ARBA MINCH UNIVERSITY

ARBA MINCH INSTITUTE OF TECHNOLOGY

FACULTY
OF

A REPORT ON INTERNSHIP AT

ARBA MINCH MEKANE YESUS WHOLISTIC EDUCATION

AND TRAINING CENTER

BY:

HABTAMU KUCHARO

ID No RAMIT/909/11

November, 2022
 Acknowledgment

First of all, I would like to thank the almighty GOD for giving me the strength to complete my
internship. And Secondly, I have a great thanks to my beloved mother, father and brothers for
all they have done for me. Again I express my special thanks to our advisor……., My
department head Mr. Atikilt and internship coordinator Mr. Amanuel for giving me their
time to cooperate with me in getting a chance to do my internship in AMWETC, Mr.
Chunche who accept my internship request and give me the opportunity and also I am
thankful to all AMWETC employee for helping me to know so many new things by showing,
responding to my question and giving necessary information that I need about the company.
Finally, I would like to thank to my friends who helped me a lot, in finishing this internship
and also in writing this internship report.
 Abstract

Our crisis in university stay, i.e. being confused in practical knowledge is a common
problem observed in us. Internship is one of the best options to overcome this problem.
Internship uses us to gain knowledge practically and it helps us in our job application for the
future.

In this paper, the main function of internship is to give a chance to apply the theoretical
knowledge acquired in class in real work space. The main purpose and significant of this paper
is to acquaint what I have earned from the internship and what we have done in our internship
stay. Our internship in AMWETC includes three types of shops; - Service shop, Engine shop
and Body and Paint shop. All included in our internship should be versatile with application
by maintaining its aesthetics and ergonomics. This paper mainly focused on internship report
and project that I have done in AMWETC. The project that I have done during my internship
is the design and analysis of all wheel nut remover for automotive.

KEY WORDS: internship, engine, service, automotive

 Table of content

Contents
Acknowledgment.........................................................................................................................ii
Abstract......................................................................................................................................iii
Table of content..........................................................................................................................iv
List of Figure............................................................................................................................viii
List of Table................................................................................................................................ix
CHAPTER 1................................................................................................................................1
1 INTRODUCTION....................................................................................................................1
1.1 Company Background and Overviews..............................................................................1
1.1.1 Main function..............................................................................................................2
1.1.2 Specific responsibilities and duties.............................................................................3
1.1.3 Vision........................................................................................................................4
1.1.4 Mission.......................................................................................................................4
1.2 Organizational structure.....................................................................................................5
1.3 Staff profile........................................................................................................................6
CHAPTER 2................................................................................................................................8
2. WORK, RESPONSIBILITIES AND ASSIGNMENTS.........................................................8
2.1. Task one: - Service workshop task...................................................................................8
2.1.1 Type- A service...........................................................................................................9
2.1.2 Type- B service...........................................................................................................9
2.1.3 Type- C service.........................................................................................................10
2.1.4 Type- D service.........................................................................................................11
2.2. Task two: - Engine shop task..........................................................................................16
2.2.1 Major parts of engine................................................................................................17
2.2.2 Assembly of engine and its parts..............................................................................19
2.3 Task three, Body and Paint Shop.....................................................................................21
2.4 Task Four: - Electrical system tasks................................................................................22
2.4.1. Starter motor and its inspection...............................................................................23
CHAPTER 3..............................................................................................................................25
3. TECHNICAL ASPECT OF THE INTERNSHIP..................................................................25
3.1 Objective of industrial internship program......................................................................25
3.2 Methods and Procedures..................................................................................................25
3.3. Technical tasks/products.................................................................................................27
3.4 Knowledge and Acquaintances........................................................................................28
3.4.1 Technical Skills Gained............................................................................................28
3.4.2 Management Skills Gained.......................................................................................29
3.4.3. Acquaintances Acquired..........................................................................................29
3.4.4. Theoretical Knowledge............................................................................................30
3.5. Challenges and problems faced and solutions attempted...................................................30
3.5.1. Challenges....................................................................................................................30
3.6. Contribution........................................................................................................................30
CHAPTER 4..............................................................................................................................32
4. Design and Development of All Wheel Nut Remover for Automotive................................32
4.1 Abstract............................................................................................................................32
4.2 Introduction......................................................................................................................32
4.3 Problem statement...........................................................................................................33
4.4 Objectives of the project..................................................................................................34
4.4.1 General objectives....................................................................................................34
4.4.2 Specific objectives....................................................................................................34
4.5 Components of the 5 in 1 wheel nut remover..................................................................34
4.5.1 Gear and pinion.........................................................................................................34
4.5.2 Shaft..........................................................................................................................34
4.5.3 Socket.......................................................................................................................34
4.5.4 Plates.........................................................................................................................35
4.5.5 Bearings....................................................................................................................35
4.5.6 Cranked lever............................................................................................................35
4.5.7 Bolt and Nut..............................................................................................................36
4.5.8 Table.........................................................................................................................36
4.6 Literature review..............................................................................................................37
4.7 Methodology....................................................................................................................40
 4.7.1 Parts of Multi Nut Remover machine.......................................................................41
4.7.2 Working principles...................................................................................................41
4.8 Limitation of this project.................................................................................................42
4.9 Product design.................................................................................................................42
4.10 Design parameters.........................................................................................................43
4.10.1 Basic parameters.....................................................................................................43
4.11 Design calculation.........................................................................................................43
4.11.1 Design of gear.........................................................................................................43
4.11.2 Design of shaft for the gear....................................................................................46
4.11.3 Design of shaft for the pinions................................................................................49
4.11.4 Design of key for the gear’s shaft...........................................................................50
4.11.5 Design of key for the pinion shaft..........................................................................51
4.11.6 Design of cranking lever.........................................................................................52
4.11.7 Design of steel plate for gear box...........................................................................56
4.11.8 Design of Bolt and Nut...........................................................................................57
4.11.9 Design of table for gear box...................................................................................58
4.11.10 Lubrication for gears.............................................................................................62
CHAPTER 5..............................................................................................................................63
5. CONCLUSSION AND RECOMMENDATIONS................................................................63
5.1 Conclusion.......................................................................................................................63
5.2 Recommendation.............................................................................................................64
REFERENCES..........................................................................................................................65
APPENDIX I.............................................................................................................................66
APPENDEX II...........................................................................................................................67
APPENDEX III.........................................................................................................................68
APPENDEX IV.........................................................................................................................70
APPENDEX V...........................................................................................................................71
PART DRAWING.................................................................................................................71
ASSEMBLY..........................................................................................................................76
SECTIONED.........................................................................................................................78
EXPLODED..........................................................................................................................79
 List of Figure
Figure 1 Service shop................................................................................................................................7
Figure 2 wrench socket, extension and others.........................................................................................10
Figure 3 Cooling system..........................................................................................................................11
Figure 4 Lubrication system....................................................................................................................11
Figure 5 Transmission system.................................................................................................................12
Figure 6 Differential system....................................................................................................................12
Figure 7 Brake system.............................................................................................................................12
Figure 8 Steering system.........................................................................................................................13
Figure 9 Suspension system....................................................................................................................14
Figure 10 Fuel tank..................................................................................................................................14
Figure 11 Engine shop.............................................................................................................................15
Figure 12 Cylinder head..........................................................................................................................16
Figure 13 Cylinder head and its inspection.............................................................................................16
Figure 14 Cylinder block and its inspection............................................................................................17
Figure 15 Engine.....................................................................................................................................18
Figure 16 Engine parts.............................................................................................................................18
Figure 17 Body and painting...................................................................................................................19
Figure 18 Problem statement...................................................................................................................27
Figure 19 Socket......................................................................................................................................29
Figure 20 Cranked lever..........................................................................................................................30
Figure 21 AutoCAD Table......................................................................................................................31
Figure 22 AutoCAD gear and pinion......................................................................................................36
Figure 23 AutoCAD designed gear and pinion.......................................................................................39
Figure 24 AutoCAD Designed Shaft for gear.........................................................................................42
Figure 25 AutoCAD Designed Shaft for pinions....................................................................................43
Figure 26 AutoCAD Designed key for gear shaft...................................................................................44
Figure 27 AutoCAD Designed key for pinions shaft..............................................................................45
Figure 28 Base plate................................................................................................................................49
 List of tables
Table 1 Types-A service..........................................................................................................................60
Table 2 type-B service.............................................................................................................................62
Table 3 type- C service............................................................................................................................63
Table 4 type- D service............................................................................................................................63
 CHAPTER 1

1. INTRODUCTION
In this chapter we try to discuss about Arba Minch Mekane Yesus Education and Training
Center (AMWETC) institute and their partnership motor and engineering company of Ethiopia
(MOENCO) Arba Minch sub dealer branch company background and vocational accessibility.
And also mission, vision and objective of the company and its organizational structure with
their staff profile. MOENCO Arba Minch sub dealer branch found in Gamo, Zone Arba Minch
city of Southern Nations, Nationalities & People Region of Ethiopia.

1.1 Company Background and Overviews

MOENCO was established in January 1959 in the heart of Addis Ababa around the area
commonly known as Mexico in small garage with a capital of 200, 000 Ethiopian birr. It was
founded by Mr. Y. D. Lappine and with the help of other resourceful people, such as Ato
Menasseh Lemma, the Governor of the National Bank of Ethiopia, and the boss of Imperial
Insurance Company. After nine years later, MOENCO took over the TOYOTA Franchise
business for Ethiopia. When INCHCAPE, a London based international organization became a
major shareholder and injected a considerable amount of capital.

As I mention earlier MOENCO started with the capital of birr 200,000 Ethiopian birr and with
financial input and encouragement of INCHAPE MOENCO now grown in terms of size and in
terms of modernization of its service shops and parts distribution centers and MOENCO
capital and reserve has now reached 36 million birr.

The present Arba Minch Mekane Yesus Technical College was established in 1971 by the
Norwegian Lutheran Mission (NLM) as technical vocational school of the Ethiopian
evangelical Church Of Arba Minch South Ethiopia Synod. Its main objective at the time was
to provide basic skill training for traditional hand crafts such as metal and wood works so as to
improve the livelihood of the people engaged in these activities. In 1982 the school was
upgraded to advanced level and accredited by the Ministry of Education to provide vocational
training to youth in the fields of Auto-Mechanics, General Mechanics and Wood work.
The school passed through numerous challenges including termination of its activities due to
the termination of external support. Since 2006 the school has been re-established and evolved
in to technical college and the economic base being the college own income and some support
from external sources. Since 2006 the activities in the college have shown a dramatic
expansion and the corresponding results in each department were very much impressing. The
college is pioneer in establishing the Drivers Training Institute (DTI) in Arba Minch town in
which considerable numbers of young people have got quality drivers’ training services. The
regular and evening academic training program has created a good technical training
opportunity for needy youth community in Gamo Zone and neighboring woredas and special
woredas from which hundreds of trainees owned their diplomas and certificates towards their
future career and income source development.

It is also very important to note that the college has established a business partnership with
MOENCO through being a sub-dealer for genuine spare parts supply in Arba Minch. The
Auto garage and genuine spare part supply services rendered in the college has saved the time
and money of the government and private sector in Gamo Zone and neighboring areas who
used to drive to Hawassa and Addis Ababa for minor and heavy maintenances of vehicles.

Besides to Technical College, the Seminary and Future Hope Academy have been emerged in
the same compound and flourishing well. The Seminary has upgraded to diploma level
education and Future Hope Academy has been delivering Kindergarten and primary education
programs for the last four years and High School education program was opened.

The assessment study conducted in 2014 has clearly identified the problem and their
underlining causes behind in administering the overall compound in general and that of the
college in particular. One among the possible solution recommended, discussed and agreed up
on is the re integration of the compound management. According, the three education and
training institutions found in the compound (the Technical College, Seminary and Future
Hope Mekane Yesus Academy) will come together under one administration. The name given
for overall administration arrangement is Arba Minch Wholistic Education and Training
Center (AMWETC).
The main function bodies forming the entire organ are the following:

 Technical training college

 Seminary
 Future Hope Mekane Yesus Academy
 Auto Garage Service
 Income Generation Unit
 Administration and finance unit.

There will be three main hierarchies of team management tiers:

 Managed Board
 Senior Management Committee, and
 Program Management Team out of which managing board is the highest
decision-making body in the Wholistic education training center (WETC).

1.1.1 Main function

The main purpose of the management board is to ensure that the education and technical
training services are being delivered as to the set quality standard and the business schemes
established to support the technical training program as to the purposes they are meant for.

Moreover, the board will develop appropriate policies and strategies to enhance the economy
of the WETC, so that the education and training programs are adequately supported by locally
generated resources.

1.1.2 Specific responsibilities and duties

 Issue academic and income generation policies of the WETC and makes decisions in
conformity with policies and principles of the synod/national church and relevant
government laws.
 Assess and proposes the organizational structure and by lows/constitution of the WETC to
be approved be the synod council;
 Approve the staffing plan and payment schemes of the WETC functioning bodies after
studied and proposed by the senior management committee.
 Evaluate and approves the strategic plan and annual activity and financial plans of the
WETC;
 Nominate 3 candidates for WETC principal position and forward it to synod office for
further process according to the by low of the synod and suspends his/her contract and
forward for final decision of synod council;
 Nominate I candidate for each program unit head position ( Technical Training College
Dean, the Seminary Dean and vise and future Hope Academy Principal,) and suspends
their contract and forward final decision/approval of synod’s Executive Board;
 Review the performance evaluation report made by SMC and gives directive for
improvement of services rendered by the different units of the WETC on biannual base
 Thoroughly review/examine the report/recommendation presented by senior management
committee on obsolete machineries and other material and take the final action;
 Review the decision made by the senior management committee if these decisions are
found contradicting to the WETC, church and government lows and policies;
 Can develop its own governing rule/discipline meeting and function;
 Approve travelling allowances such as bed and transport during field trip it different
purposes.
 Approve scholarship allowances such as pocket money, stationary, transport and
accommodation;
 Carry out other activities which have high importance found objectives of the WETC;
 Form a quorum of the board meeting

1.1.3 Vision
In the next 25 years since 2023, to see a University College

 Selected as the first choice in the region and labeled as the center of excellence in both
technical and Academic education through intensive practical teaching and innovation
approach;
 Well recognized in transforming its student ethical behavior;
 Sustainably self-reliant to run its diversity programs

1.1.4 Mission
Produce ethical and competent professions in technical and vocational training and education
through demand driven quality education and training.
 1.2 Organizational structure

EECMY SWS Council

AMH Educ. & T.C.

Board

AMH Educ. &

T.C.S.M.T

Seminary Technical AGSP Admin & FHM Income

(Bible Training Department Finance Academy Generation Unit
school College Unit

Kinderg Hallow
arten Bloc
Finance production
Tech .t .p Drivers
Garage Residence
T.I Primar
Admin, House
y

H/S & Bull

Spare Prep fattening
parts
Wood
work shop

General
Mechanics
shop
 1.3 Staff profile

AMWETC Management Board

Principal

Seminary Technical Vice and FHM Auto Garage &

Dean college Dean Academy Spare Parts
IGU Administration
manager
Coordinator and Finance Unit
H/school
ARV Head
Director
Technical
V/Dean Super Chief
Assist
Librarian Dpt.
Technician Accounta
HTechnicL Registrar ntDpt.
Auto
Technolo TechJ/ S/
Technology Auto Accountant
transfer head Secretary electrician J/
Teachers AccouSecre
E/sch. Director -Body man & painter Purchaser
Registrar

DTI Directors Teachers Cashier

Receptionist technician
Librarian Administrator
Instructors
Secretary - Sales man Gardner Archivis
Secretary t
KG Leader - Data encoder
M/driver Guards
- Counter

Teachers Store man

Janitor
job
sengar
Table 1.1 AMWETC MOENCO staff profile

No Work Position Qualification Number Of

Employers

1 Maintain and repair section Level 3 Automotive 6

2 Management Management degree 1

3 Sale section Level 3 Automotive 2
4 Cashier Accounting degree 1
5 Cleaner Level 3 Automotive 1
6 Security Finished grade 8 2
7 Data encoder 10 + 3 IT 1
8 Reception Level 3 Automotive 1
9 Finance Degree 1
10 Purchaser Accounting degree 1

Total No = 17
 CHAPTER 2

2. WORK, RESPONSIBILITIES AND ASSIGNMENTS

In our internship we worked on how cars are inspected, maintained and repaired in auto
motive garage at Arba Minch MOENCO sub Dealer Company. We try to explain in this
chapter the process is passing through. Generally we were worked deeply on service shop
because a lot of work and tasks were there. And also we worked on some shops like body and
engine shop. Therefore our report on this chapter deals on the process of inspection,
maintenance and repair in all shops.

2.1. Task one: - Service workshop task

Service workshop is one of AMWETC workshop that auto periodic service takes place and we
start our internship program. In AMWETC there are four types of periodic services: Type A,
B, C and type D service with detail inspection and adjustment. Those services are done
depending on the mileage that the car travels and by checking the previous services status on
the job card.

Figure 1 Service shop

In service shop, only type A and B periodic are takes place.

2.1.1 Type- A service

Type -A service is a service that takes place in every 5000, 15000, 25,000, 35000, 45000,
55000, 65000, 75,000 km. In this service we check or adjust as necessary, inspect and correct
or replace as necessary and lubrication will done. All the Type A service explains in Table 1.1
in appendices I

 First, we drain out the engine oil to replace with the new one, due to high heat generated
by the engine and also different reason Engine oil gradually lose its property so it must be
changed every 5000 km.
 If the car is diesel engine we have to flush the engine first to clean by inserting the flush
oil and start the motor about 20- 30 min. During flushing takes place we inspect brake
pads and disc.
 When the car is in motion the brake disc rotate with the wheels and gripped by the brake
pads to slow or stop the car at this time both discs and pads corroded so we inspect that if
replacement is needed.
 We also inspect and clean back wheels brake drums with sand paper and wash the brake
shoes. After 20 -30 min we drain out the flush oil and replace the new engine oil and
replace oil filter and fuel element, inspect air cleaner, battery, steering wheel linkage and
steering gear box oil, tightening of propeller shaft bolts and nuts, front and rear
suspension and external leakage if any.
 Lubricating steering system like steering knuckle, drag link, king pin, center arm and also
propeller shaft with grease and finally we inspect or check if any problem in lighting
system, horn, wiper and washer system.

2.1.2 Type- B service

Type B service is a service that takes place in every 10000, 30000, 50000, 70000 km. Most of
Type B services are similar with Type A. The only difference is because of the extra services
which are added. Inspecting brake disc run- out, drive shaft boots, tightening drive shaft boots,
ball joint and dust covers, brake pedal and parking brake, brake line pipes and hoses, brake
fluid, clutch fluid, water sedimentary and tire and inflation pressure. All the Type B service
explains in table 1.2 in appendices II:

 Brake Discs Run-Out: - due to friction between the disc and the brake pad the brake disc
may run out and it must be inspected and refaced again.
 Driveshaft boot may tear due to hard impact on wheel, so it must be inspected and
lubricated. And also, its bolts have to be tightened which may lose due to vibration.
 Ball joints must be inspected and lubricated to decrease friction and also dust cover must
inspect and correct.
 Brake fluid is a type of hydraulic fluid used in hydraulic brake application due to moisture
diffuses into the fluid through brake hoses and rubber seals because of this the water
content become high so it must be changed and also brake line pipes & hoses must be
inspected and corrected to protect the brake fluid against moisture.
 In fuel filter we have to inspect and correct or drain the water in water Sedimentary in
every 10,000 km to protect the fuel system from water and reduce the engine
performance.
 Clutch fluid must be inspected and corrected and also check its level because it may
reduce due to any leakage.
 Power-steering fluid level must be checked in the cylinder because it may also leak
somewhere in the power-steering system.
 The main causes of brake pedal failure are Air in the brake fluid, faulty master cylinder,
or low brake fluid level so we have to inspect and correct. Parking brake is used to keep
the vehicle motionless when it is parked. We have to inspect the cable, ratchet lock on the
lever and braking lining in the parking brake system.
 Tire air pressure gradually becomes lower even when the tire has no particular defect only
due to weather therefore tire pressure should be checked every 10,000 Km.

2.1.3 Type- C service

Maintenance work shop is one of AMWETC working place. In this working place Type C
periodic service will takes place. Type C service is done in every 20000 and 60000 km.
Services in this work shop are similar with Type A service. The only difference is because of
the extra services which are added. Inspecting and grease wheel bearing, inspecting drive belt,
vacuum pump oil hoses, exhaust pipes and mounting, differential gear oil and check or adjust
idle speed. All Type C service is explained in table 1.3 in appendices III:

 We have to inspect visually and replace if any damage in Wheel bearing and grease them.
 Differential Gear oil is inspected visually with our finger by removing the fill plug. If the
oil has any change like in color or viscosity it must be changed. And if there is any
leakage around the differential gear box we have to change the gasket.
 Vacuum pumps have a service life of many years. And the oil hoses must be inspected
and corrected if there is any leak around it, because running too low on oil will cause
catastrophic pump failure.
 If any visual damage which is occurs in the drive belt must be replaced. The cause of the
damage is excessive heat which is caused by tension so it must be inspected and corrected
with 20,000 Km.
 Idle speed is the engine revolutions per minute (rpm), while in the modern vehicles are
fitted with a built-in dashboard tachometer. We have to check and correct if the reading is
correct with exact revolution.
 Exhaust pipes and mounting May corroded by moisture because these parts remain
relatively cold and hot due to the exhaust gases and have a chance to form pools of
corrosive acid inside the system. Due to this crack and holes may exist so we have to
inspect and correct.

2.1.4 Type- D service

Repair also one of AMWETC working place, in this place Type D periodic service and other
repair of the automobiles will done. Type D service is a service which is done in every 40000,
80000 km. Type D service also similar with Type A, B, and C the difference is these extra
services are added like inspecting valve clearance, manual transmission and transfer oil, fuel
tank cap, fuel lines and connection. All Type D service is explained in table 1.4 in appendices
IV:

 We need to check and adjust valve clearance because too much clearance which make the
engine noisy and also will lost its performance. If the clearance is too tight, damage on
engines may occur. So, we have to inspect and adjust the valve clearance.
 In Manual Transmission the transmission fluid level must be checked to prevent failure it
must be inspected and corrected and replacing transmission fluid extends transmission
life, smooth rough or hard shifting problems and revitalizes seals and O-rings to help stop
and prevent leaks.
 There are other works beyond the Type D service, repair the automobile.

Figure 2 wrench socket, extension and others

 Different systems in the vehicles that we have seen in the service time

Cooling system -A cooling system is built in to the engine to cool it and prevent overheating.
The cooling system consists, radiator, water pump, thermostat, upper hoses, and lower hose.

Figure 3 Cooling system

Lubrication system- The lubrication system supplies lubricating oil to all moving parts in the
engine. Engine moving metal part is contact with each other. It includes crankshaft,
connecting rod and valve mechanism parts. lubricating oil prevent friction of this parts oil
minimizes friction and prevents wear and heat generation, cools engine parts, oil sealing b/n
piston and the cylinder bore prevents impurities from engine , protect parts from corrosion,
absorb shocks, reducing engine noise , extending engine life ,it consists oil pan, oil pump and
oil filter .
 Figure 4 Lubrication system

Hydraulic system- A Hydraulic system is one that uses the pressure of a liquid to perform
mechanical work. Example brake system

Transmission system- Transmission system is used to transmit the power from flywheel to
the rear wheels and it consists of torque convertor and Epi-cyclic gear boxes in heavy vehicles.

Figure 5 Transmission system

Differential system- The differential equalizes power to the drive wheels for turning. There
transmit system transmit the power to differential system through universal joints, slip joints
and propeller shaft.

Figure 6 Differential system

Brake system- Is used to keep vehicle in any position after it had bees actually brought to a
complete rest when the operator is present. Is used to reduce the speed of wheel and also stop
the wheel motion. For example, two semi-circular shaped brake shoes are used to apply
brakes. The brake shoe applies force on the brake drum due to friction in between brake lining
and drum, so the drum speed is reduced and stopped

Figure 7 Brake system

Steering system- Earth moving equipment has power steering (hydraulic operated). It is used
to tilt the front wheels at desired direction. It designed to prevent the wheel spring i.e. to
ensure good road holding and eliminated oscillation in the body, For example, hydraulic
steering system of dump truck, the pump is taking oil from tank through screener and paper
filter, and delivers oil to the orbital valve (DCV) through cheek valve. When two front wheels
are straight, the two piston position middle of steering cylinders. When the vehicle is taking a
right turn, the right wheel is tilted out ward and left wheel is tilt in ward. When taking left
turn, left wheel tilted out word and right wheel tilt in ward.

Figure 8 Steering system

Suspension system- An Automotive Suspension is the system of parts that give a vehicle the
ability to maneuver. A vehicle suspension can maximize the road holding, provides steering
stability with good handling and ensures the comfort of the passengers
 The Role of Suspension

 To provide Ride & Handling Performance-

 Ride - vehicle's ability to smooth out a bumpy road
 Handling - vehicle's ability to safely accelerate, brake and corner. (min roll and pitch
acceleration)
 To ensure that, steering control is maintained during suspension.
 To support the vehicle static weight
 To provide isolation from high vibration arising from tire excitation
 Maintain correct vehicle ride height
 Reduce the effect of shock forces
 Maintain correct wheel alignment
 Support vehicle weight
 Keep the tires in contact with the road
 Control the vehicles direction of travel

Those suspension systems are: springs, dampers (shock absorber) and linkages.

Figure 9 Suspension system

Fuel tank –Fuel tank is used to reserve or store fuel in a motor vehicle. Due to long time
usage, some dusts store in the fuel tank. These dust materials affect sensors and filters in the
fuel tank. So, we have to wash fuel tank in the service time and we have to check whether the
filters and sensors are working or not.
 Figure 10 Fuel tank

2.2. Task two: - Engine shop task

After the first two month stay in service shop we have assigned in engine shop task for one
month followed by the final project for the remaining one month. Engine workshop is
AMWETC’s working place. In this workshop we disassemble the engine carefully and inspect
each part for any signs of damage also check all parts for signs of overheating, wear and look
for signs of gasket seal leakage.
 Figure 11 Engine shop

First, we have to clean the engine and engine compartment before beginning to remove the
engine we lift the engine from the car with mobile crane which uses hydraulic power. The
main parts that can be inspected are cylinder head inspection, camshaft inspection, valve
inspection, cylinder block inspection, piston inspection, connecting rod inspection, crankshaft
inspection, flywheel inspection and Transmission inspection. We used approved factory
manual procedures to taste the engine. This is due to that the engine runs smoothly.

2.2.1 Major parts of engine

1. Cylinder head Cylinder Block Oil Sump
Cylinder Head -Crank shaft -Diesel
- Valve - -Water pump -fuel
2. Cylinder block Fuel Injector -
-Spinning washer
Intake and
-pulley … etc.
3. Oil sump -Exhaust Valve
--Cam shaft
 Figure 12 Cylinder head

Cylinder head and its inspection

The major function of a cylinder head is to seal the top of the cylinder block. Cylinder head
gaskets which avoid leakage of engine oil and it’s a seal between cylinder block and the
cylinder head, a new gasket should be used once cylinder head has been removed for
servicing.

Figure 13 Cylinder head and its inspection

Cylinder block and its inspection

The cylinder block is an integrated structure to have cylinder bores, main bearing bore
(housing), water jacket, camshaft bearing housing (if the engine is cam shaft in block type),
other plugs & drillings for the attachment of other parts on it.

Visually we inspect for vertical scratches of cylinder walls, visible cracks of the block surface,
inspect the cylinder block for flatness and war page by placing the long straight edge along
and diagonally on the lower mating surface of the cylinder block and using the feeler gauge to
measure war page and inspect cylinder bore Using a cylinder bare gauge, outside micrometer
and telescopic gauge we measured the cylinder diameter.

Figure 14 Cylinder block and its inspection

Piston, piston rings and its inspection

A piston generally is made with characteristics of low density and high strength to make light
in weight and to conduct higher heat produced during combustion process and to have a lower
thermal expansion, high resistance to wear i.e. good anti-friction quality. And a piston ring is a
split ring that fits into a groove on outer diameter of a piston. The three main functions of
piston ring in reciprocating engines are sealing the combustion chamber so that there is no
transfer of gases from the combustion chamber to the crank, supporting heat transfer from the
piston to cylinder wall and regulating engine oil.

First, we clean carbon deposit on the top surface and ring groove area and visually we inspect
for scoring, scuffing, burning and other visible mechanical damage and we inspected visually
the piston rings for breakage, stacking on the ring groove and also inspect the piston diameter
using micrometer.

2.2.2 Assembly of engine and its parts

During assembly of an engine we should have to remember the following points.

 Before assembly, check all parts whether there are damages or not.
 The assembly ground should be clean.
 All the disassembled parts should be cleaned and blown with compressed air.
 For hollow bolts use two asbestos washers on two sides.
 If any foreign object is on to the crank shaft, intake and exhaust tube remove the objects.
 Before assembly, select all engine parts.
 Generally, assembly step by step all engine parts as removing before.

Figure 15 Engine
 Figure 16 Engine parts

1. VALVE 6. CONNECTINGROD 11. TIMING GEAR

2. CYLINDER 7. FLYWHEEL
3. CYLINDER HEAD 8. CYLINDERS BLOCK
4. PISTON RINGS 9. CRANKSHAFT
5. PISTON 10. MAIN BEARINGS

2.3 Task three, Body and Paint Shop

Body and painting shop of AMYWETC is full service auto body shop, collision repair
specialist and glass repair facility that provides the best in customer service, frame and body
work, painting and re-finishing for Toyota models of automobiles. Body and Paint center takes
every single repair seriously, no matter how big or small the damage may be. There is quality
and integrity guiding principles to ensure what every customer is satisfied. Our Body and
Paint shop is equipped with some of the latest technology required to repair complex vehicles.
Our technicians and staff are continually trained in the latest methods required in the
automotive collision repair industry.
 Figure 17 Body and painting

2.4 Task Four: - Electrical system tasks

This task was where electrical parts are diagnosed and repaired but the company has not well
organized electrical shop. We tried to perform some tasks for a week’s inspect parking light,
front light long and short, car lock, fuel tank sensor, glow plug, ignition system.
The ignition system is usually switched on/off through a lock switch, operated with a key or
code patch. It is the system that uses the spark plug as their source where electrical energy is
input given to the spark plug. We know that in case of Internal Combustion (IC) engines,

Combustion of air and fuel takes place inside the engine cylinder and the products of
combustion expand to produce reciprocating motion of the piston. This reciprocating motion
of the piston is in turn converted into rotary motion of the crank shaft through connecting rod
and crank. This rotary motion of the crank shaft is in turn used to drive the generators for
generating power. We also know that there are 4-cycles of operations viz.: suction;
compression; power generation and exhaust.
In case of petrol engines during suction operation, charge of air and petrol fuel will be taken
in. During compression this charge is compressed by the upward moving piston. And just
before the end of compression, the charge of air and petrol fuel will be ignited by means of the
spark produced by means of for spark plug. And the ignition system does the function of
producing the spark in case of spark ignition engines. It mainly consists of a central electrode
and metal tongue. Central electrode is covered by means of porcelain insulating material.
Through the metal screw the spark plug is fitted in the cylinder head plug. When the high
tension voltage of the order 30000 volts is applied across the spark electrodes, current jumps
from one electrode to another producing a spark.

Whereas in case of diesel (Compression Ignition-CI) engines only air is taken in during
suction operation and in compressed during compression operation and just before the end of
compression, when diesel fuel is injected, it gets ignited due to heat of compression of air.
Once the charge is ignited, combustion starts and products of combustion expand, i.e. they
force the piston to move downwards i.e. they produce power and after producing the power
the gases are exhausted during exhaust operation.
In the internal combustion engine to generate such combustion, the ignition system plays a
major role. Spark plugs supply the electrical spark that ignites the air and fuel mixture that is
fed into the combustion chamber. The ignition system needs to increase the voltage from the
battery’s 12 volts to at least 20,000 volts, which is required to ignite the compressed air and
fuel mixture in the combustion chamber to create an energy-generating explosion.
To achieve such a huge surge in voltage, the ignition systems in all cars, except diesel-
powered models, use an ignition coil consisting of two coils of wire wrapped around an iron
core, known as the primary winding and the secondary winding. The ignition coil acts as an electrical
power transformer.
The goal of the ignition coil is to create an electromagnet by running the 12 volts supplied by the
battery through the primary winding. When the vehicle’s ignition system triggering switch turns off the
power to the ignition coil, the magnetic field collapses. As it does, the secondary winding captures the
collapsing magnetic field from the primary winding and converts it into 15,000 to 25,000 volts
depending on number of turns. It then supplies this voltage to the spark plug, thereby creating
combustion in the engine’s combustion chamber, thus creating energy to start and run vehicle’s engine.

2.4.1. Starter motor and its inspection

Basically our practical task is concerned on (compression Ignition-CI) diesel engine car. A
starter or starter motor is an electrical device that used to rotate (crank) internal combustion
engines so as to initiate the engine’s operation under its own power. As soon as the engine
begins to run, it got disconnected from the engine, which now relies on the combustion
process. The component is mounted on the engine’s gearbox housing, and the starter motor
gear meets flywheel’s teeth. Being an electrical component, a starter consists of a powerful
DC (Direct Current) electric motor and a solenoid. The solenoid receives positive power direct
from the battery and hearth current from the engine body. In order to turn the engine, a 12-volt
battery must be used to run the starter. This means the battery has to be sufficient enough to
power the device. When the ignition key or bottom is press, the transmission should be in park
or neutral state. The battery voltage goes to through the starter control circuit to activate the
solenoid.
The starter motor is powered by the solenoid, which helps to push the starter gear forward to
mesh with the engine flywheel. This flywheel is mounted on the engine crankshaft, so as the
starter motor spins it turns the flywheel so as the crankshaft. As soon as the engine starts, the
system disengages from the flywheel.
Common starter motor problems
There are different bad starter symptoms like, something sound off, wouldn’t crank camshaft,
smoke is coming from car, and oil has soaked the starter
Causes of starter motor
 Loose wiring to and from the starter

 Dirty connections
 Battery corrosion
 Damaged or worn-out parts in the starter system
 Oil leaks
Procedure we followed to troubleshoot problems
 Look under the hood: inspect battery and battery cables to see whether everything’s in
working order.
 Tap the starter: Try lightly tapping the starter a few times with a hard object, making sure
not to pound it. Tapping might get the electrical part back in contact with each other or
clear dirt blocking the parts.
 Check the fuel gauge.
 CHAPTER 3

3. TECHNICAL ASPECT OF THE INTERNSHIP

3.1 Objective of industrial internship program

The industrial internship program is established with the purpose to expose students to the real
working environment. So that, the students are able to relate the theoretical knowledge gained
in the class with practical knowledge in the industry. The students will also develop skills in
safety practices, work ethics, communication and management apart from that, this program
will also enable students to have a closer relations ship with the host companies. Generally,
the objectives of this training program are:

 To integrate theory with practice: students must be proficient in applying the official and
technical knowledge in to real working environment
 To introduce students to work culture with industrial practical experience the working
culture and adapt with the industrial practices as preparation before making choices in the
careers. After completing their studies.
 To give opportunity for students to work with industries practitioners. Exchange between
students and industrial practitioners work Experiences.
 To expose students to potential employers
 Enhances skill in engineering including technical writing and communication.

3.2 Methods and Procedures

Methods and procedures, which are followed when carrying out our technical tasks, are start from
simple data collection from important bodies and passes through many complex steps to reach at
right result. Only four steps are followed. Firstly, as usual, we used two forms of data collection;
primary and secondary data collection methods. Secondly, we generate possible solutions. Thirdly,
we discussed with department foreman about our solutions. Finally, accepted solutions are applied
practically.

Step -1 collecting data using primary and secondary sources

Primary sources of data collection:

Interview: -during practical work, preparing reasonable questions for whom it concern were my
habitual characteristic. This is in order to gather important information about over all of the
company. Under this category of primary data collection method, I really provide the following
questions to Mr. Mesay, Mr. Habtamu and other mechanic in the department that we have been
executed:

1. What is the reason that these much machines are out of use?

2. Is there any maintenance manual based on which you are restoring machines that are damaged?

3. From which country the company is buying spare parts?

4. Has ever danger accident been in the company? If yes what was the cases?

5. How long you did in this company as an employee?

6. About your educational status?

7. Are you interested on what are doing in and monthly salary?

8. Are you searching for job in other company? If yes, which company you asked?

9. Do you have any recommendation to the factory?

Observations: -everyday during intern period I had been observing how things were going on.

Secondary sources of data collection:

To search data under this method I read different written documents from the library of the
company. In addition to this I used web search related with Arba Minch textile Share Company,
about maintenance, kaizen, and 5s.

Step -2 generating possible solutions or ideas:

In this step I jot down all the important points that can be the possible solutions for the
problems that I faced in the company. This step is the point where I make an attempt to
generate solutions based on what I have learnt in the academic courses. I used here my
theoretical knowledge and other important information searched from different sources. The
possible solutions were, applying standardized and modernized maintaining system of
machines, implementing continuous improvement (kaizen), and 5S.
 Step -3 discussing about my ideas with whom it may concern

Every day I submit my ideas about how to overcome the problems encountered in the company for
department head and we discuss on what is written. After understanding the written materials, the
department foreman accepts some solutions that would have been possible to apply at the company
level.

As its simplicity to perform, kaizen and 5S are directly accepted. In addition, they did promise to
prepare maintenance manual based on the types of maintenance discussed above.

Step -4 apply the solutions practically

As much as possible, accepted solutions are applied with in short period of time. Some
photographic picture, as presented under the following sub-title, shows the results of
practically applied solutions.

3.3. Technical tasks or products

Generally, when I was in AMWETC MOENCO (motor and engineering company of Ethiopia)
sub dealer I observed some application of vehicle maintenance factory, and personal
communication skills have also be improved peacefully with staff members and other work
partners.

In our four month Arba Minch Auto Garage AMWETC Branch internship program we work
three types of shops namely;

 Service Shop
 Engine Shop
 Body and Paint Shop

The main goal of the internship program is to develop practical skill. During stay AMWETC
at the first two months I have worked in service shop and gained more practical skill, to list
some:

 Assembling and disassembling of some components of engine

 Checking of tanker, pump, filter and fire valve.
 Checking of main rotor brake
 Visual assessment of collective pitch and identifying the problem.
 Cleaning of pipe and hose
 Washing the full engine and cleaning dust particles it used to brush, air pressure and
washing machine.
 Assembling and disassembling of Engine step by step.
 Inspecting processing.
 Inspecting crank shaft, cam shaft, bearing, piston ring, and liner (cylinder).
 Replace the defected crank shaft tail first and conduct oil pressure test.
 Valve timing gear (cylinders valve and opening and closing angles) adjustments.

3.4 Knowledge and Acquaintances Acquired

3.4.1 Technical Skills Gained
In addition to theoretical knowledge and practical skill this internship program had also helped
me to develop and improve my personal work ethics such as:

 Honesty
 Transparency
 Accountability
 Confidentiality
 Punctuality
 Objectivity
 Respectful and
 Within the law

In this industry I have gained the most important point for my future life. Having the skills as
described above is something great for me, this indicates that the company is better place for
internship and the internship was in success.

Respecting of working ethics is one of the good ways for the development of my works. One
of the working ethics is wise use of time, using the materials wisely, and peaceful relationship
should be create with the workers and staff members.
 3.4.2 Management Skills Gained

In the beginning we applied to hosting company from different universities and they make us
work in team. I and my team mates were working so bravely in the entire time of the
internship program. For me this internship has gave the knowledge of working in team spirit.
The whole things we were up to needed a great collaboration. Nobody had any burden on him
because everybody worked wisely. Everybody on the team knows working in peace and
collaboration will have a great influence on the work. So, in general we worked hard in team
to produce great deal of work which is helpful and problem solving for the society. And also, I
have developed how to play this role during team work. In the company I have seen group
works and how the work is scheduled and how tasks are shared among members of the team
for better result and efficiency. And also giving hand for those who need my help. Some
essential skill for team working are listening, questioning, respecting, sharing and
participating. These are used during the research cycle to observe how well a team is working
together.

3.4.3. Acquaintances Acquired

In this industry every day morning there is briefing time in which plan for the day is presented
and every worker are introduced to their responsibility on achieving of the plan. Therefore,
taking part in this activity helped us to develop interpersonal communication skill. And also
on this internship program I get to meet people who offer me knowledge to share and so as
this knowledge will help me on my carrier. And I think I have been creating my business link
with this company so that I can go back and work with them after I graduated. Internship is a
great way to meet people in our field of study. An internship allows us to meet people who
might help us to land a job later on and give us the contacts in the industry we are trying to
break in to. Plus, references from people in the industry will really add weight to our
application.
 3.4.4. Theoretical Knowledge

During our stay in the university we learned much of the theoretical knowledge rather than
practical knowledge but through this internship duration we develop practical knowledge and
also upgrade our theoretical knowledge in addition to what we have learned in the university.

 Thermodynamics
 Mechanism
 IC engine
 Motor vehicle
 Fluid power
 Maintenance and machinery
 Machine design
 Strength of material
 Material science and
 Manufacturing are some fields in detail in which we have gained more theoretical
knowledge.

3.5. Problems encountered during the internship period

 Lack of personnel who is mechanical engineer with degree graduation

 Overcrowding in working area due to presence of many students
 Shortage of materials and machineries
 Shortage of safety materials

3.6. Contribution

During my stay in AMWETC I have been working in different working areas so that I was
contributing to them by being additional Man power in both service and engine shop.

 Creating peaceful working environment using interpersonal communication to solve

problems and talking to workers wisely to solve ignorance from worker.
 Preparing time schedule for all students in the company and working overtime
occasionally regarding shortage of time and overcrowding.
 Regarding material and machinery shortage efficient utilization of materials, making
useless things useful and using machineries in free time were some of solutions.
 We have also shared safety materials for many students.
 CHAPTER 4

4. Design of Multi Nut Remover for Automotive

4.1 Abstract
Tire plays a significant role in the performance of car. Removal of tire is a really a difficult
task. In order to facilitate easy removal of tire a simple tool with pitch circle diameter (PCD)
of 114.3mm has been designed. The aim of the project is to design and develop five in one (5
in 1) nut remover, the tool will help to remove all the 5 nuts simultaneously also the time
required for removing nuts will be reduced. The tool designed is easy to operate and saves
man power.

4.2 Introduction

Cars in our company have now become need and it is no more the symbol of luxury. But
replacing a punctured tire has always been a difficult task. Our company provides only L
wrench or 4 way leg wrench. But removal of tire using this tool requires more power
consumes time. Using the L wrench it is possible to remove one nut at a time. The problems
faced are longer time consumption and increased labor work. Therefore it is crucial to have a
tool that can remove all nuts in a single attempt.

While designing it is taken into consideration that the tool is economical. The tool is expected
to remove five nuts at a time with less torque and improved efficiency as compared to the
previous nut removers found in our company. The purpose of the design is to develop a tool
which facilitates easy removal, easy performance with minimum time consumption. The
objective of the project is to create a 5 in 1 nut remover with Pitch circle Diameter (PCD)
114.3mm with assistance of CAD. It will help the car owner to overcome the difficulty of tire
replacement. All the cars having PCD 114.3 mm can use this tool. Torque required to remove
single nut is around 85-95 Nm. Therefore torque required to remove 5 nuts is 475Nm.
 4.3 Problem statement

The problem I saw and tried to solve is when in the service time or sometimes the tire was
punctured; the workers in our company cannot able to remove the tire in a short time and they
spend there much time in removing all nuts one by one. The workers in our company uses
existing wheel nuts remover which is a normal L wrench that is really inconvenient and
difficult to use. It can remove only a single nut at a time and it requires man power for
removing and tightening of the nuts. Thus for old and weak peoples, the replacement of the
tire by this normal method is really inconvenient and difficult process. Therefore, to overcome
these problems I designed vehicles multi wheel nuts remover and tightener. This tool can be
operated by anyone easily and it removes all the five nuts in a single process. Thus my
projects saves time and man power and help everyone in the car’s service time.

Figure 18 Problem statement

The purpose of this project is to design 5 in 1 nut remover in terms of its functionality and also
human factors considerations. General idea of the project is to minimize the human effort
while operating the nut remover.
 4.4 Objectives of the project

4.4.1 General objectives

General idea of my project is to design, fabricate and use a 5 in 1 nut remover as a fast and an
inbuilt solution for removing five nuts at a time by applying less torque with hand.

4.4.2 Specific objectives

- To minimize the human effort while operating the nut remover.

- To provide enough torque by applying less force

- To decrease unnecessary loose of energy by the employer.

- To save the time by removing five nuts once that is lose by removing all nuts one by one.

- To save man power or energy that is lose by applying high force with L-shaped wrench.

- To provide an inbuilt car wheel nut remover.

4.5 Components of the 5 in 1 wheel nut remover

4.5.1 Gear and pinion

In this setup I used a central gear and five pinion gears. The central gear is connected to
cranked lever and thus it is driven by the lever and the other five pinion gears are meshed with
the central gear. Thus the central gear drives the all five pinion gears. The gear and pinion in
this set up is made according to the pitch circle diameter of the wheel which is 114.3 mm.

4.5.2 Shaft
A solid shaft for transferring torque is used to transfer the torque from the pinion gear
manually to the box spanner to remove the nuts. Five shafts are connected to the five pinion
gears individually and at the end of each shaft box spanners are attached to it.

4.5.3 Socket
A socket is a cylindrical type female hexagonal fit which is fitted over the common male
hexagonal head of the nut. In this case the size of the socket is taken as 17 mm. The head of
the socket wrench that is completely the same as the nut / bolt head cover and the sense of the
handle are not fixed. The socket is a hexagonal shape or size estimate which itself is either a
square. This estimate, which fits into the appropriate size of the cavity or on handle, can be
used to apply force.

Figure 19 Socket

4.5.4 Plates
In order to keep the forces and means of the gear, base plate is used to withstand the gears and
the shaft extension. To remove the weight and increases the stability of the device. The cover
plates are used to cover the gears. These are plate made of steel.

4.5.5 Bearings
A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation
between the bearing races. The purpose of a ball bearing is to reduce rotational friction and
support radial and axial loads. It achieves this by using at least three races to contain the balls
and transmit the loads through the balls. In most applications, one race is stationary and the
other is attached to the rotating assembly (e.g., a hub or shaft). As one of the bearing races
rotates it causes the balls to rotate as well. Because the balls are rolling they have a much
lower coefficient of friction than if two flat surfaces were sliding against each other. Ball
bearings tend to have lower load capacity for their size than other kinds of rolling-element
bearings due to the smaller contact area between the balls and races. However, they can
tolerate some misalignment of the inner and outer races.

4.5.6 Cranking lever

A driving lever is used in driving the central gear. The central gear needs to be driven so that
all five pinion gears meshed with the central gear also rotates. A cranked lever with maximum
force of 400N for single man is used in this setup.
 Figure 20 Cranked lever

4.5.7 Bolt and Nut

Bolt is an externally threaded (male) fastener designed for insertion through holes in
assembled parts, and is normally intended to be tightened or released by torqueing a nut. An
externally threaded fastener which is prevented from being turned during assembly and which
can be tightened or released only by torqueing a nut is a bolt. An externally threaded fastener
that has thread form which prohibits assembly with a nut having a straight thread of multiple
pitch length is a screw.

Nut is an internal thread (female) fastener with a threaded hole. Nuts are almost always used
in conjunction with a mating bolt to fasten multiple parts together. Nuts are graded with
strength ratings compatible with their respective bolts. The most common shape today is
hexagonal, for similar reasons as the bolt head. Six sides give a good granularity of angles for
a tool to approach from (good in tight spots), but more corners would be vulnerable to being
rounded off. It takes only one sixth of a rotation to obtain the next side of the hexagon and grip
is optimal. However, polygons with more than six sides do not give the requisite grip and
polygons with fewer than six sides take more time to be given a complete rotation. In our
project we use it to tight the legs with a table frame.

4.5.8 Table
The table should be from welded steel and has a maximum strength to carry the gear box. It
has a capacity of carrying light weight vehicle leaf spring.
 4.6 Literature review
Wrenches have existed for many centuries, but saw a great blossoming of development
starting in the 19th century. The first patent for a wrench was granted in 1835 to Solymon
Merrick. Meanwhile this long period, different varieties of wrenches came into existence.
Some of their description is shown in the table below;

Name of
No. wrench Purpose and application Figure
1 Box end This is a one-piece wrench with an enclosed
wrench opening that grips the faces of the bolt or nut.
The recess is generally a six-point or twelve-
point opening for use with nuts or bolt heads
with a hexagonal shape. The twelve-point fits
onto the fastening at twice as many angles, an
advantage where swing is limited. Eight point
wrenches are also made for square-shaped nuts
and bolt heads. Ring spanners are often double-
ended and usually with offset [10].

2 Open end A one-piece wrench with U-shaped opening that

wrench grips two opposite faces of the bolt or nut. This
wrench is often double-ended, with a different-
sized opening at each end. The ends are
generally oriented at an angle of around 15
degrees to the longitudinal axis of the handle.
This allows a greater range of movement in
enclosed spaces by flipping the wrench over [4].

3 Spark plug A tube with six-sided sockets on both ends. It is

wrench turned with a short length of rod inserted through
two holes in the middle of the [6].
4 Combination A double-ended tool with one end being like an
n wrench open-end wrench or open-ended spanner, and the
other end being like a box-end wrench or ring
spanner. Both ends generally fit the same size of
bolt [4].

5 Socket A hollow cylinder that fits over one end of a nut

wrench or bolt head. It may include a handle, if it does
not then it is often just referred to as a socket and
is usually used with various drive tools to make
it a wrench or spanner such as a ratchet handle, a
tee bar or a knuckle bar (single axis pivot). It
generally has a six points, eight-point or twelve
point recesses, may be shallow or deep, and may
have a built-in universal joint. [5].

6 Cone wrench A thin open-end wrench used to fit narrow

wrench flats of adjustable bearing bicycle hubs.
Called a "cone" wrench because it fits wrench
flats of the cone section of a "cup and cone" hub,
this tool is also used with some other adjustable
hub bearings. The wrench is very thin so has
little strength; to compensate, cone wrenches
typically have a large head. Most bicycle front
hubs use a 13 mm; most rears use 15mm. [8].

7 4-wayleg A socket wrench used to turn lug nuts on

wrench automobile wheels. [4].

On the basis of above survey there is a gap between the design of wrenches and modern
automobiles. Some of bolts are more complicated to open and some are very time taking
process. Here in this paper a new proposed design of multi jaw wrench is introduced for the
opening of 5 bolts of any car having pitch diameter of 114.5mm simultaneously. Today,
generally we are using box end wrench that is L-shaped for fastening and unfastening the nuts
of a car wheel. But the main problem with such combinations is that there is a requirement of
large amount of force for unfastening the nuts. Multi jaw wrench provides a better option for
fastening and unfastening the nuts by reducing the force applied along with the time involved.
 4.7 Methodology

Data analysis Discussion

Data collection Literature Design work Conclusion
and result

To accomplish my design, I have used the following methodologies.

 Problem identification

From my view, I have selected the title of my project. The title of the project is Design of
Multi wheel nut remover for automobiles. Then preparing reasonable questions for which it
concern were my habitual characteristic. This is in order to gather important information about
over all of the company. Every day, (during intern period) I had been observing how things
were going on.

 Gathering possible solution for the problem

To search data under this method I read different written documents from the library of the
company. This step is the point where I make an attempt to generate solutions based on what I
have learnt in the academic courses. I used here my theoretical knowledge and other important
information searched from different sources. Every day I submit my ideas about how to
overcome the problems encountered in the company for department head and we discuss on
what is written. After understanding the written materials, the department foreman accepts
some solutions that would have been possible to apply at the company level.

 Apply the solutions practically

As much as possible, accepted solutions are applied with in short period of time. Some
photographic picture, as presented under the following sub-title, shows the results of
practically applied solutions.
 4.7.1 Working principles

The working of the vehicles multi wheel nuts remover and tightener is simple and can be
performed by anyone. It does not require any skills or anything, just basic knowledge about
the setup is required for operation. This works under the principle of removing all the wheel
nuts at the same time by applying torque with cranked lever. It consist of a cranked lever , five
gears (pinions), central gear, five shafts which has been connected to the five pinion gears, and
box spanners at each end of the five shafts, the cranked lever is turned by single man.

 First the machine setup is placed with correct fitting of the box socket to the nuts of the
vehicle.

 Then the cranking lever is connected to the shaft of central gear. The lever drives the
central gear which drives the meshed pinion gears.

 Each pinion gear is connected with the shafts with the box spanners at the end of the each
shaft.

 As the shaft rotates the spanners also turns and the nuts in the wheels are thus removed or
tightened by the rotation of the spanners.

 The tightening and removing process can be changed by changing the rotation of the
lever. Thus all the wheel nuts can be tightened and removed by this process. It is found to
be a simple process and very much convenient for every one for the tire removal and
tightening process. Thus with this simple process I succeeded in making a convenient
process in the tire replacement technique for our company. By this setup the tire could be
easily removed and tightened more efficiently with less wastage of time and energy used.

4.7.2 Limitation of this project

This design has some problems bound up with it like:

- It is heavier compared with the latest L- shaped wrench.

- The operator must have to rotate the handle in opposite direction to nut’s
rotation.
- Five in One nut remover requires lubrication to the gear and pinions.
- The design is more complex.
 - It is not comfortable to handle compared to L wrench nut remover.
- Also it is not easy to store.
- Prototype couldn’t be done due to shortage of time and lack of materials.

4.9 Product design

Multi wheel nut remover is designed by the combination of spur gear, shaft, cranked lever,
gear box, table and box spanners. In its design the 5 small size gears and one large gear are set
in such a combination that it will perform like a sun and planet arrangement. Gears are
connected by the bearings and at the front end of small gear shaft, the spanners or sockets are
mounted. This assembly is fitted to the five nut and bolt arrangement of wheel. And efforts are
applied at the end of lever. At the same time five bolts are open simultaneously. In its design
the effort required is comparatively more than the effort of single nut opening. But the overall
performance is better than the other design. Instead of effort applied by the hand, machines
like robotic manipulators may be used to easy operation.

The project started with product design, for the design Auto CAD was used. Parametric
modeling of spur gears was done in Auto CAD. The parameters used for design of spur gear
were number of teeth and module.

4.10 Design parameters

 PCD (Pitch Circle Diameter) = 114.5mm
 Common nut sizes = M12
 Torque required, T = 475 Nm (5 nuts).
 Average force by human, F = 400N.
 Length of handle, l = 300 mm.
 Length of the lever, L = 450 mm
 Gear material = 080M40 (Mild steel)
 Face width, b = 10m.
 Pressure angle = 20˚ full depth involute teeth

4.10.1 Basic parameters

Parameters symbol Values, units

Central gear number of teeth TG 34
 Driven gear number of teeth TP 17

4.11 Design calculation

4.11.1 Design of gear
Gear transmission was the important aspect of the entire design even a slight failure of gears
will disrupt the entire system. For the proper design of gears one need to know about the
stresses acting on gear, tooth engagement meshing etc.

The type of gear selected was spur gear because they are easy to design and manufacture and
which connect two parallel and co-planar shafts. These gears have the teeth parallel to the axis
of the wheel. A part from this the velocity ratio in spur gear is constant. Keeping the above
factors in mind and selecting 080M40 for the Gear.

Properties of mild steel 080M40

 The product was to be designed for 114.3mm PCD, so the center distance between gears
had to be 57.15 mm.

 The torque required for removal of one nut is 90 N-m.

 The face width of gears is ten times module (B = 10m),

 Yield strength and Ultimate tensile strength for gear material (080M40 mild steel) is
280N per mm 2 and 550N per mm 2 respectively.

 Brilliant hardness number (BHN) = 280 HB,

 Young’s module (E) = 200000N per mm 2 and poison’s ratio = 0.3.

 The system of gear is 20° full depth involute teeth.

 Addendum a = 1×(module),

 Dedendum b = 1.25×(module),

 Tooth thickness for the system of gear is 1.5708×(module).

 The permissible bending stress for the gear and pinion is One third of ultimate tensile
strength (1/3σut).

 The entire gears are epicyclical.

 Pitch circle diameter and velocity ratio of the gears

DG DP G× D P D P D ×(G+1)
L= + →L= + → L= P
2 2 2 2 2

DG T G 34
G= = = =2 where; - L is distance b/n the center of gear and the center of
DP T P 17
pinion (mm)

- DG is PCD of gear in mm

- D P is PCD of pinions in mm

- G is gear ratio or velocity ratio

So, from the above

2× L 2× 57.15 114.3
DP = = = = 38.1mm
(G+1) (2+1) 3

DG = G× D P = 2×38.1 = 76.2mm

→ DG = 76mm and D P = 38mm

 Module (m)

DP 38
D P = m×Tp → m = = = 2.25
T P 17

m = 2.25

 Face width of the gears (B)

B = 10×m = 10×2.25 = 22.5mm

B = 22.5 mm

 Normal pressure between teeth

Torque applied on each pinion is 90N per m (90000 N /mm )

 T = 90000 N /mm

Tangential load (W T ) on the pinion is given by;

T 90000 Nmm
W T = D P = 38 mm
2 2

WT = 4736.84N

Normal load (W N ) on the pinion is given by;

WT 4736.84 4736.84
WN = = =
cos ∅ cos 20 ° 0.93969

WN = 5040.8N

Then to find normal pressure on tooth, we use the formula

WN
B=
P

WN 5040.84
p= =
b 22.5

P = 224 N /mm

 Beam strength (σb ¿

Table 4.2 Lewis form factor standard values

T 14.5° full depth 20° full depth

17 0.2639 0.3016
34 0.3267 0.3707
Y P = 0.3016 and Y G = 0.3707 σ bp ×Y P = 183.3×0.3016 = 55.3

σ bg ×Y P = 183.3×0.3707 = 67.95

We have to calculate the beam strength to the weaker one

So, f b = m×b× σ b ×Y

= 2.25×22.5×55.3

f b = 2800N
 Figure 21 Auto CAD designed gear and pinion

4.11.2 Design of shaft for the gear

The material selected for the shaft is carbon steel of grade 40C8 with Ultimate tensile strength
of 560Mpa and yield strength of 320Mpa for the material of both gear and pinion shaft.

Properties of carbon steel 40C8

For shaft purchased under definite physical specification, the permissible tensile stress (σ t)
may be taken as 60 percent of the elastic limit in tension ( σ el), but not more than 36 percent of
the ultimate tensile strength (σ u). In other words, the permissible tensile stress,

σ t = 0.6σ el or 0.36 σ u

For shafts purchased under definite physical specifications, the permissible shear stress ( τ )
may be taken as 30 per cent of the elastic limit in tension ( σ el) but not more than 18 per cent of
the ultimate tensile strength (σ u). In other words, the permissible shear stress,

τ = 0.3σ el or 0.18σ u

So, τ = 0.18(560) = 100.8Mpa

Approximately τ = 101Mpa

We have got the normal and tangential load in the previous calculation and also we know the
pressure angle (∅ )

 The weight of gear

w G = 0.00118×T G ×b× m2

= 0.00118×34×22.5×2 , 252

w G = 4.56992N
  Resultant load acting on the gear

w R = √ W N 2 +W G2 +2 ×W N ×W G ×cos ∅

= √ 5040.842 + 4.569922+2 ×5040.84 ×4.56992 × cos 20 °

= √ 25851277.32

WR = 5045.135N

The gear is mounted at the middle of the shaft

WR
→ L/2 ← → L/2 ←

W R /2 W R /2

Therefore; the maximum bending moment at the center of the gear is:-

wR L wR × L
M= × = where; L is overhanging distance
2 2 4

Let us take the overhanging distance 60mm

5045.135× 60
M= = 75,677Nmm
4

Since the shaft is under combined effect of torsion and bending.

Therefore we shall determine equivalent torque

T e = √ M 2+T 2 where, T = Twisting moment

DG
T = wt ×
2
 76
T = 4736.84 × = 179,999.9Nmm ≈ 180,000Nmm
2

T e = √ 75,6772 +180,0002 = 195,261.4Nmm

We know that the equivalent twisting moment (T e) is given by;-

π 3 π 3
Te = × τ ×d G = ×101 × d G = 19.83d G3 where, d G3 is diameter of gear shaft
16 16

Therefore;

195,261.4 = 19.83d G3
3
d G = 9,846.768 d G = 21.434mm ≈ 22mm

The shaft length is over hanging distance plus the length of shaft used for meshing with the
lever. I have taken 36mm for meshing distance. So, total distance is 60+36 = 96mm

Figure 22 Auto CAD Designed Shaft for gear

4.11.3 Design of shaft for the pinions

The shaft material of pinion is similar to that of gear.

 Weight for the single pinion

W P = 0.00118×T P ×b× m2 = 0.00118×17 ×22.5×2.25 2

W P = 2.3N

 Resultant load acting on the single pinion

W R = √ W N 2 +W P2+ 2× W N × W P × cos ∅

= √ 5,040.842 +2.32 +2 ×5,040.84 × 2.3 ×cos 20 °

W R = 5,043N
The pinion is mounted at the middle of the shaft.

Therefore; the maximum bending moment at the center of the pinion is,

wR × L
M= where; L is overhanging distance which is equal to that of gear’s shaft (60mm)
4

5,040.84 ×60
M= = 75,645Nmm
4

Since the shaft is under combined effect of torsion and bending.

Therefore we shall determine equivalent torque

T e = √ M 2+T 2 where; T is Twisting moment,

DP 38
T = wt × = 476.84 × = 90,000Nmm
2 2

T e = √ 75,6452 +90,0002 = 117,567.71Nmm

We know that

π 3
Te = × τ ×d P where; d P is the diameter of pinion’s shaft
16

π 3
Te = ×101 × d P = 19.83d P3
16

Therefore;

117,567.71 = 19.83d P3
3
d P = 5,928.78 d P = 18.1mm

From the proportion table, we take d P = 17mm.

Figure 23 Auto CAD Designed Shaft for pinions

I have taken total length of shaft for pinion gears Lp = 140mm

There are totally five shafts for five planetary gears (pinions), so this design includes these
five shafts.

4.11.4 Design of key for the gear’s shaft

The type of key I have selected for the shaft is Rectangular key made up of Mild steel having
the crushing and shear stresses of 320Mpa and 160Mpa respectively.

 Width and Thickness of the key

By using the values of shaft diameter (d G = 22mm) from the proportion of standard parallel,
tapered and bighead keys table, I have selected the width and the thickness of the key

Width (w) = 8mm and Thickness (t) = 7mm

 Length of key

By considering the shearing of key, the tangential shearing force acting at the circumference
of the shaft,

F = Area resisting shearing × Shear stress = l × w × τ

∴ Torque transmitted by the shaft,

dG d
T = F× =l×w × τ× G where; d G is the diameter of gear shaft
2 2

22
= l × 8 × 160 × = 140l
2

We know that

π 3 π 3
T= × τ ×d G = ×160 × 22 = 334,516.8
16 16

140l = 334,516.8 l = 23.76mm ≈ 24mm

By considering the crushing of key,

Torque transmitted by the shaft,

t d π 3
T = l × × σc × G = × τ ×d G
2 2 16
 7 22 π 3
= l × ×320 × = ×160 × 22
2 2 16

1,120l = 30,410.62 l = 27mm

We have to take the largest, so the length of key for the gear shaft (l) is 27mm

Figure 24 Auto CAD Designed key for gear shaft

4.11.5 Design of key for the pinion shaft

The key is made up of the same material as that of gear’s shaft key

 Width of the key

By using the shaft diameter (d P=17 mm ) value from the proportion of standard table,

Width (w) = 6mm and Thickness (t) = 6mm which is square key

The key is strong in shear and crushing because of squared

 Length of the key

By considering the shearing of key for the pinion,

Torque transmitted by the shaft is

dP
T=l×w × τ× where; d P is the diameter of pinion shaft
2

We know that

π 3
T= × τ ×d P
16

dP π 3
T = l ×w×τ× = × τ ×d P
2 16
 17 π 3
l ×6 × 160 × = ×160 × 17
2 16

l = 18.9mm ≈ 19mm

By considering the crushing of the key

Torque transmitted by the shaft is

t d π 3
T = l × × σc × P = × τ ×d P
2 2 16

6 17 π 3
= l × ×320 × = ×160 × 17
2 2 16

l = 18.9mm ≈ 19mm

The length of the key for the crushing and shearing are equal so we take either of them

l = 19mm

4.11.6 Design of Bearings

Bearing are machine elements included to support axles and shafts or sliding components.
They take up the radial and axial loads imposed on the shaft or axle or sliding member they
carry and transmit them to the casing or machine body. In this system to slide the bases
horizontally over one another the bearing must be needed. After analyzing the difference types
of bearings we have decided to select ball bearings. During selection bearing we have
considered the following parameters;

1. Basic dynamic load rating (C)

2. Basic static load rating (co)
3. Combined radial and thrust load (p)

For design project we select deep groove bearing because load capacity by the number of balls
and primarily designed to support radial loads the thrust load capacity is about 70% of the
radial load.

Bearing life
Life: number of revolution or hours operating at constant speed required the failure criterion
develop.

Rating life: design the number of revolution or hours of operation at constant speed in such a
way that 90% the bearing tested (from the same group) will computer exceed before the first
evidence of failure develops.

Basic dynamic load: contact radial load that a group of bearing can carry for l0 life.

C a
L0 = ( ¿ Where a is constant (a = 3) for ball bearing and a = 10/3 for roller bearing
F

F = applied radial load

C= dynamic load rate

 4.11.7 Design of cranking lever
I have selected 30C8 material of carbon steel for the cranking lever. The mechanical
properties of carbon steel are as shown below;

 Yield strength = 250MPa,

 Ultimate tensile strength = 400MPa and
 The permissible bending stress of the material is 72MPa

The lever can be operated either by a single person or by two persons. The maximum force in
order to operate the lever for single person may be taken as 400 N and the length of handle (l)
as 300 mm. In case the lever is operated by two persons, the maximum force of operation will
be doubled and length of handle may be taken as 500 mm. The handle is covered in a pipe to
prevent hand scoring. The end of the shaft is usually squared so that the lever may be easily
fixed and removed. The length (L) is usually from 400 to 450 mm and the height of the shaft
center line from the ground is usually one meter.

The diameter of the handle (d) is obtained from bending considerations. It is assumed that the
2
effort (P) applied on the handle acts at of its length (l).
3

The lever is designed for a single person, so maximum force (P) = 400N and length of handle l
= 300mm.

 Diameter of handle

Let d = Diameter of the handle in mm.

Since the force applied acts at a distance of 2/3 length of the handle from its free end,
therefore maximum bending moment,

2 2
M = P× L = 400× (450) = 120,000Nmm
3 3

π 3
Section module; Z= d
32

Resisting bending moment;

M = σ b ×Z therefore;
 π 3
120,000 = 72× d
32

3 32× 120 ,00

d = = 16976.53
72× π

d = 25.7mm the diameter of the handle is proportioned as d = 25mm

 Cross section of the lever arm

The cross-section of the lever arm is usually rectangular having uniform thickness throughout.
The width of the lever arm is tapered from the boss to the handle. The arm is subjected to
constant twisting moment,

2
T= ×P×l
3
And a varying bending moment which is maximum near the boss. It is assumed that the arm
of the lever extends up to the center of shaft, which results in a slightly stronger lever.

Maximum bending moment = P × L

The lever arm should be designed for 25% more bending moment.

Maximum bending moment

M = 1.25×P×L = 1.25×400×450 = 225,000

Let t = Thickness of the lever arm, and

B = Width of the lever arm near the boss (B = 2t)

1
Section module Z= ×t× B2
6

M
Using the relation σ b = the following calculation is done
Z

225,000 225,000
337,500
72 = 1 3 = 1 2 = 3
×t × B ×t ×(2 t) t
6 6

3 337,500
t = = 4,687.5 t = 16.736mm say 17mm
72

Width b = 2×17 = 34mm

Let us now check the lever arm for induced bending and shear stresses. Bending moment on
the lever arm near the boss (assuming that the length of the arm extends up to the center of
shaft) is given by;

M = P×L = 400×450 = 180,000Nmm

1 1
Section module Z= ×t× B2 = ×17×34 2 = 3,275.33mm3
6 6

M 180,000
Induced bending stress (σ b) = =
Z 3,275.33

σ b = 54.956MPa this value is less than the permissible bending stress of the material.

So, the induced bending stress is in safe limit.

We know also the twisting moment,

2 2
T= ×P×l = ×400×300 = 80,000Nmm where, l is length of the handle.
3 3

We also knows the twisting moment,

2 2
T= ×B×t 2 × τ = ×34×17 2 × τ = 80,000
9 9

80,000
τ= = 36.637MPa which is less than shear stress for the material of shaft (101MPa)
2,183.56

The induced shear stress is again in safe limit.

Let us know check the cross section of lever arm for maximum principal or shear stress

1 1
σ b(Max) = (σ b+√ σ b2 + 4 τ 2 ) = (54.956+√ 54.9562 +4 (36.637)2 )
2 2

σ b(Max) = 73.3MPa

And maximum shear stress,

1 1
√ σ b + 4 τ = × √ 54.956 + 4(36.637 ¿¿ 2) ¿ = 45.8MPa
2 2 2
τ (Max) =
2 2

The maximum principal and shear stress are also in safe limit.
  Diameter of the journal (D)

Since the journal of the shaft is subjected to twisting moment and bending moment, therefore
its diameter is obtained from equivalent twisting moment.

We know that equivalent twisting moment,

√
2
T e = P× ( 2 ×l + x) + L2 where, x is distance from the end of boss to the center of journal.
3

√
2
= 400× ( 2 ×300 +100) +4502 = 216,333Nmm
3

We know that equivalent twisting moment, (T e)

π 3 π 3
216,333 = ×τ ×D = ×101 × D = 19.83 D3
16 16

3 216,333
D = = 10,908.66
19.83

D = 22.2mm say 24mm

4.11.7 Design of steel plate for gear box

The selected material for steel plate design is high carbon steel, which have excellent weld
ability by standard fusion method both with and without filler metal.

 The density of steel plate of grade 304 L/H is 7900 Kg/m2,

 tensile strength of 515N/mm2,

 yield strength of 205N/mm2,

 BHN of 201 and resisting force of 50,777KN.

The steel material has good corrosion resistance, good oxidization resistance in intermediate
service, higher machinability, low cost and better resistance in high temperature.

 Base plate

Length and Width of the plate depends up on the pitch circle diameter of gear and pinion and
the values of addendum.
 Dp 38
L = W = 2×(L+ +Addendum) = 2×(57.17+ +2.25) = 2×78.42 = 156.84mm
2 2

L = W =157mm the plate is square.

I have taken the thickness of the plate (t) = 8mm

Here the figure below shows the base plate is square with five pinion shaft bores, four bolt
bores and one gear shaft bore.

Figure 25 Auto CAD Base plate

The bore diameter of the plate (D) is designed below in the nut and bolt design = 6.843mm.
The bolt spacing is 72° . The number of bolts is 4.

 Side plates of gear box

There length is the same as that of the previous plate (L = 157)

The width of the plate depends up on the overhanging distance of shaft. I have taken the
overhanging distance 60mm

W = 64mm and Thickness (t) = 4mm

 Cover plate of the gear box

The length and width are proportional to that of base plate but I have taken the thickness (t) =
4mm. All the gear box plates are made from the same material.

4.11.8 Design of Bolt and Nut

The selected material for bolt and nut is medium carbon steel.

Here the table below shows Metric Mechanical properties with grade making per ISO898-1
FOR carbon steel externally threaded fasteners.

Table 4.3 metric mechanical properties of carbon steel.

Metric Material Size Minimum Minimum Minimum yield
property Range proof tensile strength Mpa
class strength strength
Mpa Mpa
8.8 Medium M5-M16 580 800 640
carbon steel
Quenched
and tempered

I have selected M12 from the standard dimension of screw thread.

Designation Pitch Major Effective Minor or Core Depth of Stress area

mm diameter of pitch diameter (dc) thread (mm 2)
Nut and Bolt diameter of mm (bolt)
(d=D) mm Nut and Bolt mm
(dp) mm Bolt Nut

M12 1.75 12 10.863 9.858 10.106 1.074 84

 The bore diameter (D)

For bolts of uniform strength,

π 2 π
× D = ×( Do2- Dc2 )
4 4

D = √ Do2−Dc2 where, D is bore diameter

Do is outer diameter

Dc is core diameter

So, D= √ 122−9.8582 = 6.843mm

Although stress area is found from the table, there is formula to find it.

π dp+ dc 2
Stress Area = ( ) where, dp is pitch diameter and dc is core diameter
4 2

 Stress due to external load

The bolt is subjected to an axial load and the weakest section will be at root of the thread.
π 2
P= ×dc ×σ t
4
 π 2
= ×9.858 × 800 = 61060N
4
This is also the tensile load.
 Stress set up in the bolt (σ t)

Initial tension in the bolt;

P = 2840×d where, d is major diameter

P = 2840×12 = 34080N

4.11.9 Design of table for gear box

The various dimensions of the table are fixed as follows:

Minimum height of table = 800mm and Maximum height of table = 1000mm

Length of table = 800mm

Width of table = 500mm

All horizontal frames, supports and legs of a table are 40mm by 40mm square hallow mild
steel having a thickness of 1.5mm.

 Reaction forces on the leg of the table

When the gear box is loaded on the table, there is a reaction forces on the leg of the table
which acts in the upward direction as shown in the figure below.

WT

2F 2F

 Reaction forces
W T Is the total weight of gear box neglecting the weight of shaft, key and lever and F
is the reaction force on each leg of a table.
 ❑
∑
❑
F y =0 … … … … … … … … … … … … (4.19)

W −4 F=0

4 F=W

Therefore reaction force on each leg of a table is 0.25W.

Then the weight of the gear box is calculated as follows.

The gear box weight includes the weight of gears, pinions, and the gear box plate.

 Weight of the gear and pinion

w G = 0.00118×T G ×b× m2 = 4.56992N and

w P = 0.00118×T P ×b× m2 = 2.3N

 Weight of the gear box plate

 Volume for the base plate

For the base plate, mass (m) is equal to the density of the material ( ρ ) times the volume of the
plate (V).

W = m×g

Volume of the base plate = Total volume of base plate – volume of the bore

V bp = V Tb - V bo where, V bo is the bores of pinion shaft, gear shaft and bolt

V bo = [4×V bo(bolt) ] + [5×V bo( pinion)] + V bo (gear )

V bo (bolt ) = π r 2 ×t where, r is radius of the bore and t is the thickness of the bore.

= 3.14159 ×0.0034215 2 ×0.008

V bo (bolt ) = 2.942205×10−7 m3

V bo ( pinion) = π r 2 ×t where, r is radius of pinion shaft bore.

= 3.14159 ׿0.008

V bo ( pinion) = 1.81584×10−6 m3
 V bo (gear ) = π r 2 ×t where, r is radius of gear shaft bore.

= 3.14159׿ 0.008

V bo (gear ) = 3.041×10−6 m3

Therefore,

V bo = [4×2.942205×10−7] + [5×1.81584×10−6] + 3.041×10−6

= 1.176882×10−6 + 9.0792×10−6 + 3.041×10−6

V bo = 1.32971×10−5 m3

The volume of base plate

V bp = (L×W×t) = 0.157×0.157×0.008 = 2.465×10−4 m3

Therefore,

V p = 2.465×10−4 m3 – 1.32971×10−5 m3 = 2.332×10−4 m3

 Volume for the side plate (V sp )

V sp = (L×W×t) of the side plate

= 0.157×0.064×0.004 = 4.0192×10−5 m3 there is no bore. There are four equal side

plates for the box.

 Volume the cover plates (V cp ¿

V cp = V Tc - V bo where, V Tc is total volume of cover plate and V bo is the total bore volume

V bo = [4×V bo(bolt) ] + [5×V bo( pinion)] + V bo (gear )

V bo (bolt ) = π r 2 ×t where, r is radius of the bore and t is the thickness of the

bore.

= 3.14159 ×0.0034215 2 ×0.004 = 1.4711×10−7 m3

V bo ( pinion) = π r 2 ×t where, r is radius of pinion shaft bore.

= 3.14159 ׿0.004 = 9.0792×10−7 m3

V bo (gear ) = π r 2 ×t where, r is radius of gear shaft bore.

 = 3.14159׿ 0.004 = 1.52×10−6 m3

Therefore,

V bo = [4×1.4711×10−7] + [5×9.0792×10−7] + 1.52×10−6

= 0.73555×10−6 + 4.5396×10−6 + 3.041×10−6

V bo = 8.169×10−6 m3

V Tc = (L×W×t) of cover plate

= 0.157×0.157×0.004 = 9.8596×10−5 m3

Therefore,

V cp = 9.8596×10−5 m3 - 8.169×10−6 m3 = 9.042696×10−5 m3

 The total volume of the all plates (V T ¿

V T = V bp+ (4×V sp ¿ +V cp =2.332×10−4 + (4× 4.0192× 10−5 ¿ + 9.042696×10−5

V T = 4.84395×10−4 m3

Therefore, the mass of the plates is calculated by;

mP = V T × ρ =4.84395×10−4 m3 ×7850 Kg/m3 = 3.8Kg

So, W Plate = 3.8Kg×10m/sec 2 = 38N

 Total weight of the gear box

The total weight includes the weight of gear, pinion, and the box plate.

W T = W Gear + W Pinion + W Plate = 4.56992+2.3+38 = 44.8699 ≈ 45N

 Reaction forces

4F = W T

W T 45
F= = = 11.25N
4 4

Therefore the reaction force on each leg is 11.25N in upward direction.

 4.11.10 Lubrication for gears
From the types of gear lubrication, I have selected greases for open and enclosed gears.

Greases (For Open and Enclosed Gears)

Adhesive greases of NLGI 0, 1 or 2 consistency are sometimes used on open gears where high
temperature conditions prevail or where leakage of a thinner lubricant might contaminate
materials being processed. EP or non-EP greases can be used and application is made by
brush, paddle or pressure gun. Greases softer than NLGI No. 0 consistency are being used in
enclosed gear sets, particularly in coal mining machinery, where high operating temperature
and leakage are factors. Application is usually made by pressure gun.
 CHAPTER 5

5. CONCLUSSION AND RECOMMENDATIONS

5.1 Conclusion
In the internship I conclude that AMWETC Company provides granted full automotive
periodic service and maintenance with sufficient equipment and skilled manpower to satisfy
their customers need. Many customer services their automobile periodically and it’s very
important to get maximum life of the automobile, save the customer from unwanted extra cost
for repair and protect from traffic accident that caused by sudden failure of different parts.
Internship program benefits both students and companies. Companies got benefit through
additional man power and the student benefits from additional knowledge, technical skill and
even challenges faced.in the internship I got more knowledge and work experience that I had
before. Finally, I suggest that automotive companies should provide the chance for intern
students to practice in their organization to have more knowledge and automotive companies
like MOENCO need to be encouraged.

This internship practice had been conducted in order to the fulfillment of partial requirements
to receive degree of bachelor science in mechanical engineering at Arba Minch University and
the report has been written just as to explain what things have been done in the company
during the four months of practice.

During and after accomplishment of excellent internship periods, I reach to the end that;

 Gaining knowledge from practical work is easier than from theoretical learning process. It is
not to mean that only practical work is enough to be well professional but for students related
with technological field of study, standard and well-equipped laboratory is essential together
with class learning.
 Internship period is used to develop students’ knowledge; to create new invention, to develop
practical knowledge, to identify problems, to analysis and solving problems that faces the
societies and also helps students to test their own future life.

I had seen behavioral changes on workers of company and maintenance foreman assure to
prepare maintenance manual so that they will continue to work based on it.
 5.2 Recommendation
For Arba Minch University I suggest that the internship program is very necessary thing for
mechanical engineering department so it must be continuous. Also, I suggest that it must be
more than one semester.

And for AMWETC Company I suggest to prepare transportation service for student and to
finish and give the evaluation paper and attendance in proper time because they took many
days to give that.

AMWETC lasts long since its establishment in 1991. Due to this case most of the machines
are old and they need standardized maintenance. Therefore, the management department
should take the case in to consideration and maintenance should take place as soon as possible.

Maintenance must be in schedule so that the wastage of materials should be minimized and the
company would be profitable and effective production should be attained. AMWETC
Company should give more opportunity for students in practice. This may help them to use
full knowledge of students at low cost.

Finally, health centres should give qualified services for workers so that no one would be
absent from work place due to health problems. I tried to recommend this depending on the
information I got from some workers.
 REFERENCES

1. A Textbook of Machine Design” by V.B Bhandari. edition 3

2. “A Textbook of Automobile Engineering” by Dr. Kirpal Singh.

3. 1G.Mohankumar, 2K.Abin, 3K.Akhil, 4I.V.Akshay, 5Jisin Alex Varghese

4. 1PG Scholar, 2,3,4,5UG Students, Final year, Department of Mechanical Engineering,

Gnanamani College of Technology, Namakkal, Tamilnadu, India.

5. Innovative Design of Multi Jaw Wrench and its Analysis Dheeraj Singh1, Ashish
Srivastava2, Gaurav Verma3, Manasi Chauhan4, Amit Gupta5

6. International Journals of Mechanical and Production Engineering, ISSN: 2320-2092,

Volume 5, Issue-4, Aprl.-2017 http://iraj.in Innovative Bolt Design, ROBIN RANJAN,
2KEDAR MEHTA

7. International Advanced Research Journal in Science, Engineering and Technology.

2nd International Conference on Advances in Mechanical Engineering (ICAME-
2016) Amrutvahini College of Engineering, Sangamner Vol. 3, Special Issue 1,
March 2016 Design and Modeling of 6 In 1 All – Nut Remover for Automobile
Wheels

8. IJSTE - International Journal of Science Technology & Engineering | Volume 4 |

Issue 1 | July 2017 ISSN (online): 2349-784X, All rights reserved by www.ijste.org;
Design and Development of Multi nut Remover in Automobile Industry

9. International Material Grade Comparison Table

10. 30C8 Carbon Steel, Carbon Steel _ Mannurpet, Padi, Chennai _ Saaj Steel
Corporation _ ID_ 11134258391

11. V. B. Bhandari, Design of Machine Elements, Tata McGraw Hill Publishing House
Ltd., Second Edition.

12. Dr. N. C. Pandya, Dr. C. S. Shah, Machine Design, Charotar Publishing House Pvt.
Ltd., Seventh Edition.
 APPENDIX I
Auto-Service Department Maintenance Schedule for Periodic Service

Table 1 Types-A service

5/15/25/35/45/55/65/75,000 km service

No
COMPONENT TO BE MAINTENANCE
REPAIRED CODE
1 Brake pads disc I
2 Steering knuckle drag link king pin, R
center arm and steering linkage grease
3 Engine oil with filter R
4 Fuel element R
5 Air cleaner I
6 Battery I
7 Steering wheel linkage & gear box oil I
8 Propeller shaft grease L
9 Tithing propeller shafts bolts & nuts I
10 Front and rear suspension I
11 External leakage if any I

Key A= check &/or adjust as necessary

I= inspect & correct or replace as necessary

R= replace, change or lubricate

L= lubricate
 APPENDEX II

Table 2 Type-B service (10,000/30,000/50,000 &70,000 Km service)

MAINTENANCE
No COMPONENT TO BE REPAIRED CODE
1 Brake pads, discs & drums I
2 Steering knuckle, drag link, king pin, center arm & steering R
linkage grease
3 Brake disc run-out I
4 Drive shaft boots I
5 Tightening drive shaft bolts I
6 Ball joint & dust covers I
7 Brake pedal & parking brake I
8 Brake line pipes & hoses I
9 Brake fluid I
10 Clutch fluid I
11 Power steering fluid I
12 Steering wheel linkage & steering gear box oil I
13 Engine oil with filter R
14 Fuel filter and fuel element R
15 Air cleaner I
16 Water sedimentary I
17 Battery I
18 All light, horns, wipers & washers I
19 Propeller shafts L
20 Tightening propeller shaft bolt and nuts I
21 Bolts & nuts on chassis & body I
22 Front and rear suspensions I
23 Tire & inflation pressure I
24 External leakage if any I
 APPENDEX III
Table 3 Type- C service, (20,000km & 60,000km service)

No COMPONENT TO BE REPAIRED MAINTENANCE

CODE

` I
1 Brake pads, discs & drums
2 Steering knuckle, drag link, king pin, center arm & steering linkage R
grease
3 Brake disc run-out I
4 Drive shaft boots I
5 Tightening drive shaft bolts I
6 Ball joint & dust covers I
7 Brake pedal & parking brake I
8 Brake line pipes & hoses I
9 Brake fluid I
10 Clutch fluid I
11 Power steering fluid I
12 Steering wheel linkage & steering gear box oil I
13 Wheel bearing grease R
14 Engine oil with filter R
15 Fuel filter and fuel element R
16 Air cleaner I
17 Water sedimentary I
18 Drive belt I
19 Vacuum pump oil hoses I
20 Idle speed A
21 Battery I
22 All light, horns, wipers & washers I
23 Propeller shafts L
24 Tightening propeller shaft bolt and nuts I
25 Bolts & nuts on chassis & body I
26 Front and rear suspensions I
27 Exhaust pipes & mounting I
28 Differential gear oil I
29 External leakage if any I
30 Air conditioning/cooler refrigerant I
31 Tire & inflation pressure I
 APPENDEX IV
No COMPONENT TO BE REPAIRED MAINTENANCE
CODE
1 Brake pads, discs & drums I
2 Steering knuckle, drag link, king pin, center arm & steering linkage R
grease
3 Brake disc run-out I
4 Drive shaft boots I
5 Tightening drive shaft bolts I
6 Ball joint & dust covers I
7 Brake pedal & parking brake I
8 Brake line pipes & hoses I
9 Brake fluid I
10 Clutch fluid I
11 Power steering fluid I
12 Steering wheel linkage & steering gear box oil I
13 Wheel bearing grease R
14 Engine oil with filter R
15 Fuel filter and fuel element R
16 Air cleaner I
17 Water sedimentary I
18 Drive belt I
19 Vacuum pump oil hoses I
20 Idle speed A
21 Battery I
22 All light, horns, wipers & washers I
23 Propeller shafts L
24 Tightening propeller shaft bolt and nuts I
25 Bolts & nuts on chassis & body I
26 Front and rear suspensions I
27 Exhaust pipes & mounting I
28 Differential gear oil I
29 External leakage if any I
30 Air conditioning/cooler refrigerant I
 APPENDEX V

PART DRAWING

Plates
Central gear

Planetary gear (pinion)

Shafts of gear ad pinion
Cranking lever
Socket

Table for gear box

ASSEMBLY
SECTIONED
EXPLODED