JIMMA UNIVERSITY

JIMMA INSTITUTE OF TECHNOLOGY

FACULTY OF MECHANICAL ENGINEERING
Internship report and project

Project title: - Design of engine lifting machine

Host company: - Light vehicle maintenance directorate
Addis Abeba, Ethiopia

Internship duration: - Two months

Submission Date 03/12/2021 GC.

Jimma, Ethiopia
 INTERNSHIP REPORT AND PROJECT

Declaration
We, 4th year Jimma University Mechanical Engineering students, have undertaken our internship
experience in Light Vehicle Maintenance Directorate from June 1, 2021 G.C to July 30, 2021 G.C
under the guidance of Colonel Asmamawu Belete (company supervisor) at LVMD and Mr.
Amanuel Diriba (academic adviser).

We certified our work is original compiled according to the internship report guide given by the
University Industry Linkage of the Institute.

MEMBER ID NUMBER

1. MARUF HASSEN………………………RU1852/10
2. MULUKEN MEKONNEN……………...RT0039/10
3. ABDU NURU……………………………RU0939/10
4. GADISA ALEMAYEHU…………….….RU2753/10
5. GEMECHU TSEGA………………….….RU1556/10

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Acknowledgment
First of all, we would like to give our thanks to God, because he helped us finish our works and
guide us through this dark hour of the nation. We would like to thank our university jimma institute
of technology for giving us this chance to get practical skills and to have some important and
essential knowledge about maintenance of vehicle that would help us in our near future.

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Abstract
An internship program is mandatory to under graduate engineering students. The purpose of the
internship is to introduce students to the actual working environment. This report covers all things
what we saw and it gives detailed information on the activities carried out at light vehicle
maintenance directorate. The first part of our report describes the history and objective, its main
products and services, the overall organization, work flow and machinery capacity in our hosting
company. The second part of our report briefly explains the overall internship experience that we
have gained. We started by telling how we get into the company and in which section we have
been working in. The procedures we have followed while performing tasks and the challenges we
have faced during our internship period are covered in this report. The third part explains about
the overall benefits we gained in terms of improving our practical skills, interpersonal
communication skills, leadership skills, upgrading our technical knowledge and ethics.

Due to luck in proper cranes in the company for the corresponding proper material to be lifted,
Engine lifting machine is designed to fix this problem. It is designed according to company’s need
and criteria. This manually operated handling machine must have an excellent working principle
compared to that of the traditional one. This engine lifting machine, which can lift maximum load
up to 1000kg or 1 tone weight. Few of the parts of the lifting machine are selected depending on
their specification needed and most of them are designed regarding stress and force analysis.
Finally, we covered our conclusions and recommended our hosting company.

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Declaration ................................................................................................................1
Acknowledgment .................................................................................................... II
Abstract .................................................................................................................. III
List of Table ..........................................................................................................VII
List of Figure ...................................................................................................... VIII
CHAPTER ONE ......................................................................................................1
INTRODUCTION ................................................................................................1
1.1 Company background and overview ................................................................................. 1
1.2 Overview of the Company ................................................................................................. 2
1.2.1 Objectives ................................................................................................................... 3
1.2.2 Vision .......................................................................................................................... 3
1.2.3 Mission........................................................................................................................ 3
1.3 Establishment Capital ........................................................................................................ 4
1.4 Market ................................................................................................................................ 4
1.5 The management system ................................................................................................... 5
1.6 Organizational structure .................................................................................................... 5
1.7 Operational structure ......................................................................................................... 5
CHAPTER TWO .....................................................................................................6
INTERNSHIP EXPERIENCE ............................................................................6
2.1 Objective of the internship ................................................................................................ 6
2.2 Request and acceptance in the company ........................................................................... 6
2.3 Section of the company we were working in .................................................................... 6
2.4 The work flow in the section ............................................................................................. 7
2.4.1 Engine shop ......................................................................................................... 7
2.4.2 Body shop ................................................................................................................. 11
2.4.3 Maintenance shop ................................................................................................... 13
2.4.4 Electrical shop ........................................................................................................... 15
CHAPTER THREE ...............................................................................................20
Technical Aspects of the Internship ..................................................................20
3.1 Objective of the internship .............................................................................................. 20
3.2 Methods and procedures while working .......................................................................... 20
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3.3 Technical tasks/products.................................................................................................. 21

3.4 Knowledge and Acquaintances Acquired........................................................................ 22
3.4.1 Technical Skills Gained ............................................................................................ 22
3.4.2 Management skill gained .......................................................................................... 23
3.4.3 Communication skill ................................................................................................. 23
3.4.4 Acquaintances Acquired ........................................................................................... 24
3.5 Problems encountered during the internship (limitation) ................................................ 24
3.6 Contribution ..................................................................................................................... 25
CHAPTER FOUR ..................................................................................................26
INTRODUCTION TO ENGINE LIFTING MACHINE ................................26
4.1 What is engine lifting machine ........................................................................................ 26
4.2 Statement of problem....................................................................................................... 27
4.3 Objective .......................................................................................................................... 27
4.3.1 General objective ...................................................................................................... 27
4.3.2 Specific objectives .................................................................................................... 27
4.4 Literature Review ............................................................................................................ 28
4.4.1 Background of lifting machine or crane ................................................................... 28
4.5 Methodology of the study ................................................................................................ 30
4.5.1 Study area.................................................................................................................. 30
4.5.2 Study design .............................................................................................................. 30
4.5.3 Data collection techniques ........................................................................................ 30
4.6 Material selection ............................................................................................................ 30
4.7 Design analysis ................................................................................................................ 32
4.7.1 Part design ................................................................................................................. 32
4.8 Mechanical system Design .............................................................................................. 33
4.8.1 Design of Bolt ........................................................................................................... 33
4.8.2 Design of Nut ............................................................................................................ 34
4.8.3 Design of Pin............................................................................................................. 35
4.8.4 Design of hallow bar ................................................................................................. 38
4.8.5 Design of the main stand........................................................................................... 43
4.8.6 Design of the base ..................................................................................................... 44
4.8.7 Design of the Handle ................................................................................................ 45

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4.8.8 Design of Hook ......................................................................................................... 47

4.8.9 Design of supporter ................................................................................................... 49
4.8.10 Caster wheel selection............................................................................................. 51
4.8.11 Bearing selection ..................................................................................................... 52
4.8.13 Hydraulics system design ....................................................................................... 54
4.8.14 Design of cylinder ................................................................................................... 55
CHAPTER FIVE....................................................................................................63
Conclusion ...........................................................................................................63
Recommendation ................................................................................................64
Reference .............................................................................................................65
Appendices ...........................................................................................................66

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List of Table
Table 4. 1 Material selection for Bolt ........................................................................................... 33
Table 4. 2 Assumptions and material specification ...................................................................... 33
Table 4. 3 Material selection for Pin ............................................................................................. 36
Table 4. 4 Material specification for hallow bar ........................................................................... 38
Table 4. 5 Material specification for Base .................................................................................... 45
Table 4. 6 Material specification for handle ................................................................................. 46
Table 4. 7 Material specification for hook .................................................................................... 47
Table 4. 8 Material specification for supporter ............................................................................. 50

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List of Figure
Figure 1. 1 Ethiopia Metal and Engineering Corporation............................................................... 2
Figure 1. 2 vehicle maintained ........................................................................................................ 4
Figure 1. 3 Organizational structure ............................................................................................... 5
Figure 1. 4 Operational structure ................................................................................................... 5

Figure 2.1 Work flow in the section ............................................................................................... 7

Figure 2. 3 Body shop .................................................................................................................. 11
Figure 2. 4 Maintenance shop ....................................................................................................... 13
Figure 2. 5 Electrical shop ........................................................................................................... 15

Figure 4. 1 Bolt ............................................................................................................................. 33

Figure 4. 2 Nut .............................................................................................................................. 34
Figure 4. 3 Design of hallow bar .................................................................................................. 38
Figure 4. 4 Main stand .................................................................................................................. 43
Figure 4. 5 Base ........................................................................................................................... 44
Figure 4. 6 Handle......................................................................................................................... 45
Figure 4. 7 Hook ........................................................................................................................... 47
Figure 4. 8 Wheel .......................................................................................................................... 51
Figure 4. 9 Bearing ....................................................................................................................... 52
Figure 4. 10 Cylinder .................................................................................................................... 55
Figure 4. 11 piston rod .................................................................................................................. 58

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CHAPTER ONE
INTRODUCTION
1.1 Company background and overview
The Ethiopian Defense Industry sector is an institution under the Ministry of Defense responsible
for administering several defense industries. Its objective is to provide for and support the
Ethiopian National Defense Force. The basis for modern defense industry was laid with the
establishment of the Emperor Haile Selassie’s ammunition factory in 1953 G.C with the
cooperation of the government of Czechoslovakia.

The Metals and Engineering Corporation (METEC) is one of the institutions established by the
Federal Democratic Republic of Ethiopia (FDRE) to enable the realization of the government’s
Growth and Transformation Plan (GTP) and to accelerate the ongoing transition of Ethiopian into
industrialization and becoming a middle-income country. Since the establishment of METEC as a
public enterprise by the Council of Ministers regulation number 183/2002E.C, METEC has been
working tirelessly towards the realization of its vision, mission and objectives`

The federal democratic republic of Ethiopia established the metals and engineering corporation.
As anew by the Regulation number 183/2010G.C. council of ministers establishes the metals and
engineering corporation. This Regulation issued by the Council of Ministers pursuant to Article 5
of the Definition of Powers and Duties of the Executive Organs of the Federal Democratic
Republic of Ethiopia. Shortly, this Regulation may be cited as the Metal and Engineering
Corporation (METEC). The Metals and Engineering Corporation (hereinafter the" Corporation")
is hereby established as a public enterprise. The Corporation shall be governed by the Public
Enterprises. Supervising Authority, a body to be designated by the government shall be the
supervising authority of the Corporation. The Corporation shall have its head office in Addis
Ababa and may have branch offices elsewhere as may be necessary.

Metals and engineering corporations have many branches. Some of them are: -

• Bishoftu automotive industry

• Metal and fabrication industry
• Adama garment engineering

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• DebreZeyt aviation.
• Hibret Machine Tools Engineering
• Gafat Armament Engineering
• Homicho Ammunition Engineering
• Dejen civil Aviation Engineering
• Zuqualla Steel Rolling
• Branna Printing Enterprise

Location: - Metal fabrication industry is located in Addis Ababa city in Lideta sub city area
woreda 10 Keble 16/17 in front of African Union.

Area: - Metal fabrication industry is built on around 1000 square meter area. The company
compound is not asphalted and the drainage is not concrete, the compound fence is built with
hallow blocks so that the property of the company is not well protected and people can see the
product easily from outside.

1.2 Overview of the Company

Metal and fabrication industry is one branch of the federal democratic republic of Ethiopia Metal
and Engineering Corporation, so it has its own objective, mission and vision.

Figure 1. 1 Ethiopia Metal and Engineering Corporation

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1.2.1 Objectives
• Produce different items varying in shapes size, material design, and production
technology according to their engineering application.
• Reduce shortage of Agrio-industry material like trailer, tractor manufacturing in
our country
• Engage in maintenance and overhauling of manufacturing industries;
• Manufacture industrial machineries, capital goods and industrial spare parts;
• Expand and enhance engineering and technological capabilities through creating
partnership for the integration and interfacing industrial resources.
• To build technological capabilities of the countries defense forces by identifying
existing and potential needs and through research and development.
• Engage in any other related activities necessary for the attainment of its purposes.
• Creating knowledge that support national technology development and satisfy the
national metals fabrication industries need for achieving the required national
development goals.

1.2.2 Vision
• To enable the realization of the government’s Growth and Transformation Plan (GTP) and
to accelerate the ongoing transition of Ethiopia into industrialization and becoming a
middle-income country.
• Promoting our country by metal fabrication industry technology producing products based
on international standards and customer requirements.
• Establish the country as a progressive and an industrialized nation through metal
fabrication engineering technology.

1.2.3 Mission
• Doing for better need in metal fabrication industry.
• Doing by better technology.
• Doing for better relation between economic activities and engineering knowledge then
create developed country.
• From other factory working experience by creating linkage doing good industry level.
• By taking better technology supporting the working activities for good development.

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• Meet the demand of metals fabrication products by developing the technology and create
engineering knowledge networks that can help the country to achieve the development
goals.
• Utilizing experiences obtained from industry actual activities to hasten national industrial
development and perform work that help national economy development.
• Perform continuous technology enhancement work based on the actual and future national
requirement of metal fabrication products to get patent on net of domestically produced
items.

1.3 Establishment Capital

The federal democratic republic of Ethiopia metal and Engineering Corporation established by ten
billion irr. So that, the metal and fabrication branch total establishment capital is up to 230,000,000
Birr.

1, Fixed Assets.............................200,000,000birr
2, Finance Assets .............................20,000,000birr
3, Intangible Assets........................10,000,000birr

Figure 1. 2 vehicle maintained

1.4 Market
Primarily, the company is targeting the local market to sell its product. In the near future, it will
embark on exporting to neighboring regional markets. The AGRO- INDUSTRY and MILITARY

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sector in general and the metal industries in particular are the major market segments of the
company.

1.5 The management system

The company led and directed by one managing director who is the head of industry and also the
shop has its own manager. The responsibilities for the day to day activities of the company are
falling on the general manager whose main task is to make the company achieve its objective
effectively and efficiently. Under the general manager there are three functional departments
responsible for their respective operations. The educational background of the management
members is B.S.C engineers and above with long year experience and good track record for results.

1.6 Organizational structure

Director

human resource desk documentation desk

record desk plan and report desk

customer supervision
engineering finance
operational service and
team team
team team controlling
team
Figure 1. 3 Organizational structure
1.7 Operational structure
operational
director

substore case
team

defencive planned unplanned

maintenance correction case correction
case team team case team

Figure 1. 4 Operational structure

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CHAPTER TWO
INTERNSHIP EXPERIENCE
2.1 Objective of the internship
The objective of these 2 months of internship period includes

✓ The theoretical knowledge and corresponding practical skills.

✓ Creating awareness on us about the external environment which we will join and
work after graduation.
✓ It generally is used to develop students their practical skills, theoretical knowledge,
✓ Entrepreneurship ability, leadership and team playing skills, work ethics and others.

2.2 Request and acceptance in the company

After we receive our internship place requirement form the department, we assigned one of our
classmates to take the papers to the company to request for permission and our friend took the
papers to the company design department and told us that our request was confirmed. Then after
brake we met. Mr. Wondimu, mechanical engineering department coordinator, and he made
contact with the company.

When we arrived at LVMD on June 1, 2021 GC, we try to explain our selves for the guards at the
entrance position. they accept with glad warm well come and introduce the overall work flow,
rules, regulation a covid 19 protocol of the company.

2.3 Section of the company we were working in

Light vehicle maintenance directorate has commonly 5 work section. Each section has their own
tasks.

• Engine shop
• Body and welding shop
• Electrical shop
• Manufacturing shop
• Maintenance and repairing shop

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2.4 The work flow in the section

driver

maintenace
director

electrical maintenance
engine shop body shop
shop shop

Figure 2.1 Work flow in the section

We have been working on all those shops depending on the schedule designed by the host
company.

2.4.1 Engine shop

Figure 2.2Engine shop

Engine shop is a place where any engine parts have been removed, disassembled, cleaned,
inspected, repaired as necessary and tested using factory service manual approved procedures. An
engine is a device which transforms one form of energy in to another form. Normally, most of the
engines convert thermal energy into mechanical work and therefore they are called 'heat engines’.

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The internal combustion engine (IC-Engine) is a heat engine that converts chemical energy in a
fuel into mechanical energy, usually made available on a rotating output shaft.

➢ Objective of Engine maintenance

• To keep the performance of the engine
• To minimize car accidents
• To cease the leakage
• To satisfy the customer
• To save energy
• To avoid the worn parts
• To clean and check the parts…
➢ Some of the activities performed in engine shops are listed and explained below:

1. Safety in the shop

2. Engine overhauling steps

3. Measuring tools

4. Shop hand tools

➢ Safety in the shop: -

Safety in the shop means protecting yourself and other from possible injury. According to this we
have used carefully by using safety materials in the shop. Like safety shoes, ear protector, safety
cloth, shop layout, face mask…. etc.

➢ Engine overhauling Steps

a) Engine dismounting: in this step engine is dismounted (separated) from the vehicle to inspect
the problem.
b) Engine disassembly: -in this step we have to disassemble or take the components off to get all
the failures.
c) Engine components washing and cleaning: - In this shop when the engine is disassembled
from the car it has a lot of oils and it must be cleaned in the shop by using a compressor.
d) Engine components inspection; in this step each part of the engine measured and checked.

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e) Engine assembly / over hauling; every part of engine properly assembled.

➢ Different engine components

A. Block: -Body of engine containing the cylinders, made of cast iron or aluminum. In many older
engines, the valves and valve ports were contained in the block. The block of water-cooled engines
Include a water jacket cast around the cylinders. On air-cooled engines, the exterior surface of the
block has cooling fins.

B. Cylinder Head: -It is the top most part of the engine, which covers the cylinder block. This
will also carry the valves, rocker arms and springs for the opening and closing of the valves. It has
also inlet and exhaust ports, combustion chamber and camshaft in some engine, likewise nozzle if
diesel engine. The head contains the spark plugs in SI engines and the fuel injectors in CI engines.
Most modern engines have the valves in the head, and many have the camshaft(s) positioned there
also (overhead valves and overhead cam).

C. Head gasket: -Gasket which serves as a sealant between the engine block and head where they
bolt together. They are usually made in sandwich construction of metal and composite materials.
Some engines use liquid head gaskets.

D. Camshaft: -Rotating shaft used to push open valves at the proper time in the engine cycle,
either directly or through mechanical or hydraulic linkage (push rods, rocker arms, tappets). Most
modern automobile engines have one or more camshafts mounted in the engine head (over
headcam). Older engines had camshafts in the crankcase. Camshafts are generally made of forged
steel or cast iron and are driven off the crankshaft by means of a belt or chain (timing chain).

E. Push rods: - Mechanical linkage between the camshaft and valves on overhead valve engines
with the camshaft in the crankcase. Many push rods have oil passages through their length as part
of a pressurized lubrication system.

F. Combustion chamber: -The end of the cylinder between the head and the piston face where
combustion occurs. The size of the combustion chamber continuously changes from a minimum
volume when the piston is at TDC to a maximum when the piston is at BDC. The term “cylinder"
is sometimes synonymous with "combustion chamber" (e.g., "the engine was firing on all
cylinders.

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G. Cylinders: -The circular cylinders in the engine block in which the pistons reciprocate back
and forth. The walls of the cylinder have highly polished hard surfaces. Cylinders may be
machined directly in the engine block, or a hard metal (drawn steel) sleeve may be pressed into
the softer metal block.

E. Piston: - The cylindrical-shaped mass that reciprocates back and forth in the cylinder,
transmitting the pressure forces in the combustion chamber to the rotating crankshaft. The top of
the piston is called the crown and the sides are called the skirt.

F. Piston rings: - Metal rings that fit into circumferential grooves around the piston and form
sliding surface against the cylinder walls. Near the top of the piston are usually two or more
compression rings made of highly polished hard chrome steel. The purpose of these is to form a

seal between the piston and cylinder walls and to restrict the high-pressure gases in the combustion
chamber from leaking past the piston into the crankcase.

G. Connecting rod: -Rod connects the piston with the rotating crankshaft, usually made of steel
or alloy forging in most engines but may be al.0uminum in some small engines.

H. Connecting rod bearing; - Bearing where connecting rod fastens to crankshaft.

I. Crankshaft: - Rotating shaft through which engine work output is supplied to external systems.
The crankshaft is connected to the engine block with the main bearings. It is rotated by the
reciprocating pistons through connecting rods connected to the crankshaft, offset from the axis of
rotation.

➢ The work task that we have been executing

We have been staying in this shop for two weeks by visualizing partially how to assemble,
disassemble and repair of damaged parts of the engine

✓ Removal of an engine from vehicle

✓ Helping during the Maintenance of an engine
✓ Assists the technicians in assembly & disassembled of an engine.
✓ Cleaning of an engine block, valve spring, cylinder heads & blocks
✓ Put significant role in the arrangement of valves during the assembly process.
✓ Preparing working equipment’s during work for the mechanics

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✓ Belt adjustment after the engine assembly completed

✓ Mounting the engine to the vehicle

2.4.2 Body shop

Figure 2. 2 Body shop

Body shop is a type of service render shop. In this shop there are a lot of activities performed.
Among thus, washing, grinding, painting and welding are the main activities. This shop has its
own work execution plat form as summarized below.

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welding leveling

disassembling

washing pianting

➢ Car body consists the following components

Bonnet/hood, cowl screen, front clip, front fasica and header panel, Fender, Mud guard, Foot step
(rocker panel), Roof panel, Door hinge, Spooky (mirror), Outside door handle, regulator gear,
Center pillar, Target panel, Hood (engine cover), Top caw Vessel, Reel, Dash board (instrument
panel), Cart, Sill panel.

➢ Challenges we have been facing

Challenges are powerful indicator of solution we have been facing different challenges while
performing our tasks. Among the challenges we have facing

• Lack of working material due to this we use un proper metal

• Lack of sacker of welding smoke due to this our eye faced for sick.
• Usage of unbalanced power source
• Selection of proper electrode
• Some tasks are done by experience, not according to the manual.
➢ Measures we have been taken in order to overcome challenges
• Balancing power for the appropriate material to be welded
• We identified both grinding disc and cutting disc for correct purpose
• We also able to identify electrode types and numbers depend on material type to be
welded
• Communicate clearly the workers
• discus the problems with my friend

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These above measurements are taken collected from different sources like company’s worker
working manual, university books, encyclopedia, from workers and from friends of different
university.

2.4.3 Maintenance shop

Figure 2. 3 Maintenance shop

In this shop different automobiles maintain and repair, if there is any problem detected by the
mechanic or operator. Because of its vast working systems and it is most related to our study, we
spent most of our internship period in this shop. During this time, we know the maintenance of
engine and its working mechanisms and working principle of transmission, gear box, differential,
suspension system, propeller shaft, cooling system, lubrication system, ignition system, and
electrical system. We try to point out re-conditioned components of the engine and know their
failures and their remedy. By analyzing the creation of power in the engine and types of strokes
[intake, compression, power and exhaustion system], we develop awareness regarding to our
study. we also know mechanisms of ignition system, lubrication system and cooling system with
their maintenance methodology. In addition to this we try to see consideration of vibration in
automobiles and I try to come up with analysis of a chassis.

Regular inspection programs (equipment condition monitoring) Means paying attention to what
the machine telling you.

• Watch the gauges.

• Note the production and performance.
• Look of smoke, heat, leaks, and loose parts.
• Listen for changes in noise levels

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➢ Maintenance and repairing shop have the following work execution steps

•inspection
1

•disassemblings
2

•maintaining
3

•wiping
4

5 •assembling

•check
6

Generally, there are two ways of service in this shop. These are;

Scheduled (preventive) maintenance

This is normal way of service that is the vehicles are serviced periodically. It includes express
service, maintenance service, repair service and component service. Some of advantages of
preventive maintenance

✓ Allows scheduling down time

✓ Prevent major failures
✓ Maximize parts reusability
✓ Optimize equipment life to keep machine running
✓ Increase machine resale value

Unscheduled (break down) maintenance

Any kind of service that is not periodically serviced it included in the category like the vehicle
injured by accident. Used for unnecessary replacement of part is avoided in addition lower
downtime is required.

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2.4.4 Electrical shop

Figure 2. 4 Electrical shop

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 acythiline, if the battery is
either dead or over used
• Checking the spark of starter plug if it is created and install wires around the starter
plug
• Maintain the wires of display gauges
• Oversee the connection of dynamo meter
• Plug lights and fans

Machine found in the workshop

There are different machines that are used in this work shop, such as lathe machine, milling
machine, boring, drilling machine and their accessories.

A. Lathe machine: Lathe machines are capable of cutting or grinding symmetrical shapes into
materials such as wood and metal. There are countless practical applications associated with lathe
machines. The definition of a lathe is a machine that shapes objects by rotating them while a

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shaping tool such as a chisel is applied to its surface. To avoid injury, care should be taken while
operating lathe machines.

B. Drilling machine: It comes in many shapes and sizes, from small hand-held power drills to
bench mounted and finally floor-mounted models. They can perform operations other than drilling,
such as counter sinking; counter boring, reaming, and tapping large or small holes.

C. Shearing machine is one of two things; an industrial machine that cuts metal or a machine that
cuts the wool off sheep. An industrial shearing machine generally presses blades down into metal
sheets to punch out shapes. These shapes may be the desired end product or they may be the waste
product. While shearing metal sheets is most common, other metallic objects may be processed in
one of these machines. A sheep-shearing machine may be anything from a pair of small clippers
similar to ones found in a barber shop to a large machine that features an external power supply
and multiple clipping arms.

B. Bending Machine; Itis a machine used for the hot or cold bending of parts from flat sheet, bar,
tubular, and rolled stock. All-purpose bending machines are of several types, including three- and
four-roll (rotary) machines, roller machines, and machines with a turning traverse, template, or
arm. Three and four roll machines are used for bending sheet stock into cylindrical and conical
shells and arc-shaped components

Shop hand tool

Hand tools are used very often throughout work to loosen and tighten bolts, screws and parts; apply
impact to or mark something for adjustment or replacement etc.

• Open –end wrenches (spanners)

• Box wrenches (offset wrench)
• Combination wrench
• Adjustable wrench
• Screwdrivers
• Pliers

There are various types of pliers for use in gripping and turning and cutting wire.

A) Needle-nose pliers

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B) Locking Pliers (Vice-grip Pliers)

C) Cutting Pliers (Nippers)

D) Slip-joint Pliers

E) Socket wrench set

Installation and removal of battery terminal

Before performing electrical work disconnect the negative (-) terminal cable from the battery. If it
is necessary to disconnect the battery for inspection or repair, first disconnect the negative (-)
terminal cable.

• When disconnecting the terminal cable to prevent damage to battery terminal, loosen the
cable nut & raise cable strait up without twisting or prying it.

• Clean the battery terminals & cable ends with a clean shop rag. Do not scrape them with a
file or other abrasive objects.

• Install the cable ends to the battery terminals after loosening the nut, and tighten the nut
after installation. Do not use a hammer to tap the cable ends onto the terminals.

Be sure the cover for the positive (+) terminal is properly in place.

• During disassembly, keep parts in the appropriate order to facilitate reassembly

• Non -reusable parts: Always replace cotter pins, gaskets, O-rings, oil seals, etc. with new
ones.

• Check hose & wiring connectors to make sure that they are connected securely & correctly

• Pre-coated parts: pre-coated parts are bolts, nuts, etc. that are coated with a seal lock
adhesive at the factory. If a pre-coated part is retightened, loosened or caused to move in
any way, it must be recoated with the specified adhesive. When reusing pre-coated parts
clean of the old adhesive & dry with compressed air. Then apply the specified seal lock
adhesive to the bolt, nut or threads

• When necessary, use a sealer on gaskets to prevent leaks

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• Carefully observe all specifications for bolt tightening torques. Always use a torque
wrench.

• Use of special service tools (SST) & special service materials (SSM) maybe required
depending on the nature of the repair. Be sure to use SST & SSM where specified & follow
the proper work procedure

• When replacing fuses, be sure the new fuse has the correct amperage rating. Don’t exceed
the rating or use one with a lower rating
• Care must be taken when jacking up & supporting the vehicle. Be sure to lift & support the
vehicle at the proper locations.

• Cancel the parking brake on the level place & shift the transmission in Neutral (or N range).

When jacking up the front wheels of the vehicle at first place stoppers behind the rear wheels.

▪ When jacking up the rear wheels of the vehicle at first place stoppers before the front
wheels.

▪ When either the front or rear wheels only should be jacked up, set rigid racks & place
stoppers in front & behind the other wheels on the ground.

▪ After the vehicle is jacked up, be sure to support it on rigid racks. It is extremely dangerous
to do any work on a vehicle raised on a jack alone, even for a small job that can be finished.

The work task that we have been executing

In this shop we have been seen different electrical systems. The work task that we have been
executing includes.

➢ We differentiate battery is the main electrical power sources of a vehicle.

➢ Battery charging.

➢ Identifying the problem from the information listed on the fuse cover.

➢ Disassembly of starter motor and its parts name.

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Challenges we have been facing in electric shop

There are several challenges we faced during our task among them the following challenges takes
our focus. These are

➢ Lack of Safety equipment’s

➢ Line or cable identification problem
➢ Lack of accurate measuring instrument to see whether battery acid is weak or not.
➢ The other problem that we faced is step of terminal mounting.

Measures we have been taken in order to overcome challenges

➢ To avoid as much as we can we tried to keep ourselves from acid contact and listening the
worker’s description.
➢ Through asking and referring different sources we are able to identify cables through using
conventional colures like
▪ Red for positive terminal.
▪ Black for negative terminal
➢ We also tried to identify the steps of mounting and removing of a terminal.

Step 1: -mounting (connecting) a terminal

1. First positive terminal is plugged.
2. Second negative terminal is connected.
Step 2: - removal of a terminal
1. Negative terminal removed first
2. Positive is removed next.
All this measure achieved through asking workers, discussing with friends and usage of different
sources.

STARTING LIGHTING CHARGING IGNITION

ACCESSORIES
SYSTEM SYSTEM SYSTEM SYSTEM

In this shop electrical part of vehicle detection like the following systems takes place.

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CHAPTER THREE
Technical Aspects of the Internship
This internship program is helpful to relate the theoretical knowledge with practical knowledge
and able to organized both knowledge for real world of life.
This intern ship program also helped us to familiarize our self for working environment and have
better performance for technician skill.

• Upgrading theoretical knowledge

• Have better interpersonal communication skills.

• Able to understand about work ethics and relate issues

• Able to have team playing skill

• To know leadership skills with in working environment

3.1 Objective of the internship
The industrial intern ship program is established with the purpose to expose students to the real
working environment. So that the students are able to relate the theoretical know ledge Gained in
the class with practical knowledge in the industry.

The objective of the intern ship period includes:

➢ Creating awareness on us about the external environment which we will join and work after
graduation.
➢ To integrate theory with practice: - students must be proficient in applying the official and
technical knowledge in to real working environment.
➢ To give to give opportunity to student to work with industries practitioners. Exchange
between students and industrial practitioners work Experience.
➢ To expose students to potential employers.
➢ Enhances skill in engineering including technical writing and communication.
➢ It generally used to develop student’s theoretical knowledge, practical skills,
entrepreneurship ability, leader ship and team playing skills, work ethics and others.

3.2 Methods and procedures while working

The following methods are I have used when I have in the internship program.

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Those are;

✓ By making close relationship with company technicians for asking any questions that
make me confuse during working and by relating practical work to the theoretical
knowledge I study so far.
✓ By asking my supervisor, technicians and my friends about the ideas I have not
understand.
✓ By writing some points while people brief me with new terms.
✓ By discussing many issues with my friends who study to me in the same company.
✓ By refer manuals and books available in the company
✓ Try to take caution while I work on different machines in the workshop.

3.3 Technical tasks/products

Wheel service

Cases for wheel service

■ Decay of grease

■ Worn of bearings like in race and outrace bearings in front wheel, and knuckle

bearing.

■ Drake adjustment problem

■ Wear of brake pads beyond wear indicator

■ Wear of brake shoe

The solution we taken

● We replaced grease, inarch and outrace bearings, and knuckle bearings

● We adjusted shoe brake adjustor

● We replaced brake pad and brake shoe

Results we observed: - result we observed is normal gripping of braking system and avoid

of scrap off.

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➢ Engine reconditioning

Cases for engine reconditioning

► Leakage of oil

Solution we taken

● We changed cylinder block gasket

Result we observed: - cease the leakage.

Replace engine oil

Cases for replacing engine oil with filter

► Contamination of engine oil

► Full of impurities on the neck of fuel filter

Solution we taken

● clean oil pan by flash oil and then pour engine oil

● replace fuel filter

3.4 Knowledge and Acquaintances Acquired

I acquired much knowledge from this internship. And also I gained technical skill, Management
skill and Acquaintances.

3.4.1 Technical Skills Gained

As an engineering fourth year student, in my entire academic life I could introduce myself for basic
principles, laws, equations and formulas of science and engineering. Therefore, through this time
most lectures where theory but during the internship I able to: -

➢ Integrate theoretical knowledge into practice.

➢ Develop the ability of identifying problems and giving appropriate solution.
➢ Discover and understand the systems, parts and accessories of automotive.
➢ Be familiar with tools, equipment’s, instrument and machines.
➢ Improve leadership skills

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➢ Improve interpersonal communication skills

➢ Upgrade theoretical knowledge
➢ Analyze and interpret diverse, drawings; Interpersonal sensitivity, persuasiveness and the
ability to work as part of a team; Awareness of ethical issues and the wider impact of your
work.
➢ develop a sense of creativity, innovation and visibility

3.4.2 Management skill gained

Management skill is the critical leadership skill, is the ability to motivate a group of Peoples
towards a common goal. This internship had developed my ability of getting and Giving
information for good leadership skills. By now, leadership to me, as applied to someone to whom
other people are entrusted, is an art of inspiring other to give of their best and courage to use this
art. During internship with respect to leadership skills I have learned and convicted to have the
following attributes to be successful leader.

➢ General intelligence, to make sense of the complexity and difficulty of the task.
➢ Technical or professional knowledge and competence in their particular field
Is often the bedrock of respect for leaders?
➢ Personality-should be energetic and committed, maintain contact with people, and understand
their strengths and weaknesses.
➢ The ability to inspire, although this quality may be rather than some of the others and is perhaps
the most difficult to develop.
➢ Generally; this internship made me familiar with leadership planning, evaluation, counseling,
controlling and sharing leadership.

3.4.3 Communication skill

Interpersonal communication is the ongoing process of interaction between individuals who build
the personal knowledge of one another as they create a meaning or work output. These
Interpersonal communication skills are learned behaviors that can be improved through knowledge
practice, feedback, and reflection. When we come to internship, I got various inter personal
communication skills and abilities. They are

• Improve my listening & speaking

• Improve my feeling, idea, and feedback question

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• Respectful to other

3.4.4 Acquaintances Acquired

During the intern ship period I contacted many people like company technicians, each shop
leaders, company supervisor and manager. This relation updates my:

• Obedience culture
• Respect behavior
• Ethics
• Knowledge sharing
• Leadership and motivation
• Team work

3.5 Problems encountered during the internship (limitation)

During the internship period, we come across a number of pleasant and wonderful times in terms
of upgrading our practical skills and widening the future work career. In contrary, a number of
problems have been challenging us during the study. The following are the major problems they
have been challenging us:

• The workers of the company are not interested if we touch any materials and
equipment in order not to take the responsibility when the materials are got
damaged
• In the first time it was difficult to introduce ourselves with the department
particularly with the engineers and we were not feeling good to ask them
• We hadn’t a specific office to discuss about what we perform and acquired in that
day
• Most of the mechanics and engineers are almost busy at work. Hence, there was no
enough time to discuss with them.
• We didn’t know name of tools which they use even they call their tools by italic
name.
• Safety materials were not fully provided to us even we did not get drinking water
so we cannot get energy when we worked.
• We can’t too loose large nut and bolt because we have not enough power to fix it

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• Some workers not express their work in detail for us cause of behavior.

In order to overcome these challenges and achieve our goal it was critical to take the right
measurements. The followings are few of them.

We clearly communicate with our supervisor; we understand the problems and we tell him what
kind of tasks we are going to execute. So that to permit and provide us the required materials. We
decide together the manuals of different parts of car. Then, discuss the way to get them.

3.6 Contribution
My contributions during my internship time are:

✓ Cleaning fuel tank

✓ Bring flash oil, engine oil
✓ Grease propeller shaft joints
✓ Clean air cleaner by compressor
✓ We made Tire Changer and Brake caliper piston compressor
✓ Cleaning and washing parts of engine in engine maintenance shop
✓ Disassemble different part of by using different tools like; wrench.

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CHAPTER FOUR
INTRODUCTION TO ENGINE LIFTING MACHINE

4.1 What is engine lifting machine

Engine lifter or hoist is a tool that is used for lifting engines and other car parts, such as an engine
with a transmission out of a car. Engine hoist is just a name used to describe a tool that can be used
in car repair works for engine lifting, but also can be used to lift heavy weights in other industries
heavy objects or for lifting other objects like boxes in stores, for wood works and construction
works.

Engine lifting machine is used for lifting up heavy objects, mostly car parts like engines and
transmissions. Engine hoist is widely used tool in car workshops. Those engine hoists you see in
a car maintenance shop differ from those that are used by individuals in their smaller workshop or
garage. The reason is simple, commercial engine hoists takes up a lot of space, and individual car
repairers or enthusiasts that fixes and works with cars in their own garage usually do not have
much free space to put a large, commercial engine lifter. This is why many car tool manufacturers
are producing smaller and more compact tools for a much lower price.

Engine hoist basically has one job – lift heavy objects. To do this job, engine lifter has very durable
metal construction that can hold lift capacities up to 4 and more tons (8000 lb.). Engine lifters
come with varying lift capacities. Smaller engine hoists are able to lift weights up to ½ ton (1000
lb.), while larger hoists can lift even 8 tons (16000 lb.) heavy objects. The most common engine

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hoists are capable of lifting 1 and 2 ton (2000 and 4000 lb.) heavy objects. Weight of most regular
today’s car v4 engines and v6 engines does not exceed 2-ton limit, so these engine hoists will work
with practically any engine.

4.2 Statement of problem

Light vehicle maintenance directorate is a repair and overhaul center for variety vehicles so repair
and maintenance of these vehicles are regular and must take place for their continued operation.
This informs the reason for the ever-increasing number of such automobile repair shops in the
country. Most shops however are grossly unequipped for proper handling and job execution in the
shops. Sound professional best practice aimed at workshops injury and accident prevention and
reduction ensures the utilization of appropriate tools for any job. Motor vehicle repair and
maintenance often require the lifting of the entire vehicle or sub-assembly part of it or the lifting
up and down of its heavy components. Also, in other industries and welding shops, there are items
and repairs which need the employment of shop cranes. The lack of shop crane utilization in
LVMD and automobile repair shops not only leads to injury and accident but also to poor repair
and maintenance occurrence. The few cranes and lift facilities currently employed in LVMD
maintenance shops are all imported at exorbitant costs. There is the need for the development of
home initiated and home built shop cranes that are affordable with simplified technology which,
could be proliferated in order to ensure adequate usage of proper lifting tool in those sectors. This
project intends to address this issue from the angle of evolving the built of an affordable shop crane
using mostly available materials.

4.3 Objective
The objectives are a guideline in order to complete this project. This project is conducted to achieve
the following objectives:

4.3.1 General objective

The main objective of this project is to design engine lifting machine.

4.3.2 Specific objectives

• To design hydraulic engine lifting machine within up to 1 tone.
• To design and built a hoist machine which uses less force and better lifting
capacities thus reducing the force needed to operate this machine.

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• To design each component of the machine.

• To design and built a hoist machine which can be folded or fully disassembled for
easier compact storage and easier to transport from one place to another.

4.4 Literature Review

4.4.1 Background of lifting machine or crane
Today crane parts are made of different types of metals, heavy-duty cables, and can lift and move
objects many times heavier than the loads of ancient times. In olden times, thousands of slaves had
to be arranged whenever a heavy load had to be lifted or dragged Khurmi, (2009). Moving these
objects involves some interesting physics. The load is attached to the end of the cable, and then
cranked along pulleys to whatever height necessary. The most fun lies in the smallest piece, the
pulley. This wonderful, simple machine reduces the force of the weight of an object, and allows
less force to be used to move it than would be necessary with direct force, such as pushing it up a
ramp. The pulley divides the weight, spreads it out along the cables, and multiplies the force being
used to lift the object. The perfect condition for this is a pulley with zero friction and cables that
do not stretch. While currently impossible to reach these conditions, technology has gotten much
closer than the Ancient Greeks with their ropes and wooden pulleys. Now, with new materials and
powerful motors, cranes can be used to lift much heavier objects than ever before. In any industry,
time spent in doing a particular work is very important to management. The safety of workers can
never be ruled out. Crane accidents and emergencies are occurring with increasing frequencies in
ports around the world. This is understandable due to rapidly increasing population of cranes,
increasing crane dimensions resulting in reducing visibility and operator control, frequent adverse
weather conditions, and also crane maintenance and operating procedures not keeping up with
increasing risks and demands of a fast-paced modern terminal Larry, (2007). When all the forces
that act on a given part are known, their effect with respect to the physical integrity of the part still
must be determined Leonardo and George, (1995). It would therefore be reasonable to suppose
that fatigue failure due to lack of allowance do not occur Raymond, (1990). On 21st May 2000 the
top of a tower crane collapsed at Canada Square in the Canary Wharf area of East London.
Tragically, three of the erection crew died in the collapse. The collapse occurred near the end of
an operation to raise the height of the tower crane with an external climbing or jacking frame. The
Health and Safety Executive (HSE) understands that at that time this was only the second collapse
of a tower crane during climbing anywhere in the world. The first occurred in San Francisco on

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28th November 1989. In the automobile industry for example, the engine crane is used to lift and
mount car engines and other dexterous components during repair works or servicing. In a
modernized automobile workshop, damaged engines are kept in a spacious room allocated for such
purposes until vehicle owners approve of their state. Dismantling and cleaning of the entire engine
is also carried out in this same room. As the damaged engines pile up in the room, there is the need
to sell them to scrap dealers. Some technicians are made to halt their work in order to help load
these damaged engines into a light duty truck. Lifting of such heavy objects, whose edges are
sharp, with the hands, is very dangerous. The involvement of technicians who are busy on their
job, are deplored to the loading, which is time wasting. The objective of this paper is therefore to
create an improvement on the existing engine crane in order to aid productivity, safety of workers,
ergonomics, efficiency and effectiveness, usefulness and versatility of the cranes, for which they
are designed and manufactured.

Broughton (1958) grouped all cranes into four main categories, which remain applicable today, as
enunciated by Thompson Geoffrey (2007):

• Overhead Travelling Crane: This consist of fixed rails lying on one or two elevated
girders with the trolley or crane bridge (with hoisting apparatus) that can transverse
the length of the rails.
• The Jib Crane: This consists of an inclined member that can rotate about a central
point and suspend the load from the outer end of the inclined member.
• Gantry Crane: This is a girder or girders connected to vertical members which are
either fixed or move along tracks at the base of the vertical member, the hoisting
equipment can be usually traverse the bridge girder or girders.
• Cantilever or Tower: This is a vertical mast with a horizontal cantilever that rotates
horizontally around the vertical member. The trolley and hoisting equipment move
along the horizontal cantilever. The hydraulic shop crane or engine lifting machine
is a small cantilever crane operated manually and can be moved in all directions
through the action of the steel or rubber tires installed at the base.

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4.5 Methodology of the study

4.5.1 Study area
This study tries to summarize/cover the overall concept of layout and hydraulic engine lifter used
to raise, material in the company shops.

4.5.2 Study design

This is used to plan and makes the study for particular use; emphasizing on features such as its
appearance, convenience, and efficient functioning, based on customer focus. The data is to be
collected regarding the various processes, sequence of operations, and material flow frequency of
travel, space requirement, activities and their relationships. Finally, Process charts-(operation
process charts, flow process charts) technique is used to analyses the data & design the layout.

To reach at the desired solution, the following methods are designed:

✓ The study must be dealt with in good time.

✓ Measuring parameters must be maintained.
✓ System data must be well known
✓ Series of Steps must be carried out to perform the tasks.
✓ Safety guards &care Instructions should be included.

4.5.3 Data collection techniques

➢ Primary data collection technique
• Unstructured interviewing for higher level and lower-level workers in the work
shops
• Direct observation of the work area
➢ Secondary data collection technique
• Determining the existing layout
• referring documentation
• Layout structure of the company

4.6 Material selection

The selection of a proper material for the design purpose is a very crucial issue. The best material
is one which serves the desired objective at the minimum cost.

The following factors should be considered while selecting the material.

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✓ Availability
✓ Cost
✓ Mechanical properties
✓ Manufacturing considerations

Other factors that influence material selection are cost, availability, and ease of maintenance. Let
us see in detail how the above factors affect material selection.

Strength: - is a materials ability to withstand an imposed force or stress. Strength is a significant

factor in the material selection for a particular application. Strength determines how thick a
component must be to withstand the imposed loads. The overall strength of a material is
determined by its yield strength, ultimate tensile strength, creep and rupture strength. These
strength properties depend on the chemical composition of the material.

Yield strength: - is the region which a material changes from plastic to elastic deformation

Ultimate tensile strength (UTS); -The ultimate tensile strength (tensile stress) is a measure of the
basic strength of the material. It is the maximum stress that the material will stand and measure by
a standard tensile test.

Creep strength; -Material are often pleased in a service at elevated temperature and exposed to
static mechanical stress. The deformation under such circumstance is termed creep. It is the time
dependent and permanent deformation of material when subjected to a constant load and stress.

Rupture strength; -It is the material resistance to the fracture caused by the internal pressure of
the fluid that was present inside the tank. And it is proportional to tensile strength (UTS) which
means the material have high UTS and it have good Rupture strength.

Corrosion; is the deterioration of metals by chemical action. A materials resistance to corrosion

is probably the most important factor that influences its selection for specific application. The most
common method that is used to address corrosion in pressure vessels is to specify a corrosion
allowance. A corrosion allowance is supplemental metal thickness that is added to the minimum
thickness that is required to resist the applied loads. These added thicknesses compensate for
thinning (i.e. corrosion) that will take place during service the corrosion resistance of carbon steel
could be increased through the addition of alloying elements such as chromium, molybdenum, or

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nickel. Alloy materials, rather than carbon steel, are often used in applications where increased
corrosion resistance is required in order to minimize the necessary corrosion allowance

Fracture toughness: - refers to the ability of a material to withstand conditions that could cause a
brittle fracture. The fracture toughness of a material can be determined by the magnitude of the
impact energy that is required to fracture a specimen using Chirpy V-Notch Test. Generally
speaking, the fracture toughness of a material decreases as the temperature decrease (i.e., it behaves
more like glass). The fracture toughness at a given temperature varies with different steels and
with different manufacturing and fabrication processes. Material selection must confirm that the
material has adequate fracture toughness at the lowest expected metal temperature. It is especially
important for material selection to eliminate the risk of brittle fracture since a brittle fracture is
catastrophic in nature.

Fabric ability: - Refers to the ease of construction and to any special fabrication practices that are
required to use the material. Of special importance is the ease with which the material can be rolled
or otherwise shaped to conform to vessel component geometry requirements. Pressure vessels
commonly use welded construction. Therefore, the materials used must be weld able so that
individual components can be assembled into the completed vessel. The material chemistry of the
weld area must be equivalent to that of the base material, so that the material properties and
corrosion resistance of the weld area will be the same as those of the base material. Based on how
it made and cost of production of production, a guide to the fabrication properties of common
metals and alloys are shown below.

4.7 Design analysis

Industrial design is a type of design depends up on the production aspects to manufacture any
machine components in the industry.

4.7.1 Part design

Part design in our project classified in to two categories
• Mechanical system design
• Hydraulic system design

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4.8 Mechanical system Design

4.8.1 Design of Bolt

Figure 4. 1 Bolt

The bolts are subjected to shear stress due to the torque transmitted. The number of bolts (n)
depends on the diameter of shaft and the pitch circle diameter of the bolt.

D1=3d

Table 4. 1 Material selection for Bolt

MATERIAL SELECTED REASON FOR THE SELECTION

Steel ASTM-A36 Excellent welding properties, suitable for
grinding, punching, tapping, drilling and
machining process

Table 4. 2 Assumptions and material specification

material Ultimate Yield strength Tensile strength

strength
Steel ASTM- 4OOmpa 250 145
A36

Applied load 10KN Factor of safety 3

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➢ Design analysis

𝜎𝑦 250𝑚𝑝𝑎
σ𝑎𝑙𝑙 = 𝑓.𝑠, =83.33Mpa
3
𝐹 𝜋
σ𝑎𝑙𝑙 = 𝐴, A= 4 𝐷2

2 4∗𝐹 4∗1000
Db= √𝜋∗𝜎𝑎𝑙𝑙=√𝜋∗83.33∗106N/Pa

Db=12.36mm

4.8.2 Design of Nut

Figure 4. 2 Nut

When a bolt and a nut is made of mild steel then the effective height of nut is made equal to the
nominal diameter of the bolt. If the nut is made of weaker material than the bolt, then the height
of nut should be larger. Such as 1.5d for gun metal, 2d for cast iron (where, d is the nominal
diameter of the bolt).

Assumption

✓ Nut may experience tensile stress

✓ Applied load =10KN

Material selection

We select the same material as the bolt.

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Design analysis of nut

𝜎𝑦 250𝑚𝑝𝑎
𝜎𝑎𝑙𝑙 = = =83.33mpa
𝐹𝑆 3

𝐹 (𝐷𝑏 2 −𝑑𝑛2 )
𝜎𝑎𝑙𝑙 = 𝐴, A= *π
4

(4 ∗ 𝐹)
𝑑𝑛 = √ + 𝑑𝑏 2
𝜋 ∗ 𝜎𝑎𝑙𝑙

4∗10000
𝑑𝑛 = √ + 13𝑚𝑚2 =17.93…. approx.=18mm
4∗83.33∗107−1

Note: height of the nut is equal to the nominal diameter of the bolt 13mm because our nut
is made from hard material mild steel

➢ Calculation for washer

Assume thickness of washer=1.5mm

-outer diameter of washer = 𝐷𝑛 =18mm

-internal diameter of washer =𝐷𝑏 +clearance …………………. but we take 2mm for
clearance =13+2=15mm

4.8.3 Design of Pin

Pin is one of the most important part of our design. Pin support can resist both vertical and
horizontal forces but not a moment.it will allow the structural member to rotate but not translate
in any direction.
• Pin mainly fail due to shear
There are 3 pins in our design. If we design for pin A all other pins will be the same. We are
designing pin A because maximum load is transformed on it since it is under single shear

B C

𝑊
4

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𝑊 1
𝑆𝐼𝑁 700 = ∗
4 𝐹𝑝𝑖𝑛

10,000𝑁
𝐹𝑝𝑖𝑛= ∗ 𝑠𝑖𝑛700 =2350
4

𝐹
𝜏=
𝐴𝑃
𝜋∗𝐷𝑝2
AP= 4
4𝐹
𝜏 = 𝜋∗𝐷𝑝2

Where, F=Force in the pin

𝐷𝑝=pin diameter

𝜏 = 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑠𝑠

𝐴𝑝=area of the pin

Assumption:

➔ Load is uniformly distributed throughout the length of the pin

➔ The pin has a uniform cross section

Material selection:

➔ Malleable cast iron ASTM A 197

Reason for selection

➔ Good tensile strength

➔ Ability to flex without braking (ductility)

Table 4. 3 Material selection for Pin

Material Ultimate strength Yield strength

Malleable cast iron ASTM 𝜎𝑢 = 216Mpa 𝜎𝑦 = 207Mpa
A 197

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Take factor of safety, 𝐹. 𝑆=3

𝜎𝑦 207
𝜎𝑎𝑙𝑙 = =
𝑓𝑠 3

𝜎𝑎𝑙𝑙 =69N/𝑚𝑚2
69 𝑁
𝜏𝑎𝑙𝑙 = =34.5𝑚𝑚2
2
4𝐹
𝜏𝑎𝑙𝑙 =
𝑑𝑝2 ∗ 𝜋
4∗2350
𝐷𝑝2= 34.5∗𝜋

𝐷𝑝=9.31mm………...take standard 10mm

Now check for shear force of pin
4∗2350
𝜏= =29.92N/𝑚𝑚2
102 ∗𝜋

Therefore,𝜏𝑎𝑙𝑙 > 𝜏
34.5N/𝑚𝑚2 >29.92N/𝑚𝑚2

Therefore, the design is safe

Total dimension of the pin
Height of the pin =0.5dp
0.5*10=5mm
Diameter of the head =1.5dp
1.5*10=15mm

➢ SELECTION OF PIN LOCK:

There are different types of pin lock, but for our design we have selected split pin lock. The split
pin drops through a hole in the thread shaft and rests in a ridge on the surface of the nut. The nut
can’t become loose because the split pin stops it rotating. The split pin is inserted through a hole
in the pin body and touching surface of the pin

Split pin diameter (SD)=0.2D

SD=0.2*10mm=2mm

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4.8.4 Design of hallow bar

Figure 4. 3 Design of hallow bar

This is connected with the main stand on one side and with the hook on the other hand. It can be
manipulated by the piston rod at the center. It can move 1800 up and also rotate 3600 with main
bar since bar since it is connected to the main stand with a pin in handle materials.

➢ Material selection:
• Carbon steel cold rolled
➢ Reason for selection material
• Less cost but sufficient strength
• Strength and rigidity
• Excellent weld ability
• Improve machining properties.

material AISI UNS TREATMENT STATIC YIELD SHEAR

NO NO STRENGTH STRENGTH STRENGTH
Carbon 3140 G 31400 Normalized 891.5 MPA 883 MPA 299.9MPA
steel cold
rolled

Table 4. 4 Material specification for hallow bar

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➢ DESIGN ANALYSIS

Assumption=α=450 Factor of safety=2

sinRy W=10kN

A B

Rx 𝐹𝑝 α

750mm 𝐹𝑝𝑥 750mm

∑MA-=0

∑MA= (𝐹𝑝sin450 *750mm) -(W*1500mm) =0

𝐹𝑝=28.28KN

𝐹𝑝𝑦=Fpsin45=20KN

𝐹𝑝𝑥=Fpcos45=19.99KN

∑𝐹𝑦=0

𝐹𝑝𝑦-w-Ray=0

Ray=10 KN (Down ward)

∑F=0

∑𝐹𝑎𝑥=Rax+Fpx=0

𝑅𝑎𝑥=-19.99KN (in the negative x direction)

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RA W

1 2

Selecting section 1
Ray
M1
A v b

For shear force

∑𝐹𝑦=0
∑𝐹𝑦=Ray-V=0
Ray=V1=10KN
Taking moment at point A
∑Ma=0
∑Ma=M1-V*x=0
𝐿
M1=V1*X=10*X Where 0≤x≥ 2

Selection section 2

Ra M1

A B 𝐹𝑝 C v2

750 X-750

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For shear force

∑𝐹𝑦=0
∑𝐹𝑦=Ra-Fp-V2=0
V2=20KN-10KN=10KN
Taking moment at point b
∑Mb=0
∑Mb=M2-(Ra*750) -(V2*(x-750)) =0
𝐿
M2=22,500 -10x, Where 2 ≤ 𝑋 ≥ 𝐿

Shear force and bending diagram

Ra W

𝐹𝑝𝑦

10KN

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Since the hollow bar is made of a hollow rectangular bar, the width, height and thickness of the
bar should be determined.

H=100mm

B=60mm

T=10mm

Bending stress

𝑀𝐶
𝜎𝑏 = 𝐼

𝑏ℎ3 (𝑏−𝑡)(ℎ−𝑡)3
𝐈ℎ𝑜𝑙𝑙𝑜𝑤 = 12 - where M=bending moment
12
ℎ
C=2 I=moment of inertia

Hollow bar section bar

H=100mm

B=60mm

T=10mm
(0.06∗0.13 ) (0.06−0.01)(0.1−0.013)
𝐼ℎ𝑜𝑙𝑙𝑜𝑤= -
12 12

𝐼ℎ𝑜𝑙𝑙𝑜𝑤=1.9625*10−6 𝑚4
0.1
C= 2 = 0.05𝑚𝑚

𝑀𝐶 7500∗0.750
𝜎𝑑 = 𝐼ℎ𝑜𝑙𝑙𝑜𝑤=1.925∗10−6 𝑚𝑚=1753.25N/𝑚𝑚2

883
𝜎𝑎𝑙𝑙 = = 441.5𝑁/𝑚𝑚2
2
1753.25𝑁 441.5𝑁
Since 𝜎𝑎𝑙𝑙 > 𝜎𝑑 = >
𝑚𝑚2 𝑚𝑚2

There for the design is safe.

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4.8.5 Design of the main stand

Figure 4. 4 Main stand

Main Frame - The part that holds everything together is the main frame or upright post. The main
frame, haves two support plates on the sides which adds to the durability and stability of the tool.
Also, it has a handle with rubber grips mounted to the top part of the frame, which allows moving
the hoist easier when it is carrying a load.

Assumption
• The applied force to the stand is =10KN
• The length of main stand is =1.7m

Material selection
The same as the hallow tube.
Design analysis
Taking factor of safety 2
𝜎𝑠𝑦 = 599.8𝑀𝑝𝑎
𝜎𝑠𝑦 599.8𝑀𝑝𝑎
𝜎𝑎𝑙𝑙 = = =300Mpa
𝑓𝑠 2

Area of the rod

A=B*h=60*100=0.006𝑚2
𝐹𝑙𝑜𝑎𝑑 10000𝑁
𝜎𝑠𝑡 = = =1.66Mpa
𝐴 0.006𝑚2

Where 𝜎𝑠𝑡 = 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠

F=force applied on the main stand

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A=Cross sectional area of the main stand

Finally, we have to check the stress according to the following theories: -

1. Maximum tensile stress theory

𝜎𝑡 1
𝜎𝑚𝑎𝑥 = 2 + 2 √(𝜎𝑡 2 + 4𝜏 2 )

𝜎𝑚𝑎𝑥 ≤ 𝜎𝑎𝑙𝑙 = 239 ≤ 300

The design is safe

2. Maximum shear stress theory

1
𝜏𝑚𝑎𝑥 = √(𝜎𝑡 2 + 4𝜏 2 )
2
𝜏𝑚𝑎𝑥 ≤ 𝜎𝑎𝑙𝑙 = 239 ≤ 299.9
The Design is safe
3. Distortion theory
𝜎𝑑 = √𝜎𝑡 2 + 4𝜏 2
𝜎𝑑 ≤ 𝜎𝑎𝑙𝑙 = 280 ≤ 299.9
The design is safe
4.8.6 Design of the base

Figure 4. 5 Base

The base is used to support the whole manipulator components and as a housing of caster wheel.

Assumption
• Its length is depending on the main stand or bar and hydraulic system
components

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• Since the base is mobile that is not grounded it can be affected by stress.
Therefore, strong materials that withstand the stress needed.

Material name Tensile strength Yield strength

Hardened (annealed steel) 394𝑀𝑝𝑎 294.8 𝑀𝑝𝑎

Table 4. 5 Material specification for Base

➢ Design analysis

The maximum thickness of the base is given by

𝑃 1
Tb=C*da√(𝜎𝑦 ∗ 𝐹𝑆)

Where C=c is constant assume to be 0.4

Da=Internal diameter of shaft

Pressure=18Mpa (assumption)

Taking factor of safety, =𝐹. 𝑆=3

18𝑚𝑝𝑎 1
Tb=0.4*84mm√(294.8𝑚𝑝𝑎 ∗ 3)=4.79mm

Note: -the numbers given in the above formula are the dimension found from assumption and from
the design of the other component of the machine.

4.8.7 Design of the Handle

Figure 4. 6 Handle

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The handle is used to control and manipulate the machine according to our desirable direction and
section
Assumption
• The maximum human force is to be 1000N
• The handle is assumed as horizontal hollow beam
Material selection

Carbon and alloy steel (AISI No 1050)

Reason for selection

• Extreme hardness
• Moderate ductility
• Ability to tolerate being deformed without actually breaking.
Material name Tensile strength Yield strength
𝑐𝑎𝑟𝑏𝑜𝑛 𝑎𝑛𝑑 𝑠𝑡𝑒𝑒𝑙 𝑎𝑙𝑙𝑜𝑦 𝜎𝑡 = 813.17𝑀𝑝𝑎 𝜎𝑦 = 482.6𝑀𝑝𝑎

Table 4. 6 Material specification for handle

Design analysis

Maximum human force applied=1000N

Fh1 Fh2

75 Fr 75

∑𝐹𝑦 = 0
𝐹ℎ1 + 𝐹ℎ2 − 𝐹𝑟 = 0

∑Ma=0
(𝐹𝑟 ∗ 75) − 𝐹ℎ2 ∗ 150 = 0

500𝑁∗150𝑚𝑚
𝐹𝑟 = =1000N
75𝑚𝑚

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4.8.8 Design of Hook

Figure 4. 7 Hook
Tangential stress can be determined at points manufacturing hooks. The critical section AB can be
closely approximated by trapezoidal area with half an ellipse at the inner radius and arc of the
circle at the outer radius.

➢ Assumption
• The critical section AB is taken to be trapezoidal
• Factor of safety 2
➢ Material selection
• ASTM GRADE 60(GRAY CAST IRON)
➢ Reason for selection of material
• High compressive strength
𝑔
material name density(𝑐𝑚3 ) Tensile yield Poisons ratio Tensile ultimate
strength (𝑀𝑝𝑎) strength (𝑀𝑝𝑎)
Gray cast iron 7.5 280 0.29 450
Table 4. 7 Material specification for hook

➢ Design analysis

From the table 𝑟 = 20𝑚𝑚

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𝑏 = 30𝑚𝑚

b1 = 10mm

ℎ = 42𝑚𝑚

1
The cross-sectional area=𝐴 = 2(𝑏+𝑏1) = 840𝑚𝑚2

The distance to the centroid c from the inner edge,

ℎ(𝑏 + 2𝑏1)
𝐶𝐴 = = 17.5𝑚𝑚.
3(𝑏 + 𝑏1)

𝐶𝐵 = ℎ − 𝐶𝐴 = 24.5𝑚𝑚

𝑅 = 𝑟 + 𝐶𝐴 = 37.5𝑚𝑚

From table, the curved beam factor with C=𝐶𝐴 𝑎𝑛𝑑 𝑐1 = 𝐶𝐵 𝑖𝑠 𝑡ℎ𝑒𝑛;

37.5 37.5 + 24.5

𝑍 = −1 + [(10 ∗ 42) + (37.5 + 24.5)(30 − 10)]𝑙𝑛 (30 − 40)
840(42) 37.5 − 17.5
∗ 42 = 0.1034

The circumferential stresses are determined through the use of the following equations. P = tensile
normal load and bending moment, M =𝑃𝑅𝑎

𝑃𝐶𝐴
(𝜎𝜃)𝐴 = = 201.46𝑀𝑝𝑎
𝑍𝐴 (𝑅 − 𝐶𝐴 )

𝑃𝐶𝐵
(𝜎𝜃)𝐵 = − = −91𝑀𝑝𝑎
𝑍𝐴 (𝑅 + 𝐶𝐵 )

Where, a minus sign means compression.

Remark;
420.6
𝜎𝑎𝑙𝑙 = = 210.3𝑀𝑝𝑎
2

210.3𝑀𝑝𝑎 𝑖𝑠 𝑙𝑎𝑟𝑔𝑒𝑟 𝑡ℎ𝑎𝑛 𝑡ℎ𝑒 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑠𝑡𝑟𝑒𝑠𝑠 𝑜𝑓 201.466𝑀𝑝𝑎 𝑡ℎ𝑎𝑡 𝑐𝑎𝑛 𝑠𝑢𝑝𝑝𝑜𝑟𝑡 𝑎

𝑙𝑜𝑎𝑑 𝑜𝑓20𝑘𝑁 𝑤𝑖𝑡ℎ 𝑓. 𝑠 = 2 𝑤𝑖𝑡ℎ 𝑜𝑢𝑡 𝑦𝑖𝑒𝑙𝑑𝑖𝑛𝑔.

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4.8.9 Design of supporter

Fig 4.8 supporter

Links are supports extending from the horizontal housing to the vertical main stand with 400

Assumption

• Total applied load 10KN

• Number of link=2
• The links have same length, moment and torque.
• The length of the two link=1.4m and thickness of the two link 50mm.
• F. S=2
➢ Material selection

Carbon steel cold rolled

➢ Reason criteria for selection

• Cost and availability
• Strength and rigidity
• Reliability and durability
• Excellent weldability
• Produce uniform and hardness
• Gives good balance of toughness and strength
• Improve machining characteristics

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material treatment AISI No UNS No δst δy τy

name
Carbon normalized 3140 G31400 891.5Mpa 599.8Mpa 299.9Mpa
steel cold
rolled

Table 4. 8 Material specification for supporter

➢ Design analysis

𝛿𝑦 599.8𝑀𝑝𝑎
𝛿𝑎𝑙𝑙 = = =300𝑀𝑝𝑎
𝑓𝑠 2

Direct tensile stress on the piston rod.

𝐹𝑙𝑜𝑎𝑑 1𝑂𝐾𝑁
𝛿𝑠𝑡 = =50∗50=4𝑀𝑝𝑎
𝐴

We have to check the stress according to the following theories

1. Maximum tensile stress theory

𝛿𝑡 1
𝛿𝑚𝑎𝑥 = + √(𝛿𝑡 2 + 4𝜏 2 )
2 2

𝛿max ≤ 𝛿all= 239≤299.9

The design is safe

2. Maximum shear stress theory

1
𝜏𝑚𝑎𝑥 = 2 √(𝛿𝑡 2 + 4𝜏 2 )=239𝑚𝑝𝑎

𝜏max ≤ 𝜎all=231<299.9

The design is safe.

3. Distortion theory

𝛿𝑑 = √(𝛿𝑡 2 + 4𝜏 2 )

𝛿𝑑 ≤ 𝛿𝑎𝑙𝑙 = 280 ≤ 299 So The design is safe.

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4.8.10 Caster wheel selection

Figure 4. 8 Wheel

There is no sample or formula that can be followed to select the proper caster or wheel for a specific
application. The best choice for the longest service life and smooth operation is influenced by
several factors, including the environment, impact loading, wheel size, wheel composition and
bearing selection. The following are some of the important factors to consider in our selection
process.

A. Load capacity

Determine the heaviest load that will be supported by the casters. To obtain the minimum caster
capacity, divided the load weight by the number of casters under the load.

B. Operating surface

Determine the different floor surfaces over which the caster will operate. Rough floors produce
more wear on the wheels and caster rigs and result in uneven load distribution appears relatively
smooth, check for cracks, joints between flooring and ridges or sills between rooms. Larger wheels
may be required to bridge flooring or to travel over transitions between flooring.

C. Floor protection

Proper wheel selection may be a tread off between price, load capacity and floor protection. The
lowest cost wheel may provide the capacity need, but may be damaging to the floor. Steel wheels
have high capacity but may damage some concrete or wood floors. Polymer wheels m lower load

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rating but offer more protection for floor surfaces. Many rubber wheels can produce marks on
finished concrete or linoleum floors. A harder polyurethane or softer non polymer may be the right
choice here.

D. Rolling ease

Regardless of the type of floor surface, the larger the wheel and the harder the wheel, the easier it
will be to roll. Roller bearings carry the heaviest loads, but ball bearings are easier to roll. For
easiest rolling, use the largest ball bearing wheel with the required capacity.

E. Rolling speed

Nearly all casters are rated for capacity at walking speed. Higher speeds lower the bearing capacity.
A higher speed, power propelled application will significantly reduce the caster load rating. The
higher the speed the lower capacity. Higher speed also results in increased forces on the wheel and
rig, especially over uneven surfaces. Consult dialer for an appropriate safety factor in powered or
highest speed applications.

F. Operating environment

The operating environment can have a significant effect on the life of the wheel and caster rig.
Special bearings, finish options and wheel types are available that will accommodate conditions
such as dust, high humidity, water, corrosives, extreme temperatures and rough floor conditions.

So, considering the above six conditions and for the heaviest loads in material handling and
industrial applications we select a drop forged casters with double ball bearing nut and ball kingpin
construction that is standard caster with load capacity.

4.8.11 Bearing selection

Figure 4. 9 Bearing

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Our bearing selection is depending on the main base diameter. The following are some the
important factors to consider in our selection process.

A. LOAD

Bearing design varies depending on the size and directions of the forces that they are required to
support.

Forces can be predominately radial, axial (thrust bearings), or bending moments perpendicular to
the main axis.

B. FRICTION

Reducing friction in bearings is often important for efficiency, to reduce wear and to facilitate
extended use at high speeds and to avoid overheating and premature failure of the bearing
essentially, a bearing can reduce friction by virtue of and containing a fluid between surfaces or
by separating the surfaces with an electromagnetic field.

C. SPEED

Different bearing types have different operating speed limits. Speed is typically specified as
maximum relative surface speeds, often specified ft/s or m/s. Generally, there is considerable speed
range overlap between bearing types. Plain bearings typically handle only lower speeds, rolling
element bearings are faster, followed by fluid bearings and finally magnetic bearings which are
limited ultimately by centripetal force overcoming material strength.

D. STIFFNESS

A second source of motion is elasticity in the bearing itself. For example, the balls in a ball bearing
are like stiff rubber, and under load deform from round to a slightly flattened shape. The race is
also elastic and develops a slight dent where the ball presses on it.

The stiffness of a bearing is how the distance between the parts which are separated by the bearing
varies with applied load. With fluid bearings it is due to how the pressure of the fluid varies with
the gap (when correctly loaded, fluid bearings are typically stiffer than rolling element bearings).

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4.8.13 Hydraulics system design

Working of hydraulic jack

Hydraulic jack works on the principle of –Pascal’s laws. When the handle is operated, the plunger
reciprocates then the oil from the reservoirs is sucked into the plunger cylinder during upward
stroke of the plunger cylinder is delivered into the ram cylinder during the downward stroke of the
plunger through the delivery valve. This pressurized oil lifts the load up, which is placed on top
plate of the ram. After the work is completed the pressure in the ram cylinder is released
unscrewing the lowering screw thus the pressure release and the ram is lowered, then oil is rushed
into the reservoir. It consists of plunger cylinder on one side and ram cylinder on the other side.
These two cylinders are mounted on base which is made of mild steel. Plunger cylinder consists
of plunger which is used to build up the pressure by operating the handle. Plunger cylinder consists
of two non-return valves i.e. one for suction and other for delivery. Ram cylinder connected to
delivery valve of plunger cylinder. It is also consisting of lowering screw this is nothing but a hand
operated valve used for releasing the pressure in the ram cylinder for get down the load.

➢ Specification of hydraulic jack

✓ Rated capacity in tone
✓ Jack dimensions
✓ Lifting range in –cm
✓ Oil capacity in -cc
✓ Net weight in -kg
➢ Classification of hydraulic jack

A) According to the source of power

▪ Manually operated jacks (hand or pedal operated)

▪ Power operated jacks (pump is used
B) According to the lift of ram
▪ High lift
▪ Medium lift
▪ Low lift

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C) According to the arrangement of cylinder

▪ Vertical
▪ Horizontal
▪ Inclined
D) According to the number of cylinders
▪ Single cylinder
▪ Multi cylinder
E) According to the construction
▪ Floor mounted jack
▪ Bottle jack
▪ Trolley jack
➢ Design consideration and methodology
➢ Load (w) = 10KN
➢ Man effort handle (e) =5kg
➢ Factor of safety =3
4.8.14 Design of cylinder

Figure 4. 10 Cylinder

A cylinder is a device which converts a fluid power in to a linear mechanical force and motions. It
usually consists of a moveable parts or elements such as piston and piston rod within the cylinder

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bore. Cylinder is designed based on the hoop stress and longitudinal stress produced inside the
cylinder bore due to the internal pressure and maximum sheer stress applied on it because of
frictions created when there are losses in cylinder due to

• Oil pressure inside cylinder

• Pre-load of seal and

• Size of the sealing surface

Material selection: - Standard pipe with the following selections

➢ Wrought iron have the properties corrosion resistance, cheaper, economically computed to
casting, suitable to the intended purpose and substitute low carbon steel

Known data

➢ 𝜎𝑡 = 450 𝑀𝑝𝑎

➢ 𝜎𝑦 = 270 𝑀𝑝𝑎

➢ 𝜎𝜏𝑎𝑙𝑙 = 0.5 ∗ 𝜎𝑦 = 270 ∗ 0.5 = 135 𝑀𝑝𝑎

270
➢ 𝜎𝑎𝑙𝑙 = = 90𝑀𝑝𝑎
3

➢ 𝑓. 𝑠 =3

Assume the optimum internal diameter of the cylinder at the load is 60 mm.

The maximum internal pressure at minimum lifting height is

𝐹 𝐹 19.99𝐾𝑁
𝑃= = 2= = 7.1 𝑁⁄𝑚𝑚2
𝐴 𝜋𝑟 𝜋(30)2

Then we know that thickness of the cylinder

𝜎 +𝑃 90+7.1
𝑡 = 𝑟𝑖 [√𝜎𝑎𝑙𝑙 −𝑃 − 1] = 30 [√90−7.1 − 1] = 2.46mm ≈ 3mm for safety
𝑎𝑙𝑙

External diameter (do) = di + 2*t = 60+ 2*3 =66mm

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To determine the type of cylinder the load is: -

𝑡 3
= = 0.1
𝑑𝑖 30

1
This means, since 0.1 ≥ the cylinder is thick cylinder and this type of shell used in high
15

pressure cylinders production.

Check for longitudinal stress:

𝑃𝑑𝑖 7 ∗ 60
𝜎𝑙 = = = 35.5𝑚𝑝𝑎
4∗𝑡 4∗3

Check for hoop stress for cylinder part:

𝑃𝑑𝑖 7 ∗ 60
𝜎ℎ = = = 71 𝑚𝑝𝑎
2∗𝑡 2∗3

After having both hoop stress and longitudinal stress produced due to the internal pressure it
possible to determine the maximum shear stress created in the internal part of cylinder:
𝜎1 −𝜎3
𝜏𝑚𝑎𝑥 = , when 𝜎1 = 𝜎ℎ , 𝜎2 = 𝜎1 , 𝜎3 = 0 and 𝜎1 > 𝜎2 > 𝜎3
2

𝜎ℎ − 𝜎3 71 − 0
∴ 𝜏𝑚𝑎𝑥 = = = 35.5𝑚𝑝𝑎
2 2

Form the given data the allowable shear stress is 135mpa.

𝜏𝑚𝑎𝑥 < 𝜏𝑎𝑙𝑙 → 35.5𝑚𝑝𝑎 < 135𝑚𝑝𝑎

The design is safe.

Based on the above force analysis the maximum length of the cylinder should be 600mm.

The induced shear stress created over the cylinder surface is given by;

𝐹 20000
𝜏𝑖𝑛𝑑 = = = 0.177𝑚𝑝𝑎
𝜋𝑑𝑖 𝐿 𝜋 ∗ 60 ∗ 600

Since the induced shear stress is less than the allowable shear stress it is safe!

𝜏𝑖𝑛𝑑 < 𝜏𝑚𝑎𝑥 → 0.177 < 35.5𝑚𝑝𝑎 Hence, the design is safe.

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Design of piston rod

Figure 4. 11 piston rod

A piston rod is a rod like material or parts of the hydraulic system on which the main lode is
anchored and lifted to the required height or length. Short compression member subjected to
centrally apply may be designed on bases of direct comparison. However, long columns whose
slenderness ratio is greater are classified as columns and fail buckling. Therefore, they need to
consider the critical lode. Safe lode is the actual lode which a column can stand safely.

But in here the piston rod is subjected to fluctuating stress imposed due to variable lode for
different position of the hydraulic handling system.

Material selection: -

Due the nature of the lode acting on the piston rod the material we select is we select stainless
steel) because it has good yield strength(205MPa), tensile(UTS) strength(510MPa), good fracture
toughness, good resistance of temperature, good corrosion resistance and it can fabricate in
different mated except casting. Cold rolled, AISI 1035 having,

𝜎y =205MPa

𝜎ut =510mpa

E=207Gpa

G=89GPa

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Assumptions:

Ka (load correction factor) =0.8

Ke (fatigue strength –reduction factor) =1/kf

Kf (factor of fatigue stress concentration) =1.5

Other factors (Kb, Kc, Kd……)

1
Rankin‘s constant ,𝛼 = 7500

Critical stress =150MPa

F.S =3

The piston rod experiences a minimum stress value at the beginning of lowering to maximum
stress at the start of its lift of the same nature with in cycle. The piston rod must have the capacity
to withstand the design load and the intensity of internal pressure, since the load is 20000N.

𝜎𝑚𝑎𝑥 + 𝜎𝑚𝑖𝑛 𝜎𝑚𝑎𝑥 − 𝜎𝑚𝑖𝑛

𝜎𝑚 = 𝑎𝑛𝑑 𝜎𝑣 =
2 2

where 𝜎𝑚 – 𝑚𝑒𝑎𝑛 𝑠𝑡𝑟𝑒𝑠𝑠,

𝜎𝑣 − 𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑠𝑡𝑟𝑒𝑠𝑠

𝜎𝑚𝑎𝑥 − 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑠𝑡𝑟𝑒𝑠𝑠

𝜎𝑚𝑖𝑛 − 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑠𝑡𝑟𝑒𝑠𝑠 .

When hydraulic system is at the minimum lifting height from horizontal a compression force of
the load is 20000N. Since, the piston rod is circular in shape the cross-sectional area is given by;

𝜋𝑟 2
𝐹 = 𝜎 × 𝐴, 𝐴=
4

𝐹𝑚𝑎𝑥 4 × 20000𝑁 25464.79

𝜎𝑚𝑎𝑥 = = =
𝜋𝑑 2 𝜋𝑑 2 𝑑2
4

𝜎𝑚𝑖𝑛 = 0

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25464,79
+ 0 12732.4
𝜎𝑚 = 𝑑2 =
2 𝑑2

𝜎𝑚𝑎𝑥 − 𝜎𝑚𝑖𝑛 𝜎𝑚𝑎𝑥 − 0 𝜎𝑚𝑎𝑥 1732.4

𝜎𝑣 = = = =
2 2 2 𝑑2

The maximum safe stress which can be applied the load to the piston rod while working stress is
given by Se, where Se is fatigue endurance strength.

1 1
𝑆𝑒 = (𝑚𝑎𝑖𝑛 𝑓𝑎𝑐𝑡𝑜𝑟) × 𝜎𝑦 = (𝐾𝑎 × 𝐾𝑏 × 𝐾𝑐 × 𝐾𝑑 × 𝐾𝑒 × 𝐾𝑓 ) × 𝜎𝑦
2 2

1
𝑆𝑒 = (0.8 × 0.6667 × 1.5) × 205𝑚𝑝𝑎 𝑤ℎ𝑒𝑟𝑒, 𝐾𝑏 = 𝐾𝑐 = 𝐾𝑑 = 1 𝑓𝑜𝑟 𝑎𝑥𝑖𝑎𝑙 𝑙𝑜𝑎𝑑𝑖𝑛𝑔
2

Se =82mpa

From Good man stress

1 𝜎𝑣 𝜎𝑚
= +
𝐹. 𝑆 𝑆𝑒 𝜎𝑦

1273.4 12732.4
1 𝑑2 + 𝑑2 155.27 62.2
= = + 2
3 82 205 𝑑2 𝑑

𝑑 = √652. 42 = 25.54𝑚𝑚

Fatigue is related to cross section only but buckling needs the effective length to be considered.
Therefore, failure by fatigue may not be assurance for buckling use Rankins theory formula and
the piston rod ends considered to be fixed.

𝜎𝑐 × 𝐴
𝑃𝑐𝑟 = , 𝑤ℎ𝑒𝑟𝑒 𝑃𝑐𝑟 − 𝑐𝑟𝑖𝑡𝑖𝑐𝑎𝑙 𝑙𝑜𝑎𝑑, 𝜎𝑐 − 𝑐𝑟𝑖𝑡𝑖𝑐𝑎 − 𝑙 𝑠𝑡𝑟𝑒𝑠𝑠,
𝐿
1 + 𝑎 ( 𝐾𝑒 ) 2

𝐴 − 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑎𝑟𝑒𝑎, 𝐾 − 𝑟𝑎𝑑𝑖𝑢𝑠 𝑜𝑓 𝑔𝑦𝑟𝑎𝑡𝑖𝑜𝑛, 𝐿𝑒 − 𝑅𝑎𝑛𝑘𝑖𝑛𝑒𝑠 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡

𝜋𝑑2 𝜋(25.54)2
𝐴= = = 512.31𝑚𝑚2
4 4

𝐼
𝐾=√ , 𝑤ℎ𝑒𝑟𝑒 𝐼 − 𝑚𝑜𝑚𝑚𝑒𝑛𝑡 𝑜𝑓 𝑖𝑛𝑒𝑟𝑡𝑖𝑎
𝐾

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𝜋𝑑4
4 × (25.54)2
𝐾 = √ 642 = √ = 6.385
𝜋𝑑 64
4

Pcr =Fmax *F.S =20000*F.S

Le =a/2, a=600mm, therefore Le =245mm

Then substituting;

𝜎𝑐 × 𝐴 150 × 512.31
20000 × 𝐹. 𝑆 = =
𝐿 1 240
1 + 𝑎 ( 𝐾𝑒 ) 2 1 + ( )2
7500 6.385

768486.5
20000 × 𝐹. 𝑠 = = 64551.7
1.19

𝐹. 𝑆 = 3.3 𝑖𝑡𝑠 𝑠𝑎𝑓𝑒 𝑑𝑒𝑠𝑖𝑔𝑛 𝑏𝑒𝑐𝑎𝑢𝑠𝑒 3 ≤ 𝐹. 𝑠 ≤ 6

➢ Design of piston head

Piston head is circular in shape connected to the piston rod found inside a cylinder.

ASSUMPTION

• The head is determined by treating as a flat circular plate

• It has uniform thickness at the outer edge

• It is subjected to uniform distributed load due to the fluid pressure over internal cross
section.

Material selection

Based on the application and the material is exposed to the pressure of the fluid: thus the material
must be strong. Regarding this we select iron based super alloy steel.

Austenic AM350:

Tensile strength =1413MPa

Yield strength =1207MPa

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Modulus of elasticity =20.3Gpa

Since the piston head is assumed a flat circular object, neglecting bending of the head due to the
applied load and internal fluid.
𝜋 𝜋
𝑃𝑓 ( 4 𝐷ℎ 2 ) − 𝑃𝑎𝑡𝑚 [4 (𝐷ℎ 2 − 𝐷𝑟 2 )] − 𝑅 = 0

Where;

Pf = pressure developed by working fluid

Patm = atmospheric pressure which is equal to 101.325kpa=101.1bar

R= the applied load which is 10KN

Dr= diameter of the piston rod

Dh= diameter of the piston head

And many hydraulic fluids are working at pressure ranges 50bar to 250bar.

For our design we select 160bar

Substituting the above value in equation;

𝜋 𝜋
 160( 4 𝐷ℎ 2 ) − 101.1𝑏𝑎𝑟[ 4 (𝐷ℎ 2 − 25.542 )] − 10𝐾𝑁 = 0

125.66 × 𝐷ℎ 2 − 79.4 × 𝐷ℎ 2 − 51794.4 − 10000 = 0

46.26𝐷ℎ 2 = 41794.4

𝐷ℎ = 30.05𝑚𝑚

Diameter of piston head equal to 30.05mm.

Thickness of piston head

3𝑃 ×𝐷 2
𝑓 ℎ 3×160×30.052
𝑡 = √ 16×𝜎 =√ = 4.81𝑚𝑚 ≈ 5𝑚𝑚
𝑎𝑖𝑖 16×1207

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CHAPTER FIVE
Conclusion
Over all the internship enabled us to link and strengthen the theoretical knowledge we grasped in
our university stay and the practical knowledge in the outside industry world. Specifically, the
courses such as IC Engine, Design of Machine Element, Hydraulics and Pneumatics we took in
the Jimma University, were directly related to the hands-on practical training we had to in
maintenance of engine, gearbox, design of lifting machine. Combining the backgrounds, we
obtained from JU and LVMD.

The machine construction concept is identifying the handling hardship after we made a lot of
observation in the maintenance shop and assembly shop. The design of engine lifting machine
involves efforts to improve every necessary function of the traditional handling method. This
manually operated handling machine must have an excellent working principle compared to that
of the traditional one. This design has made improvements over crane working duration, easy
maintained and take small area. It is certainly faster, will allow lifting a load quicker and lift
maximum load up to 1000kg or 1 tone weight.

The selection evaluated with respect to the company need and other criteria, comparing the relative
strengths and weakness of the concepts, for further investigation. The current machine design used
has been chosen to become reference concept, against which all other concepts are rated.

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Recommendation
• We design the engine lifting machine that manually actuated, if everybody modifies our
project it is better to refer our documentation.
• We recommended all the companies in our country to use our project work in order to save
time and to be more productive.
• We recommended LVMD to allow material for internship students participate on
prototype.
• We only made the complete design of engine lifting machine. cost analysis is not included
due to the absence of manufacturing part is in the project.

Additionally, in each shop there is not enough lifting machine to lifting and lowering spare parts
vehicles, so in the future it is better to use our project to save time and avoid manual labor.

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Reference
❖ Automotive Engineering powertrain, chassis system and vehicle body, book, edited by
David A. Crolla, first edition 2009
❖ Advanced vehicle technology, by Heniz Heisler, second edition
❖ The motor vehicle 13th, Thirteenth edition T.K. GARRET Eng.
❖ http://www.sea.org/students/presentations/breaks_by_paul_s_gritt.pdf
❖ http://www.brakeo.com/brakes.pdf
❖ Shigley’s mechanical engineering design
❖ Machines and mechanisms fourth edition David H. Myszka
❖ A text book of machine design by R.S KHURMI
❖ Design of machineries by Norton second edition

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Appendices

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