Bahir Dar University

Bahir Dar Institute of Technology

Faculty of Mechanical and Industrial Engineering
Mechanical Engineering Program

Internship Report

Project Title: Design of Gear Pump for oil filling

Hosting Company: Horizon Addis Tyre S.C

Name ID
Addisu Ayele…………………………………………………. BDU1012208
Elyas Kebede…………………………………………………. BDU1012207
Esayas Yemane……………………………………….………. BDU1012210
Hawi Teklu…………………………………………………… BDU1012124
Mentor: Temesgen Assefa
Company Supervisor: Zinabu Yichlale
March, 2022
 Declaration
We declare that, we are fourth year Mechanical engineering student. We have undertaken our
internship program in horizon Addis tire PLC. For a period of four month with the guidance of our
advisor Mr. Temesgen Assefa. Our work is original and based on the internship report writing
guideline given by the Institute Industry Linkage office.

We have taken some data from documents and specified source. Here by state that this final
internship report has been submitted to Bahir Dar institute of technology faculty of mechanical
and industrial engineering in partial fulfillment of the requirements of an internship report. our
project will solve problems faced by oil man during lubricant oil filling to gear boxes and screw
compressors.

Student approval

Addisu Ayele

Name of Student Date Signature

Elyas Kebede

Name of Student Date Signature

Esayas Yemane

Name of Student Date Signature

Hawi Teklu

Name of Student Date Signature

Mentors approval

MR. Temesgen Assefa

Name of the Academic Advisor Date Signature

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 Acknowledgement
First of all, we would like to thank the almighty God for helping us throughout the entire time and
experience. We have to extend our greatest gratitude to BDU (BAHIRDAR UNIVERSITY) for
providing such kind of an opportunity for students to stretch their perception on how a given
production is carried out and Horizon Addis tire for giving as this opportunity. We also are grateful
to our advisor Mr. Temesgen Assefa for his insightful comments and enlightening suggestions and
guidance that helped as stay focused and work hard we would also like to thank our supervisor
Mr. Zinabu Yichlale and all the employees of Horizon Addis tire.

They all have been such a great asset to our eye-opening experience during that four months of
our internship program. Especially we must thank Mr. Wosen Demse, Mr. Tekle Yayewsew, Mr.
Leta Zerihun, Mr. Tibebe Solomon also all employees that we have encountered on the process of
gathering knowledge for giving as the time and for their patience in making sure that all our
questions have been answered.

ii
 Abbreviation

Symbol Abbreviation
Q discharge rate
N speed of motor in revolutions per minute
b face width
n number of teeth
Ra addendum radius
Rd dedendum radius
Pd diametrical pitch
M module
Pc circular pitch
A addendum
D dedendum
C clearance
Do outside diameter
Wd whole depth
T thickness of tooth
Wt tangential component
kv dynamic factor
Y geometry factor
P pitch
Kf concentration factor
rf root fillet radius
V pitch line velocity
Tm motor torque
w width of key
t thickness of key
tf thickness of the flange

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𝐿𝑠 𝑎 Surface area of the cylinder
𝑣 volume of the cylinder
Pt power transmitted
D1 Diameter of bolt circle
Tmax maximum torque transmitted
nb Number of bolts
δ stress
τall Allowable shear stress
Ρ density of the fluid
μ viscosity of the fluid
L diameter of the pipe
Re Reynold number
TDH total dynamic head
HV vertical head
Hf frictional loss
ղp efficiency of pump
Ph hydraulic power
𝜌 density of the fluid
g gravity
h total dynamic head
∆P change in pressure

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 Executive summary
The first part of our paper provides information about the background history of hosting
company and organization structure also in this chapter, we tried to present basic requirement
of tire, component of the tire, main product of the company and their customers, then comes to
mention the raw materials used.

The second chapter explains tasks we have executed in the company, challenges we faced,
measures we have taken to overcome the challenges during the internship period and all over
benefits we gained from the internship which include improving practical skill, theoretical
knowledge, team playing skill, in terms of understanding about work ethics issue, industrial
psychology and related issue. We have tried to present different manufacturing units such as
mixing section, bead wire section, duplex extruding section, textile section, building section
and curing section.

The third chapter is about design of gear pump for oil filling in order to overcome the problems
which we observed during the process of oil filling for gear box and separator. After some
calculations the main parameters of the pump are as follows; Pump head of 1.51m, Delivery
𝑚3
pressure of 1.3 Mpa, flow rate of 3.33×10-4 , Volume of fluid displaced per revolution (DP)
𝑠

of 1.998×10-5 m3/rev, pump power of 686W and Efficiency of 63.75%.

The last part of the paper explains the general conclusion and recommendation (to the company
and the university)

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Table of Contents
Acknowledgement ................................................................................................................................. ii
Abbreviation ......................................................................................................................................... iii
Executive summary............................................................................................................................... v
CHAPTER-ONE ................................................................................................................................... 1
1. GENERAL BACKGROUND OF HORIZON ADDIS TIRE PLC ........................................... 1
1.1 Company Profile ......................................................................................................................... 1
1.3 Main customer of the company.................................................................................................. 4
1.4 Raw material used....................................................................................................................... 5
1.4.1Rubber .................................................................................................................................. 5
1.5 Organizational Structure .......................................................................................................... 6
CHAPTER -TWO ............................................................................................................................... 8
2. OVERALL INTERNSHIP EXPERIENCE ....................................................................................... 8
2.1The section of the company we have been working in; ..................................................... 8
2.2 Work task we have been executing .......................................................................................... 17
2.3 Engineering methods, tools and techniques executing to performing a task ....................... 17
2.4 Challenges and problems we have faced ................................................................................. 17
2.5 Measures that we have taken to overcome challenges ........................................................... 18
2.6 Overall benefits we gained from internship ........................................................................... 18
2.6.1 Improving our practical skills ........................................................................................... 18
2.6.2 Upgrading theoretical knowledge ..................................................................................... 19
2.6.3 Improving Team Playing Skills ........................................................................................ 19
2.6.4 Improving leadership skill................................................................................................. 20
2.6.5 Working ethics ................................................................................................................... 20
2.6.6 Acquiring Entrepreneurship skills ................................................................................... 21
2.6.7 Improving interpersonal communication skills............................................................... 21
2.7 Recommendation and conclusion on our internship experience ...................................... 22
CHAPTER - THREE...................................................................................................................... 24
3.Project work ................................................................................................................................. 24
3.1 Summary of the project ............................................................................................................ 24
3.2 Problem statement and justification ....................................................................................... 24
3.3 Literature Review ..................................................................................................................... 25
3.4 Objective of the project ............................................................................................................ 26
3.4.1 Main objective .................................................................................................................... 26
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 3.4.2 Specific objective ................................................................................................................ 26
3.5 Methodology .............................................................................................................................. 27
3.6 Design Analysis.......................................................................................................................... 28
3.6.1 Pump specification ............................................................................................................. 28
3.6.2 Design of gear ..................................................................................................................... 32
3.6.3 Shaft Design ........................................................................................................................ 37
3.6.4 Pump Housing .................................................................................................................... 38
3.6.5 Design of flange coupling................................................................................................... 41
3.6.6 Bearing selection ................................................................................................................ 45
3.6.7 seal selection ....................................................................................................................... 48
3.6.8 Other components .............................................................................................................. 49
3.7 Cost analysis .............................................................................................................................. 49
3.7.1 Material cost ....................................................................................................................... 49
3.7.2 Electric cost......................................................................................................................... 52
3.7.3 Human labor....................................................................................................................... 52
3.8 Result and discussion ................................................................................................................ 53
3.9 CONCLUSION ......................................................................................................................... 54
CHAPTER FOUR........................................................................................................................... 55
4 General conclusion and Recommendation ................................................................................ 55
4.1 General Conclusion ............................................................................................................... 55
4.2 General Recommendation .................................................................................................... 55
References ............................................................................................................................................ 56
APPENDICES ................................................................................................................................. 58
APPENDIX A Part drawing .......................................................................................................... 58
Appendix B Assembly drawing...................................................................................................... 77

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List of Figures

Figure1. 1 Tires ....................................................................................................................................... 3

Figure1. 2 component of tire ................................................................................................................... 4
Figure1. 3 organizational structure ......................................................................................................... 6
Figure1. 4 work flow structure ............................................................................................................... 7

Figure2. 1Banbury mixer ....................................................................................................................... 9

Figure2. 2 Bead wire ............................................................................................................................. 10
Figure2. 3 Extruder machine ................................................................................................................ 11
Figure2. 4 Rubberizing machinery ....................................................................................................... 12
Figure2. 5 parts of tire ........................................................................................................................... 12
Figure2. 6 building machine ................................................................................................................ 13
Figure2. 7 Radial tire building machine ............................................................................................... 13
Figure2. 8 Curing machine .................................................................................................................. 14

Figure3. 1 Moody diagram ................................................................................................................... 29

Figure3. 2 pump suction and delivery................................................................................................... 31
Figure3.3 Gear nomenclature ............................................................................................................... 32
Figure3. 4Bending forces and the bending moment diagram ............................................................... 37
Figure3. 5 Bearing selection ................................................................................................................. 46
Figure3. 6 Vertical bearing reaction ..................................................................................................... 46
Figure3. 7 Horizontal bearing reaction ................................................................................................. 47

List of Tables

Table 3. 1 Standard bolt dimensions .................................................................................................... 39

Table 3. 2 Proportions of standard parallel, tapered and gib head keys. .............................................. 43
Table 3. 3 bearing selection ................................................................................................................. 45
Table 3. 4 Ball bearing selection .......................................................................................................... 47
Table 3. 5 Electric cost.......................................................................................................................... 52
Table 3. 6 gear design results ................................................................................................................ 53
Table 3. 7 Design of shaft results.......................................................................................................... 53
Table 3. 8 Design of housing results ..................................................................................................... 54
Table 3. 9 Design of coupling results ................................................................................................... 54
Table 3. 10 Pump specification results ................................................................................................. 54

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 CHAPTER-ONE

1. GENERAL BACKGROUND OF HORIZON ADDIS TIRE PLC

1.1 Company Profile

The production of tire in Ethiopia goes back to 1972, when Addis tire S.C. (ATC) the first of
its kind in the country, was established with a yearly production capacity of 60,000 tires and
45,000 tubes and a total labor force of 260 people.

Major inputs and raw materials for tire manufacturing are imported from Malaysia, India,
China, Indonesia, Egypt and Europe. Natural Rubber is one of the major inputs.

After subsequent joint venture formation between Addis tire S.C. (Government Owned) and
the Slovakian renowned tire manufacturer, MATADOR –A.S. was established in June 2004
and the operation commenced in July 2004 with the hybrid trade name MATADOR-Addis tire
S.C.

However, due to shift in business focus, MATADOR-Addis Tire S.C. transferred its share to
Continental AG on October 23, 2007. Continental AG, the world known German tire
manufacturer company, has bought all Matador holding companies in Slovakia, Russia and
Ethiopia.

Due to lack of concentration of continental AG, there was no significant progress on the
commitment of MATADOR-Addis tire S.C. in terms of upgrading the existing Bias tire
technology and commencement of Truck Radial tire production. Continental AG rather
preferred to sale its share to a potential strong national investor who can discharge all joint
venture obligations.

It was then, that the dedicated and committed investor for the development of Ethiopia, Sheikh
Mohammed H. Al-Amoudi, decided to buy the share of Continental AG through one of his
group companies, Horizon Plantation P.L.C. in January 2011. Since the ownership transfer the
name of the company changed to Horizon Addis Tire S. C. and currently the Horizon Plantation
P.L.C owns 100% share of the company.

The future perspective of horizon Addis Tire S.C. thus includes, among others, of improving
quality and performance of existing nylon products, introducing new product category
especially light truck and truck radial tires. Innovation in manufacturing practices for higher

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productivity and consistent quality products and developing technical know- how are in the
immediate programs of the company.

With improvement in production capacity, horizon Addis Tire S.C. would like to also tap
existing market potentials of COMESA which could generate commensurate foreign currency
for the country.

The company has created job opportunity to date, for 760 workers while the number will
increase to 850 with the implementation of the envisaged project. and it is located in Ethiopia,
Addis Ababa, Nifas Silk Lafto sub city, saris kebele 60 [1]

Vision, Mission and Values

• Vision • Mission

2025-06-10!! HATC develops and manufactures all types

of bias and radial tyres which are perfectly
Being a leading brand in Ethiopia, HATSC
compatible to Ethiopia and COMESA
secures and ensures 60% market share in
region; by utilizing skillful and experienced
the local market and 10% of its production
professionals and by investing in the state-
volume to the COMESA region in year
of-the-art technology from world reputable
2025.
companies; where Quality, safety, fair
price, accessibility and money back
guaranty are pillars of our management
philosophy

• Values

Horizon-Addis Tyre Share Company operates in accordance with the highest standards of
ethics in all relations with customers, suppliers, environment and community. The company
encourages innovation and diligence amongst staff and rewards accordingly and its values are:

Acronym definition of our value motto “INTEGRITY”

I: Ideal choice for Variety & Quality! N: Need base and customer driven
production and service!

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T: Team work, team spirit and mutual R: Reliable and Responsible partner!
respect!
I: Industrious and owner like sentiment!
E: Environmentally friendly products with
T: Timely responding
high concern in the production process!
Y: Your /our customer/ concern is really
G: Growth has no limit!
our concern [1]

1.2 Main Product of the Company

Figure1. 1 Tires
1.2.1 Tire

Tire is a ring-shaped component that surrounds a wheel's rim to transfer a vehicle's load from
the axle through the wheel to the ground and to provide traction on the surface over which the
wheel travels. Most tires, such as those for automobiles and bicycles, are pneumatically inflated
structures, which also provide a flexible cushion that absorbs shock as the tire rolls over rough
features on the surface the tire has to allow for easy steering, braking and cornering. It must
provide for a comfortable, safe ride. It needs to be durable.

There are two types of tire construction and three group of size they are include below

Diagonal tire construction Radial tire construction

• Passenger car (PC) • Passenger car (PC)

• Light truck (LT)

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Following are the major requirements of the tire
• Load carrying capacity • Shock absorption
• Transmit driving/braking torque • Steering response
• It should provide flotation • Fuel efficiency

1.2.1.1 Component of tire

Figure1. 2 component of tire [2]

Tire is the only engineering product, which requires three-dimensional performances. It is a
high technology product, made by combining many components. Each component has its
unique role in overall performance of tire.

• Tread • Side Wall

• Breaker • Bead Assembly
• Carcass • Bead Wire
• Body ply • Bead apex

1.3 Main customer of the company

The main customers of the company are mainly distributors who bought the finished tire from
the Host Company and sale for other merchants. Governmental minister offices are also the
main consumers. The company sold huge amount of tire for them using direct cash or credit.

4
1.4 Raw material used
Manufacturing of tire requires a large number of raw materials. These raw materials are
purchased from all parts of country and also from different countries, they are

• Malaysia • China • Europe

• Indonesia • Egypt and
Raw Materials are stored in the raw material stores (RMS), which ensures the proper storage
of raw materials to prevent deviation from their properties and to produce a best possible
product. The incoming raw materials are tested for physical and chemical properties by
technical lab & than materials are taken for further use.

1.4.1Rubber
The physical properties of rubber: -

• Specific gravity • Compression set

• Tear resistance • Abrasion resistance
There are three types of rubber
A. Natural rubber C. Reclaim rubber
B. Synthetic rubber

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 1.5 Organizational Structure

BOARD OF
DIRECTORS
Deputy General
Executive Manager,
Secretary Operations

QMR/EMR

Safety And
Security Head
Internal Audit

Plant Product Commercial Human Finance & Stores

Manager Industrialization Projects Manager Resource Economy Manager
& Manager And Manager
Quality Assurance Administration
Manager Purchasing Manager
Marketing Head
Head Health
Quality Cost
Service
Product Assurance &
Marketing Head
Industrialization Head Budget
Team Sales
Head Head
Leader Head

Technology Quality Motivation, Information

Inspection Personne Administra
Labor Technology
Team l Head tion Head
Technical Sale Relation Head
Leader and Steam And
Compounding Service Leader Development
Team Leader Team Head
Laboratory General
Leader Senior
Team General Accounts
Personnel
Leader Service Head
Affair
Sales process
Administration
Team Leader Senior Motivation, Labor
Personnel relation and
Affair Development Expert
Junior
Personnel
Affair Personnel
QMS Plant Junior Motivation, Labor Relation
Production & Plant Clerk
Engineering and
Manager Training Manager
Head Development Expert

Preparation
Head Transportation
(Mixing, Building & Power & Plant Design, Liaison Service Transportation
Tread, Bead Curing Head Automatio Maintenance Planning Officer Office Service
wire, Textile) n Head Head and Utility Clerk Office
Head

Production Industrial
Engineering Mechanical Work Utility Team Civil Work
Process
Team Leader Team Leader Leader Team Leader
Planning
Team Leader

Figure1. 3 organizational structure

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1.6 Work flow of the company

Figure1. 4 work flow structure [3]

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 CHAPTER -TWO

2. OVERALL INTERNSHIP EXPERIENCE

2.1The section of the company we have been working in;

During our internship period, we have studied all over structure of horizon Addis tire plc. We
had worked our project on specific problem which we have selected from the list of problems
that we have seen. We have been working in all sections found in the company.

Sections of the company

A. Manufacturing shop
B. Mechanical work shop
C. Maintenance department (mechanical, electrical, electronic and construction)
D. Utility
A. Manufacturing shop
Sections under manufacturing shop

I. Mixing section IV. Textile section

II. Bead wire section V. Building section
III. Duplex section VI. Curing section

I. Mixing section
Rubber compound mixing process

Rubber mixing process (RMP) is one of the determinations of physical and chemical properties
of vulcanized rubber. RMP starts from rubber mastication and then followed by rubber
chemical and filler mixing into rubber. Some of the most common rubber manufacturing
processes are extrusion, latex dipping, molding, and calendaring.

Banbury mixer also named rubber Bunbury mixer is mainly used in rubber mixing and plastic
refining. The mixer is a machine with a pair of rotors with a specific shape and a relative
rotation, which plasticizes and blends the polymer materials in a closed state with adjustable
temperature and pressure.

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 Figure2. 1Banbury mixer [4]
Working principle of the Bunbury mixer

An internal mixer consists usually of two rotors enclosed in a mixing chamber. The massive
rotors rotate toward each other at slightly different speeds. Each rotor has a blade that extends
along the length of the rotor roughly in the form of a spiral. Each rotor is cored to permit cooling
or heating by the passage of water or of an appropriate heating agent. The materials to be mixed
are fed into the mixing chamber through the feed hopper. A floating weight is operated by
compressed air and rests on top of the feed, serving to confine the material to the mixing space
and to exert pressure on it. The mixed material is discharged by a slide discharge mechanism.

Raw materials used in the mixing section.

• Carbon Black • Oil • Accelerator

• Anti-scorching • Sulfur

II. Bead wire section

Bead component preparation

The bead component of the tire is a non-extensible composite loop that anchors the body plies
and locks the tire onto the wheel assembly so that it will not slip or rock the rim. The tire bead
component includes the steel wire loop, apex or bead filler, the chafer, which protects the wire

9
bead components, the chipper, which protects the lower sidewall, and the flipper, which helps
hold the bead in place. The bead wire loop is made from a continuous steel wire covered by
rubber and wound around with several continuous loops. The bead filler is made from a very
hard rubber compound, which is extruded so as to form a wedge. The bead wire loop and bead
filler are assembled on a sophisticated machine.

Beads are bands of high tensile – strength steel wire encased in a rubber compound. Bead wire
is coated with special alloys of bronze or brass. Coatings protect the steel from corrosion.
Copper in the alloy and sulfur in the rubber cross-link to produce copper sulfide, which
improves bonding of the bead to the rubber.

Beading wire is the crucial link through which the vehicle load is transferred from rim to the
tire, which prevents vibration during driving. It significantly affects the safety, strength and
durability of tires. Bead wire is a drawn steel wire, which is manufactured from quality with
high carbon content.

Figure2. 2 Bead wire

III. Duplex extruder section

Tire tread and sidewall extrusion operation

Extrusion is one of the most important operations in the tire manufacturing process because it
processes most of the rubber compounds produced from the mixing operation and then prepares
various components for the ultimate tire building operation.

The extrusion processes

Extruded rubber products differ from those produced through molding. In extrusion, parts are
forced through a die of the required cross section under pressure of a rubber extruder. The
extrusion process begins when you feed the unvulcanized compound into the extruder. The

10
rubber travels over the flutes of the revolving screw into the die, with the pressure and
temperature increasing as the compound get closer to the die. And when it reaches the die, the
built up pressure forces the material through the die opening, where it will consequently swell
in various degrees based on the compound hardness.

Figure2. 3 Extruder machine [4]

IV. Textile section

The textile section produces one of the main integral parts of both radial and diagonal tires,
which is a thin sheet of rubber-coated textile fabric. There are different types of cords that are
classified based on the type of the material as well as the size of the cords, so different sized
car tires use different sized cords. Additionally, the rubber compounds that are used for coating
these textile fabrics also differ depending on the application of the final output. Therefore, the
combination of the different textile fabrics and the different rubber compounds create rubber-
coated textile fabrics of different properties and applications

Cord is rubberized using rolling process which is carried out on calendaring lines. These sheets
are guided to the middle nip, where textile cords are layered simultaneously between the rubber

11
sheets. The cords are coated continuously by the sheet under the high pressure generated in the
calendar nip. Rubberizing cord sheet of the specified thickness, and width is formed at the
calendar output.

Figure2. 4 Rubberizing machinery [4]

The above machines have the similar components which will be discussed below:

• Motor • Bull Gear •Adjustment • Guide.

Motors
• Gear Box • Bushing • Cooling Line
• Break Pieces
• Pinion Gear • Roller

V. Building section
Building is the process of assembling all the components on to a tire building drum. Tire
building machines (TBM) can be manually operated or fully automatic. Typical TBM operation
includes the first stage operation, where inner liner, body plies, and side wall are wrapped
around the drum. The beads are placed and the assembly turned up over the bead. In the second
stage operation, the Carcass of the tire is inflated, and then the belt package and tread are
applied.

Figure2. 5 parts of tire

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The building area in Horizon Addis consists of different types of tire building machines
including radial and bias ply tire building machines.

• Bias tire building machine

Figure2. 6 building machine [4]

Common parts of a bias tire building machine:

• Head stock • Stitcher • Drum

• Tail stock • Servicer • Foot pedal

• Radial tire building machine

The radial tire building machine in horizon Addis have same common parts as that of a bias
tire building machines discussed above except some parts.

Figure2. 7 Radial tire building machine [4]

The radial tire building machine in Horizon Addis have 2 stages. The first stage operation
involves Applying the inner liner on a building drum from the component server, applying
casing plies, then Beads, chippers, and sidewalls are assembled on the drum. After the first

13
stage is completed the output is moved to the second stage which involves assembling a belt
and tread which will be moved with a transfer ring to be assembled with the stage one output.

The transfer ring uses pneumatic system to operate. Sensors are used for safety purposes and
as a limit switch for piston movements.

VI. Curing section

Curing is the last process next to building. In this section the green tire prepared on building is
cured by high amount of temperature and pressure using curing machine (press). In the press,
heat is transferred to the green tire from the mold and bladder, which are kept at higher
temperatures by circulated cure media like steam or hot water. The transferred heat provokes
the curing reaction of the rubber compounds, thus converting the compounds to a strong, elastic
material to meet tire performance needs.

The green tire is inserted into a tire press where an internal tire bladder is inflated causing the
green tire to press up against the mold. The action of pressing up against the mold combined
with intense heat causes the rubber to conform to the mold, creating the tread and sidewall
lettering in the process.

There are three Medias depending on the application this are: -

1. Bladder media: - it is the place where the hot water is entering to heat the bladder.
2. Chamber media: - this media is found at the back of the mold. Its purpose is to heat
the mold. since this media is full of steam it may inter 6-8 minutes later the bladder
3. Hydraulic media: -this media uses the application of water pressure. Its purpose is for
mechanical movement and transportation and also to inflate the tire.

Figure2. 8 Curing machine [4]

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General components of tire curing machine

• Main Motor •Intermediate • Dome • Master Cylinder

Gear
• Gearbox • Mold • Actuator
• Main Bull Gear
• Gearbox Pinion • Chamber • Bladder
• Linkage (Arm)
• Main Cylinder • Loader

B) Mechanical workshop

Workshop is a room that contains varieties of machines, those machines are used for production
of different mechanical parts. When different mechanical components are failed in Horizon
Addis Tire production machines, those mechanical components will be manufactured in
mechanical workshop in order to replace the failed mechanical components of production
machines. We use mechanical workshop not only in maintenance but also in design of new
machines in order to manufacture the required mechanical components of the new machine.

There are various mechanical machines in workshop area, those are:

• Lathe Machines • Power Hacksaw

• Milling Machines • Hydraulic Press
• Radial Drilling Machine • Sheet Metal Bending Machine
• V stand drill machine • Sheet Metal Rolling Machine
• Shaper machine • Sheet Metal Cutting Machine
• Horizontal Boring Machine • Hand Shearing Machine

C) Boiler Room

Boilers are devices in which water is boiled and converted into steam under controlled
conditions. Boilers are an important source of energy in the process industries because they
supply steam to operate process equipment and produce the steam used throughout the process
facility. The curing section in a tire manufacturing industry uses steam to cure a green tire.

Boilers can be classified according to the flow medium inside the tubes as

15
•Fire tube boiler: - in which hot flue gases are inside the tubes and water is surrounding the
tubes

•Water tube boiler: - water is inside the tubes and the hot gases are outside.

There are 2 fire tube boilers in horizon Addis that use a grade 5 oil for generating steam at high
pressure.

Specification

• Capacity: - 4 ton per hour • Structure: - fire tube

• Pressure: - 1.25 MPa • Media: - water
• Steam temperature: - 194oc • Water circulation: - forced
• Fuel: - oil
Main parts of boiler

• Fire box • Steam distribution

• Burners system
• Economizer • Steam trap

D) compressor room

A compressor is a mechanical device that increases the pressure of a gas by reducing its
volume. An air compressor is a specific type of gas compressor. Compressors are similar to
pumps: both increase the pressure on a fluid and both can transport the fluid through a pipe

In horizon Addis tire a rotary screw type compressor is used

A rotary-screw compressor is a type of gas compressor, such as an air compressor, that uses a
rotary-type positive-displacement mechanism. These compressors are common in industrial
applications and replace more traditional piston compressors where larger volumes of
compressed gas are needed

Unlike piston compressors, in screw compressors, there are no valves or other mechanical
forces that can cause unbalance. This allows a screw compressor to operate at high speeds
while combining a large flow rate with small exterior dimensions. The ideal applications of
rotary air compressors are continuous, workplace and industrial applications.

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Main parts of screw compressors

• Electric motor • Oil separator • Sensor

• Coupling • Heat
• Gearbox exchanger
• Element • Air filter

2.2 Work task we have been executing

The working task that we have been executing during the internship period.

• We observe every section of the company when the machines are functioning.
• We were able to observe and participate while the machines are functioning, operated.
maintenance and inspection. (We were able to participate in the overall maintenance
period, which gives as a chance to assemble and disassemble some parts of machines.)
• We were able to do some designs in the design section by using CAD.
• We also get the chance to produce some parts in the workshop and also participate in
new projects like assembling new machines and recycling old machines.

2.3 Engineering methods, tools and techniques executing to performing a task

In our internship period we get to participate in a lot of activities, which helps us to know
engineering methods, tools and techniques.

Some of the engineering methods and techniques are

• Daily inspections • Cleaning

• Weekly, monthly and overall • Spare part replacement
maintenance
Some of the engineering tools used in this company are

Caliper, outside and inside caliper, dividers, ruler, thread pitch gauge, radius gauge, milling
cutter, lath cutting tool, taps and dies, wrenches, combined wrench, Allen, hammer, hallow
paunch, ruler, hand tools, snap ring, mechanical bearing puller and etc.....

2.4 Challenges and problems we have faced

We have faced many challenges in the company like;

• At the beginning of the internship we were afraid to communicate with every person in
the office and at the working area.

17
 • Unfamiliar with the sounds of machines, high temperature of the curing section and
also couldn’t get used to the dust of carbon black in the mixing area.

• Frequent machine stoppage due to lack of raw materials because of the current situation
in our country.

• Confusion of work when getting in to action.

2.5 Measures that we have taken to overcome challenges

• We tried to communicate each and • Asking about the problems before
individual worker to be closed and acting then learn and follow
friendship with them. working principles of the machines.

• Ask questions with different • Learning about professional ethics

department workers, manager, of work and also every machine’s
supervisors, engineers, technicians, safety rule.
and operators to get a data from
• Doing tasks with the workers to
their working experience in addition
learn about the work more.
refer different operation manuals

2.6 Overall benefits we gained from internship

In this internship program, we have learnt a lot significant knowledge from the factory as
whole. They were very helpful as much as they can in showing and helping us. We believe
that, we had gotten something very important.

2.6.1 Improving our practical skills

The primary importance of the internship program is improving our practical skill.

• Creativity and innovative approach • Learning about measurement tools

to solving problems and how to use them
• working principle of different • Designing methods and technique
machines used to design parts of a machine
• Manufacturing method (working • Operating different kinds of
process) of each machine machines
• Transmission mechanism of power • Problem detection methods and
in machines finding practical solution for them

18
 • How to read and execute the • How to inspect a machine
procedures set on manuals • Maintenance methods used in
• Care and Safety rules of machines different machines

2.6.2 Upgrading theoretical knowledge

In addition to the practical skill this internship program also helps us to strengthen our
theoretical knowledge and gain meaningful engineering experience to complement academic
studies. Since the practice concept runs with regarded to theory, it was easy to work and
correlate the activities and enhance our understanding on the construction process of the
building. Theoretical knowledge is dependable on principles, logic and calculations.

In the previous three years, we have been learning the theoretical knowledge. However,
observing the practical works helps to have a clear and full understanding of some points that
are difficult to understand theoretically only. This internship has great importance on upgrading
our theoretical skills.

The other chance we have in upgrading our theoretical knowledge is

• Understanding every single work • Learning about different working

with satisfactory scientific principals of machines
reasoning • How to design parts of machine
• Knowing different machine
• Referring different books and web
operations
sites whenever encounter difficulty
• Reading manuals of machines
• Asking the site engineer and the • How different systems work
supervisor when we come across a together
problem • Understanding of new working
principle of mechanism
• Safety rules

2.6.3 Improving Team Playing Skills

Team playing skills are one of the most important requirements for the proper working in any
company regardless of its size and/or service it provides. Therefore, team play skill has the
potential for help us to improve skills like:

• Polite and have a good manner, • Exhibit flexibility

19
 • To increase self confidence • To interpret the problems and
• Being able to work as a team solve the problems
• How to be a good listener and be • Giving respect for others
open minded, • How to actively participate in a
• To share knowledge between working environment
participants

2.6.4 Improving leadership skill

Leadership skill is the other basic skill an engineer should possess. This skill helps engineers
to effectively manage resources and manage man-power on site. This skill also helps
engineers to make appropriate judgments and improve their problem-solving skill. Being
innovative, passionate and being able to create helpful working environment is also the other
benefit gained from this internship.

We have been able to see different leaders in hierarchy work and lead the workers under them.
By this time, we have been able to observe that one should have great skills to be good leader.
For instance, good leadership needs;

• Having good communication skill • Skill of knowing and fulfilling

Good speaking ability; customers need,
• Having the ability to listen to others; • Good backlog management;
• Giving balanced and achievable • Having good worker handling skill;
decision; • Problem resolving skill (like
• Taking risks and being accountable resolving conflict peacefully);
for our activities and decisions; • Having good management skill;
• Developing hard working skill,

2.6.5 Working ethics

Work ethics; indicates the duties and obligations of our behavior to be right, truthful and adjust.
During this internship programs, we have tried to develop those work ethics both personal
ethics and related to work ethics.

Personal ethics like; respect for the job, punctuality, sincerity, regularity, honesty and
seriousness and other ethics. Related to work ethics Keeping certain information Maintaining
cordial relation with the client and agencies that company has Being prepared to take up new

20
task. Every worker should interact and cooperate with each other while working. That is
because of it helps to solve any systematic problems easily.

During the internship, we were considered as employees as long as we are done every work
with other regular employees. Therefore, we need to,

• Respect rules and • Give smooth relation to

regulation of the the partners
company, • Respect for all workers
• Being punctual, • Focus on working
• Be well disciplined and areas and
being honest, • Efficiently working a
given job.

2.6.6 Acquiring Entrepreneurship skills

This type of skill is a capacity to create self-own share company with others and being self-
reliant to fulfill the requirements necessarily so entrepreneurship is a key driver of economic
growth and job creation. An entrepreneurship skill can be described in the following terms;
• Owns and manages his or her • How to see the deviation between
business demand and supply,
• Identifies new opportunities • What opportunities there are in our
• Creative and innovative field,
• Controls resources to insure a • How to participate in the new
profile for the business transformation in the companies,
• How to see the way the country is
• How to see problems as
developing,
opportunities,

2.6.7 Improving interpersonal communication skills

We believe that we had gotten enough communication skill, which will help us, for the future.
Effective communication is all about conveying our message to other people clearly. It is also
about receiving information that others are sending to us.

In fact, communication is only successful when both the sender and the receiver understand the
same information. In addition to sending and receiving messages, communication skill
including

21
 • Oral presentation as well as • To make discussions
ability to work with others, • To answer questions when
• To ask different questions asked
• Frank enough with all what we • To respond to boss and the like;
do, Are the main factors
• To give fast decision making contributing to job success.
• How to develop the ability to
accept criticism,
We believe that if we cannot communicate with our colleague easily, this may make us nearly
impossible to compete effectively in the work place. In addition, it will be hard to stand in the
way of career progression. Communicating effectively therefore, essential if someone want to
build a successful career. We must also consider the circumstance surrounding such as,
situational and cultural context.
Though internship communication skill is about our nature and attitude, we learned some
formalities of communication skills. Since we believe that, the reason why we going to work
place is to learn something new, we had good relationship with almost all of the workers during
the whole four months. We ask them politely and in all the right way, and the outcome was
having a wonder full time with the workers.

2.7 Recommendation and conclusion on our internship experience

Conclusion

Horizon Addis tire manufacturing industry is a huge industry; therefore, we were able to know
and experiences a lot. The plant has been designed to produce tire from scratch until the end
which makes it a long working process. These long process lets the plant to contain all of the
mechanical engineering field like thermal, mechanical and design which helps us to know
about other fields particularly. The hugeness of the industry is a big opportunity for as to get
information about many engineering technique and methods. The program is also useful for
students to understand the relationship between work and theory. And it used to know the
answer how to transfer the theoretical knowledge into practical.

22
Recommendation

Horizon Addis tire manufacture industry has same problems that are challenging to the
workers. Those challenges affect the working environment and cause same obstacles for the
workers. These are;

• Overlap of work duties: some works are expected to do a lot work than other, which
makes the work no to be done on the due date. It would be easier to do one specific
work then the next one for more efficiency.
• Schedule of work: some of the schedule made for the works are not appropriate because
of the time overlap, not considering how heavy the work is, multiple duties at the same
time etc. Therefore, schedules must be reconsidered before giving them to the workers.
• The storage areas are far: most of the storage area are far like the tool storage, the spare
part storage, the mechanical and electrical storage area. Because of the distance from
the work are these storage areas take energy and time, it would be preferable if they
were near or could be accessible easily by making more than one.

23
 CHAPTER THREE

3.Project work
Project title: Design of Gear pump for oil filling

3.1 Summary of the project

Our project is used to avoid oil filling problem in various gear boxes and separator of a
compressor. In different sections of the company, a direct human labor is used to fill lubrication
oil, but now we can fill the oil in to gear box and the separator simply by using the oil filling
machine.

The machine is operated in such a way; first the cylinder is filled with the oil then the oil will
pass through the hose to a gear pump. The oil pump rotates mechanically by use of an electric
motor then the oil passes by the hose and finally it enters to the gear box or separator.

There are three types of oil pump that are gear type, rotary type and crescent type. In our project
we select gear type oil pump, because gear pumps are particularly suited for pumping oils and
other high viscosity fluids. They are also capable of sustaining higher pressures and flow rates
because of the more rigid shaft support and closer tolerances. After some calculations the main
parameters of the pump are as follows; Pump head of 1.51m, Delivery pressure of 1.3 MPa,
𝑚𝑚3
flow rate of 3.33×10-4 , Volume of fluid displaced per revolution (DP) of 1.998×10-5
𝑠

m3/rev, pump power of 686W and Efficiency of 63.75%.

3.2 Problem statement and justification

As it’s known lubrication system is the most essential system in every aspect of mechanical
parts which have relative movement that needs to be lubricated, because the components of the
machine will generate high temperature that leads to easily damage of parts (i.e. wear, tear,
scratch). In Horizon Addis tire manufacturing company there are systems which need proper
lubrication such as gear box, and compressor. The oil man loads the oil to the gear box and
compressor separator by hand which is inefficient, time wasting, and exhausting. The primary
aim of this project is to overcome the above problem by designing a gear pump for oil filling to
save time and energy of the oil man, and economical cost during oil filling due to wastage of
oil droplets.

24
3.3 Literature Review
Xinran Zhao and Andrea Vacca from Purdue University, United State of America designed a
gear pump using helical gear. [5] But using helical gear relative to spur gear in gear pump has
the following disadvantages: less efficient with the same size, no quite reliable, and not offering
operation with constant speed. In addition, spur gears are also considered a member of positive
transmission because they don’t have any slippage and they have simple components, very easy
to design and install in drive mechanism. Generally, spur gears are suitable for driving systems
because they have more power transmission efficiency than helical reason. Due to the above
reasons, we use spur gear instead of helical gear.

Hyun Kim, Hazel Marie and Suresh Patel from Youngstown state university, United State of
America designed a gear pump which doesn’t contain O-ring and gasket. [6] That result in
leakage, excessive wear, Reduced maintenance and inefficiency. But in our project, we used
both O-ring which will seal a wide range of pressure and prevent structural damage by reducing
critical torque on tightening and gasket which will prevent leaking and loss of pressure at
connection points where other rigid materials come together.

A gear pump moves a fluid by repeatedly enclosing a fixed volume within interlocking cogs or
gears, transferring it mechanically to deliver a smooth pulse-free flow proportional to the
rotational speed of its gears. Gear pumps are commonly used for pumping high viscosity fluids
such as oil, paints, resins or foodstuffs. They are also preferred in applications where accurate
dosing or high-pressure output is required.

Invented in the early 17th century by Johannes Kepler, gear pumps are often used
for hydraulic power applications as well as for high viscosity (thick fluid) applications. Like
all positive displacement pumps, they can pump air, and are thus self-priming. [7]

In this gear pump design an involute spur gear with a 20-degree pressure angle is chosen,
different gear pump components including gear, housing, shaft, coupling are designed in this
project.

25
3.4 Objective of the project

3.4.1 Main objective

The main objective of our project is to design a gear pump for oil filling in the Horizon
Addis tire company.

3.4.2 Specific objective

• Design of appropriate gear that can pump the required flow rate
• Select appropriate material for each component of the oil pump to reduce the leakage
of oil
• Determine the optimum pressure output of the pump that can overcome the head.

26
 3.5 Methodology

Data collection

Study previous studies on oil pump (literature review)

Design analysis each component of the machine

Design of Design of Design of Design of pump Selection of standard bolt and

gear shaft coupling housing bearing, cylinder and hose

Modelling of all components by Auto cad software

Result and conclusion

27
3.6 Design Analysis

3.6.1 Pump specification

Different terms associated with pump specification will be calculated. In order to help us
calculate those terms a discharge specification of 3.33x10-4 m3/s or 20 liters/min is taken.
since the oil man uses 60 liters of oils averagely, this flow rate enables the oil man to finish the
oil filling operation with 3 minutes and an inlet port of a standard 0.5inch (12.7 mm) diameter
is used [8], Synthetic gear oil SAE 75W-90 is the working fluid for the pump.

Pipe friction factor

Pipe frictional factor predicts the frictional energy loss in a pipe based on the velocity of the
fluid and resistance due to friction. It is used almost exclusively to calculate head loss due to
friction in turbulent flow.

For calculation of friction factor by moody chart we need the following two factors

1. Relative roughness (e/d), it is the ratio between pipe roughness by pipe inside
diameter.
2. Reynold number (R), it determines flow type laminar or turbulent

𝜌𝑉𝐷
Re = ……………………………. Equation [3. 1] where Ρ= density of the fluid
𝜇

V=velocity of the fluid

μ=viscosity of the fluid

L= diameter of the pipe

If Re ˂2000, the flow is called laminar

If Re˃ 4000, the flow is called turbulent

Given roughness(e) = 0.005mm for flexible rubber tubing

Inside diameter (d) = 12.7mm

Synthetic gear oil SAE 75W-90

𝐾𝐺
Density (ρ) = 0.887×103 𝑚3

𝑚𝑚2
Viscosity (μ)= 110 = 11×10−4 m2/s
𝑠

28
 𝑚3
Flow rate (Q)= 3.33×10−4 𝑠

𝑒
Relative roughness (𝑑)

𝑒 0.005𝑚𝑚
=
𝑑 12.7𝑚𝑚

= 0.003937
𝜌𝑉𝑑
Re = 𝜇

𝑄
V=𝐴

3.33×10−4
= ∏(6.35)2

𝑚𝑚
=2.629×10−6 𝑠

𝑚
=2.629×10−3 𝑠

0.887×103 ×2.629×10−3 ×0.0127

Re = 1.1×10−4

=269.23

Therefore, the flow is laminar

Figure3. 1 Moody diagram

29
By using Reynold number and relative roughness we can find pipe friction factor from the
moody chart which is f=0.029

Total dynamic head

Total dynamic head = vertical head + frictional loss

TDH = HV + HF……………………………….………………...Equation [3. 2]

where HV= vertical head
vertical head is the distance between pump suction point to delivery point
Hv = 1.5m – 0.048m

= 1.452m

Friction head loss = f × total pipe length…………………………. Equation [3. 3]

Hf = f × L

= 0.0029 × 2m

= 0.058m

TDH = HV + Hf

= 1.452m + 0.058m

= 1.51m

Efficiency of pump

𝑃ℎ
Efficiency of pump = …………………………………. Equation [3. 4]
𝑃𝑖

where Ph = hydraulic power

Pi = power input to the pump shaft

ղp = efficiency of pump

Ph = Q * 𝜌 * g * h ………………………………………. Equation [3. 5]

where Q = flow rate

𝜌 = density of the fluid

g = gravity

h = total dynamic head

30
Ph = 3.33x10-4 * 0.887x105 * 9.81* 1.51 = 637.5 W

Power input to the pump shaft = motor input power = 1000 W

637.5
ղp = x 100% = 63.75 %
1000

Delivery pressure and power of pump

Pump

Figure3. 2 pump suction and delivery

On the above figure, there is a pump which is used for delivering fluid from a lower reservoir
in to an upper reservoir. In order to calculate the power consumed by the pump, understanding
a little bit more about the required delivery pressure is needed. The pump needs to elevate the
fluid through a maximum height of 1.51 meters. Now if there was a larger quantity of fluid in
that lower tank, that would actually assist the pump because it would provide that pressure. But
considering the worst-case scenario, which is assuming the lower tank is almost empty.
Therefore, the pressure behind the pump (suction pressure) is 0 (negligible) compared to the
pressure upstream of the fluid.

Q∆P
P= ………………………………………………………………….……Equation [3. 6]
ղ𝑝

where P = power

∆P = change in pressure

ղ𝑝 = efficiency of pump

Q= flow rate

∆P = static pressure + dynamic pressure + hydrostatic pressure ………………. Equation [3. 7]

31
 𝜌𝑉 2
∆P = static pressure + +𝜌*g*h
2

0.887𝑋105 𝑥(2.629𝑥10−3 )2
∆P = + 0.887x105 * 9.81* 1.51 = 1313900 Pa
2

3.33x10−4 𝑥 1313900
P= = 686 Watt
0.6375

The appropriate type of pump for the above pump specification is a gear type due to the high
viscosity of the working fluid, its easiness to use and maintain, and its low cost.

3.6.2 Design of gear

External gear pumps with spur gears are classified as low capacity pumps. When capacity
higher than 912 liters per minute is required helical and herringbone gears are employed. [9]
our project uses a spur gear. The geometry of the relevant components determines the flow rate
of the pump. Thus, the first stage in this work involved a geometrical design to determine the
dimensions of all components to satisfy the target discharge, followed by stress analysis to
determine the most appropriate available material

A) Geometrical design
20o involutes gear is selected. Because, 20 degree gives better tooth bending strength. It also
permits less minimum number of teeth on small gears. The 20-degree involute gear cutter in
Horizon Addis was limited to a minimum of 12 number of gears. The motor available in
Horizon Addis tire for our project has a speed of 1000rpm.

Figure3.3 Gear nomenclature [10]

32
Volume of fluid displaced per revolution (DP)

The volume of fluid displaced per revolution is equal to volume of fluid trapped within the
space of gear teeth and housing

60∗𝑄
Dp= …………………………………….……. Equation [3. 8]
𝑁

where Q=discharge rate &

N=speed of motor in revolutions per minute

60∗3.33𝑥10−4
Dp = m3/rev
1000

DP =1.998x10-5 m3/rev

➢ Circular pitch diameter (D)

The face width(b) must be longer than the diameter of discharge port. This implied that b >
12.7mm. Design considerations indicates that face width should be greater than 8/Pd but less
than 16/Pd.

Let b=34mm for initial design

𝜋[𝑏𝐷 2 ](9𝑛−2.35)
Dp= ……………………………………… Equation [3. 9]
8𝑛2

where b = face width

n = number of teeth

𝜋[0.034𝐷 2 ](9∗12−2.35)
1.998x10-5= 8(12)2

D=0.0456m say D=46mm

Check by using the second condition

8𝐷 16𝐷
<b< …………………………………………Equation [3. 10]
𝑛 𝑛

8(46) 16(46)
<34<
12 12

30.66<34<61.3

This implied that the two constraints were satisfied, so b=34mm and D=46mm.

➢ Addendum radius(ra)

33
 𝐷(2+𝑛)
ra= ………………………………………. Equation [3. 11]
2𝑛

46(2+12)
ra= mm
2(12)

ra=26.83mm

➢ Dedendum radius(rd)

𝐷(𝑛−2.5)
rd= ……………………………………………Equation [3. 12]
2𝑛

46(12−2.5)
rd= mm
2(12)

rd=18.2mm

➢ Diametrical pitch(pd)

Pd=n/D…………………………………………………. Equation [3. 13]

Pd = 12/46 = 0.26/mm

➢ Module(m)

m=D/n ……………………………………………............Equation [3. 14]

m =46/12 = 3.83

➢ Circular pitch(pc)

𝜋𝐷
Pc= 𝑛 ……………………………………………………Equation [3. 15]
𝜋46
Pc= = 12.06𝑚𝑚
12

➢ Addendum(A)

A=1/pd……………………………………………………Equation [3. 16]

A =3.84mm

➢ Dedendum(D)

1.25
D= 𝑝𝑑 ……………………………………………………. Equation [3. 17]

D=4.8mm

34
 ➢ Clearance(C)

0.25
C= 𝑝𝑑 …………………………………………………. Equation [3. 18]

C=0.96𝑚𝑚

➢ Outside diameter (Do)

2
Do=D+𝑝𝑑………………………………………………. Equation [3. 19]

𝐷 = 53.69𝑚𝑚

➢ Whole depth(wd)

2.25𝐷
𝑊𝑑 = ………………………………………………Equation [3. 20]
𝑛

𝑊𝑑 = 8.625𝑚𝑚

➢ Thickness of tooth(T)

T=pc/2 …………………………………………………. Equation [3. 21]

T= 12.06/2 = 6.03mm

B) Stress analysis and material selection

The useful transmitted load that is involved in transmission of power is the tangential
component of force.

Tangential component (wt)

𝑘𝑣 ∗𝑏∗𝑌∗𝛿
Wt= Equation3. 22
𝑃𝑑 ∗𝐾𝑓

Where kv = dynamic factor, b = face width, Y= geometry factor, δ = stress, Pd = diametral

pitch and Kf = concentration factor. rf is root fillet radius

𝑡 𝑡
Kf = 0.18+( )0.15 ( )0.45 Equation3. 23
𝑟𝑓 𝑙

where rf = root fillet radius, l= working depth, t=tooth thickness

0.3
rf = 𝑃 ………………………………………………………. Equation [3. 24]
𝑑

0.3
rf= 0.26 =1.154mm

2
l=𝑃 ………………………………………………………. Equation [3. 25]
𝑑

35
 2
𝑙 = 0.26 = 7.69mm

𝑃𝑐
t= ………………………………………………………. Equation [3. 26]
2

t= 6.03mm

6.03 6.03
Kf = 0.18+(1.154)0.15 (7.69)0.45

Kf = 1.32
2𝜋𝑁 𝐷
V= ∗2 ………………………………………………. Equation [3. 27]
60

2𝜋∗1000∗0.046
𝑉= 120
= 2.41 𝑚/𝑠 where v is pitch line velocity

Kv = 3/(3+V) …………………………………………………Equation [3. 28]

kv = 0.55

The torque required to drive an ideal pump at constant speed is given by:
𝐷𝑝
T = 2𝜋 (P1-P2)………………………………………………….Equation[3. 29]

where p1-p2 is the maximum pressure the pump should withstand which is taken as 10.2 x 105

1.998𝑥10−5
T= (10.2x105)
2𝜋

T = 3.24 N.m

Efficiency of torque transmission from motor to pump was taken as 65%.

3.24
Tm = 0.65 = 4.98 N.m where Tm is motor torque

Load per tooth (Wtooth)

𝑇𝑚 ∗2
Wtooth = …………………………………………………. Equation [3. 30]
𝐷

4.98∗2
Wtooth= = 216.5 N
0.046

Dynamic Load (Wd)

3+𝑉
Wd = [Wtooth]…………………………………………………Equation [3. 31]
3

Wd = 390.4 N

A 0.4%C hot-rolled steel is selected on the basis of cost and its strength

36
 𝑘𝑣 ∗𝑏∗𝑌∗𝛿
Wt = ………………………………………………………. Equation [3. 32]
𝑃𝑑 ∗𝐾𝑓

0.55∗0.34∗0.264∗365∗106
Wt = = 5.25x106 N
0.26∗1.32

The design is considered satisfactory when the tangential load is equal or greater than the
dynamic load on the gear.

Since Wt ≥ Wd, our design is Safe.

3.6.3 Shaft Design

The bending load was earlier found to be 216.7 N. The loading configuration shown in Figure
indicate that the reactions RA and RB are given by,

Figure3. 4Bending forces and the bending moment diagram

Bending load = 216.7 N

RA = RB = 108.25 N

Max Bending Moment = RA * 56.5 *10-2 = 3.89 Nm.

16
max = πd3 √M 2 + T 2 ………………………………………….……. Equation [3. 33]

Variation in pressure from suction to discharge suggested that shaft would be subjected to
fatigue load and a factor of safety of four was used to account for fatigue. By applying the
maximum shear stress theory of failure, the shaft diameter will be calculated

Since the shaft was to operate in oil medium, corrosion was not considered and thus mild
steel (σt =217Mpa) is used.

16∗8
d3 = √(3.89)2 + (3.24)2
πδty

d = 9.83, say d = 10 mm

37
3.6.4 Pump Housing
The maximum possible torque in the shaft is

π d3  π d3 δ𝑡𝑦 π (0.01)3 (217∗106 )

Tsmax = = = ……………………………… Equation [3. 34]
16 2∗16 2∗16

Tsmax = 28.3 N.m

Maximum pressure associated with the torque of 28.33 N.m can be calculated as

𝑝 𝐷
Tsmax = 28.3 = 2𝜋 (𝑃1 − 𝑃2 )

1.998𝑥10−5
28.3 = (∆𝑃)
2𝜋

ΔP = 8.89 MPa

This pressure could just cause failure of the shaft and only a marginal difference would ensure
a sacrificial failure of the shaft before the housing. A margin of 1.1 was adopted in this design.

ΔP * 1.1 = 9.78MPa

The two stress components in thin pressure vessels are, circumferential and axial stresses. The
circumferential stress is more critical in cylindrical pressure vessels and it is given by

𝑃∗𝑟
σy= ……………………………………………………. Equation [3. 35]
𝑡

Steel with a yield strength of 220.63Mpa and a factor of safety of 1.5 is used

r=ra+0.5c

r = 26.83+0.5(0.96) =27.31mm
9.78𝑥106 ∗ 0.0273
𝑡= 𝑚 = 7.2𝑚𝑚
220.63𝑥106
say t=8mm`

Bolt design for housing cover

Bolts are basic mechanical component which are used to fasten parts which are meant to be
attached, bolts are generally used along with washers and nuts. With screw thread along a
portion of bolt length it consists of a head and cylindrical body and to match those of the bolt,

38
the nut is a member of the pair having internal threads. To prevent loosening and crushing
washers are often used.

• Material used=Mild steel

• Ultimate tensile strength=440 MPa

• Shear strength= 345 MPa

• Factor of safety=1.5

A bolt with a specification of M4 and M10 is going to be designed from standard table which
has a required parameter for designing bolt

Table 3. 1 Standard bolt dimensions [11]

Designation Pitch Major Effective Minor or core Depth of Stress
mm or or pitch diameter thread area
nominal diameter (dc ) mm (bolt) mm2
diameter Nut and mm
Nut and Bolt
Bolt (dp ) mm
(d = D) Bolt Nut
mm

(1) (2) (3) (4) (5) (6) (7) (8)

Coarse series
M 0.4 0.1 0.400 0.335 0.277 0.292 0.061 0.074
M 0.6 0.15 0.600 0.503 0.416 0.438 0.092 0.166
M 0.8 0.2 0.800 0.670 0.555 0.584 0.123 0.295
M1 0.25 1.000 0.838 0.693 0.729 0.153 0.460
M 1.2 0.25 1.200 1.038 0.893 0.929 0.158 0.732
M 1.4 0.3 1.400 1.205 1.032 1.075 0.184 0.983
M 1.6 0.35 1.600 1.373 1.171 1.221 0.215 1.27
M 1.8 0.35 1.800 1.573 1.371 1.421 0.215 1.70
M2 0.4 2.000 1.740 1.509 1.567 0.245 2.07
M 2.2 0.45 2.200 1.908 1.648 1.713 0.276 2.48
M 2.5 0.45 2.500 2.208 1.948 2.013 0.276 3.39
M3 0.5 3.000 2.675 2.387 2.459 0.307 5.03
M 3.5 0.6 3.500 3.110 2.764 2.850 0.368 6.78
M4 0.7 4.000 3.545 3.141 3.242 0.429 8.78
M 4.5 0.75 4.500 4.013 3.580 3.688 0.460 11.3
M5 0.8 5.000 4.480 4.019 4.134 0.491 14.2
M6 1 6.000 5.350 4.773 4.918 0.613 20.1
(1) (2) (3) (4) (5) (6) (7) (8)

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
M 10 1.5 10.000 9.026 8.160 8.876 0.920 58.3
M 12 1.75 12.000 10.863 9.858 10.106 1.074 84.0

39
From the above table, design parameters for M4 bolt are:

➢ Pitch=0.7mm

➢ Nominal diameter(d)=4mm

➢ Effective or pitch diameter of nut and bolt=3.545mm

➢ Minor or core diameter of bolt(dc)=3.141mm

➢ Depth of thread=0.429mm

➢ Area of stress=8.78mm2

From the above table, design parameters for M10 bolt are:

➢ Pitch=1.5mm

➢ Nominal diameter(d)=10mm

➢ Effective or pitch diameter of nut and bolt=9.026mm

➢ Minor or core diameter of bolt(dc)=8.126mm

➢ Depth of thread=0.92mm

➢ Area of stress=58.3mm2

The bolt with M4 is subjected to tensile stress. So, we have to check the failures.

𝑊
𝑝= ………………………………………….…Equation [3. 36]
𝐴

𝑤 = 𝑝. 𝐴 = 9.78mpa * 4852.9mm2=47462N

W in each bolt 47462/24 = 1977N

4𝑥𝑤
𝜎 = 𝜋𝑑𝑐 2 ……………………………………………...Equation [3. 37]

4𝑥1977
=𝜋3.1412

=255.14Mpa

255.14MPa<293MPa, the design is safe.

40
3.6.5 Design of flange coupling
A flange coupling usually applies to a coupling having two separate cast iron flanges. Each
flange is mounted on the shaft end and keyed to it. The faces are turned up at right angle to the
axis of the shaft. One of the flanges has a projected portion and the other flange has a
corresponding recess. This helps to bring the shafts into line and to maintain alignment. The
two flanges are coupled together by means of bolts and nuts. The flange coupling is adopted to
heavy loads and hence it is used on large shafting. [11]

Protective type flange coupling is selected since it avoids danger to the work mans

Protected type flange coupling: In a protected type flange coupling, the protruding bolts and
nuts are protected by flanges on the two halves of the coupling, in order to avoid danger to the
workman. The thickness of the protective circumferential flange (tp) is taken as 0.25 d. The
other proportions of the coupling are same as for unprotected type flange coupling.

Outside diameter of hub, D = 2 d………………………………………….…Equation [3. 38]

Length of hub, L = 1.5 d………………………………………….…………Equation [3. 39]

Pitch circle diameter of bolts, D1 =3 d……………………………………. Equation [3. 40]

Outside diameter of flange, D2 = D1 + (D1 – D) = 2 D1 – D = 4 d …….…Equation [3. 41]

Thickness of flange, tf = 0.5 d………………………………………………Equation [3. 42]

Number of bolts = 3, for d up to 40 mm

= 4, for d up to 100 mm

= 6, for d up to 180 mm

. So, we know the following values:

Power transmitted, P = 1000 W

Speed 0f input shaft, N = 1000 rpm

Allowable shear stress for shaft of mild steel material, τs=40 MPa

Material selected for flange is gray cast iron, 𝜏c = 14 MPa

41
Where, d = Diameter of shaft or inner diameter of hub,

D = Outer diameter of hub,

d1 = Nominal or outside diameter of bolt,

D1 = Diameter of bolt circle,

n = Number of bolts,

tf = Thickness of flange

τs, τb and τk = Allowable shear stress for shaft, bolt and key material respectively

τc = Allowable shear stress for the flange material i.e. cast iron,

σcb, and σck = Allowable crushing stress for bolt and key material respectively [11]

The protective type of cast iron flange coupling is designed as discussed below:

A) DESIGN FOR HUB

First of all, let’s find the outer diameter of the hub(D). We have already calculated that the
diameter of the shaft is 10mm.

D=2 d

D= 2 × 10 = 20 mm

And length of the hub, L= 1.5 d= 1.5 × 10 = 15 mm

Let us now check the induced shear stress for the hub material which is cast iron, by considering

it as a hollow shaft. We know that the maximum torque transmitted (Tmax),

𝜋 𝐷 4 −𝑑4
Tmax = 16 𝑥 𝜏𝑐 𝑥 ( )
𝐷

𝑃𝑥60 1000∗60
Tmax = 1.25Tmean = 1.25( 2𝜋𝑁 ) = 1.25(2𝜋∗1000) =11.9N-m = 119x102 N-mm

𝜋 204 −104
119x102 = 16 𝑥 𝜏𝑐 𝑥 ( )
20

τc = 8.08 MPa

42
Since the induced shear stress in the hub is less than the permissible value of 14 MPa, therefore
the design for hub is safe.

B) DESIGN FOR KEY

Since the crushing stress for the key material is twice its shear stress, therefore a square key
may be used

Table 3. 2 Proportions of standard parallel, tapered and gib head keys. [11]

Shaft diameter Key cross-section Shaft diameter Key cross-section

(mm) upto and (mm) upto and
including Width (mm) Thickness (mm) including Width (mm) Thickness (mm)

6 2 2 85 25 14
8 3 3 95 28 16
10 4 4 110 32 18
12 5 5 130 36 20
17 6 6 150 40 22
22 8 7 170 45 25
30 10 8 200 50 28
38 12 8 230 56 32
44 14 9 260 63 32
50 16 10 290 70 36
58 18 11 330 80 40
65 20 12 380 90 45
75 22 14 440 100 50

we find that for a 10 mm diameter shaft,

Width of key, w= 4 mm

and thickness of key, t = w = 4 mm

The length of key (l) is taken equal to the length of hub.

l= L = 15 mm

Let us now check the induced stresses in the key by considering it in shearing and crushing.

Considering the key in shearing. We know that the maximum torque transmitted (Tmax),

𝑑 10
119x102 = l * w * 𝜏𝑘 * 2 = 15*4*𝜏𝑘 * 2

𝜏𝑘 = 39.6 MPa

43
Considering the key in crushing. We know that the maximum torque transmitted (Tmax),

𝑡 𝑑 4 10
119x102 = l * 2 * 𝛿𝑐𝑘 * 2 = 15*2*𝛿𝑐𝑘 * 2

𝛿𝑐𝑘 = 79.2 MPa

Since the induced shear and crushing stresses in key are less than the permissible stresses,
therefore the design for key is safe.

C) DESIGN FOR FLANGE

The thickness of the flange ( tf) is taken as 0.5 d.

tf = 0.5 × 10 = 5 mm

Let us now check the induced shear stress in the flange, by considering the flange at the junction
of the hub in shear. We know that the maximum torque transmitted (Tmax),

𝜋𝐷 2 𝜋202
119x102 = x tf x τc = x 5 x τc
2 2

τc = 3.79 MPa

Since the induced shear stress in the flange is less than the permissible value of 14MPa,
therefore the design for flange is safe.

D) DESIGN FOR BOLT

Let d1= Nominal diameter of bolts.

Since the diameter of shaft is 10 mm, therefore let us take the number of bolts,

n=3

and pitch circle diameter of bolts,

D1=3 d= 3 × 10 = 30 mm

The bolts are subjected to shear stress due to the torque transmitted. We know that the
maximum torque transmitted (Tmax),

𝜋 𝐷1 𝜋 30
119x102 = 4 (d1)2 τb x n x 2
= 4 (d1)2 30 x 3 x 2

44
 d1 = 3.35 mm

Assuming coarse threads, the nearest standard diameter of the bolt is 4 mm (M4). So, d1=4
mm.

Other proportions of the flange are taken as follows:

Outer diameter of the flange,

D2=4 d= 4 × 10 = 40 mm

Thickness of the protective circumferential flange,

tp= 0.25 d= 0.25 × 10 = 2.5 mm

3.6.6 Bearing selection

Bearings are a stationary machine element which supports a rotating shaft. the life of bearing
in hours can be from 450 up to 7700. Thus, for our design take 7700 hr. as the life of bearings
with the shaft having maximum speed of rotation of 1000rpm.

Table 3. 3 bearing selection [12]

45
Reaction force on bearing can be calculated as

Figure3. 5 Bearing selection

Wt and Wr are tangential and radial forces acting on tooth

Wt= Wtooth(cos200) ……………………………………Equation [3. 43]

Wt= 216.5*cos200 = 203.44N

Wr=Wtoothsin200 ………………………………….……Equation [3. 44]

=216.5*sin200=74.05N

Vertical components [11]

Figure3. 6 Vertical bearing reaction

∑ 𝐹𝑦 = 0

Wt – Rbv = 0

Rbv=Wt=203.4N

46
Horizontal component

Figure3. 7 Horizontal bearing reaction

Figure 3.4 horizontal bearing reaction

∑ 𝐹𝑥 = 0

Wr – Rbh = 0

Rbh=wr=74.05N

Equivalent radial force on bearing (W)

W2 = Rbh2 + Rbv2

W=216.5

From India manufacturing catalogue of deep groove ball bearing we selected a bearing with a
bearing designation number of 6000 having a bore diameter equal to diameter of shaft 10mm.

Table 3. 4 Ball bearing selection [12]

47
Dynamic load(C) on bearing

𝐿 = 60𝑁𝐿ℎ ……………………………………. Equation [3. 45]

L=60*1000*7700

L=462*106

1
𝐿 𝑘
C=W[106 ]

1
462∗106 3
C=216.5[ ]
106

C=1.36KN

Dynamic capacities of bearing selected; C = 4.6KN. Since the dynamic load rating of the
selected bearing is greater than the required dynamic load capacity; i.e 4.6KN > 1.36KN. The
selected bearing is suitable

3.6.7 seal selection

A mechanical seal is simply a method of containing fluid within a vessel (typically pumps,
mixers, etc.) where a rotating shaft passes through a stationary housing or occasionally, where
the housing rotates around the shaft.

O-rings are round, ring-shaped sealing devices that sit in a groove between two parts, which
are often cylindrical. It is the compression of the two parts that allow the O-ring to form an air
or liquid-tight seal. Generally, O-rings can withstand pressure and vibration within their
application. Based on their shape, O-rings can be designed for both static and dynamic
applications.

While O-rings are typically round and vary in thickness, gaskets are flat seals that sit between
two flat surfaces. Gaskets are often circular, however they can be cut into virtually any shape,
including square, triangle, rectangle or any other complex form.

In the gear pump a rotating shaft rotates through a housing in order to prevent leakage an O
ring seal with 10 mm diameter and a gasket with the shape of the housing cover will be used.

48
3.6.8 Other components
➢ Cylinder (oil tank): it is used to carry the oil. The available oil tank has a shape of a
cylinder with height 60cm and radius of 18 cm. It has two holes in the top and bottom
part of the cylinder.

The volume of the cylinder is calculated by the formula:

𝑣 = π𝑟 2 ℎ………………………………….………Equation [3. 46]
𝑣 = π × (18𝑐𝑚)2 × 60𝑐𝑚
𝑣 = 61041.6 𝑐𝑚3

➢ Hose: it used to transport the oil from cylinder to oil pump. Flexible rubber hose is
used as material for the hose. Same hose is used for the outlet.
➢ Wheel: it used to move the machine from one place to another by pushing the pusher.
➢ Basement: it used as a base supporter in our machine. All components of the simple
machine are seat in the sheet metal.

3.7 Cost analysis

3.7.1 Material cost

A) Gear material

➢ Volume
𝑣 = 𝜋𝑟 2 ℎ
v= 𝜋(26.8)2 (34)
v=76976 mm3
➢ Density
𝜌 = 7849.05𝑘𝑔/𝑚3
➢ Mass
M= 𝜌 ∗ 𝑣
M=7849.05*76976x10-9 kg
M=0.604kg
Since there are two gears the mass is multiplied by two

M=1.208kg

Cost=mass x cost per kg.

=1.208kg *42.69birr per kg

=51.6birr

49
B) Shaft material

I, driver shaft II, Driven shaft

➢ Volume ➢ Volume
𝑣 = 𝜋𝑟 2 ℎ 𝑣 = 𝜋𝑟 2 ℎ
v= 𝜋(5)2 (72) v= 𝜋(5)2 (42)
v=5654.86 mm3 v=3297 mm3
➢ Density ➢ Density
𝜌 = 7840𝑘𝑔/𝑚3 𝜌 = 7840𝑘𝑔/𝑚3
➢ Mass ➢ Mass
M= 𝜌 ∗ 𝑣 M= 𝜌 ∗ 𝑣
M=7840.05*5654.86x10-9 kg M=7840.05*3297x10-9 kg
M=0.44kg M=0.25kg
Cost=mass x cost per kg. Cost=mass x cost per kg.

=0.44kg *40.23birr per kg =0.25kg *40.23birr per kg

=17birr =10.5birr

Total shaft material cost = 17birr + 10.5 birr=27.5 birr

C) Housing material

➢ Volume
𝑣 = 116.8 ∗ 42 ∗ 8 ∗ 2 + 2(𝜋 ∗ 35.32 + 55.2 ∗ 35.3)
𝑣 = 90212.16𝑚𝑚3

➢ Density
𝜌 = 7500𝑘𝑔/𝑚3
➢ Mass
M= 𝜌 ∗ 𝑣
M=7500kg/m3*90212.16x10-9 kg
M=0.676kg
Cost=mass x cost per kg.

=0.676kg *45birr per kg

=30.42birr

D) Hose with nipple

The hose has a total length of 3m long

Cost =length x cost per meter
=3m x 100birr per meter
=300 birr

50
 E) Wheel

Four wheels with a total cost of 400 birr will be bought.

F) Bolts

There are 17 M4 bolts and 2 M10 bolts.

M4 bolt total cost = number of M4 bolts * cost of a single M4 bolt

M4 bolt total cost =17*10birr

M4 bolt total cost =170birr

M10 bolt total cost = number of M10 bolts * cost of a single M10 bolt

M10 bolt total cost =2*12birr

M10 bolt total cost =24birr

Total bolt cost = 24 + 170 = 194 birr

G) Bearing

2 bearings will be needed for the project

2 bearings will be needed for the project which costs a total of 300 birr

Total bearing cost = number of bearings * cost of each bearing

Total bearing cost = 2 * 800 birr

Total bearing cost = 1600 birr

H) coupling material

➢ Volume
𝑣 = 𝜋102 (10) + 𝜋202 (5)
v=94200 mm3
➢ Density
𝜌 = 7300𝑘𝑔/𝑚3
➢ Mass
M= 𝜌 ∗ 𝑣
M=7300*94200x10-9 kg
M=0.068kg
Cost=mass x cost per kg.

=0.68kg *40.23birr per kg

51
 =30.6birr

I) Basement material

A total of 0.3 m2 square sheet metal and rectangular metal bar with a length of 2.5m which
costs approximately 200 birrs are required for the basement.

j) Seal material

o ring seal and gasket have a total cost of 100 birr

k) Cylinder material

➢ Volume
𝑣 = 2𝜋𝑟𝑡ℎ + 2𝜋𝑟 2 𝑡
v= 2𝜋(180)(1)(600) + 2𝜋(180)2 (1)
v=271433.6 mm3
➢ Density
𝜌 = 7840𝑘𝑔/𝑚3
➢ Mass
M= 𝜌 ∗ 𝑣
M=7840.05*271433.60x10-9 kg
M=2.12kg
Cost=mass x cost per kg.

=2.12kg *40.23birr per kg

=85.28birr

3.7.2 Electric cost

Table 3. 5 Electric cost

Electric machine Cost

Lathe 100birr
Milling 100birr
Welding 60birr

3.7.3 Human labor

An estimated 5 hours of human labor is required. 50 birr per hour will be payed therefore a
total of 250 birr will be needed.

Total cost = material cost + electric cost + human labor= 3014.12birr

52
3.8 Result and discussion
All the procedures and analyses in this project are done by considering all parts and some
standard materials are used. The work performed in this project is designed to help the workers
by creating a comfortable working condition, and highly decrease the labor force. This project
meets the proposed objectives and gives a solution to the identified problem in the selected
work section.

Table 3. 6 gear design results

Face width (b) 34mm

Circular pitch diameter (D) 46mm
Addendum radius (𝑟𝑎 ) 26.83mm
Dedendum radius (𝑟𝑑 ) 18.2mm
Diametrical pitch (𝑝𝑑 ) 0.26mm
Module (m) 3.83mm
Circular pitch (𝑝𝑐 ) 12.06mm
Addendum (A) 3.8mm
Dedendum (D) 4.8mm
Clearance (C) 0.96mm
Outside diameter (𝐷𝑜 ) 53.69mm
Whole depth (𝑊𝑑 ) 8.625mm
Thickness of tooth (T) 6.03mm
Concentration factor (𝑘𝑓 ) 1.32
Dynamic factor (𝑘𝑣 ) 0.55
Root filet radius (𝑟𝑓 ) 1.154mm
Working depth (I) 7.69mm
Tooth thickness (t) 6.03mm
Torque to derive an ideal pump (T) 3.24 N.
Motor torque (Tm) 4.98 Nm.
Load per tooth (𝑊𝑡𝑜𝑜𝑡ℎ ) 216.5 N
Dynamic load (𝑊𝑑 ) 309.4 N
Tangential load (𝑊𝑡 ) 5.25×106 N

Table 3. 7 Design of shaft results

Diameter 10mm
Length 113mm

53
 Table 3. 8 Design of housing results

Maximum possible torque (𝑇𝑠𝑚𝑎𝑥 ) 28.3 Nm.

Maximum pressure (ΔP) 9.78 MPa
Radius(r) 27.31mm
Thickness(t) 8mm

Table 3. 9 Design of coupling results

coupling
key flange hub bolt
width 4mm Thickness 5mm diameter 20mm pitch circle diameter 30mm
thickness 4mm protective thickness 2.5mm length 15mm d1 3.35mm
length 15mm d2 40mm

Table 3. 10 Pump specification results

Pipe friction factor (f) 0.029

Vertical head (HV) 1.452m
Frictional loss (Hf) 0.058m
Total dynamic head (TDH) 1.51m
Hydraulic power (𝑝ℎ ) 4.375 × 10−3 W
Efficiency 63.75%
Power 686 watt
Flow rate 3.3*10-4 m3/s
Fluid displaced per revolution 1.998x10-5 m3/rev

3.9 CONCLUSION
The design analysis of the oil filling machine is successfully carried out in this work. This work
indicated a good prospect for the design small machines equipment which will serve as a spring
board for proper utilization of time and energy. This leads to effective use of oil and human
labor. The project plays an important role in the reduction of oil wastage, time wastage and
human labor. The components of this gear pump are fabricated by machining. Further work is
required to add other type of oils in the process. An improved gear pump with much more
efficiency using any mechanism is also advisable.

54
 CHAPTER FOUR

4 General conclusion and Recommendation

4.1 General Conclusion

This internship experience was very helpful in terms of applying Engineering methods, tools
and techniques in to works it also helped us to improve our practical skill, theoretical
knowledge, team playing skills and leadership skills additionally it helped us to upgrade our
work ethics and industrial psychology basically it helped us to identify major challenges and
problems in the company due to this we have identified major problem and proposed a designed
solution during the analytical method of designing we tried to analyze basic mechanical
components and modeled all parts in Auto Cad. Generally, our stay was very helpful and
interesting.

4.2 General Recommendation

During this intern ship program an observation has been made toward some problems and those
observations leads to some recommendations which are: -

• Workers should be kind and free to give intern students responsibilities and works based
on their quality
• Working problem solving projects by intern students should be free from bureaucracy
• Safety materials should be given to students.
• Poor protocols about transmitted diseases like Covid-19 therefore we recommend to
work on it.
• Further work is required to add other type of oil which will be pumped.
• It’s better if they give students same work tasks & leave it to them. Simply trust them.
• Making the gear pump more efficient will be advisable.

55
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57
 APPENDICES

APPENDIX A Part drawing

GEAR SPECIFICATION

MODULE 3.83
NUMBER OF TEETH 12
PITCH DIAMETER 46
TEETH THICKNESS 6.03
ADDENDUM RADIUS 26.83
DEDENDUM RADIUS 18.2
PRESSURE ANGLE 20°

4.0

11.8

Ø10.0

34.0

Ø26.0

34.0

DRAWN BY ELYAS, ADDISU, ESAYAS

AND HAWI BAHIR DAR UNIVERSITY
BAHIR DAR INSTITUTE OF TECHNOLOGY DRAWING NO.
CHECKED BY TEMESGEN A. SCHOOL OF MECHANICAL
AND INDUSTRIAL ENGINEERING 01
DATE 05/01/2022

MATERIAL HOT ROLLED TITLE: DRIVER AND DRIVEN GEAR SCALE 1:1
STEEL

58
59
 113.0
Ø10.0
34.0 15.0

2.5

60
DRAWN BY ELYAS, ADDISU, ESAYAS
AND HAWI BAHIR DAR UNIVERSITY
BAHIR DAR INSTITUTE OF TECHNOLOGY DRAWING NO.
CHECKED BY TEMESGEN A. SCHOOL OF MECHANICAL
AND INDUSTRIAL ENGINEERING 02
DATE 05/01/2022
TITLE: SHAFT
MATERIAL MILD STEEL SCALE 1:1
61
 R35.3
50.0
R27.3
8.0
35.0
Ø4.0
Ø26.0

45° 45°
Ø10.0
Ø12.7
58.4

23.0

46.0
125.8 Ø4.0 116.8

62
45° 45°

8.0
51°

9.1
Ø10.0 47.0 21.0 17.6
19.8 42.0
94.0

DRAWN BY ELYAS, ADDISU, ESAYAS

AND HAWI BAHIR DAR UNIVERSITY
DRAWING NO.
BAHIR DAR INSTITUTE OF TECHNOLOGY
CHECKED BY TEMESGEN A. SCHOOL OF MECHANICAL
03
AND INDUSTRIAL ENGINEERING
DATE 05/01/2022
MATERIAL STAINLESS TITLE: PUMP HOUSING SCALE 1:1
STEEL
63
 6.9

Ø4.0

8.0 M4

8.0

64
6.9 16.0 3.0
4.0

DRAWN BY ELYAS, ADDISU, ESAYAS

AND HAWI BAHIR DAR UNIVERSITY
BAHIR DAR INSTITUTE OF TECHNOLOGY DRAWING NO.
CHECKED BY TEMESGEN A. SCHOOL OF MECHANICAL
AND INDUSTRIAL ENGINEERING 04
DATE 05/01/2022

TITLE: M4 BOLT AND NUT SCALE 1:1

MATERIAL MILD STEEL
 17.3

Ø10.0
17.3

M10.0
20.0

65
20.0
40.0 7.5

10.0

DRAWN BY ELYAS, ADDISU, ESAYAS

AND HAWI BAHIR DAR UNIVERSITY
BAHIR DAR INSTITUTE OF TECHNOLOGY DRAWING NO.
CHECKED BY TEMESGEN A. SCHOOL OF MECHANICAL
AND INDUSTRIAL ENGINEERING 05
DATE 05/01/2022

TITLE: M10 BOLT AND NUT SCALE 1:1

MATERIAL MILD STEEL
66
 4.0 Ø40.0
30.0
15.0 0.4
10.0 Ø39.3

120° Ø20.0

Ø10.0

4.0

67
M4 (3 BOLTS @120°)

DRAWN BY ELYAS, ADDISU, ESAYAS

AND HAWI BAHIR DAR UNIVERSITY
BAHIR DAR INSTITUTE OF TECHNOLOGY DRAWING NO.
CHECKED BY TEMESGEN A. SCHOOL OF MECHANICAL
AND INDUSTRIAL ENGINEERING 06
DATE 05/01/2022

TITLE: PROTECTIVE FLANGE COUPLING WITH SCALE 1:1

MATERIAL CAST IRON
ITS KEY, SHAFT AND BOLT
68
 570.0 600.0

Ø12.7

24.9

Ø390.0

Ø360.0

Ø50.0

DRAWN BY ELYAS, ADDISU, ESAYAS

AND HAWI BAHIR DAR UNIVERSITY DRAWING NO.
CHECKED BY TEMESGEN A. BAHIR DAR INSTITUTE OF TECHNOLOGY
SCHOOL OF MECHANICAL 07
AND INDUSTRIAL ENGINEERING
DATE 05/01/2022
MATERIAL MILD STEEL
TITLE: CYLINDER SCALE 1:1
69
70
 30.0 30.0

30.0

960.0

30.0 48.0

Ø390.0

Ø390.0

550.0

140.0
30.0
30.0
250.0
500.0

DRAWN BY ELYAS, ADDISU, ESAYAS

AND HAWI BAHIR DAR UNIVERSITY
BAHIR DAR INSTITUTE OF TECHNOLOGY DRAWING NO.
CHECKED BY TEMESGEN A. SCHOOL OF MECHANICAL
AND INDUSTRIAL ENGINNERIN 08
DATE 05/01/2022

TITLE: BASEMENT SCALE 1:1

MATERIAL CAST IRON

71
72
 Ø10.0
45°
Ø4.0
Ø40.0
45°
Ø32.0
Ø26.0
Ø20.0
Ø16.0
Ø16.0
56°
Ø10.0

9.5 29.0 10.0 10.0

48.0 4.0

14.0
7.0

20.0
Ø4.0

12.5

20.0 90.0
45.0 131.0

25.0

5.0
5.0

8.9 7.0

15.0

4.0

DRAWN BY ELYAS, ADDISU, ESAYAS

AND HAWI BAHIR DAR UNIVERSITY
BAHIR DAR INSTITUTE OF TECHNOLOGY DRAWING NO.
CHECKED BY TEMESGEN A. SCHOOL OF MECHANICAL
AND INDUSTRIAL ENGINEERING 09
DATE 05/01/2022
TITLE: MOTOR SCALE 1:1
MATERIAL

73
74
 Ø10.0 Ø4.0

75
8.0
16.0

42.0

DRAWN BY ELYAS, ADDISU, ESAYAS

AND HAWI BAHIR DAR UNIVERSITY
BAHIR DAR INSTITUTE OF TECHNOLOGY DRAWING NO.
CHECKED BY TEMESGEN A. SCHOOL OF MECHANICAL
AND INDUSTRIAL ENGINEERING 10
DATE 05/01/2022
TITLE: DRIVEN SHAFT SCALE 1:1
MATERIAL MILD STEEL
76
Appendix B Assembly drawing

77
78
79