GAMBELLA UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTEMENT OF MECHANICAL ENGINEERING

INTERNSHIP REPORT AND PROJECT
HOSTING COMPANY: DEREJE LEMA
AUTOMOTIVE GARAGE
DURATION OF INTERNSHIP: March- June2016 E.C

Student Name ID №
Jemal Nurye--------------------------------------------RNSc/0422/2013
Advisor: Mr. Ashagre Abebe

SUBMISSION DATE: Oct, 2017 E.C

GAMBELLA, ETHIOPIA
Final Report and Project

DECLARATION

I am Jemal and I understand that this report is involve collaboration with other individuals and
organizations, and I actively engage in effective communication and teamwork to developed a
productive and collaborative environment. This report succeed depend on various factors,
including the availability of resources, support from company (at Dereje Lema Garage) and
supervisors, and the whole circumstances. I am prepared to adapt and make necessary thing by
the report. By taking this project, I enhance my knowledge, skills, and practical experience at
Dereje Lema Garage

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APPROVAL SHEET FOR ADVISOR

He hereby confirm our commitment to providing the necessary guidance, support, and resources
required for the successful completion of the report. He supervised and evaluated the progress of
the report and provide assistance as needed for me. By approving this report, he Acknowledge
that it aligns with the academic requirements and objectives of the University. I believe that the
report has the potential to help to the advancement of knowledge and benefit to me and the
organization.

Project Advisor:
Name: Mr.Ashagre Abebe
Position: lecturer in Gambella university
Department: Mechanical engineering
Date: March-June 2016 E.C.
Signature:

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ACKNOWLEDGMENT
First of all, I would give the glory to ALLAH, and next I extend my heartfelt thanks to my
advisor, Ashagre Abebe for their invaluable support throughout the report. I am grateful by their
expertise, guidance, and continuous encouragement, which have been instrumental in shaping the
direction of this report. Their insightful feedback and constructive comment have significantly
enriched the quality of my work. I would like to acknowledge the support and cooperation
extended by the faculty members of Mechanical Engineering Department. Their profound
knowledge, dedication, and teaching have laid a strong foundation for my academic growth and
inspired me to this report. I extend my appreciation to the staff members of Dereje Lema Garage
who have provided assistance in various aspects of the report. Their administrative support,
access to resources, and technical assistance have been invaluable in executing the report
effectively. Lastly I want give my beholden to who guide me.

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ABSTRACT

This report explores the practical application of knowledge acquired during a four-month garage
internship. The primary focus was to bridge the gap between theoretical understanding and real-
world implementation in a hands-on environment. Throughout the internship, I engaged in
various projects that enhanced my technical skills and provided insights into the mechanics of
the industry. By actively participating in tasks and collaborating with experienced professionals,
I was able to gain valuable experience that significantly contributed to my professional
development. The findings indicate that immersive, practical experiences are essential for
reinforcing theoretical knowledge, ultimately leading to improved competency in the field. This
internship not only enriched my skill set but also fostered a deeper understanding of industry
practices.

Key word: engine, body and frame, control system, electrical system

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Table of Contents
DECLARATION........................................................................................................................................i
APPROVAL SHEET FOR ADVISOR....................................................................................................ii
ACKNOWLEDGMENT..........................................................................................................................iii
ABSTRACT..............................................................................................................................................iv
List of Figure.............................................................................................................................................ix
LIST OF TABLE......................................................................................................................................xi
LIST OF SYMBOLS...............................................................................................................................xii
PART ONE..................................................................................................................................................xiii
CHAPTER ONE........................................................................................................................................1
1.introcaction of the company..................................................................................................................1
1.1 History of a company........................................................................................................................1
1.2 Overall view of the garage................................................................................................................2
1.3 vision, mission, and goal of a company............................................................................................3
1.3.2 Vision:.........................................................................................................................................3
1.3.3 Mission:......................................................................................................................................3
1.3.4 Goals...........................................................................................................................................3
1.4 work flow of the company................................................................................................................4
1.5 The main costumer of the company maintenance...........................................................................6
CHAPTER TWO.......................................................................................................................................7
2. OVERALL INTERNSHIP EXPERIENCE.........................................................................................7
2.1 How I get in the company.................................................................................................................7
2.2 Section of the Company I Have Been Working.................................................................................7
2.3 Engine................................................................................................................................................8
2.3.1 Main parts of engine categorized by their function..................................................................9
2.4 Body and Frame..............................................................................................................................20
2.4.1 Here are the main parts of a car body:....................................................................................20
2.5 Transmission System......................................................................................................................27
2.5.1The main components of a typical transmission system include:...........................................28
2.6. Electrical system............................................................................................................................30
2.6.1Here are some key components and functions of a car's electrical system:...........................31

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2.7 Control system................................................................................................................................32

2.7.1 Here are some type of control system....................................................................................33
2.8 Car maintenance.............................................................................................................................34
2.8.1 Task one (servicing)..................................................................................................................34
2.8.2. Task two (Changing Shock absorber)......................................................................................35
2.8.3 Task three (Changing clutch)....................................................................................................36
2.9 Welding...........................................................................................................................................37
2.10 Lubrication....................................................................................................................................37
2.10.1 Here are some key functions of lubrication:.........................................................................37
2.11 Problems Encountered during the Internship Period...................................................................38
2.11.1 Internal problems..............................................................................................................38
2.12 Challenges encountered during the internship............................................................................38
CHAPTER THREE.................................................................................................................................39
3. OVERALL BENEFIT OF INTERNSHIP.........................................................................................39
3.1 General objective............................................................................................................................39
3.2 Here are some benefit of internship..............................................................................................39
3.2.1 In Terms of Practical Skills:......................................................................................................39
3.2.2 In Terms of Upgrading Theoretical Knowledge:......................................................................40
3.2.3 In Terms of Improving Personal Communication Skills:..........................................................40
3.2.4 In Terms of Improving Team Playing Skills:.............................................................................40
3.2.5 In Terms of Improving Leadership Skills:.................................................................................41
3.2.6 In Terms of Work Ethics Skills:.................................................................................................41
3.2.7 In Terms of Entrepreneurship Skills:........................................................................................41
CHAPTER FOUR...................................................................................................................................43
4. TECHNICAL ASPECT OF THE INTERNSHIP.............................................................................43
4.1 Methods and procedures while working........................................................................................43
4.2 Technical tasks/products................................................................................................................45
CHAPTER FIVE.....................................................................................................................................46
CONCLUTION AND RECOMMENDATION.....................................................................................46
CONCLUTION.......................................................................................................................................46
RECOMMENDATION...........................................................................................................................47
PART TWO.............................................................................................................................................48
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INTERNSHIP PROJECT..................................................................................................................48
DECLARETION.........................................................................................Error! Bookmark not defined.
ACKNOWLEDGMENT.............................................................................Error! Bookmark not defined.
EXECUTIVE SUMMARY.........................................................................Error! Bookmark not defined.
ABSTRACT.................................................................................................Error! Bookmark not defined.
CHAPTER ONE......................................................................................................................................49
1. DESIGN OF HYDRAULIC BEARING PULLER............................................................................49
1.1 Introduction....................................................................................................................................49
1.1.1 Background of Bearing Puller..................................................................................................49
1.1.2 Types of Hydraulic Bearing Puller............................................................................................50
1.2 Component of hydraulic bearing puller..........................................................................................53
1.3 Problem Statement.........................................................................................................................55
CHAITER TWO......................................................................................................................................57
2. OBJECTIVE OF THE PROJECT.....................................................................................................57
2.1 General Objective of the Project....................................................................................................57
2.2 Specific Objective of the Project.....................................................................................................57
2.3 Scope and Limitation......................................................................................................................57
2.3.1 Scope of the Project.................................................................................................................57
2.3.2 Limitation On the Project.........................................................................................................57
2.4 Significance of the Project..............................................................................................................58
2.5 Literature Review............................................................................................................................58
CHPTER THREE...................................................................................................................................60
3. MATERIAL AND METHODOLOGY..............................................................................................60
3.1 METHODOLOGY..............................................................................................................................60
CHAPTER FOUR...................................................................................................................................66
4. DESIGN ANALYSIS...........................................................................................................................66
4.1 General Design Considerations of Hydraulic bearing puller..........................................................66
4.1.1 Force Analysis..........................................................................................................................66
4.1.2 Geometrical Analysis...............................................................................................................68
4.1.3 Design components of Hydraulic bearing puller.....................................................................70
4.1.4 Selection of appropriate material for machine components..................................................81
4.2 Working Principles of Hydraulic Bearing Puller..............................................................................83
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CHAPTER FIVE.....................................................................................................................................84
5. CONCLUSION AND RECOMMENDATION..................................................................................84
5.1 Conclusion.......................................................................................................................................84
5.2 Recommendation............................................................................................................................85
References................................................................................................................................................86
APPENDIX..............................................................................................................................................87
Appendix 1...............................................................................................................................................87
Appendix 2...............................................................................................................................................88

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List of Figure
Part one
Figure1. 1 work flow of the company.............................................................................................5
Figure 2.1 car engine.......................................................................................................................8
Figure2.2 Cylinder block.................................................................................................................9
Figure 2.3 Cylinder head...............................................................................................................10
Figure 2.4 piston............................................................................................................................10
Figure 2.5 piston rings...................................................................................................................11
Figure 2.6 connecting rod..............................................................................................................11
Figure 2.7 crankshaft.....................................................................................................................12
Figure 2.8 manifold.......................................................................................................................13
Figure 2.9 gudgeon pin or piston pin.............................................................................................14
Figure 2.10 spark plug...................................................................................................................14
Figure 2.11 carburetor...................................................................................................................15
Figure 2.12 flywheel......................................................................................................................15
Figure 2.13 automobile governor..................................................................................................16
Figure 2.14 engine bearing............................................................................................................17
Figure 2.15 supercharger...............................................................................................................17
Figure 2.16 turbocharger...............................................................................................................18
Figure 2.17 radiator.......................................................................................................................19
Figure 2.18 rocker arm..................................................................................................................19
Figure 2.19 hood or bonnet............................................................................................................20
Figure 2.20 front bumper...............................................................................................................21
Figure 2.21 the crash guard or bulbar............................................................................................21
Figure 2.22 wiper blade.................................................................................................................22
Figure 2.23 quarter panel...............................................................................................................22
Figure 2.24 roof.............................................................................................................................23
Figure 2.25 sunroof........................................................................................................................23
Figure 2.26 side view mirror.........................................................................................................24
Figure 2.27 rear view mirror..........................................................................................................24
Figure 2.28 Car doors....................................................................................................................25
Figure 2.29 door handle.................................................................................................................25
Figure 2.30 trunk...........................................................................................................................26
Figure 2.31 wheels.........................................................................................................................26
Figure 2.32 dashboard...................................................................................................................27
Figure 2.33 transmission system....................................................................................................28
Figure 2.34 clutch..........................................................................................................................28
Figure 2.35 gearbox.......................................................................................................................29
Figure 2.36 drive shaft...................................................................................................................29
Figure 2.37 differential..................................................................................................................30
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Figure 2.38 electrical system.........................................................................................................30

Figure 2.39 battery.........................................................................................................................31
Figure 2.40 wiring and cables........................................................................................................31
Figure 2.41 power source..............................................................................................................32
Figure 2.42 control system............................................................................................................32
Figure 2.43 steering system...........................................................................................................33
Figure 2.44 breaking system..........................................................................................................34
Figure 2.45 lubrication...................................................................................................................38
Part two
Figure1.1 removal of bearing using sliding hammer.....................................................................50
Figure 1.2 removal of bearing hammer and chisel........................................................................50
Figure 1.3 multi-jaw puller............................................................................................................51
Figure 1.4 sliding hammer.............................................................................................................52
Figure 1.5 hydraulic puller............................................................................................................52
Figure 3.1 design step of hydraulic bearing puller........................................................................61
Figure 4.1 hydraulic pressure force...............................................................................................67
Figure 4.2 design of main frame....................................................................................................70
Figure 4.3 loads distribute.............................................................................................................71
Figure 4.4 load cd..........................................................................................................................71
Figure 4.5 load distribute joint A...................................................................................................74
Figure 4.6 load distribution joint B................................................................................................75
Figure 4.7 load distribution joint C................................................................................................75
Figure 4.8 load distribution joint D...............................................................................................76
Figure 4.9 design of frame bar.......................................................................................................76
Figure 4.10 design of connecting rods...........................................................................................77
Figure 4.11 pulling jaws................................................................................................................78
Figure 4.12 Load of puller jaws.....................................................................................................79
Figure 4.13 double rod piston........................................................................................................81
Figure 4.14 hydraulic cylinder.......................................................................................................82

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LIST OF TABLE
Table 1 Hydraulic bearing puller design data_________________________________________63
Table 2 Mechanical properties of materials used______________________________________63
Table 3 Components of Hydraulic bearing puller_____________________________________63
Table 4 range of the design_______________________________________________________69
Table 5 range of base area_______________________________________________________69
Table 6 dimension of frame bar___________________________________________________76
Table 7 dimension of connecting rods______________________________________________78
Table 8 dimension of inlet and outlet port___________________________________________80
Table 9 dimension of hydraulic cylinder____________________________________________82
Table 10 dimension of selecting material____________________________________________83
Table 11 Mechanical properties of materials_________________________________________87
Table 12 Mechanical properties of materials_________________________________________88

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LIST OF SYMBOLS
MOENCO: Motor and engineering company of Ethiopia
NGO: non-government organization
IC: Internal Combustion
N: Newton
MM: Milimeter
MPA: Megapascal
GPA: Gigapascal
F: Force
P: Pressure
A: Area
KN: Kilonewton

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PART ONE

INTERNSHIP
REPORT

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CHAPTER ONE
1.Introduction of the company
1.1 History of a company
In this chapter I will express the overall part of Dereje Lemma garage with my gained knowledge
from the internship. Dereje Lemma Garage is a company that operates in the automotive
industry. They have established a partnership with MOENCO, the Motor and Engineering
Company of Ethiopia. MOENCO is located in Gambella, which is a city in the Gammbella
Region of Ethiopia. The partnership between Dereje Lemma Garage Company and MOENCO
likely involves collaboration and mutual support in various aspects of the automotive sector. This
could include areas such as vehicle repairs, maintenance services, spare parts supply, and
possibly even sales and distribution.

MOENCO, short for "Motor and Engineering Company of Ethiopia," is a prominent automotive
distributor and assembler in Ethiopia. MOENCO was established in 1959 as a joint venture
between the Ethiopian government and Toyota Tsusho Corporation, a trading company join with
Toyota Motor Corporation. The company's primary objective was to address the growing
demand for automobiles in Ethiopia and develop the country's automotive industry. Initially,
MOENCO focused on importing and distributing Toyota vehicles and spare parts in Ethiopia. As
the demand for automobiles increased, the company expanded its operations and established a
local assembly plant(industry) in 1964. The assembly plant played a significant role in the
development of the Ethiopian automotive industry, as it allowed for the production of vehicles
within the country. Over the years, MOENCO continued to expand its product range and
dealership network. It introduced various Toyota models into the Ethiopian market and provided
after-sales services and spare parts. The company's commitment to quality and customer
satisfaction helped it establish a strong presence in the Ethiopian automotive sector. In addition
to its core business of vehicle distribution and assembly, MOENCO has been involved in
community development initiatives in Ethiopia. For example, the company has supported
education and healthcare programs and has contributed to environmental conservation efforts.

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As of my knowledge cutoff in September 2021, MOENCO had become one of the largest
automotive companies in Ethiopia, with a widespread network of dealerships and service centers
across the country. It had also expanded its operations beyond Toyota vehicles and represented
other renowned automotive brands.

1.1.2 History of Dereje Lema garage

Dereje Garage is a company that specializes in providing non-stop automated vehicle repair
solutions. With a focus on high quality and cost-effectiveness, Dereje Garage has been providing
automotive repair and auto-body services since January 1999.One of the key aspects of Dereje
Garage's services is their commitment to using genuine parts supplied by MOENCO, the Motor
and Engineering Company of Ethiopia. By sourcing authentic parts, Dereje Garage ensures the
reliability and longevity of their repairs. The company has made significant progress and growth,
thanks to the involvement of skilled and experienced individuals within the organization. They
have established a strong presence in various sectors including government, banking, large
corporations, telecommunications, non-governmental organizations (NGOs)

1.2 Overall view of the garage

1. General Manager: The individual responsible for overseeing the overall operations of the
garage, setting strategic goals, managing staff, and ensuring efficient functioning of the business.

2. Vice Manager: Assists the general manager in various managerial tasks, provides support,
and may act as a deputy in the absence of the general manager.

3. Human Resources (HR): Handles recruitment, employee relations, training, payroll, and
other HR-related functions within the garage.

4. Finance Department: Manages financial operations, including budgeting, accounting,

invoicing, financial analysis, and reporting.

5. Store Keeper: Responsible for inventory management, procurement of spare parts, tools,
and equipment, and maintaining stock records.

6. Chief Mechanic: The senior-most mechanic in the garage who oversees and supervises the
mechanics' work, ensures quality repairs, and provides technical guidance.

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7. Senior Mechanic: Experienced mechanics who perform complex repairs, troubleshoot

mechanical issues, and mentor junior mechanics.

8. Assistant Mechanic: Supports senior mechanics, assists in vehicle inspections, performs

routine maintenance tasks, and carries out minor repairs.

9. Auto Body Repair: Professionals specializing in repairing and restoring the bodywork of
vehicles, including fixing dents, scratches, and structural damages.

10. Body Painting: Experts in automotive painting and finishing, responsible for providing paint
jobs, color matching, and applying protective coatings.

11. Reception: Handles customer inquiries, schedules appointments, manages paperwork, and
provides administrative support.

12. Security: Ensures the safety and security of the garage premises, monitors access, and
safeguards against theft or unauthorized activities.

13. Cleaner: Responsible for maintaining cleanliness and orderliness in the garage, including
sweeping, mopping, and maintaining hygiene in work areas.

1.3 vision, mission, and goal of a company

1.3.2 Vision:
The vision is to contribute to the development of Ethiopia's automotive industry and play a
pivotal role in the country's economic growth. The company aspires to be recognized as a trusted
and reliable partner, providing innovative and sustainable mobility solutions to its customers.

1.3.3 Mission:
The mission is to deliver superior automotive products and services to its customers while
maintaining the highest standards of professionalism, customer satisfaction, and social
responsibility. The company strives to create value for its stakeholders and contribute to the
well-being of the communities in which it operates.

1.3.4 Goals
 Customer Satisfaction: the company aims to achieve high levels of customer
satisfaction by providing reliable, safe, and technologically advanced vehicles. The

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company focuses on delivering exceptional customer service and maintaining long-term

relationships with its customers.
 Market Leadership: the company strives to maintain a leading position in the Ethiopian
automotive market. The company aims to consistently offer a wide range of high-quality
vehicles that meet the diverse needs of customers, while also expanding its market share.
 Innovation and Sustainability: the company is committed to promoting innovation and
sustainability in the automotive industry. The company aims to introduce new
technologies, fuel-efficient vehicles, and environmentally friendly practices to reduce its
carbon footprint and contribute to a more sustainable future.
 Employee Development: the company recognizes the importance of its employees and
aims to provide a supportive and rewarding work environment. The company focuses on
employee development, training, and empowerment to foster a skilled and dedicated
workforce.
 Social Responsibility: the company is dedicated to making a positive impact on the
communities it serves. The company actively engages in corporate social responsibility
initiatives, supporting education, healthcare, environmental conservation, and other
community development projects.

1.4 work flow of the company

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Manager

Supervision

Mechanical
Electrical

Electrical
Tire exchange Materials store
and others
working area(I have
been work on this
location)

Painting and
welding area

Figure1. 1 work flow of the company

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1.5 The main costumer of the company maintenance

 Vehicle Owners: The primary customers of maintenance services at garages are vehicle
owners. These can include individuals who own personal cars, motorcycles, trucks, or
other types of vehicles.
 Fleet Owners: Businesses or organizations that own a fleet of vehicles, such as
transportation companies, delivery services, or government agencies, often rely on
garages for the maintenance and repair of their vehicles.
 Commercial and Industrial Clients: Garages may also provide maintenance services to
commercial and industrial clients who use specialized vehicles or machinery for their
operations. This can include construction companies, agricultural businesses, or
manufacturing facilities.
 Insurance Companies: In cases of vehicle accidents or damage, insurance companies
may direct their clients to specific garages for repairs and maintenance services.
 Rental Car Companies: Garages may also serve rental car companies by providing
routine maintenance, inspections, and repairs for their rental fleets.

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CHAPTER TWO
2. OVERALL INTERNSHIP EXPERIENCE
2.1 How I get in the company
Before some month, I preferred my born place country Kombolcha because it is one of the most
industrial country in Ethiopian but unfortunately I can’t go by the case of some conflict. And
finally I prefer Dereje Lema garage. It has many qualified technicians (mechanics) who can give
us a detailed knowledge about Automotive.

2.2 Section of the Company I Have Been Working

The main objective of the company is to promote the durability of vehicles and machines while
offering on-site maintenance and repair services to ensure uninterrupted operations. It possesses
dedicated facilities to facilitate these activities.

 It has different sub division workshops to accomplish different tasks such as:
1. Engine
2. Body and frame
3. Transmission system
5. Electrical system
6. Control system
7. Car maintenance
8. Welding
9. Lubrication

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2.3 Engine
An engine is a machine or device that converts a source of energy into mechanical work. It
typically involves the combustion of a fuel or the use of some other form of energy to produce
motion or generate power. Engines are used in a wide range of applications, including
transportation (such as car engines and aircraft engines), power generation (such as gas turbines
and steam engines), and industrial machinery (such as internal combustion engines and electric
motors). Engines can be categorized based on the type of energy they use, such as internal
combustion engines, steam engines, or electric motors.

 Car engine, also known as an automotive engine or a motor, is a type of internal

combustion engine specifically designed for use in automobiles. It is responsible for
converting the potential energy stored in fuel into mechanical energy, which propels the
vehicle and powers various systems within it. Car engines can vary in size, configuration,
and fuel type. Common engine configurations include inline, V-shaped, and horizontally
opposed. They can be powered by gasoline (petrol), diesel, or alternative fuels such as
ethanol or natural gas.

Figure 2.1 car engine(references 8)

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2.3.1 Main parts of engine categorized by their function

1. Cylinder block
Cylinder Block is the main part of the IC (Internal Combustion) engine. It is the part where all
the functions of the engine take place inside it, such as intake, Suction, Compression,
Combustion, Exhaust, etc. The function of the cylinder in IC engines is to hold the fuel and guide
the piston.
The cylinders are made of Cast iron and Cast steel by the process of casting to handle all the
temperature and pressure which is generated after the combustion of fuel. So the cylinder is
designed in such a way that its compressive strength is high. It also requires cooling in the engine
cylinder because of high pressure and temperature.

Figure2.2 Cylinder block(references 8)

2. Cylinder head
The cylinder head is the top cover of the engine cylinder which covers the cylinder from the
topside to seal the cylinder and does not give a permit to air and gas to enter and exit from the
system.The head is made as per design requirements by cast iron or aluminum by the
manufacturing process of forging or casting. The cylinder head consists above the cylinder
block and contains various components such as a spark plug in a petrol engine, inlet valve,
exhaust valve, and injector for fuel supply in case of a diesel engine.For proper leak proof
between cylinder and cylinder head, an asbestos packing and metal gasket are provided.

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Figure 2.3 Cylinder head(references 8)

3. Piston
A Piston slides inside the cylinder in reciprocating motion and transfers mechanical energy to
the crankshaft with the help of connecting rod. The piston is designed in such a way that it is
strong, light, and sufficient to handle the pressure and temperature which is generated after the
combustion of fuel. The piston is made up of cast iron or sometimes made of aluminum alloy.

Figure 2.4 piston(references 8)

4. The piston rings

The piston rings are used to provide the sealing effect between the cylinder and the piston. It
helps to do not leak the engine’s combustion gas and bypass the piston and also helps to
overcome the friction around the piston. Piston rings are made up of cast iron and alloy cast iron.

It is of two types:

1. Compressor Ring (Pressure Ring)

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2. Oil Controller Ring

Compressor Ring transfers heat from the piston to the cylinder liner and it is inserted into the top
grooves of the piston. Compressor rings are also used to overcome the side thrust over the piston
which causes fluctuations.
The oil controller ring maintains the proper lubrication between the cylinder and the piston and is
placed under the pressure ring. It also maintains access to lubrication.

Figure 2.5 piston rings(references 8)

5. The connecting rod

A connecting rod is used to connect the piston to the crankshaft with the help of a piston pin and
crank pin. Connecting rod transmits the reciprocating motion of the piston to into rotary motion
of the crankshaft so this is works as a lever arm that transfers the motion from one end to another
end. One end is called the big end which is connected to the crankshaft and another end is called
the small end which is connected to the piston. Connecting rod made up of Low carbon steel, for
the small engine, it is made up of cast aluminum alloy by the manufacturing process of Heat
treatment and forging process.

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Figure 2.6 connecting rod(references 8)

Crank means simply rotating or turning the engine’s crankshaft. The crank works as a rotating
member that receives power from the connecting rod and transmits to the crankshaft, so the
crank works as a lever between the connecting and crankshaft.

6. Crankshaft

In an engine, the crankshaft receives the power or efforts or thrust by the piston through the connecting
rod and transmits this power of reciprocating motion of the piston into rotary motion of the crankshaft
which is further connected to the flywheel and transmission shaft which is used to move the vehicle.
Crankshaft made by casting and forging process using the material of alloy steel or cast iron.

Figure 2.7 crankshaft(references 8)

7. Combustion Chamber

The combustion chamber is enclosed with a cylinder head, cylinder walls, piston head where the
combustion of fuel has occurred. Aluminum is used as a material in the combustion
chamber because it dissipates heat higher than cast iron. In the combustion chamber, four-round
holes are used for valves to reside.

8. Manifold
 There are two manifolds in the engine Intake and Exhaust Manifold.

Intake manifold: The intake manifold is connected to inlet valves, it is the pipe that helps to
provide air-fuel mixture into the engine for proper combustion.

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Whereas in diesel engine intake manifold is used for bringing only air to the combustion
chamber.
Exhaust Manifold: Exhaust manifold is responsible for taking out the exhaust gases from
the combustion chamber after combustion which is further connected to the exhaust valves and
its design and construction are the same as the inlet manifold.

Figure 2.8 manifold(references 8)

9. Intake and Exhaust valves:

Intake and Exhaust valves both are responsible for regulating and controlling the charge of air
and fuel mixture for coming and burning in the combustion chamber and thereafter to go out the
charge of the air from the engine cylinder. Both valves are situated either on the cylinder head or
on cylinder walls in various shapes generally mushroom shapes existed.

10. Gudgeon Pin or Piston pin

Gudgeon pins connect the piston to the connecting rod at the small end. It is also called a Piston
pin, a piston pin made hollow for lightweight.

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Figure 2.9 gudgeon pin or piston pin(references 8)

11. Spark Plug

The spark plug is a device that is used to generate the spark between the two electrodes and
ignited the combustible mixture within the combustion chamber. It should be able to withstand
fluctuating pressure and temperature.

Figure 2.10 spark plug(references 8)

12. Carburetor
The process of preparing a combustible fuel-air mixture outside the Spark Ignition engine
cylinder is called Carburation. A carburetor is a device that atomizes the fuel and mixes it with
air. A carburetor is used in a petrol engine, it is a mixing device to supply the engine with an air-
fuel mixture. It atomizes the fuel and mixes it with air in varying proportions to meet the
condition of automotive engines. It is also used to reserve the quantity of fuel supply and
maintain fuel at a constant head. The carburetor is connected with the intake manifold of the
engine.
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Figure 2.11 carburetor(references 8)

13. Flywheel
Flywheel means fluctuation of energy, it reserves the energy and uses this energy when requires
it. A Flywheel is an inertial (force) energy storage device.
The flywheel absorbs mechanical energy and serves as a reservoir during the period when the
supply of energy is more than the requirement and releases it during the period when energy is
less than required.

Figure 2.12 flywheel(references 8)

14. Governor (Automobile)

Governor controls the variations of load and maintains the speed of the engine within a specific
unit. It controls the speed of the engine by regulating the supply of fuel. In governor, there are
metal valves that rotate about an axis and generate centrifugal force. Governor is a self-acting
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device. It controls the speed of the engine. When the load on the engine suddenly increases the
engine speed will be decreased greater decrement in engine speed can stop the engine. It is
connected to the engine crankshaft when the speed of the engine decreases, the governor also
slows down and the sleeve moves downward that opening the valve of fuel supply with the help
of lever increment in fuel increase the speed of the engine to mean speed. Whereas, in the second
case when the load on the engine decreases, Governor also decreases the fuel and controls the
speed.

Figure 2.13 automobile governor(references 8)

15. Engine Bearing

The bearing is a machine part that gives a free rotation of the shaft with minimum friction. It
supports other moving elements and permits a relative motion between the contact surfaces of
the members and elements while carrying the load. Several Bearing is used in the engine in
which a bearing that allows the crankshaft to rotate is named engine bearing. It is a device that is
used to reduce the friction between moving parts of machine elements to provide movement in a
desired with minimum power losses.

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Figure 2.14 engine bearing(references 8)

16. Supercharger
It is the method of supplying air at an increased density to the engine so that more amount of fuel
can be burned in the same cylinder space. So supercharging is achieved by raising the pressure of
the inlet by means of a pressure boosting device called a Supercharger.

Figure 2.15 supercharger(references 8)

Objectives of supercharging

 To obtain more power from an existing engine

 Supercharging is used to maintain power output
 To get more power output for a given weight of the engine.

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Advantages of supercharging
 It increases the power output
 Greater induction of charge mass
 Better atomization of fuel
 Better mixing of fuel and air
 More complete and smoother combustion
 Reduces exhaust smoke and
 Increase overall efficiency.

17. Turbocharger
In this method, the supercharger is driven by a gas turbine which uses the energy of exhaust
gases. The turbine is connected to the compressor by a turboshaft. The air sucked by the turbine
into the compressor is thrown outward by centrifugal force.

Figure 2.16 turbocharger(references 8)

18. Radiator

The radiator is used in engine cooling systems for heat transfer where it helps to transfer thermal
energy from one medium to another medium for cooling and heating purpose. A radiator is a
heat exchanger which eliminates excess heat from the system.

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Figure 2.17 radiator(references 8)

19. Rocker arm

The rocker arm of an internal combustion engine is an oscillating lever that changes radial
movement into linear movement; this kind of device is properly known as a reciprocating lever.
With the help of the spinning motion of the overhead camshaft that opens and closes the valves
and turns it into the up-and-down movement. Rocker arms are generally made of steel. Rocker
arms have contained high strength for their weight, and employ a good deal of leverage. So both
rocker arm and push rod are used in automotive vehicles in opening and closing of valves and to
make transmission between crank End to the camshaft. Depend upon the engine block or their up
head block or down head, so it depends on which engine we are using. Rocker arm is used to
opening and closing of inlet and exhaust valves.

Figure 2.18 rocker arm(references 8)

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2.4 Body and Frame

The body refers to the outer shell or structure that encloses the passenger compartment, engine,
and other mechanical components. It is the part of the car that provides protection,
aerodynamics, and the overall appearance. The body of a car is typically made of metal panels,
such as steel or aluminum, which are welded or bolted together to form a rigid structure.
However, modern cars also incorporate other materials, such as composites or plastics, to
improve weight savings, fuel efficiency, and safety.

2.4.1 Here are the main parts of a car body:

1. Hood or bonnet
The hood allows direct access to the engine compartment for maintenance and repair purposes.
In addition, it also protects these parts from direct sunlight and dust. A hidden latch is commonly
used along with the hood to hold it securely when you’re taking a look inside your car.

Figure 2.19 hood or bonnet(references 8)

2. Front bumper
The bumper may seem like an additional part but the simple structure actually plays an important
role in your car. Generally, bumpers are bars that protect a vehicle when it collides with
something. The function of the front bumper is to protect your car if a sudden collision happens.
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In this case, it absorbs most of the impact during low-speed collisions to prevent serious damage
to the driver, vehicle, and passengers.

Figure 2.20 front bumper(references 8)

3. The crash guard or bulbar

The crash guards are mounted to the front frame or chassis of the car. This is mostly seen in
SUVs to protect them from damage in case of an accident. These are the essential car body parts
that play a key role to keep the vehicle moving after a collision. These are typically made of
heavy-duty steel and can effectively shield the front end of the vehicle. Moreover, the design of
this accessory gives a stylish look to your vehicle and also provides real protection.

Figure 2.21 the crash guard or bulbar(references 8)

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4. Wiper Blade
Almost all vehicles including cars, trucks, buses, etc. have wiper blades and are very important
for the clear vision of the driver. These are used to clear snow, water, and/or debris from the
vehicle’s front window so that the operator can see what lies ahead of them.

Figure 2.22 wiper blade(references 8)

5. Quarter Panel
It is a side section of an automobile body that usually wraps around the wheel well, between the
door and trunk lid, or between the door and the hood. It supports the back panel and other rear
panels which may include the trunk of the car, as well as the rear fenders/bumpers.

Figure 2.23 quarter panel(references 8)

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6. Roof
A roof is the top part of a vehicle that sits above the passenger compartment, protecting the
vehicle occupants from sunlight, wind, rain, and other external elements. The car ceilings are
typically coated with headliners that provide insulation against heat and noise, and also hide
wires and hardware for electrical components, antennas, and other accessories.

Figure 2.24 roof(references 8)

7. Sunroof
The sunroof gives passengers a clear view of the sky, keeps the car ventilated, and lets the
sunlight in, creating a feeling of open space. This is a type of panel on the roof of a car that either
slides or can be pulled out to allow light in.

Figure 2.25 sunroof(references 8)

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8. Mirrors
There are mainly two types of mirrors used in vehicles that are side-view mirrors and rear-view
mirrors.

a. Side-View Mirror

These are also known as wing mirrors. These mirrors are located on the exterior of the vehicles
to help the driver see areas behind and side of the vehicle or outside the driver’s peripheral
vision. Also, it will alert the driver about possible accidents that happen from behind. The
advantage of side mirrors being convex is that you get a wider view of each side of the car which
helps reduce blind spots.

Figure 2.26 side view mirror(references 8)

b. Rear-View Mirror
They serve multiple purposes that help to keep you safe as a driver. It gives you an alert driving
experience by allowing you to see behind your vehicle without turning your head. In addition,
they are especially important when a vehicle is moving in reverse gear.

Figure 2.27 rear view mirror(references 8)

9. Car Doors
A door is a type of opening, usually hinged on the exterior of a vehicle. Sometimes it is attached
to other mechanisms such as a track to enter and exit the vehicle. There are different types of car

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doors available that most people might not be aware of. Doors often include windows for
visibility from inside the car and can be locked to secure the vehicle. These are operated
manually or with the help of power supplied by the vehicle. Power doors are used in minivans,
luxury vehicles, or modified cars.

Figure 2.28 Car doors(references 8)

10. Door Handle

Door handles help the driver or passengers to get in or out of the car. Door handles are the most
important component as they contain door locks. Usually, we use the door handle to unlock the
car from outside or inside. There are different types of door handles available according to the
car model.

Figure 2.29 door handle(references 8)

11. Trunk
The trunk lid (also known as dickey) of a car is the main storage or luggage compartment which
is often located at the rear of the vehicle such as sedan, coupe, or convertible. The trunk of a car

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is more than just storage and must be used for the actual purpose of carrying goods. It is an
important storage space, so it is necessary to clean it regularly. Also, keep in mind that if you are
loading more luggage then the engine will consume more fuel.

Figure 2.30 trunk(references 8)

12. Wheels

The most basic and important parts of a car body that have always been in use are the wheels.
These are circular forms that generate rotary motion and are responsible for moving the car from
one point to another. The tire is the rubber part that wraps around the wheel and grips the road
surface. Although the wheels can spin without tires, the car does not go very far. Without them,
the wheels of the car would slip on the road faster without moving forward. Nowadays, there
are different types of tires easily available in the market.

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Figure 2.31 wheels(references 8)

13. Dashboard
The dashboard is the controlling panel of any kind of vehicle. This is also known as dash or
instrument panel. It lies within the central console of a vehicle and is usually located directly
ahead of the drive. The dashboard shows the driver tools and controls for operating the vehicle. It
has simple controls (example, steering wheel) and an array of instrumentation to show speed,
fuel level, and oil pressure. Modern types usually feature information, climate control, and
entertainment systems.

Figure 2.32 dashboard(references 8)

2.5 Transmission System

The transmission system in a car is responsible for transmitting power from the engine to the
wheels in order to propel the vehicle forward or backward. It consists of a series of components
that work together to control the speed and torque output of the engine and allow the driver to
select different gear ratios.

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Figure 2.33 transmission system(references 8)

2.5.1The main components of a typical transmission system include:

1. Clutch
The clutch connects and disconnects the engine from the transmission. When the clutch is
engaged, power from the engine is transmitted to the transmission. When the clutch is
disengaged, the engine's power is disconnected from the transmission, allowing for gear changes
or when the vehicle is at a stop.

Figure 2.34 clutch(references 8)

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2. Gearbox
The gearbox, also known as the manual transmission, is a set of gears arranged in different gear
ratios. By shifting gears, the driver can adjust the speed-to-torque ratio of the engine's power
output. In a manual transmission, the driver manually operates the clutch and shifts gears using a
gear shift lever.

Figure 2.35 gearbox(references 8)

3. Drive Shaft:
The drive shaft is a rotating shaft that transmits power from the transmission to the differential,
which distributes power to the wheels

Figure 2.36 drive shaft(references 8)

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4.Differential
The differential allows the wheels to rotate at different speeds while receiving power from the
drive shaft. This is necessary when the vehicle is turning, as the wheels on the inner and outer
sides of the turn have to travel different distances.

Figure 2.37 differential(references 8)

2.6. Electrical system

The electrical system in a car refers to the network of electrical components and circuits that
provide power and control various electrical functions in the vehicle. It plays a crucial role in
powering essential systems and accessories, as well as enabling communication and control
between different part of the car

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Figure 2.38 electrical system(references 8)

2.6.1Here are some key components and functions of a car's electrical system:

1. Battery
The battery is the primary power source for the electrical system. It supplies electrical energy to start the
engine and provides power when the alternator is not generating electricity. It also stabilizes voltage
fluctuations in the system.

Figure 2.39 battery(references 8)

2. Wiring and Cables

The electrical system is interconnected through a network of wiring and cables. These
conductors carry electrical current to various components and ensure reliable communication and
power distribution throughout the vehicle.

Figure 2.40 wiring and cables(references 8)

3. Power source

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He electrical power source is primarily the vehicle's battery. The battery provides electrical
energy to power various electrical components and systems in the vehicle, even when the engine
is not running. It supplies power to the starter motor to start the engine, and it also supports the
operation of lights, audio systems, dashboard instruments, and other electrical accessories.

Figure 2.41 power source(references 8)

2.7 Control system

The control system in a car refers to the collection of components and technologies that manage
and regulate various functions and operations of the vehicle. These systems work together to
ensure safe and efficient operation while providing comfort and convenience to the driver and
passengers.

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Figure 2.42 control system(references 8)

2.7.1 Here are some type of control system

1. Steering system
The steering system in a vehicle is a collection of components and mechanisms designed to
allow the driver to control the direction of the vehicle's movement. It enables the driver to
change the course of the vehicle by turning the front wheels. The primary function of the steering
system is to convert the driver's input from the steering wheel into rotational motion of the front
wheels, causing the vehicle to turn. It provides a mechanical connection between the steering

wheel and the wheels, allowing the driver to steer the vehicle with precision and control.

Figure 2.43 steering system(references 8)

2. Breaking system
The braking system in a car is a vital component that enables the driver to slow down or stop the
vehicle safely. It utilizes various mechanisms to convert the kinetic energy of the moving vehicle
into heat energy through the process of friction. The braking system consists of several key
components:

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Figure 2.44 breaking system(references 8)

2.8 Car maintenance

Car maintenance garage is another critical section at Dereje Lema garage. The company’s
certified technicians possess extensive knowledge and expertise in servicing Nissan vehicles.
They offered a comprehensive range of each Nissan mode. From routine oil change to complex
repairs, car motors provided top-notch service at their service center equipped with advanced
tools and diagnostic equipment.

 Wheel alignment
 Battery maintenance
 Servicing
 Changing clutch
 Changing shock absorber

During the internship, I was assigned to especially on car maintenance department and I had
done activities that are discussed below.

2.8.1 Task one (servicing)

In our internship program, we have been involved in servicing cars at a car maintenance shop.
We have learned how to perform oil changes, including draining the old oil, replacing the oil
filter, and adding new oil. We have also assisted with tire rotations and wheel alignments,
ensuring that the tires are properly balanced and aligned for optimal performance. Additionally,
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we have been responsible to inspect and replace brake pads, rotors, and calipers. This involves
removing the old brake components, checking for wear and damage, and installing new parts as
needed. We have also learned how to test car batteries using a battery tester and replace them if
necessary.

Fluid checks and top-ups have also been a part of my internship experience. We have been
responsible for checking and topping up fluids such as coolant, transmission fluid, power
steering fluid, and brake fluid. This helps to maintain the vehicle's performance and prevent any
potential damage. We have also been involved in air filter replacement, where we remove the old
air filter and install a new one to ensure clean airflow to the engine.

Overall, our internship program has provided us with valuable hand-on-hand experience in
servicing cars at a car maintenance shop. We have learned various maintenance tasks and gained
a deeper understanding of the importance of regular vehicle servicing for safety, reliability, and
longevity.

2.8.2. Task two (Changing Shock absorber)

In our internship program, involves removing the old shock absorbers, which are responsible for
controlling the movement of the suspension system and providing a smooth ride.

To change the shock absorbers, we first lift the car using a power lift. Then, we remove the
wheels to access the suspension components. Using a wrench and socket set, we disconnect the
mounting bolts that hold the shock absorbers in place. Once the old shock absorbers are
removed, we inspect them for any signs of leakage, damage, or wear. If they are worn out or
damaged, we discard them and prepare to install new ones. If they are still in good condition,
they can be reused.

Before installing the new shock absorbers, we make sure to apply a thin layer of grease or anti-
seize compound to the mounting bolts to prevent rust and ensure easy removal in the future. We
then align the new shock absorbers with the mounting points and tighten the bolts securely.
After installing the new shock absorbers, we lower the car back down and reinstall the wheels.
Finally, we perform a test drive to ensure that the new shock absorbers are functioning properly
and providing a smooth and controlled ride. Changing shock absorbers is an important part of

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maintaining a car's suspension system and ensuring optimal handling and comfort. By learning
this skill during my internship program, we have gained valuable knowledge and experience in
servicing and maintaining cars.

2.8.3 Task three (Changing clutch)

In addition, we have been responsibility to change shock absorbers, we also had the opportunity
to change the clutch on cars during my internship program. The clutch is a vital component of a
manual transmission system, as it allows for smooth engagement and disengagement of power
between the engine and the transmission. To change the clutch, we first lift the car using a
power lift. Then, we remove the transmission from the engine by disconnecting the driveshaft
and any other necessary components. Once the transmission is removed, we locate the clutch
assembly and remove the pressure plate, clutch disc, and release bearing. These components are
responsible for transferring power from the engine to the transmission. Before installing the new
clutch, we inspect the flywheel for any signs of damage or wear. If necessary, we resurface or
replace the flywheel to ensure proper clutch engagement. Next, we install the new clutch
components, including the pressure plate, clutch disc, and release bearing. We make sure to align
them properly and tighten the bolts securely. After installing the new clutch, we reinstall the
transmission onto the engine and reconnect any previously disconnected components. We ensure
that all connections are tight and secure. Finally, we lower the car back down and perform a test
drive to ensure that the new clutch is functioning properly. This includes testing for smooth
engagement and disengagement of gears and assessing overall clutch performance. Changing
the clutch is a complex task that requires technical knowledge and skill. By learning this skill
during my internship program, we have gained valuable experience in maintaining and servicing
manual transmission systems in cars.

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2.9 Welding
Welding is a materials joining process in which two or more parts are coalesced at their
contacting surfaces by a suitable application of heat and/or pressure. The assemblage of parts
that are joined by welding is called a weldment. Welding is most commonly associated with
metal parts, but the process is also used for joining plastics.

2.10 Lubrication
Lubrication refers to the process of reducing friction and wear between two surfaces in relative
motion by introducing a lubricant between them. A lubricant is a substance that helps to
minimize the contact and friction between moving surfaces, allowing them to slide or roll more
smoothly against each other. The primary function of lubrication is to provide a protective film
between the contacting surfaces. This film of lubricant separates the surfaces, preventing direct
metal-to-metal contact and reducing friction.

2.10.1 Here are some key functions of lubrication:

1. Friction reduction: The primary purpose of lubrication is to reduce friction between moving
parts. Friction generates heat and causes wear, and by introducing a lubricant, the frictional
forces are minimized, leading to improved efficiency and reduced energy consumption.

2. Wear protection: Lubrication forms a protective layer that prevents direct contact between
the moving surfaces. This reduces wear and extends the lifespan of the components, such as
bearings, gears, and engines.

3. Heat dissipation: Lubricants also help in dissipating heat generated by friction and other
sources. They absorb and carry away heat from the lubricated components, preventing
overheating and associated damage.

4. Corrosion prevention: Lubricants can provide a barrier against moisture and contaminants,
protecting the surfaces from corrosion and rust.

5. Sealing and contamination control: In some applications, lubricants act as a sealant,

preventing the entry of contaminants and foreign particles into the system. They maintain a clean
and controlled environment, reducing the risk of damage.
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Figure 2.45 lubrication(references 8)

2.11 Problems Encountered during the Internship Period

2.11.1 Internal problems
 There are no enough safety materials.
 There are no enough working tools. When they remove bearings, they
used hammer and chisel. This technique results While performing
our tasks it was not that much easy to understand the working
environment and the rule of the company which is the most important
for us to stay in the company.
 There is a lack of sorting the tools.

2.11.2 External problems

Our university is not relasse our internship money on the beagning time, by this case i get lack of
transport price.

2.12 Challenges encountered during the internship

 During Internship we face challenges in communicating with stuffs
especially language barrier.

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CHAPTER THREE
3. OVERALL BENEFIT OF INTERNSHIP
Internships are highly important for students as they provide a range of benefits that contribute to
their personal, academic, and professional growth. First and foremost, internships offer students
practical experience in their chosen field. This real-world experience allows them to apply the
knowledge they have gained in the classroom to practical situations. By working on actual
projects and tasks, students develop a deeper understanding of their field of study. Internships
also play a crucial role in skill development. Students have the opportunity to acquire and refine
a variety of skills. Additionally, internships foster the development of transferable skills like
communication, teamwork, problem-solving, critical thinking, and time management, which are
highly valued by employers. Lastly, internships often serve as a pathway to future job
opportunities. Many companies use internships as a way to identify and recruit talented
individuals for full-time positions. By impressing employers during their internship, students can
increase their chances of being offered a job upon graduation.

3.1 General objective

The objective of the internship is to provide hands-on experience and practical training in various
technical aspects related to car maintenance. This includes diagnosing and repairing engine
issues, performing brake system maintenance, conducting electrical system repairs, carrying out
routine maintenance tasks, repairing and replacing suspension components, and troubleshooting
and repairing cooling systems. The internship aims to develop the intern skills and knowledge in
automotive systems and equip them with the necessary expertise to diagnose and repair different
car maintenance issues.

3.2 Here are some benefit of internship

3.2.1 In Terms of Practical Skills:
1. Hands-on Experience: Internships provide an opportunity to apply theoretical knowledge in
real-world scenarios, allowing individuals to gain practical skills specific to their field of interest.
This practical experience enhances their understanding of industry practices, tools, technologies,
and methodologies.
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2. Technical Proficiency: Internships expose individuals to industry-specific software,

equipment, and processes, enabling them to develop technical skills relevant to their chosen
profession. They can learn how to operate specialized machinery, use software tools effectively,
or perform tasks that require specific technical expertise.

3. Problem-Solving Abilities: Through internships, individuals encounter real-world challenges

and problem-solving situations. They learn to think critically, analyze issues, and develop
effective solutions. This cultivates their problem-solving skills, adaptability, and the ability to
handle unexpected situations.

3.2.2 In Terms of Upgrading Theoretical Knowledge:

1. Practical Application of Theory: Internships bridge the gap between theoretical knowledge acquired
through academic studies and its practical application in a professional setting. Interns get hands-on
experience that complements their classroom learning and helps them understand how theoretical
concepts translate into real-life scenarios.

2. Industry Insights: Internships provide individuals with a deeper understanding of industry trends,
current practices, and emerging technologies. This exposure enhances their theoretical knowledge by
giving them practical examples and real-world context, making their theoretical foundation more relevant
and up-to-date.

3.2.3 In Terms of Improving Personal Communication Skills:

1. Professional Networking: Internships offer opportunities to interact with professionals,
colleagues, and mentors, allowing individuals to build professional relationships and expand
their network. Effective communication is crucial in establishing connections, expressing ideas,
and collaborating with others.

2. Interpersonal Skills: Internships involve working with diverse teams and interacting with
individuals from various backgrounds. This fosters the development of interpersonal skills such
as active listening, empathy, conflict resolution, and building rapport, all of which are essential
for effective communication.

3.2.4 In Terms of Improving Team Playing Skills:

1. Collaboration: Internships often require working as part of a team to achieve common goals.
Interns learn to collaborate, contribute ideas, respect diverse opinions, and work collectively
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towards achieving shared objectives. This cultivates their teamwork and cooperation skills,
preparing them for future collaborative work environments.

2. Relationship Building: Internships provide opportunities to interact and build relationships

with team members and colleagues. Through teamwork, interns learn how to contribute to a
harmonious work environment, foster positive relationships, and effectively communicate within
a team structure.

3.2.5 In Terms of Improving Leadership Skills:

1. Taking Initiative: Internships allow individuals to take on responsibilities and demonstrate their
ability to work independently. This nurtures their leadership potential by encouraging them to take
initiative, make decisions, and show proactive behavior.

2. Project Management: Interns may be assigned projects or tasks that require them to manage
resources, set goals, and meet deadlines. Through these experiences, they develop skills in planning,
organizing, and leading projects, enhancing their leadership capabilities.

3.2.6 In Terms of Work Ethics Skills:

1. Professionalism: Internships expose individuals to professional work environments, where
they learn the importance of punctuality, accountability, and maintaining a strong work ethic.
They develop skills in time management, meeting deadlines, and delivering high-quality work
consistently.

2. Adaptability: Internships often involve exposure to dynamic work environments and

changing priorities. Interns learn to adapt quickly, be flexible in their approach, and handle
diverse responsibilities. These experiences enhance their work ethics, resilience, and ability to
thrive in different work settings.

3.2.7 In Terms of Entrepreneurship Skills:

1. Innovation and Creativity: Internships provide opportunities for individuals to contribute
ideas, solve problems creatively, and think innovatively. They may work on projects that require
entrepreneurial thinking, encouraging them to explore new possibilities and develop an
entrepreneurial mindset.

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2. Business Acumen: Interns gain exposure to the business side of their industry, understanding
factors such as market trends, customer needs, and competitive landscapes. This exposure helps
develop skills in strategic thinking, business planning, and identifying opportunities for
innovation and growth.

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CHAPTER FOUR
4. TECHNICAL ASPECT OF THE INTERNSHIP
During my internship in a DEREJE LEMA garage, I had the opportunity to learn and work on
various technical aspects related to car maintenance. This hand-on-hand experience allowed me
to gain practical knowledge and enhance my skill in field. I had an opportunity to work on d/t
types of vehicles, ranging from small cars to large trucks. This exposure helped me understand
the unique challenges and requirements of each vehicle type. Some of these technical tasks
included:

 Changing oil, filters

 Conducting electrical system repairs
 Performing brake system maintenance
 Changing clutch
 Diagnosis test of engine
 Inspect and repair electrical system
 Overhauling injection pump
 Overhauling engine
 Changing shock absorber etc…

4.1 Methods and procedures while working

1. Safety training: The intern will receive comprehensive safety training to ensure they
understand and adhere to all safety protocols in the car maintenance shop. This includes
proper handling of tools and equipment, wearing protective gear, and maintaining a clean and
organized work area. They will also be trained on emergency procedures and how to handle
hazardous materials.

2. Shadowing: The intern will observe and shadow experienced technicians to understand the
work flow and processes in the car maintenance shop. They will learn by observing how
tasks are performed and how technicians interact with customers.

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3. Hands-on training: The intern will gradually be given opportunities to perform maintenance
tasks under the guidance of experienced technicians. This will involve tasks such as oil
changes, tire rotations, and filter replacements. The intern will receive step-by-step
instructions and feedback on their performance.

4. Diagnostic training: The intern will learn how to use diagnostic tools and equipment to
identify issues with engines, electrical systems, and other car components. They will be
taught how to interpret diagnostic codes and troubleshoot problems. This may involve hands-
on practice with different diagnostic tools.

5. Repair and maintenance tasks: The intern will be assigned repair and maintenance tasks
based on their skill level and progress. This can include tasks such as brake system repairs,
suspension component replacements, and cooling system troubleshooting. They will receive
guidance and support from experienced technicians throughout the process.
6. Documentation and record-keeping: The intern will learn how to accurately document
their work, including recording repairs performed, parts used, and any additional
recommendations or observations. They will be taught how to maintain organized records for
future reference and customer communication.

7. Teamwork and communication: The intern will be encouraged to work collaboratively

with other technicians and communicate effectively with colleagues and customers. This
includes discussing repair strategies, seeking advice when needed, and providing clear
explanations to customers about repairs performed. They will also learn how to communicate
any challenges or issues they encounter during their work.

8. Continuous learning: The intern will be encouraged to ask questions, seek clarification, and
actively engage in ongoing learning opportunities. This can include attending workshops or
seminars on new car technologies or participating in online training courses. They will also
be encouraged to stay updated on industry trends and advancements.

9. Performance evaluation: Regular performance evaluations will be conducted to assess the

intern progress and provide feedback for improvement. This may involve reviewing

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completed tasks, evaluating their technical skills, and assessing their ability to work
independently. The intern will receive constructive feedback and guidance on areas that need
improvement.

10. Gradual independence: As the intern gains more experience and demonstrates proficiency
in various car maintenance tasks, they will be given more independence to work on their own
projects under supervision. This will help build confidence and prepare them for future
employment in the automotive industry. They will still have access to support and guidance
from experienced technicians as needed.

4.2 Technical tasks/products

In the first week we just start our work by learning safety rule of the company and all of rule and
regulation that we must follow. Safety is denoted as duty that helps to keep ourselves from
injury. The word safety also refers to the precondition people take to prevent accidents and harm
damage. The Cause of accident may be unsafe condition, unsafe act and Personal failure.

So we learnt how to protect and keep ourselves from any accident while working on the different
area of the company especially performed work on the machines.

It took us two weeks to know more about the workers, machines and supervisor of the company.
While we are working, it gave as the best opportunity to know more about the working principal,
its components, working tools and process. After we observe and knowing the company rule and
regulation we start to participate in different activities like employer.

These activities are:

 Servicing
 Mounting and unmounting engine
 Changing clutch
 Changing shock absorber
 Changing hand pump
 Diagnosis test of engine
 Inspect and repair electrical system

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 Overhauling injection pump

 Overhauling engine etc…

CHAPTER FIVE
CONCLUTION AND RECOMMENDATION
CONCLUTION
In conclusion, the internship at the garage during the four-month period has been a
transformative experience. It has contributed to the development of practical skills, the upgrading
of theoretical knowledge, the improvement of personal communication skills, the enhancement
of team playing and leadership skills, the cultivation of a strong work ethic, and exposure to
entrepreneurship. The internship has played a pivotal role in preparing for a successful career in
the automotive industry and has provided a solid foundation for future professional growth.

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RECOMMENDATION

Based on my four-month garage internship, several recommendations can be made to enhance

future research and practical training experiences: Ensuring adequate materials and tools for
employees is crucial. Organizations should assess their inventory regularly and provide the
necessary resources to facilitate effective learning and project completion. Developing structured
training programs that incorporate both theoretical and practical components can optimize the
learning experience. This will help interns gain a balanced understanding of concepts and their
applications.

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PART TWO
INTERNSHIP
PROJECT

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CHAPTER ONE
1. DESIGN OF HYDRAULIC BEARING PULLER

1.1 Introduction
During the internship program at DEREJE garage, I had the opportunity to contribute by making
the project on hydraulic bearing puller. The purpose of the project is to design and make model
of tool that could effectively remove bearings from shafts and flywheel.

1.1.1 Background of Bearing Puller

Bearing puller is a hand tool used to remove bearings or other tightly fitted components from a
shaft or an axle. Its history dates back to the early 1900’s when the automobile industry was
booming and the need for efficient bearing removal tools was growing rapidly. Before the
bearing puller, people used hammer and pry bars to remove bearings from machines which was
often a time consuming and dangerous process. But in Ethiopia so many automobile service and
maintenance companies and garages still uses hammers and pry bars.

In 1907, Charles E. Miller invented the first bearing removing tool in the United States, which
was a simple two jaw puller. The two jaw puller worked by gripping the bearing with claws or
jaws and applying a pulling force to remove it from shaft. This design is still used today.

As technology progressed, advancements were made to the bearing puller design, including
multi-jaw pullers, slide hammer and hydraulic press attachments. With these improvements, the
efficiency and safety of bearing of bearing removal increased, making it an essential tool in any
mechanic’s work.

Today, the bearing puller is still an incredibly useful and necessary tool that is widely used in
many industries, including automotive, and construction. As machines and equipment continue
to advance, so will the design and functionality of the bearing puller.

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Figure1.1 removal of bearing using sliding hammer (references 4)

Figure 1.2 removal of bearing hammer and chisel (references 4)

1.1.2 Types of Hydraulic Bearing Puller

There are many types of bearing puller classified based on their design, usage and mechanism.
1.1.2.1 Multi-jaw puller

A multi jaw puller, also known as a universal puller or a three jaw puller, is a type of bearing
puller that is widely used in various industries for removing bearings, gears, pulleys, and other
press-fit components from shafts or hubs.

The design of a multi jaw puller typically consists of three or more arms or jaws that are evenly
spaced around a central screw or spindle. These jaws are adjustable and can be positioned to grip

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onto the outer edge of the component being removed. By turning the central screw, force is
applied to the jaws, causing them to grip the component tightly and exert a pulling force,
allowing for its removal.

Multi jaw pullers are commonly used in automotive repair shops, machine shops, and
maintenance departments, where the removal of press-fit components is a frequent task. They
have become an essential tool for professionals and DIY enthusiasts alike, offering a reliable and
efficient solution for disassembly.

Figure 1.3 multi-jaw puller(references 4)

1.1.2.2 Sliding hammer

A sliding hammer bearing puller is a tool used to remove bearings from a shaft or housing. It
consists of a sliding weight, commonly known as a hammer, attached to a long handle or shaft.
The puller works by striking the weight against a stationary surface, causing it to slide along the
shaft and exert a pulling force on the bearing. This force helps to dislodge the bearing from its
seating and allow for its removal. Sliding hammer bearing pullers are commonly used in
automotive repairs, machinery maintenance, and other applications where bearing removal is
required.

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Figure 1.4 sliding hammer(references 4)

1.1.2.3 Hydraulic puller

A hydraulic bearing puller is a specialized tool used to remove bearings or other components
from a shaft or housing. It operates on the principle of hydraulic pressure to generate a pulling
force, making it easier to disassemble machinery or equipment.

The hydraulic bearing puller typically consists of a hydraulic cylinder, a pump, a hose, and
various accessories such as pulling arms and attachments. The hydraulic cylinder is connected to
the pump, which is used to create pressure by pumping oil into the cylinder. The pressure
generated is then transferred to the pulling arms or attachments, allowing them to grip the
bearing and pull it out.

Hydraulic bearing puller is its ability to generate high pulling forces without much effort from
the user. This makes it suitable for removing bearings that are tightly fitted or have been in use
for a long time, where conventional methods may not be effective.

Figure 1.5 hydraulic puller (references 4)

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1.2 Component of hydraulic bearing puller

A hydraulic floor jack is a type of car jack that uses hydraulic pressure to lift a vehicle off the
ground. The components of a hydraulic floor jack include:

 Hydraulic fluid: this is the fluid that is used to transfer force from the pumping mechanism to
the hydraulic cylinder. It is usually oil-based and helps to lubricate the moving parts of the
bearing puller. It is responsible for transmitting and amplifying the force applied by the user. It
creates pressure in the hydraulic fluid, which is then transferred to a piston. The hydraulic fluid
acts as a lubricant, reducing friction between the moving parts within the bearing puller.
 Main frame: The main frame on a hydraulic bearing puller is a critical component that provides
the structural support and stability necessary for proper bearing extraction. It ensures proper
alignment of the hydraulic puller components. It holds the hydraulic cylinder, support beams,
and other parts in place, ensuring they are positioned correctly relative to the bearing and its
housing. It provides a stable base for the hydraulic bearing puller. It prevents any unwanted
movements or vibrations during the bearing extraction process, which is essential for safe and
efficient operation. It typically made of heavy-duty steel to withstand the high forces exerted
during bearing extraction. It is designed to be robust and durable, ensuring longevity and
reliability even with frequent use.
 Double Piston rod: A double piston rod refers to a type of piston rod used in certain types of
cylinders. Unlike a single piston rod, which has a single rod extending from one side of the
piston, a double piston rod has rods extending from both sides of the piston.
The double piston rod design offers some advantages compared to the single piston rod design.
Firstly, it provides increased stability and balance to the cylinder, as the forces acting on the
piston are distributed more evenly. This can result in smoother and more controlled movement of
the cylinder.

Additionally, the double piston rod design allows for greater mechanical advantage in certain
applications. By attaching different components or mechanisms to each rod, the cylinder can
generate different forces or perform different tasks simultaneously.

 Double Piston rod cylinder: A hydraulic double piston rod cylinder is a type of hydraulic
cylinder that incorporates two piston rods instead of the usual single rod. This design offers
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several advantages over single-rod cylinders, including increased stability, improved precision,
and higher load-carrying capabilities.

The double piston rod cylinder consists of a cylinder barrel that houses two pistons with a rod
extending from each side. The two piston rods are connected to the same piston, which moves in
opposite directions when hydraulic pressure is applied. This symmetrical movement ensures
equal force and displacement on both sides of the cylinder, resulting in a balanced and stable
operation. Moreover, the double piston rod cylinder can handle higher loads compared to single-
rod cylinders. The additional rod provides increased stability and load-bearing capacity, making
it suitable for applications that require heavy lifting or high force output.
 Frame bar: In the context of a bearing puller, a frame bar refers to a specific component within
the tool. A bearing puller is a tool used to remove bearings from a shaft or housing. It typically
consists of a main frame or body that houses the pulling mechanism.
The frame bar is designed to securely hold the bearing puller jaws in place and ensure proper
alignment and stability during the bearing removal process. It is often adjustable in length to
accommodate different bearing sizes and can be locked into position. The frame bar plays a
crucial role in providing the necessary leverage and support to effectively remove bearings
without damaging the surrounding components.
 Connecting rods: It is a component of the machine that connects the piston to the frame bar. It is
responsible for transferring the linear motion of the piston into reciprocated motion of pulling
jaws.
 Pulling jaws: Bearing puller jaws are a set of gripping tools used to remove bearings from shafts
or housings. "Jaws" refer to the gripping mechanism of the bearing puller that holds onto the
bearing during the removal process. The jaws are typically adjustable to fit different bearing
sizes and are designed to securely grip the bearing for efficient and safe removal. They are
typically made of hardened steel and are designed to securely grip the inside ring of a bearing
while applying force to remove it. The jaws of a bearing puller are shaped to match the contours
of the bearing's inner ring, allowing for a secure and non-damaging grip. When using a bearing
puller, it is important to ensure that the jaws are properly aligned with the bearing's outer ring to
prevent damage. The puller jaws should be tightened evenly to distribute the force evenly across

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the bearing. Additionally, lubricating the jaws and the bearing with oil or grease can help
facilitate the removal process. Overall, bearing puller jaws are essential tools for safely and
efficiently removing bearings from shafts or housings in various mechanical applications.
 Inlet and outlet ports: In a double piston rod cylinder, there are typically two sets of inlet and
outlet ports. These ports are used for the introduction and removal of fluids, such as compressed
air or hydraulic fluid, which actuate the cylinder. The inlet ports are where the fluid is supplied
to the cylinder. They allow the fluid to enter the cylinder chambers and apply pressure to the
pistons. The fluid can be supplied through hoses or tubing connected to these ports.
The outlet ports, on the other hand, are where the fluid is discharged or released from the
cylinder. They provide an exit path for the fluid that has been used to actuate the cylinder. This
fluid may be released back into the system or drained out depending on the application.

The placement and configuration of the inlet and outlet ports will vary depending on the specific
design of the double piston rod cylinder. However, they are typically located on opposite sides of
the cylinder barrel to allow for balanced and efficient operation. The inlet and outlet ports are
essential for the proper functioning of the double piston rod cylinder.

1.3 Problem Statement

We got this idea during the internship at Dereje garage. When we change bearings from flywheel
and also from shafts. Many mechanical systems require the removal of bearings for maintenance
or replacement purposes. Current bearing removal methods often involve manual force or the use
of mechanical bearing pullers, which can be time-consuming, labor-intensive, and may cause
damage to the bearing or surrounding components. There is a need for an efficient, reliable, and
user-friendly solution that can safely and quickly remove bearings from their housings without
causing any damage.

Traditional methods of removing bearings from machinery and equipment often involve using
excessive force. This not only increases the risk of equipment failure but also prolongs the
maintenance and repair process. Therefore, there is a need for a more efficient and effective
solution for removing bearings. The hydraulic bearing puller aims to address this problem by
providing a tool that can safely and easily remove bearings without causing damage or requiring
excessive force.
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The hydraulic bearing puller should be able to securely grip the bearing and apply an appropriate
amount of force to remove it from the shaft or housing. It should also be versatile enough to
accommodate different sizes and types of bearings, making it suitable for a wide range of
machinery and equipment. And also it should be user-friendly, allowing operators to easily set up
and operate the tool. It should be durable and withstand the rigors of heavy-duty industrial use,
ensuring long-term reliability and cost-effectiveness. It should provide a reliable and efficient
solution for removing bearings, reducing the risk of damage, and minimizing downtime during
maintenance and repair operations.

In my special design, we used to make hydraulic bearing puller for both removing from the hubs
and shafts, I designed it to give two purposes in one.

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CHAITER TWO
2. OBJECTIVE OF THE PROJECT
2.1 General Objective of the Project
The main objectives of this project is to design and develop a tool that can efficiently remove
bearing from 16 to 36mm internal diameter from shafts and flywheel using hydraulic force with
lifting capacity of 7539.825N.

2.2 Specific Objective of the Project

 To select appropriate materials for machine components
 To design main frame
 To design frame bar
 To design connecting rods
 To design pulling jaws
 To do part drawing and assembly drawing by using SOLIDWORK
 Making the model of the machine

2.3 Scope and Limitation

2.3.1 Scope of the Project
The scope of this design project was on the detail design and analysis of each component of
hydraulic bearing puller to draw out the detail drawing of each component and assembly drawing
using AutoCAD or SOLIDWORK software with the help of software, I test my design by
simulation and also model making using cardboard.

2.3.2 Limitation On the Project

When designing of hydraulic bearing puller, there are various obstacle or challenges that may be
arise. Because of political stability and civil war in our city results a volatile and unsafe
environment and also it causes lack of internet. It may be challenging to ensure the safety of
team members and equipment, communicate with our advisors and getting knowledge from

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internet. So it limit me not to go further on modifying our design. Therefore, Safety is the
priority.

2.4 Significance of the Project

The significance of the project on designing a hydraulic bearing puller lies in its potential to
improve efficiency, safety, and effectiveness in the removal of bearings in various industries.
Hydraulic bearing puller can significantly reduce the time and effort required to remove
bearings. The use of hydraulic power allows for greater force application, making it easier to
dislodge stubborn or tightly fitted bearings. Bearing removal can be a challenging task, often
involving heavy machinery and potential risks of injuries. The design of a hydraulic bearing
puller with proper safety features can minimize hazards and provide a safer environment for
operators. The efficient and timely removal of bearings can lead to cost savings by minimizing
downtime during equipment repairs and maintenance. A hydraulic bearing puller can facilitate
quick bearing replacement, improving productivity and reducing operational losses. The efficient
and timely removal of bearings can lead to cost savings by minimizing downtime during
equipment repairs and maintenance. A hydraulic bearing puller can facilitate quick bearing
replacement, improving productivity and reducing operational losses.

2.5 Literature Review

A literature review is a critical evaluation and summary of current knowledge on specific topic It
involves researching, synthesizing and analyzing published literature, scholarly articles, books
and other credible sources relevant to the topic under investigation. The purpose of a literature
review is to identify key themes, gaps and inconsistencies in the existing literature provide an
overview of the current state of knowledge.

According to Prof. Francis B. Abella et al. (2017) -h–ve studied about electrically powered
bearing puller. They highlight that electrical control of the bearing puller to motorize the pulling
process of manual bearing puller. It allows easy pulling of the bearing with lesser time
consumed. The steps of utilizing this device start with the control of the toggle switch to setup
positioning and pulling process. The push button sets positioning and alignment. According to
lecturer Emagbetere Eyere et al. (2018), develop a simple, low cost, less weight and less energy
to operate mechanical puller. A 3 arms mechanical bearing puller was designed, and stresses on
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its part with irregular shape were analyzed using finite element method. The fabricated model
prototype was tested by using it to remove bearing stock on a shaft, the resulting performance
was satisfactory.

According to Rakesh Y. Suryawanshi et al. (2015), he studied about the use of Hydraulic system
is used to remove bearings safely without causing any damage. The unsafe and excessive
hammering cause’s damage of bearing surface or sometimes chance to failure and excessive
human effort required. The purpose of modification are required less human effort, simplicity of
operation, Removing and installing bearing done without damaging bearing surface, compact,
portable and well suited. Finally he conclude that hydraulic bearing puller based on hydraulic
system on the principle of Pascal’s law which states that “Pressure distribution in enclosed
cylinder is uniform in all direction.

According to D. Ramesh et al. (2019), In order to remove and installed bearing safely, to make
modification in tradition method. The modification made in installing and easy removing
bearing. The purposes of modification are simplicity of operation, removing and installation of
bearing done without damaging bearing surface, compact, portable, well suited, low
Multifunctional, safe, versatile.

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CHPTER THREE
3. MATERIAL AND METHODOLOGY
3.1 METHODOLOGY
Methodology is a general guide line or procedure which, are used to solve problems to design
my project which is, design of Hydraulic bearing puller. I will try to follow the following
procedure.

The following are the steps involved in the design of Hydraulic bearing puller:

1. Problem identification: The first step in designing a hydraulic bearing puller is to

identify the problem that needs solving. This may involve determining the lifting
capacity needed, which is taking into account the force required to pull the bearing from
hubs and shaft, as well as other requirements or constraints.
2. Company requirement: The design is made by the company requirement especially.
3. Research and literature review: Study existing hydraulic bearing puller designs in the
market. Analyze their features, strengths, and weaknesses. This will help in gaining
insights into what works well and what can be improved in the new design.
4. Conceptual Design: Once the problem has been identified, the next step is to come up
with possible solutions in the form of conceptual designs. These designs should take in
to account factors such as calculating the hydraulic pressure needed. This involves
calculating the force required to lift the load and then determining the size of the pulling
jaws for the use of different sizes of bearing.
5. Detail design: Once a suitable conceptual design has been selected, the next step is to
create a detailed design that takes into account all of the specifications and requirements
of the hydraulic bearing puller. This involves creating 3D models, performing stress
analysis, and selecting appropriate materials and components.
6. Model making: the last is model making of the hydraulic bearing puller.it helps for better
understanding of the design I made.

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Figure 3.1 design step of hydraulic bearing puller

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3.2 MATERIAL SELECTION

Material selection is important in designing the project to avoid the misuse of the
materials or components used. In addition, in the selection of components, the safety
aspect should also be emphasized as the project produced must be used safely.

When selecting materials for a hydraulic bearing puller, there are several factors to
consider:

 Strength and durability: The material should have sufficient strength to withstand the forces
applied during the bearing pulling process. It should also be durable enough to resist wear and
tear over time.
 Corrosion resistance: Hydraulic bearing pullers may come into contact with various substances,
including water, oil, and chemicals. Therefore, materials that are resistant to corrosion, such as
stainless steel or coated steel, are preferred.
 Weight: The weight of the material impacts the overall weight of the hydraulic bearing puller.
Too much weight can make it difficult to handle and maneuver. Hence, lightweight materials like
aluminum or certain plastics may be considered.
 Cost: The cost of the material should be taken into account, as it affects the overall cost of the
hydraulic bearing puller. Balancing the desired qualities of strength and durability with
affordability is important.
 Machinability: Some materials may be easier to machine and shape into the desired components
for the hydraulic bearing puller. Factors such as hardness, ductility, and workability should be
considered to ensure ease of manufacturing.
 Thermal resistance: Hydraulic bearing pullers may generate heat during use due to friction.
Materials with good thermal resistance properties can help prevent distortion or damage caused
by high temperatures.
 Surface finish: The material's surface finish can affect the overall appearance and smooth
operation of the hydraulic bearing puller. Consider materials that can be easily finished or coated
to provide a smooth and aesthetically pleasing surface. By considering these factors, one can
choose materials that meet the functional requirements, cost constraints, and manufacturing
feasibility for a hydraulic bearing puller.
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o Our material selection is based on the following specification:

Table 1 Hydraulic bearing puller design data

Parameter Value
Load 4000N
lifting height 75mm
Diameter of the bearing could be removed 16mm-36mm

The following table states mechanical properties of materials that we used when designing
hydraulic bearing puller.

Table 2 Mechanical properties of materials used

Materials Mechanical Properties

Hardness Tensile Yield Elongation Young’s Modulus

strength strength

Stainless 70- 515-760MPa 205- 50-60% 193-200GPa

steel
90HRC 310MPa
AISI 4340 500HB 1310- 930- 10-20% 205GPa

1530MPa 1080MPa
HSLA steel 180-240 450-900MPa 290- 10-15% 190-210GPa

HB 550MPa
High carbon 55- 600- 500- 2-10% 200-210GPa
steel 65HRC 1600MPa 1500MPa

Table 3 Components of Hydraulic bearing puller

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Components of Materials Selected Reason for selection

Hydraulic bearing puller

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Hydraulic double piston Stainless steel High corrosion resistance, high

rod Cylinder
temperature resistance, high resistance

To chemicals, high strength and

durability.

Main frame AISI 4340 High strength, high hardness, good

wear resistance, good machinability,
good heat resistance, versatility.

Frame bar HSLA steel High strength, excellent toughness,

good corrosion resistance, high fatigue
strength, cost effective.

Connecting rods High carbon steel High strength and hardness, good wear
resistance, excellent durability, and
good heat treatment response.

Double piston rod Stainless steel High corrosion resistance, high

temperature resistance, high resistance
to chemicals, high strength and
durability.

Shaft pusher Medium carbon Good Weld ability, good machinability,

high strength and durability, cost
steel effective

Pulling jaws High carbon steel High strength and hardness, good wear
resistance, excellent durability, and
good heat treatment response.

Bearing holder High carbon steel High strength and hardness, good wear
resistance, excellent durability, and
good heat treatment response.

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Hydraulic fluid Polyglycol High viscosity, good chemical stability,

excellent lubricity, low toxicity.

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CHAPTER FOUR
4. DESIGN ANALYSIS
4.1 General Design Considerations of Hydraulic bearing puller
When designing a hydraulic bearing puller, there are several key considerations that need to be
taken into account in order to ensure that the jack is safe, reliable, and efficient. Some of the
most important design consideration includes load capacity, determining of size, lifting range
and pumping mechanism.

4.1.1 Force Analysis

Force analysis is an essential step in the design of a hydraulic bearing puller. This analysis
involves calculating the forces that will act on the bearing to remove during use and ensuring that
the bearing puller can withstand these forces without failure.
o The following are the forces that need to be considered:

4.1.1.1 Hydraulic pressure Force

The hydraulic pump or handle applies pressure to the hydraulic ram, which exerts a force on the
bearing puller attachment.

Hydraulic pressure force=hydraulic pressure × area of piston

𝐹=𝑃×𝐴

Then we have to calculate hydraulic pressure applied by the hydraulic bearing puller.

𝑃 = 𝐹⁄𝐴

P- Hydraulic pressure

F- Force required to remove the bearing A-

Effective area of cylinder

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Figure 4.1 hydraulic pressure force(references 5)

We assume the force require: 𝐹 = 4𝐾𝑁 To
calculate effective area of cylinder:

𝐴 = 𝜋𝑅2 − 𝜋𝑟2

R- Area of piston r- Area of piston rod

𝐴 = (14𝑚𝑚)2 − 𝜋(6𝑚𝑚)2

𝐴 = 615.752𝑚𝑚2 − 113.097𝑚𝑚2

𝐴 = 502.655𝑚𝑚2 Then
calculate hydraulic pressure:
𝑃 = 𝐹⁄𝐴

𝑃 = 4000𝑁⁄502.655𝑚𝑚2

𝑃 = 7.958𝑀𝑃𝑎 Finally
calculate hydraulic pressure force:

𝐹=𝑃×𝐴

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𝐹 = 7.958𝑀𝑃𝑎 × 𝜋𝑅2

𝐹 = 7.958𝑀𝑃𝑎 × (14)2

𝐹 = 4899.997𝑁

4.1.1.2 Friction Force

To calculate the friction force involved in a hydraulic bearing puller, you'll need to consider several
factors, including the hydraulic pressure applied, the effective area of the hydraulic cylinder, and the
coefficient of friction between the bearing puller and the bearing or gear being pulled.

Given that the hydraulic pressure applied is 7.958MPa, effective area of cylinder 502.655mm 2 and the
coefficient of friction between the bearing puller jaw and the bearing can be taken as 0.6 but if it is
lubricated it can be reduce to 0.3.

Friction force can be calculated by using the equation:

𝐹𝑓 = µ × ℎ𝑦𝑑𝑟𝑎𝑢𝑙𝑖𝑐 𝑝𝑟𝑒𝑎𝑠𝑢𝑟𝑒 × 𝑒𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑎𝑟𝑒𝑎

𝐹𝑓 = 0.3 × 7.958 𝑀𝑃𝑎 × 502.655𝑚𝑚2

𝐹𝑓 = 1200.039𝑁

4.1.2 Geometrical Analysis

To perform a geometric analysis of a hydraulic bearing puller, we would typically examine its
components and geometry to understand how they interact and determine the functionality of the
tool. While I don’t have specific information about the hydraulic bearing puller model you are
referring to, I can provide a general overview of the geometric aspects and components
commonly found in hydraulic bearing pullers. Some of the geometrical considerations for the
design of a hydraulic bearing puller include:

4.1.2.1 Lifting capacity

When we calculate the lifting capacity of a hydraulic bearing puller, we need to consider several
factors, including the hydraulic system's maximum operating pressure, the effective area of the
hydraulic cylinder, and the load capacity of the puller mechanism itself.
Maximum hydraulic pressure = 15𝑀𝑃𝑎
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Effective area of hydraulic cylinder =502.655𝑚𝑚2

Lifting capacity can be calculated by using the following equation:

𝐿𝑖𝑓𝑡𝑖𝑛𝑔 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 𝐸𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑎𝑟𝑒𝑎 × 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 ℎ𝑦𝑑𝑟𝑎𝑢𝑙𝑖𝑐 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒

𝐿𝑖𝑓𝑡𝑖𝑛𝑔 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 502.655𝑚𝑚2 × 15𝑀𝑃𝑎
𝐿𝑖𝑓𝑡𝑖𝑛𝑔 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 7539.825𝑁

4.1.2.2 Height range

The height range of the jack is determined by the length of its piston rod, which extends from the
piston and pushes against the load. The length of the rod will determine how high the load can be
lifted.

Table 4 range of the design

Minimum height the puller 39 mm

to grip the bearing

Maximum extension of 75 mm

hydraulic cylinder
Height range 26 mm

The maximum lifting height can be determined by using:

𝐻𝑒𝑖𝑔ℎ𝑡 𝑟𝑎𝑛𝑔𝑒

= 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑒𝑥𝑡𝑒𝑛𝑡𝑖𝑜𝑛

− 𝑀𝑖𝑛𝑖𝑚𝑢𝑚 ℎ𝑒𝑖𝑔ℎ𝑡 𝑡ℎ𝑒 𝑝𝑢𝑙𝑙𝑒𝑟 𝑡𝑜 𝑔𝑟𝑖𝑝 𝑡ℎ𝑒 𝑏𝑒𝑎𝑟𝑖𝑛𝑔

𝐻𝑒𝑖𝑔ℎ𝑡 𝑟𝑎𝑛𝑔𝑒 = 26𝑚𝑚

4.1.2.3 Base area

The base are of the bearing puller is important for stability during lifting. We selected the base of
the hydraulic bearing puller to have a rectangular shape.
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Table 5 range of base area

Length of the base 20mm

Width of the base 30mm

4.1.3 Design components of Hydraulic bearing puller

4.1.3.1 Design of main frame

Figure 4.2 design of main frame

The main frame on a hydraulic bearing puller is a critical component that provides the structural
support and stability necessary for proper bearing extraction. It ensures proper alignment of the
hydraulic puller components. It holds the hydraulic cylinder, support beams, and other parts in
place, ensuring they are positioned correctly relative to the bearing and its housing.

Then we have make structural analysis to know loads distribute to every member of the frame:

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Figure 4.3 loads distribute(references 5)

First we select member CD: member CD is fixed on member EA and FB Assumption:
neglect the weight of cylinder.

Figure 4.4 load cd(references 5)

Let Ma = Fixed end moment at A
Mb = Fixed end moment at B

Ra = Reaction at A

Rb = Reaction at B.

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The above four are unknown i.e., Ra, Rb, Ma and Mb are unknown.

(1) B.M. Diagram

Due to symmetry, the end moments Ma and Mb will be equal. Hence the B.M. diagram due to
end moments will be a rectangle by AEFB. Here the magnitude of Ma arid Mb are unknown.
The bending moment diagram for a simply supported beam carrying a point load at the center
will be a triangle with the maximum B.M. at the Centre equal to𝑊 .𝐿
.

4 Equating the areas of the two bending moment diagrams, we get:

Area of triangle ADC = Area of rectangle AEFB

1
⁄2 × AB × CD = AB × AE

1
⁄2 × L × 𝑊 4𝐿 = L × 𝑀𝑎

𝑊. 𝐿
𝑀𝑎 =
8
𝑊. 𝐿
𝑀𝑎 = 𝑀𝑏 =
8

(2) S.F. Diagram

Equating the clockwise moments and anti-clockwise moments about A, we get:

𝑅𝑏 × L + 𝑀𝑎 = 𝑀𝑏 + W ×
𝑀𝑎 = 𝑀𝑏

𝑅𝑏 × L = W ×
𝑊
𝑅𝑏 = 2
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Due to symmetry, 𝑅𝑎 = 𝑊2

(1) Slope and Deflection

The B.D at any section between AC at a distance x from A is given by,

𝑑2𝑦

𝐸𝐼 𝑑 𝑥2 = 𝑅𝑎 × 𝑥 − 𝑀𝑎

𝑑2𝑦 𝑊×𝑥 𝑊×𝑙

𝐸𝐼 𝑑𝑥2 = 2 − 8

Integrate the above equation, we get

𝑑2𝑦 𝑊 𝑥2 𝑊 × 𝐿

𝐸𝐼 𝑑𝑥2 = 2 × 2 − 8 × 𝑥 + 𝐶1

At x=0, 𝑑𝑦𝑑𝑥=0. Hence 𝑐1 = 0

Therefore, the above equation becomes as

𝑑𝑦 𝑊𝑥2 𝑊 × 𝐿

𝐸𝐼 = − ×𝑥
𝑑𝑥 4 8

Integrate the above formula then we will get,

𝑊 𝑥3 𝑊𝐿 𝑥2

𝐸𝐼𝑦 = × − × + 𝐶2
4 3 8 2

At x=0, y=0 hence 𝐶2 = 0

𝑊. × 𝑊 × 𝐿𝑥2

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𝐸𝐼𝑦 = −
12 16

The deflection is maximum at the center of the beam, where𝑥 = 𝐿. Hence substituting 2

𝐿
𝑥 = in the equation.
2

𝑊 𝐿2 𝑊×𝐿 𝐿2

𝐸𝐿𝑦𝑚𝑎𝑥 = () − ×()
12 2 16 2

−𝑊𝐿3

𝑦𝑚𝑎𝑥 =
192𝐸𝐼
Therefore, the deflection is downward

After finding Ra and Rb we can find the load distribute to all members by joint method, 1.
First we start from joint A

∑ 𝐹 𝑥 = 0 𝑅𝑎𝑥

Figure 4.5 load distribute joint A(references 5)

= 0, because there is no horizontal component

𝑅𝑓 + 2𝐾𝑁 = 0

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𝑅𝑓 = −2𝐾𝑁
This means it’s downward

2. Joint B

∑ 𝐹𝑥 = 0 𝑅𝑏𝑥
Figure 4.6 load distribution joint B(references 5)
= 0, because there is no horizontal component
∑ 𝐹𝑦= 0

𝑅𝑔 + 2𝐾𝑁 = 0

𝑅𝑔 = −2𝐾𝑁

3. Joint C

∑ 𝐹𝑦 = 0

Figure 4.7 load distribution joint C(references 5)

𝑅𝑑 − 2𝐾𝑁 = 0 Rd=2KN
4. Joint D

∑ 𝐹𝑦 = 0
𝑅𝑒 − 2𝐾𝑁 = 0
5.
6.
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7 𝑅𝑒 = 2𝐾𝑁

Figure 4.8 load distribution joint D(references 5)

4.1.3.2 Design of Frame bar

Figure 4.9 design of frame bar

The frame bar is designed to securely hold the bearing puller jaws in place and ensure proper
alignment and stability during the bearing removal process.

The dimension of the frame bar that is determined considering the load capacity and the selected
material is stated as follows:

Table 6 dimension of frame bar

Length mm
Height mm
Thickness mm

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4.1.3.3 Design of connecting rods

Figure 4.10 design of connecting rods

To calculate the dimension of connecting rods for the design of hydraulic bearing puller, the
following steps are followed:

Shape and size: The connecting rods should be designed to fit the specific shape and size of the
load being loaded. For our design,

Given: Radius = mm

𝐴 = 𝜋𝑟2

𝐴 = (3𝑚𝑚)2

𝐴 = 9.42𝑚𝑚2

Then we have to calculate Stress analysis of connecting rods:

𝐹
𝜎=
𝐴
We can take the force:

Force=4KN, for both rods

Force =2KN, for single rod

2000𝑁
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𝜎 = 9.42𝑚𝑚2

𝜎 = 212.31𝑀𝑃𝑎
Table 7 dimension of connecting rods

Radius 3 mm
Length 222 mm
Area 9.42 𝑚𝑚2
shape Cylindrical

4.1.3.4 Design of pulling jaws

Figure 4.11 pulling jaws

Calculating the puller jaws in a hydraulic bearing puller involves considering their geometry,
strength, and the forces involved in the bearing extraction process. While the specific
calculations can vary depending on the design and type of puller jaws.

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Figure 4.12 Load of puller jaws

The jaws of a hydraulic bearing puller are typically equally spaced from the hydraulic cylinder to
ensure balanced and uniform distribution of the pulling force on the bearing or gear being
removed. This design approach helps maintain stability, reduce excessive stress concentrations,
and prevent misalignment or deformation during the bearing extraction process.

First we have to calculate the safety factor:

Safety factor = 𝑗𝑎𝑤 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ

𝑎𝑝𝑝𝑙𝑖𝑒𝑑 𝑓𝑜𝑟𝑐𝑒

𝑗𝑎𝑤 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ = ℎ𝑦𝑑𝑟𝑎𝑢𝑙𝑖𝑐 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 × ℎ𝑦𝑑𝑟𝑎𝑢𝑙𝑖𝑐 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟

𝑎𝑟𝑒𝑎 × 𝜇

𝑗𝑎𝑤 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ = 15𝑀𝑃𝑎 × (15𝑚𝑚)2 × 0.3

𝑗𝑎𝑤 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ = 3180.86𝑁

The applied force for single jaw is 2KN,

3180.86𝑁
𝑠𝑎𝑓𝑒𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 =
2000𝑁

𝑠𝑎𝑓𝑒𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 = 1.59

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Then we have to calculate stress analysis: Analyze the stress levels in the puller jaws to ensure
they remain within acceptable limits. This involves calculating the stress distribution and
verifying that the material's strength is not exceeded under the applied forces.

𝐹
𝜎=
𝐴

Force on single jaw = 2KN

A - Contact area b/n puller jaw and bearing puller

𝐴 = 3𝑚𝑚 × 5𝑚𝑚

𝐴 = 15𝑚𝑚2

2𝐾𝑁

𝜎 = 15 𝑚𝑚2

𝜎 = 133.3𝑀𝑃𝑎
Table 8 dimension of inlet and outlet port

Inner diameter rea

Inlet port 5mm 78.54mm2
Outlet port 5mm 78.54mm2

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4.1.4 Selection of appropriate material for machine components

4.1.4.1 Double rod piston

Figure 4.13 double rod piston

To select the appropriate double rod piston for a hydraulic bearing puller, we need to consider
the load distribution, Rod Alignment, and hydraulic pressure.

If the diameter of the piston rods of a double piston system is the same, the load distribution will
be equal between the two pistons. This is because the load is shared between the two pistons in
proportion to their respective areas. Since the areas of the two pistons are equal if the diameters
of their piston rods are the same, the load will be equally distributed between them.

The rod alignment of a double piston is critical to ensure optimal performance and efficiency of
the mechanism. It refers to the precise positioning and alignment of the connecting rods that
connect the two pistons.

A well-aligned double piston system enhances the overall efficiency of an engine or compressor,
as it allows for smoother operation, improved torque output, and reduced wear on the
components. The proper alignment also helps to prevent any vibrations, noise, or potential
damage that may occur due to misalignment.

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4.1.4.2 Hydraulic cylinder

Figure 4.14 hydraulic cylinder

To determine the appropriate hydraulic cylinder for the design of a hydraulic bearing, several
factors such as load capacity, stroke length and operating pressure must be considered.
The values of these factors are stated as follows:

Table 9 dimension of hydraulic cylinder

Load capacity 7539.825 N

Stroke length 80 mm
Operating pressure 7.958𝑀𝑃𝑎 𝑀𝑃𝑎

Based on these factors, a hydraulic cylinder that meets or exceeds these requirements is selected.

4.1.4.3 Design of inlet and outlet port

In a double piston rod cylinder, there are typically two sets of inlet and outlet ports. These ports
are used for the introduction and removal of fluids, such as compressed air or hydraulic fluid,
which actuate the cylinder.

The inlet ports are where the fluid is supplied to the cylinder. They allow the fluid to enter the
cylinder chambers and apply pressure to the pistons. The fluid can be supplied through hoses or
tubing connected to these ports.
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The dimension of the inlet and outlet port that is determined considering the hydraulic pressure
and the selected material is stated as follows:

Table 10 dimension of selecting material

Diameter Area Force distribution

Piston rod 1 12mm 113.1mm2 2000N
Piston rod 2 12mm 113.1mm2 2000N
Piston 28mm 615.75mm2

4.2 Working Principles of Hydraulic Bearing Puller

When the hydraulic fluid enters to the hydraulic cylinder’s inlet port 1, it push the piston
downwards and the frame bar that connected with the piston also moves downward. The
adjustable jaws entered to the inside hole of bearing and adjust the jaws until they grip the
bearing to be removed. Then the hydraulic fluid enter to the inlet port 2 and pushes the piston
upwards and the frame bar also moves upward. Finally the bearing will remove from the fly
wheel. We don’t have to forget to oil it for smooth removal.

When we use it to remove bearing from shaft, frame bar is replaced by shaft pusher and
additional component called bearing holder is mounted on main frame. When the hydraulic fluid
enters to the hydraulic cylinder inlet port 2, it pushes the piston upward and the shaft pusher also
moves upward. Then the shaft with bearing mounted on it placed on bearing puller. Then the
hydraulic fluid enters to the inlet port 1, it pushes the piston downward and the shaft pusher also
moves downward. Finally, the shaft pusher pushes the shaft and remove the bearing.

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CHAPTER FIVE
5. CONCLUSION AND RECOMMENDATION
5.1 Conclusion
The hydraulic bearing puller is an efficient and effective tool for removing bearings from various
mechanical systems. It offers numerous advantages over traditional methods such as manual
pulling or using a gear puller. First of all, the hydraulic bearing puller provides a significant
amount of force, making it capable of removing even the most stubborn bearings. This eliminates
the need for excessive physical exertion and reduces the risk of injury for the operator. Secondly,
the hydraulic system allows for precise control and adjustment of the pulling force, ensuring that
the bearing is removed without causing damage to the surrounding components. This is
particularly important when working with delicate or sensitive machinery. Additionally, the
hydraulic bearing puller is versatile and can be used on a wide range of bearing sizes and types.
This makes it a valuable tool for various industries such as automotive, manufacturing, and
maintenance. Furthermore, the ease of use and quick setup of the hydraulic bearing puller
contribute to increased efficiency and reduced downtime during maintenance or repair
operations.

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5.2 Recommendation
During the work, I get many problems. To overcome these problems the company should fulfill
safety material and give knowledge about them, sorting tools in comfortable way to easily find
them, and cars should be arranged in order.

Based on the information gathered in this project, it is recommended to further explore the
advancements in digital controls and automation in hydraulic bearing pullers. This can involve
researching and implementing technologies that allow for remote control, monitoring, and
precise adjustment of pulling forces. Additionally, investigating the integration of sensors and
feedback systems into hydraulic bearing pullers can enhance their performance and ensure
accurate and efficient bearing extraction.

Overall, continued research and development in hydraulic bearing pullers will contribute to
improving efficiency, safety, and productivity in bearing extraction processes. The
recommendations provided here can serve as starting points for future projects and investigations
related to hydraulic bearing pullers.

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References
1. Emagbetere eyere. (2012). development of mechanical puller. international jornal of
innovative science and research technology.
2. B.Abella, p. F. (2017). Electrically controlled bearing puller. IJET.

3. Naresh, T. (2022). Hydraulic bearing removal Press. IRJETS.

4. Rakesh, S. (2015). Design and fabrication of Hydraulic bearing puller and pusher.

International Journal for Innovation Research in science and Technology.

5. Ramesh, D. (2019). Safely removal and instalation of bearings.

6. L Morello, Lorenzo Rosti Rossni (2011) component design volume 1

7. L Morello, Lorenzo Rosti Rossni (2011) system design volume 2

8. John Fenton(1980) vehicle body layout and analysis

9. POE artificial intelligent

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APPENDIX

Appendix 1
Mechanical properties of materials

Table 11 Mechanical properties of materials

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Appendix 2
Detail drawing of each part and exploded view

Table 12 Mechanical properties of materials

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