ARBA MINCH UNIVERSITY

INISTITUTE OF THECHNOLOGY
Dep'tMe chanicalEn
gineerin g
Title; DESIGN OF ENGINE
STAND
Pursued At: Ethiopian Road Authority Nekemte District.
Department of: Mechanical Engineering (Auto Motive Engineering)

Name Of Students
1. Dagagaa Taganye
2. Kaleb
3. Samuel Raga
4. Dinka

Advisor Name: ______________

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 DECLARATION
We certify that the idea, design and experimental works, results, analyses and conclusions set
out in this project are entirely our own further certify that the work is original and has in any
other course or institution except where specifically stated. To certify that our work is
original, we are giving the following signature accordingly.
INTERNEE
Signature:
Date:
HEAD OF THE DEPARTMENT
Mechanical Eng. Dep’t Arba Minch University
Signature:
Internship
Project effort except where other indicated and acknowledged. We were not previously
submitted for the assessment.
Internal Examiner
1. Name: __________________________
Signature: _______________________
Date: ___________________________
2. Name: __________________________
Signature: _______________________
Date: ___________________________
3. Name: __________________________
Signature: _______________________
Date:___________________________

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 ACKNOWLEDGMENT
First of all, we would like to thanks our Almighty GOD. Next to that we would like to
thanks our advisor at Ethiopian Road Authority Nekemte district Mr. Adisu Mesele
for advising us in such a good manner. Again, we are greatly indebted to all lecturers
of Mechanical Engineering Department. We have special thanks to all staff members
of Mechanical Engineering Department for their valuable commitment to make us
interested in Mechanical Engineering. Our acknowledgement also extends to
ETHIOPIAN ROAD AUTHORITY because the company for allowing us to practice
our internship program for first time from Arba Minch Universitywhich had lasted for
about four months. During our stay the staffs of the HUMAN RESOURCE
MANAGEMENT (HRM) were very encouraging, helpful and supportive. Our special
thanks go to our Advisor ______________and to all of the follow workers for their
concern, support and encouragement. We are grateful to our relatives and friends for
their encouragement and wishes of successful accomplishment.

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 ABSTRACT

Engine stands are the most essential devices for a company like the Ethoipian Road Authority
Nekemte District. Because this company deals with the maintenance of earth-moving vehicles.
Surprisingly, there are no proper engine stands in the maintenance workshops of the company
which directly lead to the need for design and maintenance of heavy duty engine stand. The
purpose of this project is to design and manufacture engine stand which is believed to greatly
improve the current working condition of the engine maintenance workshop. The current engine
stands in the workshops are not safe for both the engine and the workers. Also, it does not allow
for effortless and quick maintenance. If this project is carried out it will have significant
contribution for the improvement of engine maintenance as well as productivity of the industry.
The projects will cost less than the cost of damages to engines during the current maintenance
condition of the company’s workshops. Therefore, if the project is approved it is guaranteed to
increase the maintenance safty of the company.

III
Contents
DECLARATION...........................................................................................................................................................II
ACKNOWLEDGMENT...............................................................................................................................................III
ABSTRACT.................................................................................................................................................................IV
CHAPTERONE..............................................................................................................................................................1
INTRODUCTION..........................................................................................................................................................1
1.3 Organizational Profile and Location.....................................................................................................................2
1.3.1 Size of the Company and Types of Agency...................................................................................................3
1.3.1 Vision of ERA................................................................................................................................................3
1.3.2 Mission of ERA.............................................................................................................................................3
1.4 OrganizationalStructure........................................................................................................................................4
1.4.1CorporatePlanningandBusinessDevelopmentDivision...................................................................................4
1.4.2 Road Construction Division...........................................................................................................................5
1.4.3 Equipment Management and Maintenance Division.....................................................................................5
1.4.4 Purchase and Supply Division.......................................................................................................................5
1.4.5 Finance Management Division......................................................................................................................5
1.4.6 Human Resource Management Division.......................................................................................................6
1.4.7 ICT and Organizational Development Division............................................................................................6
1.4.8 Internal Auditing Services Division...............................................................................................................6
1.4.9 Legal Services Division.................................................................................................................................7
1. 5 Main Purposes Of The Establishment Of ERA...................................................................................................7
CHAPTER TWO............................................................................................................................................................8
WORK RESPONSIBILITY AND ASSIGHNMENT....................................................................................................8
2.1 Work Responsibility.............................................................................................................................................8
2.1.1 Engine Maintenance Shop.............................................................................................................................8
2.1.1 Machine Shop..............................................................................................................................................10
2.1.3 Body Repairing Shop...................................................................................................................................10
2.1.4 Electricity Shop............................................................................................................................................11
2.1.5 Lubrication And Cleaning Shop..................................................................................................................11
2.1.6 Tire Repairing Shop.....................................................................................................................................11
2.2 Major Vehicle System.........................................................................................................................................12
2.2.1 Fuel System..................................................................................................................................................12
2.2.2 Ignition System............................................................................................................................................12
2.2.3 Starting system.............................................................................................................................................12
2.2.4 Charging System..........................................................................................................................................13
2.2.7 Purpose of the cooling system.....................................................................................................................13

IV
 2.2.8 Lubrication System......................................................................................................................................14
2.3 Basic Engine Parts..............................................................................................................................................15
2.4 Some Components Of The Engine.....................................................................................................................15
2.5 Auto Electricity...................................................................................................................................................17
2.5.1 Starter Motor Problem And Solution...........................................................................................................18
2.6 Suspension System..............................................................................................................................................18
2.6.1 Component Of Suspension System..............................................................................................................19
2.7 Brake System......................................................................................................................................................20
2.7.1 Air Brake System.........................................................................................................................................20
2.7.2 Hydraulic brake system................................................................................................................................20
2.7.3 Mechanical Brake System............................................................................................................................21
2.8 Motor Vehicle Work Shop Tools........................................................................................................................22
2.9 Challenges During Internship.............................................................................................................................23
2.10 Theoretical Knowledge.....................................................................................................................................23
2.11 Entrepreneurship Skills.....................................................................................................................................23
2.11.1 Practical Skills...........................................................................................................................................24
2.11.2 Team Playing Skill.....................................................................................................................................25
2.11.3 Leadership Skills........................................................................................................................................25
2.12 Work Ethics......................................................................................................................................................26
2.13 Value Of Academic Background During Internship........................................................................................28
2.13.1 Academic Requirement..............................................................................................................................28
2.13.2 Importance Of Additional Coursework Prior To Intern............................................................................28
2.14 Detailed personal critique of self......................................................................................................................28
2.15 Professional Growth..........................................................................................................................................29
CHAPTERTHREE.......................................................................................................................................................30
Technical Aspect Of The Internship.............................................................................................................................30
3.1.2. Specific Objectives.....................................................................................................................................30
3.2. Methods And Procedures While Working.........................................................................................................30
3.3. Technical Tasks /Products.................................................................................................................................31
3.3.1. Short Term Check Ups................................................................................................................................31
3.3.2. Long Term Check Ups................................................................................................................................33
3.3.3. Seasonal Check Ups....................................................................................................................................34
3.4 Knowledge and Acquaintances Acquired...........................................................................................................35
3.4.1. Practical Skill..............................................................................................................................................35
3.4.2. Inter Personal Communication Skill...........................................................................................................36
3.4.3. Use Of Interpersonal Communication........................................................................................................36
3.4.4. Team Playing Skill......................................................................................................................................36
3.4.5. Leadership skills.........................................................................................................................................36
3.4.6. Work ethics.................................................................................................................................................37

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 3.4.7. Entrepreneur skills......................................................................................................................................37
3.5. Problem Encountered During TheInternship Period..........................................................................................38
CHAPTER FOUR.........................................................................................................................................................39
4. PROJECT CARRIED OUT......................................................................................................................................39
4.1 INTRODUCTION..............................................................................................................................................39
4.1.1ENGINE STAND.........................................................................................................................................39
4.2 STATEMENT OF THE PROBLEM..................................................................................................................39
4.3 Objectives...........................................................................................................................................................40
4.3.1 General Objective........................................................................................................................................40
4.3.2 Specific Objectives......................................................................................................................................40
4.4 Significant Of The Project..................................................................................................................................40
4.5 Scope Of The Project..........................................................................................................................................40
4.5.1 Types Of Engine Stands...............................................................................................................................40
4.6 Literature Survey................................................................................................................................................42
4.7 Material Selection...............................................................................................................................................42
4.8 Project Methodology And Material Selection....................................................................................................43
4.8.1 Project Management....................................................................................................................................43
4.8.2 Data Collection............................................................................................................................................43
4.8.3 Data Analysis Method..................................................................................................................................44
4.9 Design Process....................................................................................................................................................44
4.9.1 Function Structure........................................................................................................................................44
4.9.2 Design Concept Generation.........................................................................................................................44
4.9.3 Design Concept Evaluation..........................................................................................................................45
4.9.4 Product Definition........................................................................................................................................45
4.10 Working Principles...........................................................................................................................................48
4.11 Design Calculation............................................................................................................................................49
4.11.1 Design Of Worm........................................................................................................................................49
4.11.2 Design Of Worm Gear...............................................................................................................................50
4.11.3 Design Of Worm Shaft..............................................................................................................................53
4.11.4 Checking For Self Locking Of The Worm................................................................................................55
4.11.5 Design Of Worm Gear Shaft......................................................................................................................55
4.11.6 Bearing Selection Of The Worm...............................................................................................................56
4.11.7 Bearing Selection Of The Worm Gear.......................................................................................................58
4.11.8 Design Of Key For Worm Gear.................................................................................................................59
4.11.9 Design Of Bolts..........................................................................................................................................60
4.11.10 Design Of Column...................................................................................................................................61
4.11.11 Design Of Lever Arm..............................................................................................................................62
CHAPTER FIVE..........................................................................................................................................................64
CONCLUSION AND RECOMMENDATION............................................................................................................64

VI
5.1 Conclusion..........................................................................................................................................................64

VII
 CHAPTERONE

INTRODUCTION
Internship serves as an introduction to industrial company (mechanical company) and thus provides the
student basic knowledge essential to this profession. Internship program is to increase the practical
knowledge of students. Opportunity to not only use and develop industry enhances some of the skills
that are transferable to any professional work setting. Design to provide general insights, business or
organizational contexts or the significance of technical and engineering professions in our society.
Depending on the inclinations of the part of the internship offers considerable leeway and individual
responsibility in deciding how to structure the practical training. This allows the student to individually
design the engineering internship in accordance with the activities outlined in the training and
education plan. An internship program is prepared for students to develop practical knowledge,
problem solving ability and confidence of students. Pursuing an internship can assist you in develop of
your strengths, values and interests which will enable you to better align your personal and professional
direction. Material handling is one of many factors that contribute to the improvement of a company’s
performance. Materials handling is the movement, storage, control and protection of materials, goods,
and products throughout the process of manufacturing, distribution, consumption and disposal. The
primary objective of a material handling system is to reduce the unit cost of production.
 Asphalt road construction
 Gravel road construction
 Bridge construction
Ethiopian construction works:
 To work as a contractor and carry out road and bridge construction, maintenance and
enhancement works in Ethiopia as well as other countries.
 The Corporation will also provide construction equipment and machineries maintenance
services.
 The Corporation will also provide construction equipment and machineries and rental.
 The Corporation also plans to manufacture construction equipment and sale.
 To perform other related activities to achieve its goal.

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1.3 Organizational Profile and Location
ERA has reorganized its operations and regulatory departments as independent institutions. The
former Operations Department has been reorganized as a public contractor as Ethiopian Roads
Construction Corporation (ERCCO) by council of Ministries Regulation No.248/2011 with the
purposes of Engaging in domestic and overseas and the Regulatory Department has been
reorganized as ERA by council of Ministries Regulation No.247/2011 with responsibility to plan
and manage the road network and supervise road works and is accountable to Ministry of
Transport. The highest authority of ERA is laid on the Board of Directors. ERA is directed by
the Chief Executive Office called the Director General. Under the Director General there are
three Deputy Director Generals (DDGs). These are Deputy Director General of Planning & ICT,
Engineering Operations Deputy Director General, and Human Resource & Finance Deputy
Director General.
Location: The corporation has its head office located in Guard Shola, Addis Ababa. In addition
to this, the corporation through its business units has many projects located all around the
country. ERA of Nekemte district is found in East Wallaga, Oromia national regional state. It is
1Km from Wallaga University West
Table 1-1 Distribution network ofERAareasfollows

Branches Status
Addis Ababa Head Office
Nekemte Operatingbranch
Adigrat >>
Gondar >>
Jimma >>
Kombolcha >>
Debre-Markos >>
Dire-Dawa >>
Shashemene >>
Alemgena >>
Sodo >>

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1.3.1 Size of the Company and Types of Agency
Ethiopian Road Authority has an authorized capital of Ethiopian birr 20 billion. This shows that
the corporation is the biggest constructions company in the country, In addition to this the
corporation currently more than 15,000 workers. This also makes it the largest construction
company in terms job opportunity creation.

Types of Agency: The corporation is a result of the amalgamation of two formerly independent
public enterprises, namely the Ethiopian Road Construction Corporation and the Ethiopian Water
Works Construction Enterprise.

Figure1- 1-Nekemte District ERA

1.3 Vision and Mission of Company
1.3.1 Vision of ERA
The Ethiopian Road Authority is dedicated to become a world-renowned competent
ConstructionCompany in 2026 G.C.

1.3.2 Mission of ERA

➢ To satisfy the customers and stakeholders of the Corporation by delivering:
 Roads and bridges construction, rehabilitation, upgrading and maintenance.
 Construction equipment and machineries maintenance.
 Construction materials production and sales.

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  Services timely, with competitive price and environmentally friendly manner.

➢ To engage in domestic and overseas construction works as a contractor in constructing,

upgrading and maintaining roads, bridges and other civil works
➢ To engage in the business of maintaining construction equipment and machinery
➢ To engage in the rental business of construction equipment and machinery.
➢ To undertake in any other related activities necessary for the attainment of its purposes

1.4 Organizational Structure

Figure1- 2 Organizational Structure

1.4.1CorporatePlanningandBusinessDevelopmentDivision
Main functions:
➢ Annual operational planning.
➢ Road construction and maintenance single price division.
➢ Preparing the budget for the corporation’s head office and its projects as well as insure
implementing the working plan.

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➢ Preparing corporate evaluation reports for upper management.

1.4.2 Road Construction Division

Main functions:
➢ Enabling the Ethiopian Road Construction Corporation’s road construction projects to
achieve their goals and the entire corporation to maintain its competitiveness in the
Construction Industry.
➢ Conducting construction works according to standards.
➢ Providing the necessary components for road construction projects on a timely and
balanced basis.
➢ Following and evaluating the completion of road construction projects.

1.4.3 Equipment Management and Maintenance Division

Main function:
➢ Strengthen the central equipment work unit and provide the necessary maintenance for
the equipment.
➢ Production of various spare parts to reduce shortages and cost.
➢ Inspecting equipment regularly and providing maintenance for their proper
functioning
1.4.4 Purchase and Supply Division
Main function:
➢ Conducting single and collective purchases and distribution of purchased items
1.4.5 Finance Management Division
Main functions:
➢ Until the middle of the fiscal year, the Cooperation should register any property it took
over from ERA and gives new ID number before the end of the fiscal year.
➢ Closing accounts at the end of the budget year.
➢ Payment of government imposed charges on a timely manner.

1.4.6 Human Resource Management Division

Main functions:

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 ➢ Planning and implementing the corporation’s human resource requirements and
supply.
➢ Regularly training provided by the department and implementing teaching programs.
➢ Providing general services for the corporation’s head office.

1.4.7 ICT and Organizational Development Division

Main functions:
➢ Implementing and regulating new changes to the corporation.
➢ Guiding the corporation’s department heads and employees towards conducting
proper business environment practices.
➢ Implementing a system that measure the success of department heads and rewards
them accordingly.
➢ Conducting studies on methods of improving the corporation’s resource management
and efficiency.
➢ Providing a network to allow for efficient communication within the corporation,
allowing for information follow-up and better decision making.
1.4.8 Internal Auditing Services Division

Main functions:
Prepare a sampling report that to analyze the risk and work processes, including equipment
maintenance, purchases, supply, and finances, of the road construction and maintenance projects
relying on the other departments in the head office. The report includes data on finance, assets,
management, and information technology.
Prepare a sampling report on the working progress, operations, and targets of the road
construction and maintenance projects as well as the head office.
Identifying current operation problems that interfere with the corporation’s goal in order improve
the practices.
1.4.9 Legal Services Division
Main functions:

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Following up on open cases incoming and prepare appropriate respond and arguments for
ongoing court cases of the corporation and preparing adequate information in order to protect the
interest of the corporation.

1. 5 Main Purposes Of The Establishment Of ERA.

 To engage in the business of maintaining construction equipment and machinery.
 To engage in the rental business of construction equipment and machinery.
 To produce and sell construction materials.
 To undertake in any other related activities necessary for the attainment of its purposes.
 To solve the problem, arise related with the road quality in Ethiopia.
 To give standardized car maintenance, repair replacement of the parts.

 To design and production of the materials for car replacement

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 CHAPTER TWO

WORK RESPONSIBILITY AND ASSIGHNMENT

2.1 Work Responsibility

The shop is mainly opened for the purpose of keeping vehicles and machines long life and also
giving maintenance and repair on site to let the work not to stop. It has its own structures for
performing the tasks. It has different sub division of workshops to accomplish different tasks
such as:
1. Engine maintenance shop
2. Machine shop
3. Body repairing shop
4. Electricity shop
5. Welding shop
6. Lubrication and cleaning shop
7. Tire repairing shop

2.1.1 Engine Maintenance Shop

In this shop the engine of heavy duty and light duty vehicles overhaul maintenance were
performed. Engine is one of the largest parts of the vehicles and has different part that assembles
on it. It is composed of three main parts.
These are:
Cylinder head
Cylinder block (main block) and
Crank case.
In engine repair shop there are many tasks could be done. These tasks have their own steps.
These are disassembling, washing, inspection, maintenance and assembly.

a) Disassembling
In this stage’s engines disassembled into components and parts. All parts of engines will be
disassembled and small parts such as bolts, nuts, etc. put in a dish. Similarly, crank shaft, piston

8
head, and other heavy parts will be hosted by the crane and sit on washing machine. There is no
different method or unique machine to disassembling process simply uses a number of wrenches.

b) Washing
After disassembling, parts and components of engines will be washed. This washing machine
initially used steam to wash. But now it is not working and instead of steam it uses hot water.

c) Inspection
After parts have been washed, the next stage will be inspection. The first part of the inspection
process will be the visual inspection. Through this process we will recognize if there are any
problems like, crack and breakage on the engine housing and the other part.

d) Maintenance
After the parts of engine (mainly the crank shaft, camshaft and engine cylinder) have been
inspected, if there is a faulty part it will have to be maintained to suitable value.

e) Assembly
Unlike disassembling work group, the assembly section follows a set of procedures as set by
manufacturer on the manual. Special tools may be used in assembly specific to the part that will
be assembled. Most of these tools are custom made to lessen the difficulty and reduce the time
that the assembly process causes.

Figure 2- 1 Engine Maintenance Shop

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2.1.1 Machine Shop
In this shop there are different types of machines like lathe, milling, shaper, hydraulic press and
drilling machine were found to modify or to make the different vehicle parts and construction
equipment. In a machine shop, machinists use machine tools and cutting tools to make parts that
can make in the shop like gears for gearbox as bolts, shafts, bushes and washers.
Lathe machine: It is one of the most versatile and widely used machine tools all over the world.
It is commonly known as the mother of all other machine tool. The main function of a lathe
machine is to remove metal from a job to give it the required shape and size.
Hydraulic press machine: This is the machine used for press and disassembles different
cylindrical attached parts like piston line.
Drilling machine: It is a machine tool designed for drilling holes in metals. It is one of the
most important and versatile machine tools in a workshop in drilling machine the drill is
rotated and feed along its axis of rotation in the stationary work piece
Shaper machine: is a machine tool in which the plane and flat surface is produced by a single
point cutting tool by a reciprocating motion. In which the ram moves the cutting tool backward
and forward in a straight line to generate the flat surface. The flat surface may be horizontal or
vertical. Operations performed on shaper machines are all type of flat surfaces which may be
horizontal, inclined, or vertical.

2.1.3 Body Repairing Shop

In this shop there are many types of job to be performed but the mains are maintaining
body, forging body and painting, servicing the mirror, Radiator welding and etc. Body shop is a
part 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 steps.
These are;
 Disassembly of the vehicle/Body parts
 Making strut of the body if it is necessary
 Welding, grinding and etc. of the body if it is necessary.
A. Painting shop: different types of cars were painted in this painting room after their body
would be completely finished. And this shop must be cleaned and out of dust.

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B. Body building shop: if the body of the cars were damaged by accident or by any other
reason, their body were changed or repaired in this shop. But there is shortage of some machines
applicable for body reparation like bending machine. Mostly they did by welding (oxyacetylene)
and arc welding

Figure 2- 2 Body replacing shop

2.1.4 Electricity Shop

In this shop the vehicle electric system maintains such as battery functionality, lighting systems,
starter motor and alternator.
To repairing and assembling of different electrical components of vehicles such as:
 Charging system
 Starting system, lighting system
 Battery, power generating and transfer to different accessories of the vehicle

. Figure 2- 3Electricityshop

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2.1.5 Lubrication And Cleaning Shop
The lubrication system makes sure that every moving part in the engine gets oil so that it can
move easily. The two main parts needing oils are the pistons (so they can slide easily in their
cylinders) and any bearings that allow things like the crankshaft and camshafts to rotate freely. In
most cars, oil is sucked out of the oil pan by the oil pump, run through oil filter to remove any
dirty, and then squirted under, high pressure onto bearings and the cylinder walls. The oil then
trickles down into the sump, where it is collected again and the cycle repeats.
2.1.6 Tire Repairing Shop
In this shop tires were changed and repaired and also air filled to the tire. In this shop there is an
air compressor driven by electric motor is available.

Figure 2- 4Tire Repairing Shop

2.2 Major Vehicle System

1) Fuel system
2) Ignition system
3) Starting system
4) Charging system
5) Lighting system
6) Cooling system
7) Lubrication system
8) Exhaust system
2.2.1 Fuel System
❖ Provides correct mixture of air and fuel for efficient combustion.

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❖ Alters the air-fuel ratio with changes in operating conditions such as engine temperature,
speed, and load.
Fuel system types:
❖ Diesel injection system
❖ Carburetor system.

2.2.2 Ignition System

It needs in gasoline engines to ignite the air fuel mixture to produces an extremely high voltage
surge, which operates the spark plug. An electric arc jumps across the tip of each spark plug at
the correct time, causing the air-fuel mixture to burn
❖ Produces 30,000-volt spark across spark plug.
❖ Distributes high voltage spark to each spark Plug in correct sequences.
❖ Times the spark so it occurs as piston is nearing top dead center.
❖ Varies spark timing with load, speed, and other conditions.

2.2.3 Starting system

An electric starting motor rotates a crankshaft until it “fires” and runs on its power. When the
key is turned to the start position, current flows key is turned to the start position, current flows
the battery through the starting system circuit. The starting motor turns, and the starting motor
pinion gear engages a gear on the flywheel, turning the crankshaft

2.2.4 Charging System

Replaces electrical energy drawn from the battery by forcing electric current back into it. When
the engine is running, the alternator produces electricity to recharge the battery and operate other
electrical devices. The voltage regulator controls system voltage
Recharges battery after cranking
 Supplies the car’s electricity when the engine is running
 Provides output voltage slightly higher than battery
Voltage Components:
1. Alternator
2. Voltage Regulator

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3. Wiring
4. Indicator
5. Drive Belt
2.2.7 Purpose of the cooling system
The cooling system is designed to perform the following jobs.
To maintain the highest and most efficient operating temperature within the engine.
To remove excess heat from the engine.
To bring the engine to the operating temperature as quickly as possible.
Servicing Radiator: Radiator is a heat exchanger that enables heat from the engine coolant to be
transferred to the cooler air that passes through the core. That means its purpose is to allow fresh
air to reduce the temperature of the coolant. The coolant circulates through a radiator core that
exposes a large surface area to air flow. The number and size of tubes and fins determine the
radiator surface and heat transfer ability.
Radiator pressure cap: -To improve cooling efficiency and prevent evaporation surging loss, a
pressure cap is used on the radiators.
Generally, the pressure cap is used to:
 Increase the pressure on the cooling system
 Reduce the capitations system
 Protect the radiators and radiators loses
 Prevent or reduce surging
2.2.8 Lubrication System
The lubrication system makes sure that every moving part in the engine gets oil so that it can
move easily. The two main parts needing oil are the pistons (so they can slide easily in their
cylinders) and any bearings that allow things like the crankshaft and camshafts to rotate freely.
In most cars, oil is sucked out of the oil pan by the oil pump, run through the oil filter to remove
any grit, and then squirted under high pressure onto bearings and the cylinder walls. The oil then
trickles down into the sump, where it is collected again and the cycle repeats.
Function of lubrication oil: While lubricating oil is normally considered to be a substance that
reduces wear and friction between moving surfaces, it performs a number of other important
function in the engine among them.

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1. Minimizes wear: -Without adequate lubrication, bearings would wear rapidly and the heat
generated from friction would cause bearing failure so that the crank shaft and other parts would
be damaged. In sufficient lubrication on the cylinder walls would cause rapid wear and gearing
of the cylinders, pistons and rings.
2. Minimizes heat: - The oil absorbs a lot heat as it cools the cylinder walls and moves around
the piston oil control rings to the inside of each piston. The oil absorbs heat as it flows through
the clearance at the crank shaft main bearings, connecting rod bearing and piston pin cam shaft
bushings. Wherever the oil travels on its journey through the engine, it picks up heat.
3. Forms a seal: - performed by engine lubricating oil is that to help seal pressure within the
combustion chamber of each cylinder. A film of oil on the cylinder wall functions within the
cylinder in two walls. It protects the cylinder walls and piston rings from excessive wear, and it
blocks the escape of gases from the combustion chamber. It accomplishes the layer task by
filling the very small irregularity between the rings and the cylinder walls.
Note: -For an engine in good condition with a proper oil film on the cylinder walls and piston
rings the escape of gases /blow by /is must be zero.
4. Act as a cleaning agent: - As oil circulating through the passages in the engine that direct it to
the bearing and other parts it washes these passages. This oil also washes the metal particles by
product of combustion and other foreign matters from bearings and journal surfaces

2.3 Basic Engine Parts

Engine is the vehicle's main source of power. The engine uses fuel and burns it to produce
mechanical power. It is used to converts Chemical Energy into Mechanical Energy. The heat
produced by the combustion is used to create pressure which is then used to drive a mechanical
device.
Engine consists of three main parts. Those
 Cylinder head
 Cylinder block
 Oil sump
Cylinder head: - it forms the top of the combustion chamber and is exposed to great heat and
pressure. They are casted from cast iron or aluminum alloy. They are machined to take the

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various parts that are attached to or installed in ahead. The cylinder head is used to make
compression and exit process.
It Contains:
 Intake and Exhaust Valves
 Rocker arm
 Rocker shaft
 Different holes for water and oil passages
Cylinder block (Engine block): it is the body of an engine. It houses the crankshaft and has a
bearing surface on which a crankshaft revolves. Many other parts are locating within the cylinder
block. The block is a casting that has large holes for the cylinder bores. It also has;
 Water jackets and coolant passages.
 The crank shaft
 Starter motor
 Water pump and other many parts.

2.4 Some Components Of The Engine

Table2- 1 Component of Engine

✓ Intake valve ✓ Cylinder Head

✓ Crank shaft ✓ Cam shaft
✓ Timing chain ✓ 0il pump
✓ Bearing shell ✓ Water pump
✓ Fly wheel ✓ Exhaust Valve
✓ Valve spring ✓ Piston
✓ Connecting rod ✓ Piston Ring
✓ Cylinder ✓ Inlet Manifold
✓ Exhaust manifold ✓ Rocker Arm
✓ Rocker Cover ✓ Wrist Pin
✓ Valve Spring ✓ Stator Motor
✓ Cam shaft ✓ Fly wheel

A. Connecting Rod
The connecting rod has two principal tasks:

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✓ It connects the piston to the crankshaft.
✓ It converts linear movement (linear force) of the piston in to rotary movement (torque) of
Crank shaft.

Figu
re 2- 5Connecting rod

B. Crankshaft
The task of the crankshaft in a motor vehicle engine is convert the linear force exerted by the
piston and transmitted by connecting rod into the rotary motion; So that the force becomes a
torque. Most of this torque is transmitted to the clutch or transmission vehicle. But small
proportion is needed to drive the valve gear, the oil pump, the distributor, the fuel supply system,
the cooling system and generator. Works with connecting rod used to change reciprocating to
rotary motion and to drive various mechanism to receive power from the piston.
C. Piston
A piston slides up and down a cylinder and pushes the crankshaft around. The piston connects to
the crankshaft via the connecting rods
D. Piston Rings
Each piston has two compression rings and one oil control ring to help seal the piston in the
cylinder.
E. Valves
Valves can be divided into two groups:
➢ Intake valves control the flow of the air/gas mixture into the engine.
➢ Exhaust valves control the flow of exhaust out of the engine

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Figure 2- 6 Exhaust and in take valves
E. Timing Chain/Belt/Gears
These parts are used in different combinations and configurations to connect the crankshaft to the
camshaft. They keep the valves’ opening and closing timed with the piston movement. Timing
belts should be replaced every 100,000 Km or every five years.
Power Train: A car power train system shows that the power transmission starting from the
output shaft that transmit power from engine to the axle shaft of the vehicle. The axle may be
only rear or front axle or for both axle shaft.
Engine => flywheel => pressure plate– transmission-transfer case (transfer box) – propeller shaft
differential (front or rear) – tires and wheels.

2.5 Auto Electricity

This is where the electrical part of the car is checked and repaired. Some of the activities are:
 Check and maintenance of all the lighting system.
 Check and replacement of car battery.
 Check and repair of alternator and starter.
 Check and maintenance of all the electrical system inside the car.
 Check and repair of starter motor.

2.5.1 Starter Motor Problem And Solution

Starter motor is a motor which converts electrical energy in to mechanical energy it transmits
through the drive mechanism to the engine’s flywheel. The starter motor receives electrical
power from the battery.

1 Problem: Vehicle doesn't start at all

Solution:

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  Check battery voltage (12.6 volts no load).
 Check for loose or corroded connections, or bad cables.
 Check fuses and fusible links (if failed, determine cause and correct).
 Test external starter relay or neutral safety switch (if equipped).

2 Problem: Starter just clicks but doesn't start

Solution:
 Check battery voltage (12.6 volts no load).
 Check for loose or corroded connections, or bad cables.
 Check ground straps between engine and chassis.

3 Problem: Starter cranks slowly.

Solution:
 Check battery and connections.
 Check for loose or undersized cables.
 Check for excessive voltage drop (usually caused by loose or dirty connections).
 Check external starter solenoid (if so equipped).

2.6 Suspension System

The main purpose of suspension system is to support the weight of the vehicle.
Suspension system includes spring, shock absorber and axle. The suspension system is located
between the frame and axles, it is designed to mitigate and reduce impact and vibration from the
ground, at the same time to transfer different kinds of forces and torques acting on the wheels
and frame. When an automobile run on a rough road surface the vertical reaction force on the
wheels by the road surface is normally of an impact nature.

2.6.1 Component Of Suspension System

❖ Spring: It absorbs road shocks or impacts due to bump in road by oscillating.
These are: -
 Coil spring

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  -Leaf spring
❖Damper: They reduce the tendency of the carriage unit to continue to “bounce up” and down
on its springs.
A. Rigid (solid) axle suspension
B. Independent suspension system

A. Rigid axle suspension

In rigid axle suspension, a wheel is mounted at each end of a solid, or undivided, axle or axle
housing. This type of suspension has the advantages of strength and low cost, but it provides less
efficiency and comfort than independent suspension. Most passengers’ cars use rigid axle
suspension only at the rear. Rigid-axle front suspension systems are usually found only on heavy
duty vehicles and trucks. Since the axle connects with wheels, any condition that affects one
wheel affects the other. In case one wheel is raised by a bump in the road, the axle will be tilted.
Thus the motion of the raised wheel is passed to the other wheel. Since the frame of the car is
attached to the axle, the car body is also tilted.

B. Independent Suspension systems

Independent suspension systems provide a separate mounting for each wheel. There is no
connection between the wheels as there is when a rigid axle is used. Therefore, the linear motion
of one wheel is not transmitted to the other and there is no tilting of an axle, which in turn might
tilt the entire car. Most independent front suspension systems use coil springs, there are several
methods of mounting the springs. One method is to locate each spring between a lower control
arm and the frame; another method is to locate each spring between an upper control arm and
spring lower above the frame.

2.7 Brake System

2.7.1 Air Brake System
Air brake uses air pressure to move brake shoe. It can get large brake force with small pedaling
force. Therefore, this type of brake is used in large types of vehicles.
It includes:

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❖ Air compressor; Engine drives this. It makes compressed air. To regulate the air pressure in
the tank, un-loader valve is attached on the suction valve.
❖ Air tank; there are 3 kinds of tanks, wet tank, front tank and rear tank. Wet tank is to remove
moisture from compressed air. Front and rear tank accumulate the compressed air for each front
and rear system.
❖ Brake valve; the brake pedal operates this valve. It sends compressed air to relay valve
according to the depressing condition of the pedal. To control the front and the rear system
simultaneously, there are two valves inside of it.
❖ Relay valve; each of the front and the rear system has this valve. It works according to the
compressed air from brake valve and controls the compressed air from the tank to the brake
chamber. When the brake pedal is released, the compressed air in the brake chambers is
exhausted from this valve.
❖ Brake chamber; It receives the compressed air from relay valve and makes to rotate the
brake cam in the drum brake.

2.7.2 Hydraulic brake system

The brake hydraulic system transmits force from the service brake pedal to the brake linings
while stopping. In addition to transmitting force the hydraulic system has valves that sense,
modify and limit pressure. The system has a master cylinder, wheel cylinders, hydraulic valves
that either alters, delay, maintain, or compare pressure. Steel brake lines & flexible brake hoses
deliver the brake fluid under pressure to the wheel cylinder. The pressure in the system is the
same throughout the brake lines regardless of the size or length of the lines. Force is multiplied
by using different size pressure areas in the master cylinder & wheel cylinders.

2.7.3 Mechanical Brake System

The mechanical brake system use cable to transmit force.
Example: hand brake.
The hand brake is used to keep a vehicle in a stationary position and as an emergency brake
when the service break fails. It is applied on the rear wheels on most cars.
It can be integral i.e., use the same set of brake shoes with service brakes, Independent i.e., use a
different set of shoes. It is applied either by hand or by foot depending upon the design.

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Types of brake depending on the materials which is hold
1. Disk type brake
2. Drum type brake
Replacing brake pad /shoe: -
After recommended kilometers the vehicles must service depending on required inspection
because most of the components are exposed to wear and corrosion the brake pad also work with
high friction area so it will wear out after some kilometers. We have changed the pad of Toyota
low duty vehicle.
First disassembled the tire and components around their and couth out the hub and scratching the
asbestos material then remove the rivets after cleaning we replace the new pad and riveting
finally assembled on its provided place.
The steps in which we follow to replace the brake pad are listed below: -
 Stop the vehicle on leveled area and insert support under the tires
 Lift with jack - Disassemble the wheel
 Disassemble the calipers push out the pad
 Clean surfaces and the components around there
 Collect and inspect disassembled components
 Replace the new pads
 Assemble the components in correct paces

2.8 Motor Vehicle Work Shop Tools.

Motor vehicle work shop tools are tools that are used for servicing motor vehicle components
operation. Tools that uses in the company are hand tools and power tools.
Hand tools: - the mechanics hand supplies the energy to operate them. Hand tools includes: -
a) Screw drivers: - is used to drive or turn screws. They can be classified as: -flat blade type,
Philips head type and off set type screw drives.
b) Hammers: -Hammers are used for driving in parts. Several models of softheaded hammers
are available for preventing damage to the part being struck.
c) Wrenches: - are to turn screws, nuts and bolts with hexagonal heads. They are different types
of wrenches. These are: -

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➢Box-End Wrenches (offset Wrench); Used for tightening and loosening nuts and bolts.
Unlike the open-end wrench, the box-end wrench grips the nut or bolt on six sides to turn it
securely without slipping when strong tightening or loosing force required.
➢Socket wrench: The socket wrench is used in combination with different types of handles and
extension bars for safe and speedy loosening and tightening in difficult positions
➢Combination wrench: -It used to remove bolts from different part of the vehicle based on
part number.
➢Adjustable Wrench; the jaw opening can be adjusted to properly fit nuts and bolts to loosen
or tighten them.
➢Open-End Wrenches (Spanners); Used for loosening and tightening nuts and bolts
Responsibility
The responsibility had taken during the internship
 Respecting the rule and regulation of company.
 Respecting the colleagues.
 Submitting the report on time.
 Punctuality.
 Wearing personal protective equipment.
 Honesty.
 Keep the secret of the company.
 Good material handling.

2.9 Challenges During Internship

There are many challenges during the first weeks of our intern ship program. Those challenges
are come from us and from the workers of the company and as well as from the job itself.
 The biggest challenge is to know the behavior of the workers.
 There is also challenge in knowing part name this is because that the name of the part in
Italic language.
 The workers of that company cannot understand an English language, so that it was
difficult to understand our questions when we ask by English Language.

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2.10 Theoretical Knowledge
❖ Nekemte ERA is a company that applies most of the theoretical teaching that were acquired at
university, like machine elements and machine design, hydraulics and pneumatics, maintenance,
mechanisms of machinery, and internal combustion engines. So that the theoretical knowledge
was upgraded.
❖ Internship program gives the opportunity to apply theoretical knowledge obtained at
university. Almost all the courses learned were mainly focused on theory, thanks to this
internship program, theoretical knowledge was supported by practical skill i.e. tangible
knowledge gained especially on IC engine and reciprocating machine and machine
design.
❖ Our theoretical knowledge got strength by those practical activitie have seen in the
company.
The theoretical knowledge could upgrade by:
❖ Seeing practically and get more information through observation.
❖ Asking the maintenance operators and other responsible person to the different machines
in different department.
❖ By relating with theories, calculations, machine type difference, working principles,
efficiencies and properties of machines.
❖ By using manuals and other materials from the company.

2.11 Entrepreneurship Skills

In the job-training at ERA of Nekemte district the intern perceive the new opportunities that are
being made and how the technical community can participate in the new transformation, hence
developing the entrepreneurial skills. Entrepreneurial skill is not only about seeing opportunities;
also developed the skills on how to manage a company, motivate the workers, and break into the
market and so
To be a wide range of competence entrepreneur must have to be fulfilling the following:
 Management skill (time, money, energy…) Communication skill (e.g. the ability to sell
ideas, search problems and know how to solve).
 The ability to work both as part of a team and independently
 Able to research effectively (available market, supplier, customers and the competition)

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  Able to plan coordinate and organize effectively.
 Self-motivated and disciplined
 The ability to multi task and work under pressure
 The ability to network and make contacts

2.11.1 Practical Skills

To improve practical skills first there must be theoretical knowledge, so t h e theoretical
knowledge taken for the past four years improves the theoretical based practical skills.
The practical skills and knowledge gained were:
 Creativity and an innovative approach to solve practical problems.
 Critical thinking and the ability to evaluate designs and projects.
 Practical skills on how to assembly and disassembly of engine.
 The steps that should be taken to overhaul an engine which are assembly, disassembly,
inspection and reconditioning in engine shop were well practiced.
Nekemte ERA employs many of workers and those workers are appointed a task, according to
their individual skills task might be appointed to two or more persons. In this case interpersonal
communication skills are essential. Dividing the task and assigning it to different people is more
suitable than individuals trying to do one thing. This will also ensure faster completion of the
task.
Interpersonal communication helped us in the following cases:
 Finding a solution for a particular problem within a short period of time.
 Finishing a given task in a short period of time.
 Sharing ideas.
In the internship program, the intern could communicate with each department manager,
maintenance heads and operators, company heads training centers and peoples around marketing,
finance, supply that are responsible for their own authority.
During interpersonal communication intern could develop their verbal and nonverbal symbols:
Verbal: - during communicating, that the way of or the speaking must be clear and light words
to make easy for understanding.

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Non-verbal: - when communicate with someone, the act, sign and symbols must be regular.
Example: Eye contact and gesture.
2.11.2 Team Playing Skill
In this internship program acquired valuable team working skills. In terms of team playing
gained the following skills.
 The ability to work cooperatively and task sharing.
 The ability of sharing responsibility, understanding others idea.
 The ability of handling responsibility, working diligently, and finishing the task on time.
 The amazing thing in our intern are our cooperation between us, confidence in the group
members, respecting seniority and before taking actions our individual opinions are
comes in to one great idea (by sharing ideas}, even to get permissions some facilities
from the hosting company, all we have responsibility to ask.
 Solving some problems in group, we spent most of our times together with pleasure.
 Encouraging team members to share ideas and the like.

2.11.3 Leadership Skills

Experience to trap some of the following good ideas about leadership skills:
❖ A manager or a leader is a coach, not a player. The leader can still perform some of the tasks
but the emphasis is on showing other peoples on how to accomplish work and then motivating
them to sustain their performance.
Example:
 If a team member makes a mistake, the manager does not take over, but instead offers a
constructive suggestion.
 If there is conflict between members the manager or leader must resolve the conflict in a
good way with his problem-solving method or negotiate them.
The main skill acquired during the four months of stay of internship is the skill of Leadership.
The task of facilitating a smooth operation of any work is appointed to the leaders. One of the
skills to a leader to know the tasks to be done. If the leader does not have at least some
knowledge of the task, it would be unable to lead the taskforce to any point.
❖ The key qualities of a good leader that is to have a great idea, and assembling a team to bring
that concept to life. When sees a problem or comes up with an idea, they would tell to the team

26
members and discuss on ways to improve the situation. Sharing tasks and takes responsibility on
what we had to do.
❖ Good performance and behavior, may good performance come from the leader displays a
helpful constructive attitude and giving emotional support.

2.12 Work Ethics

❖ The key qualities of a good leader that is to have a great idea, and assembling a team to bring
that concept to life. When sees a problem or comes up with an idea, they would tell to the team
members and discuss on ways to improve the situation. Sharing tasks and takes responsibility on
what we had to do.
❖ Good performance and behavior, may good performance come from the leader displays a
helpful constructive attitude and giving emotional support.
Work ethics and discipline are one of the major factors for the step to professionalism. Issues
that are related to work ethics like punctuality, honesty, loyalty, and performance are what we
make a company a success or fail.
There are two commons types of ethics
These are: -
A. Personal ethics
B. Professional ethics

A) Personal Ethics
These principles of personal ethics are values which are expected to be possessed by all
individual in their life, and contribute a lot for a smooth interaction among individual peaceful
coexistence of a society.
Experience gained in the company concerning personal ethics includes:
✓Honesty
✓Fairness
✓Compliant to the law
✓Refusing unfair advantage
B) Professional Ethics

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Professional ethics refers to the standards or a set of moral Principle for regulating behavior of a
certain defined profession. In order to consider that an activity to be a profession, it should be
carried out by one who has advanced education, knowledge, and skills. Thus for developing
healthy working environment and increase productivity, ethical work conduct is important
medium.
The following are some of the professional ethics gained during the internship period.
✓Punctuality-means keeping the companies work beginning and ending time and to complete
a given task within the given period.
✓Reliability - the worker should be qualified for the task he /she are supposed to perform. He or
she must have appropriate skill and knowledge for the task assigned.
✓Honesty – regarding this value each worker regardless of its status should abstain from bad
behaviors such as cheating, bias, corruption etc.
✓Cooperation - each worker should be interacting and cooperate with each other while
working. That is because it is through such system problems could be easily solved.
✓Impartiality
✓Transparency and openness
✓Accountability
In ERA there are job disciplines for operator to increase or develop a good team spirit and
friendly relationship among themselves and machine safety. For example: eating, smoking inside
the production area is prohibited.
During the internship, the intern engaged in practical work/job disciplines like:
➢ Punctuality: it has its own benefits
The company will be more productive
Employee will be motivated morally and beneficially
Employee will improve industrial culture

2.13 Value Of Academic Background During Internship

The internship program has good chance to improve practical skill highly. Student can develop
their skill by participating in different part as we had learned theoretically in our department
course. From those courses the most commonly related are machine design, fluid mechanics,
maintenance, turbo machine, IC engine, Motor Vehicle and etc.

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2.13.1 Academic Requirement
All courses learned in fourth year are essential for our intern program study. Majority of the
coursework required for internship that gained in previous semester syllabus. Generally, to speak
loudly all the requirement are important for intern session but the level of requirement will vary
depending on the approach of the internship and company through which the intern takes place.
2.13.2 Importance Of Additional Coursework Prior To Intern
Additional coursework that are essential for our internship program are courses such as power
fluid which given for those students in other universities. This course is mandatory for hydraulic
and pneumatic system.
Also, we suggest that some supportive software’s such as AUTOCAD. are crucial prior to
internship. It is necessary to prepare some curriculum for the introduction of mechanical
software’s. It is important to take some coursework in software’s. It is important to take some
coursework in detail such as motor vehicle and IC engine i.e. MVE-1 & 2 and IC Engine-1&2,
because our activities are related with automotive maintenance. Those coursework enhances our
capability, knowledge and skill.

2.14 Detailed personal critique of self

The knowledge gained and skills acquired through this internship are things that complemented
and enhanced the education we obtained in the class room.
The intern allowed participating in preventive maintenance and daily repair. Thought out the
internship able to maintain, repair, replace and generate reports for our advisor through the
company.
Thought out this experience, we were able to be fully immersed in what it means to be
entrepreneur and were given a realistic picture of an everything that it takes to open store. We are
very grateful for the program and what it has done for us in getting a job right after graduation.
Skill gained during the internship such as;
Communication
Leadership
Entrepreneurship

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2.15 Professional Growth
 Understanding organization structure.
 Attaining base level technical skill.
 Giving relevancy for previous study.
 Exercising directed creativity and initiative. Expanding knowledge regarding relevant
issue. Building relationship with professional peers.

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 CHAPTERTHREE

Technical Aspect Of The Internship

3.1. Objective of the internship
The internship program that we have taken has two main objective those we called general and
specific objectives let see individual.

3.1.1. General Objective

The main objective of internship is creating an opportunity for students to gain practice in a real
world under the guidance of a knowledgeable supervisor and to bridge the gap between the
academic environment and a future participate in an internship to be more confident and more
qualified when seeking future employment.
3.1.2. Specific Objectives
1) To improve my practical kill
2) To enhance my theoretical knowledge
3) To improve my interpersonal skills
4) To develop team working habits
5) To enhance leadership skills
6) To acquainted with the work ethics of the companies
7) Understanding company management
8) Idea about safety.

3.2. Methods And Procedures While Working

Basic maintenance procedure
1 Check all fluid: including engine oil power steering brake and transmission as well as
windshield washer solvent and anti-freezer
2 Check the hose and belts: to make sure they are not cracked brittle frayed loose or showing
signs of wear
3 Check the battery: and replace if necessary make sure the cable connection is clean tight and
corrosion free

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4 Check the brake systems: annually and have the brake linings rotors and drums inspected at
each oil change
5 Inspect the exhaust system: for leaks damaged or broken sup9orts brackets and hangers
6 Schedule attune up: to help the engine deliver the best balance of power and fuel economy and
produce the lowest level of emission
7 Check the heating ventilating and A/C system: as proper heating and cooling performance is
critical for interior comfort and for safety reasons such as defrosting
8 Inspect the steering and suspension system annually including shock absorbers struts and front
end components
9 Check the tires including tires pressure and tread depth check for any signs of bulges and bald
spots uneven wear indicates a need for wheel alignment
10 Check the wipers and lighting so you can see and be seen replace worn wiper blades and
so you can see clearly when driving during precipitation.

3.3. Technical Tasks /Products

3.3.1. Short Term Check Ups
For proper vehicle maintenance, inspect the following:
Oil and coolant levels
Every month, or every few gas fill-ups and especially before any longer road trips, it’s a good
idea to get under the hood of your car and inspect both the oil and coolant levels while the engine
is cool. Low levels of either can lead to engine problems if left unchecked. Refer to your owner’s
manual to locate both on your specific vehicle.
Air filter
Your engine’s air filter is what regulates the air that flows into your engine and helps keep out
debris and particulate. By making certain that your air filter is flowing properly, you can improve
your fuel efficiency, decrease your emissions, and help ensure the life of your engine. This can
be done easily at home, so check your owner’s manual for instructions and how often it needs to
be changed.
Tire pressure and tread depth
Since well-maintained tires are integral to a safe, fuel-efficient ride, make it a habit to visually
inspect your tires often. Check the pressure in your tires every month, and before long trips or

32
carrying extra load. Don’t forget the spare. A tire pressure gauge will be needed to check your
tire pressure. Also, during the colder months, note that tire pressure drops one pound with every
10 degree decrease in pressure. Your owner’s manual will tell you how much air pressure your
tire needs. You can check your tread depth using the simple penny method
Headlights pressure turn signals and parking light
It’s important that the lights on your vehicle are properly functioning, but oftentimes it can be
easy item to overlook. Once a month, turn on your headlights when you’re parked in front of a
flat surface and check that both headlights are working properly and well positioned. Walk
around your car and visually inspect both turn signals and your parking lights. Have a friend
stand behind the car while you engage the brakes to be certain that your brake lights are
functional.

Oil and filter

The motor oil in your vehicle’s engine serves a whole slew of functions: it lubricates the moving
parts, helps act as a sealant against debris, cools the engine, reduces wear and tear, and helps
prevent engine corrosion. Keeping it clean is vital for good engine health. Depending on your car
and what kind of oil you’re using, you may need to change both the oil & oil filter as much as
every 3 months or 3000 miles. Many newer vehicles’ owners’ manuals will recommend
changing your oil less frequently – often in-between 5,000 and 10,000 miles. Check your vehicle
owner’s manual and consult with a professional to be certain what is appropriate for your
vehicle.
Rotate tires
Depending on your vehicle alignment, usage, and many other factors, the tread wear patterns on
your tires may vary between the front and back tires, or even from one side of the tread to the
other. Rotating your tires will help to extend the service life of your tires by more evenly
balancing the tread wear, and helping prevent noise and vibration problems. Wax vehicles
Making certain to wax your vehicle every six months after washing it won’t just keep it shiny,
it’ll also help to keep both the paint in good shape and reduce the chance of rust. Many irritants
such as dust, sand, and salt can build up and environmental factors like ozone and ultraviolet
light can cause microscopic damage, but waxing can help minimize this by forming a protective
seal to extend your paint’s life

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3.3.2. Long Term Check Ups
Transmission fluids
Much like the oil in your engine, transmission fluid is a lubricant that helps keep all of the
moving parts inside of your transmission functioning properly. Whether you’re driving an
automatic or manual transmission vehicle, it is essential that you have your transmission fluid
checked and changed when needed to avoid costly transmission damage or replacement. Follow
the vehicle manufacturer’s recommendation

Transmission case fluid

In four-wheel or all-wheel drive vehicles, the transfer case is what shifts power from the
transmission to the axles. You’ll need to have the transfer case fluid checked according to the
vehicle manufacturer recommendations to make certain that it is properly filled and leak-free.
This will require you getting under the vehicle, so bringing it into a professional is
recommended.

Inspect shock and struts

The shocks and struts on your car function to control the impact and rebound as your vehicle
passes over bumps in the road and are an essential part of your auto’s steering system. They
should be inspected by a professional every 50,000 miles or bring your car in to the shop if you
notice a decrease in smoothness or loss of control when driving.

Coolant fluid exchange

The radiator in your car is a vital component that helps keep your engine cool and functioning
properly. Having your coolant system flushed regularly will help get rid of contaminants that can
build up inside as well as ensure that your radiator is filled to a proper level. Check your vehicle
manufacturer’s recommendation to find out how often your coolant should be exchanged,

Spark plugs
The spark plugs in your engine ignite the gas and air mixture that ultimately powers your
vehicle. If your spark plugs aren’t functioning properly, your engine will lose power and won’t

34
run at optimal capacity. Have a professional check and replace any faulty spark plugs depending
on vehicle mar recommendations or when you feel a decrease in your engine’s power.

Serpentine belt
Although may seem like a simple piece of rubber, your vehicle’s serpentine belt is essential to
keeping your car running by powering peripheral devices such as your alternator, power steering
pump, and air conditioner compressor. Visually inspect the belt to ensure that it is free of cracks
or other wear and tear. Replace id damaged or according to your vehicle manufacture’s
recommendation.

Front and/or rear differential

The differentials are devices that split the torque or power from the engine and allow it to send
power to the tires. In front or rear-wheel drive vehicles, there is only one differential, but in 4-
wheel and all-wheel drive vehicles, there is both a front and rear differential, and possibly even a
Centre differential. Like many parts of your vehicle, the differentials need to be kept lubricated
to ensure proper functionality. Have a professional check and change fluid whenever your
vehicle manufacturer recommends it.

3.3.3. Seasonal Check Ups

The needs of your vehicle can vary by season and driving conditions. Following are a few
suggestions to add to the notes section of your vehicle maintenance checklist:
Replace windshield wires
Windshield wipers need to be replaced about once every year, or whenever the effectiveness is
compromised. In winter months, it could also be a good idea to install winter wiper blades for
optimum performance. You should also pull your wipers away from the window when parked
during the winter to prevent ice build-up.

Battery performance check

Your car battery is one of the most important components for your vehicle to run. A car battery
supplies large amounts of electrical current for the starter, engine and other electronic accessories

35
in the vehicle. Extreme temperatures affect the performance of the battery so regular battery
testing will ensure that battery will perform when you need it to.

Change tires
Depending on where you live and the winter driving conditions you might encounter, you might
want to switch your tires in cold, snowy months to a winter/snow tire. When the temperature
hovers at or below freezing consistently, the tire compounds in non-winter tires hardens,
decreasing traction and handling performance while increasing braking distance. Winter tires are
had tread patterns and compounds designed to remain soft in the cold and provide grip in snow,
slush, and icy driving conditions.

Check coolant levels

It’s also important to check your antifreeze levels in your radiator in winter months to keep your
radiator or engine components from freezing. A 50/50 mix of antifreeze to water is generally
recommended, but check your owner’s manual or with a professional to be certain.
Sticking to a car maintenance schedule, and keeping good records of what you’ve done, an help
extend the life of your vehicle and protect you against breakdowns, expensive repairs, and other
unwelcomed surprises.

3.4 Knowledge and Acquaintances Acquired

3.4.1. Practical Skill

We have developed a confidence to do the given work practically without any problem and we
also observed that practical works is more simple than theoretical. As we have seen there is a big
difference between theoretical and practical skills. Theoretical knowledge is not always
unfulfilled in practical application through time it might seem that way.
Gaining knowledge from practical work is easier than from theoretical learning process and we
have gained a practical skill of different kind of software’s when we design and write our project
and report.

36
3.4.2. Inter Personal Communication Skill
During these four months, we have been able to upgrade our communication skill to a whole new
level and gained confidence on how to ask different questions, to make discussion.
3.4.3. Use Of Interpersonal Communication
• To give and collect information
• To influence the attitude and behaviors
• To form contracts and maintain relationship
• To express personals needs and understand the needs of others
• To make decision and solve problem
• To anticipate and predict behavior
• To improving formal communications
• We have developed the communicating respect for other people or professionals which will
enable us to reduce conflict and increase participation or assistance in obtaining information or
completing tasks.
• We have developed how to control the feeling that emerge in difficult situations and respond
appropriately; instead of being over whelmed by emotion

3.4.4. Team Playing Skill

During our stay in ERA Nekemt district, we have learned that it is difficult to go ahead and do
something without having a strong team spirit. Team work is important because it can speed up
process and make things run more efficiently and allows goals to be reached in an efficient and
timely method.
A good team will generate and nurture or develop bond of trust and confidence, both
inthemselves and one another. This will positively affect their self-esteem, confidence in their
colleagues, and possibly their loyalty to the company increasing productivity and ultimately,
company profit

3.4.5. Leadership skills

During internship, we have been able to upgrade our leadership skills to a whole new level. To
achieve leader ship skills it requires high level commitment to learn from each experience we
face. We have observed that a good leader is well principal individual who focuses on a common

37
goal and eliminate excess fear and doubt from his employees and work for a common good of
all.

3.4.6. Work ethics

• We have developed about moral duties and obligations.
• We have developed sincerity, respect for the job, regularity, punctuality, seriousness.
• We have developed how to keep certain information confidential, how to maintaining cordial
relation with the clients and agencies that a company has and how to being prepared to take up
new tasks.
• We understood the effects of ethical problem related to work like impolite behavior, lack of
punctuality, disregard of rules and procedures and disrespect for the job.

3.4.7. Entrepreneur skills

Application of energy and passion towards the creation and implementation of new ideas and
creative solutions. Essential in gradients includes the willingness to take calculated risks in terms
of time, equity, or career, the ability to formulate an effective venture team; the creative skill of
building solid business plan and finally the vision to recognize opportunity where others see
chaos, contradiction and confusion.
There are some of the entrepreneur skills that we have developed:
• Initiative: how to have the motivation to take the initiative and creative.
• Responsibility: we developed how to be responsible for our actions and understand the
important of responsibility.
• Creativity: we developed a sense of creativity, innovation and visibility.
• Communication: we developed the ability to communicate our ideas network and connect with
others.
• Leadership: we developed the ability to develop the leader ship and be in charge of a project, or
company.
• Problem solving: we developed the ability to solve simple or complicated problems

38
3.5. Problem Encountered During The Internship Period
When we were performing our work tasks, we faced different kinds of problems. Other
challenges faced that affect the efficiency of the company as a whole are:
• Shortage of safety materials like: safety closes during welding, chemical treatments for
painting, gloves, helmets, etc.
• Shortage of working material tools
• The working place is so rough and exposed to dust.

39
 CHAPTER FOUR

4. PROJECT CARRIED OUT

4.1 INTRODUCTION
4.1.1ENGINE STAND
An engine stand is a very important tool that every mechanic should have which is commonly
used to repair large and heavy gasoline or diesel engines. It uses heavy cantilevered support
structure to hold the engine in midair so that the mechanic has access to any exposed surface of
the engine. While small single-piston engine can commonly be laid on a table for repair, a large
engine is normally meant to be supported from its engine mounts or from the flywheel
transmission case mounts and fragile components such as oil pans and valve covers would be
crushed if the large engine were placed on a flat surface. Engine stands are typically mounted on
large casters so that an engine can be moved around the shop to different test and repair stations,
and the engine can often be rotated in midair to provide easier access to underside surface of the
engine. The engine stand is commonly used in combination with engine crane to remove or
install an engine in a vehicle, break in that engine, and perform repairs. Engine stand is also used
to turn the position of an engine in a full circle using torque turning with appropriate pin for lock
to prevent sliding of the shaft that is rigidly tighten with an engine in bolt. Engine stand is mainly
constructed from simple rectangular bar metal by simple welding process of its different
components of the stand. On the other hand, an engine stand is illustrated having a universal
mounting apparatus for securing loads such as different sizes of automotive engines and the like
to a rotatable face plate which has a wheeled stand.

4.2 STATEMENT OF THE PROBLEM

In hosting company there are a lot of problems which can influence the work progress in Our 4
months’ duration in ERA. In the ERA Nekemte District there is no suitable engine stand for the
purpose of assembling and disassembling while maintaining an engine. The workers place an
engine on a simple support beam or plate form. This is not comfortable since the engine cannot
be rotated and workers do not have access to the underside and various areas of the engine. Also,

40
it will take more time to assemble and disassemble an engine which will slow down the overall
vehicle maintenance process.

4.3 Objectives
4.3.1 General Objective
The main objective of this project is the design, Analysis, and Simulation of heavy duty engine
stand to eliminate the lack of proper engine stand in the workshops.
4.3.2 Specific Objectives
To design an engine stand which allow 360-degree rotation of the engine?
To design an engine stand with gear box to minimize operator’s effort.
To design an engine stand with low cost of production.
To minimize the total time of engine maintenance.

4.4 Significant Of The Project

This project is very significant since it focuses on solving the problem with the current working
situation for engine assembly. It aims in designing and manufacturing of engine stand which
could have several importance including, holding the engine at a comfortable height to work on
and give access to all the various areas of the engine, allowing the engine to rotate giving access
to the underside, and move the engine around workspace for better space management.

4.5 Scope Of The Project

This project includes the design of engine stand using the total design approach, analysis
including detail and assembly drawings.
4.5.1 Types Of Engine Stands
There are different types of engine stands based on the arrangement and shape of the engine
cylinders. Some of them are:
Heavy duty engine stands
Medium duty engine stands
Flat engine stands
Heavy stand is a stand for inline cylinder engines or a v-type cylinder engine which is used to
hold and rotate the engine with the required degree while maintenance. It helps to avoid the

41
complexity of assembling and disassembling of engines since the engines are heavy. This type of
engine stand uses two columns or posts to support the engine from two ends.

Figure4. 1Heavy Duty Engine Stands

Medium duty engine stands are also used for inline cylinder engines or v-type cylinder engines.
It is used to hold and rotate medium weight engine with the required degree while maintenance.
This type of engine stand has only on column and supports the engine from on end.

Figure4. 2Medium engine stands

Flat engine stands are used for putting an engine after it is removed from a vehicle before going
through maintenance process. It is also used to put an engine after maintenance process is
finished. This engine stand does not allow engine to be rotated in any degree. It is only used to
place an engine outside of its vehicle.

Figure4. 3Flat engine stands

42
4.6 Literature Survey
The Rolls-Royce engine stand is ground based engine-built stand which has been designed on the
basis of two manipulators. It has its unique features such as 45-degree positioning wheel with
ball lock pin which secures engine giving eight angles of maintenance access, sturdy welded
steel construction, easy maneuvering with two swivel and two rigid heavy-duty casters, center
foot operated grips firmly to stabilize stand during maintenance operation, and handy oil
recovery pan. Mountain MTN5138 engine stand is a perfect stand for small-type engines with
weight up to half a ton. It has a very strong and stable steel construction despite the small size.
The size is a benefit because this engine stand will mostly fit between legs of engine hoists. This
Mountain engine stand has a very good and durable steel construction that is perfectly suited for
holding engines up to 0.5 tons (1000 lb.). It has the square type shape and construction can be
very stable if even heavier engines are placed on it. Two support plates and other problems.

4.7 Material Selection

Material selection plays a very important role machine design. For example, the cost of materials
in any machine is a good determinant of the cost of the machine. More than the cost is the fact
that materials are always a very decisive factor for a good design.
The choice of the particular material for the machine depends on the particular purpose and the
mode of operation of the machine components. Also, it depends on the expected mode of failure
of the components. The selection of the materials is done according to their mechanical
properties (Strength, stiffness, elasticity, hardness and toughness) based on the particular
working conditions. The properties are:
Strength: it is the ability of a material to resist the externally applied force without break down
or yielding the internal resistance offered without break down or yielding the internally applied
force is called stress.
Stiffness: it is the ability of a material to resist deformation under stress.
Elasticity: it is the property of a material to regain its original shape after deformation when the
external force is removed.
Hardness: is embraces difference properties such as resistance to water, scratching, deformation
and machinablity etc. it also measures of the ability of a metal to cut another metal.

43
Toughness: it is the property of a material to resist fracture due to high impact loads like
hammer blows, when heated this property decreases.

4.8 Project Methodology And Material Selection

4.8.1 Project Management
Project management refers to planning and overseeing the tasks necessary to achieve a goal. It is
important because it ensures proper expectations are set around what can be delivered. It also
helps to have better control of the variables which contribute to the well- being of the project
process. For these reasons we tried to follow some procedures which will enable the whole
project to be efficient and effective. Since the engines at ERA Nekemte District workshop are
very huge and heavy, the engine stand should heavy duty engine stand. The design project is
done following certain procedures in order to complete it properly. These procedures are:
•Identifying the problem with the current engine stand
•Find possible solutions for the problem
•Prepare project proposal
•Select the required material for the project design and analysis
•Design each components of the engine stand
•After designing draw part and assembly drawing of the engine stand
•Determine the manufacturing process of each component

4.8.2 Data Collection

There were different data collection methods we have used from the beginning to the end of this
project.
The major data collection method was observation which enabled us to identify the problems
with the current engine assembly difficulties without proper engine stand. We also tried to
collect data through interviews.

We interviewed some of the workers in the engine maintenance workshop and we were able to
gather information on what should the engine stand we are going to design include in order to
solve the identified problems.

44
4.8.3 Data Analysis Method
After collection of data it was important to analyze in order to choose which ones are relevant
and which are not for the design project. To do this we used qualitative data analysis method that
seeks to reduce and make sense of vast amounts of information from different source. After
analyzing the data collected we were able to identify what should the design project include
meeting the requirements and objectives.
After completing this step we began the design process by formulating a function structure,
generating design concepts, and evaluating these concepts. These steps are discussed as follow:

4.9 Design Process

4.9.1 Function Structure
The function structure shows the sequential order in which different processes of this project are
done. Boxes represent processes and arrows represent the flow or direction of sequence. Boxes
which are drawn in series show that the processes cannot be completed simultaneously and
parallel boxes show processes which can be done simultaneously.

45
 Literature Review Design Concept Design Concept
Generation Evaluation

Design of Worm Design Calculation Product Definition

Design of Worm Gear Design of Worm shaft Design of Worm

shaft

Bearing Selection of Worm

Bearing Selection of Worm

Gear
Design of Handle
Design of Key

Detail Drawing
Design of Bolt

Figure4. 4Function structure

46
4.9.2 Design Concept Generation
Design concepts were generating by referring to previously used engine assembly techniques and
mechanisms. There are different design concepts according to the need and specifications. For
this project we generate design concepts which deals with gear box mechanism. This engine
stand has columns which are going to be operated manually with a gear box mechanism. This
concept will have more expensive and decrease the amount of effort needed by the operator.

Figure4. 5Engine stand with gear box

4.9.3 Design Concept Evaluation

After we generate the design concept generation it will be evaluated by using design calculation.
4.9.4 Product Definition
The engine stand which is going to be designed in this project has different members. These
members are discussed as follows.
I. Worm and worm gear
Worm and worm gear drive is used to drive the shaft which is connected to the engine mounting
plate. The worm gear arrangement will provide 90-degree power transmission and helps reduce
the operator effort.

47
Figure4. 6Worm and worm gear

II. Caster
Caster is wheeled device which can be mounted at the bottom of the engine stand to enable
relatively easy rolling movement of the engine stand. It is important for the engine stand to move
around the workshop easily and casters will provide that ability.

Figure4. 7Caster
III. Mounting plate and arms
These are the parts of the engine stand where the engine is going to be bolted and held. The
arrangement can be rotated 360-degree with the help of a handle which makes every part of the
engine easy to reach.

Figure4. 8Mounting plate and arms

IV. Solid shaft

Shaft is a rotating member which is used to transmit rotating power or torque. It will transmit the
rotation from the worm-gear arrangement to the plate where the engine is held.

48
Figure4. 9Solid shaft

V. Hollow shaft
Hollow shaft is a member in which the solid shaft passes through. It will act as hub for the solid
shaft and guide its motion.

Figure4. 10Hollow shaft

VI. Bearing
It is a machine element which supports another moving machine element and guides its motion.
It will support the worm and worm wheel. The two main types of bearing are sliding contact
bearing and rolling contact bearing. The type of bearing used for this project is rolling contact
bearing because of availability.

Figure4. 11 Rolling contact bearing

VII. Key
It is a machine element which is used to connect rotating machine element to a shaft. It prevents
relative motion between two parts and enables torque transmission. In this case a key is used to
connect shaft to the worm gear
VIII. Main frame
Rectangular hollow steel is used for the horizontal and square hollow steel for vertical members.
The horizontal and vertical members are the main building blocks of the engine stand. Two

49
vertical members will hold the engine from the two ends axially. The horizontal members will
connect the vertical members and act as the base of the engine stand. Also, casters will be fixed
on the horizontal members

Figure4. 12Rectangular hollow steel

IX. Lever arm
It is an arm keyed at right angle to the end of the worm shaft, by which motion is imparted to the
worm gear. It mainly suffers from torsion stresses so medium carbon steel is usedas it combines
merits of malleability and sufficient torsional strength.

Figure4. 13 Lever arm

X. Braces
Braces offer the necessary support for the engine stand so they should be sturdy and long lasting.
Support braces are necessary for heavier engines.
This applies for stand that support engines more than 2 tons heavy. For these components to
work as expected, the weld should also be of high quality.

Figure4. 14 Brace

50
 XI. BOLTS
A bolt is s form of threaded fastener with an external male thread. Bolts are used to hold the
engine through the mounting arm. They are fitted on the engine through the fly wheel mounting
internal threads

Figure4. 15Bolt

4.10 Working Principles

Engine stands are all of the same design. They have a head which usually has four arms. Because
every engine is mounted differently, these arms can be adjusted to reach various positions.
Generally an engine will be mounted to the stand at the flywheel end, using four of the holes that
the transmission attaches to. You’ll want to make sure you’ve got suitable bolts before you start -
often the transmission bolts will be too short to fit through the arms of the engine stand.

4.11 Design Calculation

Material selected for the design calculation
Worm = hardened steel
Worm Gear = Alloy cast Iron,
Endurance limit, σe=210MPa
Ultimate strength, σu = 420MPa
Allowable static stress, σa =140MPa
4.11.1 Design Of Worm
Initial assumptions taken for the design calculation process:
Distance between the shafts, x=180mm
Velocity ratio = 5
Let, ƖN = Normal lead, and
ʎ = Lead angle

51
 x
The value of will be minimum corresponding to
ln
Cot3ʎ = V.R or cotʎ = √3 VR
cotʎ = √3 5
cotʎ = 1.7099
ʎ=cot-11.7099
x 1
ʎ=30.3190 We know that (1/sin30.3190+5/cos30.3190 )
ln 2 π
From table 1, we find that for a velocity ratio of 5, the number of starts or threads on the worm,
n-Tw=6
Table 4- 1Number of starts to be used on the worm for different velocity ratios

Velocity ratio(VR) 36and above 12to36 8to12 6to12 4to10

Number of start or Single Double Triple Quadruple Sextuple
thread on worm
(n=T0
Therefore, axial pitch of the threads on the worm, Pa
Pa = 1/n = 168.55/6 Pa = 28.09mm
Therefore, module, m = Pa/π = 28.09/π
m = 8.924 say 9mm (standard value of module
Therefore, axial pitch of the threads on the worm, Pa
Pa = πm = π*9 =28.27mmAns
Axial lead of the threads on the worm,
Ɩ = Pa.n = 28.27*6 = 169.65mm Ans and
Normal lead of the threads on the worm,
ƖN =Ɩcosʎ = 169.65*cos30.3190 = 146.44mm Ans
We know that the center distance
ln
x= ¿
2π
146.44
x= ¿
2π
x = 33.307(1.9809+5.7922) = 181.168 say 182mm Ans
Let Dw -pitch circle diameter of the worm.

52
 1
We know that, tanλ=
πDw
1 169.65
DW = = =92.34 mm Ans
πtanλ πtan 30.3190
Since the velocity ration is 5 and the worm has sextuplet threads
(I.e. n = Tw = 6) therefore number of teeth on the worm gear,
TG = V.R*n = 5*6 = 30
Length of the worm or length of threaded portion is,
LW = PC (4.5+0.02TW) = 28.27(4.5+0.02*6) = 130.6074mm
Therefore, Pc = Pa
This length should be increased by 25 or 30mm for safety. Say LW = 155mm Ans.
We know that depth of tooth
h = 0.623pc= 0.623*28.27 = 17.6122mm Ans.
And addendum,
a = 0.286pc= 0.286*28.27 = 8.085mm Ans.
Therefore, outside diameter of worm gear
Dow = Dw+2a = 92.34+ (2*8.085) = 108.5mm Ans.
4.11.2 Design Of Worm Gear
Pitch circle diameter of worm gear,
DC = m.TG = 9*30 = 270mm Ans.
Therefore, outside diameter of worm gear,
DOG = DG+0.8903PC = 270+0.8903(28.27) = 295.2mm Ans.
Throat diameter,
Dr = DG+0.572PC = 270+0.572(28.27) = 286.2mm Ans.
Face width of worm gear,
b = 2015PC+5mm = 2.15(28.27) +5 = 66mm Ans.
Let us know check the designed worm gearing from the standpoint of tangential load, dynamic
load, and static load and wear load.
Check for the tangential load
Let NG be speed of worm gear in rpm
NW
Velocity ratio of drive, V . R=
NG

53
 Nw
NG= =10 /5=2 rpm
VR
Therefore, Torque transmitted,
T = P*60/2πNG = 15.7*60/2π*2 = 74.96N.m
Tangential load acting on the gear,
WT = 2*Torque/DG = 2*74.96/0.27 = 555.27N Ans.
Pitch line or peripheral velocity of worm gear,
v = π.DG.NG/60 = π*0.27*2/60 = 0.028m/s
Therefore, velocity factor,
CV = 6/(6+v) = 6/(6+0.028) = 0.995
Tooth form factor,
y = 0.154-0,912/TG = 0.154-0.912/30 = 0.1236
Since the material selected for the worm gear is alloy cast iron, allowable static stress is
σο=140 MPa
Designed tangential load,
WT = (σa.CV).b.πm.y = (140*0.995)66*π*9*0.1236 = 32129.6N
Since the value is more than the tangential load acting on the gear,WT = 555.27N,
Therefore the design is safe from the stand point of tangential load.
CV= 6/(6+v) = 6/(6+0.028) = 0.995
Tooth from factor,
y = 0.154-0.912/TG = 0.154-0.912/30 = 0.1236
Since the material selected for the worm gear alloy cast iron, allowable static stress is
σ0 =140MPa
Designed tangential load
WT = (σa.CV).b.πm.y = (140*0.995)66*π*9*0.1236 = 32129.6N
Since the value is more than tangential load acting on the gear, WT = 555.27N,
Therefore the design is safe from the stand point of tangential load. Check for dynamic load
Dynamic load,
WD = WT/CV = 32129.6/0.995 = 32291.1N
Since this is greater than WT = 555.25N, therefore the design is safe from standpoint of dynamic
load.
Check for static load or endurance strength

54
Flexural endurance limit for cast steel is σe = 210MPa
Therefore, static load or endurance strength,
WS = σe*b*π*m*y = 210*66*π*9*0.1236 = 48620.15N
Since this is greater than WT = 555.27N, therefore the design is safe from the standpoint of static
load of endurance strength.
Check for wear, Assume material for worm as hardened steel. Load stress factor for hardened
steel and alloy cast iron K = 0.345
Pitch line or peripheral velocity of the worm gear,
v = π*DG*NG/60 = π*0.27*2/60 = 0.028m/sec
Therefore, velocity factor,
CV = 6/ (6+v) = 6/ (6+0.028) = 0.955
Tooth form factor,
y = 0.154-0.912/TG = 0.154-0.912/30 = 0.1236
Since the material selected for the worm gear is alloy cast iron, allowable static stress is
σa=140MPa
Designed tangential load,
WT = (σa*CV)*b*πm*y = (140*0.995)*66*π*9*0.1236 = 32129.6N
Since the value is more than the tangential load acting on the gear, WT = 555.72N, Therefore the
design is safe from the standpoint of tangential load.
Check for dynamic load
Dynamic load,
WD= WT/CV = 32129.6/0.995 = 32291.1N
Since this is greater than WT = 555.27N, therefore the design is safe from the standpoint of
dynamic load.
Check for static load or endurance strength
Flexural endurance limit for cast steel is 210MPa
Therefore static load or endurance strength,
WS= σe*b*π*m*y = 210*66*π*9*0.1236 = 48620.15N
Since this is greater than WT = 555.27N, therefore the design is safe from the standpoint of
Static load or endurance strength.

55
Check for wear Assume material for worm as hardened steel. Load stress factor for hardened
steel and alloy cast iron K = 0.345
Therefore limiting or maximum load for wear,
WW= Dc.b.k = 270*66*0.345 = 6147.9N
Since this is greater than WT = 555.27N therefore the design is safe from the standpoint of wear.
4.11.3 Design Of Worm Shaft
Let dW be diameter of worm shaft
Torque acting on worm gear shaft, (25%overloadad)
1.25∗P∗60 1.25∗15.7∗60
Tgear= = =93.7 Nm=93.7∗103 N
2 πNG 2 π∗2
Therefore, Torque acting on worm shaft, (taking 89% efficiency)
Tgear 93.7 3
T worm= = =21.056 Nm=21.056∗10 Nm
VR∗η 5∗0.89
Tangential force on the worm, (equal to axial force on the worm gear)
2∗T WORM 2∗93.7∗103
WT= = =456.057 N
DW 92.34
Axial force on the worm, (equal to tangential force on the worm gear)

2∗T GEAR 2∗93.7∗103

Wa= = =694.07 N
DG 270
Radial or separating force on the worm and worm gear,
WR = WA*tanØ = 694.07*tan 250 = 323.65N
Assume distance between bearings of worm shaft equal to the diameter of the worm gear, i.e.
X1 = DG = 270mm
Therefore, bending moment due to radial force in the vertical plane,
WR∗X 1 323.65∗270
= =21846.38 N .mm
4 4
Bending moment due to axial force in vertical plane,
WA∗DW 694.07∗92.34
= =16022.6 N . mm
4 4
Total bending moment in vertical plane,
M1 = 21846.38+16022.6 = 37868. 98N.mm
Bending moment due to tangential force in horizontal plane,

56
 W T ∗Dw 456.057∗270
M 2= = =30783.84 Nmm
4 4
Therefore, Resultant bending moment on the worm shaft,
M worm= √ M 1 + M 2 =√ 37868.98 + 30783.84 =48802.29 Nmm
2 2 2 2

Equivalent twisting moment on the worm shaft,

T ew=√ Tworm + Mworm =√ ¿ ¿ ¿
2 2

Also, equivalent twisting moment is, (assume τ = 50MPa)

Tew= π/16*τ (dw)3 , 53151.29 = π/16*50(dw)3 , 53151.29 = 9.8174(dw)3
(dw)3 = 5413.945 or dw = 17.6mm say 20mm Ans. Let us know check for the maximum shear
stress induced. Actual shear stress,
16 Tew 16∗53151.29
τ= 3
= 3
=33.83 MPa
π (dw) π (20)
Direct compressive stress on the shaft due to the axial force,
Wa 694.07
σ c= = =2.20 MPa
π 2 π 2
(dw) (20)
4 4
Therefore maximum shear stress,
1 1
σ 2 + 4 τ 2= √ 2.20922 +4∗33.837 2=33.853 MPa
2√ c
τ max=
2
Since the maximum shear stress induced is less than 50MPa (assumed), therefore the design of
worm shaft is safe.
4.11.4 Checking For Self Locking Of The Worm
1 2 1 2
η= −tan ϕ= −tan 25=0.3913=39.13 %
2 2
Since the efficiency is less than 50% the worm is self- locking.
4.11.5 Design Of Worm Gear Shaft
Let dG be diameter of worm gear shaft .We have calculated above that,
Axial force on the worm gear = 456.057N
Tangential force on the worm gear = 694.07N
Radial or separating force on the worm gear = 323.65N
Bending moment due to axial force on the worm gear in vertical plane,
Axial force∗DG 456.057∗270
¿ = =30783.85 Nmm
4 4

57
Let us take the distance between bearing of worm gear shaft is X2 = 200mm
Bending moment due to radial force of the worm gear in vertical plane will be,
Radial force∗X 2 323.65∗200
¿ = =16182.5 Nmm
4 4
Therefore total bending moment in vertical plane,
M3 = 30783.85 + 16182.5 = 46966.35N.mm
Bending moment due to tangential force in the horizontal plane,
M4 = Tangential force *X2 = 694.07 *200 = 34703.5N.mm
Therefore bending moment on the worm gear shaft,
M gear =√ M 32 + M 42 =√ 46966.352 +34703.52=58396.67 Nm
We have already calculated torque acting on the worm gear shaft, Tgear = 93.7*10 3 N.m
Therefore equivalent twisting moment on the worm gear shaft,
T eg= √ T gear + M gear =√ ¿ ¿
2 2

Also, equivalent twisting moment is, (assume τ = 50MPa)

Teg = π/16*τ(dG) 3 , 11047.7 = π/16*50(dG)3 , 11047.7 = 9.8174(dG)3 ,
(dG)3 = 11246.12 or dG = 22.4 say 30mm Ans. (Because of engine load)
Let us now check the maximum shear stress induced. Actual shear stress,
16 Teg 16∗110407.7
τ= 3
= 3
=20.215 MPa
π (dG) π (30)
Direct compressive stress on the shaft due to the axial force,
Axial force 456.57
σ c= = =0.6452 MPa
π 2 π 2
∗(dG) ∗(30)
4 4
Therefore maximum shear stress,
1 1
√ σ c + 4 τ = √ 0.6452 +( 4∗20.21) =¿
2 2 2 2
τ max=
2 2
Since the maximum shear stress induced is less than 50MPa (assumed), therefore the design of
worm gear shaft is safe.
4.11.6 Bearing Selection Of The Worm
From the above calculation we have,
WR = 323.65N
WA= 694.07N

58
NW= 10rpm
Since the average life of the bearing is 5 years at 300 days a year 10 hour per day, Therefore life
of the bearing in hours,
LH = 5*300*10 = 15000 Hours
Life of bearing in revolutions
L = 60N*LH = 60*10*15000 = 9*106 rev
Basic dynamic equivalent radial load,
W = x.v.WR +y.WA
In order to determine the radial load factor, x, and axial factor, y, we require WA/WR and
WA/C0. Since the value of basic static load capacity C0 is not known, therefore let us assume
WA/C0 =0.5.Now from the table 2, we find that the values of x and y corresponding to WA/C0
=0.5 and WA/WR = 694.07/323.65 = 2.1445 (which is greater than c=0.44) are, x=0.56 and y=1
Table 4- 2value of x and y for dynamically loaded deep groove ball bearing

Dynamic equivalent radial load (V = 1 for most bearings),

W = (0.56*1*323.65) + (1*694.07) =875.314N
From table 3, we find that for uniform and steady load, the service factor (KS) for ball Bearing is
1.Therefore, bearing should be selected for W = 875.314N
Table 4- 3Values of service factor (KS)

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Basic dynamic load rating, (K= 3 for ball bearings}
C = W (L/106 ) 1/K = 875.314(9*106 /106 ) 1/3 = 1820.726N
From Table 3, let us select bearing No.200 with the following basic capacities
CO=2.24 KN ∧C=4 KN
WA /CO=694.07/2240=0.309
Table 4- 4Basic static and dynamic capacities of various types of ball bearings

From table4- 2, the values of x and y are, x = 0.56 and y =1.2

Substituting these values, we have dynamic equivalent load is, W = (0.56*1*323.65) +
(1.2*694.07) = 1014.128N
Therefore basic dynamic load rating,
C = W*(L/106)1/K = 1014.128(9*106/106)1/3 = 2109.47N = 2.1KN
From table 4, for shaft fitting the bearing number 204 having C = 10KN, may be selected.
Therefore, the bore diameter = 20mm
Outside diameter = 47mm
Width =14mmAns
4.11.7 Bearing Selection Of The Worm Gear
From the above calculation we have,
Radial force = 323.65N
Axial force = 456.057N
NG = 10 rpm

60
Since the average life of the bearing is 5 years at 300 days a year 10 hour per day.
Therefore, life of the bearing in hours,
NH = 5*300*10 = 15000Hrs
Life of bearing in revolutions,
L= 60N*LH = 60*10*15000 = 9*106 rev
Basic dynamic equivalent radial load,
W = x*v*WR+Y.WA
In order to determine the radial load factor, x, and axial factor, y, we require WA/WR and
WA/C0. Since the value of basic static load capacity C0 is not known, therefore let us assume
WA/C0 = 0.5.Now from the table 2, we find that the values of x and y corresponding to WA/C0
= 0.5 and
WA/WR = 456.057/323.65 = 1.409 (which is greater than c = 0.44) are, x = 0.56 and y = 1
Dynamic equivalent radial load (V = 1 for most bearings),
W = (0.56*1*323.65) + (1*456.057) = 637.301N
From table 2, we find that for uniform and steady load, the service factor (KS) for ball bearings
is 1.
Therefore, bearing should be selected for W = 637.301N. Basic dynamic load rating, (K = 3 for
ball bearings)
C = W (L/106)1/K = 637.301(9*106/106)1/3 = 775.238N

From table 4, let us select bearing No. 200 with the following basic capacities, C0 = 2.24KN and
C = 4KN, then WA/C0 = 456.057/2240 = 0.203
From table 1, the values of x and y are x = 0.56 and y = 1.4
Substituting these values, we have dynamic equivalent load is, W = (0.56*1*323.65) +
(1.4*456.057) = 819.7238N
Therefore basic dynamic load rating
C = W (L/106)1/K = 819.7238(9*106/106)1/3 = 997.145N = 0.997KN
From table 4, let us select bearing No. 200 with the following basic capacities,
C0 = 2.24KN and C = 4KN, then WA/C0 = 456.057/2240 = 0.203
From table 1, the values of x and y are x = 0.56 and y = 1.4
Substituting these values, we have dynamic equivalent load is,

61
W = (0.56*1*323.65) + (1.4*456.057) = 819.7238N
Therefore basic dynamic load rating
C = W (L/106 ) 1/K = 819.7238(9*106 /106 ) 1/3 = 997.145N = 0.997KN
From table 3, because this bearing supports the load of engine, the bearing number 206 having C
= 15.3KN may be selected.
Therefore, the bore diameter = 30mm
Outside diameter = 62mm
Width = 16mm Ans
4.11.8 Design Of Key For Worm Gear
Material selected for key is low carbon steel with,
σy = 370MPa and σu = 440MPa
Assumption, Factor of safety = 4
From the table 4, we find that for a shaft diameter of 30mm,
Width of the key, w =10mm
Thickness of key, t = 8mm
Table 4- 5proportion of standard parallel, tapered and gib head keys

Let length of key is L and it’s obtained by considering the key in shearing and crushing.
Considering shearing of the key, shearing strength is,
T = L*W*τK*d/2

62
And τK = σY/2F.S = 370/2*4 = 46.25MPa
Therefore, T = L*10*46.25*30/2 = 6937.5LN.mm………………….a1
Torsional shearing strength of the shaft
T = π/16*τS*d3 = π/16*50*303 = 265071.9N.mm…..……………….a2
From equation a1 and a2
265071.9 = 6937.5L, L = 265071.9/6937.5 = 38.21mm
Considering crushing of the key, crushing strength is,
T = L*t/2*σc*d/2
And σc = σy/F.S = 370/4 = 92.5MPa……………….b1
T = L*8/2*92.5*30/2 = 5550LN.mm…………………….b2
From equation b1 and a2
265071.9 = 5550L, L = 265071.9/5550 = 47.76mm
Taking the larger value,
L = 47.76mm say 50mm Ans
4.11.9 Design Of Bolts
Material selected for the bolt is 304 stainless steel with yield strength.
σY = 215MPa
Safety factor assumed is F.S = 2
Number of bolts, n = 8
Engine weight P 200lb = 8900N
The internal thread found on the engine for fitting the bolt is 12mm.
Therefore, diameter of the bolt d = 12mm
Considering shearing of the bolt, shearing strength is,
Pload = πd2 τbolt/4
Pload = p/n = 8900/8 = 1112.5N
Therefore shearing strength we be,
1112.5 = π122 τbolt/4
τbolt = 4*1112.5/π122 = 9.84MPa
But allowable shear stress is,
τall = σy/2F.S = 215/2*2 = 53.75MPa
Since τbolt = 9.84MPa is less than τall = 53.75MPa, the design is satisfactory.

63
Considering crushing of the bolt, crushing strength is,
Torque transmitted
T = k*d*peach = 0.2*12*1112.5N = 2670N.mm
k = 0.2 for non lubricated bolts
Therefore crushing strength is,
σC bolt = 2T/πd3 /4 = 2*2670/π123 /4=3.9345MPa
But allowable crushing stress is,
σC all = σy/F.S = 215/2 = 107.5MPa
Since σC bolt = 3.934MPa is less than σC all = 107.5MPa, the design is satisfactory.

4.11.10 Design Of Column

The column is the vertical supporting member for the engine stand which supports the engine
load.
The material selected for the column is mild steel with crushing stress σ c = 320MPa The ideal
working height for most humans on engine repair is 130mm. Therefore, the length of the column
is assumed to be L = 100mm.
The steel is square section b = h and thickness of column is assumed to be 4mm. Now let us
check whether the column is safe or not by using Rankine’s formula.
f c∗A
P= 2
1+α ¿
k ( )
Where, P = critical load
Fc = crushing stress
A = cross sectional area of column
Ɩe = Equivalent length of column
α = Rankine’s constant
k = least radius of gyration

h t

b
Since the column is fixed on end the effective length, Le = 2L = 2000mm

64
Load coming at the column is, P = Pengine/2 = 4450N
Rankine’s constant for mild steel, α = 1/7500
Area of cross section, A = [(bh)-(b-2t)*(h-2t)] = 4bt + 4t2 = 1664mm2 , since b = h
2 2
bh ( b−2 t )( h−2 t)
Moment of inertia, I = − =2363392 mm4
12 12

Radius of gyration, k =
√ √
I
A
=
2363393
1664
=37.686 mm

Therefore crushing load

fcA 320∗1664
P= = =387.1 KN
( )
2
2000 2
( )
1+a ¿
k 1+
1
7500 37.686
Since the load coming at the column is much less than the crushing load, the design is safe
4.11.11 Design Of Lever Arm
The lever arm has L-shape and the length of this lever is selected as, Ɩ = 180mm.
Let d = Diameter of handle in mm
The load applied by the operator is assumed to be 50N. And σb = 100N/mm2
The force applied acts at a distance of one-third of the length of the handle from its free end.
Therefore maximum bending moment is,
M = (1 – 1/3)*P*Ɩ = (1 – 1/3)*50*180 = 6000N.mm
Section modulus,
Z = (π/32)*d3 = 0.0982d3
Therefore, twisting moment is
M = σb*z = 100*0.0982d3
d = 8.485mm say 10mm Ans
Cross section of the lever arm
Let t =thickness of the lever arm in mm
b = width of lever arm in mm
Assume width is twice the thickness.
The lever arm is to be designed for 25% more bending moment.
Therefore, maximum bending moment is
M =1.25∗P∗l=1.25∗50∗180=11250 Nmm

65
Section modulus¿ ()
1
6
1
()
∗t∗b2= ∗t∗( 2t )2=0.667 t 3
6
M 11250
α b= , 100=
Z 0.667 t 3
t = 5.53mm say 6mm Ans.
b = 2t = 12mm Ans
Let us now check the lever arm for induced bending. Bending moment on the lever arm near the
boss (assuming that the length of the arm extends up to the center of shaft) is given by,
M = p∗l=50∗80=9000 Nmm
M 9000 62.5 N
α b= = =
Z 144 mm
2

Therefore, the induced bending stress is within safe limits.

66
 CHAPTER FIVE

CONCLUSION AND RECOMMENDATION

5.1 Conclusion
This design project aims in designing and analysis of heavy duty, manually operated engine with
gear box drive. The main objective of the design project is to eliminate the lack of engine stand
in the maintenance workshops of Industry. It aims to design an engine stand with low cost of
production which will improve the current working condition and provide ease in engine
maintenance. Design concepts are generated by referring to previous designs and literatures. The
best design concept is selected considering cost, availability, efficiency, and other criteria. After
selecting the best alternative design calculation for each component is carried out. Generally, we
can say that most of the design objectives are met throughout the project.

5.2 Recommendation
Due to the limited time we had at the ERA, we were not able to manufacture the engine stand
which is designed in the project. So, we recommend the Industry and other mechanical and
Manufacturing Engineering students who are going to take internship in this Industry in the
future to develop the prototype and check the general functionality of the project.

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APPENDICE
Detail drawings and assembly drawing of the engine stand.

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