MIZAN TEPI UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMEENT OF MECHANICAL ENGINEERING

INTERNSHIP REPORT
PURSUED AT: ETHIOPIAN ROAD ADMINISTRATION, NEKEMTE, OROMIA, ETHIOPIA
TITLE: DESIGN AND ANALYSIS OF MULTI NUT REMOVER MACHINE
DURATION: THREE MONTHS

Name of student university

Gemechis Wendimu……………… Miza tepi university
Hunde Jirata ………………….. Miza tepi university
Burka Mulatu …………………… Miza tepi university
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Declaration
We are here to announce that the work, which is being submitted to the Ethiopian Construction
Works Corporation for the training report, is for the final exercise program. All relevant
information resources used in this paper are correctly acknowledged. This is to ensure that the
above statement given by the candidate is correct to the best of our knowledge and belief.

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Acknowledgement
God's Side We would like to thank all the employees of “ETHIOPIAN ROAD
ADMINISTRATION” for their generous help during the internship. We would like to thank the
helpers in all the workshops We put on. Help has good experience and as We are new to such
activities its information and guidance during training and with our families
God. Lastly‚ each and every member of the ECWC has done their best to ensure that we had a
successful time with us during the internship and we greatly appreciate their Hospitality and
hope that they will continue this good practice for the students alongside us.

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Abstract
This report is the result of an Internship, conducted while we were in the Ethiopian Construction
Works Corporation. This gave us an opportunity to put into practice the theoretical knowledge
we gained during our study. The internship also provided a real opportunity to gain valuable
experience to bridge the gap between study and the start of working life. Furthermore, the actual
exposure offered an experiential learning component that could reinforce prior theoretical
knowledge, as well as the motivation we are perusing with Mechanical Engineering.
Additionally, our experiential learning has proven helpful in developing skills in details about
Engine, Transmission, Gear box, steering and brakes. We also consider that car automotive
work depending on the company is work like car maintenance, car maintenance, Vehicle
inspection, Technical Services and troubleshooting various car troubleshooting. We have
decided that car is a running engine, car air conditioning system, car electrical system, car brake
system, injection system etc. In this case we understand important safety when working on cars
and machines, how to get power in motor air and from fuel (how power is produced), cooling
systems to protect our engines from overheating and burned out, lubrication systems to reduce
friction, how to start a car using a starter, how to fuel at the combustion chamber where we slide
(distribute), how power trains transfer power to each other, brake systems and their assemblies,
clutch systems and their assemblies. We also decided on the measurements and troubleshooting
that was found in that company with employees with long experience and good skills on cars.
For example, reducing the wastage of time and labor by converting labor-intensive tasks to
machines. In this context we understand how to solve problems and communication skills,
learning through socializing and getting along with employees.

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ACRONOMY AND ABBREVIATION

ECWC-Ethiopian construction work corporation
Eng’g-Engineering
Dep’t-Department
ERCC- Ethiopian road construction corporation
EWWCE- Ethiopian Water works construction enterprise
ERA- Ethiopian Road Administration
NOMENCLATURE
PCD- pitch circle diameter
M-module
Np- number of teeth of driven gear Ng- number of teeth of driver gear b- Face width
VR- velocity ratio
- pressure angle
J- Geometry factor for spur gear
GR- gear ratio
Fb- beam strength
F- Force
Ft- tangential force
FOS- factor of safety
P- Power

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Pg-power transmitted ring gear

Pp- power transmitted by pinion gear LH- hand lever δy- yield strength δu- ultimate tensile
strength
Feff- effective load of gear teeth
Y- Lewis form factor
Ka- combined shock and fatigue factor
Km-load distribution factor
Kv- dynamic factor

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TABLE OF CONTENTS page

Declaration ----------------------------------------------------------------- I
Acknowledgement --------------------------------------------------------------------II
Abstract --------------------------------------------------------------------- III
ACRONOMY AND ABBREVIATION ---------------------------------------------IV
NOMENCLATURE ------------------------------------------------------------- IV
List of figures -----------------------------------------------------------------------VIII
List of tables ------------------------------------------------------------------------IX
CHAPTER ONE -------------------------------------------------------------1
Introduction --------------------------------------------------------------1
1.3. COMPANY INFORMATION ---------------------------------------------------- 1
1.3.1 Background of The Organization ----------------------------------------------------1
1.3.2 Main Purposes of The Establishment of ECWC -------------------------------2

1.3.3 Location of ECWC -----------------------------------------------------------------2

1.3.4 Vision and Mission of The Company ----------------------------------------------3
1.3.5 The Main Customers of The ECWC: ----------------------------------------------3
1.3.6 Structures of The Ethiopia Construction Works Corporation--------------------3
1.3.7 Competitive Advantage of The ECWC--------------------------------------- 4
1.3.8 The Main Branches of ECWC ------------------------------------------------------5
1.3.9 Major Businesses of The ECWC ---------------------------------------------5
CHAPTER TWO ------------------------------------------------------------------------6
2.1. WORK DONE ------------------------------------------------------------------------6
2.1.1. Engine Shop -----------------------------------------------------------------------7
2. Cleaning and Inspection -------------------------------------------------------------13
2.1.2. Machine Shop ---------------------------------------------------------------------18
2.1.3. Electrical service shop------------------------------------------------------- -----21
2.1.4. Body shop --------------------------------------------------------------------23
2.1.5. Welding shop -------------------------------------------------------------------24
2.1.6. Tire shop --------------------------------------------------------------------24
2.2. CHALLENGES FACED DURING OUR INTERNSHIP -------------26

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2.2.1. Methods to Overcome These Challenges: -------------------------------26

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2.3. SKILLS WE HAVE GOT -------------------------------------------------26

CHAPTER THREE -------------------------------------------------------------------29
3.1 INTRODUCTION ----------------------------------------------------------30
3.2. PROBLEM STATEMENT -------------------------------------------------30
3.3. OBJECTIVE ---------------------------------------------------------------------30
3.4 Scope of study ---------------------------------------------------------------------31
3.5. WORKING PRINCIPLE ---------------------------------------------------------------31
CHAPTER FOUR -----------------------------------------------------------------------32
4.1 LITRATURE REVIEW ------------------------------------------------------------32
4.2 MATERIAL AND METHOD ---------------------------------------------------32
4.3 DESIGN OF EACH COMPONENT -------------------------------------------32
4.3.1 Design Calculation -------------------------------------------------------------34s
4.3.2. Design of Spur Gear -------------------------------------------------------------37
4.3.3 Design of Shaft ------------------------------------------------------------------------38
4.3.4 Design of Casing ---------------------------------------------------------------39
4.3.5 Design of Hand Lever ----------------------------------------------------------------39
4.3.6 Design of Bearing ---------------------------------------------------------------40
4.3.7 Design of Box Spanner Socket-------------------------------------------------- 41
CONCLUSION -----------------------------------------------------------------------44
RECOMMENDATION -----------------------------------------------------------------45
APPENDIXES ------------------------------------------------------------------ 46

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List of figures page

Figure 1.1 Ethiopian construction works corporation ............................................................... 2
Figure1.2 ECWCgarage..............................................................................................................6
Figure 2.1 Engine ...................................................................................................................... 8
Figure 2.2 crankcase .................................................................................................................. 9
Figure2.3 connecting rod .......................................................................................................… 10
Figure2.4 camshaft .................................................................................................................... 11
Figure2.5 bearing ....................................................................................................................... 11
Figure2.6 disassembled engine .................................................................................................. 12
Figure2.8 Transmission system ................................................................................................. 14
Figure2.9 clutch ......................................................................................................................... 15
Figure 2.10 braking system ....................................................................................................... 17
Figure 2.11 Disc brake ...............................................................................................................18
Figure 2.12 drum brake ............................................................................................................. 18
Figure 2.13 shaper machine ....................................................................................................... 20
Figure 2.14 Features made in machine shop ............................................................................. 21
Figure 2.15 starter ...................................................................................................................... 22
Figure 2.16 Body shop ...............................................................................................................23
Figure 2.17 Oxy-acetylene and Arc welding ............................................................................. 24
Figure 4.1 Assembly from diffirent side ……………………………………………………..35
Figure 4.2 Exploded view of assembly ………………………………………………………36
Figure 4.4 Driver and driven grats in mesh ………………………………………………….43
Figure 4.5 place ………………………………………………………………………..44
Figure 4.6 shafts ………………………………………………………………………45
Figure 4,7 driven gear ……………………………………………………………………4 6
Figure 4.8 Driver gear ……………………………………………………………… 46
Figure 4.9 Manufactured plate ………………………………………………………………47
Figure 4.10 manufactured driven …………………………………………………………….48
Figure 4.11 Manufactured shafts …………………………………………………………….49

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List of tables
Table 1.1 branches of ECWC .................................................................................................... 5
Table 2.1 Transmission problems with remedies ...................................................................... 16
Table 4.1 A summary of design specification ………………………………………………38

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CHAPTER ONE
INTRODUCTION
An internship is job training for professional careers. Generally, an internship consists of an
exchange of services for experience between the student and organization. Students can also
use an internship to determine if they have an interest in a particular career, to create a network
of contacts. Internships exist in a wide variety of industries and settings. An internship may be paid,
unpaid, or partially paid (in the form of a stipend).Stipends are typically a fixed amount of
money that is paid out on a regular basis. Usually, interns that are paid through stipends are paid
on monthly basis. Paid internships are common in professional fields including medicine,
architecture, science, engineering and technology. A typical internship lasts between one and four
months, but can be shorter or longer, depending on the organization involved. Most students apply for
internships during their summer and winter breaks. In some Universities, internships during the
college breaks are compulsory and a part of the curriculum. It is common that previous interns
become employees to the organization once they have acquired the necessary skills and experience.
Moreover, many engineering students also term their training period in certain industrial organization
as an internship.

1.3. COMPANY INFORMATION

1.3.1 Background Of The Organization
The Ethiopian Construction Works Corporation is a newly established public enterprise with the aim
of becoming a leading, preferred and competitive construction contractor. The corporation was a result
of the amalgamation of two formerly independent public enterprises, namely the Ethiopian Water
Works Construction Enterprise (EWWCE) and the Ethiopian Road Construction Corporation
(ERCC).Although it is a new enterprise in its current form, the Ethiopian Construction Works
Corporation (ECWC) has, therefore, accumulated experience in the construction industry. Currently,
the corporation has two operational sectors: the water infrastructure construction sector, and the
transport infrastructure construction sector. The two sectors in turn have different projects located in
different parts of the country. The headquarters of the corporation is located in the city of Addis
Ababa, and situated in the building of the former Ethiopian Water Works Construction Enterprise,
around Gurdi Shola. The Ethiopian

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Construction Works Corporation is newly established on December 18/2015 based on council of

ministers Regulation No 366/2015. This corporation is amended by council of ministers Regulation
No 390/2016, on September 28/2016.

Figure 1.1 Ethiopian construction works corporation

1.3.2 Main Purposes of The Establishment of ECWC
To engage in domestic and overseas construction works as a contractor in constructing, upgrading and
maintaining roads, bridges and other civil works:
To engage in the business of maintaining construction equipment and machinery;
To engage in the rental business of construction equipment and machinery;
To produce and sell construction materials;
To undertake in any other related activities necessary for the attainment of its purposes.
To solve the problem arise related with the road quality in Ethiopia.
To give standardized car maintenance, repair replacement of the parts.
To design and production of the materials for car replacement.
1.3.3 Location of ECWC
The head quarter of the ECWC is located around Gurd Shola, Addis Ababa, Ethiopia. The corporation
has also more than 183 projects and offices around the country. But we were worked at Nekemte
District.
1.3.4 Vision and Mission Of The Company
1.3.4.1 Vision:
To be globally competitive construction works contractor and to take the leading position in Africa.
To be a worldwide competent construction company by 2025

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1.3.4.2 Mission:
To satisfy the customers and stakeholders of the Corporation by delivering.
Roads and bridges construction, rehabilitation, upgrading and maintenance
Construction equipment and machineries maintenance and lease
Construction materials production and sales,
Services timely, with competitive price and environmentally friendly manner.
1.3.5 The Main Customers of The ECWC:
Ethiopian transportation
Constructions agencies
Ethiopian electric power corporation and others
Ethiopian Road Authority
1.3.6 Structures of The Ethiopia Construction Works Corporation
Ethiopia Construction Works Corporation (ECWC) Nekemte District has the following structure and
department brake down with their overall work flow in the organization in this case the main customer
of Ethiopia Construction Works Corporation is Ethiopian Road Authority (ERA). Most Activities of
ERA are under taken by ECWC.
Among them I had been working in Equipment maintenance staff and under this staff there are about
five main shops for mainly Vehicle maintenance and product service (Bolt and nut)…. For instance If
a vehicle need to have service or any maintenance activities (Changing Brake shoe) 1st the Driver
contact equipment maintenance staff Mechanical Engineering then the staff open shop order and send
to the Inspector by giving the key of the vehicle to the Mechanic Inspector. Finally the Inspector
arranges the mechanics and orders them to do the given job in a given time.

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1.3.7 Competitive Advantage of The ECWC

Thus, the two most important competitive advantages of the corporation are:
Its geographical presence:
As indicated in the tables below, the corporation has different projects located strategically throughout
the country. This makes the Ethiopian Construction Works Corporation the most accessible
construction contractor in the country. This geographical presence can be an advantage even to indulge
in different construction projects found in neighboring countries.
Its human and material resources:
It is a fact that human resources are among, if not the most decisive factors influencing the
competitiveness of any company. The Ethiopian Construction Works Corporation currently has more
than 15,000 workers among them 800 workers are under Nekemte District. This is in fact a huge asset
if the corporation uses this resource in an efficient and productive manner.

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Therefore, the huge human resources that the corporation has can yield it a competitive advantage in
the industry.
1.3.8 The Main Branches of ECWC

Branches Status
Addis Ababa Head office
Nekemte Operating branch
Adigrat >>
Gondor >>
Jimma >>
Kombolcha >>
Debre-Markos >>
Dire-Dawa >>
Shashemene >>
Alemgena >>
Sodo >>

Table 1.1 branches of ECWC

1.3.9 Major Businesses of The ECWC
The Ethiopian Construction Works Corporation has been established for state-of-the-art construction
solutions. The following are among the major construction businesses that the corporation renders:
Highways, bridges, railways, and ports.
Surface and subsurface water supply development.
Dam construction.
Hydropower development.
Irrigation infrastructure, river diversions.
Industrial projects and warehouses.
Residential and commercial building construction.
Management of dam and irrigation infrastructure.
Management of bulk water production.

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Construction machinery, equipment and warehouse leasing services.

Civil engineering works.

Figure 1.2.ECWC garage

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CHAPTER TWO
2.1. WORK DONE
The company is mainly opened for the purpose of keeping vehicles and machines long life and also
giving maintenance and repair on site to let the work not to stop. It has its own structure for
performing tasks. It has different sub division to accomplish different tasks. There are many shops in
this company. Those are:-
Mechanic or Engine shop
Machine shop
Body shop
Welding shop
Electrical service shop
Tire shop
Before we described our task in the above shops first lets we describe some tools and equipment’s that
commonly used during maintenances. In ECWC shops there are various tools used. Most of them are
manuals (operated by hands). These tools are:-

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Torque Wrenches,
Sockets and Ratchets,
Screw drivers& Spanners
Combination and box
Hammers, chisel, and Vise
2.1.1. Engine Shop
Engine is a mechanical device that converts chemical energy (fuel) into kinetic energy (motion). An
internal combustion engine is the engine in which combustion (burning of fuel) takes place in the
cylinder of engine by burning of the fuel high temperature and pressure force generates. This pressure
force used to move the vehicle or rotate wheels by use of some mechanism. In an engine many parts
work together and achieve to be a goal of converting chemical energy of fuel into mechanical energy.
These parts are bolted together and the combination of all these parts is knows as engine.

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Figure 2.1: Engine

2.1.1.1 Stationary Parts of Engine
The stationary parts of an engine include the cylinder block and cylinders, the cylinder head or heads,
and the exhaust and intake manifolds. These parts furnish the framework of the engine.
All movable parts are attached to or fitted into this framework.
2.1.1.2 Engine Cylinder Block
The cylinder block is the basic frame of a liquid-cooled engine whether it is in-line, horizontally
opposed, or V-type. The cylinder block is a solid casting made of cast iron or aluminum that contains
the crankcase, the cylinders, the coolant passages, the lubricating passages, and, in the case of flathead
engines, the valves seats, the ports, and the guides. The cylinder block is a one piece casting usually
made of an iron alloy that contains nickel and molybdenum. This is the best overall material for
cylinder blocks. It provides excellent wearing

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qualities and low material and production cost, and it changes dimensions only minimally when
heated. Another material used for cylinder blocks, although not extensively, is aluminum. Aluminum
is used whenever weight is a consideration. However, it is NOT practical to use for the following
reasons:
Aluminum is more expensive than cast iron.
Aluminum is not as strong as cast iron.
Because of its softness, it cannot be used on any surface of the block that is subject to wear. This
necessitates the pressing, or casting, of steel sleeves into the cylinder bores. Threaded holes must also
be deeper. This introduces extra design considerations and increases production costs.
Aluminum has a much higher expansion rate than iron when heated. This creates problems with
maintaining tolerances
2.1.1.3 Crankcase
The crankcase is that part of the cylinder block below the cylinders. It supports and encloses the
crankshaft and provides a reservoir for lubricating oil. The crankcase is the basic foundation of all air-
cooled engines. It is made as a one- or two-piece casting that supports the crankshaft, provides the
mounting surface for the cylinders and the oil pump, and has the lubrication passages cast into it. It is
made of aluminum since it needs the ability to dissipate large amounts of heat. On air-cooled engines,
the oil pan usually is made of cast aluminum and is covered with cooling fins. The oil pan on an air-
cooled engine plays a key role in the removal of waste heat from the engine through its lubricating oil.

Figure 2.2 crankcase

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2.1.1.4.CylinderHead
It covers and encloses the top of the cylinders. Combustion chambers, small pockets formed in the
cylinder heads where combustion occurs, are located directly over the cylinders. Spark plugs (gasoline
engine) or injectors (diesel engine) protrude through holes into the combustion chambers. Intake and
exhaust ports are cast into the cylinder head. The intake ports route air (diesel engine) or air and fuel
(gasoline engine) into the combustion chambers. The exhaust port routes burned gases out of the
combustion chamber.
2.1.1.5.Connecting Rods
Connecting rods connect the pistons to the crankshaft to convert reciprocating motion into rotary
motion. The connecting rods are in the form of an I-beam. This design gives the highest overall
strength and lowest weight. They are made of forged steel but may also be made of aluminum in
smaller engines.

Figure2.3 connecting rod

2.1.1.6.Crank shaft
The crankshaft is located in the bottom of the engine and is the part of the engine that transforms the
reciprocating motion of the piston to rotary motion. It transmits power through the flywheel, the
clutch, the transmission, and the differential to drive your vehicle. Crankshafts are usually made of
cast iron or forged steel. Forged steel crankshafts are needed for heavy-duty applications, such as
turbocharged or diesel engines. A steel crankshaft is stiffer and stronger than a cast iron crankshaft.

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Figure 2.4 crankshaft

2.1.1.7 Camshaft
The camshaft provides for the opening and closing of the engine valves. The cam shaft is enclosed in
the engine block. It has eccentric lobes (cams) ground on it for each valve in the engine. As the
camshaft rotates, the cam lobe moves up under the valve tappet, exerting an upward thrust through the
tappet against the valve stem or the pushrod.

Figure 2.5 camshaft

2.1.1.8 Engine Bearings
Bearings are installed in an engine where there is relative motion between parts. Camshaft bearings are
called sleeve bearings because they are in the shape of a sleeve that fits around the rotating journal or
shaft, as shown in Figure below View A. Connecting rod or crankshaft (main) bearings are of the split
or half type, as shown in Figure below B. On main bearings, as shown in Figure, View C, the upper
half is installed in the counter bore in the cylinder block. The lower bearing half is held in place by the
bearing cap. On connecting rod bearings, the upper-bearing half is installed in the rod and the lower
half is placed in the rod cap. The piston pin bearing in the connecting rod is of the full round or
bushing type.

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Figure2.6 bearing
Most Engine Problem:
Most engine problem we have seen during our internship time
Engine noises
Low oil pressure
Engine over heating
Loss of power, misfiring
Hard starting
Service year and maintenance time
Sound during operation
Electrical system
Once the problem is identified by the technicians possible solutions is done.
Measurement taken:
1. Disassembling Engine:
Engine disassembly is carried out in a sequence as follows.
Remove the water pump; exhaust manifold, oil filter, thermostat, crankshaft pulley, oil pump and
timing gears.
Remove cylinder head.
Remove oil pan.
Remove piston and connecting rod assembly (give the numbers on pistons and connecting rods for
easy reassembling.
Remove flywheel and crankshaft.

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2. Cleaning and Inspection:

After disassembling all the parts, clean and inspect them carefully, replace the defective parts.
All parts should be cleaned with kerosene and dry them with the compressed air.
The cylinder walls may be inspected for scoring. The cylinder may require re boring or re honing if
scores are present.
To inspect piston for scores, remove the ring without breaking them. In case of deep scores, replace
the piston. While light scores may be polished off. Measure the clearance between the sides of the
piston in the cylinder. In case they are scored.
Replace them.
Inspect the piston ring for damage or wear. If these are defective, replace them.
Inspect the connecting rod small end and big end bearings. If these all scored or pitted. Service with
the rebutting.
Check the valve face and seat. If any part is defective service the valve face with the valve re facing
and cut the valve seat for correct setting of valves.
In this work shop mostly repaired Engines are starting from the smallest to the biggest one. This
engines it`s have different types like V8, D4D, 5L, 3F and etc.

Figure 2.7 disassembled engine

2.1.1.9 Transmission Systems
It is the mechanism through which the driving torque of the engine is transmitted to the driving wheel
of the vehicle. The transmission is a sort of speed and power changing device needed between the
engine of the automobile and its driving wheel. A transmission system includes:

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Clutch, ✓ Final drive, and

Gear box, ✓ Differential system.
Propeller shaft,
The essential parts of the gear box are-the gear case consisting of two halves these are: -
Drive shaft assembly,
Counter shaft assembly ,
Main shaft assembly,
Synchronizing device assembly
Reverse speed gear assembly  Gear shifting mechanism.

Figure
2.8 Transmission system
Requirements of Transmission System:-
Provide means of connection and disconnection of engine with rest of power train without shock and
smoothly.
Provide a varied leverage between the engine and the drive wheels ✓ Provide means to transfer power
in opposite direction.
Enable power transmission at varied angles and varied lengths.
Enable diversion of power flow at right angles.
Provide means to drive the driving wheels at different speeds when required.

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2.1.1.9.1 Clutch
A clutch is a mechanism which engages and disengages power from engine to transmission. When the
clutch is engaged, the power flows from the engine to the rear wheels through the transmission system
and the vehicle moves. Clutch is disengaged when:
Starting the engine,
Shifting the gears,
Idling the engine

Figure 2.9 clutch

The clutch principle is based on friction. When two friction surfaces are brought in contact with each
other and pressed they are united due to friction between them. If one is revolved the other will also
revolve. The friction between the two surfaces depends upon:
Area of the surface, o Pressure applied upon them,
Coefficient of friction of the surface materials
Here one surface is considered as driving member and the other as driven member.

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Most transmission problem we have been seen:-

Transmission problems with remedies
NO PROBLEM CAUSE REMEDY
1 Transmission Low lubricant level. Refill lubricant
noise Input shaft gear badly worn or Replace input shaft gear
broken. Replace input shaft bearing
Input shaft bearing badly worn or Correct misalignment
broken.
Replace countershaft drive gear
Wear in countershaft drive gear Wear
in reverse and/or reverse idler gear Replace the worn gear

Countershaft bearings badly worn Replace countershaft bearing

2 Transmission Engine clutch not releasing. Detect and repair as necessary.

difficult Distorted or burred output shaft Correct or repair
to splines. Readjust the linkage.
shift Improper adjustment of shift linkage. Re-correct clutch adjustment.
Incorrect clutch adjustment. Use the proper grade of
Incorrect lubricant. lubricant.

3 Transmission Damage oil seals. Replace the oil seals.

leaks oil Damaged or missing gaskets. Replace the O - rings.
Case or cover bolts loose or missing. Replace the gaskets.
High lubricant level. Tighten or replace the bolts.
Loose or broken input shaft bearing Use the proper grade of
retainer. lubricant.
Worn shift lever seals. Replace the seals.

Table 2.1 Transmission problems with remedies

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2.1.1.10 Braking systems

Figure 2.10 braking system

Purposes of braking system:

Stop the vehicle by converting the kinetic energy of the vehicle to heat energy.
Heat energy is created in the brakes by friction.
Friction is created between a moving and a non-moving surface at each wheel to generate the heat.
Disc and drum brakes are the most common type of braking systems used.
2.1.1.11 Disc brake:
In a disc brake, the fluid from the master cylinder is forced into a caliper where it presses against
piston’s. Piston in turn squeezes two brake pads against the disc (rotor), which is attached to wheel,
forcing it to slow down or stop.

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Figure 2.11 Disc brake

2.1.1.12 Drum brakes
The drum brake has a metal brake drum that encloses the brake assembly at each wheel. Two curved
brake shoes expand outward to slow or stop the drum which rotates with the wheel
Shoes press against a rotating surface. In this system that surface is called a drum. Drum brake also has
an adjuster mechanism, an emergency brake mechanism and lots of springs. The shoes are pulled away
from the drum by the springs when the brakes are released.

Figure 2.12 drum brake

2.1.2. Machine Shop
A machine shop is a room, building, or company where machining is done. Machining can be defined
as the operation of removing the excess metal by means of a cutting tool, in the machine tool; to obtain
the desired shape, size and surface finish.

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Purpose of machine tools

to improve production rates
to reduce cost of production
to reduce fatigue of workers
to achieve better quality
Machines available in machine shop are:
Drilling machine Hack saws
Shaper machine. Grinding machines
Lathe machine Hydraulic press
• Milling machine
Drilling machine: is a machine tool designed for drilling round hole in metallic and nonmetallic
materials. The cutting tool is a multi-point cutting tool knows as drill or drill bit. Operations done by
drilling machine are
Drilling ✓ Tapping
Boring ✓ Counter boring
Reaming
Shaper machine: is a machine tool in which the plane and flat surface is produced by a single point
cutting tool by a reciprocating motion. In which the ram moves the cutting tool backward and forward
in a straight line to generate the flat surface. The flat surface may be horizontal or vertical.

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Figure 2.13 shaper machine

Operations performed on shaper machines are all type of flat surfaces which may be horizontal,
inclined, or vertical.
Lathe machine: is one of the earliest machine tools and one of the most versatile and widely used as a
machine tool for performing the machine operations.
The most common operations which can be performed on lathe machine are:-
Facing Cutting
Drilling Grooving
Boring Knurling
Threading Shaping
Milling machine: is a process of metal removal cutting by means of multi teeth of metal (points)
rotating tools called cutter.
Grinding machine: is a process of removal by the abrasive action of a revolving wheel
(grinding wheel) from the surface of the blanks, in order to bring it to the required shape and size.
Operation performed by grinder
Surface grinding
Face grinding
Power saw: This is just used for cutting different types of metals.

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Hydraulic press machine: This machine is used for pressing the material which have high rigidity or
it`s difficult to press by man power. For example; to press the bearing to torque bushing rod.
The machine shop Services include:
Boring Washers
Teeth of loader (grader) Nut
Shafts Spacer
Bolts Other spare parts

Figure 2.14 Features made in machine shop

2.1.3. Electrical service shop
This shop is need special attention rather than other shop because there is some acids and battery
cables that may damage our body and need special care. In this shop device maintained are like stator,
alternator, and battery.
Starter:-It is essential to start the automotive Engine. The crank most run fast enough for air fuel
mixture to enter the cylinder. An electronic starter or starting motor does this job. It convert electrical
energy from the battery into mechanical energy that rotates the crank shaft. It

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has two basic parts an armature and a field fram

e.

Figure 2.15 starter

Parts of starter are:- ✓ Main housing (yoke)

Over running clutch, and pinion gear assembly
Armature
Field coils with brushes attached
brush holder and solenoid
Starter motor trouble shouting:-
Possible causes Remedy
Weak or dead battery Charge or replace the battery
Bad starting system cables Replace/repair cables connections
Bad ignition switch or wiring Replace /repair the switch wiring
Bad starter solenoid Replace starter solenoid
Alternator: Alternator is one of the most important electrical components used to charge automotive
battery. The main components of alternator are; Rotor, Stator, Regulator, Rectifier or diodes, Carbon
brush, lending, Pole, Fans, Pulleys belts, Outer cover or casing or housing This shop is doing so many
works, like maintenance of alternator, starter, servicing the battery,

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repairing the construction machine controller, maintenance of the light system, horn, wiper and any
system that is related with electric.
In this shop, most of a vehicle`s electrical systems are maintained and replaced by a new one.
Maintenance of electrical system contains:
Filling the battery with proper proportion of water and acid.
If the battery is either dead or over used, recharging of the battery.
Maintain the wires of display gauges
Preparing the distilled water by purifier to mix with sulphury acid
2.1.4. Body shop
In this shop there are many types of job to be performed but the mains are maintaining body, forging
body and painting, servicing the mirror .In this shop there are a lot of activities performed. Among
thus, washing, grinding, painting and welding are the main activities.
Painting shop: different types of cars were painted in this painting room after their body would be
completely finished. And this shop must be cleaned and out of dust .Therefore this application there is
no openings.
Body building shop: if the body of the cars were damaged by accident or by any other reason, their
body were changed or repaired in this shop. But there is shortage of some machines applicable for
body reparation like bending machine. Mostly they did by welding (oxyacetylene and arc welding).

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Figure 2.16 Body shop

2.1.5. Welding shop

In this shop different construction molds and different vehicle components were got welded and in
this shop there are different welding machines like arc welding, oxyacetylene gas welding machines
were available for their work.
It is known that welding is a process of joining similar or dissimilar metal together by application of
heat with or without the application of pressure and filler material. In this shop most the works are
undertaken by Arc welding because it is safer than that of the gas welding. Welding of broken hose
and other activities are undertaken by electric arc welding.

Figure 1.17 Oxy-acetylene and Arc welding

In case of oxy-acetylene it use equipment such as oxygen gas cylinder- which is painted black and it
has pressure regulator (right handed) to regulate flow as well as to lower the pressure of the gas. The
shop is mainly uses oxy-acetylene and arc welding. Most vehicles are welded by oxy-acetylene
because the thickness of the body is very less.
2.1.6. Tire shop
Tires shop is one of the types of workshop which is available Ethiopia construction work
corporation garage. In this shop so many works is doing, those works are:
Checking the pressure of the tires

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Inflating the tires

Maintaining the bump (attaching the bumper) and etc.
In this to perform the above works it uses different types of machines, such as
air compressor, air pressure gauge, grinder, and etc.
Air compressor: in this shop air compressor is used to inflating the tires. To
inflating the tiers first of all the compressor must be filled by the
atmospheric air and the starting to inflating, but the result is reading from
the gauge.
Wheel fixing
Wheel studs and nuts attach the wheel to the hub.
The wheel studs press through the hub or axle flange.
The taper on the wheel nuts secures and centers the wheel.
Wheel studs usually have a right hand thread.
If it is a left hand thread, it can be marked with “L”
Metric threads can be marked with m or metric.
Wheel nut torque
Correct torque of wheel fixing is vital for all vehicles, and nearly all require the use of a torque wrench
Excessive torque can lead to wheel or hub distortion, causing run out and vibration.
Low torque may allow wheel nuts to work loose and wheels to come off
Nuts should always be tightened in a diagonal pattern.

2.2. CHALLENGES FACED DURING OUR INTERNSHIP

Some of the challenges we had faced during our internship are:

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First time we went there, we were ordered to get safety clothes by ourselves.
Service problem
Technician approach
The technician use Italic language for the materials
2.2.1. Methods to Overcome These Challenges:
We have bought safety clothes by ourselves.
We discussed with manager and they are approved to us to get service.
First time when we enter to the enterprise we afraid the technician, but gradually we related to each
other and discussed as friendly.
We tried to advise them so they may know the vehicles parts by English
2.3. SKILLS WE HAVE GOT
We have got experiences from this company like;
Punctuality and respecting the company rule.
How to keep our safety during work.
How to design and managing of work flow of one company.
We got experiences on investment casting specifically precision casting as well as its work flow.
We got practical as well as theoretical knowledge on machine and their operation procedure.
In terms of practical skill:
Creativity and solving problems.
The ability to analyze and interpret complex data

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Critical thinking and the ability to evaluate design, plan and project
Awareness of ethical issue
Effective assessment and management of risk, resource and time
We have developed a confidence to do the given work practically without any problem and we
also observed that practical works is more simple than theoretical. As we have seen there is a big
difference between theoretical and practical skills. Theoretical knowledge is not always
unfulfilled in practical application through time it might seem that way.
It’s important to realize that in the work place, what matters is not the amount of practical
experience or theoretical back ground that an individual’s has, what matters is how much an
individual is able to effectively deal with the realities around him.
In terms of inter personal communication skill:
During our internship program we had able to build up the following interpersonal relationship
or communication skills.
Truthfulness and honesty
Respectful
Inter-dependent
Friendship
We improve our speaking
We improve our communication skill
To give and collect information
To influence the attitude and behaviors
To form contracts and maintain relationship
In terms of teamwork skill:
active participation
Listens actively
Cooperate and Help other
Demonstrates reliability
Works as a problem solver
Treats other in respectful and supportive manner
Sharing ideas openly and willingly and
Clarifying team goals
In terms of Leadership skill:

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During our internship time, we have been able to upgrade our leadership skills to a whole new
level. To achieve leader ship skills it requires high level commitment to learn from each
experience we face. We have observed that a good leader is well principal individual who
focuses on a common goal and eliminate excess fear and doubt from his employees and work for
a common good of all.
In terms of work ethics:
We have developed about moral duties and obligations.
We have developed sincerity, respect for the job, regularity, punctuality, seriousness.
We have developed how to keep certain information confidential, how to maintaining cordial
relation with the clients and agencies that a company has and how to being prepared to take up
new tasks.

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CHAPTER THREE
3.1 INTRODUCTION
An automobile is one of the most basic and fascinating things that one could own. Cars have now
become a need and it is not only the symbol of luxury anymore. Car maintenance, for example,
is one of the key factors in determining its life span. This includes a basic knowledge of
changing the car’s tire. But replacing a punctured tire has always been a difficult task. Every car
manufacturer provides tools such as L wrench and jack but easy and fast removal of nuts using
these tools requires a skilled person. We designed a remover with 110 pitch circle diameter to
replace L-shaped nut removers and jack which allows driver to remove all nuts at once with less
energy consumption and save time. Several static load analyses were performed in order to find
safety factor of design. The fabrication of all wheel nut removers’ tool was completed by
milling, welding and fitting process. [1]
In a day-to-day life there are many problems where there are needs of lot of effort and time to do
that specific work. A little but important work that all people would do often is opening a wheel
of a vehicle. It is a fact that a huge effort is required to open a single nut of a car wheel and it
will become a tedious task to open the wheel in extreme atmospheric conditions. It also creates
problem when there is an emergency situation.
3.2. PROBLEM STATEMENT
During tire removing Operation the person was supposed to remove individual nuts to remove
the tire which has very high fatigue level.
So, Our Intention was to remove all nuts at a time, to reduce human fatigue level.
Multi-nut opener is a device designed at developed for loosening or tightening of wheel hub nuts
for
Hilux
Land cruiser
Toyota

3.3. OBJECTIVE

When it comes to changing tires, most people find it exhausting and time consuming,
because of the traditional way used for changing tires, which is using the tire lug wrench.
Due to the difficulties that people face in changing tires, we came up with the idea of this
project which is to make the procedure of changing tires much easier and time saving.
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This project has two main objectives, which are designing and manufacturing an
automotive tire changing mechanism, reduce the time taken to change tires and
optimizing the weight of the prototype.

3.4 Scope of study

We have plan to design multi nut remover worked by manual power this tool can be operated by
any one of different ages from young people to old people as it is easy to use and light in weight.
The vehicles multi wheel nuts remover reduces the time in the normal process and also the man
power used.
3.5 Significance of the study
The significance of this study is that it will reduce labor force and used to save our time will
performing nut removing process.

3.6. WORKING PRINCIPLE

Generally, spur gears are used for transmitting power between non parallel intersecting shafts. So
spur gear arrangement is used for actuating the six socket spanners at a time. Six pinion gears
and one ring gear are used. The ring gear is meshing with six auxiliary pinion gears which are in
turn connected to a gear whose axle containing the socket spanners at its end. The auxiliary
pinion gear connected to a hollow shaft (main shaft) which is acting as a guide for follower. A
lock nut arrangement is provided for connecting the main shaft to follower at any desired
position. When the ring gear is rotated the auxiliary pinion gears are also rotated which in turn
gives a rotary motion to the socket spanner.

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CHAPTER FOUR
4.1 LITRATURE REVIEW
In our paper Adjustable Multi nut wheel opener is a special purpose tool made to open/close all
the five nuts of a wheel in one time with less effort. Although various methods are used for
opening nuts, they require a lot of effort to open a single nut. The main objective of work is to
develop a single tool with multiple mechanisms, which can be made use during assembling and
dismantling of wheels in automobiles. It can be successfully used as a standard tool irrespective
of the model of the vehicle. Also it can be used in assembly line of automobiles, garages,
workshops and service stations. In the paper of B. Sivakumar a gear or "gear wheel" is a rotating
machine part having cut teeth, or cogs, which mesh with another toothed part in order to transmit
power. Two or more gears working in tandem are called a transmission and produce mechanical
advantages through a gear ratio and thus may be considered a simple machine. Gears are mostly
used in the mechanical field for power transmission, this project report on stress analysis of spur
gears. Spur gear made of cast iron which is use for high strength. In the paper of A. S.Ud gave
Multiple-spindle drilling machines are used for mass production, a great time saver where many
pieces of jobs having many holes are to be drilled. Multi- spindle head machines are used in
mechanical industry in order to increase the productivity of machining systems. The multiple
spindle drilling machines is a production type of machine. It is used to drill two holes in a work
piece simultaneously, in one setting. The holes are drilled on number of work pieces with the
same accuracy. So we adopt the basic design for over project [2]

4.2 MATERIAL AND METHOD

The materials used for the design of the various machine components are based on the type of
force that will be acting on them, expected work or function, the environmental
conditions in which they will function, useful physical and mechanical properties, cost and
availability in the local market or the environment.
The working procedures adopted in fabricating the developed machine illustrated as bellow:-

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4.3 DESIGN OF EACH COMPONENT

3.1 Design Constraints

3.1.1 Safety
Safety is considered to be an essential requirement for any project. Therefore, in this
project, we will follow the international standards for choosing types of materials and
parts being used that will lead to prevention of any failures caused by the mechanism.

3.1.2 Social & Economics

As we know, time is money. Therefore, using our project will save a lot of time, because
it’s fast and can screw or unscrew 5 lug nuts simultaneously. In addition, compared to the
available mechanisms to change tires in workshops such as impact wrenches, our project
is faster.

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3.1.3 Engineering Standards

The project is consisting of many components, which are; gears, bearings, shafts, motor,
and spanners. All of these components were selected based on existing standards such as
SKF catalogue, and American Iron and Steel Institute.

3.1.4 Manufacturability
Our project can be manufactured easily, and it can be used in a wide range of applications
such as tire manufacturing companies, workshops and portable using. On one hand,
gears, bearings, and shafts will be manufactured based on their availability in the market.
On the other hand, the motor will be selected based on the calculations of torque,
horsepower and its availability in the market.

3.1.5 Time
As we all know, time is money, and our project is going to perform efficiently and save
time by screwing and unscrewing all lug nuts simultaneously. Instead of using the normal
way to unscrew nuts such as lug wrench, our prototype will allow the user to unscrew all
5 nuts in one move by using a gear train system to generate a torque to unscrew the five
nuts simultaneously

3.1.6 Quality
Quality of projects is a very important aspect of any design, and in our design we are
making sure that the quality of materials used in the system and its parts is good and
meets the standards.

3.2 Design Methodology

Our project can be divided into five phases. First phase is brainstorming where we collect
information about the basic design aspects. In addition, using brainstorming method can
specify the features of our design. In this phase, we define the major aspects needed for
building the prototype such as, gears, shafts, bearings and spanners. Also, in this phase
we conduct the Gantt chart, where we divide the tasks and their time durations for the
project. Second phase includes gathering information about the conceptual design of our
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project from, books, journals, and old projects.

Third phase, is analysis and calculation of design. This phase is considered to be an

important phase where manufacturing the prototype depends on it. This phase has a lot of
calculations that include dimensions such as gears centers, pitch diameter, thickness of
gears, size of shafts, number of teeth, and ratio of gears. Moreover, the calculations
include the torque required to unscrew one nut, power transmitted from the motor and
factor of safety (FOS). Additionally, the design of our prototype is made using
SolidWorks. SolidWorks includes all dimensions of the parts, 2D drawing, and assembly
of the parts. Fourth phase is buying parts and manufacturing in market. Also, estimating
the cost and the availability of parts in market whether there are gears, shafts, spanner
and joints, because some parts need to be made in workshops. Finally, fifth phase
includes welding, assembly of parts in workshops and testing our prototype.

3.3 Design, calculations and selections

Figure 4.1: Assembly from different sides

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Figure 4.2 Exploded view of assembly

As shown in figures above, our design has three levels because we couldn’t design a
different size of gears at the one level with a 114.3 PCD without avoiding gear
interference. So, we started to build our design on an actual wheel hub, and we designed
three levels to avoid the gear interference problem. See figure below.

Figure 4.3: Car hub

The first level of our design has two driven gears and one driver gear. While the second
level has two driven gears and one driver gear. Lastly, third level has one driven gear and
one driver gear. Therefore, the total number of driven gears is five, and for the driver

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gears it’s three. All driven and driver gears are held by 6 shafts. Moreover, gears and shafts are
held by a circular plate and six ball bearings to reduce the rotational friction
and support radial loads. Finally, in top of the shaft there is a wheel spanner to unscrew
the lug nuts. Table 3.1 shows a summary of the design specification for gears, shafts, and
the circular plate.

Table 4.1: A summary of design specification

Driver Gear Driven Gear Circular plate Shaft

No. of Teeth (mm) 15 31 - -

PCD (mm) 15.624 35.624 114.3 -

Diameter (mm) 37 37.5 240 25

Module 2.5 2.5 - -

Thickness (mm) 14 14 10 -

Pressure angle 20 20 - -

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Length (mm) - - - 111

3.3.1 Gears Calculation

Figure 3.4: Driver and driven gears in mesh

Table 3.2: Driver and driven gears parameters

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N driven= 31 N driver=15 D driven=71.24 D driver= 31.24

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3.4 Product Subsystems and Components

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Figure 4.5: Plate

Figure 4.5 shows the plate used in our project which has 114.3 mm PCD that will hold
the bearing, shafts, gears and spanners.

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Figure 4.6: Shafts

Figure 3.6 shows the shafts used that will rotate and transfer the power to other shafts to
unscrew the nuts.

Figure 4.7: Driven Gears

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Figure 4.7 shows the driven gears with 31 teeth will rotate and transmit the torque to
other shafts to unscrew the bolts.

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Figure 4.8: Driver Gears

Figure 4.8 shows the driver gears with 15 teeth will rotate and transmit the torque to other
shafts to unscrew the bolts

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4.5 Implementation

Figure 4.9: Manufactured plate

Figure 4.9 shows the plate that is made from cast iron with 13 mm thickness. Each hole
has a circle with 47 mm in diameter to hold the bearing from falling down.

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Figure 4.10: Manufactured driven gears

Figure 4.10 shows driven gears with 31 teeth have a keyway to ensure that there is no
relative rotation between two parts and it also enables torque transmission.

Figure 4.11: Manufactured shafts

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Figure 4.11 shows the 25 mm diameter shafts have keyways to prevent relative rotation.

Figure 4.12: Manufactured driver gears

In figure 4.12, the picture on the left in figure 3.12 shows driver gears with 15 teeth.
While the picture on the right shows the three gears attached to shafts after applying heat
treatment to increase the hardness.

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Figure 4.13: Lock washers

In figure 4.13, the purpose of using lock washers is to keep bearing from coming loose.

: socket wrench

it’s a small tool for tightening and loosening nuts of different sizes.

Figure 4.16: The final prototype (top view)

In figure 4.16, it shows the final prototype from the top view.

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Figure 4.17: The final prototype (front view)

In figure 4.17, it shows the final prototype from the front view.

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Advantages
Simple in construction.
Less weight
Less cost
It saves time as compared to other devices.
It can operate easily.
Limitations
It will not use for all type of vehicle
It requires man power
Applications
Automobile workshops
Automobile Manufacturing units
Garage

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CONCLUSION
To sum up, we successfully managed to design and manufacture an automotive tire changing
mechanism that can unscrew 6 lug nuts of a wheel simultaneously. In addition, this project can
be used in a variety of applications such as tire manufacturing companies and workshops.
Moreover, while working on this project during the semester, we have gained a lot of skills. For
example, we used the theoretical knowledge that we have gained from mechanical engineering
courses and apply it in our project practically to design and manufacture our prototype.
Additionally, this project wouldn’t have been completed, without the equal contribution of each
team member in completing the tasks. Finally, working on this project taught us how to work
under pressure, especially that this semester was short.

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RECOMMENDATION
We recommended ECWC Nekemte district the following points:
This company should work correlation with Mizan Tepi University to support the student to visit
these automobile parts periodically so, they can understand easily what they learned by theory
when they see practically.
In order to increase accuracy and durability of maintained components, the company should
implement the use of CAD software’s like Solid works and Catia.
In order to decrease time consumption on mounting an engine for test after inspection and
maintenance, the company should invest on buying an engine stand.
Using older machines does not make competent, so the company has to use latest machines such
as CNC machines to become successful company regardless of time management and upgrading
its production capacity

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REFERENCES
R. S. Khurmi and J. K. Gupta, “[A Textbook for the Students of B A TEXTBOOK OF A
TEXTBOOK OF A TEXTBOOK OF A TEXTBOOK OF A TEXTBOOK OF Top.”
S. Pruthvi, R. Keval, P. Harsh, P. Dhaval, and M. Pankajkumar, “‘ MULTI NUT REMOVER ,’”
vol. 8, no. 5, pp. 962–965, 2021.
K. B. K. Reddy, “Design & Fabrication Of Multi Nut Removing And Tightening Tool For A Car
Wheel,” pp. 7848–7851, 2018.
S. K. Mondal, “Design of Joint Design of Joint,” pp. 1–263.
R. N. Natarajan, “Machine design,” Handb. Mach. Dyn., no. I, pp. 11–28, 2000, doi:
10.1038/042171a0.

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