Design and analysis of portable power hacksaw with coolant and lubrication system

The study aims to design and analyze a portable power hacksaw capable of cutting small workpieces mainly wood, plastic, and commonly used metal. This topic was chosen as today's hacksaws lack portability and lubrication facilities. Theoretical calculations were done to select the hacksaw material and dimensions based on the loads experienced by it. The CAD design was prepared using Solidworks. Three-dimensional Finite Element Analysis was used to conduct a structural analysis of the model. Parameters like total deformation and von-Mises stress of various components of the hacksaw were evaluated. Different cutting blade materials were analyzed on Ansys workbench as well. CFD analysis was performed using Ansys Fluent on the nozzle to study the pressure points and the respective velocity streamlines of the coolant. Design optimization was carried out for various components of the hacksaw using a generative design approach. The finite element analysis results indicated that the proposed design was structurally safe and optimized. CFD analysis of the nozzle provided valuable insights regarding lubricant flow characteristics. Blade material analysis allowed the selection of an appropriate blade material for cutting purposes. The introduction of a lubrication regime provided a novel approach to tackling issues like high blade temperatures and workpiece surface finish.