Kelvin K Koske Project-1
Kelvin K Koske Project-1
Kelvin K Koske Project-1
INDEX NO : 4011030227
ENGINEERING.
1
DECLARATION
I declare that this Trade project is my own original work and it has not been presented to the
Kenya National Examination council or any other examination body for the purpose of training.
SIGNATURE: ……………………………
DATE : …………………………..
SUPERVISOR
SIGNATURE: ……………………………
DATE : ………………………………….
i
DEDICATION
I dedicate this write-up to my family and friends. They have been of great assistance to make all
this a success through their contribution in terms of finances and moral support as I take up this
assignment.
ii
ACKNOWLEDGEMENT
I sincerely appreciate the heavenly father for the good health, strength and provision throughout
the production process of this work.
My gratitude to my beloved parents and friends who did wonderful laborious and costly task in
the support of this work. I am also indebted to my supervisor for the guidance towards the
accomplishment of this work.
I wish to acknowledge the larger RTI fraternity for the incredible support in my academic
journey with the aim of realizing what I’m worth in national building.
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ABSTRACT
The trade project contains the following,
CHAPTER ONE
In this chapter the introduction of the project is captured. This include the background
information in which the project will be located in the automobile workshop. It also includes the
problem statement, that is the challenges to be solved thus aims of the project and the objective
of the project, the scope of project and limitations affecting the project, theoretical statement, the
definition of the concept under the working principles of the project, the hypothesis and the data
technique of the project obtained from different sources.
CHAPTER TWO
In this chapter the literature review of the project is discussed i.e. the components in which the
project consist of their functions, the material used and the reason for using the component.
CHAPTER THREE
This chapter has an outlook of the project designing and construction i.e. obtaining the forces
required or excreted by the design of different components used in the project. It also contains
the component layout and the maintance schedule.
CHAPTER FOUR
The findings and the data analysis are tabulated rom this chapter, this is by getting the test
procedures and result, the project cost analysis, objectives of whether the original objectives are
met, the application and the significance of the result and also the recommendation of the trade
project.
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TABLE OF CONTENTS
DECLARATION ............................................................................................................................. i
DEDICATION ................................................................................................................................ ii
ACKNOWLEDGEMENT ............................................................................................................. iii
ABSTRACT ................................................................................................................................... iv
CHAPTER ONE ............................................................................................................................. 1
1.1 BACKGROUND INFORMATIONS ................................................................................... 1
1.2 PROBLEM STATEMENT ................................................................................................... 2
1.2.1 Aims of The Object ........................................................................................................ 3
1.2.2 Project Objectives ........................................................................................................... 4
1.3 SCOPE AND LIMITATION ................................................................................................ 5
1.3.1 Scope .............................................................................................................................. 5
1.3.2 Limitations ...................................................................................................................... 6
1.4 THEORETICAL STATEMENT .......................................................................................... 7
1.5 DEFINITION OF CONCEPT ............................................................................................... 8
1.5.1. Working Principle.......................................................................................................... 9
1.5.2 The Moving Parts ......................................................................................................... 10
1.5.3 The Transmission Principle of Force............................................................................ 11
1.6 THE HYPOTHESIS ............................................................................................................ 12
1.7 DATA TECHNIQUES/METHORDS ................................................................................ 13
1.7.1 Data collection .............................................................................................................. 13
1.7.2 Data presentation .......................................................................................................... 14
1.7.3 Data Analysis ................................................................................................................ 15
CHAPTER TWO .......................................................................................................................... 16
2.0 LITERATURE REVIEW .................................................................................................... 16
2.1 THE BEARING REMOVER ARMS ................................................................................. 16
2.2 THE HYDRAULIC JACK.................................................................................................. 17
2.3 JACK SEATS...................................................................................................................... 18
2.4 THE JACK ROD................................................................................................................. 19
2.5 THE BOLTS AND NUTS .................................................................................................. 20
CHAPTER THREE ...................................................................................................................... 21
3.0 PROJECT DESIGN AND CONSTRICTION .................................................................... 21
3.1 DESIGN OF THE HYDRAULIC JACK. ........................................................................... 23
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3.2 DESIGN OF BEARING REMOVER ARMS .................................................................... 25
3.3DESIGN THE JACK SEAT ................................................................................................ 26
3.4 DESIGN THE JACK ROD ................................................................................................. 28
3.5 THE BOLTS AND THE NUTS.......................................................................................... 29
3.6 MAINTENANCE SCHEDULE .......................................................................................... 31
CHAPTER FOUR ......................................................................................................................... 33
4.0 FINDINGS AND DATA ANALYSIS ................................................................................ 33
4.1 DESIGN FINDINGS AND OBSERVATIONS. ................................................................ 33
4.2 DATA ANALYSIS ............................................................................................................. 34
4.3 PROJECT COST ANALYSIS ............................................................................................ 35
4.4 APPLICATION AND SIGNIFICANCE ............................................................................ 37
4.4.1 Application ................................................................................................................... 37
4.4.2 Significance .................................................................................................................. 38
4.5 RECOMMENDATION ...................................................................................................... 39
CONCLUSION ............................................................................................................................. 40
REFERENCES ............................................................................................................................. 41
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CHAPTER ONE
DESIGN AND FABRICATION OF A HYDRAULIC OPERATED BEARING REMOVER
SYSTEM
The hydraulic operated bearing remover will be used to remove the bearings located in the
gearbox, engine, the hub and differential unit.
(ii)Improve safety.
The other bearing remover methods used in the automobile industry are;
1
1.2 PROBLEM STATEMENT
The challenges to be solved by this hydraulic operated bearing remover system are;
2.Wastage of time
3.Damges on the bearing. The use of hydraulic operated bearing remover method will reduce the
damages on the bearing, usually seen when using the two-arm bearing puller method and splitter
plates method.
2
1.2.1 Aims of The Object
1. Strong bearing remover arms to avoid damages on the bearing.
2. The use of hydraulic jack to provide more effort applied in the removal of the bearing thus
making it easy.
3. The use of jack seats to provide more stable location of the bearing remover on the jack.
4. The use of jack rod to apply more force and reduce time used in the bearing removal.
5. The bolts and nuts hold the bearing remover on to the jack firmly thus improving safety during
bearing removal.
3
1.2.2 Project Objectives
1.Design bearing remover arm
6.Maintanance schedule
7.Project costing
4
1.3 SCOPE AND LIMITATION
1.3.1 Scope
The designed hydraulic operated bearing remover, will be located in the automative, to be used
in the removal of bearings.
The hydraulic bearing remover system, eases the removal of the bearing, improve safety, reduces
time wastage and provide more advanced technology to the informal sectors.
1.The bearing remover is portable and will be used in removing the bearings located in the
gearbox, engine hub, axle and differential unit.
2.The hydraulic bearings remover will be serviced by the use of oil and application of grease to
the moving parts to reduce friction.
3.The oil will be applied to surfaces of bearing remover to be more efficient and avoid rusting.
4.The arms and the screw caps of the designed hydraulic bearing remover will be replaced in
case of any breakage.
5.The materials to be used in the design of the hydraulic operated bearing remover are; steel
5
1.3.2 Limitations
The challenges expected from the hydraulic operated bearing remover system will be;
2.Corrosion of the arms, seats, bolts and nuts thus use of oil and grease to avoid it.
3.The cost of acquiring the arm of replacement may be higher together with the screw caps.
4.Improved technology or the use of more advanced technology may bring more competition.
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1.4 THEORETICAL STATEMENT
(a) The bearings are expected to be removed by the hydraulic operated bearing remover system,
are located in the engine, gearbox, the hub, the drive shaft and the differential unit.
2.Roller bearings.
3.Thrust bearings.
4.Plain bearings.
(C)The use of hydraulic bearing remover saves the man power, low cost and also saves time.
(d)The hydraulic principle applied is the use of hydraulic jack which provides force in the
removal of the bearing.
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1.5 DEFINITION OF CONCEPT
The principle use by the hydraulic operated bearing remover is the hydraulic lifting system.
3.Torque.
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1.5.1. Working Principle
1.Use of hydraulic jack handle.
4.The bearing remover is attached to the ram and the other pulling end of the bearing remover is
attached to the bearing.
5.When the jack is operated the bearing remover goes upward and so the bearing is pulled out of
its place.
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1.5.2 The Moving Parts
(I)The ram in the jack
. The ram holds the hydraulic bearings remover by the use of bolt and nuts.
. When the force is applied to the hand the upward and downward movement make the ram to
move thus moving the bearing remover.
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1.5.3 The Transmission Principle of Force
When the handle is pushed upwards and downwards, the high-pressure oil in the hydraulic jack
pushes the ram connected to the bearing remover, which provide force for easy removal of the
bearing.
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1.6 THE HYPOTHESIS
1.The hydraulic operated bearing remover arms should be able to produce a torque of about 4
tonnes and strong force that can easily pulls the bearing.
2.The hydraulics force produced by the hydraulic jack should not be less than 5 tonnes for easy
removal of the bearing due to the force applied.
3.The strength of the jack seats should be high for better holding of the arms.
4.The pulling force of the arms should be very high and the material used in its production
should be non-corrosive and resistance to wear for it to be long lasting.
5.The lifting and the pulling forces of the rod used in the jack should be high to avoid it from
getting broken during bearing removal.
6.The securing bolts and nuts should be resistance to corrosion, have high strength, high
resistance to wear for it to hold the bearing remover tightly into the jack.
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1.7 DATA TECHNIQUES/METHORDS
1.Direct observation
(i) Service the engines, gearbox, differential and how they overhaul them.
(III)Jack used in the lifting the vehicles. Most of the organizations use the hydraulic jack.
(IV)Methods used in their bearing removal, Isuzu use the splitter plate method while Toyota and
Subaru use the two-arm bearing puller method.
This data will help on improving the quality of work done in the formal sectors.
2.Questionnaires
Questionnaire on;
(I). Method used in bearing removal. Isuzu motors mainly uses the splitter method while both
Toyota and Subaru use the two-arm bearing puller method.
(II)The jack used in lifting the vehicles in all organization is the vehicle in all organization is the
hydraulic operated jacks.
(III)How overhauling the engine, gearbox, and differential unit are carried out
3. Internet
1.Steps and procedure on how to overhaul, service and assemble the engine, gearbox and
differential unit.
2.More strong tools to use; spanners, jack that reduces time wastage.
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1.7.2 Data presentation
1 Graphs
They are used to analyze the different data collected from the three automobile organizations.
They use of two arm bearing puller is mostly used then the splitter plate bearing remover
method.
2.Tables
Tables are down to differentiate on how the three automobile organizations overhauls, service
and assembles the engine, gearbox and differential unit.
3.Pictorial
Used for later reference on the different tools used i.e spanners and jacks
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1.7.3 Data Analysis
Statistical method is used to analyze the most used or commonly used spanners, jacks and
methods of overhauling and servicing the engine, gearbox and differential unit from the three
organizations.
15
CHAPTER TWO
DESIGN AND FABRICATION OF A HYDRAULIC OPERATED BEARING REMOVER
SYSTEM
The reason for using the arms is to provide more safety and easy removal of bearing.
The bearing remover should be strong to enable it to provide more safe way of bearing remover
and thus the bearing remover arms will be made of mild steel since it has high strength.
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2.2 THE HYDRAULIC JACK
The functions of the jack are to provide force in which the bearing remover is applied for it to
easily pull the bearing.
It also reduces the effort used by the operator in removing the bearing.
The materials used for making the hydraulic jack is steel due to its strength.
The reason for using the hydraulic jack is that it reduces the fatigue employed by the worker.
It also saves time in bearing removal since the force applied is high.
17
2.3 JACK SEATS
The function of the jack seat is where the bearing remover is joined on to the jack
Reasons for using it is to provide a good holding position of the bearing remover onto the
hydraulic jack.
The materials used in making the seats is mild steel to provide high stress.
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2.4 THE JACK ROD
The function of jack rod is to provide the force required in pulling the bearing.
The mild steel has high strength and stress making it suitable for the component.
Reasons for using the jack rod is to provide more force required thus;
. saves time
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2.5 THE BOLTS AND NUTS
The function is to hold the bearing remover firmly on to the jack seats.
They also hold the bearing remover arms firmly on their location.
The material used to make the bolts and nuts is mild steel.
.It improves safety of the operator if it firmly holds the arms on to the jack.
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CHAPTER THREE
DESIGN AND FABRICATION OF HYDRAULIC OPERATED BEARING REMOVER
SYSTEM
Width 12mm
Width 28mm.
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Outside diameter 24mm
Width 7mm
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3.1 DESIGN OF THE HYDRAULIC JACK.
The total force exerted by the hydraulic jack is obtained by;
Pressure=Force/Area
The piston is made of mild steel and the maximum limit of compressive stress that a mild steel
specimen can bear is 407.9N/mm2
(J=F/A)
J=407.9N/mm2
Force=Stress x area
=407.9N/mm2X314.2mm2
=128162.18 N
1kg=9.81N
(128162.18X1/9.81)=13064.4kg
1tonne=1000kg
13064.4x1/1000
=13.064tonnes
Force=407.9N/mm2x1963.5mm2=800911.65N
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1kg=9.81N
800911.65/9.81
=81642.37kg
1tonne=1000kg
1x81642.37/1000
=81642.37kg
81.642 tonnes
(13.064tonnes +81.642tonnes)
=94.706 tonnes.
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3.2 DESIGN OF BEARING REMOVER ARMS
Data on bearing remover arms from the different sources.
= (Force produced/Area)
1 tonne=10KN
1KN=1000N
10KN=10000N
4 tonnes =40KN
(40X1000) =40000N
Area (LXW)
1800 x3=5400mm2
(400000/5400) =7.407N/mm2
25
3.3DESIGN THE JACK SEAT
Data on the jack seats from different.
Stress force/area
Force=2 tonnes
20 x10000= 20000N
𝜋 ∗ 302 /4=706.86mm2
(20000/706.86) =28.29N/mm2
2.8x10000=28000N
28000/1256.64=22.28N/mm2
Stress=2.5x10000=25000N
26
(A= (𝜋𝑑2 /4) =) 𝜋 ∗ 302 /4=706.9mm2
25000/706.9
=35.37N/mm2
27
3.4 DESIGN THE JACK ROD
Data from various sources.
Pressure= force/area
Force=25N
P (25/314.16) =0.0796N/mm2
Force=18N
P=(18/314.16)=0.0573N/mm2
Force=20N
P(F/A)
20/314.16=0.06366N/mm2
28
3.5 THE BOLTS AND THE NUTS
Data on bolts and nuts from different sources.
The sources in which the data were acquired are; Isuzu General Motors, villa motors, Subaru
General Motors and Toyota General Motors
Material strength=400Mpa
M12 bolt=diameter=1.75
Bolt strength=400x2.405
=962Mpa
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M16 bolt
=2.5
400x4.909
=1963.6Mpa
M20
400x7.069
=2827.6Mpa
M24
400x9.621
=3848.4Mpa
30
3.6 MAINTENANCE SCHEDULE
The equipment Checks and services Period of services
The hydraulic jack checks
. Check for the cylinder inside
the jack if it is in correct state. 1month
. Check the piston if has any
breakage or cracks.
. Check the oil level in the tank
Inside the jack.
service
. If the cylinder inside the jack
got any damage then replace
With new ones.
. If the piston has cracks replace
with new ones.
. Then if the oil level is below the
preferred top up.
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Bearing remover arm checks 2months
. check for any crack or a arm.
service
If thare is any cracks or breakage replace
With new ones.
The jack seats Checks 2 months
Check if thare is any cracks.
service
If thare is any weld the part
Jack rod checks 2months
Check for the crack in the rod
service
If thare is any replace with new one or
weld the cracked placed.
Securing bolt and nuts checks
Check for any slip in the bolts then do
Check for the cracks
Check if thare is rust
service
If thare is any slip of the bolts then do
Threading of it or replace with new
ones
If thare is rusting in it, then clean the bolts
And nuts using the oil
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CHAPTER FOUR
33
. A hydraulic jack which provides more effort to help in removal of the bearing.
. Bearing remover arms which are strong to avoid damage of their bearing
. Jack seats to provide stable location of the remover arms on the jack.
Jack rod which provides force and enable the lifting pressure of the jack thus reducing time
wastage.
. Bolts and nuts to hold the bearing remover firmly on to the jack seats improving safety during
the bearing removal.
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2.The bearing remover arms suitable for the projects should be able to produce a pressure of
7.407N/mm2 and excrete a force of 4 tonnes.
3.The jack seat suitable for the project should be able to produce a stress of range between
28.29N/mm2. And 35.37N/mm2 as from the data in chapter 3.
4.The jack rod used should produce a pressure of the range 0.0796-0.06366N/mm2 with a force
of 25N from the data excreted from different source seen in chapter 3
5.The bolts and nuts suitable for this project made of mild steel should be able to have a strength
and range 962Mpa and 3848Mpa as excreted from different sources in chapter 3. But the
preferred best bolts and nuts used should have a strength of 1963.6Mpa.
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Hydraulic jack cylinder 1 1500 1500
piston 1 1200 1200
oil 1litre 1100 1100
grease 1kg 900 900
Bearing remover arms arms 3 2000 6000
Jack seats seats 3 500 1500
Jack rod rod 1 800 800
Bolts and nuts bolts 3 100 300
nuts 3 100 300
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4.4 APPLICATION AND SIGNIFICANCE
4.4.1 Application
This project will be applied in the car industry i.e the genersl motors in the removal of the
different bearings in the different parts of the vehicle.
I. Ball bearings
iii.plain bearings
For the;
I.gearbox
ii.engine
iii.differential unit
iv.the hub
37
4.4.2 Significance
The application of this project will be applied in the car industry will enable the following
significance;
38
4.5 RECOMMENDATION
The operator dealing with the hydraulic bearing remover should ensure good handling of the tool
should also adhere to the maintenance mentioned in chapter three to enable smooth running of
work when using the bearing remover.
The operator should also incorporate. the bearing remover in the correct and good places eg the
gear box,engine,differential unit and hub to avoid damages of the tool and also to ensure safety.
39
CONCLUSION
In order to remove and installed bearing safely, to make modification in traditional methord.The
modification mode in easy removing and installing bearing. The purpose of the project are
simplicity of operation and removing bearing.
40
REFERENCES
1.Mohammed Abuzoid, Mohammed Husnain “INBULT HYDRAULIC JACK IN
AUTOMOBILE VEHICLES”. International journal of innovation in Engineering and
Technology, vol.2 Issue 2April 2013,ISSN:2319-1058.
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