Mattu University

College of engineering and technology

Department of Mechanical engineering

Intern Hosting Company: Ethiopian Construction Works

Corporation

Final Report on Internship and Project Entitled, Design of

drum brake extractor
Duration: Mid-April to Mid-July

Name ID No
Hisham Munewor Ru 4360/ 13
Habtewold Fenta Ru 1741/ 13
Fitsum Befikadu Ru 4208/ 13

Submission Date: Oct, 4 2024

Mattu, Ethiopia
Statement of Declaration
We, Hisham Munewor, Habtewold Fenta, and Fitsum Befikadu, hereby declare that we have
successfully completed our internship at the Ethiopian Construction Works Corporation
(ECWC) as part of our academic and professional development.

Internship Details:

• Intern Names: Hisham Munewor, Habtewold Fenta, Fitsum Befikadu

• Internship Title: Mechanical Engineering Interns
• Internship Duration: Mid-April to Mid-July
• Department: Engine Shop and Electric Shop
• Supervisor Name: Biniyam
• University: Mattu University

Declaration of Completion:

We collectively declare that during the period of our internship, we adhered to all ECWC
regulations, safety standards, and company guidelines. The experience and knowledge gained
through this internship will contribute greatly to our future careers as mechanical engineers.

Signatures:

• Name:______________________
Date: ______________________
• Name:______________________
Date: ______________________
• Name:______________________
Date: ______________________

For Office Use Only:

• Supervisor’s Name: ______________________

• Supervisor’s Signature: ______________________
• Date: ______________________

I
Acknowledgment
We extend our thanks to the Construction Equipment Maintenance Unit for their cooperation
and valuable insights, which were essential in completing this work.

Our heartfelt appreciation also goes to our families and friends for their encouragement, and to
our department for providing the necessary resources and facilities.

Finally, we acknowledge the efforts of every group member, whose teamwork and dedication
made this project possible. Thank you all for your contributions and support.

II
Abstract
This paper is aimed at discussing the overall activity in the internship period that we are engage
with it. With a reference and reliance on the outline for an internship report, generally this paper
will try to discuss about the brief history of the internship hosting company, Ethiopian
Construction Works Corporation, the overall internship experience, and benefits we gained from
the internship and other related topics. Although the internship period was only three months, we
got a lot of important things like we develop practical skills, how to manage our self if we want
to do private task in addition to being employee, how to react with the employers in the company
and to develop communication skill, organizational skill, responsibility in the task-fulfillment,
cooperation with colleagues and other issues.

This project focuses on the design and development of a manually operated drum brake
extractor, aimed at simplifying the removal of drum brakes without damaging the components.
The design leverages mechanical principles to create a tool that is low-cost, lightweight, and easy
to operate. The methodology includes detailed material selection, force calculations, and
structural analysis to ensure durability and efficiency. Challenges such as optimizing the tool’s
ergonomics and cost-effectiveness were addressed through careful design considerations. The
result is a drum brake extractor that reduces labor effort, enhances safety, and provides a reliable
solution for automotive service centers. This tool has the potential to significantly improve brake
maintenance procedures by reducing time, labor, and associated costs.

III
Table of Contents
Statement of Declaration ........................................................................................... I
Acknowledgment ...................................................................................................... II
Abstract ....................................................................................................................III
List of figures .......................................................................................................... IX
List of tables.............................................................................................................. X
PART ONE: INTERN REPORT ...............................................................................1
1 Chapter one..........................................................................................................1
1.1 Introduction ................................................................................................1
1.1.1 Background of the Company ..................................................................1
1.2 Overview of Products and Services ...........................................................3
1.3 The main customer or users of its services ................................................4
1.4 The overall organization and work flow of the company ..........................6
1.5 Maintenance workflow...............................................................................6
2 Chapter Two ........................................................................................................8
2.1 How we got into the company ...................................................................8
2.2 Tire-Based Machinery/Equipment Maintenance Shop ............................10
2.3 Chain-Based Machinery/Equipment Maintenance Shop .........................10
2.4 Construction Machinery/Equipment Maintenance Shop .........................11
2.5 The main procedures of engine repair......................................................12
2.6 Work tasks we executed ...........................................................................13
2.7 Loader Engine Repair...............................................................................13
2.8 Dozer Transmission Stuck .......................................................................15
2.9 Hydraulic Winch Oil Leak .......................................................................16
2.10 Bulldozer Engine and Radiator Repair ....................................................17
2.11 Electronics and Electrical Maintenance Group ........................................18
2.12 Industrial Electric and Electronics Shop: .................................................19
2.13 Auto Electric Maintenance Shop: ............................................................20

IV
 2.13.1 General Workflow of the Electronics and Electrical Maintenance
Group 20
2.13.2 Collaboration with Other Units..........................................................21
2.14 Major Maintenance Works .......................................................................22
2.14.1 Maintenance Works ...........................................................................22
2.15 Identified Challenges in the Shop ............................................................23
2.16 Recommendations ....................................................................................24
3 Chapter Three ....................................................................................................25
3.1 Overall Internship Experience..................................................................25
3.2 Benefits Gained from the Company.........................................................25
3.2.1 Practical Skill Development .................................................................25
3.2.2 Theoretical Knowledge Enhancement ..................................................26
3.2.3 Interpersonal Communication Skills.....................................................26
3.2.4 Teamwork Skills ...................................................................................26
3.2.5 Leadership Development ......................................................................27
3.2.6 Understanding of Work Ethics..............................................................27
3.2.7 Entrepreneurship Skills .........................................................................27
PART TWO: PROJECT WORK .............................................................................30
4 Chapter four .......................................................................................................30
4.1 Introduction to the Design of a Drum Brake Extractor............................30
4.2 Background History of Drum Brake Systems..........................................30
4.3 Challenges in Drum Brake Maintenance and Need for an Extractor ......31
4.4 Modern Applications ................................................................................31
4.5 Drum Brake Systems................................................................................31
4.5.1 Components of drum extractor .............................................................33
4.6 OBJECTIVE.............................................................................................33
4.6.1 General Objective .................................................................................33
4.6.2 Specific Objective .................................................................................34
4.7 Scope ........................................................................................................34

V
 4.7.1 Significance ...........................................................................................34
4.7.2 Limitation ..............................................................................................34
5 Chapter five .......................................................................................................35
5.1 Literature review ......................................................................................35
6 Chapter six .........................................................................................................37
6.1 Methodology ............................................................................................37
6.2 Data collection method ............................................................................38
6.2.1 Primary data collection methods ...........................................................38
6.2.2 Secondary data collection methods .......................................................38
6.3 Material selection .....................................................................................39
7 Chapter seven ....................................................................................................41
7.1 Detail Design of Drum Brake Extractor ..................................................41
7.2 Significance of the Detailed Design.........................................................41
7.3 Design of power screw .............................................................................43
7.4 Design of cross bar ...................................................................................48
7.5 Design of nut for cross-section ................................................................50
7.6 Design of jaw ...........................................................................................56
7.7 Design of bolt ...........................................................................................61
7.8 Nut design ................................................................................................63
7.9 Assembling process ..................................................................................65
8 Chapter eight .....................................................................................................67
8.1 Manufacturing Process .............................................................................67
8.1.1 Design Phase .........................................................................................67
8.1.2 Material Procurement ............................................................................67
8.1.3 Manufacturing Process ..........................................................................68
8.1.4 Forging ..................................................................................................68
8.1.5 CNC Machining ....................................................................................68
8.1.6 Thread Rolling/Cutting: ........................................................................68
8.1.7 Heat Treatment:.....................................................................................68

VI
 8.1.8 Welding: ................................................................................................69
8.1.9 Assembly ...............................................................................................69
8.1.10 Surface Finishing ...............................................................................69
8.1.11 Quality Control ..................................................................................69
8.1.12 Packaging and Distribution ................................................................69
9 Chapter nine.......................................................................................................71
9.1 Cost analysis .............................................................................................71
9.2 Material Costs ..........................................................................................71
9.2.1 Power Screw: ........................................................................................71
9.2.2 Cross-bar: ..............................................................................................71
9.2.3 Jaw: .......................................................................................................71
9.2.4 Handle: ..................................................................................................72
9.2.5 Bolt: .......................................................................................................72
9.2.6 Nut: ........................................................................................................72
9.2.7 Total Material Cost: ..............................................................................72
9.3 Machining Costs .......................................................................................72
9.3.1 3. Labor Costs .......................................................................................72
9.4 Total Cost .................................................................................................72
9.4.1 Additional Costs:...................................................................................73
9.4.2 Total Costs: ...........................................................................................73
10 Chapter ten ...............................................................................................74
10.1 Result and Discussion ..............................................................................74
10.1.1 Result .................................................................................................74
11 Chapter eleven ..........................................................................................76
11.1 Conclusion And Recommendation ..........................................................76
11.1.1 Conclusion .........................................................................................76
11.1.2 Recommendation ...............................................................................76
12 Chapter twelve..........................................................................................77
12.1 Drawing of part and assembly..................................................................77

VII
 12.1.1 Part and assembly ..............................................................................77
12.1.2 part drawing .......................................................................................77
12.2 Assembly drawing ....................................................................................83
13 Bibliography .............................................................................................85

VIII
List of figures

Figure 1 head office of Ethiopian construction works corporation ................................................ 1

Figure 2 Ethiopian construction works corporation timeline ......................................................... 2
Figure 3 Services of Ethiopian construction works corporation ..................................................... 4
Figure 4 Key customers and users of ECWC ................................................................................. 5
Figure 5Organizational structure of Ethiopian construction works corporation ............................ 6
Figure 6Maintenance workflow ...................................................................................................... 7
Figure 7 breakdown of machinery maintenance units .................................................................... 9
Figure 8 heavy duty equipment or instrument maintenance department ...................................... 12
Figure 9 engine repair procedure .................................................................................................. 13
Figure 10 electronics and electrical maintenance department ...................................................... 18
Figure 11 electrical repair and maintenance process .................................................................... 21
Figure 12 comprehensive benefits of internship experience......................................................... 28
Figure 13 diagrammatic expression of the methodology .............................................................. 37
Figure 14 diagrammatic expression of data collection method .................................................... 38
Figure 15 power screw .................................................................................................................. 47
Figure 16 Cross-bar analyses ........................................................................................................ 48
Figure 17 Cross bar cross section ................................................................................................. 49
Figure 18 Design of handle .......................................................................................................... 54
Figure 19 Handle........................................................................................................................... 56
Figure 20 Jaw ................................................................................................................................ 60
Figure 21 Bolt ............................................................................................................................... 63
Figure 22 Nut ................................................................................................................................ 65
Figure 23 Assembly of drum extractor ......................................................................................... 66
Figure 24 2D drawing of cross-bar ............................................................................................... 77
Figure 25 2D drawing of power screw ......................................................................................... 78
Figure 26 Drawing of jaw ............................................................................................................. 79
Figure 27 2D drawing of handle ................................................................................................... 80
Figure 28 2D drawing of bolt........................................................................................................ 81
Figure 29 2D drawing of drum extractor ...................................................................................... 83
Figure 30 3D drawing of drum extractor ...................................................................................... 84

IX
List of tables

Table 1 yield and tensile strength for some hot-rolled and cold-rolled steels .............................. 42
Table 2 mechanical property of AISI-1015 steel .......................................................................... 42
Table 3 mechanical property of mild steel .................................................................................... 42
Table 4 mechanical property of ASTN-A36 ................................................................................. 42
Table 5 mechanical property of AISI-1020 .................................................................................. 42
Table 6 mechanical property of AISI-1030 .................................................................................. 43
Table 7 Basic dimensional for square threads in mm (normal series) according to IS 4694-1968
(reaffirmed 1996 ........................................................................................................................... 44
Table 8 values of and R for commonly used cross section in curved beam .............................. 57
Table 9 design dimensions of screw threads, bolts and nuts ........................................................ 62
Table 10 Material cost .................................................................................................................. 73
Table 11 Power screw specification ............................................................................................. 74
Table 12 Cross bar specification ................................................................................................... 74
Table 13 Handle specification ...................................................................................................... 74
Table 14 Jaw specification ............................................................................................................ 75
Table 15 Nut specification ............................................................................................................ 75

X
PART ONE: INTERN REPORT
1 Chapter one
1.1 Introduction
1.1.1 Background of the Company

The Ethiopian Construction Works Corporation (ECWC) is a state-owned enterprise with an

authorized capital of over 374.8 million USD. Established in 1947, ECWC specializes in
constructing vital infrastructure such as highways, bridges, airfields, dams, irrigation systems, and
water supply facilities, in addition to buildings and the manufacturing of building materials. The
corporation utilizes its extensive expertise to offer solutions in engineering design, project
development, and management from the execution stage to commissioning for both domestic and
international clients.

Figure 1 head office of Ethiopian construction works corporation

Throughout its history, ECWC has evolved by merging with various organizations, including the
Ethiopian Road Construction Corporation and the Ethiopian Water Works Construction
Enterprise. These mergers have enhanced its capacity to deliver a wide range of services, from
assembling construction equipment and vehicles to producing and renting out spare parts and
maintenance services. The corporation's mission is to provide high-quality engineering,
construction, and investment works locally and abroad while also aiming to be among the top ten
leading construction and manufacturing companies in East and Central Africa by 2030.

ECWC values teamwork, commitment, quality, cost-effectiveness, accountability, safety, and

continuous improvement. These core values guide the corporation's operations as it continues to
develop projects in diverse sectors, including transport infrastructure, water infrastructure,

1
building construction, and the production of construction inputs. Additionally, ECWC engages in
agricultural activities, real estate, and the production and leasing of construction equipment.

With over 75 years of experience, ECWC employs more than 15,000 permanent and contract
workers, including over 1,400 professional engineers and 1,600 senior technicians. The
corporation has completed over 200 major projects, some of which extend to international
locations, such as Djibouti. ECWC's diverse portfolio includes airfield construction, dam and
irrigation projects, road construction, and building projects across Ethiopia and beyond, with
notable contracts ranging from hundreds of millions to billions of Ethiopian birrs.

Figure 2 Ethiopian construction works corporation timeline

Figure 1.2 Ethiopian construction works corporation timeline

2
In 2015, the Ethiopian Construction Works Corporation (ECWC) was formed through the merger
of the Ethiopian Road Construction Corporation and the Ethiopian Water Works Construction
Enterprise. In 2016, the corporation expanded by incorporating the Ethiopian Prefabricated
Building Parts Production Enterprise. This consolidation strengthened ECWC's position in
Ethiopia's construction industry.

Driven by a vision to foster growth and innovation in the construction sector, ECWC remains a
leading force in Ethiopia's development efforts, continuously expanding its services and expertise.

1.2 Overview of Products and Services

The Ethiopian Construction Works Corporation (ECWC) operates through several specialized
units, providing a wide range of products and services that contribute to Ethiopia’s infrastructure
and development initiatives.

The Construction Unit handles critical projects in transport infrastructure, water infrastructure,
and comprehensive building construction, including interior fit-outs.

The Manufacturing Unit supports these efforts by producing construction materials, both for the
corporation’s internal use and the broader market.

The Project Development and Management Unit offers project management services, including
design, research and development (R&D), training, and certification, ensuring projects adhere to
quality and regulatory standards.

The Agricultural Unit focuses on food crop production and has plans to establish Agro-processing
plants, contributing to Ethiopia's agricultural and industrial sectors.

The Real Estate and Housing Development Unit specializes in prefabricated housing
construction and large-scale real estate projects, addressing the growing demand for housing.

3
ECWC’s Investment Unit facilitates collaborations and investments through partnerships, such
as GIW, ECWC-RISING, and HONGFA GROUP, enhancing the corporation’s growth and
impact.

Figure 3 Services of Ethiopian construction works corporation

The Equipment and Machineries Unit is responsible for the assembly, maintenance, leasing, and
fabrication of construction equipment and molds, supporting ECWC’s operational needs and
contributing to the wider construction industry.

Through these integrated services, ECWC plays a vital role in Ethiopia's infrastructure
development and economic progress.

1.3 The main customer or users of its services

The Ethiopian Construction Works Corporation (ECWC) serves a wide range of customers,
primarily focusing on vehicle maintenance and repair services through its dedicated equipment
maintenance team. The vehicles serviced by the corporation are typically used for transportation
and construction purposes, ensuring that they remain operational for various projects and
government functions. ECWC’s customers include several prominent entities within Ethiopia,
such as the Sugar Corporation, the Ethiopian Road Authority, and the Train Corporation, all of
which rely on the company for regular maintenance and repair of their fleets. In addition, ECWC
provides services to regional and central government bodies, including the Federal Supreme
Court and other government organizations that require vehicle maintenance. The corporation also
extends its services to neighboring countries, working with international partners to support
infrastructure and development initiatives. The airport runway maintenance projects and
collaborations with regional governments further showcase the corporation's critical role in
sustaining Ethiopia’s transportation and construction sectors. Through these partnerships, ECWC
plays a vital role in maintaining the vehicles that drive large-scale infrastructure projects and
governmental operations across the country.

4
The Ethiopian Construction Works Corporation (ECWC) serves a broad range of customers,
focusing on the repair and maintenance of vehicles used primarily in transportation and
construction. Through its equipment maintenance team, the corporation ensures the functionality
and efficiency of vehicles critical to both public and private sector projects. ECWC’s services
extend to major governmental and regional organizations, playing a key role in supporting
infrastructure development and operational efficiency across various sectors. The corporation
maintains a diverse clientele, including government bodies, large corporations, and neighboring
countries that rely on its vehicle maintenance expertise. This support is crucial for transportation,
construction, and infrastructure projects across Ethiopia and beyond.

Key customers and users of ECWC's services include:

• Sugar Corporation
• Ethiopian Road Authority
• Train Corporation
• Regional Governments
• Federal Supreme Court
• Central Government
• Organizations that require vehicle maintenance
• Airport runway maintenance projects
• Neighboring countries

During our internship, we learned that the Ethiopian Construction Works Corporation (ECWC)
not only repairs vehicles used for transportation and construction but also services privately owned
cars. Additionally, power generators play a significant role in the range of machinery repaired by
the corporation. This diversification allows ECWC to cater to a broader range of clients, extending

Figure 4 Key customers and users of ECWC

5
beyond public and government sectors to include private vehicle owners and essential machinery
like power generators, which are crucial for both industrial and infrastructure projects.

1.4 The overall organization and work flow of the company

A well-structured management system is essential for any organization to thrive, functioning as

the brain that coordinates and drives all activities. Establishing a well-defined management
structure is the foundation for fostering collaboration and ensuring that all departments and teams
work together seamlessly. The Ethiopian Construction Works Corporation (ECWC) has developed
a comprehensive management system designed to oversee and streamline its operations. This
system not only ensures that construction projects and services are delivered at the highest quality
but also focuses on cost-efficiency and timely execution.

Figure 5Organizational structure of Ethiopian construction works corporation

By effectively managing resources and processes, ECWC is able to achieve success both locally
and internationally, while maintaining competitive standards in the industry. Through its robust
management system, the corporation continues to deliver on its mission of providing high-
quality, affordable construction services that meet the demands of the market.

1.5 Maintenance workflow

Since our internship program focused on heavy-duty machinery maintenance, I had the opportunity
to closely observe the detailed process that equipment undergoes when brought in for repairs. The
first step in the maintenance workflow involves the equipment owner coming to the inspection
unit with a Request for Service (RFS) form. This form is essential as it documents the equipment's
maintenance needs. Once the RFS is submitted, a thorough physical inspection of the equipment
is conducted by the inspection team. Based on their findings, they open a Shop Repair Order

6
(SRO), which directs the equipment to the appropriate shop for the required repairs. In some cases,
the work may move between different shops through internal shop orders, ensuring that the
necessary expertise and tools are available at each stage.

Once the equipment reaches the designated shop, the foreman reviews the SRO to verify that all
the necessary maintenance activities are properly documented. After confirming the required tasks,
the foreman assigns technicians to begin work on the equipment. However, before the technicians
proceed with any maintenance activities, they perform an additional physical inspection to double-
check the current status of the equipment, particularly focusing on any missing parts or
components that might have been overlooked in the initial inspection.

After completing this re-check, the technicians begin the repair work. Depending on the nature of
the problem, they may use specialized machinery or tools to complete their tasks. Throughout the
repair process, if it becomes evident that new spare parts are required, the shop supervisor steps in
to formally request the necessary parts to ensure the repair proceeds without delay.

Figure 6Maintenance workflow

This structured and methodical approach ensures that the maintenance work is thorough, efficient,
and addresses all the issues identified. By involving multiple checks and coordination between
inspection, repair, and spare parts management, the process minimizes errors and guarantees that
the equipment is restored to optimal working condition before being returned to service. This
system not only highlights the importance of organized repair workflows but also underscores the
critical role of communication and coordination within maintenance teams.

7
2 Chapter Two
2.1 How we got into the company

Our journey to joining the company began with a visit to the head office, located in Addis Ababa,
around Gurd Shola, just above the Ethiopian Athletics Federation. Upon arrival, we headed to the
Human Resources (HR) department where we submitted the official letter provided by our
university. After presenting the letter, we were asked to fill out a form and instructed to return the
following day for our placement confirmation.

The next day, we received an acceptance letter from the HR department along with our placement
details. We were assigned to the Equipment and Machinery Unit, located in Kality, Addis Ababa,
near Wuha Limat. That same day, we went to the unit and handed over our letter of placement
along with all the necessary documents. The team at the unit guided us to their HR department,
where our documents were reviewed and our placement was finalized. We were then assigned to
different areas—some of us were placed in heavy-duty machinery equipment maintenance, while
others were assigned to light-duty machinery maintenance.

Later that afternoon, we had a scheduled meeting where we were introduced to key figures,
including foremen, engineers, and other important personnel. During the meeting, we were given
an overview of the workflow, our working hours, and what was expected from us during the
internship. The following day, we began our first day of work, fully prepared and wearing our
overcoats, ready to contribute and learn in our respective roles.

On our first day at the company, we were introduced to Mr. Tesfaye, the head of the Heavy-Duty
Equipment Machinery Unit and our supervisor. We also met Mr. Biniyam, the foreman and head
of the engine shop, as well as Mr. Petros, the head of the electrical shop.

The following day, we officially joined the company’s engine shop maintenance department,
where we were introduced to Mr. Getu, a senior technician, and Mr. Temesgen, another senior
technician. They gave us a tour of the maintenance rooms where we would be working and
provided an orientation on the various equipment and tools.

In just a few days, we became familiar with the environment and gained a solid understanding of
the company’s operations. The tasks we performed during our internship are discussed in detail in
the following sections.

The section we have been working at was In the Heavy-Duty Equipment Machinery
Maintenance Unit, there are three main groups that handle the maintenance of various types of
machinery and equipment. These groups are structured to ensure that all aspects of the
equipment's repair and upkeep are managed efficiently. They are as follows:

1. Construction Machinery and Equipment Maintenance Group:

This group focuses on maintaining and repairing construction-related machinery. It is
further divided into three specialized shops, each addressing different types of machinery:

8
 • Tier-Based Machinery or Equipment Maintenance Shop: Handles tier-based
machinery, focusing on the specific needs of this type of equipment.
• Chain-Based Machinery or Equipment Maintenance Shop: Specializes in
maintaining chain-driven construction machinery.
• Construction Machinery or Equipment Maintenance Shop: Provides general
maintenance and repair services for a variety of construction machinery and
equipment.
2. Auxiliary Machinery and Equipment Maintenance Group:
This group is responsible for the upkeep and repair of auxiliary machinery. It operates
through one dedicated shop:
• Auxiliary Machinery or Equipment Maintenance Shop: Focuses on the
maintenance and repair of auxiliary equipment, including power generators, as
well as performing engine check-ups after repairs.
3. Electronics and Electrical Maintenance Group:
This group deals with both industrial electrical systems and automotive electrical
components. It is divided into two distinct shops:
• Industrial Electric and Electronics Shop: Specializes in repairing and
maintaining industrial electrical systems and electronic components.
• Auto Electric Maintenance Shop: Focuses on the maintenance and repair of
electrical systems found in heavy-duty vehicles and machinery, such as starters,
alternators, and wiring.

Figure 7 breakdown of machinery maintenance units

These groups work collaboratively to ensure that all aspects of the equipment and machinery are
maintained to the highest standards, ensuring both operational efficiency and longevity.

We spent the majority of our internship in the construction machinery and equipment maintenance
shop, as well as in the electronics and electrical machinery maintenance shop. This focus allowed
us to gain hands-on experience and develop our skills in both areas.

9
2.2 Tire-Based Machinery/Equipment Maintenance Shop

In this shop, the focus is on maintaining and repairing machinery and equipment that operate on
rubber tires, such as wheel loaders, graders, dump trucks, and other heavy construction vehicles.
Workflow:
Inspection: Every machine undergoes a thorough inspection before being serviced. This includes
checking tire conditions (tread depth, pressure, signs of wear), suspension, steering alignment, and
brake systems.
Diagnosis: Based on the inspection, we diagnose any issues with the tires or associated
components, such as axles, hubs, or brakes.
Maintenance: Common tasks include tire replacements, air pressure adjustments, wheel balancing,
alignment corrections, and brake pad replacement.

Tools Used:
• Torque wrenches for tightening lug nuts
• Hydraulic jacks for lifting heavy equipment
• Tire changers and wheel balancers

2.3 Chain-Based Machinery/Equipment Maintenance Shop

This shop deals with construction equipment that uses tracks or chains, such as bulldozers,
excavators, and track loaders.
Workflow:
Inspection: We inspect the condition of the tracks, rollers, sprockets, and idlers for wear,
misalignment, or damage.
Track Tensioning: Ensuring the proper tension of the chains/tracks is essential. If tracks are too
tight, they cause excessive wear; too loose, they can come off.

Replacement and Repairs: Damaged links, worn-out shoes, and broken sprockets are replaced. The
hydraulic systems controlling the track mechanisms are also serviced.

10
Tools Used:
• Track press for removing and installing track pins and bushings
• Welding and cutting tools for fabricating track components
• Heavy-duty lifting cranes for large-scale track assembly

2.4 Construction Machinery/Equipment Maintenance Shop

This is a more generalized maintenance shop where a wider range of construction equipment, such
as cranes, compactors, and mixers, is serviced.
Workflow:
Comprehensive Diagnostics: Each machine undergoes a full system check, including hydraulics,
engines, electrical systems, and any specialized parts.
Routine Maintenance: This includes changing engine oil, replacing hydraulic fluids, checking and
replacing filters, and inspecting hydraulic hoses and fittings.
Repair and Overhaul: Major repairs like engine overhauls, hydraulic cylinder replacements, or
electrical wiring repairs are conducted.

Tools Used:
• Engine hoists for lifting large components
• Torque wrenches for critical fastening
• Electrical diagnostic tools like multimeters and oscilloscopes

General Workflow in All Shops:

• Work Order Generation: Maintenance starts with a work order, which is generated
based on scheduled service intervals or after a machine breaks down.
• Parts Ordering and Inventory Management: For any repairs, parts are ordered or
pulled from the shop's inventory.
• Quality Checks: After repairs or maintenance, machines are tested to ensure they
meet performance and safety standards before being returned to service.
• Documentation: Each maintenance task is logged into the system, providing a
record of work done and ensuring future reference for machine history.

11
In the construction machinery and equipment maintenance shop, where we spent most of our
time due to the high number of engines and prioritized projects, the majority of our work
involved loader engines, grader engines, transmissions, hydraulic winches, and dozer engines.
We also frequently dealt with bulldozer engines and transmissions. However, we rarely
encountered issues with chain and tire-based machinery or equipment.

Figure 8 heavy duty equipment or instrument maintenance department

2.5 The main procedures of engine repair

The engine repair process consists of several key stages that ensure the engine is restored to
optimal condition. It begins with the careful disassembly of the engine, during which all
components are methodically removed. This allows technicians to fully access the internal parts.
Once disassembled, each part is thoroughly cleaned to remove grease, dirt, and debris that could
interfere with the repair process. This cleaning is crucial as it helps to ensure accurate inspections
and prevents contamination during reassembly. After cleaning, a detailed inspection takes place.
This involves both visual checks to identify obvious signs of wear, cracks, or damage, and
precise measurements of critical components, such as cylinders, bearings, and pistons, using
specialized tools like micrometers and calipers. These measurements ensure that each part meets
the manufacturer’s specifications for performance and safety. After the inspection, the engine is
partially reassembled to keep the components safe and secure while waiting for any required
replacement parts. Once these new parts arrive, the engine is again disassembled for a final
cleaning, ensuring that any dust or contaminants accumulated during the waiting period are
removed. In the final step, the engine is fully reassembled with the new and reconditioned parts.
Great attention to detail is applied to ensure proper alignment, secure installation of seals and
gaskets, and correct torque specifications for bolts. After the engine is fully assembled, it

12
undergoes rigorous testing to ensure it operates efficiently, meets performance standards, and is
ready for use in the field.

2.6 Work tasks we executed

Major maintenance tasks performed in the construction equipment maintenance shop, detailing the
Figure 7 Engine repair procedure
repair procedures, issues identified, and the outcomes of each task. The focus is on four major
equipment repairs: the loader engine, dozer transmission, hydraulic winch oil leakage, and

Figure 9 engine repair procedure

bulldozer engine and radiator system. Each task is analyzed with respect to the root cause of the
problem, the repair methods employed, and recommendations for preventing future failures.

• Loader Engine Repair

• Dozer Transmission Stuck,
• Hydraulic Winch Oil Leak
• Bulldozer Engine and Radiator Repair

2.7 Loader Engine Repair

We received a loader engine with no prior service history. During the inspection, the technicians
and I detected unusual noises emanating from the engine. Upon cleaning it with oil, we noticed
signs of corrosion and rust, indicating a water-oil mixture inside the combustion chamber.
Further inspection revealed that the pistons were stuck. We proceeded to carefully disassemble
the connecting rods, and upon removing the cylinder liner, we observed cracks and wear on the
liner. Additionally, one of the connecting rods was loose, which explained the source of the noise
we had heard earlier. After thoroughly cleaning the engine housing, we measured the liner and
concluded that both the connecting rod and liner needed to be replaced, as the wear and friction
had severely damaged them. We submitted a materials request form for these parts, but

13
unfortunately, the replacement components were delayed for over two months due to inventory
issues, preventing us from completing the repair in a timely manner.

• Background:

The loader engine in question arrived without any prior service history, making diagnosis
more challenging. During the initial inspection, abnormal noises were heard from within
the engine, suggesting internal issues. Further investigation revealed the presence of a
water-oil mixture, which is a clear indication of potential internal damage.

• Inspection and Diagnosis:

The engine was cleaned with oil to remove contaminants, which allowed us to see the
extent of the corrosion and rust inside the combustion chamber.

The pistons were found to be stuck, which necessitated the careful disassembly of the
connecting rods.

Upon removing the cylinder liner, we observed significant cracking and wear.

The connecting rod was also loose, and upon further examination, we confirmed that it
was the primary source of the noise.

• Measurements and Conclusion:

The engine housing and components were thoroughly cleaned and measured to assess the
extent of the damage.

We determined that the connecting rod and cylinder liner were severely worn due to
friction, and both needed to be replaced.

• Actions Taken:

A request form was submitted for a new connecting rod and cylinder liner. However, due
to inventory delays, the required materials were not received for over two months,
resulting in prolonged downtime for the loader.

• Recommendations:

To avoid such delays in future repairs, it is recommended that a more proactive approach
be taken in managing spare parts inventory. Additionally, regular maintenance checks
should be enforced to avoid internal engine corrosion and water contamination.

14
2.8 Dozer Transmission Stuck

A dozer with a stuck transmission arrived from a project site. During our inspection, we found that
it was unable to shift gears and the torque converter was not functioning properly. Upon
disassembly with the technicians, we discovered that the root cause was overwork and
negligence—despite the early warning signs, the operator had chosen not to service the
transmission. As we dismantled the torque converter and examined each disc layer, we found
significant signs of burning and deformation. The transmission housing itself was severely burnt
and cracked, indicating a catastrophic failure. After identifying the damaged components, we
submitted a report with the required materials. However, the senior technicians calculated that the
cost of repairs was extremely high, and sourcing the necessary parts was a major challenge. To
keep the project on schedule, we suggested using a transmission from another dozer that was out
of service due to an engine problem, but had a fully functioning transmission. The team agreed,
and we proceeded with that solution.

• Background:

A dozer was brought into the shop with transmission issues; it was unable to shift gears,
and the torque converter was not functioning. This equipment had come directly from an
active project site.

• Inspection and Diagnosis:

During the inspection, it was discovered that the transmission had been severely
overworked without adequate maintenance, leading to complete failure.

Disassembly of the torque converter revealed extensive damage, including burnt and
deformed discs.

The transmission housing was found to be burnt and cracked, which indicated that the
issue had been ongoing and neglected by the operator.

• Root Cause:

The failure was caused by overwork and lack of maintenance, as confirmed by the
technicians. Despite early warning signs, the operator did not take the necessary steps to
service the transmission, which led to the catastrophic failure.

• Actions Taken:

A detailed report was submitted, outlining the materials required for the repair, including
new torque converters, discs, and transmission housing components.

Due to the high cost and complexity of sourcing the parts, it was determined that using
parts from another non-operational dozer was a more feasible solution. This alternative

15
 dozer had a functioning transmission but a faulty engine, making it an ideal donor for
parts.

• Outcome:

The team approved the suggestion, and the transmission from the out-of-service dozer
was successfully installed, allowing the project to proceed without significant delays.

• Recommendations:

It is recommended that operators receive regular training on identifying early warning

signs of mechanical failure. Preventive maintenance schedules should be strictly enforced
to avoid similar catastrophic transmission failures in the future.

2.9 Hydraulic Winch Oil Leak

We were tasked with inspecting a hydraulic winch that was leaking oil. Unfortunately, there was
no service history or manual available, so we had to diagnose the issue through careful testing.
Upon inspection, we found that the housing was cracked and unable to retain oil. As a solution,
we suggested replacing the winch entirely with another hydraulic winch. While the replacement
winch passed oil retention tests, we faced difficulties getting it to function properly due to the lack
of a manual. Through trial and error, we deduced that the solenoid system required three solenoids
for proper functioning: one for intake, one for output, and one for neutral. We submitted a request
for the necessary materials, but due to delays, we were unable to complete the job in a timely
manner.

• Background:

A hydraulic winch was brought in with significant oil leakage. No service history or
operational manuals were available, adding complexity to the repair process.

• Inspection and Diagnosis:

Upon initial inspection and testing, it was clear that the winch housing had developed
cracks, which prevented it from holding oil effectively.

The lack of a manual made it difficult to diagnose the system’s overall function and
potential issues beyond the oil leak.

• Actions Taken:

A replacement hydraulic winch was installed. However, testing revealed that without
proper documentation, it was challenging to get the system running optimally.

16
 Through troubleshooting, it was determined that the winch required three solenoids to
manage intake, output, and neutral functions. This was deduced based on standard
hydraulic system principles and testing.

A request was submitted for the required solenoids, but the necessary components were
delayed, preventing further progress.

• Outcome:

The hydraulic winch replacement was partially successful, but the lack of timely
materials hindered full functionality.

• Recommendations:

The acquisition of operational manuals for all equipment should be prioritized. In

addition, better coordination between maintenance teams and parts suppliers is necessary
to ensure timely availability of critical components. Implementing regular checks for
hydraulic systems could prevent unexpected failures and reduce downtime.

2.10 Bulldozer Engine and Radiator Repair

• Background:

One of the largest bulldozers in the fleet was reported with severe overheating issues. The
repair process took nearly three weeks due to the size and complexity of the machine.

• Inspection and Diagnosis:

The initial inspection suggested possible gasket failure or corrosion in the engine block.
The engine was subsequently disassembled for a more detailed inspection.

After cleaning the entire engine, it was reassembled and tested. However, after just three
hours of operation, the overheating issue reoccurred, causing the engine to shut down.

• Cooling System Focus:

After the engine’s second failure, I advised the team to investigate the cooling system in
detail.

Testing revealed that the radiator was functional, but the air-cooling system, specifically
the fan, had been installed incorrectly. Furthermore, the water-cooling system had not
been assembled according to manufacturer specifications.

• Actions Taken:

17
 The entire cooling system, including the radiator and fan, was disassembled and
thoroughly cleaned. The components were then reassembled following the
manufacturer’s manual. A coolant was added to the system to prevent future corrosion.

• Outcome:

Following the corrections to the cooling system, the bulldozer operated successfully
without overheating, and no further issues were reported.

• Recommendations:

To prevent overheating in heavy machinery, special attention should be given to the

correct installation and maintenance of cooling systems. Proper use of coolant is critical
in preventing corrosion, and strict adherence to manufacturer guidelines during assembly
is essential.

In conclusion the equipment maintenance tasks highlighted in this report demonstrate the critical
importance of regular preventive maintenance and the need for timely access to replacement
parts. Future operations will benefit from improved inventory management, operator training,
and adherence to manufacturer specifications in repair processes. These steps will help reduce
downtime, prevent costly repairs, and ensure the longevity of the machinery.

2.11 Electronics and Electrical Maintenance Group

This group plays a vital role in ensuring the functionality and safety of both industrial electrical
systems and automotive electrical components used in heavy-duty equipment and machinery.

Figure 10 electronics and electrical maintenance department

18
The group is divided into two specialized shops, each with its specific responsibilities and
workflows:

• Industrial Electric
• and Electronics Shop

2.12 Industrial Electric and Electronics Shop:

This shop focuses on the maintenance and repair of large-scale industrial electrical systems and
electronic components. The workflow involves several stages, each with specific tools and
procedures to ensure the machinery’s optimal performance.

Procedures:

• Initial Inspection and Diagnostics:

The process begins with a thorough inspection of the industrial electrical system. Using
diagnostic tools such as multimeters, oscilloscopes, and infrared thermometers,
technicians identify electrical faults or issues such as short circuits, insulation failures, or
system overloads.
• Troubleshooting:
Once the problem is identified, troubleshooting is conducted using circuit testers,
megohmmeters, and thermal imaging tools to further pinpoint the issue. The goal is to
ensure no underlying problems are missed before proceeding with repairs.
• Component Testing and Repair:
Components such as transformers, motor control centers, circuit breakers, and
programmable logic controllers (PLCs) are tested and repaired or replaced as needed.
This might involve rewiring circuits, replacing faulty fuses or relays, and realigning
control systems.
• Reassembly and Final Testing:
After the repair work is completed, the machinery or electrical system is reassembled,
and final testing is performed to verify that it is operating within safety and performance
standards. Specialized equipment, such as load testers and function generators, are used
to ensure the repaired systems are fully operational.

Tools Used:

• Multimeters (to measure voltage, current, and resistance)

• Circuit testers and voltage detectors

19
2.13 Auto Electric Maintenance Shop:

This shop focuses on the electrical systems of heavy-duty vehicles and construction machinery,
such as starters, alternators, wiring systems, and other key components. The electrical systems in
these vehicles are vital to ensure smooth operations and safety.

Procedures:

• Initial Assessment and Diagnostic Testing:

Upon receiving a vehicle or piece of machinery, the technicians perform an initial
assessment using OBD-II (On-Board Diagnostics) scanners, digital multimeters, and
battery testers to identify electrical faults. This could involve testing the vehicle’s battery,
alternator, starter motor, and wiring harness.
• Component Breakdown and Repair:
After identifying the problem, the faulty electrical components are either repaired or
replaced. Technicians might need to remove and test parts like starters, alternators, fuses,
and wiring harnesses. Alternators and starter motors are often dismantled and rebuilt,
ensuring that brushes, windings, and bearings are functioning properly.
• Rewiring and Circuit Testing:
If there are issues with the wiring, technicians will repair or replace the damaged wiring
using tools such as wire crimpers, strippers, and soldering irons. Proper insulation and
cable routing are critical to prevent future electrical faults.
• Reassembly and Performance Testing:
After the repairs, the system is reassembled, and performance tests are conducted to
ensure the electrical system is fully operational. Load testers are used to simulate real-
world electrical loads to verify the system's reliability under operational conditions.

Tools Used:

• Battery testers (to check the health and charge of batteries)

• Wiring harness tools (including crimpers, wire strippers, and soldering irons)
• Alternator and starter motor rebuild kits
• Load testers (to simulate operational loads for final testing)

2.13.1 General Workflow of the Electronics and Electrical Maintenance Group

The workflow for both the Industrial Electric and Auto Electric shops follows a detailed and
structured process to ensure the successful maintenance of electrical systems:

1. Work Request:
The process begins when a request for electrical repair or maintenance is received
through a Service Repair Order (SRO). The SRO contains details about the issues
reported, and the equipment is assigned to the relevant shop.
2. Preliminary Inspection and Diagnosis:
Technicians conduct a thorough inspection using specialized diagnostic tools to assess

20
 the current condition of the electrical system. In this step, issues are identified, and the
scope of work is defined.
3. Troubleshooting:
Further diagnostics are performed to pinpoint the exact cause of the failure. This may
involve removing components for detailed testing or using diagnostic software to analyze
faults in electronic control systems.
4. Repair or Replacement:
Based on the diagnostic results, technicians either repair or replace the faulty
components. The process involves fixing or replacing electrical parts such as wiring,
motors, sensors, or controllers.
5. Reassembly and Testing:
Once the repair is completed, the machinery or vehicle is reassembled. A comprehensive
test is then performed to ensure the electrical systems are fully functional and meet the
operational standards.
6. Final Inspection and Handover:
After the repair and testing, a final inspection is conducted to verify that the equipment
meets safety and performance requirements. The equipment is then handed over for use.
7. Figure 1.3 breakdown of machinery maintenance units

Figure 11 electrical repair and maintenance process

2.13.2 Collaboration with Other Units

The Electronics and Electrical Maintenance Group collaborates closely with other units within
the Heavy-Duty Equipment Machinery Maintenance Unit. For example:

• Coordination with the Construction Machinery Maintenance Group to ensure that

machinery needing both mechanical and electrical repairs is fully serviced.

21
 • Collaboration with the Auxiliary Maintenance Group for repairs on equipment like
power generators that require both electrical and mechanical attention.

The Electronics and Electrical Maintenance Group is essential for maintaining the
operational efficiency of both industrial equipment and heavy-duty vehicles. Through a
well-structured workflow, skilled technicians ensure that the electrical systems in these
machines function reliably and safely. This group’s work plays a critical role in the overall
maintenance strategy of the company, keeping the machinery in top working condition and
minimizing downtime.

2.14 Major Maintenance Works

As part of the ongoing evaluation of the Electronics and Electrical Maintenance Shop, a detailed
inspection of the key processes, equipment, and challenges faced within the shop has been
conducted. This report outlines the basic maintenance procedures currently in place, identifies
the challenges the shop is facing, and provides recommendations aimed at improving the overall
efficiency, safety, and effectiveness of the operations.

2.14.1 Maintenance Works

1. Starter Motor Maintenance:

• The starter motor converts electrical energy from the battery into mechanical rotational
energy to start the engine. The armature is powered by current, which interacts with the
poles of the field, creating an attraction and repulsion force that moves the armature in
and out. This mechanical action eventually cranks the camshaft, which starts the engine.
• Procedure:

▪Inspect armature and field poles for wear and tear.

▪Ensure current flow from the battery is uninterrupted.
▪Clean and lubricate moving parts where necessary.
▪Replace worn components if needed.
2. Alternator Maintenance:

• Alternators are responsible for charging the battery and powering the
electrical system while the engine is running. They have replaced DC
generators due to their smaller size, increased efficiency, and dependability.
• Procedure:

▪ Inspect bearings, diodes, and slip rings for damage.

▪ Perform voltage output tests to ensure optimal performance.
▪ Replace worn or damaged parts, including belts.

• Generator Maintenance:

22
 o The generator applies the principle of electromagnetic induction, converting
mechanical energy supplied by the engine into electrical energy. This is critical
for powering the electrical systems in machinery.
o Procedure:
▪ Check for issues in the armature windings, bearings, and brushes.

▪ Inspect the generator for electrical shorts and mechanical wear.

▪ Test output and voltage regulation to ensure it meets required
specifications.
3. Battery Maintenance: Batteries are crucial to the functioning of electrical systems.
Regular maintenance ensures their longevity and reliability.
o Procedure:
▪ Inspect for corrosion around terminals, signs of leakage, or cracks in the
case.
▪ Check the electrolyte level and add distilled water if necessary.
▪ Clean corrosion off the terminals using wire brushes and other cleaning
tools.
▪ Perform a battery capacity test to evaluate load, output, and overall
performance.

2.15 Identified Challenges in the Shop

Several challenges have been noted during the inspection of the shop:

1. Shortage of Raw Materials:

The shop frequently experiences shortages in essential materials, particularly high-quality
copper wire, which is critical for motor and alternator repairs. The availability of
necessary spare parts is also limited, affecting the ability to perform repairs promptly.
2. Lack of Safety Equipment:
There is a noticeable shortage of essential safety gear, including protective eyewear,
gloves, and other personal protective equipment (PPE). This increases the risk of
workplace injuries.
3. Limited Skilled Manpower:
The shop suffers from a shortage of skilled electricians and technicians, which leads to
delays in repair work and affects the overall efficiency of the department.
4. Inconsistent Power Supply:
Frequent power outages and a lack of backup power sources disrupt work and cause
significant delays in maintenance tasks, especially those requiring electricity for
diagnostic machines and repairs.
5. Outdated Battery Charging Methods:
The battery charging methods in the shop are traditional and outdated. Modern battery
testing and charging systems could significantly improve performance and efficiency.

23
2.16 Recommendations

1. Upgrade to Modern Machines and Tools: It is essential to invest in the latest tools and
machinery to improve the accuracy and speed of maintenance tasks. Modern testing
machines for diagnosing electrical faults, load testers, and advanced battery testing
equipment will streamline the process and ensure better results.
2. Ensure Availability of High-Quality Raw Materials: A consistent supply of high-
quality copper wire, spares, and other essential materials is crucial. By sourcing better
suppliers or improving inventory management systems, the shop can minimize delays
caused by shortages.
3. Provide Adequate Safety Gear: Safety must be a top priority in an environment where
workers handle electrical components and machinery. The shop must be supplied with
appropriate PPE, such as safety glasses, gloves, and insulated footwear, to protect
workers from potential hazards.
4. Increase Skilled Manpower: Hiring additional skilled technicians or providing existing
workers with advanced training will improve overall performance. Upskilling the
workforce will enable the shop to handle more complex maintenance tasks efficiently.
5. Establish Reliable Power Backup Systems: To address the issue of inconsistent power
supply, the shop should consider investing in power backup solutions such as generators
or uninterruptible power supply (UPS) systems. This will ensure continuous operation
during power outages, minimizing disruptions in workflow.
6. Upgrade Battery Maintenance Systems: Introducing modern battery testing and
charging equipment will not only enhance efficiency but also ensure that battery
performance is optimized, reducing downtime due to power-related issues.

In conclusion The Electronics and Electrical Maintenance Shop plays a vital role in maintaining
the heavy-duty machinery and vehicles used across various operations. By addressing the
identified challenges and implementing the recommended improvements, the shop can enhance
its overall efficiency, reduce downtime, and ensure a safer working environment for its
technicians. Continuous investment in modern equipment, skilled personnel, and safety standards
will help the shop meet the growing demands of the company’s operations.

24
3 Chapter Three
3.1 Overall Internship Experience

Internships are an essential bridge between academic learning and real-world practice. They offer
students the opportunity to apply the knowledge and theories they’ve gained in the classroom to a
professional setting, thereby enhancing their skills. Through internships, students can gain
practical experience, network with professionals, and better understand the career paths they are
considering. Employers also benefit from internships by observing, guiding, and assessing
potential future employees.

Internships provide numerous advantages, including:

• Practical Skill Development: Students enhance their abilities by applying theoretical

knowledge to real-life tasks and challenges.
• Interpersonal Communication Improvement: Working in a team environment
strengthens communication and relationship-building skills.
• Leadership and Teamwork Skills: Internships often involve working with diverse teams
and managing tasks, improving both leadership and collaboration abilities.
• Understanding Work Ethics: Interns gain insights into professional conduct, such as
punctuality, integrity, and the importance of teamwork.
• Entrepreneurship Skills: Exposure to workplace dynamics encourages creative problem-
solving and business-related skills.

In our three-month internship, we benefited from:

• Gaining Work Experience: By determining the best fit for our skills and interests, the
internship helped us improve our work experience.
• Building Networks: We expanded our professional network by interacting with colleagues
and team members.
• Developing Workplace Competencies: We learned valuable workplace skills, including
problem-solving, research, and resourcefulness.

3.2 Benefits Gained from the Company

3.2.1 Practical Skill Development

While we primarily contributed design and creative ideas, the company exposed us to a variety of
challenges that helped us sharpen our practical skills. These include:

• Goal Setting and Planning: We learned how to set achievable goals and then create
actionable plans to accomplish them.
• Project Management and Organization: The internship allowed us to develop basic
project management skills. We learned how to coordinate efforts among team members to
meet objectives efficiently.

25
By working in a professional setting, we became more adept at handling tasks methodically,
balancing resources, and managing timelines—skills that are invaluable in any career.

3.2.2 Theoretical Knowledge Enhancement

The internship also enabled us to deepen our theoretical knowledge. While university education
gave us a solid foundation, we quickly realized that real-world problems often require more than
what’s taught in the classroom. Solving issues during our internship required us to:

• Research New Information: We continuously sought additional knowledge to

complement what we already knew, by consulting books, colleagues, and online resources.
• Problem-Solving with Theory: Our theoretical knowledge became more practical as we
applied it in day-to-day work situations.

This continuous learning process not only enhanced our problem-solving abilities but also
improved our capacity to think critically and adapt our theoretical knowledge to practical
scenarios.

3.2.3 Interpersonal Communication Skills

Effective communication is vital in any workplace, and our internship helped us significantly
improve in this area. Some specific interpersonal skills we developed include:

• Effective Communication: We regularly discussed ideas, shared our vision, and

contributed solutions to challenges within the company.
• Active Listening: Engaging in conversations with team members required us to listen
carefully and process information before responding, improving our communication skills.
• Building Relationships: Through day-to-day interactions, we strengthened personal
connections with colleagues and fostered a collaborative atmosphere.
• Conflict Resolution and Negotiation: When differences of opinion arose, we worked
toward mutually beneficial solutions, enhancing our negotiation skills and conflict
resolution capabilities.

By improving our communication skills, we became more effective team members and learned
how to convey ideas and collaborate productively with others.

3.2.4 Teamwork Skills

Our internship emphasized the importance of teamwork. We learned how to collaborate effectively
with people from diverse backgrounds, each bringing different ideas and approaches to the table.
Specifically:

• Cultural Exchange and Collaboration: The internship gave us the opportunity to work
with individuals from different backgrounds, which helped us become more adaptable in
our interactions.

26
 • Professional Collaboration: We constantly interacted with skilled professionals and
fellow interns, learning from their insights and contributing our own ideas.

Working in this collaborative environment allowed us to build strong teamwork skills, which are
crucial for future career success. We gained confidence in sharing our ideas while being open to
feedback and learning from others.

3.2.5 Leadership Development

Leadership is about more than just being in charge; it’s about guiding, motivating, and supporting
a team. Our internship provided us with numerous opportunities to develop leadership skills:

• Soft Skills and Leadership: We learned that technical knowledge alone isn’t enough.
Leading a team requires a balance of soft skills such as communication, empathy, and
decision-making.
• Project Leadership: As future engineers, we expect to take on leadership roles, whether
as project managers or team leads. This internship gave us insights into the leadership
qualities required in these roles, such as responsibility, accountability, and strategic
thinking.

By observing and practicing leadership in small ways, we became better prepared for the
managerial aspects of our future careers.

3.2.6 Understanding of Work Ethics

One of the most important lessons we learned during our internship was about work ethics, which
go beyond just doing the job. We developed a sense of professionalism and integrity that shaped
how we interacted with others and approached our tasks. Some key lessons include:

• Commitment to the Team: We learned the importance of showing dedication to both our
individual work and the collective goals of our team.
• Respectful Collaboration: Treating colleagues with respect and collaborating with a
problem-solving mindset became second nature.
• Integrity and Accountability: We learned the importance of doing the right thing even
when faced with difficult decisions. We also understood the value of honesty, punctuality,
and maintaining a professional demeanor in the workplace.

Work ethics aren’t just about avoiding negative behaviors; they’re about fostering a positive,
responsible, and respectful working environment.

3.2.7 Entrepreneurship Skills

Finally, the internship gave us a taste of entrepreneurship by allowing us to observe and practice
key entrepreneurial qualities. We learned that entrepreneurship is about more than just starting a
business—it involves a mindset focused on innovation, risk-taking, and perseverance. Specific
entrepreneurial traits we developed include:

27
 • Confidence and Multi-Tasking: We gained confidence by successfully managing
multiple tasks, such as creating solutions, marketing ideas, and analyzing outcomes.
• Innovation: We learned to identify and seize opportunities, thinking creatively to solve
problems and improve existing processes.
• Risk Management: We observed how entrepreneurs take calculated risks, and we
practiced taking small, incremental steps toward larger goals.

The entrepreneurial mindset we developed is more than just a foundation for starting a business;
it's a versatile skill set that enhances our ability to navigate and thrive in various professional
environments. This mindset is centered around key qualities like innovation, adaptability,
problem-solving, and resilience, all of which are crucial in today’s fast-changing world.

Whether we’re leading a team or working independently, this mindset empowers us to approach
challenges with confidence and creativity, turning obstacles into opportunities.

our internship experience has been incredibly enriching. We developed practical skills, deepened
our theoretical knowledge, improved communication and leadership abilities, and gained a strong
understanding of work ethics and entrepreneurship.

Figure 12 comprehensive benefits of internship experience

28
In summary, these skills not only prepare us for future career challenges but also help us excel in
our academic pursuits. Through this internship, we have grown both professionally and personally,
and we are confident that these experiences will shape our future success.

29
 PART TWO: PROJECT WORK
4 Chapter four
4.1 Introduction to the Design of a Drum Brake Extractor

A drum brake extractor is a specialized tool designed to facilitate the safe removal of drum
brakes, a key component in many braking systems, particularly in older vehicles and heavy
machinery. Drum brakes operate by pressing brake shoes outward against the inner surface of a
rotating drum. While reliable, these braking systems can be difficult to maintain or repair due to
the tight integration of the components and the strong springs that hold them together. Over time,
drum brakes also tend to seize or corrode, making removal by conventional means challenging.
This is where a drum brake extractor becomes essential.

The drum brake extractor serves multiple functions:

• Reducing time: Without an extractor, mechanics often resort to forceful methods that
can damage both the brake drum and the surrounding components.
• Safety: Removing a drum brake without specialized tools can lead to injury due to the
high tension in the springs. The extractor applies controlled force, ensuring the brake is
released safely.
• Preventing damage: Drum brakes are often made from cast iron or similar materials that
can crack if mishandled. The extractor helps to evenly distribute the load, reducing the
risk of damage.

4.2 Background History of Drum Brake Systems

The history of drum brakes dates back to the early 20th century. Louis Renault, a French
automobile manufacturer, is credited with inventing the first mechanical drum brake in 1902.
The system used a set of brake shoes, which pressed against a rotating drum attached to the
vehicle’s wheel. This system was widely adopted throughout the automotive industry due to its
simplicity and durability.

By the 1950s, drum brakes had become the standard in the automotive industry, used on almost
all vehicles. However, as the need for better braking performance arose, especially in high-speed
cars and larger vehicles, drum brakes started to be replaced by disc brakes, which offered better
cooling and braking efficiency.

Despite the decline in their use in passenger cars, drum brakes remain popular in certain sectors:

1. Heavy-duty vehicles: Drum brakes are still widely used in trucks, buses, and industrial
machinery, as they can handle heavy loads better than disc brakes.
2. Low-cost vehicles: In many developing markets, drum brakes are preferred for their cost-
effectiveness and ease of maintenance.
3. Emergency and parking brakes: In many vehicles, drum brakes are used as a secondary
or emergency braking system.

30
4.3 Challenges in Drum Brake Maintenance and Need for an Extractor

The maintenance of drum brakes presents unique challenges:

• Corrosion and rust: Over time, the brake drum can corrode, seizing onto the wheel hub
and making it difficult to remove.
• Heat and wear: Repeated heating and cooling cycles, especially in heavy-duty vehicles,
can cause the brake drum to expand and contract, leading to tight fits.
• Tensioned springs: The springs in a drum brake system are under considerable tension,
which can make manual removal dangerous without the proper tool.

The drum brake extractor was developed to address these specific challenges. It is designed to:

• Apply uniform pressure: The extractor grips the brake drum and applies a uniform
pulling force to dislodge it from the wheel hub.
• Avoid damage to components: By pulling the brake drum evenly, the extractor reduces
the risk of damage to the drum or wheel hub.
• Ensure operator safety: The controlled force provided by the tool minimizes the risk of
injury due to unexpected release of tensioned components.

4.4 Modern Applications

While drum brakes have largely been replaced by disc brakes in modern passenger cars, they still
have a critical role in certain applications. As a result, tools like the drum brake extractor remain
important for:

• Heavy machinery and trucks: These vehicles still rely on drum brakes due to their
ability to withstand heavy loads and challenging conditions.
• Older vehicles: Classic cars and older models continue to use drum brake systems.
• Motorcycles and bicycles: Drum brakes are sometimes used in lower-end bicycles and
motorcycles.

In terms of design, modern drum brake extractors are evolving to become more efficient, lighter,
and easier to use. They often incorporate hydraulic or pneumatic assistance to reduce the
physical effort required by the operator, allowing for faster and safer brake drum removal.

4.5 Drum Brake Systems

The major systems of an automobile are the engine, fuel system, transmission,
electrical system, cooling and lubrication system, and the chassis, which
includes the suspension system, braking system, wheels and tires, and the
body. These systems found in every form of motor vehicle and are designed
to interact with and support each other.

31
A brake is one of the most important controls of the vehicle. This is a combination of
some interactive parts it is done by converting the kinetic energy of the vehicle into
the heat energy which is dissipated into the atmosphere and this slows down the
vehicle within the smallest possible distance.
There are two kinds of service brakes, the brakes that stop vehicle while driving. They
are disc brake and drum brake

A. Disc brakes are now standard on nearly all automobiles. They’re

usually positioned on the front axle, but they can also be found on the
back. A disc brake stops a wheel by grabbing a spinning disc or rotor,
with a caliper fitted with brake pads.
B. Drum brakes are braking system that slows a vehicle by creating
friction by pressing brake shoes against the inside surface of a metal
drum linked to the wheel.

Components of drum brake

• CAM
• Brake drum
• Brake lining
• Brake shoe
• Brake plate
• Anchor
• Return spring
A rapid, dependable, and non-destructive approach is required for performing routine
or corrective maintenance on rotating systems. Using a hammer and drift pins to
remove stuck bearings, gears, pulleys, and other components from shaft can cause
damage to the shaft or the component. Furthermore, such a way of removing stuck
components might be hazardous to one’s health and constitutes an occupational
hazard. While occupational dangers have long been a worry, in the motor business,
dangerous practices have apparently resulted in injuries and other work-related health
difficulties. A puller is also known as an extractor, is capable of safely removing
rotating components caught in a shaft.
Nearly a century ago, the development of a puller for removing components from
shafts began. Hydraulic and mechanical pullers are the two types of pullers available.
Hydraulic pullers work on the basis of hydraulic principle. They are more convenient
and faster to utilize, and they are well-suited for big extraction forces. Local
technologies in developing countries make hydraulic pullers difficult and costly to
acquire.
The screw, a bolt/head, a linkage arm (jaw), and a handle make up the mechanical
puller, which is a simple device with few and easy-to-assemble components. Jaws
come in two or three sizes. The mechanical puller works on the power screw concept,
which means they convert angular motion into linear motion to convey power.

32
4.5.1 Components of drum extractor

Drum extractor is the assembly of the following components: -

A. Power screw the power screw is used to convert rotary motion into
translator motion.
While these converting processes the screw transmit power.
B. Handle It is a device used to rotate or drive the screw by manpower.
C. Puller jaw it is a curved or bent device foe caching, holding or pulling
purpose.
D. Bolt and nut A screwed joint is mainly composed of 2 elements i.e.,
nut and bolt. The screwed joints are widely used where the mechanical
parts are required to be readily connected or disconnected without
damage.
• Bolt – a bolt is a form of threaded fastener with an external
male thread which can help us to connect jaws with cross-bar.
• Nuts – small pieces of metal which a bolt can be screwed into.

E. Cross-bar It is a bar which also contain internal threaded hole in the

middle.it used to assemble the jaw and screw, and also it helps to
support the jaw and to pull the screw by its internally threaded hole.

1.1.2 Statement of the problem

We had the opportunity to observe problems in various working sections while working at
Ethiopian construction works corporation.
The majority of maintenances in the light duty shop of our host company are performed on the
vehicle’s braking system. The pulling and changing of braking drum in particular takes a lot of
time and more than one or two mechanics’ power. This approach of braking system maintenance
is improper because it takes a long time (not machine assisted). A drum extractor would be
effective in solving such difficulties.
4.6 OBJECTIVE
4.6.1 General Objective

The general objective of designing a manually operating brake drum extractor is to

create a mechanical tool that allows technicians and mechanics to safely, efficiently,
and effectively remove brake drums from vehicle wheels, without the use of hydraulic
or pneumatic systems. This tool should be lightweight, durable, user-friendly, and

33
capable of applying sufficient force to remove even seized or rusted brake drums in a
controlled manner.

4.6.2 Specific Objective

• To design power screw and handle.
• To design crossbar and jaws.
• To design bolts and nuts
• To select appropriate materials with desired properties for the
design of different components.
• Analyzing overall cost of the machine.

4.7 Scope
The project scope is primarily concerned with the design of a drum extractor with a
capacity of 20KN load, as well as the design and material selection for the components
power screw, crossbar, handle, jaw, bolt and nut using various engineering concepts.
By theoretically clarifying and analyzing each part, prepare their part and assembly
drawing of the machine in 2D and 3D models using solid work.
4.7.1 Significance

This project has a wide range of implications for various people, both directly and
indirectly. Some of them are as follows:

• Reduce time consumption: this is primarily useful for customers who

have spent time standing in line for their car to be repaired. This project
will shorten the time missed due to a car being late for maintenance or
time spent extracting a drum. Secondly, if time is used widely, the
corporation will be profitable.
• Reduce energy loss: this project ends up saving lost power for drum
pulling.
• Reduce labor force: if mechanics have used this tool, they can easily
carry out their work, many repair work programs can be completed in
a short period of time, lessen time consumption and manpower.
• Size: because the design is lightweight and portable, it is quick and
easy to transport and store.
4.7.2 Limitation
• We have not manufactured the project.
• The project is applicable only for heavy duty vehicles.

34
5 Chapter five
5.1 Literature review

A hydraulic system plays very important role in almost all the application in
automobile industries, small service center, aircraft industries. The hydraulic puller
and pusher are a special arrangement which attached to a hydraulic jack, bearing
clamp and shaft clamp respectively. Consistent and equal force is applied so that the
bearing can easily remove from the shaft without damaging surface finish of the shaft.
It works on the principle of Pascal’s law. (1)
In this work, a simple, low cost, less weight and less energy to operate mechanical
puller was developed. The puller screw shaft was first design for, followed by the nut
and then its collar top. Non-conventional shapes were assumed for the collars and
handles. Finite element analyses were used to evaluate the von-missed stress in the
arm and collar which had complex shape. Maximum weight of the load to be pulled
is 4KN. The designed 3 arm mechanical bearing puller was fabricated and was
successfully used to remove a number of bearings stuck in shaft. (2)
Traditional method of bearing removal or installation is hammering which causes
several problems. The Unsafe and excessive hammering cause damage of bearing
surface and sometimes chance to failures. The modification is made which makes easy
removal and installation of bearing. Pneumatic bearing puller and pusher which are
based on Pascal’s law “pressure distribution in an enclosed cylinder is uniform in all
direction” are developed to solve the conventional hammering process. This project
is mainly focused to reduce the human effort and the wear and tear that occurs while
mounting and unmounting a bearing. (3)
This journal deals with the installation and removal of bearings with the hydraulic
effort and how the hydraulic cylinders and control valves are installed for the effective
mounting and unmounting of bearing. (4)
In this journal an example of torture test is used in analysis of stresses in power screw.
Torture test is used in industries manufacturing screw jacks so that there is no
misalignment or problem while using screw jack. One end of the shaft of screw jack
is fixed and flange is given a torque. The model is drawn in pro E. then the model is
transferred to ANSYS. The stresses between the flange and the shaft are analyzed
using ANSYS. The analytical values of stresses are found out and compered to the
stresses found out using ANSYS. (5)

In the design and development of extraction tools like drum brake extractors, several key
takeaways emerge from the integration of hydraulic, pneumatic, and mechanical systems. First,
hydraulic systems, operating under Pascal’s Law, provide consistent force that is equally
distributed, making them ideal for precision operations in industrial environments. They ensure
minimal damage to components during the removal process by applying uniform pressure.

Mechanical pullers, on the other hand, focus on simplicity, cost-effectiveness, and ease of use.
Through stress analysis and careful design of parts such as the puller screw shaft and collar,

35
these pullers are tailored to withstand specific load conditions. The use of finite element analysis
(FEA) helps ensure that the puller can handle designated loads while maintaining structural
integrity.

Pneumatic systems also follow Pascal's Law but offer a more refined approach by using
compressed air, which significantly reduces the manual labor required. These systems eliminate
the risk of damaging components during installation or removal, as they minimize excessive
force and distribute it more precisely.

Lastly, integrating stress analysis using advanced simulations ensures that components like
power screws and their assemblies can endure high loads and extreme conditions. The
combination of these technologies leads to more reliable and durable tools, reducing wear on
machinery and improving overall efficiency in mechanical operations. These design principles
result in a tool that is safer, more efficient, and capable of handling demanding industrial
applications.

36
6 Chapter six
6.1 Methodology
Diagrammatic expression of the methodology

Figure 13 diagrammatic expression of the methodology

37
6.2 Data collection method
We collected the necessary data in this study using primary and secondary data
collection methods, as well as a few measurements of the physically available
brake drums to obtain precise and clear data to our design.

Figure 14 diagrammatic expression of data collection method

6.2.1 Primary data collection methods

A. By direct measurement of drum, we found in light duty and heavy-duty shops

• Outside diameter = 73mm, 90mm, 104mm, 200mm, 380mm
• Inside diameter = 68mm, 85mm, 98mm, 185mm, 370mm
• Height = 50mm, 65mm, 90mm
B. Interview: by interviewing some mechanics in the light and heavy-duty shops.

6.2.2 Secondary data collection methods

Written materials related to our work

• Books
• Journals

38
6.3 Material selection
Material selection is an essential step in the design process. It is a design-led process
in which the material selection process uses the design requirements as input to come
up with materials that have the desired properties for the part to be designed to
function well.
The common engineering materials used in making machine components include;

• Cast iron
• Steel
• Copper and its alloys
• Aluminum and its alloys
• Plastics and others

As a result, the appropriate material for the design of drum puller components should
be chosen.
The following factors must be considered when selecting the best material for the
design.

A. Specific strength and mass

To get a screw shaft of high strength and low density, it is desirable to choose
a material with high yield stress, the ability to carry external load without
failure, and a low density. As a result, the goal of the material selection process
should be to maximize the quantity of particular strength.

B. Resistance to abrasive wear

Most of engineering materials in contact with one another are subjected to

surface wear due to relative motion. It is therefore desirable to select a material
from the candidate materials with low wear rate or capacity to resist abrasive
wear at the thread surfaces.
C. Availability, cost and affordability

It is also preferable to choose a material with the highest affordability rating.

Relative cost of the material is used in finding or calculating the affordable
rates. Therefore, the availability of the material and the cost of processing the
material into the finished product need to be taken into account and considered
as supporting information when making the final choice of the material.
D. Heat transmission properties

39
 As we all know, there is always a relative motion between the screw and the
nut, which causes friction and heat, which can change the mechanical
properties of the material.

E. Other notable aspects include corrosion resistance, electrical and mechanical

properties, and heat transmission properties, and others.
• Power screw
• ASTM minimum tensile and yield strength for some hot-rolled and
cold-drawn steels

40
7 Chapter seven

7.1 Detail Design of Drum Brake Extractor

A drum brake extractor is an essential tool used to safely and efficiently remove brake drums
from a vehicle's wheel hub. In automotive maintenance, brake drums often become seized or
difficult to remove due to rust, corrosion, and extended wear. This can make servicing brake
systems challenging, time-consuming, and potentially damaging without the proper tools. A
brake drum extractor alleviates these issues by applying controlled, even pressure to remove the
drum without causing damage to surrounding components, ensuring the safe and proper
maintenance of the braking system.
7.2 Significance of the Detailed Design
This detailed design of the brake drum extractor is critical for advancing automotive
maintenance tools, particularly in resource-limited settings where high-tech or powered
alternatives may not be available. The design presented aims to balance simplicity and
performance, leveraging mechanical principles such as leverage and force distribution to create a
tool that can:

• Operate without power sources: Ideal for rural or mobile mechanics who may not have
access to hydraulic or pneumatic equipment.
• Reduce downtime and labor costs: A tool that quickly and safely removes brake drums
will reduce the time needed for brake repairs, allowing mechanics to work more
efficiently and with fewer risks of damaging parts.
• Extend tool lifespan: By using durable materials and designing for ease of maintenance,
the extractor will offer long-term value and reliability for frequent use. Using the data
below let’s see the details

AISI NO. Tensile Yield strength

strength (Mpa)
(Mpa)

1006 300 170

1010 320 180
1015 340 190
1018 400 220
1020 395 294
1030 470 260

41
Table 1 yield and tensile strength for some hot-rolled and cold-rolled steels

We chose annealed steel (AISI-1015) for the screw because of its hardness, cost
and wear resistance capacity. It’s also easy to manufacture, and the annealing
process is employed to soften the material.
Material Tensile strength Yield strength
Mpa Mpa
Structural steel (AISI- 340 190
1015)
Table 2 mechanical property of AISI-1015 steel

• Handle

The selected material for the handle is mild steel which is relatively low cost,
has high strength and toughness, corrosion, wear and fatigue resistance.
Material Tensile strength Yield strength
Mpa Mpa
Mild steel 430 220
Table 3 mechanical property of mild steel

• bolt and nut

The bolt and nut are a connection used to connect the cross bar and the jaws.
We selected structural steel ASTN-A36.
Material Tensile strength Yield strength
Mpa Mpa
Structural steel 400 250
Table 4 mechanical property of ASTN-A36

• jaws

The selected material is annealed steel AISI 1020 because of its hardness,
resistance to wear and relatively have low cost.
Material Tensile strength Yield strength
Mpa Mpa
AISI-1020 395 294
Table 5 mechanical property of AISI-1020

42
 • Cross –bar

Selected material annealed steel AISI-1030 due to its strength and wear
resistance
Material Tensile strength Yield strength
Mpa Mpa
Structural steel 470 260
Table 6 mechanical property of AISI-1030

7.3 Design of power screw

Material selection for screw is AISI-1015 with yield strength 284Mpa and
tensile strength 386Mpa.

A. Assumptions
o Maximum weight of load to be pulled is W= mg =20KN, for the reason
that……
o Factor of safety = 2, because AISI-1015 is ductile material and ductile
materials have lower factor of safety.
• The thread is square and single started
thread
• The length of screw Z= 300mm The
length of threaded part z=250mm o Material
property;

F.S = 2

Allowable / working / stress;

Core diameter calculation

43
 (Normal series)
Nominal Major diameter Minor Pitch Depth of thread Area of
diameter Diameter
Bolt Nut Bolt Nut core
(d1)
(d) (D) (dc) (p) (h) (H) (Ac)mm2

22 22 22.5 17 227
24 24 24.5 19 284
26 26 26.5 21 5 2.5 2.75 346
28 28 28.5 23 415
Table 7 Basic dimensional for square threads in mm (normal series) according to IS 4694-1968 (reaffirmed 1996

d= 22mm

p= 5mm

The lead is defined as the axial distance that the screw would move in one complete
revolution.
For the usual case of single-threaded screw, the lead is equal to the pitch.

Helix is the shape formed by the thread of screw and it is calculated as;

Helix angle ( or load angle:

= =0.0816

44
 The coefficient of friction depends upon factors like material of screw and nut,
work-man ship in cutting screw, quality of lubrication, unit bearing pressure
and rubbing speeds. The value of coefficient ( ) with average workman ship
and running condition assumed 0.18.
Friction angle (

Self –locking refers to the condition in which a screw cannot be moved without
external force. A screw will be self- locking if the friction angle is greater than
helix angle ( ) Hence we can say that the screw is self-locking.

Effort applied to the circumference of screw to lift the load is calculated as;

Torque requires to rotating the screw;

Since the screw is subjected to a twisting moment, therefore torsional shear stress is
induced. This is obtained by considering the minimum cross-section of the screw. We
know that torque transmitted by the screw,

Or shear stress induced;

45
Where;

Direct compressive stress ( ) due to axial load may be determined by dividing

the axial load
(W) by minimum cross-sectional area of the screw (Ac) i.e., area
corresponding to core diameter
(dc).

Principal stresses

46
Maximum principal stress is given by;

Maximum principal stress ( permissible stress (

Maximum shear stress is given as;

Maximum shear stress ( permissible shear stress ( )

These maximum compressive and shear stresses are less than from the
permissible stresses, hence the power screw design is safe.

Figure 15 power screw

47
7.4 Design of cross bar
Material selected for the cross bar is AISI-1030

o Assumptions

Factor of safety= 2

Width = 400mm

Height= 40mm

Breadth=30mm

o Material property;

Permissible stresses calculated as;

190mm 190mm
A B

380mm
-

Figure 16 Cross-bar analyses

48
 Maximum bending moment occurs at point B

h=40m

b=30
Figure 17 Cross bar cross section

Moment of inertia of the cross-section about the neutral axis (I), distance from
neutral axis to the extreme fiber (y) and section modulus (Z) A Textbook of
Machine Design" by R.S. Khurmi and J.K. Gupta. Table 5.1 properties of
commonly used cross-sections page 130 is given as;

In engineering practice, the machine parts of structural members may be

subjected to static or dynamic loads which cause bending stress in the sections
besides other types of stresses such as tensile, compressive and shearing
stresses.

Bending stress ( ) given as;

49
 Since the maximum bending stress ( ) is less than the
allowable stress (i.e., ) the design is safe.

Shear stress ( ) is the ratio of maximum force (P) and area of the cross section
(A). The area of rectangular hallow section is given as;

Average shear stress ( ;

Maximum shear stress ( );

The maximum shear stress (0.75Mpa) is much less than the allowable shear
stress (85.25Mpa) so the design is safe.

7.5 Design of nut for cross-section

Assuming that the load is distributed uniformly over the cross-sectional area
of nut

Bearing pressure on the nut =

Let n= number of threads

in contact with the screw h=
height of the nut t=
thickness of the nut

50
Height of nut

But for the sake of construction, we take the height of

the nut as 40mm. If the height of the nut
is safe

Therefore, the height we take for the nut is safe height

Thickness of nut

Outer diameter of nut

51
Let = outer diameter of nut

= outside diameter of nut collar

= tearing strength of nut

= crushing of the collar of nut

Determine outer diameter of nut considering tearing strength of nut,

Considering the crushing of the collar of the nut we can determine outside
diameter of nut collar

52
Checking crushing stress at collar

The crushing stress is less than from the allowable stress

therefore the design is safe.
Torque required overcoming the friction at the end of screw assuming
uniform wear condition

Where Coefficient of friction (0.18 considering bad

lubrication) Mean radius

Total torque required to rotate the screw

53
Head of screw

Figure 18 Design of handle

Material selected for the handle which is used to rotate the power screw is mild
steel.

o Material property;

= 110Mpa

The total torque to which the handle subjected,

Assuming a person force intermittently the length of handle

required;

54
Diameter of handle obtained by considering bending effect

The height of screw head is usually taken as twice the diameter of handle.

Since the handle is exposed to torsional stress. It’s better to calculate the shear
stress of handle by using the torsional equation.

55
 Shear stress of the handle is less than from the allowable shear
stress therefore the design is safe.

Figure 19 Handle

7.6 Design of jaw

Material selected for the design of jaw is AISI-1030 steel.

o Material property;

Radius of curvature of the neutral axis and radius of curvature of

the centroidal axis formula is determined from Table 5.2. Values
of and for various commonly used cross-sections in curved
beams from the book machine design, RS
Khurmi, JK Gupta 14th edition page (138-140)

56
 Section Values of

C N
b
e 𝑅𝑖

𝑅𝑛
R

𝑅𝑜

Table 8 values of and R for commonly used cross section in curved beam

Were,
h = horizontal side of rectangle
b = vertical side of rectangle
C = centroidal axis
N = neutral axis
e = distance from the centroidal axis to the neutral axis
R = radius of curvature of centroidal axis
R¡ = radius of curvature of the inside fiber
Ro = radius of curvature of the outside fiber Rn = radius of curvature of the neutral axis

Area of section at X-X,

Radius of curvature of the neutral axis,

57
Radius of curvature of the centroidal axis,

Distance between centroidal axis and neutral axis,

Distance between the load and the centroidal axis,

Distance from the neutral axis to the inside fiber,

Distance from the neutral axis to the outside fiber,

58
Bending moment about the centroid axis,

Direct tensile stress at section X-X,

Maximum bending stress at the inside fiber,

Maximum bending stress at the outside fiber

59
Resultant stress at the inside fiber,

Resultant stress at the outside fiber,

Figure 20 Jaw

60
7.7 Design of bolt
Material selected to bolt design is AISM-A36 structural steel.

o Material property,

All forces acting on the body (P)=5311.9N

Core diameter if bolt,

61
 From table 11.1 design dimensions of screw threads, bolts and nuts according
to IS: 4218(part ш) 1976 (reaffirmed 1996) by using the value of its easy to
determine another dimension.
Designation Pitch Major or Effective Minor or core Depth of Stress
mm nominal or Diameter thread area
diameter pi (bolt) mm2
tch (dc) mm
nut and mm
diameter
bolt
nut and Bolt Nut
(d=D)
bolt (dp)
mm
mm

M7 1 7.000 6.350 5.773 5.918 0.613 28.9

M8 1.25 8.000 7.188 6.466 6.647 0.767 36.6
M10 1.5 10.000 9.026 8.160 8.876 0.920 58.3
M12 1.75 12.000 10.863 9.858 10.106 1.076 84.0
M14 2 14.000 12.701 11.546 11.835 1.227 115
M16 2 16.000 14.701 13.546 13.835 1.227 157
Table 9 design dimensions of screw threads, bolts and nuts

The value of is between 6.466 and 8.160 so we approximately take, The

coarse series M10 bolt for our design.

Where;

62
 Maximum Shear stress,

Maximum shear stresses the allowable shear stress

the design is safe.

Figure 21 Bolt

7.8 Nut design

The nut is used to lock the bolt that used for joining the jaws and the cross bar.
The material selected to the nut design is similar with the bolt.
Width of nut is equal to nominal or major diameter of bolt,

All forces acting on the body

63
Assuming the load is distributed uniformly over the cross-sectional area of nut
and taking the maximum bearing pressure , and then
number of threads is calculated as:

Checking the crushing and shearing stresses on the threads,

• Crushing stress

, Therefore, the design is safe

• Shear stress across the thread of bolt

The average shear stress for the bolt obtained by using the following
relation,

Where b is the width of the thread section at the root,

64
 ), Therefore, the
design is safe.

• Shear stress across the threads of nut

The average shear stress across the thread of nut is obtained by the using
the following relation.

, therefore, the design is safe.

Figure 22 Nut

7.9 Assembling process

It is necessary to properly assemble each component in order to use the drum
brake extractor effectively, so here is a guide on how to do so.

1. Attach the power screw to the cross-bar.

2. Fasten the jaw to the cross-bar. Jaws are interlocked on both sides of
the cross-bar.
3. Install a bolt in the jaw and a cross-bar hole to tighten the jaw on the
cross-bar.
4. Using an open or closed wrench, insert nut to each bolt.

65
 5. Enter the handle into the hole in the power screw.

Figure 23 Assembly of drum extractor

A. Working principle
The following steps must be followed in order to remove the brake drum with
brake drum extractor.

• Place the brake drum puller’s two jaws evenly around the flange of the
brake drum.
• Make sure the screw in the middle of the brake drum puller lies above
the wheel hub center.
• Attach the brake drum puller’s screw tightly with a screwdriver
(handle). Tighten the screw until the brake drum puller is completely
encircled by the brake drum. Do not overtighten the power screw.
• Remove the brake drum by pulling it away from the wheel in an
outward motion.

66
8 Chapter eight
8.1 Manufacturing Process
8.1.1 Design Phase

The design phase is foundational to the manufacturing process. It involves multiple stages to
ensure the product is optimized for both performance and manufacturability.

• Component Identification: The drum brake extractor consists of several key

components: the power screw, jaws, crossbar, handle, and support bolts and nuts.
Each of these has its own function:
o The power screw is the main mechanism that drives the extraction.
o The jaws grip the brake drum and are typically designed to handle a range of
sizes.
o The crossbar provides structural stability and connects the jaws to the power
screw.
o The handle allows the user to manually turn the power screw, initiating the
extraction.
• Material Selection: Material selection is critical for ensuring that the drum brake
extractor is strong enough to handle high loads without failing. Typically, materials such
as medium-carbon steel (like AISI 1040, 1050) or alloy steel (like AISI 4130, 4140) are
used. These materials are known for their high tensile strength and toughness. Steel
provides good wear resistance and can withstand significant loads without permanent
deformation.
• CAD Modeling and Stress Analysis: CAD (Computer-Aided Design) software is used
to create 3D models of the brake extractor. During this phase:
o The dimensions of each component are finalized based on the design
requirements.
o Finite Element Analysis (FEA) can be employed to simulate how the extractor
will perform under load, identifying areas that may be susceptible to stress or
deformation.
o Iterations are made in the design to optimize the performance, strength, and
weight of the extractor.

8.1.2 Material Procurement

Once the design is complete and materials are selected, the next step is to procure raw materials.
The following materials are commonly used:

• Forged steel blanks for components like jaws and arms, ensuring they have the
necessary strength.
• High-strength steel bars for the power screw and other parts subjected to tensile forces.
• Tool steel for parts that require higher wear resistance, such as jaws or gripping surfaces.

67
8.1.3 Manufacturing Process

This stage involves the actual production of the parts, starting from the raw material to final
machining.

8.1.4 Forging

• Forging is often used for critical components like the jaws and arms. This process
involves heating the metal and then shaping it using dies under high pressure. The
advantage of forging is that it increases the material’s strength through grain refinement.
• Forging makes the material denser and stronger compared to parts produced by casting or
machining alone. After forging, the parts are typically trimmed and machined to final
shape.

8.1.5 CNC Machining

• CNC (Computer Numerical Control) Machining is employed for precise shaping of

components such as the power screw, crossbar, and jaws.
o Turning operations are used for cylindrical components like the screw, where
the threads are cut and precise tolerances are maintained.
o Milling operations are used for shaping parts like the crossbar, where slots or
holes are needed for assembly.
o CNC machining ensures high precision and repeatability, essential for parts that
require close dimensional tolerances.

8.1.6 Thread Rolling/Cutting:

• For the power screw, the threads can be made by thread rolling, which forms the
threads through cold-working and is preferred due to its strength (rolled threads have a
higher fatigue life compared to cut threads).
• In some cases, thread cutting may be used, especially for smaller production runs, where
material is removed to create the threads. This process ensures that the threads fit
properly and can handle the applied torque.

8.1.7 Heat Treatment:

• After machining, critical components undergo heat treatment to enhance mechanical

properties like hardness, toughness, and wear resistance. Heat treatments include:
o Quenching: Heating the metal and then rapidly cooling it in water or oil. This
increases the hardness but may make the material brittle.
o Tempering: This follows quenching, where the part is reheated to a lower
temperature and then cooled. This reduces brittleness while retaining hardness.
o Case hardening or carburizing may be used for surface parts like jaws to make
the surface harder and more resistant to wear while keeping the core tough and
ductile.

68
8.1.8 Welding:

• Welding is sometimes required to join components like the handle or jaws if the design
calls for it. Arc welding or TIG welding is typically used, depending on the material and
thickness. Welding ensures a permanent joint between parts but requires careful
inspection for defects such as cracks or voids.

8.1.9 Assembly

Once all components are machined and heat-treated, the assembly phase begins:

• Fitting the power screw into the crossbar and ensuring that the threads align properly.
• Attaching the jaws to the crossbar using bolts and nuts, ensuring that the alignment is
correct for gripping the drum.
• Mounting the handle onto the power screw so that it can be operated manually. During
this process, each component is inspected for proper fit and alignment.

8.1.10 Surface Finishing

Surface finishing enhances the durability and appearance of the drum brake extractor. Key
processes include:

• Galvanizing: A zinc coating is applied to prevent corrosion, especially if the extractor

will be used in harsh environments like automotive repair shops.
• Powder Coating: A powder coating may be applied for aesthetic reasons and additional
corrosion protection. Powder coatings are durable and resistant to wear.
• Polishing/Grinding: This is done on areas like the jaws where precision contact surfaces
are required. Grinding ensures a smooth surface, reducing friction and wear.

8.1.11 Quality Control

After assembly, the drum brake extractor undergoes rigorous quality control tests:

• Load Testing: The extractor is subjected to loads that simulate the real-world forces it
will experience. This ensures that the materials and assembly can handle the specified
loads without failure.
• Dimensional Inspection: Components are checked against the design drawings to ensure
they meet the specified tolerances.
• Functional Testing: The extractor is tested by using it to remove an actual drum brake in
a controlled environment. This ensures the tool operates smoothly and effectively.

8.1.12 Packaging and Distribution

After passing quality control, the finished drum brake extractor is:

• Cleaned to remove any manufacturing residues such as oils, greases, or metal shavings.

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• Assembled if it was shipped disassembled, and all parts are packed securely to prevent
damage during transportation.
• Packaged with protective materials such as foam or cardboard to prevent damage during
shipping. Clear instructions are often provided to guide the user through the tool’s proper
operation.

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9 Chapter nine
9.1 Cost analysis
Cost analysis is a crucial aspect of the design process for a drum brake extractor,
encompassing materials, machining, and labor costs. To calculate materials cost, one must
first identify the necessary materials, such as AISI 1015 steel for the power screw and
forged steel for the jaws. Next, the volume hV of each component is determined using
geometric formulas, such as V=πr2hV = πr2 =πr2h for cylindrical parts. The density of the
materials, typically around 7870 kg/m³ for medium-carbon steel, is then used to calculate
the mass of each component by multiplying the density by the volume. This mass is then
multiplied by the cost per kilogram to obtain the total materials cost. For machining cost,
one should identify the processes required, such as CNC turning or milling, and estimate
the machining time based on the complexity of each part. By multiplying the estimated
hours by the operational cost per hour, the machining cost can be calculated. Labor cost
involves estimating the total hours needed for assembly and testing, which is then
multiplied by the hourly wage of the workers. Finally, the total cost of the drum brake
extractor is obtained by summing the materials, machining, and labor costs, ensuring that
the design remains economically viable for production.

9.2 Material Costs

The main material used for the drum brake extractor is AISI 1015 steel, AISI 1030 steel, AISI-
A36 and Mild Steel averagely priced at 7 USD per kg, which converts to 875 ETB/kg (using
the exchange rate of 125 ETB/USD). The total material cost is calculated based on the mass of
each component and the price per kilogram.

9.2.1 Power Screw:

• Volume (V): 0.000114 m³

• Density (ρ): 7870 kg/m³
• Mass (M): 7870 kg/m³×0.000114 m³=1.4 kg7870 =1.4kg
• Cost (C): 1.4 kg×875 ETB/kg=1225 ETB

9.2.2 Cross-bar:

• Volume (V): 0.00048 m³

• Mass (M): 7870 kg/m³×0.00048 m³=3.8
• Cost (C): 3.8 kg×875 ETB/kg=3325 ETB.

9.2.3 Jaw:

• Volume (V): 0.000096 m³

• Mass (M): 7870 kg/m³×0.000096 m³=1.02 kg
• Cost (C): 1.02 kg×875 ETB/kg=892.5 ETB

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 • Since there are two jaws:
892.5 ETB×2=1785 ETB892.5

9.2.4 Handle:

• Volume (V): 0.000094 m³

• Mass (M): 7870 kg/m³×0.000094 m³=1.2 kg
• Cost (C): 1.2 kg×875 ETB/kg=1050 ETB

9.2.5 Bolt:

• Volume (V): 0.00006675 m³

• Mass (M): 7870 kg/m³×0.00006675 m³=0.75 kg
• Cost (C): 0.75 kg×875 ETB/kg=656.25 ETB
• Since there are two bolts:
656.25 ETB×2=1312.5 ETB656.25

9.2.6 Nut:

• Volume (V): 0.00001178 m³

• Mass (M): 7870 kg/m³×0.00001178 m³=0.47 kg
• Cost (C): 0.47 kg×875 ETB/kg=411.25 ETB
• Since there are two nuts:
411.25 ETB×2=822.5 ETB

9.2.7 Total Material Cost:

Total Material Cost=1225+3325+1785+1050+1312.5+822.5=9439 ETB

9.3 Machining Costs

The machining cost is 22,500 ETB. This includes the cost for machining operations like cutting,
shaping, drilling, and finishing the components to precise dimensions.
9.3.1 3. Labor Costs

The hourly labor cost is 9240 ETB. With two workers working for 10 hours, the total labor cost
is calculated as:

Labor Cost=9240 ETB/hour×20 hours=184,800 ETB

9.4 Total Cost

Finally, summing up all the components gives the total cost for the drum brake extractor:

Total Cost=Material Cost + Machining Cost +Labor Cost

Total Cost=9439 ETB+22,500 ETB+184,800 ETB=216,739 ETB

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The final total cost of manufacturing the drum brake extractor, considering the market values, is
216,739 ETB. This includes material, machining, and labor costs, ensuring the product is
fabricated using AISI 1015 steel and processed according to required specifications.

Component Mass (kg) Cost per kg (ETB) Material Cost (ETB)

Power Screw 1.40 875 1,225

Cross-bar 3.80 875 3,325

Jaw (x2) 2.04 875 1,785

Handle 1.20 875 1,050

Bolt (x2) 1.50 875 1,312.5

Nut (x2) 0.94 875 822.5

Table 10 Material cost

9.4.1 Additional Costs:

• Machining Cost: 22,500 ETB

• Labor Cost: 184,800 ETB

9.4.2 Total Costs:

• Total Material Cost: 9,520 ETB

• Total Project Cost: 216,820 ETB

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10 Chapter ten
10.1 Result and Discussion
10.1.1 Result

The drum extractor machine is made up of the above major parts which are power
screw, crossbar, jaw, handle, bolt and nut. All components are designed using same
core design principles. The maximum principal and maximum shear stress theories
are used to ensure the safety of the components. Each component dimensions are
carefully calculated.
Power Screw

Length of screw 300mm

Material property AISI-1015
Mainor diameter Dc 17mm
Helix angle 4.67
friction angle 10.24
Max principal stress 113Mpa
Max shear stress 64.4Mpa
Table 11 Power screw specification

Cross bar
Height 40mm
Material Selected AISI-1030
Permissible Stress 170.5Mpa
Average Shear Stress 0.5Mpa
Maximum Shear 0.75Mpa
Bending Stress 126.2N/mm^2
Table 12 Cross bar specification

Handle
Material property Mild Steel
Shear stress handle 32.97Mpa
allowable Shear stress handle 55Mpa
Diameter of Handle 20mm
Table 13 Handle specification

Jaw
Material property AISI-1030
Length of jaw 320mm
Area 300mm^2
radius of Curvature of neutral axis 28.85mm

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 Radius of curvature of the centroidal axis 35mm
Distance between the centroidal axis and 6.15mm
neutral axis
distance between the load and the centroidal 35mm
axis
distance from the neutral axis to the inside 3.85mm and 21.15mm
fiber and out fiber respectively

Bending moment about the centroidal axis 350000Nmm

Direct tensile stress 33.33Mpa
Maximum bending stress at the inside fiber 29.22Mpa
Maximum bending stress at the outside fiber 79.6Mpa
Table 14 Jaw specification

Bolt
Material property AISM-A36 structural steel
Core diameter dc 8.160mm
pitch diameter dp 10mm
Maximum shear stress 45.6Mpa
Allowable Shear stress 62.5Mpa
Average shear stress of the bolt 25.3Mpa

Nut
Material property AISI-A36 Structural stress
Width 10mm
pitch 1.5mm
length 15mm
Maximum Bearing pressure 30N/mm^2
Number of threads 10mm
Crushing stress 8Mpa
Allowable Shear stress 62.5Mpa
Average shear stress of nut 22.5Mpa
Table 15 Nut specification

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11 Chapter eleven
11.1 Conclusion And Recommendation
11.1.1 Conclusion

During our time at ECWC, we learned how to evaluate and apply our
theoretical knowledge in real-world settings and also recognized that it is
difficult to directly apply our theoretical knowledge to actual problems in
industries or projects such as this one because it requires some experience to
apply theoretical knowledge to practical problems, which the intern program
provides. We are certain that after graduation, we will have more confidence
working as employees in factories.
In terms of the project, the work itself was also intriguing from a variety of
perspectives. Handling this internship project allowed us to understand several
techniques in the automotive engineering stream and mechanical engineering
in general, among other things. Furthermore, the project has been created to
assist in the resolution of issues encountered during the replacement of drums.
That is, by utilizing this work tool, you can quickly remove or replace the drum
without any difficulty or problem. The machine also prevents energy waste,
time consumption, noise, and material wear, among other things. It was
specifically intended to reduce problems and challenges for ECWC when
replacing drum brakes.

11.1.2 Recommendation
• Recommendation for the company

The project has been developed so that all of its components may be made in
ECWC. As a result, advice to the corporation is that the company will benefit
in the future if it begins to manufacture. The company will be able to save
money and time

• Recommendation for the design

• The work tool operates manually
• It’s designed to remove the brake drum easily

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12 Chapter twelve
12.1 Drawing of part and assembly
12.1.1 Part and assembly

12.1.2 part drawing

Figure 24 2D drawing of cross-bar

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Figure 25 2D drawing of power screw

78
 Jaw

Figure 26 Drawing of jaw

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Figure 27 2D drawing of handle

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Figure 28 2D drawing of bolt

81
Figure 28 2D drawing of nut

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12.2 Assembly drawing

Figure 29 2D drawing of drum extractor

83
Figure 30 3D drawing of drum extractor

84
13 Bibliography
1. Design and development of hydraulic bearing puller and pusher. Keshuala
jay dip, kahar Harshal, Patel harsh, Rakesh R. Patel. April 2019,
IJIRSET-International Journal of Innovative Research in Science,
Engineering and Technology.

2. Development of a mechanical puller. Emagbetere eyere, oreko, Benjamin

U. Fuoma. 7, July 2018, IJISRT International Journal of Innovative Science
and research technology, Vol. 3.

3. Design and Analysis of Pneumatic Bearing Pusher and Puller. C. Senthil

Kumar, S. Raja, L.vadivel kannar. 11, November 2018, IJMET-
International Journal of Mechanical Engineering and Technology, Vol. 9,
pp. 696-703.

4. Design and Fabrication of Hydraulic Bearing Puller and Pusher. Rakesh

y.suryawanshi, Pranay Ramteke, Niraj Patil, Deepak Kumar, Dr A.V
vanalkar. April 2015, IJIRST-International Journal for Innovative
Research in Science and Technology.

5. Analysis of Stress Square Threaded Power Screw Using ANSYS. N. Lenin

Rakesh, Jose Ananth vino.
2017, IJPAM-International Journal of Pure and Applied Mathematics, Vol.
116, pp. 455-460.

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