DEBRE BERHAN UNIVERSITY

COLLAGE OF ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERIN

INTERNSHIP FINAL REPORT AND PROJECT

PROJECT TITLE: - KING PIN PRESS MACHINE

Hoist Company: - Amhara Water Works Construction Enterpriser, Bahir dar

Time Duration: - Three Month

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Prepared By Tadele Melaku Date, 08/05/2015 E.C

Debre Berhan Ethiopia

 BACKGROUND OF ENTERPRISE AND DESIGN OF PROJECT

Table of Contents Page

List of Figure ...................................................................................................................................... i

List of tables .................................................................................................................................... iii
Declaration ...................................................................................................................................... iv
Acknowledgement ........................................................................................................................... v
Abbreviation .................................................................................................................................... vi
Abstract ......................................................................................................................................... viii
CHAPTER ONE................................................................................................................................... 1
INTRODUCTION .................................................................................................................................................. 1
1.1 Background of the Enterprise ....................................................................................................................... 1
1.2 Organizational Structure of AWWCE .......................................................................................................... 5
CHAPTER TWO.................................................................................................................................. 6
OVER ALL INTERTIOP EXPERIENCE ............................................................................................................. 6
2.1 How We Get the Company .......................................................................................................................... 6
2.2 The Section of the Company we have Been Working in.............................................................................. 6
2.3 How Does the Work Flow in the Section Looks like ................................................................................. 28
2.4 Work Task We Have Been Executing ........................................................................................................ 29
2.5 Procedures We Have Been Using For Performing Tasks........................................................................... 29
2.6 How Good We Have Been in Performing the Task ................................................................................... 29
2.7 Challenges We Have Been Faced During Performing the Task................................................................. 30
2.8 Measures We Have Taken to Overcome the Challenge ............................................................................. 30
CHAPTER THREE ............................................................................................................................. 31
Over All Benefit We Gain in the Internship Program .......................................................................................... 31
3.1 In Terms of Upgrading Our Practical Skills ............................................................................................... 31
3.2 What We Gained in Terms of Upgrading our Theoretical Knowledge ...................................................... 31
3.3 What We Gained in Terms of Improving Industrial Problem-Solving Capacity ........................................ 32
3.4 What We Gain in Terms of Improving Our Team Playing Skills .............................................................. 32
3.5 What We Gain in Terms of Improving Our Leadership Skill .................................................................... 33
3.6 What We Gain in Terms of Understanding about Work Ethics Related Issues ......................................... 33
3.7 In Terms of Entrepreneurship Skills........................................................................................................... 34
 BACKGROUND OF ENTERPRISE AND DESIGN OF PROJECT
3.8 Interpersonal Communication Skills .......................................................................................................... 34
3.9 Conclusion and Recommendation .............................................................................................................. 35
CHAPTER FOUR............................................................................................................................... 37
DESIGN OF THE PROJECT (KING PIN PRESS) ............................................................................................. 37
Abstract ................................................................................................................................................................ 37
Introduction .......................................................................................................................................................... 38
4.1 Background of the Project .......................................................................................................................... 38
4.2 Problem Statement ..................................................................................................................................... 39
4.3 Objective of the Study ................................................................................................................................ 39
4.4 Scope and Limitation of the project ........................................................................................................... 39
CHAPTR FIVE................................................................................................................................... 40
Literature Review ................................................................................................................................................. 40
CHAPTR SIX ..................................................................................................................................... 41
Detail Design Methodology of Project work........................................................................................................ 41
6.1 Methodology .............................................................................................................................................. 41
CHAPTER SEVEN ............................................................................................................................. 43
Detail Design of the Project ................................................................................................................................. 43
7.1 Design Analysis of Some Machine Components ....................................................................................... 43
7.2 Material Selection ...................................................................................................................................... 47
7.3 Selection of Bolt and Nut ........................................................................................................................... 48
7.4 Cost Analysis of Materials and Labor ........................................................................................................ 55
CHAPTER EIGHT .............................................................................................................................. 56
RESULT AND DISCUSION ............................................................................................................................... 56
8.1 Result.......................................................................................................................................................... 56
8.1.1 Assemble ............................................................................................................................... 57
8.2 Discussion .................................................................................................................................................. 58
CHAPTER NIGN ............................................................................................................................... 59
CONCLUSION AND RECOMENDATION ....................................................................................................... 59
9.1 Conclusion.................................................................................................................................................. 59
9.2 Recommendation ........................................................................................................................................ 59
Bibliography ................................................................................................................................. 60
 BACKGROUND OF ENTERPRISE AND DESIGN OF PROJECT

List of Figure Page

Figure 2.2.1 Starting System ........................................................................................................... 7
Figure 2.2.2 Dc and Ac Motor ........................................................................................................ 8
Figure 2.2.3 Lighting System.......................................................................................................... 9
Figure 2.2.4 Typical Vehicle Alternator ....................................................................................... 10
Figure 2.2.5 Ignition System ......................................................................................................... 10
Figure 2.2.6 Accessory System ..................................................................................................... 11
Figure 2.2.7 Car Engine ................................................................................................................ 11
Figure2.2.8 Cylinder Block........................................................................................................... 12
Figure 2.2.9 Piston ........................................................................................................................ 12
Figure 2.3.0 Piston Head ............................................................................................................... 13
Figure 2.3.1 Crank Shaft ............................................................................................................... 13
Figure 2.3.2 Oil Sump ................................................................................................................... 14
Figure 2.3.3 Cam Shaft ................................................................................................................. 14
Figure 2.3.4 Engine Valve ............................................................................................................ 15
Figure 2.3.5 Spark Plug and Fuel Injector .................................................................................... 15
Figure 2.3.6 Push Rod ................................................................................................................... 16
Figure 2.3.7 Manifold ................................................................................................................... 16
Figure 2.3.8 Piston Ring ............................................................................................................... 16
Figure 2.3.9 Gasket ....................................................................................................................... 17
Figure 2.4.0 Cooling System Part ................................................................................................. 17
Figure 2.4.1 Fuel System .............................................................................................................. 18
Figure 2.4.2 Lubrication System ................................................................................................... 18
Figure 2.4.3 Manufacturing Shop ................................................................................................. 19
Figure 2.4.4 Oxyacetylene Welding ............................................................................................. 20
Figure 2.4.5 Arc Welding ............................................................................................................. 20
Figure 2.4.6 Grinding .................................................................................................................... 20
Figure 2.4.7 Mechanical Shop ...................................................................................................... 21
Figure 2.4.8 Power Train Components ......................................................................................... 22
Figure 2.4.9 Fly Wheel ................................................................................................................. 22

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 BACKGROUND OF ENTERPRISE AND DESIGN OF PROJECT

Figure 2.5.0 Clutch ....................................................................................................................... 23

Figure 2.5.1 Gear Box ................................................................................................................... 24
Figure 2.5.2 Differential ............................................................................................................... 25
Figure 2.5.3 Power Flow in Differential ....................................................................................... 25
Figure 2.5.4 Wheel with Tire ........................................................................................................ 26
Figure 2.5.5 Steering System ........................................................................................................ 26
Figure 2.5.6 Suspension ................................................................................................................ 26
Figure 2.5.7 Disk Break, Drum Break, Engine Break and Brake Shoe ........................................ 27
Figure 2.5.8 Break Power Flow from Pedal to Wheels ................................................................ 28
Figure 2.5.9 Work Flow in Maintenance Shop ............................................................................. 28
Figure 4.0 King Pin ....................................................................................................................... 38
Figure 7.0 Reaction Force Finding ............................................................................................... 43
Figure 7.1 Simple Beam Like Structure Base Plate...................................................................... 44
Figure 7.2 Bending Moment Diagram .......................................................................................... 44
Figure 7.3 Base Plate .................................................................................................................... 45
Figure 7.4 Analysis of Cover Plate ............................................................................................... 46
Figure 7.5 Design of Bolt and Nut ................................................................................................ 46
Figure 7.6 Basic Profile of Thread ................................................................................................ 47
Figure 7.7 50ton hydraulic jack .................................................................................................... 48
Figure 7.8 Nut Standard Value ..................................................................................................... 50
Figure 7.11 2d Nut Drawing ......................................................................................................... 54
Figure 8.1 2d Assemble Drawing ................................................................................................. 57

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List of table Page

Table 1 List of Machineries ............................................................................................................ 2

Table 2 Standard of concentration value....................................................................................... 47

Table 3 material properties ............................................................................................................ 48

Table 4 Design dimensions of screw threads, bolts and nuts.......................................................... 51

Table 5 nut standard dimension ...................................................................................................... 54

Table 6 Stress analysis result for working plate ............................................................................. 56

Table 7 Stress analysis result for cover plate .................................................................................. 56

Table 8 Stress analysis of bolt and nut result .................................................................................. 56

Table 9 Cost analysis of result ......................................................................................................... 57

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Declaration
I want to declare that the internship practice has been done from November 06, 2015 E.C to January 30,
2015 E.C with the guidance of MSc Ashenafi and Agegnew who are the advisors of our IOT company
and internship practice respectively. We have been working in practical in the department of maintenance
and do a project on design of king pin press machine powered by 50 ton bottled jack.

NAME: Tadele Melaku Signature:

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Acknowledgement
First of all, I would like to thank our God keeping us healthy and alive, next we gratitude our department
for setting up this internship program so that we could gain practical skills and hence strengthen our
theoretical skills. We would also thanks greatly our advisor MSc Ashenafi, he always support us by
giving comment on our project.

Next, we would also like to thanks our hosting company AWWCE workers for their willingness to answer
and express any new thing for us especially Mr. Agegnew, he is the supervisor of internship program and
he is generous. The workers of AWWCE are sociable and free to show us what they know in the shop. We
know that we didn’t say enough so we want to thank everyone who has contributed on our internship stay.

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Abbreviation
AWWCE Amhara Water Works Construction Enterpriser
Auto CAD Auto Computer Aided Design
fy The summation of force in the Y
RA Reaction force on A
RB Reaction force on B
MA The maximum bending moment at A
L Length
V Shear force
Mmax Maximum bending moment
X Maximum bending stress
Ymax Maximum deflection
C Maximum deflection per two
W Load
B Base of plate
H height of plate
I Momentum inertia
N Factor of safety
all Allowable Stress
UTs Ultimate Tensile Strength
T Thickens
D Diameter
Kt Stress concentration factor
nominal Nominal stress
D Nominal diameter of bolt
P Pitch
H Length of Head or Nut
B diameter of head

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Ld Length of un threaded
Pd pitch diameter
Dc core diameter
LT Length of threaded

 Pia
V Volume
M Mass
R Radius
At Stress area
Pi initial tension in a bolt
t Tensile stress

c Compression stress
VL Volume of screw

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Abstract
This report mainly incorporates the overall three-month internship report and the project
done in convectional mechanical shop. The three-month intern report primarily deals with
the experience and benefits gained from the six shop (welding shop, manufacturing shop,
electrical shop, engine shop, machine shop, and mechanical shop) we had been working
on, in mechanical shop for maintenance of different vehicles. It also talks about the brief
history of the company with its main products, customers and organizational workflow.

The project (kingpin press) targets in tackling the problem on removing kingpin. During
maintenance or replacing of king pin by removing, it needs more than two man power.
The project shows how to solve the above mentioned problem using common machine
elements like nuts, working plates, bottled jack, cover plates, and bolts. This report
contains the design of some component guided by AutoCAD software with part and
assembly drawing of the machine and selected some components on index.

Finally, the whole report ends with some crucial recommendations and conclusions.

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CHAPTER ONE
INTRODUCTION
1.1 Background of the Enterprise
In this chapter we are going to discuss about the background history of AWWCE, mission, vision,
principles, objective, product and its organization structure. This chapter will give the brief explanation
about the organization how and when the organization was established and it shows the internal
structure of AWWCE.

In 1993 the Ethiopian water works construction enterprise has opened branch offices in the north eastern
Ethiopia in Kombolcha and north-west Bahir Dar. It was accountable for rural infrastructure and
economic development bureau as a manager of a regional bureau from 1993-1995 thus regional
government was deemed to restructure autonomously and restored as title of Amhara Water Works
Construction Enterprise (AWWCE) with Amhara national regional council proclamation no.15/1996.
The organization was founded with 5 rigs, 180 human resources and one million capitals. As the
enterprise development horizon is widening and raising its capital growth to one billion with
proclamation no.166/2009, AWWCE have got an authority of constructing roads, hydroelectric powers,
buildings, irrigation projects and administrating irrigation projects which are constructed by the its own.
Currently except hydroelectric construction, it is participating in all construction sectors.

The enterprise has been given duties and responsibilities of constructing water supply, irrigation, road
and building construction sectors. Generally, now the organization has 2846 human resource, 2002
machineries and 4.8 billion capitals (background AWWCE).

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Table 1 List of Machineries

No. Type of equipment Quantity No. Type of equipment Quantity

1 Dump truck 1001 11 Cargo truck 17

2 High bed 3 12 Loader 23

3 Low bed 5 13 Compactor 19

4 Fuel truck 6 14 Fork lift 6

5 Shower truck 23 15 Dumper 7

6 Dozer 21 16 Wagon drill 6

7 Grader 10 17 Mobile Mixer 5

8 Excavator 26 18 Crasher 6

9 Crane 23 19 Tractor 10

10 Light vehicles 188 20 Construction equipment 597

Total 2002

Vision of the Enterprise

 To be one of the leaders in construction industry in Africa for the coming 20 years.
Mission of the Enterprise

 To provide adequate water supply, irrigation structures, road and housing both in terms of
quality and quantity, wide construction service and quality work in the region and in the
country thereby continuously increasing the construction capacity of the enterprise, time
and resource usage and makes the enterprise long-lasting and profitable.

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Objective of the Enterprise

 Strengthen its capacity in construction industry, Improving time and resource utilization,
Creating sustainable profitability and availing quality service to the customers.

 Its Main Products or Services

Raw materials of the Enterprise

Since the enterprise is working mainly on construction and electro mechanical its main raw materials are

 Construction materials like cement, sand,

 Electro mechanical materials like generator, motor, surface and submersible pump
different sizes of cables breakers pipes.
 HDP pipes and jaw membrane
 Spare parts for all mechanical and electrical equipment’s
Main products of the enterprise
As a construction enterprise its products are finished and well-constructed

 Small scale and large Irrigation construction.

 Water supply construction
 Building construction.
 Road construction.
 Automotive maintenance service.
 Electro Mechanical supply and installation.
 Heavy duty machineries driving training institute and renting machineries

 Main customers and end users of the enterprise

Main customers

1. Federal Water resource development and energy

2. Amhara water resource development bureau
3. Governmental and non-governmental organizations
4. Higher educational institutions (colleges, universities)
5. Construction materials factories and suppliers
6. Machineries and spare part suppliers

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7. Machineries renting companies

End users

 Peoples who are living around the construction area which belongs to them.
 Individuals who take work agreement with the enterprise.
Over all organization of the Enterprise

An organization structure clarify the roles of personal of an Organization and to determine who has
to do what task, which is responsible for what, objective to be achieved, who is to report to whom
and to remove the obstacles for performance caused by confusion and uncertainty of job assignment
as well as to make easy decision-making and communication networks reflecting and supporting
organization objectives.

Board of Internal audit

management office

Legal expert
office
General Manager

Plan administration and

AWWCE Head public communication
office

West Amhara Eastern Amhara Equipment admin

construction construction and maintenance
office office office

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1.2 Organizational Structure of AWWCE

1.2.1 Over All Wok flow of the Enterprise
Amhara water works construction enterprise has many work flow styles which varies from department
to department. The following shows one of the enterprise department i.e. Equipment Administration and
maintenance office work flow.

Equipment operator Equipment

Equipment
administration
inspection office
office

Equipment
inspection officer Electrical
engineer

Technicians Mechanical
 Electricians engineers
 Mechanics
 Body and
welding Manufacturing
engineers

Store keeper and

tool man

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CHAPTER TWO
OVER ALL INTERTIOP EXPERIENCE
2.1 How We Get the Company
The university industry linkage program is planned to create a good interaction between universities and
industries, and also create students that have the capability of facing and solving practical problems. Due
to these Gondar University has given a great deal attention to this program in helping students, starting
from searching companies that are willing to be part of this program to giving essential documents and
schedules.

After we received internship paper or form, directly we had gone to a company that is our department
assigned and the general manager make a reception for us. We make a greeting with company’s member
and knowing about working environmental condition. We had enjoyed a peaceful time throughout
internship period.

2.2 The Section of the Company we have Been Working in

As we are mentioned above AWWCE commonly works on constructing roads, hydroelectric powers,
buildings, irrigation projects and administrating irrigation projects. When it does those two common
works in a facilitate way uses its own heavy-duty trucks, light duty vehicles, machineries, mixers,
dozers, excavators and so on. For those all machinery and vehicles a company have maintenance
shop. This shop is divided in to four sub branches like electrical shop, engine shop, machine shop,
welding shop and mechanical shop. Addition to these shops it has tire repair and inflation shop. Among
those sections, we have been commonly working on the mechanical shop and welding shop, through
entire period of internship.

The main four shops found in Amhara Water Works Construction Enterpriser maintenance shop are;

I. electric shop
II. engine shop
III. machine shop
IV. mechanical shop
We have seen the real and ideal information of each shop within weekly interval sequentially during
internship period.

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2.2.1 Electric Shop

In this shop we have gained the idea of mechatronics and most of its components are maintained.
Mechatronic components or electrical components like Starting motor, charging, lighting, ignition and
accessory systems are maintained that are found in automotive system.

Figure 2.2.1 starting system

Motor is a machine which converts an electrical energy to mechanical energy. Its action is based on the
principle that when a current caring conductor is placed in a magnetic field, it experiences a mechanical
force, which rotates flywheel to crank the engine. Components of starting system are battery, fuse,
ignition switch (relay switch), starter motor (brush, armature, field coils), and starter solenoid, sprig
clutch

 Battery used as source of energy for motor.

 Ignition switch used as switch to control the system.
 Solenoid used to engage lever that pushes out the pinion.
 Sprig clutch used to engage and dis engages the pinion.
 Ring gear meshes with pinion to drive flywheel.
Since starting motor is DC motor that have winding on the rotor part and this wounded wire gate its
current through the commentator and carbon brush. But in AC motor the rotor doesn’t have wounded

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wire to receive electric power by conduction rather it has aluminum shielded bare to make the magnetic
field produced due to an induction like

Figure 2.2.2 dc and ac motor

Working principle of starting system

When the DC power from starting battery is applied to the solenoid, when ignition switch is on,
solenoid engages a lever that pushes out the drive pinion on the starter driveshaft and meshes the
pinion with the starter ring gear on the flywheel of the engine.
One the engine cranks, the ignition switch is off, a spring in the solenoid assembly pulls the pinion
gear away from the ring gear, and the starter motor stops.
The starter’s pinion is clutched to its drive shaft through an overrunning sprang clutch, which
permits the pinion to transmit drive in one direction only. In this manner, drive is transmitted
through the pinion to the flywheel ring gear, but if the pinion remains engaged the pinion will spin
independently of its drive shaft. This prevents the engine driving the starter, for such back drive
would cause the starter to spin fast as to fly apart.

2.2.1.1 Lighting System

The lighting system of a motor vehicle consists of lighting and signal devices mounted to the front,
rear, sides and some cases at the top. The main advantage of presence of light system in a vehicle
is to see vehicles presence, position, and direction of travel, driver’s intentions, and priority for
emergency cares. It also gives additional information about power train condition by displaying in
the dashboard. There are many types of car lights. These are; head lights (low beam and high
beam), tail lights, fog lights, signal lights and so on. Components of lighting system are bulb, wire,

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source, and switch. Among these in internship period we can disassemble and test different types
of bulbs with circuit diagram.
From intern ship we have been gained about installation of light system every point of car body is
ground where as the positive charge must be properly plated prevent a vehicle from danger. This
power comes from the alternator (generator), by converting crankshaft mechanical energy in to
useful electrical energy, used to drive both starting system and lighting system.

Figure 2.2.3 lighting system in vehicles

2.2.1.2 Charging System

As we seen in internship time we can relate theoretical idea about alternator and its components
with practical by disassemble each part.
Charging system consists of the alternator, regulator, diode, and interconnected wire.
Alternator generates electrical energy from crank shaft rotation by using diode rectification to
convert AC to DC. Whereas regulators are regulate voltage of the output.
The electrical energy produced by alternator is used to drive all electrical system of a vehicle
including recharge of battery.

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Figure 2.2.4 Charging system

It is driven by a belt that is powered by the rotation of the engine to produce electric by law of
electromagnetism. This belt goes around a pulleys connected to the front of the engine crank shaft
and is usually responsible to driving water pump, power steering pump and air condition
compressor’s. Belts will require periodic adjustment to maintain the tension of the belt. Car battery
is recharged because it loses its voltage due to initiating starter motor. Each car battery has 12V.

2.2.1.3 Ignition System

The purpose of ignition system is to generate a high voltage from the car having 12 volts battery
and to send this to each sparking in turn, ignition the air fuel mixture in the engine combustion
chamber.

Figure 2.2.5 Ignition system

2.2.1.4 Accessory System

Accessory system contains all systems found in the dashboard of vehicle. This dashboard is the control
unit located ahead of vehicle’s driver, displaying instrumentation and control for the vehicle operation.

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These operation are speed, fuel level, oil pressure, climate control, direction FM radio, taps are
displayed in dash board accessory system.

Figure 2.2.6 Accessory system

2.2.2 Engine Shop

Engine is a mechanical work beside a machine for converting energy into motion or the energy is
usually supplied in the form of a chemical fuel, such as oil or gasoline, steam, or electricity,
and the mechanical work is most commonly delivered in the form of rotary motion of a shaft.

Figure 2.2.7 car engine

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In engine shop all engines and its component parts are all disassemble, assemble and service. In this
shop we can disassemble and assemble engine and its components. So engine shop engine and
components are fully serviced within required quality. These maintained components are in shop are;

1. Cylinder block is the main part of the engine in which combustion of fuel takes place and other
parts like piston, connecting road, crankshaft, water jacket etc.

Figure 2.2.8 cylinder block

Piston is placed in the cylinder and transmits thrust to the connecting rod. It compresses the air fuel
mixture and converts the fuel energy to mechanical energy and transmits power to crankshaft.

Figure 2.2.9 Connecting road and piston

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2. Connecting road it connects piston to crank shaft and transmit the motion and thrust of the
piston to crank shaft. The lower end of connecting road is connected to the piston called
gudgeon pin, whereas the bigger end is connected to crank shaft called crank pin.
3. Cylinder head us fitted on the top of the cylinder block and used to seal the working end of
cylinder and not to permit entry and exit of gases on cover head valve of the engine. The valves,
spark plug, camshaft, rocker arm are fitted on it.

Figure 2.3.0 piston head.

4. Crank shaft is located at the bottom of cylinder block it converts reciprocating motion in to
rotating motion to drive a vehicle.

Figure 2.3.1 crank shaft

Oil sump it is bolted at the lower cylinder block. All the oil for lubricating the movable parts
placed on it. This oil sump has two components first one gear pump used to pump oil from
reservoir to engine parts and the second Strainer (filter oil dirty enter into engine for lubrication).
This gear pump get a driving power from crank shaft by using gear that meshes with crank shaft
spline. Without oil friction will increase and the engine may burn out within a short period of
time.

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Figure 2.3.2 oil sump

Cam shaft is placed either in the cylinder head or at the bottom of the cylinder block. The main
function of cam shaft is to open and close valves at proper timing in multi cylinder engine.

Figure 2.3.3 cam shaft

5. Valves is fitted on the cylinder head, regulates the flow of air fuel mixture inside the cylinder and
exhaust gas outside the cylinder block. When both inlet and outlet valves are closed no pressure
can go outside of cylinder block.

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Figure 2.3.4 engine valve

Fuel injector and spark plug for diesel engine and petrol engine respectively.
Fuel injector used in petrol engine, fitted on the cylinder head, to inject fuel to highly compressed air.
Also spark plug used in petrol engine, fitted on cylinder head, to ignite air fuel mixture inside the
cylinder at the end of each compression stroke.

Figure 2.3.5 spark plug and fuel injector

Push rod it is used when camshaft is situated in the bottom of cylinder head. It regulates the timing of
valves open and close through rocker arm and camshaft.

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Figure 2.3.6 pushrod

6. Manifold is bolted on the cylinder head one each inlet and exhaust to distribute air fuel mixture
and exhaust gases respectively.

Figure 2.3.7 manifold

7. piston rings (compression ring and oil ring)

Compression ring it is a piston ring which helps to protect the compressed air not enter into the oil sump.

Oil ring it is a piston ring which helps to reduce the friction between the piston and cylinder and to
protect the pumped oil not enter in to the compressed air.

Figure 2.3.8 piston ring

8. Gaskets are used to seal cylinder head and cylinder so no pressure is allowed escape.

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Figure 2.3.9 gasket

9. Engine springs these bearing used to support crankshaft.
Correspondingly to disassemble and assemble engine components we have seen some engine systems.
These engine systems are

 Cooling system.
 Fuel system.
 Oil system.
Cooling system used to minimize engine heat during operation. This is done by circulating coolant
liquid usually water mixed with an antifreeze solution (keep engine parts from rust). A pump driven by
engine drives hot coolant water out of the engine to the radiator, which form of heat exchanger and
regulated by thermostat valve. The proses of cooling system and its components are shown bellow

Figure 2.4.0 cooling system part

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Fuel system is a combination of fuel tank, pump (screw pump), filter, and injector or carburetor. The
function of fuel system is to store and supply fuel to engine.

Figure 2.4.1 fuel system

Oil system (lubrication system) is a combination of oil pan, oil level, oil pump (mostly gear pump), oil
filters. Main function of oiling or lubrication system is minimization of engine parts friction.

Figure 2.4.2 oiling or lubrication system.

2.2.3 Machine Shop

This shop has three sub branched shops. These are

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 manufacturing shop.
 welding and grinding shop and
 material and equipment shop.
Manufacturing shop
In this shop there are many machines to manufacture many accessory parts of a vehicle. This shop play
great roll in company through minimization of cost to by accessory parts by produce them. In this shop
there are press machine, lathe machine, drill machine and also grinding and arc welding. Some products
produced in machine shop are;

 hinge bolts, nuts.

 radiator fan by using aluminum.
 adjust diameter of shafts and related materials.

Figure 2.4.3 manufacturing shop (lathe machine)

Welding and grinding
Welding is joining of parts whereas grinding is cutting of parts, so in this shop many vehicle parts that
need welding and grinding performed in this shop.

According to our company there are two types of welding

 oxyacetylene welding by using compressed oxygen and acetylene to weld serious

engineparts that can’t be performed by arc welding.

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Figure 2.4.4 oxyacetylene welding

electric are welding this welding that uses electric power supply to create an electric are between
electrode and the base material to melt the materials at the welding point.

Figure 2.4.5 arc welding

Grinding is a method of cutting, smoothing and chamfer any materials in machine shop.

Figure 2.4.6 grinding

Material and equipment shop

This shop materials to be machined, measuring instruments and equipment store.

 Material like tungsten, bronze, mild steel, aluminum.

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 Measuring instruments like caliper, micro meter, meter etc.,

 Equipment like hammer, electrodes, chisel etc.

2.2.4. Mechanical Shop

We call it the most technical shop among the whole shop. There is almost uncountable work are
performed here. Any kind of problem is first diagnosed in this shop and then replay it to one of the
above department if necessary but many times they may also solve the problem.

Figure 2.4.7 mechanical shop

This shop is vast and most vehicle parts maintained here. These are:

 Tire replacement.
 Brake shoe replacement.
 Power train maintenance.
 Car Body repair.
 Repairing all parts around engine.
Power train

Power train maintenance is permanently serviced in this shop. Power train includes transmission of
power from engine up to wheels. Some components of power train are shown in figure below.

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Figure 2.4.8 powertrain components

All component parts serviced except engine, maintained in engine shop. This power train except engine
is called drive train.

Flywheel

It is disk shaped drive train part. A flywheel is a rotating mechanical device that is used to store
rotational energy. Flywheels have a significant moment of inertia and thus resist changes in rotational
speed.

 It is connecting on the back of crank shaft.

 It uses keep the balance of crank shaft. Used to crank engine mesh with starting motor
pinion gear, transfer power to clutch.

Figure 2.4.9 flywheel

Clutch

Is a mechanical device that connects and disconnects two collinear shafts operating by Friction principle
and hence heat dissipation.

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Figure 2.5.0 clutch

Necessity of Clutch

 Allows gradual engagement of two rotating plates.

 Engine flywheel, Clutch disk and Pressure plate.
 Provide positive linkage capable of transmitting maximum engine torque.
 Rapidly separate engine from drive train and re–engage engine to drive train.
 Thrust springs provide force between pressure plate and flywheel to load clutch disk .
Requirements of Clutch

 Torque Transmission
 Gradual engagement
 Heat dissipation
 Dynamic balancing
 Vibration dam ping
 Size
 Free pedal play
 Easy in operation
 Lightness
Transmission

It is one of the parts of the power transformer on the vehicle which means to transfer power by
receivingfrom clutch into propeller shaft.

It refers simply to the gearbox that uses gears and gear trains to provide speed, torque, and directionchange
conversions from a rotating power source to another device.

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Figure 2.5.1 gear box

Necessity of Transmission

 To vary the torque to overcome the various resistance acting against the vehicle
motion at various speeds.
 To vary the tractive effort of the vehicle available at various speeds in order to
overcome the various resistance.
 To start the vehicle from rest, with the engine running continuously.
 To Stop the vehicle by disconnecting the drive when appropriate.
 Directional (forward and reverse) control may also be provided. Single ratio
transmissions also exist, which simply change the speed and torque (and sometimes
direction) of motor output.
General gear box is used to adjust speed and torque, direction, and transfer power from clutch to drive
shaft though universal and slip joints.

Drive shaft

Drive shaft is a mechanical component for transmitting torque and rotation. A torque carriers drive shaft
subjected to torsion and shear stress. To allow for variations in the alignment and distance between the
driving and driven components, drive shaft frequently incorporates one or more universal joints, jaw
couplings or rag joints. Drive shaft transfer power from gear box (transmission) to differential.

Differential gear train

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A differential is a gear train with three shafts that has the property that the angular velocity of one shaft
is the average of the angular velocities the others, or a fixed multiple of that average.

Figure 2.5.2 differential

Differential consists of one input, the drive shaft and two outputs which are the two drive wheels,
however the rotation of the drive wheels are coupled to each other by their connection to the roadway.

Figure 2.5.3 power flow in differential

Wheel

A wheel is a circular component that is intended to rotate on an axle bearing. The wheel is one of the
main components of the wheel and axle. A rim has two components. These are rim, spoke and hub.

Rim is outer edge of a wheel, holding tire, and spoke radiating from hub to connect rim, whereas hub is
the center of the wheel, typically house a bearing and also called rim- rider

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Figure 2.5.4 wheel with tire

Some additional system that I have seen are steering system, suspension system, brake system

1. Steering system is a mechanism of controlling vehicle direction to allows different steering angles of
the steered wheels during cornering. Amplify the torque generated manually by and adequate amount.

Figure 2.5.5 steering system

2. Suspension system An Automotive Suspension is the system of parts that give a vehicle the
ability to maneuver and it maximize the road holding, provides steering stability with good
handling and ensures the comfort of the passengers.

Among different types of suspension, we have seen leaf spring and coil spring suspension

a) coil spring b) leaf spring

Figure 2.5.6 suspension

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3. Brake system a brake is mechanical device that inhibits motion by absorbing energy from a moving
system. It is used for slowing or stopping a moving vehicle, wheel, axle, or to prevent its motion. Most
often accomplished by means of friction.

Most brakes commonly use friction between two surfaces pressed together to convert the kinetic
energy of the moving object into heat, though other methods of energy conversation may be employed.
For example, regenerative braking converts much of the energy to electrical energy which may be stored
for later use. Other methods convert kinetic energy in to potential energy in such stored forms as
pressurized air or pressurized oil. Eddy current brakes use magnetic fields to convert kinetic energy in to
electric current in the brake disk, fin, or, rail, which is converted in to heat.

Friction brake in automotive is store braking heat in the drum brake or disc brake while braking then
conduct it to the air gradually. When traveling downhill some vehicles can use their engine brake
exhaust brake.

A b

C ) d)

Figure 2.5.7 disk brake, drum brake (hydraulic and air), engine brake respectively

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 BACKGROUND OF ENTERPRISE AND DESIGN OF PROJECT

Figure 2.5.8 brake power flow from pedal to wheel

From above figure when a driver apply a force on pedal, this force multiply its power in master cylinder
and pressurized oil or air flow in to wheel.

2.3 How Does the Work Flow in the Section Looks like
A maintenance shop gives a service for all machineries and vehicles that used for facilitate road and
bridge design, construction and renew. It is core part of a company to facilitate its task. So we are
attending our internship period in this maintenance shop. Work flow in maintenance shop is as shown
below diagram 2

AWWCE maintenance work shop

Electric
Engine shop
shop

Machine and
Mechanical raw material
shop shop

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2.4 Work Task We Have Been Executing

As any mechanic in the shop, we execute any maintenance work in the shop with respecting rule and
regulation of maintenance shop like dressed a proper cloth and shoe. Mechanical maintenance is fitted
with our study and we seriously spent most of our internship time in this maintenance.

Immediately after we enter in to the shop, we started critically looking at every work and ask question
about what solution come up with for the required problem. In the first two couple of weeks, we adopt
how mechanics and electricians perform their activities and what kind of tools they are using for each
maintenance parts.

Next, we started working with some mechanics in helping them. We simply disassemble and tight some
screw, bolt and nut and do some simple tasks. At the middle of our internship period, we started taking
order from those experienced mechanics and execute those tasks based on the orders. Finally, even if we
were not fully got the experience, but our confidence and morale were grown high in executing any
maintenance and repairing tasks in the shop.

2.5 Procedures We Have Been Using for Performing Tasks

As training student, we have been using execution procedure for maintaining any vehicle and
machinery.These vehicle and machinery maintaining procedures are:

1) Inspection and identification of the problem

2) Disassemble the part of the vehicle/machine which is going to be maintained.
3) Maintain disassemble part (including lubrications, air cleaning and tightening).
4) Wiping or clean treated spare parts.
5) Assemble apart which get maintenance.
6) Checkup operation of assembled part
By following these procedures, we practice maintenance of machinery’s and now we can fix any
problems related to it.

2.6 How Good We Have Been in Performing the Task

We have always committed to our work and present to work place within a given entrance time, and
dressed our cloths and safety shoes. Then we began our practice with in great moral and initiation
Because of the first chapter for our practical work. So, this is why we had very passionate to do every
kind of work, related to theoretical knowledge with practical and develop about practical application.

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After some time goes, we can identify problems found in shop and we try to fix them by asking senior
mechanic and by relate theoretical knowledge. This condition initiates us to asking mechanics and
electricians any question which confuses us by considering their field. Due to asking again and again
correspondingly and by obeying them we can improve our smooth relationship with workers that were
in the beginning.

2.7 Challenges We Have Been Faced During Performing the Task

All human beings tried to survive this world through go with good things and fight with wrong things to
pass challenges. With the same manner when we were doing our task we have been faced some
challenges in company. Some of challenges we have been faced during internship period are:

 There was unwillingness of employers to show and tell about the component and its
functions during maintenance of any vehicle and machine.
 Shortage of tools and accessory parts of machineries for maintenance and do project
prototype.
 Not safe working environment (sunny, dirty, and formless)
 No distribution of safety cloths and shoes.
 There was a language problem which means the workers most of time use italic
language.

2.8 Measures We Have Taken to Overcome the Challenge

Measurements we take for challenges during internship period are listed as shown below;

 We had tried to make good relationship with employers by obeying and helping for all
mechanics or employers.
 Use available tools and accessory parts to do prototype.
 Bought safety cloth and shoes available in local market.
 We tried to arranging those formless work areas using kaizen principles.
 WE tried to cleaning the working place by telling to the company manager in order to
make clean with in a proper time.
 We tried to communicate and to know the italic name of the material by asking the
workers (htt).

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CHAPTER THREE
Over All Benefit We Gain In the Internship Program
3.1 In Terms of Upgrading Our Practical Skills
There is a big difference between what we taught in class room and what we find through working.
Knowing this the faculty has provided internship program to students to narrow the gap. This is a great
way to put in practice the theoretical knowledge acquired through university in which there is no enough
machineries and laboratory. For us, an internship is also an important step towards a solid career in the
future.
During internship we had tried to perform our task or duty actively with a sense of responsibility,
accountability and smart worker. Our passion and commitment to work in the garage helped us to feel as
a real mechanic and improve our practical knowledge incredibly. In Amhara Water Works Construction
Enterpriser garage we have been observing, understanding and analyzing the application, operation and
maintenance of different machine parts.
We gained much more multidimensional practical skills like;
 How to maintain different machine parts.
 How to assemble and disassemble different mechanical systems
 How to organize work flow.
 How to identify the problem of certain machine.
 How to solve the problem in recommended ways.
 How to operate a machine safely.
 How to service different machines and machine parts.
In addition, these we also acquired the following benefits;

 How cooperation is very important,

 We develop sense of owner ship; we feel that every property is ours and we are responsible for
every property.
 In general, it made us responsible and accountable citizen.

3.2 What We Gained in Terms of Upgrading our Theoretical Knowledge

The internship program allowed us to apply theoretical knowledge learnt throughout our university
education where there is no enough machineries and laboratory in practical environment. It is a link

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between theoretical knowledge and concepts learned in the classroom setting, and real time industry
applications.
From this internship we
 Reinforced our technical competencies,
 Improved our analytical skills,
 Are able to experience firsthand the constant need for adaptability and creativity required in
today’s world.
Because we were in the company which is relatively developed in technology and it has lots of
experienced personnel in each maintenance section, we have had a good opportunity to improve our
theoretical knowledge in addition to have good practical experience. The practical skills we got makes
us to realize, understand and grasp more theoretical knowledge and helps us to have good skills in terms
of applying theoretical knowledge in to practical and vice versa. This is due to visible and practically
done activities are unforgettable in nature.

3.3 What We Gained in Terms of Improving Industrial Problem-Solving Capacity

In Amhara Water Works Construction Enterpriser garage we face several problems such as shortage of
material or faller of machine in the production time. Such types of problems are mostly occurred in the
company but all problems are their Owen solution not all solution are riling solution we are consider the
cost and efficiency of that solution according to this problem are solved in the company this all are help
us improve our industrial problem-solving capacity.

3.4 What We Gain in Terms of Improving Our Team Playing Skills

Nowadays it is almost impossible to avoid being a member of team in work place. Because of the
acceptability, reasonability, speed and accuracy of activities find to be always better than those done
individually. Teamwork has a dramatic effect on organizational performance. An effective team can
help an organization to achieve incredible results. Team works need strong team players to perform
well. Teams need people who speak up and express their thoughts and ideas clearly, directly, honestly,
and with respect for others and for the work of the team. That's what it means to communicate
constructively. Such a team member does not shy away from making a point but makes it in the best
way possible in a positive, confident, integrity and respectful manner.
Since we were working in group, we acquired almost all the above advantages offered by team work.
So, it's important to know our team working strengths and weakness for our personal and career
development. Also, we have seen that the one who have better idea was more acceptable than any other

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whatever his or her position in the company. From this we have understand that to be acceptable in any type
of task it is better to have convincing ideas. So, we got better experience in terms of team playing skills.

3.5 What We Gain In Terms of Improving Our Leadership Skill

In this internship program, we think partly avoid the bad image we had for the leaders. We have brought
in a society who thinks the leadership as stand for power and dominance over the other. Therefore, we
have not accustomed to thinking of leaders as servants. We tend to emphasis on their position, payment,
and other rewards of privileges rather than their responsibility. By now, leadership to us, as applied to
someone to whom other people are entrusted, is an art of inspiring others to give of their best and
courage to use this art. In short it is a mechanism of influencing others to accomplish a certain task.

During the internship with respect to leadership skills we have learned and convicted to have the
following attributes to be successful leader:

 General intelligence, to make sense of the complexity and difficulty of the task.
 Technical or professional knowledge and competence in their particular fields is often the
bedrock of respect for leaders.
 Personality - leaders should be energetic and committed, maintain contact with their people, and
understand their strengths and weaknesses.
 The ability to inspire, although this quality may be rarer than some of the others and is perhaps
the most difficult to develop.

3.6 What We Gain in Terms of Understanding about Work Ethics Related Issues
In the company we have that work ethics is one of the great criteria for any worker to be stayed and
upgraded on his/her job. For example, some of the guiding ethics of the defense military in the company
includes;
 Priority for the country and its nation
 Always have good personality
 Absolute cast of minds for democracy
 Achieving great success in any responsibility
Working with those workers of the company having these types of work ethics make us to develop the
following moral imperatives in addition to those work ethics mentioned above.

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 Contribute to society and human well-being.

 Avoid harm to others.
 Be honest and trustworthy.
 Be fair and take action not to discriminate.
 Respect property rights (Honor copyrights and patents; give proper credit; not steal, damage, or
copy without permission).
 Respect the privacy of others.
 Honor confidentiality.

3.7 In Terms Of Entrepreneurship Skills

It is clear that all graduates cannot be employed in government and nongovernmental company
(organization). Hence it is very important to be a job creator to reduce unemployment.
Internship plays a great role for improving our entrepreneurship skills in multidirectional ways. Among
these ways some of that we have gained benefits includes: -
 Increases our attitude to be creative and innovative through practical knowledge
 How organize and control resources to ensure the profit for our business
 The way how to manage and own our business
 How to identify new products (services) opportunities
 Allows too willing to take calculated risks is risk eliminates
 Desire for immediate feed back
 Be skilled at organizing are professional
 To be desire for responsibility.

3.8 Interpersonal Communication Skills

In general, this internship helps us much to improve our interpersonal communication skill in terms of:
 How to ask a question in a polite way and answer politely
 How to communicate with our managers and what will expect from us as manager if we have a
chance to be
 How to give comments keeping our workers moral good if they fail something and appreciate
their well-done tasks
 How to develop a friendly relationship regardless of our age, sex, work stage etc.

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 How to make others to understand complex concepts in a simple way simply by observing their
environment
 How to solve problems with negotiation
 How to understand written and spoken information and produce our technical report

3.9 Conclusion and Recommendation

3.9.1 Conclusions
From this internship program we got a great experiences and benefits, because we got more practical
skill, theoretical knowledge, work experience and how the combined effect of these influences the work
efficiency of one person. Above all by having this intern ship work we fill confidence, and develop a
sense of “we can do”. We also got that any work without work ethics is nothing and work ethics is the
key element for any types of work tasks.
Generally, our staying in Amhara Water Works Construction Enterpriser garage during internship
program helped us to improve all our personalities just like interpersonal communication skills and team
playing skills.
To sum up we can conclude that this internship program helped us to improve and develop our:-
 Practical and theoretical knowledge
 Interpersonal communication skills
 Team playing ability and skills
 Leadership ability and skills and
 Work ethics related issues, etc.…

3.9.2 Recommendation
Based on what we have seen and gain during our intern ship program we have drawn the following
recommendations.
 The company should have established a project design, development and expansion board that
able to modify activities and create new ideas and strategies to improve customer satisfaction
based on current needs.
 The Company and the institute should follow up and support because they have fresh mind and
high motivation that makes them to do more. This makes them to contribute a lot to not only the
company and the country but also to the world.

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 The intern should concern on those problem facing areas and solve that problem which benefits
in the intern, the company and our nation as a whole.
 The University should arrange some practical visit in some courses before and after the
internship program. Because it helps the student understand what they are learnt in laboratory
and lecture classes easily.
 The university should select best companies that can give best experience to the students
according to their field of study because many of the students cannot see products from
designing to manufacturing most of them can able to see only maintenance this reduce multi-
tasking of the students.
 The company should give enough salary to the workers to keep them in the company.
 The company should be clean the working area by employing its own workers.
 If an award is available for those students who have better project it will motivate the next
generation and can achieve what our country plan to reach in science and technology.
 More and compact interconnection should be formed between the institute and the hosting
companies not only during intern ship period but also at any time.

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CHAPTER FOUR
DESIGN OF THE PROJECT (KING PIN PRESS)
Abstract
Kingpin is a spear part of a vehicle which helps to connect beam axle and stub axle of the
front leg of the vehicle in order to move the wheel with in different angle, and also the
main pivot in the steering mechanism of car or the vehicle and Press is pressure exerting
machine tool. The statements of the problem that lead to study are Waste of time,
Material damage and Waste of energy during the removing of kingpin for maintenance.
The general objective of the study is to design kingpin press machine and specific to
design; working plate, cover plate and screw thread, and to select nut, hydraulic jack.
Methodology design
(Work plate screw thread, and cover plate) and to select (hydraulic jack and nut).design
analysis (stress analysis, bending moment, cost analysis and deflection).
To conclude the project, it is good and can be manufacture as the result of our analytical
value safeties of each part. Recommended
Key words (king pin press machine, methodology, stress analysis, cost analysis, 2D
AutoCAD part and assemble drawing).

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Introduction
4.1 Background of the Project
Kingpin press is a combination of two words which means kingpin and press. Kingpin is a spear part of
a vehicle which helps to connect beam axle and stub axle of the front leg of the vehicle in order to move
the wheel with in different angle, and also the main pivot in the steering mechanism of car or the
vehicle.

Figure 4.0 King pin

Press is pressure exerting machine tool. It is used in vehicle or car for the removing of king pin during
the operation of maintenance or repair time. It represents an important part of manufacturing in vehicle
being used for removing king pin by small amount of force without damaging of the vehicle parts. This
machine having different components such us bolt, nut, working table which is the placed of hydraulic
jack, and cover plate which is designed and 50-ton hydraulic jack and lever which is selected.
Hydraulic deals with the law governing the equilibrium and motion of fluid and their application to the
solution of specific problems in various fields of engineering (Jain R. , 2012). The king pin press is
invaluable equipment in the market or in the shop especially for removing the king pin from the
connection of stub axle and beam axle (Sumaila, M. and Ibhadode, A.O.A., 2011). A king pin press is a
device using a hydraulic jack to generate a compressive force. It uses the hydraulic equivalent of a
mechanical lever, and was also known as a Bramah press after the inventor, Joseph Bramah of England
(Parker, 2013). He invented and was issued a patent on this press in 1795. As Bramah (who is also
known for his development of the flush toilet) installed toilets, he studied the existing literature on the
motion of fluids and put this knowledge into the development of the press (Carlisle, R, John Wiley &
Sons, 2004). King pin presses are preferred when the pin required more than one man power in order to
remove (Lange, 1975).

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4.2 Problem Statement

The statements of the problem that lead to study are waste of time, material damage and waste of energy
during the removing of kingpin for maintenance.

4.3 Objective of the Study

4.3.1 General Objective

The general objective of the study is to design kingpin press machine.

4.3.2 Specific Objective

 To design working plate,
 To design cover plate,
 To design screwthread,

4.4 Scope and Limitation of the project

In the company of AWWCE workers will remove king pin for maintenance and reinstall into front
wheel. Due to perform this task they work on their hand manually and the material will damage.
Hence,we can overcome that problem by design and use a product of king pin press to inter and
remove out king pin. To design the project, Knowledge of material behavior is required not only to
avoid failures, but also equally to permit maximum economy of material choice and amount used.
This project will not function at a pressure greeter than 50ton.because we design by a material which is
functional at the presser. When a mechanics use this project for more than 50ton, it will be break down
due to material safety rule.
Problem justification
 Easy to replace the tire
 Avoid material injury
 Minimize time during the working period

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CHAPTR FIVE

Literature Review
To design a king pin press which can force 50ton, we should have knowledge about this king pin press
characteristics and the design mechanism of that king pin press. hence to attain this knowledge we read
many literatures which are written by different scholars about the king pin press. Those literatures are
listed below.

1) Prof .S .V Tawade to write about the reduction of the deflection of 50 Ton mild steel plate during
the pressing time of the plate in order to get the desired shape .
2) Dr. R. J. Patil to write the deflection reduction of the plate of mild steel for the load of 50 ton.
3) Prof. S.A. Chaudhart to write the reduction of mild steel plate for the Appling of 50 Ton
hydraulic press machine.

Asst. Professor, Dept. of Mechanical Engineering, Navsahyadri Engineering Collage, Pune India. To
write the deflection reduction in C- Structure of 50 Ton hydraulic press Machine Used to Press Stainless
Steel Plates to Get Desired Shape and Dimensions (Placeholder2).

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CHAPTR SIX
Detail Design Methodology of Project work
6.1 Methodology
In this chapter we discuss about the task of this project, the raw material which is used to design this
project and the necessary presiders for our design project. This project is discussing about the design of
king pin press.
We are done a practice in Amara water work construction enterprise in ordered to apply the
theoretical learning and do a project to solve a problem in the company. This project is submitted by
softcopy and send to the advisor by email. So we design this type of king pin press appropriately. To
perform the task, we need use different things as a raw material for this project. As we mentioned above
this project will collect or submitted to the adviser by email and we should done this project by the
computer on Microsoft word. Hence the computer as well as the computer program is one of the raw
materials to design effectively. Because without the computer and its program, we cannot do these
project as we prefer.
The design project has presser effect, so we use very strong material selected and appropriate
shapes. To design the project, we need use different metals which have different grades. To select this
material type we use standard tables and codes which is acceptable to the world designer to design
standard manufacturing task. Mostly ASSME code is the beset one and many designers use this code
and it used as a guide line for design any type of mechanical products. The dimension of mechanical
products is found out either by calculation or by using standard tables or codes. So we also use ASME
Code Section VIII div 1 to decrease our complex calculation and get a dimension easily.
To do this project we will be calculate many parameters like thickness of plate, applied load and
other dimensions. Because our task is designing a king pin press as a project with a net accurate stable
design. Without a good dimension and wrong material, the designed project has no value and it will
damage and fail out. So, we design all parameters effectively. To calculate this dimension, we use a
matlab formula and solve or simplified the equation.
General guideline or procedure which is used to solve problem to design our project of vertical
pressure vessel are the following: -

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Problem identification

Material selection

Design required parameter

Design analysis

Result

No
If it is safe

Yes

Cost analysis

Result and discussion

Modeling and assembly

Conclusion and
recommendation

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CHAPTER SEVEN
Detail Design of the Project
7.1 Design Analysis of Some Machine Components

7.1.1 Bending moment and stress analysis of the base plate

 Bending moment of the plate for the applied load of 50 KN

We take the assumption that the project can applied 50ton and to work efficiently.

Simple free body diagram

Figure 7.0 Reaction force finding

First to find the reaction force

FY= 0, RA + RB – F = 0

F = RA + RB

50KN = RA + RB

+ MA = 0, RB * L – F * L  2 = 0,

RBL = FL2

RB = 25 KN

RA + RB – F =0

RA + 25 KN – 50 KN = 0

RA = 25 KN

Therefore to find the maximum bending moment we find moment equation by using section
method.

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Figure 7.1 simple beams like structure base plate

As we know the maximum bending moment occurs at L  2

Therefore we take momentum equation at section 1

Figure 7.2 Bending moment diagram

 Fy = 0, 25 KN – V = 0

V = 25BKN

+ M= 0, M – 25 KN * X

M = 25X KN

Therefore, maximum bending moment is at x = L  2

Mmax = 25 KN * X, Where X = L  2 = 0.5m  2 = 0.25m

Mmax = 25 KN * 0.25 m = 6.25 KN = 6250 Nm

 Stress analysis of the plate

 Normal stress for the beam in bending stress

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Assumption:-
 There is no shear stress on the plate
 There is no torque on the plate
 There is only axial load on the plate

Figure 7.3 base plate

x = Mmax * C  I , Where I is second momentum of inertia

x = maximum bending stress

C= Ymax  2, Ymax = is maximum deflection

Ymax = WL3  48EI Where E = 210 * 109 pa,

W = Load = 50KN

L = Length = 50 cm

Ymax = 50KN * (0.5m)3  48 * 210 * 109 pa * 41.67 * 10-9m4

= 0.0018631m

C = Ymax  2 = 0.0018631m  2 = 0.00093155m =0.09 mm

I = b*h3  12 = 0.5m * (0.01)3  12 = 41.67 * 10-9 m4

x = Mmax * C  I = 6250Nm * 0.00093155m  41.67 * 10-9 m4

x = 139.72 Map

2D base plate

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 BACKGROUND OF ENTERPRISE AND DESIGN OF PROJECT

Figure 7.4 2d base plate drawing

7.1.2 Design Analysis of Rectangular Cover Plate

 Stress concentration and maximum stress induced

To analyze the cover plat, we limit the stress concentration on the cover plat and calculate the amount
ofstress induced on it.

Figure7.5 analysis of cover plate

Given; b= 50cm, t = 1cm, dh= 5cm, w = 25KN = 2500N

Nominal stress = w𝑒igℎ𝑡 , Area= (b – d) t = (50cm – 5 cm)1cm = 45cm2

𝐴𝑟𝑒𝑎

nominal = 25*103N / 45*10-4 m2 = 5.56Mpa

Ratio of diameter of hole to width of plate

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 BACKGROUND OF ENTERPRISE AND DESIGN OF PROJECT

d / b = 5/50 = 0.1

From khurmi table 6.1,

Table 2 Standard of concentration value

d/b 0.1

Kt 2.69

Kt = 2.69

Maximum stress, maximum= Kt*nominal = 2.69*5.56Mpa = 14.9564Mpa

Factor of safety = maximum stress / working or design stress

= maximum / design = 14.9564Mpa / 5.56 Mpa = 2.69

Figure7.6 2d Cover plate drawing

7.2 Material Selection

The selection of proper material for engineering purpose is one of the most difficult problems for the
designer. The best material is one which serves the desired objective at minimum cost.
We considered the following condition to select a desired material. [6]
 Availability of the material
 Suitability of the material for the working condition in service
 The cost of the material

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 BACKGROUND OF ENTERPRISE AND DESIGN OF PROJECT

Table 3 material properties

Material Density Yield Tensile Bending Ultimate Shear Compressive Young’s Crushing
strength stress stress stress stress stress modules stress
Kg/mm^3
Mpa Mpa Mpa Mpa Mpa Mpa Mpa Mpa
Mild
Steel 7850 250 150 165 450 140 300 210000 330
Hence we select mild stile to design king pin press by considering the above pre condition which work
for 50ton without damming.
50 ton hydraulic jack this is selected to do protect as a sample.

Figure 7.7 50-ton hydraulic jacks

Factor of safety adopted for mild steel is 1.15

Therefore, Maximum allowable load is ultimate tensile strength divided by factor of

safety.Which is denoted by: - all = UTs  n = 450 Map  1.15 = 391.3 Map

From our calculation the design is safe because maximum bending stress is less than bending stress of
mild steel, which means x < b material = 139.72 Map < 165 Map .

Allowable stress is always less than the ultimate tensile strength, which means all < UTs, 391.3 Map <
450 Map. Therefore, our design is safe.

7.3 Selection of Bolt and Nut

A screw thread is formed by cutting a continuous helical grove on a cylindrical surface.

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 BACKGROUND OF ENTERPRISE AND DESIGN OF PROJECT

A screwed joint is mainly composed of two elements i.e., a bolt and nut. The screwed joints are widely
used where the machine parts are required to be readily connected or disconnected without damage to
the machine or the fastening.

This may be for the purpose of holding or adjustment in assembly or service inspection, repair or
replacement or it may be for the manufacturing or assembly reasons.[6]

Figure 7.8 design of bolt and nut

Advantages of screwed joints

1. Screwed joints are highly reliable in operation

2. Screwed joints are convenient to assemble and disassemble
3. A wide range of screwed joints may be adapted to various operating conditions.
4. Screwed are relatively cheap to produce due to standardization and highly efficient
manufacturing process.
Forms of screw threads
Metric thread It is an Indian standard thread k is similar to B.S.W threads .it has an included
angle is 600 instead of 550. The basic profile of the thread is below on fig 5.6 and the design
profile of the nut and bolt is shown on fig 5.7.

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 BACKGROUND OF ENTERPRISE AND DESIGN OF PROJECT

Figure 7.9 basic profile of thread

Figure 7.10 design profile of the nut and bolt. [6]

P= pitch
H =0.86603* 2.5 = 2.165

D1 = d-1.0825*2.5 = 20-2.70625=17.29375

H1 =5 *H = 0.625*2.165 = 1.353125
8

D2 = d2 = d – 0.6495*p =20-0.6495*2.5 = 18.37625

d3=d-1.2268*p=20-1.2268*2.5=16.933

h3 = 17 * H= 0.70833*2.165= 1.5335
24

r = 𝐻 = 2.165 = 0.3608
6 6

7.3.1 Screw Threads

Assumption: -

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 BACKGROUND OF ENTERPRISE AND DESIGN OF PROJECT

 There is no shear stress

 There is no torque
 There is tension load due to applied load on base plate
L = 85 cm or 850mm

D= 20mm
LT = 2D + 25, L> 200 mm, LT = 2*20mm+25mm=65mm=6.5cm

2D = 2* 20mm = 40mm=4cm
2D + 4 = 2*20mm+4mm= 44mm=4.4cm
0.75D= 0.75*20mm= 15mm=1.5cm
0.15D= 0.15*20mm=3mm=0.3cm
Standard dimension of screw thread

The design dimension 0f 1.5.0 screw thread for screw bolts and nuts of curse and time series are shown
in below table.

Table 2 Design dimensions of screw threads, bolts and nuts

According to IS: 4218 (Part III) 1976 (Reaffirmed 1996) (Refer Fig. 11.1)

Designation Pitch Major or Effective Minor or core Depth of Stress area

nominal or pitch diameter (dc)mm thread mm2
Mm
diameter diameter (bolt)mm
nut and nut and
bolt(dm) bolt
(dp)mm Bolt Nut
Mm

Coarse 2.5 20 18.376 16.933 17.294 1.534 192

series

Then LT = 2D + 25 for L > 200mm

LT = 2*20mm + 25mm = 65mm

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 BACKGROUND OF ENTERPRISE AND DESIGN OF PROJECT

Therefore, length of threaded is 65mm

Length of unthreaded portion in grip; Ld. = L – LT = 850mm – 65mm = 785 mm

 Stress analysis of screw thread

1. Internal stress due to screwing up force
2. Stress due to external force
3. Stress due to combination of stress at 1 and 2 (RS Khurmi,JK Gupta, 2005).
Initial stress due to screwing up force

Tensile stress due to stretching of screw thread

Pi = 2840Dn

Pi = initial tension in a screw and

d = nominal diameter of bolt in mm

Pi = 2840 * 20mmN = 56800N

To find permissible stress

P = t * At, where At = cross sectional area at bottom of the thread (I . e stress area) . t =
permissible stress.

56800N =  *  (𝑑𝑝+𝑑𝑐)2 , where 𝑑𝑝 = pitch diameter

t
4 2

𝑑𝑐 = core or miner diameter

56800N =  *  (18.376+16.933)2
t
4 2

t = 231.84 Mpa

Compression or crushing stress on threads

1 𝑝
c = , where d = major diameter
4 (𝑑2−𝑑𝑐2)𝑛

dc= minor diameter

n = No of thread in arrangement

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 BACKGROUND OF ENTERPRISE AND DESIGN OF PROJECT

Pitch = 2.5mm, LT = 65mm , n = 65 / 2.5 = 26

c = 1 56800𝑁 = 6.142 Mpa

4 ((0.02)2)−(0.016933)2)26

Stress due to external force

Tensile stress

We know that external load applied

P = (dc) 2 t * n, where dc = root or core diameter of thread

4

n = number of bolts

p = 50KN

4 50𝐾𝑁
t = * (𝑑𝑐)2*𝑛


4 50*1000𝑁
t = * (0.016933)2*2 = 111.1Mpa


Stress due to combined force

The resultant axial load on a bolt depends up on the following factors

1. The initial tension due to tightening of the bolt

2. The external load
P = p1 + 𝑎 * p2 = p1 + k* p2 (substituting 𝑎
= k)
𝑎+1 𝑎+1

p1 = initial tension due to tightening of the bolt

p2 = external load on the bolt and

a = Ratio of elasticity of connected parts to the elasticity of bolt

p = 56800N + (0.1)50000N , Where k = 𝑎

= 0.1
𝑎+1

P = 61800N

4 618*1000𝑁
t = * = 274.5683Mpa
 (0.016933)2*2

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 BACKGROUND OF ENTERPRISE AND DESIGN OF PROJECT
UTs 450 Mpa
n= = = 1.6, Therefore our design is safe
t 274.5683Mpa

 Selection of nut
We select mild steel material to design nut the same as bolt flange joint because of easily workable, very
hard, yet malleable, good for construction, easy to shape and machine and very flexible and can be
harden.
Table 4.10 material selection for the nut design
by reading from the above standard table we get:
 Minor or core diameter of nut (dc) = 17.294mm
 Effective or pitch diameter of nut (dp) = 18.376mm
 Nominal or major diameter of nut and bolt (d=D) = 20.000mm. [6]

Table5 nut standard dimension

M20, B=30mm, H = 16 mm

Figure 7.11 2d nut drawing

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 BACKGROUND OF ENTERPRISE AND DESIGN OF PROJECT

7.4 Cost Analysis of Materials and Labor

7.4.1 Cost Analysis of Each Component

 Cost of plate
Material types mild steel, Density = 7850 kg / m3, cost per kg = 0.7$
Rectangular working plate, length = 500mm, width = 200mm, thickness = 10mm
Volume = L*W*T = 1*10-3m3
Density = mass/volume
Mass= Density*Volume = 7850 kg / m3 *1*10-3m3=7.85 kg
Cost = m*cost per kg = 7.85kg*0.7$= 5.5$
Cover plate the same cost with working plate
Therefore, cost of working and cover plate= 2*5.5$=11$

 Cost of screw
VL=r2h=3.14*(10mm)2*850mm=266900mm3
Volume of the bolt = VL = 266900 mm3
Mass of bolt (m) = *v = 7850 kg / m3 * 266900*10-9 m3 = 2.095165kg
Cost = m*cost per kg = 2.095165kg *0.7$/kg
Cost = 1.47$
Cost For two screws=1.047$ *2 = 2.094$

 Cost of nut
V = r2h = 3.14*(15mm) 2*16mm = 11304*10-9m3
m= *v= 7850 kg / m3 * 11304*10-9m3= 0.088736kg
Cost= m*cost / kg = 0.088736kg*0.7$/kg= 0.062$
Cost for four nuts= 4*0.062$=0.25$
Therefore the total cost of the king pin press = (11$+2.094$+0.25$)*52birr =693.9birr and 2000birr for
50ton hydraulic jack

Total cost =2693.9birr

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 BACKGROUND OF ENTERPRISE AND DESIGN OF PROJECT

CHAPTER EIGHT
RESULT AND DISCUSION
8.1 Result
Table 6 Stress analysis result for working plate

Reaction Maximum Maximum Momentum Maximum Factor Maximum

Force bending deflection of inertia(I) Bending of Allowable
moment (Ymax) stress safety Load
(Mmax) (X) (n) (all)
RA=RB= 6250Nm 0.0018631m 41.67*10-9 139.72Mpa 1.15 391.3Mpa
25KN C=Ymax / 2= m4
0.09mm

Table 7 Stress analysis result for cover plate

Nominal d/b Kt Maximum Factor of

stress stress(MAX) safety(n)
5.56Mpa 0.1 2.69 14.956Mpa 2.69

Table 8 Stress analysis of bolt and nut result

Length of Initial Permissible Compression Stress Stress due Factor

tension stress Stress due to to of
in bolt external combined safety
Load Force (n)
Un Threa 56800 231.84Mpa 6.142Mpa 111.1 274.5683 1.6
threa d N Mpa Mpa
ded

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 BACKGROUND OF ENTERPRISE AND DESIGN OF PROJECT

Table 9 Cost analysis of result

Material Part Cost in $

Base plate 1 5.5
Bolt 2 0.125
Nut 2 0.125
Cover plate 1 5.5
Hydraulic jack 1 38.46
Total Cost = 51.9$

8.1.1 Assemble Drawing

The final assembly drawing which is drown with its dimension will see as below

Figure 8.1 Assemble Drawing

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 BACKGROUND OF ENTERPRISE AND DESIGN OF PROJECT

8.2 Discussion
Under this project we used some components these are base plate, cover plate ,
screw ,and nut for 50KN force of hydraulic bottled jack , and All things are good like
stress, and deflection , so design also safe or good. But according to screw thread to get
6.5cm threaded length from M20 calculation however this threaded length not allowed
the cover plate to connect with axle, so by adding 9cm we get 15.5cm, so when the
manufacturer starts to make thread for bolt must be to add that amount of that vale. If we
use other dimensional diameter we get very large threaded length, so we have only that
preferable method mean adding that value.

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 BACKGROUND OF ENTERPRISE AND DESIGN OF PROJECT

CHAPTER NINE
CONCLUSION AND RECOMENDATION
9.1 Conclusion
In my internship program at Amhara Water Works Construction Enterpriser. We improve our practical
skills, work ethics, patriotism, meeting and networking peoples so that helps us opportunities in the
future.

One main thing that we have learned through this internship is how things were made, time
management skill as well as self -motivation when we first started, we did not think that we were going
to be able to make our self-work for a full day it seems impossible.

I have been working for consecutive three months internship period and we enjoyed this line of work.
Since, I have upgraded my knowledge about our field mechanical engineering. Intern had made us
profitable since we have got enough knowledge about our field with the necessary benefits.

9.2 Recommendation
Anyone who wants to design this project again we recommended the following things

 The Company should full fill those raw materials that an intern needs to do his/her project
 It can be made by welding instead of fastener

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(n.d.). Retrieved from https://westvalley.mastermuffler.net
(n.d.).
(n.d.). background AWWCE.
Carlisle, R, John Wiley & Sons. (2004). hydrolic press. Scientific American Inventions and Discoveries.
Jain, R. (2012). Production Technology. 17th Edition, , i, 806-824. . New Delh: Khanna Publishers.
Jain, R. (2012). Hydrolic press. In Production Technology. 17th Edition (pp. 806-824). New Delhi:
Khanna .
Lange, K. (1975). Handbook of Metal Forming . New York: McGraw-Hill.
Parker, D. (2013). Aircraft Manufacturing in the Los Angeles Area in World War II. In Building Victory
(pp. 20-87). Cypress, Canada.
RS Khurmi,JK Gupta. (2005). Machine design,14ed.
Sumaila, M. and Ibhadode, A.O.A. (2011). Design and Manufacture of a 30-Ton Hydraulic Press.
Assumption University Journal of Technology, 196-200.

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