 10, 12, and 16 (always even) and given the mains
frequency of 50 cycles / sec. By considering and analyzing the above motor speed we take
375RPM for our motor.

3.1.5 Geometrical Analysis:

It describes the geometrical arrangements of component or parts with the relation to each other
and how these parts fit in order to fulfill the required assembly of the machine. It also tells us the
all over dimension of the machine such as length, width and height. By considering and
analyzing of working mechanism of vertical band saw machine, ergonomics factor, the position
which the machine will be stand(work place) and safety condition of the operator, the
geometrical arrangement of the vertical band saw machine is will be as following figure and it’s
over all dimensions are 176mmx116mm height and length respectively.

Component
No. Part name Quantity No.

1. 2
Pulley
2. 1
Axle shaft
3. 1
Frame
4. 1
Blade
5. 1
Table
Blade guide
6. 4
 7. Blade tension 1
adjustment Screw
8. Support of blade tension 1
adjustment
9. 1
Shaft
10. Table support and tilt of 1
table
11. 2
Gear

3.1.6 Design of gear

A mechanical drives defined as mechanize, which is intended to transmit mechanical power over
a certain distance, usually involving a change in speed and torque. In generally the mechanical
drive is required between the prime mover such as electric motor and a part of operating
machines. Mechanical drive is used on account of following reason;

 The torque and speed of the machine are always different than that of electric motor or
engine.
 Machine usually run at low speed and required high torque.
 In certain machines variable speed are required for operation, whereas motor runs at
constant speed.

The selection of proper mechanical drive for a given application depend upon number of facts
such as, center distance, velocity ratio, shaft arrangement, maintenance considerations and cost.
For this design we select gear drive because of it has the following advantages over belt and
chain drives;

 It is positive drive and velocity ratio remain constant

 The center distance between the shafts is relatively small, which result in compact
construction.

 It can transmit power, which is beyond the range of belt or chain drive.
  It can transmit motion at very low speed, which not possible with the belt drive.

 The efficiency of gear drive is very high even up to 90% for spur gear.

Gears are broadly classified in to four groups; spur gear, helical gear, bevel gear and worm gear.
By considering and analyzing the function properties of four gears we select spur gear for this
design. Spur gears: The teeth are cut parallel to the axis of the shaft. It is used for only the shafts
are parallel. The profile of the gear tooth is in shape of an involute curve and remains identical
along the entire width of the gear.

Let given Z1 =16 teetℎ

Assume gear ratio 6:1

Z2 Z
i= , 6= 2 , Z 2=96 teetℎ
Z1 16

Z 2 n1 96 375 rpm
Then, = = =
Z 1 n2 16 n2

n2=63 rpm

Material used for gear cast steel for both gear and pinion.
Step 1: To identify wear number since the material the same for both gear and pinion. But pinion
is wearer than gear. Then the design is based on the pinion.

Step 2: Design

a) Tangential tooth load

6
9.55 ×10 × p ×C s
F t= Where P=power in kW
n ×r

C s=Service factor for light shocks

n=rpm of pinion

d1 m z 1 16 m
r= = = =8 m For pinion
2 2 2

Types of 3 hours/day 8 to 10 hours/day 24 hours

Intermittent operation
 service/Types of load

Steady shocks 0.8 1 1.25

Light shocks 1.00 1.25 1.50

Medium shocks 1.25 1.50 1.80

Heavy shocks 1.5 1.80 2.00

6
9.55 ×10 × 6.8 kw ×1.25 2705.8
F t= = … … … … … … … … … … … … … … … … eq ( 1 )
375 ×8 m m

b) Lewis equation for tangential tooth load

F t=δ o ×b × y × p × k

Where, δ o=138Mpa

Assume width=10m, (m=modules),

Y= Lewis factor for 200 full depth involute

0.912 0.912
Y =0.145− =0.145− =0.097
Z1 16

P=pitch

b=face width =10m, m=2.5

K v =¿Velocity factor

F t=δ o ×b × y × p × k v =138× 10 m× π ×m ×0.097 × k v

2
F t=433.32 m k v … … … … … … … … … … … … … … … … … … … … … … … … … … … eq(2)

From the equation (2) and equation (1)

2705.8
433.32m2 K v= =433.32 m3 k v = 2705.8
m
 2705.8
m3 k v = = 6.245,
433.32

But, k v for full depth involute;

3 m π × d 1× n (m z 1)n1
For v m ≤ 7.5 , v m= 1
=π
3+v m s 6000 6000

πm (16 ×375)
v m= =0.314 m
6000

Trial (1) Assume m=2. 5 for standard values of module recommended serves of modules for gear
mm:1,1.25,2,2.5,3,3.5,4,4.5,5,5.5,6,7,8,9.10,11,12,14,16,18,20,22,25,28,32,36,40

v m=0.314 × 2.5=0.785 m/s

3 3
k v= = = 0.8
3+v m 3+0.785 m/s

3
m k v =2.5 × 0.8=12.5
3
m k v =6.24

If the right hand side > left hand side the selection module is suitable. Then,

m3 k v =¿ >6.24 that means, 12.5>6.24 then 2.5 modules adopt.

Step 3: dimensions

 Pitch diameter (d 1) for pinion d 1=m z 1=2.5×16=40mm

 The gear diameter(d 2)=m z 2=2.5×96=240mm
d 1+ d 2 40+240
 Center distance(a)= = =140mm
2 2
 Face width(b)=10m=10×m=10×2.5=25mm
 Pitch(p)= πm=7.85mm
2705.8 2705.8
 Tangential tooth load( F t ¿= = =¿1082.32N
m 2.5
 Clearance(c)=hf-ha =3.12= 5-2.5mm
 Tooth depth(h)= hf+ha = 3.125+2.5mm = 5.625mm
p
 Tooth thickness(t)= = πm/2 = 3.925mm
2
  For full depth involute dedendum diameter
 Addendum(ℎ a)=1×2.5 = 2.5mm
 Dedendum( ℎf )=1.25×m = 1.25×2.5 = 3.125

Addendum diameter

For pinion (d a 1 ¿=d 1+2ℎ a=40+2×2.5=45

For gear (d a 2 ¿=d 2+2ℎ a==240+2.5=245mm

Dedendum diameter

For pinion (d f 2 ¿=d 1-2ℎ f =40−2×3.125=33.75mm

For gear (d f 2 ¿=d 2-2ℎ f =240−6.25=233.75

Step 4: teeth dynamic load and wear resistance load

21 v (F t +bc )
a) Dynamic load ( F d ¿=F t + where F t=1082.02N
21 v+ ¿ ¿

V =0.785 m/ s

For full 200 depth involute steel and cast iron.

0.0125=99.57KN/mm for full depth, at Vm=0.785 m/s

f=0.124, where f=permissible error in mm

F=0.0125, C=99.57

99.57 ×0.124
F=0.124, C=x C= =987.7 N /mm
0.0125

21× 0.785 ( 1082.32+ 25× 987.7 )

F d=1082.32+
21× 0.785+¿ ¿

b) Wear resistance load ( F w ¿

2× Z 2 2 ×96
F w =d 1 ×b ×Q × K Wℎere ,Q=ratio factor = = =1.714
Z 1+ Z 2 16 +96

b = 25mm

d = 40mm
 F w =40 × 25× 1.714 × K =1714.28 k

For safe design F w > F d

Then, 1714.28K ¿3482.46N

3482.46 N
K¿ , at K>2.03 from table for K>2.03 at α =200 the recommended hardness at K=2.19
1714.28 N
F w =¿=1714.2×2.19=3754.3N, then F w > F d, so design safe.

For the pinion=400BHN and for gear =350BHN.

Load stress factor K

Brinell NO Brinell NO δfc(Mpa) at
o
20
Pinion Gear
400 300 896.63 1.7521
350 350 896.63 1.8963
400 350 962.89 2.1935
400 400 1034.47 2.5241

3.1.7 Design of shaft

A shaft is a rotating machine element which is used to transmit power from one place to another.
The power is delivered to the shaft by some tangential force and the resultant torque (or twisting
moment) set up within the shaft Permits the power to be transferred to various machines linked
up to the shaft. In order to transfer the power from one shaft to another, the various members
such as pulleys, gears etc., are mounted on it. These members along with the forces exerted upon
them causes the shaft to bending. In other words, we may say that a shaft is used for the
transmission of torque and bending moment. The various members are mounted on the shaft by
means of keys or Splines.

Material selection for Shafts

The material used for shafts should have the following properties:

1. It should have high strength.

2. It should have good machinability.
3. It should have low notch sensitivity factor.
 4. It should have good heat treatment properties.
5. It should have high wear resistant properties.

The material used for ordinary shafts is carbon steel of grades 40 C 8, 45 C 8, 50 C 4 and 50 C
12.The mechanical properties of these grades of carbon steel are given in the following table.
mecℎanical properties of steels used for sℎafts .

3.1.7 Design of pulley

Pulleys are used to transmit power from one shaft to another shaft b this design in blade of band
saw used in steady of belt. In band saw machine, pulley provide power, as support and guidance
for the blade. The upper pulley can be raised and lowered to tension the blade. The lower pulley,
which is drives the blade, connected to the shaft which is used to transmit the power from the
motor by means of pinion and gear. The principal part of pulleys is: hub, arms and rim.

Diameter of pulley may be obtained either from velocity ratio or by considering centrifugal or
hoop stress. From the two methods we use the velocity ratio to get pulley diameter as follow

Let say the, N is the rpm of the lower pulley or gear.

m
V =60 ,this is the cutting speed of carbon steel .
min

N=63 rpm, tℎis is tℎe cutting rpm of carbon steel

D=the diameter of lower pulley

V =π × D × N
 m
60 =3.14 × D ×63=0.3033 m=303.3 mm
min

Therefore D 303.3mm and upper pulley and lower pulley have the same diameter. For large
pulley arm used. The number of arm depends on the size of the pulleys if number of arm 4, for
the pulley diameter from 200 to 600mm. if number of arm 6, for the pulley diameter from 600 to
1500mm. if number of arm 8, for the pulley diameter for large pulleys.

From these results our pulley has four arms. The arm can be straight or curved. The straight arm
is lighter and stronger than curved arms we select straight arm for this pulley. In design, each
arm is considered as cantilever beam, fixed at the hub and loaded at the rim. For safety design,
the length of arm may be taken as equal to the radius of the pulley. Further, it is usual to assume
that about half number of arms is loaded, since the arm of blade is around 1800 .

Let T1 torque transmitted

R= Radius of pulley

n= Number of arm

T
Tangential load act on each arm, F t= , wℎere T =1031 Nm , ¿ pulley .
R ×n

1031 Nm
F t= −3
=1701 Nm
151.5 ×10 × 4

Maximum bending moment.

2T 2T 2 ×1031 Nm 3
M max = × R= = =515.5 ×10 mm
R×n n 4

If the width of the blade is known, then width of the pulley or face of the pulley (B) is taken 25%
greater than the width of blade.

B = 1.25b; where b = Width of blade

B=1.25×13=16.25mm

Power transmitted by the pulley (P); P=( T 1 −T 2 ) × V

Where T 1 is the tension in the tight side of the blade

T 2 is tension in the slack side of the blade

V is the speed of the pulley

m
P=( T 1 −T 2 ) × V =6.8 ×10 3=( T 1 −T 2 ) ×1
sec

P=T 1 − T 2=6.8 ×103 … … … … … … … … … … … … … … … … … … . eq ( 1 )

We know that the power transmitted

T1 μ× θ
=e wℎere ,θ is tℎe angle of contact tℎe pulley∧blade
T2

μ is cofficient of friction between blade∧pulley

π
θ=(180 −2 α ) rad
180

r1 − r2
sin α= wℎere , r is radius of pulley
c

c is center distance between tℎe pulleys . But , r 1=r 2 , tℎen

r1 − r2
sin α = =0 , sin α =0
c

α =sin −1 ( 0 )=0

π
θ=( 180− 2× 0 ) rad=πrad
180

T1 μ× θ
=e ,θ = πrad and μ=0.3
T2

T 1 0.3× π
=e =2.56 … … … … … … … … … … … … … … … … … … … … … … … … … .eq ( 2 )
T2

From equation (1) and (2)

3
T 1=2.56 T 2 ∧T 1 −T 2=6.8 ×10 , ¿ tℎis find value of T 1∧T 2 .
3
2.56 T 2 −T 2=6.8 ×10
3
1.56 T 2=6.8 ×10
 3
6.8× 10
T 2= =4358.9 N
1.56

From equation (1), T 1 −T 2=6.8 × 103

3
T 1 − 4358.9 N =6.8 ×10

T 1=11158 N

m
Since the velocity of the blade (pulley) is less than 10 .Therefore the centrifugal tension need
sec
not to be considered.

Pulley bore size: The pulley bore size is equal to the diameter of the hub on which it is to be
mounted. The inner diameter of the hub is equal to the shaft diameter; d ℎi =d sℎ.The outer
diameter of the hub is will be determined as follow, outer diameter of hub d ℎo =2 d , for small
shaft diameter, where d is shaft diameter.

d = 40mm, from the shaft calculation.

So we calculate outer diameter of as follow;

H d =2 d=2 × 40 mm=80 mm

Length of hub: The length of hub is equal to the key length. It may be taken as Length of hub
π ×d
( Lℎ )= , where d is diameter of shaft, which equal to 40mm.
2

π × 40 mm
Hl= =62.8 mm
2

Let us now check the induced shear stress for the hub materials which is grey cast iron with
permissible stress 30Mpa. Considering the hub as hollow shaft .we know that maximum torque
which equal to;T max=f . s × T =2.051× 1031 Nm=2114.58 Nm

T max=
π
16
×τ c (
D2 −d 2
D )
( )
2 2
π 80 − 40
2114.58 ×103 = ×τ c
16 80
 3
2114.58 ×10
τ c= =22.4 Mpa
94200

It safe because shear stress less than permissible stress.

Design of Axle

An axle similar in shape to the shaft, is stationary machine element and used to transmission of
bending moment only. It is simply acts as supported for some rotating body.

The material used for the axle is carbon steel grade 45c8.

sut = 610 to 700Mpa

σ el=350 Mpa

Maximum permissible working stress for transmission shafts, according to American

Engineering (ASME) code for the design of transmission shaft, the permissible tensile stress (
σ b¿ .

σ b=0.6 σ el∨0.36 σ el

σ b=0.6 × 350Mpa = 210Mpa

Axle subjected to bending moment only then the maximum stress (tensile or compressive stress
is given by the bending equation;

M σb
= … … … … … … … … … … … … … … … … … … …. eq (1 )
I Y

Where, M=bending moment

I=moment of inertia of cross sectional area the axle.

σ b=bending stress.

Y=distance from neutral axis to the outer most fiber.

π d
I= × d 4 ∧Y =
64 2

π 3
Substituting in equation (1) M = × σ b ×d
32
 M pulley

The maximum bending moment act on the pulley. Therefore maximum bending moment:

M =W × L

Where W = total tension by the lower pulley=15.496KN

L = length of axle shaft

3
M =W × L=15.496 ×10 ×75=1162200 Nmm

π 3
M= × σ b ×d =1162200 Nmm
32

3 32 ×1162200 Nmm
d= =¿ 56400.363mm3
π ×210 Mpa

d=38.35=40 mm¿ tℎe standard .

Design of sunk key

Key: After deciding the key length from proportion, the width and thickness of key the key are
determined by considering the shearing and crushing failure of the key.

These are the standard form of keys used in practice and may be either square, rectangular or
circular in cross section. The ends may be square or round. Generally half the thickness of the
key fit into the shaft key ways and the remains half is in hub key ways. These keys are used for
heavy duty as they fit between the key and the shaft is positive.

Sunk keys may be classified as taper, parallel, and woodruff keys.

Taper sunk key: These are in the form of square, rectangular and circular in cross section. The
keys are uniform in width but tapped in the thickness. The bottom surface of the key is straight
and the top surface taped.

Parallel or feather key: Is the type of sunk key, uniform in width and thickness as well.
From the above types of sun keys we select tapped (rectangular) for this design.

Tapped sunk key:

Let, T, torque transmitted

D, diameter of shaft

L, length of key

b, width of key

T, thickness of key

σ c =permissible compressive stress∈tℎe key material .

τ = permissible sℎear stress∈tℎe key material

T 2T 2× 1031 Nm
F t= = = =51550 N
d d 0.04 m
2

The effect of force on the key is to induce two possible mode of failure such as shearing and
crushing. It is assumed that the half thickness of key in the shaft and the remains half in the hub.
Considering shearing failure;

2T
F= =lb
d

2T F
τ= =
d lb
b

Considering crushing failure;

2T t
F= = ×l σ c
d 2

4T 2 F
σ c= =
dlt ¿

Shaft Width Thickness of

diameter(mm)up key(mm) key(mm)
to and included
6 2 2
 8 3 3
10 4 4
12 5 5
17 6 6
22 8 7
30 10 8
38 12 8
44 14 9
From the table, width, thickness and length will be for the shaft diameter =40mm

Width of key =12mm

Thickness=8mm

Length of key l=1.5 d =1.5× 40=60 mm

Since the crushing stress for the key materials is twice its shear stress (i.e. σ ck =2 τ k), therefore
tapped key used. The material used for key is grey cast iron with permissible stress is 450Mpa.

Let us now check the induced stress in the key by considering it in shearing and crushing stress.

Considered the key in shearing. We know that maximum torque=2114.58Nm

d
T max=l× b× ×τ
2 k

3 40 mm
2114.58 ×10 Nmm=60 mm ×12 mm × × τk
2
3
2114.58× 10 Nmm
τ k= =146.8Mpa
14400 mm

Now considering the key in crushing stress. The material used for the key is grey cast iron
which has permissible stress of 450Mpa.We know that maximum torque of shaft is
3
2114.58 ×10 Nmm.

t d
T max=l× × × σ ck
2 2

3 8 mm 40 mm
2114.58 ×10 Nmm=60 mm × × × σ ck
2 2
 3
2114.58 ×10 Nmm
σ ck= =440.5 Mpa
4800

So the key is safe because of crushing and shearing stress less than permissible stress.

Design of blade

Selection of band saw frame

All band saws are essentially the same, regardless of size. They are relatively simple machines

with easily accessed parts that serve obvious functions. Take some time to familiarize yourself

with the location and names of the various parts.

The frame is the most important part of a band saw. It supports the pulley, guides, table, and the
motor.The frame material also has to remain stable

throughout temperature and humidity

 Reference
[1] Website, http/www.band saw machine. [Online].

[2] Website, http/www.history of band saw machine. [Online].

[3] Design of machine elements second edition VB Bhandari Rezired Professor and head of
department of mechanical engineering.

[4] Design of machine elements (volume-2) T.Krisha Rao B.E, MS (T-M), ph.dMBA
Gandhiji Institute of Science and Technology.

[5] Fundamental of metal cutting and machine tools second edition B.L.Juneja department of
mechanical engineering.

[6] Machine tool design and numerical control NK Mehta formerly Professor Indian institute
of technology.

[7] www.bahco.com

[8] X. Xu, Y. Yu, Sawing performance of diamond with alloy coatings, Surf. & Coat. Tech.,
198, 459- 3 46(2005).

[9] www.grizzly.com vertical metal cutting band saw.

[10] R. Okai, S.J. Mitchual, K. Frimpong-Mensah, Optimization techniques for

minimizing saw teeth deflection and lumber thickness variation, Prec. Eng., 30, 1, 39–46
(2006).

[11] I.S. Buyuksagis, Effect of Cutting Mode on the Sawability of Granites Using
Segmented Circular Diamond Sawblade, Int. J. Mach. Tool. & Manu183, 399-406 (2007).

[12] T. Thaler, P. Potocnik, I. Bric, E. Govekar, Chatter detection in band sawing based on
discriminant analysis of sound features, Appl. Acou77, 114–121 (2014).

[13] www.lenox tools .com

[14] www.cascom.army/ordnance