DECLARATION

We declare that the internship report comprises our own work. In compliance with accepted practices, we have
dually acknowledged and refereed all materials used in this work. we hereby declare that this document at Amhara
Rural Road Construction Agency. The project that the internship program under way in ARRCA auto engine
garage, under the guidance of Instructor Mr. Tsegeye, by the title of internship final report, totally prepared by us
except those documents used as a reference, listed on the reference section.
Approved by:
Students and University mentor name, signature and date.
Advisor name: Mr Tsegaye signature _________ date______________
NAME ID NO
Endalew Awoke----------------------------------01416/09
Enyew Awoke------------------------------------01440/09
Tilahun Mengstie-------------------------------03864/09

i
 AKNOWLEDGEMENT
First of all, our grateful to above all, goes to the creator and governor of the two worlds, the almighty GOD, Jesus
Christ, his mother Saint Marry, all his Angels and Saints for his incalculable and marvelous gifts to us.

We would like express our special thanks to our academic mentor Mr.Tsegaye. For his unreserved supervision,
prudent guidance and suggestions in responding our question and made valuable discussions that we had.

Additionally, we want to thank the supervision Getaneh, from the host organization, (the chief mechanic) who
helped us to grasp basic practical knowledge. helping us to complete this internship program.

Executive Summary
In the four months stay at the project called ARRCA Garage office, practical automotive work experiences were
harvested.
ii
In the internship program the fundamentals of automotive engineering works were very practiced in the interim
project. As it was overhauling project, most auto engine activities were touched and got practiced. The activities like
differential maintain engine overhauling, brake service and electrical systems are practically undergone.
Specifically, in the auto engine process with the guidance of the supervision engineer and the mentor, a lot auto
engine quality supervision and controlling skills were developed. Finally, a lot of automotive construction work
experiences were taken from the internship program. And the detail processes are shown in this document.

Table of Contents
DECLARATION..................................................................................................................................................................i
AKNOWLEDGEMENT......................................................................................................................................................ii
Executive Summary.......................................................................................................................................................iii
CHAPTER ONE................................................................................................................................................................1
INTRODUCTION............................................................................................................................................................1
1.1 Back ground.............................................................................................................................................................1

iii
1.2 Objective of company..............................................................................................................................................3
1.3 Vision, Mission, Values and Institutional Culture....................................................................................................3
Main products or services..............................................................................................................................................4
1.4 Organizational Structure………………………………………………………………………………………..………………………………………….5
1.5 Work flow of the company’s maintenance shop.....................................................................................................6
CHAPTER TWO...............................................................................................................................................................7
Overall Internship experience........................................................................................................................................7
2.1 Benefits gained from company..............................................................................................................................7
2.1.1 Improving our practical skills..........................................................................................................................7
2.1.2 Upgrading our theoretical knowledge...........................................................................................................7
2.1.3 Improving our team playing skill....................................................................................................................8
2.1.4 Improving our leadership skills......................................................................................................................8
2.1.5 Work ethics and industrial psychology..........................................................................................................9
2.1.6 Entrepreneurship skill....................................................................................................................................9
2.1.7 Interpersonal communication skill.................................................................................................................9
2.2 Work tasks that have executing......................................................................................................................10
2.3 Engineering method...........................................................................................................................................11
2.4 Challenges faced while performing our work tasks...........................................................................................15
2.5 Problems faced while performing work tasks....................................................................................................16
2.6 Solutions to overcome problems........................................................................................................................17
2.7 Recommendation and conclusion......................................................................................................................18
2.2.1 Recommendation........................................................................................................................................18
2.2.2 Conclusion....................................................................................................................................................18
CHAPTER THREE...........................................................................................................................................................19
PROBLEM IDENTIFICATION..........................................................................................................................................19
PART TWO....................................................................................................................................................................19
CHAPTER ONE..............................................................................................................................................................19
INTRODUCTION............................................................................................................................................................19
1 1 Background.........................................................................................................................................................19
1.2 Problem of statement.........................................................................................................................................22
1.3 Objective of study...............................................................................................................................................22
1.3.1 General objective.........................................................................................................................................22
1.3.2 Specific objectives........................................................................................................................................22
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 1.4. Scope and Limitations the project.....................................................................................................................22
1.4.1 Scop of the project.......................................................................................................................................22
1.4.2 Limitation of the project..............................................................................................................................23
Beneficiaries..........................................................................................................................................................23
1.6 Methodology......................................................................................................................................................23
CHAPTER TWO.............................................................................................................................................................24
Literature review..........................................................................................................................................................24
CHAPTER THREE...........................................................................................................................................................26
Geometrical Analysis....................................................................................................................................................26
3.2 Material Selection...............................................................................................................................................28
3.3 Component Design.............................................................................................................................................28
Design of engine plate........................................................................................................................................28
Design of amounting arms..................................................................................................................................29
Design of bolts....................................................................................................................................................30
Vertical bar (post)...............................................................................................................................................32
Finding Bending Moment...................................................................................................................................32
Finding Bending Stress.......................................................................................................................................34
Design of shaft....................................................................................................................................................34
Design of Shaft holder........................................................................................................................................35
Design of Handle................................................................................................................................................35
Design of Locking pin.........................................................................................................................................35
Selection of Wheel Caster..................................................................................................................................35
3.4 Manufacturing Procces.......................................................................................................................................36
3.5 Assemble Procces...............................................................................................................................................36
3.6 Cost analysis........................................................................................................................................................37
Cost analysis of engine plate...............................................................................................................................37
Cost analysis of vertical bar................................................................................................................................37
Cost analysis of sha.............................................................................................................................................38
Cost analysis of Shaft holder...............................................................................................................................38
Cost analysis of handle........................................................................................................................................38
CHAPTER FOUR............................................................................................................................................................39
Results and Discussion.................................................................................................................................................39
4.1 Result......................................................................................................................................................................39
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4.2 Discussion………… …………………….……………………………………………………………………………………………………………………..39
Reference.................................................................................................................................................................51
List of equations

Acronym
AC ………………. cross sectional area
ARRCA…………...Amhara rural road construction agency
dc ………………. core diameter
dm ………………mean diameter
do ………………. outer diameter
F. S ………………...safety factor
FPULL ……………...pull force /load acting to the screw/
ID ……………...inner diameter of puller
OD ……………. outer diameter of puller
pb ………………. bearing pressure
sy ………………. yield strength
st ………………. Tensile strength (stress)
Tn………………...thickness of the nut
T ………………...Torque
wcr ……………...creping load
σall ……………...allowable tangential stress
σc …………….... compression strength (stress)
σD ………………distortion stress
τ ………………. shear stress
τall …………….... allowable shear stress
η…………………………..efficiency
w…………………………..width
l……………………………length
p……………………………pitch
p……………………………power

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Stmax…………………….maximum tensile stress
τ max………………………maximum shear stress
p…………………………..bearing pressure
di………………………...outer diameter
dc………………………….core diameter
n…………………………….number of thread
τ n………………………..shear stress in the nut
τ s…………………….shear stress in the screw
E………………………….elastic modules
A ………………………….area
r………………………….radius
I………………………….moment of inertia
L………………………...equivalent or effective length
LIST OF FIGUR
Figure 1.1 ARRCA Head office………………………………………………………………………………1
Figure 1 Organizational structure………………………………………………………………………… 5
Figure 2 work flow of the company………………………………………………………………………… 6
Figure 3 Engine assembly………………………………………………………………………………………………………………………11
Figure 4 Engineering method………………………………………………………………………………12
Figure 5 Flashlight…………………………………………………………………………………………. 13
Figure 6 Socket……………………………………………………………………………………………... 13
Figure 7 Wrench………………………………………………………………………………………….. 13
Figure 8 Oil filter……………………………………………………………………………………………. 14
Figure 9 Screw driver………………………………………………………………………………………. 14
Figure 10 Jack stands………………………………………………………………………………………. 15
Figure 11 Vertical var………………………………………………………………………………………. 33

vii
 CHAPTER ONE

INTRODUCTION

1.1 Back ground

Amhara Rural Road Construction Agency (ARRCA) was established in 1987 E.C. with the
main objective of road construction. ARRCA is located in Northern part of the country
specifically in Bahir Dar .ARRCA starts its work with 180 manpower and 2.2 million
capitals but at the current time it is grown and become a big industry with 1500 manpower
and 2.4 billion capitals. As ARRCA is a social enterprise, it has some charity works and
social activities for the community like supporting 20 children those have no family different
material supports for the local community policing and schools. The main activities in this
industry are equipped with appropriate technology,

figur 1. 1: ARRCA head offi

when the Derge regime was overthrown in 1991,major political reforms took place
and a federal system was initiated. In line with the new political set-up, responsibility
for administering different roads became decentralized and the previously classified
road network was categorized into federal and regional roads. While trunk and link
roads fell under the administration of the federal Ethiopian Roads Authority,
responsibility for rural roads was transferred to the newly established regional Rural

8
Roads Authorities. A more detailed and clarified separation of responsibilities
between the Ethiopian Road Authority and the Rural Roads Authorities was later
formulated in the Road Sector Development Program.
The Ethiopian Roads Authority was reestablished at the federal level under
the direct supervision of the Ministry of Works and Urban Development
(Fortune 2009b) by government proclamation No. 80/1997. In contrast to its
predecessor – the Ethiopian Transport Construction Authority – the Ethiopian
Roads Authority became exclusively responsible for road infrastructure. As a
consequence of the priority given to road infrastructure in the Ethiopian
People’s Revolutionary Democratic Fronts policy, the road sector in general
and the Ethiopian Roads Authority in particular were recently strengthened
compared to other government institutions. As a public sector entity, the
Ethiopian Roads Authority’s general mandate is “to regulate, plan and
manage the federal road network of Ethiopia, which includes construction,
maintenance, upgrading and rehabilitation so that it will achieve the overall
objective of economic development, growth and poverty reduction”. The
Ethiopian Roads Authority, as the highest governmental body in the road
sector holds three 12. The founding year of the Ethiopian Transport
Construction Authority could not be reconstructed through the documents
available for this paper. First, the Ethiopian Roads Authority is responsible for
the improvement and expansion of the road network at the federal scale. This
encompasses the planning, construction and maintenance of all trunk roads as
well as linking roads. While trunk roads refer to those “...extending from
Addis Ababa to connect major urban and regional centers...”, linking roads
include mainly roads, which connect

or lead to two or more region. Second, the Ethiopian Roads Authority is

responsible for the overall sector planning of the Ethiopian road network as
the formulation of the Road Sector Development Program and the Ethiopian
Rural Travel and Transport (sub-) Program. Its third responsibility is to
support the regions’ Rural Roads Authorities in professional as well as
institutional regard. As indicated above, the Ethiopian Roads Authority is also

9
 planning the “...overall rural road network and programming” and
collaborates with the Rural Roads Authorities. In operational terms, the
Ethiopian Roads Authority gives technical advices and assistance, and also
provides and coordinates different training activities. However, the RRA’s
general responsibility is to improve and expand the regions rural road
network. This network excludes the roads already classified as ERA’s federal
roads and the urban roads independently administered by the municipalities.
The RRA’s duties are further clarified in accordance with the RSDP:
 Preservation of the existing network;

 Provision of access to agricultural potential, food deficit and neglected areas;

 Improvement of the availability and management of equipment for

the construction and maintenance of roads;
 Promotion of the use of labor-based technologies and community
participation in regional and local program;
 Provision of community based integrated village travel and transport services;

 Reduction of the adverse environmental effects through improved design

standards;
 Improvement of resource mobilization through suitable road pricing.

1.2 Objective of company

The main objective of the company is road construction in the country.
 Road construction and maintenance service
 Heavy duty machinery and generator maintenance
 To perform efficiently rural road construction
 To build will experience human resource
 Providing heat treatment and painting services

1.3 Vision, Mission, Values and Institutional Culture

Vision

10
  To perform efficiently rural road construction and maintenance in the region
and to satisfy the need of people up to 2017.
Mission
 To build well experienced human resource and modern technology in the state.

Values
 Well-being of work place and environmental ecology
 Quality and money saving
 Critical thinking
 Improve customer service process
 Reasonability
 Scientific process
 Encourage group work
 Delegacy /enthusiasan and stability
 Good ethics

Institutional Culture
 Planning and implementing is our characteristics
 Institutional strength is human resource
 Our assurance of success is people beneficiary and satisfaction.

Main products or services

The main services of the company are:

 Maintenance for heavy and light vehicles
 Giving services for heavy and light vehicles

The end user of the its services

The main users of its services are its company

11
1.4 Organizational Structure

Fig. 1 Organizational structures

12
 1.5 Work flow of the company’s maintenance shop

Fig.
2
work flow of the company

13
 CHAPTER TWO

Overall Internship experience

2.1 Benefits gained from company

2.1.1 Improving our practical skills

In internship program improve practical skills and experiences that make me

Effective in working with light and heavy vehicles. Now we have confidence to do any tasks
on vehicles. This confidence is gained during internship programs.

The theoretical knowledge that we got during the last three and half of years is greatly
improved practically at present .The vehicle that we know by theory before is know we can
experience It practically and maintain and service it we develop a great experience and
confidence to handle vehicles assertively.

These are the benefits we gained

 Improving maintenance of vehicles

 Improving servicing of vehicles

 Improving arc welding and gas welding skills

2.1.2 Upgrading our theoretical knowledge

Knowledge and understanding of:

 The fundamentals of vehicle technologies e.g. vehicle systems

such as chassis, engine, transmission, electrical, air conditioning,
high voltage vehicles, etc.
 The types, and associated characteristics, of light vehicles e.g.
front- or rear-wheel drive, four-wheel drive, etc.
 Diagnostic principles and logical problem-solving techniques.

14
  Emerging automotive technologies and the impact will have on
the knowledge and skills technicians will require in the future.

2.1.3 Improving our team playing skill

In this internship program we improve the following team playing skills:-

Improve showing genuine commitment. we genuinely committed to my cause.

 Improve adapting to situations easily and quickly.

 Improve confident communication. w e can express my ideas

clearly and honestly without staying in the shadows.
 Improve reliability and responsibility.

 Improve actively listening.

 Improve sharing my opinions.

 Improve supporting and respecting others.

2.1.4 Improving our leadership skills

During the internship program we have learned and convicted to have the
following attributes to be effective leader:

 Communication

Leader need to be able to clearly and succinctly explain to your

employees everything from organizational goals to specific tasks.
 Motivation

Leaders need to inspire their works to go the extra mile for their
organization . you may build employee self esteem through
recognition and rewards, or by giving employees new
responsibilities to increase their investment in the company.
 Delegating

15
 Leader need to identify the skill of each of his employees, and assign
duties to each employee based on his or her skill set.
 Creativity

Leaders have to make a number of decision that do not have a clear

answer; leader therefore need to be able to think outside of the box.
 Responsibility

A leader is responsible for both the successes and failure of his or her
team. Therefore, leaders need to be willing to accept blame when
something does not go correctly.

2.1.5 Work ethics and industrial psychology

Work Ethics and discipline is one of the major factors for the step to professionalism.
Issues that are related to work ethics like punctuality, honesty, loyalty, and
performance are what make a company a success or a failure. The workers in a
company should be motivated to work. They should be punctual and deliver products
on time. Workers should understand the value of time and use it effectively.
The other factor that is related to work ethics is maintaining a peaceful environment at
work place. There are some workers that quarrel with everybody in reach. This kind
of behavior interrupts the work progress and affects the whole company. Workers
should also treat the company’s property as their own and try to handle it respectfully.
Most of the issues that are related to work ethics are also related to the motivation of a
worker’s .Unless a worker loves what he does and has a goal, his performance will
deteriorate. Therefore, the company should do some things in order to elevate the
workers motivation. In our opinion, the best way of doing this is paying the workers
per time. This will initiate the worker to work overtime and too deliver the product in
time. One of the other methods of motivating the worker in setting up workshops in
order to inform, entertain and motivate the workers.

2.1.6 Entrepreneurship skill

After our internship experience we develop intensive confidences how to
create work and business for us and our society. We came up with some new

16
 ideas and alternatives to improve production with a minimized cost and work
on service area for individual income, therefore it figure out that our
entrepreneurship skill has been improved.

2.1.7 Interpersonal communication skill

We have developed to communicate with Amharic and English in the work place
and at the office also communicate with Italic language with technicians especially, on
tools and components.This experience give us a chance to communicate well with
anyone in everywhere for the future.

Section of the company we working and why?

We are working on the garage section of the company .In garage section we
working maintenance and service of vehicles. we working in garage because it
is the part of mechanical engineering.

2.2 Work tasks that have executing

 Disassembled ,assembled and Serviced different types of brake systems like;
 Air brake system
 Hydraulic brake system and
 Air and hydraulic for different types of car servicing the following
activities were performed such as; Brake Shoe, wheel cylinder, seal,
bearings, bolts and nuts welding or replacement if necessary and
changing of greases.
 Check defective alternators and test charging voltage. This diagnosis is
performed using a multi meter. In this process, the parts of
alternators that should be checked are regulator, slip rings, carbons,
diodes, windings and bearings.
 Start a car with dead battery. To start the engine of a dead battery car,
we used a jumper and connect the dead battery to working battery of
another car.
 Fit brake lights and closed open linings.

17
 Weld body and broken parts of automobiles and paint car bodies (body
maintenance). Body of acar maintained using gas welding and arc or stick
welding and painted by required colors.

 Change engine, transmission and differential oils based on the manual

of the manufacturer.
 Replace oil, fuel and air filters based on the manual of the
manufacturer or as their defectiveness.
 Replace broken synchronizers and bearings during transmission servicing.
 Service engines like replacing of pistons, piston rings, linings,
measuring crank shaft oil clearance etc.

 Valve lapping (intake and exhaust valves).

 Replace fuel return line.
 Replace roller and track group of a dozer.
 Understood practical works when technicians do.
 Asked technicians about the servicing and maintenance procedure.
 Helped technicians on practical work.
 Tried to understand the problem in the company, especially, in the garage part.
 Comment technicians when they face a problem.
 Record problems and search on different sources to solve it.

18
 Fig. 3 Engine Assembly

 Tools
The most common tools in a mechanics set include the following:
Flashlight: A flashlight is one of the most-used tools in an auto repair
shop.It helps the Mechanic see anywhere for visual inspections,
maintenance and repairs

19
 Fig. 5 Flashlight [4]
Socket sets and wrenches: These have two different measurement systems.

One is metric and one SAE (or standard). The metric system has

measurements in millimeters (mm). SAE has measurements in

inches or fractions of inches (1/4, 5/16, etc.). Wrenches often have

an open end and an opposite box end.

Fig. 6 Socket ratchet wrench [4]

Fig. 7 Wrench set [4]

20
Oil Filter Wrench: Has a prying mechanism like other wrenches but one end
has a belt that wraps around the object being unscrewed, which is much
bigger in diameter than the regular bolts and hex-head screws that other
wrenches are used for.

Fig. 8 Oil filter wrench [4]

Screwdrivers: both Philips head (the cross-section looks like a cross or plus
sign) and flat tipped (or slotted).When using screwdrivers, try to match the
size of the screwdriver head with the screw. Also try to avoid stripping the
head of the screw (this has occurred when you can firmly turn the screwdriver
against the head of the screw continually and the screw never rotates).

Fig.9Screwdrivers set [4]

Jacks: These are used to lift the vehicle. Some are rotated by hand. Other
higher-end jacks are pumped. Some are hydraulic.

Jack Stands: These are used to keep the vehicle elevated after it has been
raised with the jack. They have a wide square base and come to an apex where
the car rests on them.

21
 Fig. 10 Jack stand [4]

 Techniques
 To tighten and loose bolts and nuts extension levers are used to multiply force.
 To make brake adjustment count the number of threads (should be
equal on each side of front or rear wheel of the vehicle).

 Fitch fuel from the tank through tube by creating vacuum in it by using mouth.
 If tool is not available perform the activities by hand.
 Lubrication is made if bolt or nut is highly tighten to lose it.
 Use plastic hammer to not damage the parts.

2.4 Challenges faced while performing our work tasks

 Working area was not comfortable.

 There was no modern device to deal on a problem.

 Could not found documents easily about the company.

 No employees are skill full on modern automotive technology to

assist us.

 No diagnosis was taken on sensors and actuators.

 Mostly service is given for old models of the

vehicle( we haven’t a chance to get a practice on new

22
 model of vehicles).

 Moving forward, employers want the assessment

process to reflect the increasing complexity of vehicle
systems, the emergence of many unfamiliar
technologies and the importance of an individual’s
behavior as well as their skill.
 No internet accesses in the company.
 The company has no transportation service for us.
 Language problem: - technicians use Italic language to call tools
and parts of the vehicle.

2.5Problems faced while performing work tasks

 Bolts are loosened or tighten by using wrenches acted by

man force.

 Bearings are lubricated without any tool (simply by hand).

 Removing or separating of kingpin is performed by
hammering.
 When air cleaners are dirty, they are cleaned directly to the
environment.
 Old (wear) brake shoes are removed from their lining by
hammering.
 Heavy tires (tires of loaders, Sino trucks, Nissans,
etc.) are assembled with the contribution of three
or more technicians.

 Transmissions and engine assemblies are moved

from the car to service place and back to the car
are using human force.

2.6 Solutions to overcome problems

23
 Loosening and tightening of bolts by man power is
time consuming, enervating and also may not tighten
to the required torque. So, we recommend that using
pneumatic or electric impact wrench is selected.
 Removing king pin by hammering is time consuming
and enervating. So, we recommend that using
hydraulically operated tool is better.
 Cleaning air cleaners directly to the environment
pollutes materials around their and also damage
human beings due to dust and other tiny particles in
it. To overcome this problem, it is better to clean
using in a closed container. The container should have
water reservoir to suck dusts, and air clear holder
inside it.
 Removing wear brake shoes using a hammer is
enervating, consumes more time and causes
asbestosis. So, we recommend that using
hydraulically or mechanically operated pressing tool
to remove the rivets connecting the lining and shoes
is better.
 Assembling and disassembling of heavy tires by using
three or more man power is time consuming and also
may cause damage on technicians. So, it is necessary
use a simple tire carriage tool which simply carries
the tire and move freely to the required place of the
car.
 Moving transmissions and engine assemblies using
man force is enervating and more time consuming.
So, we recommend them by using a forklift, to move
transmissions and engine assemblies are better.

24
 2.7 Recommendation and conclusion
2.7.1 Recommendation
The advisors (shop and school) should manage and assist us near by the shop.
Different services such as network, transport safety materials should be given
us in company. It will be very important task if the institute and the company
give special attention for prototype of the project in addition to paper work.

2.7.2 Conclusion
The internship program gives us tangible advantage for improving our
practical skill as well as theoretical knowledge. It enables us to be confidential
citizen for our country. Also, this program has a power to strengthen the
relationship between the company and the educational institute.

CHAPTER THREE

PROBLEM IDENTIFICATION
Problems that we got from the companys are:-
There are many problems in ARRCA automative garage,but these problem could not
solve due to different cases like management problem and budget,some problems are,

25
  Valve spring removal
 Break shoe rivating machine
 Rim and tyre separating machine
 Cylinder liner remover machine
 Engine stand

But, from the above listed problems we have to select engine stand for our project
work. because of ,
 To save time and money
 To maintenance any part of engine
 To decrease labour force
 To increase the efficiency work

PART TWO

CHAPTER ONE

INTRODUCTION

1 1 Background
There is no device for holding engine probably when the repair them when the disassemble
engine, it is difficult to handling engine because its complexity and the weight.
Near about is 450kg average weight of any company engine. These is cause to difficult handling
for repairing the worker our engine stand to resolve problem of handling engine and make safe
environment for the worker.

26
We decided to provide this engine to company worker with low cost. For eliminating or reducing
cost we use hallow stainless steel material for making engine stand. We also use the design
parameter and calculation for minimizing the weight of engine stand.
Parts of an engine stand
The basics of an engine stand are same for all stands, but each engine stand can have its specifics
like different post position, leg and wheel count and other.
 Base, bars (legs) and caster

The base of engine stand similar as engine hoist, consist of legs, caster, and base tubes. Engine
stand usually come with 3-6 caster. The most common wheel count for engine stand is four. Four
wheeled stand and do not take more space as six wheeled stands. Some stands have only three
casters. These stands are good for engine with weight less than ¼-½ tons, but usually are
unstable with heavier engines. Five and six wheeled stands are made for large and heavier
engines and will support load over 2 tons. Smaller engine stands have only one leg, while larger
stands have two legs, similar to an engine hoist. Stands with two legs are more stable and usually
can be used with larger engines. Some engine stands are foldable, which means that one or all
legs of the stand can be folded, so it takes up less space when not being used. When stand is
going to be used, legs need to be locked in the right position with special, durable steel locking
Internship report 2013.E.c

 Post and braces

Post of the engine stand is made from heavy duty, durable and thick steel, so it can support heavy
engines on the stand. Basic stands made for less heavy engines usually have only upright post
and do not need any support braces. Stands that can hold heavier engine (2 ton and above)
usually have additional support brace for extra durability and safety for holding engines with
weight capacity close to the allowed weight limit of the stand.

 Head plate and mounting arm

Engine stand parts that are responsible for mounting the engine are head plate and mounting
arms. Mounting arms are screwed to the head plate and can be adjusted to fit most engine blocks.
Most engine stands come with four mounting arms. Engine needs to be mounted to the stand

27
with special mounting bolts, but usually they need to be bought separately and vary in size and
length between different engine block.
 Rotating mechanism and Handle

The most important part of engine stand is head. It consists of rotating mechanism and mounting
plate. Rotating mechanism is located into the head of engine stand. On the back of the head there
is a turning handle. The handle is located behind the engine stand head and equipped with two
rubber grips for easier handling .With help of this handle, a person operating the stand is able to
turn engine stands head and the mounted engine 360 degrees around. On the head there is a
special hole, or multiple holes for locking the mounting plate with engine from rotating. This
way you can rotate the engine to a position you need and lock it there with a locking pin. Some
engine stands have a gear box instead of turning handle. Turning heavier engine may be difficult
and requires a lot of strength. This special gear box makes engine stand that have an automatic
rotating mechanism that makes process of rotating a heavy engine practically effortless.
Advantage and disadvantage of engine stand
Advantages
 Made from sturdy and tensile material to ensure the stability of it

 The head of the stand is rotatable 360 degree allowing for allowing for
easy access to all sides of the engine.

 caster lets you move the stand around easily

 It is easy to assemble and disassemble the stand so it can be taken apart

and stored away only to be reassemble in minute when it is needed again

 Can hold engine that weight ½ ton -2 ton

 The price of the stand is based on the carried weight

Disadvantage
 There have been some problems for those who have purchased this stand with mounting
holes not lining up upon assemble,

 The price for the stand might seem pretty steep

28
 1.2 Problem of statement
In this company the engine assembly and disassembly is done. There is no device for holding
engine properly during engine repairing. It is very difficult to handling engine because of the
complexity as well as weight, and it causes backache to the technician and it takes more time to
repairing so select this topic.

1.3 Objective of study

1.3.1 General objective

 The main objective of this study is to design engine stand that help the technician in
all aspects.

1.3.2 Specific objectives

The following are specific objectives, which are accomplished at the end of the project
 Design and analysis of each components of engine stand.

 To design the component of engine stand selecting suitable materials

 Analysis the procedure for each component, holding plate, bolt for plate fitting, base etc.

 Estimate the cost of the engine stand

 Check the design whether it is safe

 To draw each component using solid work software.



1.4. Scope and Limitations the project

1.4.1 Scop of the project
In this project the scope is starting from data collection from different source like
journal, internet, books etc. up to part and assembly drawing with solid work cad
about multipurpose machine has been included without manufacture.

29
Generally in this project design or paper covers geometrical analysis, stress
analysis, force analysis and cost analysis from appropriate material selection
and also other related information are included.

1.4.2 Limitation of the project

Thire is not enough time
Do not access internate
Have not efficient budget
Lack of access operation material

Significance of the project

Benefits
 It is easy operation
 Portable and operated by one person
 It is saving time and labor force during operation.
 Easily maintenance and low cost.
 It has less vibration during operation.

Beneficiaries
People who are performing different operation simultaneously for production
based industry. People who are living in remote place and work shop use this
machine

1.6 Methodology

30
1.6.1.Data Collection

 Primary data

We have seen the engine stand parts that is mounting arm is inserted in to the engine
block and the engine plate is tie with nut and bolt with the vertical bar, during use
engine stand minimizing the labor force and savings time. Doing efficient works

31
  Secondary data

We get informations and mor knowledges about the holding machine that is engine
stand from different types of jornals ,magazines and internates

32
CHAPTER TWO

33
 Literature review

Billy mill(1890)/ Enginse stand, Pittsburgh automotive, review

This product is made by the Pittsburgh automotive company, which also makes other type of
tools for automotive repair such as engine hoist. The total capacity of this engine stand is 3/8
tons (750lb), which is not the highest capacity amongst engine stands, but should be enough to
hold most 4 cylinder engines. For large v6-v8 engines we recommend that you look at engine
stand with ½ ton (900lb) and higher storage capacities. This tool has got a simple design and is
very easy to use for storing smaller engine block.[1]

Claud C.Hunter.(1986) The automobile it self has to be raised ,make sure it is property
supported adequate stands .chock the wheels mounting the engine on a work stand after
removing the engine from the engine compartments.[2]

Jack Erjavce(1993) Raise the engine and position it next to an engine stand,mounting the
engine to the engine stand with bolts .most stands use aplate with several holes or adjestable
arms,the engine must be supported by at least four bolts that fit.[3]

Jack J.Thiessen(1994).The engine,in its up ward stock ,which is accomplished by by the

preponderance of whight at the pump end of the beam ,raises up up the and in as in that case,the
injection valve can not be opened ,the engine stand still the coke be slightly opened[4]

Theme.K.( 2013) the engine stand has been designed on the basis of two manpulaters,which can
be used in acomplate range of engine .the engine tooling has been designed to exacting standards
and the supporting tooling like the cariers and interface tooling were all subject to individual
strength tests.They are the new players in theaviation market has an agreement with accompany
with hydro for products and services related to engine built and ground supporting system.[5]

Rolls Royce(2014) engine stand is good example brand for engine repair and automobile
maintainance,Also it gives the readers information about Rolls Royce engine stand having its

34
unique and district designes and platforms in terms of mechanisms,functions,featurs and designs.
[6]

Reilo,A.(2014) engine stand is avery important tool that every mechanic should have .The
equipment is commonly used to repair any gasoline diesel engine .usually it has acantilevered
support structure that can hold any type of engine in midair.This will give the mechanic to meet
access and reach any part of the This .engine stands are meant to repair large engine,especially
it’s fragile components like valves and oil pans.[7]
This parts will be crushed if the engine is placed on a flat surface .on the other hand ,engine
stand is avery function tool for engine repaire and automobile maintenance which has destinict
mechanism and functions that would help the automechanic to repair and fix engines.[8]

CHAPTER THREE

Geometrical Analysis

Design of engine plate

35
The engine plate of the engine stand is made up of stainless steel. So that the Tensile strength
(σᵼ=420) and

Yield strength (σᵧ=350)

Take factor of safety, n=2

After calculating the allowable stress we can find the diameter of the holes by using the relation

τ = P/2A
2
= 4P/2лd

But τ = 0.5*Yi/2…………………………………………… Guest’s theory

To check whether the design is safe or not, we must calculate the maximum stress (σ max), given by

2
σt= P/A = 4P/лd

Design of amounting arms

The mounting arm of the engine is made up of stainless steel
The elongation finger is used to engine far from stand plate
σt= P/A and A = л(do2-di2)/4

Design of bolts
We select mild steel material since:
 Material selection = mild steel

 Tensile strength (σt) = 478 N/mm²

 Factor of safety = 2

 Number of bolts = 4

The external load is taken up by a number of bolts, then

2
P = лdc /4*σt*n
2
dc = 4*P/(лσt*n)

Vertical bar (post)

36
σt = P/A

Design of shaft
The shaft is used to transfer power from the handle to the engine plate that is necessary to rotate
the plate in order to rotate the engine .the design of the shaft is done by considering twisting
moment produced on its operation.
σt = P/A but A = л(do2-di2)/4
T = P*60/(2лN)

Shaft holder
find the shear stress
2 2
σt= P/A but A = л(do -di )/4

Handle
2
A= лd /4
Locking pin
2
A = лd /4

3.2 Material Selection

Selection of a suitable material must take into account the suitability of the material for
fabrication (particularly welding) as well as the compatibility of the material with the process
environment such as:-

 Safety during working

 Machinability

 Productivity

 Low cost over the working life

The material properties are very important in the selection of the material. Some important
mechanical properties which are considered in material selection are:-
 Strength.

 Roughness i.e. fracture resistance

37
  Hardness i.e. wear resistance

 Corrosion resistance
But the following factors should also be considered, which the material is:-
 Availability of the material

 Suitability of material for the working consideration service

 The cost of the material and easily fabrication

3.3 Component Design

Design of engine plate

The engine plate of the engine stand is made up of stainless steel. So that
the Tensile strength (σᵼ=420) and
Yield strength (σᵧ=350)
Take factor of safety, n=2
Therefore yield strength 350 N/mm²
Length of engine plate = 25cm
Width of engine pate = 25cm
Thickness of engine plate =2cm
Maximum weight of engine P = 450 Kg
= 450*9.81
=4414.5 N
Now we can calculate allowable stress

σt = 350/2 =175 N/mm2

After calculating the allowable stress we can find the diameter of the holes by using the relation
τ = P/2A
= 4P/2лd2
But τ = 0.5*Yi/2…………………………………………… Guest’s theory
= 0.5*350/2 =87.5 = N/mm2
d2 = 4P/2лτ
= 4*4414.5/ (2*3.14*87.5) = 32.2mm2

38
d = 5.67mm
Take d =10mm
To check whether the design is safe or not, we must calculate the maximum stress (σmax), given
by
σt= P/A = 4P/лd2
= 4*4414.5/(3.14*102) = 56.2N/mm2
Therefore; the allowable stress is greater than the maximum stress (σ>σmax) the above design is
safe

Design of amounting arms

The mounting arm of the engine is made up of stainless steel
The elongation finger is used to engine far from stand plate

The Length of finger is 5cm, inner diameter (di) =19mm and outer diameter (do) = 26mm
The allowable stress is

σt= P/A and A = л(do2-di2)/4 = л(262-192)/4 = 247mm2

Then there are 4 amounting arms so, p/4 = 4414.5/4 =
1103.6N σt = 1103.6/247 = 4.46N/mm2
Therefore; the allowable stress is greater than the maximum stress (σ>σmax) the above design is
safe

Design of bolts
We select mild steel material since:

Mild steel is the most widely used steel which is not brittle and cheap in price. Mild steel is not
readily tempered or hardened but possesses enough strength. Mild steel is very much suitable as
structural steel.

Force exerted at bolt = 4414.5 N

 Material selection = mild steel

 Tensile strength (σt) = 478 N/mm²

39
  Factor of safety = 2

 Number of bolts = 4

The external load is taken up by a number of bolts, then

P = лdc2/4*σt*n
dc2 = 4*P/(лσt*n)
= 4*4414.5/(3.14*478*4) = 2.94mm2
dc = 1.7mm
d = dc/0.84

= 1.7/0.84 =2mm but d = 10mm standard

Where d =nominal diameter of bolt
dc = core diameter of bolt

Coarse series = M18

Pitch =14.933 mm
Major or nominal diameter = 18 mm
Depth of thread (Bolt) = 1.534mm
To calculate the overall dimension of the bolt we have to use the thickness of the plate (T=
20mm). After this we can calculate the total length of the bolt (L), the height of the bolt head
(H) and the length of the thread (Lt) mounting arm length (Lm = 50mm).
Lt = 1.5d

40
= 1.5*18mm = 27mm
H = 0.8d
= 0.8*18mm =14.4mm
L = Lt+H+T+Lm
=27 +14.4+20+50 = 111.4mm

Design of Vertical bar(post)

we select stainless steel
We take that 150mm length square and 20mm thickens so,
A = 1502 - 1102 =10400mm2
σt = P/A
= 4414.5/10400 = 0.424N/mm2
Therefore 0.42 is less than work stress so, the design is safe.

Figure 17 vertical bar

Finding Bending Moment

Since it is cantilever carrying a uniformly distributed downwards vertical load and the bending
moment is at 45cm from left end.
L = 85cm = 0.85m and z = 45cm = 0.45m

A B

41
Moment respect to A is (4)
MA = W(L-Z)2/2
=4414.5(0.85-0.45)2/2 = 353.16Nm
A B

-1/2W(L-Z) 2

Shear force at a distance 45cm from A is

F = W(L-Z)
= 4414.5(0.85-0.45) = 1765.8N

W(L-Z)
A B

Finding Bending Stress

M = σb *(do4-di4)/6do
353.16*103 = σb *(1504-1104)/6*150
= σb *399822.22
Therefore it is less than work stress so, the design is safe

42
 Design of shaft

The shaft is used to transfer power from the handle to the engine plate that is necessary to rotate
the plate in order to rotate the engine .the design of the shaft is done by considering twisting
moment produced on its operation.
 Length of shaft = 30cm
 Time taken T = 2s
 Outside diameter (do) = 10cm
 Inside diameter (di) = 5cm
 F.s = 2
 N = 10rpm
 power=force * perpendicular distance / time

= 4414.5 * 0.85 /2 = 1876.16 W

Twisting moment on the shaft is calculated on the following

T = P*60/(2лN) = 1876.16 * 60/2*3.14*10

T= 29.88Nm and
σt = P/A but A = л(do2-di2)/4 = л(1002-502)/4

= 5890mm2
σt = P/A
4414.5/5890=0.7494N/mm

Therefore 0.7494 is less than work stress so, the design is safe.

Design of Shaft holder

Take diameter: Di=11cm
DO=13cm
Length: l=20cm
Then find the shear stress
σt= P/A but A = л(do2-di2)/4 = л(1302-1102)/4

A=3769mm2
=4414.5/3769 = 1.17N/mm2

43
 Design of Handle
Take: - Diameter = 40mm
Length = 500mm
A = лd2/4 = л*0.042/4
= 1.56*10-3m3

Design of Locking pin

Take: - diameter =10mm

Length = 10cm
A = лd2/4
= л*0.012/4 = 7.854*10-5

Selection of Wheel Caster

Many varying and individual factors must be considered to make the selection of the good wheel
caster that will do the best job for our design. Now we consider the weight of the engine. The
heavier load the larger the wheel required for the caster .The weight of the load is influence on
the mobility of the wheel. By considering the load and Floor condition we select caster. The
diameter of wheel is 7.5 cm.

Stress for welding

The stresses in welded joints are difficult to determine because of the variable and
unpredictable parameters like homogeneity of the weld metal, thermal stresses in the welds,
changes of physical properties due to high rate of cooling etc. The stresses are obtained, on the
following assumptions:
1.The load is distributed uniformly along the entire length of the weld, and
2.The stress is spread uniformly over its effective section.
The following table shows the stresses for welded joints for joining ferrous metals with mild
steel electrode under steady and fatigue or reversed load [4].

Table 3.2 Stresses for Welded Joints (3)

44
3.4 Manufacturing Procces
To manufacture our design ,use the machine list below
Lathe machine-to produce bolt and nut
Arc welding machine-to weld the engine stands part
Hand grinding machine-to smoothing the welded part of engine stand
Verner caliper-to measure the diameter of bolt
Drilling machine-to drill the hole
Sand paper-to smooth the welded part of engine stand

3.5 Assemble Procces

Engine stand are assembled by applying manual force to the engine,inorder assemble and
disassemble of the engine stand.This operated by manual power by
using man power.As the head of vertical bar adjesting the four mounting arms fit to the engine
plate and ahandle bar behind the engine head and also adjusting the locking pins as well as
supportings at the base of the engine stand

3.6 Cost analysis

Any design when he or she design a new material the cost analysis is the basic objective in the
design. The cost material most the of the packing is pound on dollar prices is an indication of the
cost of the some commonly used material is
The material selected is as follow
- Stainless steel
-mild steel

Cost analysis of engine plate

Volume = l*w*t

45
 = 250*250*20 = 1250000mm3=1.25*10-3 m3
Weight = V x Density, density of selection material is 7870kg/m3

= 1.25*10-3*7870 =
9.8375kg Cost = 1.2$ per
kg
So, cost =1.2*9.8375*29birr =342.345birr
Cost analysis of mounting arms
V = A*L but A = л(do2-di2)/4 = л(262-192)/4
A= 247mm2=2.47*10-4m2
= 2.47*10-4*0.05 =1.235*10-5m3
W=V*ρ
1.235*10-5*7870 = 0.097kg there are 4 mounting
arms
= 0.097*4 =0.388kg =
Cost = 0.388*1.2*29=13.52birr

Cost analysis of vertical bar

A = 1502 - 1102 =10400mm2 = 0.0104m2

V=A*L
= 0.0104*1 = 0.0104m3
W=V*ρ
0.0104*7870 = 81.85kg
But the total bar is 4 so,
WT = 81.85*4 = 327.4kg
Cost =327.4*1.2*29= 11393.24birr
Cost analysis of shaft
A = л(do -di )/4 = л(102-
2 2

52)/4 = 58.9cm2 = 5.89*10-

m2

V=A*L
= 5.89*10-3 *0.3 = 1.78*10-3 m3
W=V*ρ
= 1.78*10-3*7870 =13.9kg

46
Cost = 13.9*1.2*29=483.72birr

Cost analysis of Shaft holder

A = л(do2-di2)/4 = л(1302-

1102)/4 3769mm2

V=A*L
= 3.769*10-3*0.2 = 7.5*10-4m3
W=V*ρ
= 7.5*10-4*7870 =5.9kg = 5.9$
Cost = 5.9*1.2*29=206.4birr

Cost analysis of handle

A = лd2/4 = л*0.042/4
= 1.25*10-3m3
V=A*L
= 1.25*10-3*0.5 =6.28*10-4m3
W=V*ρ
= 6.28*10-4*7870 =4.94kg = 4.94$
Cost = 4.94*29*1.2 = 172.08birr
Cost of bolt is
M18 = 99*4 =396birr
M14 = 54*10 = 540birr
Cost of labor 7000birr
Cost of pin =80birr
Total cost=cost of
Labor+cost of material
Total cost=cost of engine
plate+cost of mounting
arm+cost of vertical
bar+cost of shaft+cost of
shaft holder+cost of
handle+cost of bolt+cost
of pin

47
Total
cost=342.345+13.52+113
93.24+483.72+206.49+39
6+540+80+7000
Total cost =20455bir

CHAPTER FOUR
Result and Descusio

4.1 Result
In the entire there are 7 major components, which are the basic parts of engine stand. These parts
have their own properties, dimensions, materials and strength.

Engine stand plate L=25cm

W=25cm

t= 2cm
2
σt =56.2N/mm

Mounting arm L=5cm

Di=11cm
Do=26cm
t=2cm
2
σt =4.46N/mm

Vertical bar L=15cm

W=15cm
T=2cm
2
σt =0.424N/mm
2
σb = 0.88N/mm
Shaft L=30cm
Do=10cm
Di=5cm
2
σt =0.7494N/mm

48
 T= 29.88Nm

Shaft holder Di=11cm

Do=13cm
L=20cm
2
σt =1.17N/mm

Handle D=40cm
L=50cm

Locking pin D=10cm

L=10cm

4.2 Discussion
Generally the over all geometry of this engine stand enables the mechanic not only to
disassemble but also to assemble the engine stand during repair of the engine. The simplicity of
the component and no need of lubrication makes it easy to maintain. Basically it can save time
and human force.

CHAPTER FIVE

CONCLUSION AND RECOMMENDATION

5.1 Conclusion
Generally engine stand is a device which is used to holding the engine. It has their own role to
garage worker with low cost. For eliminating or reducing cost we use hollow steel material for
Making engine stand.
From all the calculation parameter steel is better with compare to aluminum so for making
stand Select steel material.
Maximum stresses are produced on the stud. But the design load at 4414.5N with high factor of
safety of steel the stud does not fail so stand design is safe.

5.2 Recommendation

49
Design of engine stand in mo project paper was designed theoretically, but if it is applied to
practically it has great significance for the users.
To apply this designed project paper in practical the following manners are main factors that
should be improved for those who have interest to apply. Those factors are the economy for the
proper design system, bringing all necessary equipment’s material and shortage time should be
improved (avoided).

We also recommend that all garage worker must be use engine stand for safe for labor workers

50
Drby:endalew eneyew & tilahun WOLDIA UNIVERSITY SCALE 1:1

Ch by:Mr Tsegaye FACULTY OF TECHNOLOGY Dr no 1

Date 26/6/2013

group Part name shaft with plate

section

51
Drby:endalew eneyew & tilahun WOLDIA UNIVERSITY SCALE 1:1

Ch by:Mr Tsegaye FACULTY OF TECHNOLOGY Dr no 2

Date 26/6/2013

group Part mounting arm

section

52
Drby:endalew eneyew & tilahun WOLDIA UNIVERSITY SCALE 1:1

Ch by:Mr Tsegaye FACULTY OF TECHNOLOGY Dr no 3

Date 26/6/2013

group Part name locking pin

section

53
Drby:endalew eneyew & tilahun WOLDIA UNIVERSITY SCALE 1:1

Ch by:Mr Tsegaye FACULTY OF TECHNOLOGY Dr no 4

Date 26/6/2013

group Part name vertical bar

section

54
Drby:endalew eneyew & tilahun WOLDIA UNIVERSITY SCALE 1:1

Ch by:Mr Tsegaye FACULTY OF TECHNOLOGY Dr no 5

Date 26/6/2013

group Part horothontal bar

section

55
Drby:endalew eneyew & tilahun WOLDIA UNIVERSITY SCALE 1:1

Ch by:Mr Tsegaye FACULTY OF TECHNOLOGY Dr no 6

Date 26/6/2013

group Part name shaft holder

section

56
Drby:endalew eneyew & tilahun WOLDIA UNIVERSITY SCALE 1:1

Ch by:Mr Tsegaye FACULTY OF TECHNOLOGY Dr no 7

Date 26/6/2013

Group Part name handle

section

57
Drby:endalew eneyew & tilahun WOLDIA UNIVERSITY SCALE 1:1

Ch by:Mr Tsegaye FACULTY OF TECHNOLOGY Dr no 8

Date 26/6/2013

Group Assemble drawing

Section

58
 Holding shaft bolt Mounting arm head plate nut

Shaft
Handle Support leg

Host

Locking pin
base

Caster

Reference
1. ARRCA‟s year reports 2008e.c.

59
2. Engineering fundamentals of Ic engines (WWPulkrabek). pdf
3. Text book of machine design by R.S kuhrmi and j.k gupta
4. shingly, s mechanical engineering designs, eight edition
5. Marine Barracks‟ automotive engine maintenance‟ Ten edition
6. Cambridge university engineering department, Materials data book, 2003 edition
7. Jovinal, R.C, and Marshal, K.M, Fundamentals of Machine Component design,3 rd.
edition, John Wilay, New York, 2000.
8. TM 9-8000 Principles of Automotive Vehicles maintenance
9. RobertL.Mo “Machine Element in Mechanical Design “, fourth Edition,
10. William D. Callister, Jr. Materials Science and Engineering 7th Edition
11. Robert L. Norton “Machine Design” an integrated approach. Third Edition. Worcester
Polytechnic Institute. Worcester, Massachusetts U.S.A
12. Kay, M.G., 2012, Materials Handling Equipment
13. Materials Handling Handbook, New York; McGraw-Hill
14. Budynas − Nisbett “Shigley‟s Mechanical Engineering Design”, Eighth Edition

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