INTERNSHIP REPORT

PROJECT TITLE: ENGINE REPAIR STAND

HOSTING COMPANY: JOHHNY GENERAL AUTO CAR MAINTENANCE AND
ASSEMBLY

Start date for internship; 01/07/22 - End date of internship; 30/09/22

BY; 1, Tsion Abera …………………………………………………………………………Ru3249/11

2, Tsigereda Assefa ………………………………………………………………………Ru4041/11

Advisor; Mr. Abiyou Solomon

Submission Date; 14.Nov.2022
 Declaration
We hereby declare that the work which is being presented in this project is original work of
our own, with the help of our academic and company advisors in Johnny general auto service.
We Tsion Abera and Tsigereda Assefa Mechanical engineering students, have under taken our
internship experience in Johnny general auto car maintenance and assembly (JGACMA) from a
period of 01 July to 30 September 2022 for three months under the guidance of Mr. Abiyou
Solomon (Academic Advisor). Department of mechanical engineering, Jimma institute of
technology, Ethiopia. All relevant resources of information in this paper have been duly
acknowledged. We honestly declare that this written document is our own work.

Student name Signature

Tsion Abera

Tsigereda Assefa

Academic advisor name Signature

Mr. Abiyou Solomon

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 Acknowledgement
First of all, we would like to express our heartfelt gratitude to our almighty God for his
unrestricted power and his mother grace on doing the design in our internship time. we would
like to thank Jimma Institute of Technology and mechanical engineering department for giving
us this internship opportunity with in our hosting company for three consecutive months also We
would like to thank the Johnny General Auto Car Maintenance And Assembly PLC managing
director Johnny Parseghian, Deputy manager Gizachew Tamesgene, supervisor Abel Habte and
our internship advisor Mr. Abiyou Solomon And we would like to extend our special thanks to
the mechanics who works on this company for their continuous unreserved support,
encouragement and professional advice in our project. Their broad knowledge experience
assisted us through our project and their sharp insight helped us to identify interesting study
problem.

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 Executive summary
This internship report is on a three-month regular program on a company in JGACMA. It was a
good experience sharing and learning that we pass in the company. So that this report includes
the different benefits gained and a problem-solving trial by doing a project in designing a
machine that helps the company to avoid the problem.

The objectives of the project to improve the maintenance work for an engine by way of engine
repair stand design. This will reduce time, effort and efficiency will greatly improve.

This paper consists of design analysis, material selection, detail drawing of each part and
assembly drawing of engine repair stand. This equipment is constructed from different parts such
as Handle, Support, Base, Shaft, Mounting plate and Arm, Worm Gear, Bolt and Nut. From the
design analysis that is the stress-strain calculated values of engine repair stand can perform
intended function without failure during maintenance of engine. This equipment is manufactured
easily with low cost due to this when this equipment is fabricated small, medium and also large
garages use this repair engine stand they maintain the engine in international standard, they can
improve the efficiency of the garage.

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TABLE OF CONTENTS
Acknowledgement ………………………………………………………………………………………...iii
Executive Summary …………………………………………………………………………………….....iv
List of figure ……………………………………………………………………………………………..viii
List of table ………………………………………………………………………………………………..ix
Acronyms and Abbreviations ………………………………………………………………………………x
Chapter one ……………………………………………………………………………………………...…1
Background of Johnny general auto car maintenance and assembly ………………………………………1
1.1 History of company ………………………………………………………………………………...…1
1.2 Over view of company……………………………………………………………………………..….2
1.2.1Vision …………………………………………………………………………………………….2
1.2.2Mission …………………………………………………………………………………………...2
1.2.3Goal ……………………………………………………………………………………………....2
1.2.4Future plan ……………………………………………………………………………………….2
1.3 Main product and services ……………………………………………………………………………3
1.4 Main customers ……………………………………………………………………………………….4
1.5 Organizational structure of company …………………………………………………………………5
Chapter two ………………………………………………………………………………………………...8
The overall internship experience ………………………………………………………………………….8
2.1 How we to get to company …………………………………………………………………………...8
2.2Maintenance shop ……………………………………………………………………………………..9
2.2.1Engine maintenance ……………………………………………………………………………....9
2.2.2Transmission/gear box/ maintenance ……………………………………………………………10
2.2.3Clutch maintenance ……………………………………………………………………………...11
2.2.4Differential maintenance ………………………………………………………………...............12
2.3 Inspection work shop ………………………………………………………………………..............12
2.3.1Radiator maintenance …………………………………………………………………………...14
2.4 Body work shop ……………………………………………………………………………………..15
2.5 Latest diagnostics and auto electric work shop ……………………………………………………...16

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 2.5.1Car diagnostics test ……………………………………………………………………………...16
2.5.2Auto electric shop ……………………………………………………………………………….17
2.5.3Battery shop ……………………………………………………………………………………..17
2.6 Nova verta painting booth …………………………………………………………………………...18
2.7 Fiber glass repair and construction ………………………………………………………………….19
2.8 Challenge and their measurement ……………………………………………………...……………19
2.8.1Measurement …………………………………………………………………………………….20
Chapter three ……………………………………………………………………………………………...21
The overall benefits of the internship …………………………………………………………………….21
3.1 In terms of practical skill ……………………………………………………………………………21
3.2 In terms of upgrading theoretical knowldgment …………………………………………………….21
3.3 In terms of inter personal communication skill ……………………………………………………..22
3.4 In terms of team playing skill ……………………………………………………………………….23
3.5 In terms of understanding about work ethics ………………………………………………………..23
3.6 In terms of leadership skill …………………………………………………………………………..24
3.7 In terms of enter premiership skill …………………………………………………………………..24
Chapter four ………………………………………………………………………………………………26
Design and analysis of engine repair stand ……………………………………………………………….26
4.1 Background ………………………………………………………………………………………….26
4.2 Literature review …………………………………………………………………………………….27
4.3 Statement of problem ………………………………………………………………………...……...28
4.4 Working principle of gingene repair stand…………………………………………………………..28
4.5 Objective of project ………………………………………………………………………………….29
4.5.1General objective ………………………………………………………………………………..29
4.5.2Specific objective ………………………………………………………………………………..29
4.6 Significance of the study……………………………………………………………………………..29
4.7 Scope of the study …………………………………………………………………………………...29
4.8 Limitation ……………………………………………………………………………………………29
4.9 Methodology…………………………………………………………………………………………30

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 4.10 Material selection ………...………………………………………………………………………...33
4.11 Analytical method…………………………………………………………………………………..34
4.11.1 Design of support ……………………………………………………………………………...34
4.11.2 Design of mounting arm ………………………………………………………………………35
4.11.3 Design of bolt for holding engine ……………………………………………………………..36
4.11.4 Design of nut and bolt for fastening mounting arm …………………………………………...38
4.11.5 Design of worm, worm gear, shaft and key …………………………………………………...39
4.11.6 Bearing selection ………………………………………………………………………………55
4.11.7 Design of handle ………………………………………………………………………………57
4.11.8 Design of base …………………………………………………………………………………60
4.11.9 Design of wheels for front and rear legs ………………………………………………………61
4.11.10 Selection of bearing ………………………………………………………………………….62
Chapter five ………………………………………………………………………………………………64
Result and discussion …………………………………………………………………………………….64
Cost analysis ……………………………………………………………………………………………...66
Chapter six ……………………………………………………………………………………………….69
Conclusion and recommendation …………………………………………………………………………69
6.1 Conclusion …………………………………………………………………………………………..69
6.2 Recommendation …………………………………………………………………………………....69
Reference ………………………………………………………………………………............................70
Appendix I ………………………………………………………………………………………………...73
Appendix II………………………………………………………………………………………….…….78

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List of figure
Figure 1.1 Johnny general auto work shop ………………………………………………………………...1
Figure 1.2 Service work shop ……………………………………………………………………………...2
Figure 1.3 VIP work shop ………………………………………………………………………………….4
Figure 1.4 Structural organization of the JGACMA ……………………………………………………….5
Figure 1.5 Work flow of JGACMA ………………………………………………………………………..6
Figure 2.1 Engine work shop ………………………………………………………………………………9
Figure 2.2 Transmission/gear box/ ………………………………………………………………………..11
Figure 2.3 Inspection work shop ………………………………………………………………………….14
Figure 2.4 Radiator ……………………………………………………………………………………….15
Figure 2.5 Body work shop ……………………………………………………………………………….16
Figure 2.6 Car diagnostic test …………………………………………………………………………….16
Figure 2.7 Battery work shop ……………………………………………………………………………..18
Figure 2.8 Nova verta work shop …………………………………………………………………………19
Figure 2.9 Boat work shop ………………………………………………………………………………..19
Figure 4.1 Universal engine stand ………………………………………………………………………...27
Figure 4.2 Traditional engine disassemble method on tire ……………………………………………….28
Figure 4.3 Flow chart ………………………………………………………………………………...….. 30
Figure 4.4 Support ………………………………………………………………………………………...34
Figure 4.5 Reaction force on adaptive mounting arm …………………………………………………….35
Figure 4.6 Mounting arm………………………………………………………………………………….36
Figure 4.7 Bolt ……………………………………………………………………………………………38
Figure 4.8 Nut …………………………………………………………………………………………….39
Figure 4.9 Worm and worm thread dimension …………………………………………………………...40
Figure 4.10Worm and worm gear ...………………………………………………………………………46
Figure 4.11 Sunk key ……………………………………………………………………………………..52
Figure 4.12 Worm gear assembly…………………………………………………………………………54
Figure 4.13 Bearing house………………………………………………………………………………...57
Figure 4.14 Lever dimension……………………………………………………………………………...57

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Figure 4.15 Handle ………………………………………………………………………………………..60
Figure 4.16 Base ………………………………………………………………………………………….61
Figure 4.17 Design of caster wheel ……………………………………………………………………….62
Figure 4.18 Bearing ………………………………………………………………………………………62
Figure 4.19 Assembly of engine repair stand …………………………………………………………….63
Figure 4.20 Maximum principal stress analysis of engine repair stand …………………………………..64
Figure 4.21 Maximum principal elastic strain analysis of engine repair stand …………………………...64
Figure 4.22 Total deformation analysis of engine repair stand …………………………………………...65

List of table
Table 2.1 Three month apparent schedule ……………………………………………………………........8
Table 4.1 Material properties ……………………………………………………………………………..32
Table 4.2 Design dimensions of screw threads, bolt and nut ……………………………………………..37
Table 4.3 Number of starts to be used on the worm for different velocity ratios ………………………...41
Table 4.4 Proportion for worm thread …………………………………………………………………....42
Table 4.5 Properties for worm gear ………………………………………………………………………43
Table 4.6 Load stress factor for different materials ………………………………………………………45
Table 4.7 Proportions of standard parallel, trapered and gib head keys ………………………………….52
Table 4.8 Service factors for bearing carrying geared shafts ……………………………………………..55
Table 5.1 Cost analysis …………………………………………………………………………………...66
Table 5.2 Material cost for each part ……………………………………………………………………..66
Table 5.3 Machining cost ………………………………………………………………………………....67
Appendix II ……………………………………………………………………………………………….78
Standard table of bearing …………………………………………………………………………………78
Table 1 Principal dimensions for radial ball bearing……………………………………………………...78
Table 2 List of bearing for various types of machines ……………………………………………………79
Table 3 Values of X and Y for dynamically load bearing ………………………………………………..80
Table 4 Basic static and dynamic capacities of various types of radial ball bearing ……………………..81

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 Acronyms and Abbreviation
JGACMA - Johnny General Auto Car Maintenance and Assembly
VIP - Very Important Person
LN – normal lead (mm)
l- Lead angle (mm)
DW - pitch circle diameter of the worm (mm)
h- Depth of tooth (mm)
a- addendum (mm)
m – Module (mm)
DOW- outside diameter of worm gear
L - Length (mm)
t - Thickness (mm)
w - Width (mm)
A - Area (mm2)
DG-pitch circle diameter of the worm (mm)
DOG-outside diameter of worm gear (mm)
a – Rankine constant
k – Radius of gyration (mm)
I – Moment of inertia of column (mm4)
T – Torque (N/mm)
W–Load (N)
σb – Bending stress (N/mm2)
σcr – Crushing stress (N/mm2)
σul – Ultimate stress (N/mm2)
y - Yield stress (N/mm2)
E – Modulus of elasticity (N/mm2)
F.S – Factor of safety
DW- pitch circle diameter of the worm

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 CHARTER ONE
Background of Johnny General Auto Car Maintenance and Assembly PLC
(JGACMA)
1.1. History of the company
JOHNNY GENERAL AUTO SERVICE is a company located in Addis Ababa, Ethiopia. The
company is mainly working in Vehicle Maintenance business sectors. Johnny General Auto Car
was established in March 1996 E.C. It provides garage services as well as maintenance, painting,
body work and mechanical. Johnny General Auto is a workshop specialized in vehicles repair,
vehicle services and used cars trading in Addis Ababa Ethiopia. It was established at 1996. Since
that time Johnny General Auto has been building unbreakable relationships with its clients.
Johnny General Auto workshop is provided with the best professional diagnostic tools and their
equipment are periodically updated. Our technicians are qualified and they have a lot of
experience. Our Promise Customer satisfaction is the core of our car service and car repairs;
therefore we are committed to ensuring that you get the best car service specials performance,
reliability and enjoyment out of your car at the best possible price. We constantly improve our
own efficiency, ensuring that we always source guaranteed parts at the best prices. Add to this
the fact that we only employ fully qualified technicians in our car repair workshop, plus our
procedures are based on the latest international industry developments. You can trust us to do the
best job at the best value for money with regards to an excellent vehicle service. Reliable,
Affordable, Friendly - this is Johnny General Auto Workshop.

Figure 1.1 Johnny General Auto Workshop

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1.2 OVERVIEW OF THE COMPANY
1.2.1 Vision
Our vision is to maintain our leading position in the industry and to continue to be the leaders in
the latest automotive collision repair technologies and equipment.
1.2.2 Mission
Our mission is to provide the best automotive repair service in East Africa. We strive to be the
best in what we do to provide high-end automobiles with the care and maintenance they deserve,
as well as to ensure our customers’ safety and confidence on the road at all times.
1.2.3 Goal
Our goal is to continue to develop and evolve, with current plans for the establishment of an auto
assembly plant under evaluation. This assembly plant is seen as a natural extension of our current
activities.
1.2.4 Future plan
JGACMA continues to develop and evolve, with current plans for the establishment of an auto
assembly plant under evaluation. This assembly plant is seen as a natural extension of our current
activities.
JGACMA would like to thank you for your continued patronage, and would also like to ensure
you that we will continue to provide the best of service in the future. If you should have any
questions regarding our services, please do not hesitate to contact us.

Figure 1.2 Service workshop

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1.3 Main Products And Services
The company is mainly opened for the purpose of keeping vehicles and machines long life and
also giving maintenance and repair on site to let the work not to stop. It has its own structure for
performing tasks. It has different sub division to accomplish different tasks.
Car body repair
Our car body repair shop is equipped with the latest in spray-booth technology.
Which enables us to paint and cure an entire car hours instead of days? The spray
booth is also equipped with special filers to eliminate any toxic fumes exhausted
during the painting process. This expensive investment was mad to ensure our
customers speedier service delivery while also operating our facility as a “green”
enterprise.
Latest diagnostics technology
Our car repair center is equipped with the latest electronic diagnostic systems.
Our customers’ vehicles benefit from accurate and speedy diagnostics, saving
them considerable worry, time, and money.
Fiber glass repair and construction department
Our Fiber glass repair department is equipped to repair fiber glass boats. We use
the latest technology and materials to repair fiber glass boats. We can handle your
cosmetic needs – buff and compound – fiber glass painting – custom painting –
color matching. Furthermore we repair or replace boat structural problems such as
floors – stringers and transom.

Well trained and professional staff

We have invested heavily in both tools and the development of our staff. Our
staffs are periodically enrolled in special technical and service provision training
courses to enhance their awareness of new technological advancements and best-
in-class customer service practices.
End-to-end service
Our facility and staff are fully capable of offering all kinds of services, from
towing of malfunctioning vehicles, to repair and services for damaged autos, to
basic maintenance services (such as oil change, all mechanical repairs, engine
over hall alarm installation, etc.) JGACMA has as its goal to serve as a “one-stop-
shop” for all of its customers’ automobile needs.

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1.4 Main Customers
We have been creating close relationship with its customers. We have created data base and
conduct annual customer satisfaction survey on our service delivery quality. This system has
helped us to improve our performance. The company gives different services like maintenance of
auto motives and boats.
The main customer of the Johnny general auto most of them are the governmental organization
and privet customer such as;

 Balezaf Alcohol and Liquors Factory PLC

 Ethiopian defense force
 Rainbow foam
 Privet customer and so on.

Figure 1.3 VIP Workshop

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1.5 Organizational Structure of the Company

Deputy Manager

Internal Planning

Legal Service

General Manager Information Technology

Communication

Finance

Figure 1.4 Structural organization of the JGACMA

Work flow in this section look like

The work flows of the Johnny General Auto as show below each and every section have its own
responsibility. If one section of the section does not work properly and the all section may not
work and the work which has doing may be late so they work properly.

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 General Managing Director

Fiber glass repair and

construction department
Body and Painting Mechanical and Electrical
department department

Supervisor

Chief Experts Chief Experts Chief Experts

Experts Experts Experts

Figure 1.5 Work flow of JGACMA

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  General Manager: Controls the overall work flow in all sections and achieved tasks.
 Supervisor: is responsible for receiving orders that come for maintenance or any other
task and assigning a responsible expert on the work, check finished tasks give permission
for installation are the tasks that perform by the supervisor.
 Chief mechanics: is a Forman and his main activities are helping the mechanics when
they face problem that is beyond their capacity. He also checks the vehicle by driving the
vehicle on long distance.
 Mechanics: These are the workers that make maintenance activities

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 Chapter Two
The Overall Internship Experience
2.1 How we to get to the company
Among different companies visited during the selection of internship hosting company, there were
several criteria’s that had been put in place. Such as; Knowing about the company and find out if it
interests us to stay there for the internship period, if there is internship vacancy, and convenience of the
company’s location. Based on the above criteria, JGACMA has been selected because it encompass
workshops which provides the following opportunities,
a) Engine maintenance,
b) Car body repair,
c) Fiber glass repair and construction,
d) Nova verta painting booth and
e) Electric and latest diagnostics system.
As a well-equipped and staffs of long year work experience, practical work is done in fully
equipped workshop which provides a realistic working garage environment.

Table 2.1 Three Month apparent schedule

Weeks Work shop Study methodologies
Week 1 Identification of all shops, tools and working
with the adept persons some days to  Remember theoretical
understand the behavior of the shop and the principles to relate with
work. practical situations.
Week 2 Vehicle inspection work shop
Week 3 VIP inspection work shop
Week 4 Maintenance work shop
 Search in the internet
 Transmission/gear box/ maintenance about new things.
and replacement
Week 5 Maintenance work shop
 Engine maintenance/ replacement
Week 6 Maintenance work shop Assemble and disassemble
 Differential and Clutch maintenance/ working pieces with the
replacement help of experts.

Week 7 Diagnostics system and Auto electric work

shop
 Discuss on the problems
and share ideas.
Week 8 Vehicle lighting and Battery work shop

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Week 9 Body work shop
Week 10 Painting work shop  Grasp some problems try
 Nova verta painting booth to fix by designing any
Week 11 Fiber glass and construction work shop device or by developing
any theory.
Week 12 Collect data from adept person toward engine
repair stand

2.2 Maintenance shop

2.2.1 Engine maintenance
An engine is like the heart of car. It is a dives that use a heat engine that converts chemical
energy in a fuel into mechanical energy, usually made available on a rotating output shaft.
Chemical energy of the fuel is first converted to thermal energy by means of combustion or
oxidation with air inside the engine. This thermal energy raises the chemical. In this shop we are
working disassembling of an engine, assembling, inspection, maintenance of an engine.

We perform the following task in this shop

 Replacing of piston because of wearing
 Replacing of crankshaft bearing
 Replacing of spark plugs and wires
 Replacing fuel injection nozzle
 Replacing oil pan
 Assembling and disassembling of an engine

Figure 2.1 Engine work shop

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To identify the problem of an engine by methods like check for usual noise for vibration at all
engine speed, check for rough idling and misfiring and other sounds.
 Detecting the problem or malfunctioning components of the engine
 Collect necessary equipment to perform the task. Equipment like open and ring wrench,
T-handle, speed handle, short and long extension, socket wrench, Allen key, hammer,
plier, torque, sand paper, makers, ratchet, hand carts and so on
 Disassemble the engine to find the detected malfunction part. After that check the
component whether it is replaced by another one or it can give the desired service after it
pass through maintenance process. If the component has a total failure replace by the new
one. Otherwise, wash the component by using diesel and pressurized water.
 After disassembling and washing we inspect the engine component when there is wear
component. During inspection it the main component of maintenance of an engine and
we inspect such as engine block, crankshaft, cam shaft, journal/shell bearing and the
valves. For the inspection of these parts we will use instrument like the micrometer,
Varner caliper, and magnetic stand with a dial, dial gage and bore gage using those
material we measure the diameter those component using dial gage and maintain until it
over come to the standard value by facing of boring of welding
 Then after taking these tests we take the result and compare them with the allowable
values of manual. If the value is within range, we can pass it as usable and if it is out of
range it will be either maintained or replaced. Inspection of the valve will be
accomplished by checking whether the valve gained is usable or not and if the valve head
fits with the engine block opening.
 The final step is assembling of an engine properly with the help of the manual. The
manual help the how many torque is need for each part of the engine and so on. Then it
goes to engine testing room after pass this test it gone to install to the bus to give service
for the user.

2.2.2 Transmission/gear box/ maintenance

In this shop we are work on the gearbox maintenance and we also seen the assembling of the
transmission. Every engine produces the most horse power and torque (twisting power) at or near
a certain speed however the wheel does not always need the same amount of power, so the
transmission multiplies torque by sending power between different sized gears. When a small
gear turns a large gear the bigger gear rotates more slowly and sending more power to the wheel.
Working task in this section is;
 Replacement of spur and helical gear
 Replacement of spacing ring
 Changing of tuber bearing
 Changing of gear box oil

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Procedures we followed
 To identify the problem or malfunction of the gear box of the car by checking the marsh
of the car is shriveling to select the selected number they can identify the problem and
collect the material that used to maintained the transmission such as open and close
wrench, bearing pull set up, pliers, stove
 Then using those materials, they disassemble the gear box and wash the debris that is
found on the gear, smear the component by oil in order to reduce wearing of the gear.
 After smearing us re- assemble the transmission and we also change wear component and
oil by the new one.

Figure 2.2 Transmission /gear box/

2.2.3 Clutch maintenance
Clutch is the main component of the vehicle which used to engage and disengage the clutch from
the engine and transmit.
 In this team they maintain the clutch and its component they identify the problem by
hearing the sound and they use necessary equipment.
 The prior to putting the clutch back together they resurface the flywheel and install a
new pilot bearing, we apply a drop of adhesives to the thread of the bolt prior to bolting
the fly wheel of the engine.
 Then clean the flywheel and pressure plate with acetone to ensure an oil free surface
make sure to use the correct alignment when replacing the disc up to the flywheel and
replace by the new one.

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2.2.4 Differential maintenance
Differential has hypoid gears. These are specialized gears which transmit the rotation of the
drives shaft 90 degrees in order to turn the axles and correlating wheels and tires. There are
spider gears inside the center section of the differential that allow the wheels to travel different
distances while turning.
Working task in this section is
 Replacement of differential gear (ring gear, side gear, drive pinion, differential pinion)
 Changing lubricates oil.
Procedures we followed
 To identify the problem or malfunction of the differential of the car by checking the
transmission they can identify the problem and collect the material that used to maintain
the transmission such as open and close wrench, bearing pull set up, pliers and so on.
 Then using those material, they disassemble the differential and wash the debris that is
found on the gear, smear the component by oil in order to reduce wearing of the gear.
 After smearing us re- assemble the transmission and we also change wear component and
oil by the new one.

2.3 Inspection workshop

In this workshop we worked on how gearbox /transmission/, engine and differential oil change
and all other inspected component when the oil become squalor. All automotive have inspection
schedule on the condition of how many kilometers they travel. So, when the time comes they
checked up in this workshop based on the manufactured company inspection catalog. In the
inspection process the technicians check on the all vehicle systems and they give
recommendations.

We performed the following tasks

 Check/replace the engine oil and replace oil filter
 Check/replace fuel filter
 Inspect tire for pressure and wear
 Inspect of air filer
 Cheek all light
 Power steering fluid
 Lubricate lock
 Check on the cooling system
 Check/replace break pad and shoe
 Check all suspension system
Change the oil, replace the air filter, inspect fuel cap, and change other fluids (transmission fluid,
power steering fluid) and other inspection issues. Vehicle may have different inspection
requirements at 30,000 miles, 90,000 miles, and 150,000 miles and at other intervals as indicated
manual.

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We followed the following steps
 Engine oil should be checked each time the vehicle is refueled. Most engines,
have a dipstick to indicate the oil level. Turn the engine off, Remove the dipstick
then Wipe off the end of the dipstick with a paper towel then after Put the
dipstick back in, Take it out to look at the level at the tip.
 If the coolant is low then it needs to be replenished with the proper type of
coolant and mixture. The proper mixture is a 50/50 ratio of coolant and distilled
water. It is important to use distilled water because the impurities in other water
would circulate through the system and ruin the system over time. Coolant can be
purchased pre-mixed in a 50/50 solution if desired.
 Windshield Washer Fluid: There may be a clear reservoir for windshield washer
fluid. Refer to the manual for the location.
 Power Steering Fluid: There may be a clear reservoir for power steering fluid. If
there is, then it can be checked the same way as the brake fluid described above.
If the power steering fluid is not in a clear reservoir then it will have a dipstick.
Refer to manual for the location of the reservoir and the type of fluid that should
be used. Low power steering fluid is an indication of a leak and it should be
investigated.
 Transmission Fluid: Refer to the manual for the location of the transmission
fluid. Some vehicles have a dipstick but many new vehicles do not have one. In
some vehicles you have to go underneath the vehicle to check this fluid. If the
fluid is low, then there is a leak and it should be investigated. The fluid should
also be red. If it is black and/or has a burnt smell then there is a problem with the
transmission.
 Replace brake pad and shoe: Jack the vehicle up and remove the wheel, remove
the dust cap with a screw driver, use a ratchet to unscrew the axle bearing nut,
twist the drum as you pull it backward to remove it, spray the drum with rust
remove if its stuck, then after pulling out old brake pad (use pliers to remove the
primary brake shoe springs, pull out the brake shoe clips, remove the parking
brake cable, pull the brake shoe set free from the braking plate), replacing brake
pads.
 Air filter: Consult the owner manual for the location of the air filter. Remove the
air filter. Inspect for visual signs of dirt and debris. Hold the filter up to a
fluorescent light; you should be able to see light coming through the filter. If
there is any doubt then change it.

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 Figure2.3 Inspection workshop

2.3.1 Radiator maintenance

The radiator is connected to the engine which canals through which a liquid is pumped this liquid
can be water or other coolant such as anti-freezer by taking the liquid through the engine it heats
up the liquid and take outside of the engine to let it cool down it located in the front of the
vehicle grill in order to benefit from the airflow as the vehicle moves.
We perform the following task
 Radiator coolant level
 Radiator for antifreeze leak of damage
 Air conditioners interior vent temperature
 Hoses
 Thermostat
 Pressure cap
 Blower
Producers we followed in radiator shop during radiator work: -
 The first step in this process is washing dirt and debris out of the fins of the radiator. This
is done by adding the radiator into a sink which is full of water and blowing air across it.
In this process soap is also included. Therefore when the air blows in the water bubbles
will form and wash away the dirt accumulated
 Then the radiator again dipped in to a sink which is full of water and the air blower
through the inside of the radiator in order to determine where the piping may have been
ripped. After the faulty place is determined, the next step will be to reconditioning it
using the welding method. Then to determine the welding is efficient, again we dip the
radiator into the water and see there is any bubbles come out. The final step is dry by the
air and prepare to check up if it not works they change the new one.

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 Figure 2.4 Radiator

2.4 Body work shop

In this workshop we worked the outer body part of the vehicle. When the vehicle damaged
because of the crash or something the experts in this shop fix this problem. To perform the task,
they used different methodologies like punching with hammer and welding.
We perform the following tasks:
 Welding of the body
 Replacement of the font and side mirror
 Cutting folding and punching of the body
 Maintenance and installation of headlight
 Replacement of the driver chair and the passenger sit
We followed the following steps when we are in body workshops
 When the vehicle gets an accident they take the repair to the shop and they observe
deeply to identify the problem.
 The next step is collecting the type of material and appropriate equipment’s such as
hammer sand paper, electrode, rivet, screw driver compressor.
 After collecting the necessary equipment if the vehicle has get some dent, scratch of high
damage the work done for those repayment are not identical if the vehicle is scratched
they used the gypsum and after the gypsum is dry polish the scratch part by the sand
paper after that they paint the scratched using compressor until it.
 Similar color as the all body.
 If the body has large dent they cut out and replace it by the new metal by welding.
 Using electric arc welding of oxyacetylene welding type after welding they punch by the
hammer until it similar to the other body and grind by using grinder and paint gypsum to
fulfill if there is any hole and polish with sand paper. The final step is painting and
installing to the service.

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 Figure 2.5 Body workshop
2.5 Latest diagnostics system and auto electric work shop
2.5.1 Car diagnostics test
Car diagnostics tests scan car components and systems to check for issues with components like
the engine, transmission, oil tank, throttle, and many more. Because car diagnostic test require
specific devices and expertise to read correctly. Specifically, they check for;
 Car engine or individual components.
 Car transmission and responsiveness.
 Problems with brake responsiveness.
 Potential contamination or faults car exhaust system.
 Signs of wear and tear or breakage with major components, such as the fuel injector,
ignition coils, and throttle

Figure 2.6 Car diagnostics test

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 2.5.2 Auto electric shop
In this show we worked the maintenance of electric component of the car and we identify the
component of those components, those components the basic unit of bus electric system we
perform so many task.
The task we perform: -
 Maintenance of starter
 Maintenance of alternator
 Different gauges. such as fuel gauge, speedometer, tire pressure gauge
 Head light, taillight, and external
 Wind shield wiper
To identify the problem of the starter, alternator or other electric component the turn on the
motor and hear if there is any sound or check whether the starter turns the engine in normal
speed
 After identifying the problem use appropriate equipment such copper winding wrench, so
on but it is difficult to describe all procedure of electric component.
 Starter is located on the back of the engine or the front of the transmission, the starter
cranks the engine when the ignition switch is turned on and is strike the fly wheel and the
motor start. If the component of the starter can have maintained or otherwise they replace
by the new one. They recommend having your starter tested to make sure it is drawing
the correct amount of current every spring.
 The alternator is electric charge it has various part are contained in an aluminum housing
and generate direct current for recharging the vehicle of the battery if the alternator is
malfunction that cause poor light, dead battery, the dashboard warning light you may
having problem with the bus so if it maintained they replace the winding or the diode of
the alternator or they replace by the new one.

2.5.3 Battery shop

In this shop we work the charging of the car which is lead acid storage battery and it is an
electrochemical device that produces voltage and delivers electric current .the battery is primary
source of electrical energy used for in the vehicle. Car battery store electricity it has two
terminals or posts one is marked negative and the other is marked positive a cable connects the
negative terminals to the engine block.
We Executed the of tasks Recharging car battery at this shop
We followed the following steps during changing bus battery
 If the car battery is not working change the electrochemical which is the Composition of
sulfuric acid and distil water, the composition 65% of acid and 35% of distillate water,
not their type because it may contain some impurity because of this we use distillate
water it the mixture of both.

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  The batteries is the type that need water added to it cell check it regularly unscrew the six
round cap on the top and check the fluid level in each cell using hydrometer. If the fluid
level is below the fill mark adds water to fill.
 After filing the water clear the battery terminals with I wire brush and clean the top with
a solution of water and baking soda check the cables to make sure they are tight on the
terminals

Figure 2.7 Battery workshop

2.6 Nova verta painting booth

These workstations are tailored with air flow and heating capacity requirements for spray
applications up to 9 square feet, which can be a concern with ever changing paint materials.
Complete line of replacement and repair parts; booth floor parts, bumer parts, filter media, heat
exchanger, motor, pneumatics, misc. hardware, lighting, electrical, ducting, fans and so on.
Improve production, increase efficiencies, and improve bottom line with the wind system nova
verta. The wind system improves flash and cure times by evenly increasing air velocity with in
the paint booth, providing an extra boost to air movement that is particularly useful when using
waterborne coatings.

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 Figure 2.8 Nova verta painting booth
2.7 Fiber glass repair and construction
Fiber glass is a durable and solid product when used properly. We use the latest technology and
materials to repair fiber glass boats. We can handle your cosmetic needs – buff and compound –
fiber glass painting – custom painting – color matching. Furthermore we repair or replace boat
structural problems such as floors – stringers and transom.

We followed the following steps;

 Apply the first coat of the mixed resin. This is known as a “seal coat.”
 Apply the Fiberglass cloth. Wait until the coverage is complete to move on to
 Apply Second coat of mixed resin
 Apply Third coat and finish coat
 Sand the boat and apply protectant
 Dry and set.

2.8 Challenges and their measurement

There are many challenges that we have been facing during performing tasks.
 The first one is misunderstanding. This is the first problem I face during the internship
period the know the component and material of the auto motive in italic name because of
this we got some confusion and we try to cross check engineering name of the
component.
 We also get challenges when they send as to come tings we could not get easily because
they are not putting things in order to easily to use, to put and visualize so because of this
are not apply the kai Zen 5s rules.
 The other problems that we observe are highly affect the overall flow process of the shop.
These are: -

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1. Layout of the shop: we mean that the work shop is so stressed and hot in the afternoon
2. Maintained automobile parking place
3. Spare part supply
4. Useless machines
5. Place for the end product
The above main problems affect the flow process of the shop by losing time, crowded of
working place, decreasing life time of the machine, safety of the workers.
2.8.1 Measurements
 We see all shop have their own problems or challenges to avoid such challenges we made
solution to make the work flow easy and comfortable working environment they apply
kai Zen theorem. And by removing unwanted material to change the layout of the work
shop and according to the spare part they try to solve the shortage of the accessor.
 We try to solve some of the challenge such as misunderstanding of the bus component
words they use italic name so to overcome this misunderstanding we try to convert those
word by their engineering names.

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 Chapter Three
The Overall Benefits of the Internship
3.1 In terms of practical skill
 We have developed a confidence to do the given work practically without any problem
and we also observed that practical works is more simple than theoretical. As we have
seen there is a big difference between theoretical and practical skills. Theoretical
knowledge is not always unfulfilled in practical application through time it might seem
that way.
 It’s important to realize that in the work place, what matters is not the amount of practical
experience or theoretical back ground that an individual’s has, what matters is how much
an individual is able to effectively deal with the realities around him.
 Gaining knowledge from practical work is easier than from theoretical learning process
and we have gained a practical skill of computer when we write our project and report.

3.2 In terms of upgrading theoretical knowledge

During this period of the internship we upgrade our theoretical knowledge by relating with
practical knowledge. For example, we have seen the condition when the component of the
automobile fail, we gain detail and clear way of how the automotive maintenance schedule
design either weekly or monthly or yearly, we also seen how inspection the vehicles and can
identify the automobile component with function.
Practical skills are help to relate the application of knowledge, theory and/or skills students have
developed in higher education to complete real life tasks. When undertaking practical tasks,
students need to use their common sense, to be proactive and follow health and safety
procedures. There are many careers that require practical skills and several others which have
practical elements engineering is one of the careers that requires practical skills. From this
internship program, we had a good chance to improve our practical skills highly. Depending on
the fact we got many things from internship especially on the course of maintenance. During this
internship period, we are gained different practical skills like:
 Apply knowledge - use knowledge and skills learnt during your course to complete
practical work-based tasks and problems. For example:
1 Engine maintenance-in this part we see all the arts that are exist in an engine that we studied
in different lecture courses. We get knowledge about steps during tighten and losses of engine, it
doesn’t perform, but it has manuals. We think we get a great skill it helps us for the future
courses like, maintenance.
2 Suspension system maintenance-in this part we see the components of suspension system
and we also observe that parts that we did not see but we studied in lecture class (dumper).

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3 Gearbox and differential maintenance-we see the components of gearbox and differential
in detail. We observe how this vehicle parts are maintained and what parts are most of time
failed. We observe the gearbox and differential oil that we did not see and touch.
4 Break disc maintenance-in this part we see different types of brake system and we also
perform replacement the worn out parts.
 Complete practical activities safely-During this internship we have been learn about
complete practical tasks safely, be aware of, and follow, health and safety policy and
procedures; carry out a risk assessment when we were working to identify potential
dangers and take action to remove them. Also, we were taking a responsibility for others
safety, means consider their safety as well as our own.
 Use best practice - be aware what it considered best practice in the industry, role and
task which you are working on. Follow best practice where it is feasible and applicable to
the practical situation you are working on.
 Increase performance – when we were in internship program we also improve to be
conscious of how our performance is measured and aim to complete the task or
responsibility in line with these expectations. In addition to that we improved how we can
follow instructions and complete the given task with its requirements at the right time.
 Be proactive – Before we got in the internship program we had very poor proactive skill
it means misgiving to perform practical tasks. When we finished our internship
everything is totally changed we have confidence to find and take on new practical tasks
and responsibilities.

3.3 In terms of inter personal communication skill

During these Three months, we have been able to upgrade our communication skill to a whole
new level and gained confidence on how to ask different questions, to make discussion. Use of
interpersonal communication,
 To give and collect information
 To influence the attitude and behaviors
 To form contracts and maintain relationship
 To express personals needs and understand the needs of others
 To make decision and solve problem
 To anticipate and predict behavior
 To improving formal communications
 We have developed the communicating respect for other people or professionals which
will enable us to reduce conflict and increase participation or assistance in obtaining
information or completing tasks.  We have developed how to control the feeling that
emerge in difficult situations and respond appropriately; instead of being over whelmed
by emotion.

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3.4 In terms of team playing skill

During our stay in JGACMA, we have learned that it is difficult to go ahead and do something
without having a strong team. Team work important because it can speed up process and make
things run more efficiently and allows goals to be reached in an efficient and timely method. A
good team will generate and nurture bond of trust and confidence, both in themselves and one
another. This will positively affect their self-esteem, confidence in their colleagues, and possibly
their loyalty to the company increasing productivity and ultimately, company profit.

3.5 In terms of understanding about work ethic

In its simplest definition, a system of moral principles is called ethics. Ethics are therefore
concerned with these sorts of moral decision like how to live an ethical life, rights and
responsibilities, right and wrong language, what is good and bad and so on. Being honest, having
a positive attitude, taking initiative, caring about coworkers, doing more than expected, being
reliable and responsible, learning new skills and being a team player are also examples of a
strong work ethic. Among staff ethical behavior ensures work is completed with integrity and
honesty and staff that are ethical adhere to policies and rules while working to meet the aims of
the enterprise. Basic work ethics for any organization should include the following components.
Components we have been understand during our internship experience:
 Uniform rules and regulations: An ethical organizational example is the common
treatment of all staff, i.e., with the same respect, regardless of race, culture, religion, or
lifestyle, with equal chances for promotion. Therefore, small company managers should
desist from favoring any one employee, for it can lead to lawsuits and is also highly
counterproductive.
 Communication of the rules and Regulation to all employees: Company policies must
be clearly communicated to each employee with a transparency at all levels of the
hierarchy. Employees are the spine of all organizations and should have a say in the
goals and objectives of a firm.
 Respect for Employees: Respect employees and in return receive the same. Regulations
should not be so rigid, and therefore, don’t expect staff to attend work two days before a
marriage. If somebody is not well, don’t ask them to attend office unless or until there’s
an emergency. No matter how urgent a deadline or heated that tempers become, remain
diplomatic and poised and show grace under pressure. Whether serving a client, meeting
a customer or meeting with management, do the best to respect others opinions, even in
stressful circumstances. It shows one values others individual worth and professional
contribution
Honesty and Confidentiality: This is the core element of work ethics, all the other elements are
based on honesty. Be honest about your successes and failures, take credit only where due, do
not steal other’s works or ideas, and own up to your failures. Any confidential information of

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documents you have should remain confidential. You cannot discuss it or show it to anyone else,
other than the people authorized to do so.
 Fairness and Openness: Be fair to all, do not practice favoritism. Treat everyone as
equals. Share your ideas, results and resources with the other team members, so that
everyone has the same opportunity and know.
 Reliability and Dependability: Means being punctual for work and meetings,
delivering assignments within budget and on schedule. Be reliable about keeping
promises for reputation precedes one so that clients, customers, and colleagues do trust
in you to do all that you say you will everyone appreciates the stability this embodies.
 Determination and Dedication: Obstacles cannot stop you as they are a challenge to be
overcome. Embrace challenges positively and know that your role is to solve problems
with purpose and resilience. Continue until the job is complete, and delivered. “It’s good
enough” is not sufficient for you and the team, as you aim to be “outstanding” in content
and quality. Put in the extra hours to get things right by attending to detail and
excellence.
 Responsibility and Accountability: Take responsibility for your thoughts, actions,
behavior and work and accept responsibility personally for one’s actions and outcomes
in all situations, plus avoid excuses when work does not proceed as planned admitting
mistakes or oversights are used as a learning curve and will not be repeated again.
Employers expect employees to attain to high standards, and they should fully support
staff who accept responsibility, instead of passing the buck.
 Competence: Improve your performance and competence by constantly learning and
including the new learning into your work.
 Initiative and Legality: Do not be afraid to put forth your ideas or volunteer for work
within the legal boundaries, do not break or twist the law to fit your agenda.

3.6 In terms of leadership skills

During the Three months in JGACMA, we have been able to upgrade our leadership skills to a
whole new level. To achieve leader ship skills it requires high level commitment to learn from
each experience we face. We have observed that a good leader is well principal individual who
focuses on a common goal and eliminate excess fear and doubt from his employees and work for
a common good of all.

3.7 In terms of entrepreneurship skills

The term entrepreneur is defined as an individual who organizes or operates a business or
businesses. Entrepreneurship has traditionally been defined as the process of designing,
launching, organizing, and managing a business venture along with any of its risks in order to
make a profit. Before we were joined the internship program we had very little knowledge about
entrepreneurship. But when we were finish the program we gained the basic knowledge and

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ideas about entrepreneurship and necessary skills to be good entrepreneur. Below we list out the
skills every entrepreneur must have to be successful.

1. The ability to Communication: We may think communication is less of an issue, since we

don’t have staff to interact with. But we have still got to maintain clear lines of communication
with our customers via email and phone.
2. The ability to prepare Strategy: It’s easy to think about the “right-now” aspect of our
business, because the results are easy to see. Without a constant eye on our business’ strategy
and skilled assessment of that strategy relative to the industry and our competition, we can’t hope
to grow it over time and remain competitive in the marketplace.
3. The ability to manage money: Very simply, if we can’t manage money, we can’t manage a
business. To run a successful business, we should still have a decent understanding of our
finances, profit margins, cash flow and funding. The more comfortable we are with all of these
numbers, the more confident we will be, and the better decisions we will make. If we have an
accountant to handle all the number crunching, that is great, but don’t use them as a crutch to
keep us from digging in and really understanding where our money’s going. It is our duty to rein
in costs, optimize efficiency and find ways to grow revenue
4. The ability to relieve stress: Stress is no laughing matter. If we allow ourselves to get
frustrated and upset by setbacks, we will struggle as an entrepreneur. We should learn how to use
stress to our benefit is essential.
5. The ability to be productive: This is a big topic, because there is no one right way to be
productive that works for everyone. Learn about our peak energy times, our routines, and the
productivity tools that work for our in order to create our own plan for success.
6. The ability to identify strengths and weaknesses: As a business owner, we don’t need to be
perfect at everything. We have to understand where we are strong and where we are weak.
Assessing this will inform everything from the business decisions we make, to the partners we
bring on, and to the employees we hire.
7. The ability to deal with failure: No business venture is a straight line to success; knowing
how to deal with up sand downs are essential. Remember that every successful person out there
failed dozens of times before getting a win. Failure isn’t the end, it is just a data point on the way
to success.

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 Chapter Four
Design and Analysis of Engine Repair Stand

There are a number of problems that exist on the company work area. Those problems are:-
 Absence of car engine repair stand.
 Absence of car lifting device in the light vehicle maintenance shop.
 Absence of modern gear box dropping machine except hand operated chain.
 Absence of modern car air filter cleaning machine. etc.

The solutions that were proposed for the problems listed above are:
 Designing gear driven engine repair stand.
 Designing of a hydraulically operated car lifting device for a light vehicle maintenance
shop in order to eliminate the problems that the mechanics were faced while servicing the
parts that exists at the bottom of the car.
 Designing automatic air filter cleaner machine
 The basic reasons (criterial) while choosing our design are with respect to time, cost,
availabluty and to save man power. It is because the machin is in able to handle an engine
which is up tp 400kg. due to this heavy weight it is hard to repiar the engine easily the
engine.

4.1 Background
Engine repair stand are used in the positioning and moving of automobile and light truck
engines in a wide variety of vehicle maintenance and service facilities. This project designs an
engine repair stand for light duty [1]. The engine repair stand include a 3600 rotating head,
which efficiently puts the engine in the optimal work position, rugged full swivel casters and
heavy duty tubular steel construction. It is very safe for both the engine and the operator; the
engine can rotate by using rotational mechanism that is by using handle bar. The operator can
maintain the engine in all position without dismantling the engine from the machine. Cylinders
and other internal components of the engine can be easily disassemble and maintain. It is
movable from place by using steel casters.
Generally the engine repair stand has the following advantages for the company as well as
the medium and small garages, reduce engine maintenance time, improve the performance of the
company, and reduce human power with respect to engine maintenance work. Most of its parts
are constructed from steel [2-4]. These paper present important aspects, force analysis of part,
the assembling process of the machine, the operation and instruction of the machine.
Most automotive maintenance industries maintain the engine by putting on a tire, ground
and on table this requires additional and maximum human power to rotate the engine, it takes
time, it increase maintenance cost, it reduce the performance of the company and most especially
the output is not efficient.

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4.2 Literature Review
An engine stand is an apparatus that is used to hold an engine after it is extracted from a vehicle
or prior to installation. It is primarily used to safely hold the block in place while a mechanic or
engine builder breaks down, repairs, or rebuilds an engine. The stand is generally constructed
from high-grade iron or steel, features rollers for easy portability in the engine shop, and rotates
on a fixed axis to allow the engine builder easy access to every part of the engine while on the
stand.

With the wide variety of different engines in existence, there are nearly as many types of engine
stands in the marketplace. A stand that is proper for small automobile engines is ill-suited to the
larger engines required by trucks, trailers and heavy industrial equipment. Also, v-block engines
sometimes require an engine stand that is designed differently than stands suitable for in-line
engine blocks [1].
Prof.M.D.Salunke, studied universal engine stand is holding all types of engine with different
manufacturer, with dimensions this device is very useful for can garage worker. Due to this
simple construction worker easily hold engine on this stand and perform the requiring operation.
All the material, dimensions, parameters figure shows the simple constructional details of
universal stand.

Figure 4.1 Universal engine stand

Matin Bagwan and Subham Sarwade [8], studied different companies making the two wheeler.
Sell of these companies bikes per day in showroom 2 to 3. Like Bajaj, Honda, Yamaha, etc. And
near about 1 bike for full engine maintenance in workshop. There are two types of engine in
commonly used for making bikes are vertical and second horizontal. In local workshop or
showroom service center there is no proper fixture for holding engine is present in now day. Due
to the complicated construction and weight engine handling is difficult for the worker.

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4.3 Statement of The Problem
In heavy duty Garage and maintenance coordinator the mechanics have bothered to assemble and
disassemble the engine but they have disassembled on tire (Figure4.2). During this operation it
was difficult to rotate and disassemble the other side of the engine. Because of this problem we
have planned to design an engine stand to solve a problem.
An engine stand machine is to be designed to assemble, disassembled and rotates the engine. It is
manually operated machine by applying human force of 100N to the wheel. This human force
multiplied by the worm gear and worm thread. Therefore, the resulting energy is able to rotate
the engines that are attached to the mounting plates.

Figure 4.2 traditional engine disassembled method on tire

4.4 Working Principle Of Engine Repair Stand

The engine is picked up by using fork lift and put the engine on the stand and bolts the side of
engine to the mounting arm or plate. The stand has Circular handle that rotate worm thread, as
worm tread rotate it drive worm gear connected to worm gear shaft. This shaft is rotated at low
speed and also connected to bear housing shaft in which mounting plate attached. As mounting
plate rotates engine tends to rotate since it is bolted on the plate. We can rotate the engine in
clockwise or anti-clockwise direction as per the required side to be disassembles. When we
complete Overhaul maintenance and inspection, parts are assembled easily again in engine repair
stand.

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4.5 Objective of the Project
4.5.1 General objective
The general objective of our project is to design engine repair stand.

4.5.2 Specific objective

 To design support
 To design worm gear, thread, shaft and key
 To select bearing
 To design bolt for holding engine
 To design mounting arm
 To design base
 To design circular handle
 To design wheels for front and rear leg

4.6 Significance of the study

 The product should be light enough to easily move around.
 The product must have minimal cost.
 The stand must be durable.
 The design must be able to be produced easily and with as few parts as possible.
 The engine stand must easily be operated by one person,
 Low maintenance requirement, and Safe for operation.
 The stand is activated by hand crank, which easily turns the fully adjustable 360 rotating
engine mounting head.

4.7 Scope of the study

This study is focusing on a device which is used to stand repairing engine. It includes the
designing of various parts of engine repair stand.

4.8 Limitations
Unavailability of journals and periodicals in the library, dependence on materials from internet.

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4.9 Methodology
The design project starts by starting the problem statement and proceeds by collecting
background information on the problem type and the possible solution to it.
While designing engine repair stand for the workshop the following methods are followed;
 Observe the different problems in the company
 Select a problem, which is more necessary to the company
 Make literature review of the problem
 Collect data for the project
 Select the possible mechanism which will give the desired motion
 Select the material best suited for each member
 Doing the size of each member and simulation
 Draw the detailed drawing of each component and assembly by using solid work

Problem identification

Proposing solution
Literature review
setting objectives

Sketching and CAD design

Finalize concept (solid work)

Design analysis
Computation by
using ansys

Result and discussion

Figure 4.3 flow chart

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4.9 Material Selection
Material selection of a material is the first requirement of a design project.
There are many considerations to select the material for design purpose such as: -
 Cost of the material
 Availability of material
 The types of objects to be designed
 Suitability of materials for design conditions like stress etc.
We selected Indian standard , because more available and inexpensive than British, American,
German, japanese and russian standards[11].
 Depending up on the above criteria uses the following materials.
Steel:

 Have higher strength, hardness and toughness,

 High values of hardness and strength can be achieved for components with large section
thickness
 Possess higher harden ability,
 Retain their strength and hardness at elevated temperature &have higher resistance to
corrosion and oxidation

Stainless steel:

Stainless steel is not a single material but the name for a family of corrosion resistant steels. In
general, stainless steels have:
 Higher corrosion resistance
 Higher cryogenic toughness
 Higher work hardening rate
 Higher hot strength
 Higher ductility
 Higher strength and hardness
 A more attractive appearance
 Lower maintenance

Mild steel:

Mild steel is one of many different grades of steel which are produced internationally. Mild steel
is very strong due to the low amount of carbon it contains. Mild steel has a high resistance to
breakage. Mild steel, as opposed to higher carbon steels, is quite malleable, even when cold.

Phosphor bronze:

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Phosphor bronze is a bronze alloy that contains a mixture of copper, tin and phosphorous.
Phosphor bronze alloys
 Good to excellent corrosion resistance.
 Good cold workability for blanking,
 Drawing, forming and bending, shearing and stamping

Why phosphor bronze is used for worm wheel?

The phosphor bronze is widely used for worms drive in order to reduce wear of the worms which
will be excessive with cast iron or steel.
There is a high degree of sliding along the teeth of the gear from the drive shaft.

30C8 steel:

30C8 steel is characterized by:

 good weld ability,
 good machine ability, and
 High strength and impact properties in either the normalized or hot rolled condition.

45C8 steel:
Carbon steels have carbon as the key alloying element in their composition. They also contain up
to 0.4% silicon and 1.2% manganese. In addition, the residual elements such as copper,
molybdenum, aluminum, chromium and nickel are present in these steels.

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Table 4.1 material properties (Use Indian standard designation)
s.no Name of parts Material Strength Quantity

1 Engine mounting or head plate Stainless [𝜎𝑡]=650MPa 1

steel
[𝜎𝑦]=275MPa
2 Phosphor [𝜎𝑡]=100MPa 1
Worm gear bronze
[𝜎𝑐]=90 MPa
[𝜏 ]=80 MPa
3 Worm Steel [𝜎𝑡]=310MPa 1

[𝜎𝑦]=180MPa
4 Engine mounting arm Mild steel [𝜎𝑡]=100MPa 4
[𝜏 ]=50 MPa

5 Bolt for holding engine Mild steel [𝜎𝑡]=100MPa 4

[𝜏 ]=50MPa
6 Circular handle 30C8carbon 𝜎𝑡𝑢=500MPa 1
steel
𝜎𝑦=400MPa
7 Support Mild steel 𝜎𝑐=320 MPa 1

𝜏=400MPa
8 Bolt for fastening gearbox, arm and bear Steel [𝜎𝑡]=100MPa 12
housing
[𝜏 ]=50MPa

9 Nut for fastening gearbox, arm and bear Mild steel 𝜎𝑐=320MPa 12
housing 𝜏=400MPa

10 Gear box and bear housing shaft 45C8 steel 𝜎𝑡𝑢=700MPa 1

𝜏𝑢=500MPa

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 4.11 Analytical Method
4.11.1 Design of Support
Material for support is mild steel: σc=320MPa, τ =400MPa
Assuming a factor of safety=5 (F.S is 3 to 6 based on the critical buckling load)
The support must be designed for buckling load of:
Wcr=400Kg×9.81×5=19620N …………………………………………………….(1)
Considering the cantilever support is subjected to a buckling or crippling load, then the width
and thickness of support may be obtained by Rankin’s formula for columns.
Let, t = thickness of the support and b = width of the support
Assuming the width of support is equal to the thickness of the support b=t, Cross-sectional area
of the support A=t2, and moment of inertia of cross-section of the support:
1 1
I=12 t × t 3 = 12 t 4
I t4 t2
Radius of gyration, K=√A = √12t2 = √12 = 0.288t ……………………….(2)
For one end fixed and another end free, C=0.25
Equivalent length, L = 2l = 500 × 2mm = 1000
1
Rankin’ s constant,a = 7500
According to Rankin’s formula, buckling load (Wcr),by using eq 1 and 2
σc×A
Wcr = L 2
1+a( )
K
320t2 320t2
19620 = 1 1000 2
= 3616.898
1+ ( ) 1+
7500 0.288t t2

t 4 − 98.1t 2 − 354817.6938 = 0
Width and thickness, t = 38.4 ≈ t = 40mm

Figure 4.4 Support

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4.11.2 Design of Mounting Arm

600mm
𝑩𝒀

𝑩𝑿
ffghh 500mm

Figure 4.5 Reaction force on adaptive mounting arm

Assuming that the center of gravity of the engine is at the geometrical center of a box
representing the outer dimensions of the engine. Applying laws of mechanics, the reaction on
the adaptive engine connector can be found as follows,

Bx, reaction force in negative X axis. BY, reaction force postive Y aixs.

x horizontal distanse form center upto end.

y vertical distanse from center of mounting arm to center of handle.

W
300mm

BX

600mm

BY

The summation of moments at point B is zero, Σ𝑀𝐵 = 0

⇒ (−𝑊 × 𝑥) + (𝐵x × 𝑦) = 0 ……………………………………………..(1)
𝑊×𝑋 (𝑀𝑔)×𝑋 (400×9.81)×0.3
𝐵x = = = = 6540N
𝑦 𝑦 0.18

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The summation of forces in the x direction is equal to zero, Σ𝐹𝑋 = 0

𝐵𝑦 = 𝑊 = 3924𝑁 …………………………………………………(2)
Resultant force at point B will be, by using eq 1 and 2

𝐵 = √𝐵𝑋 2 + 𝐵𝑦 2 = √65402 + 39242 = 7626.9𝑁

𝐵𝑦 3924
tan 𝜃 = 𝐵 ⇔ 𝜃 = 𝑡𝑎𝑛-1 ( 6540 ) = 30.96°
𝑥

The material selected for the adaptive engine connector is a Mild Steel. Which has yield strength
of 207MPa?
The point where the adaptive engine is connected to the head plate is fully constrained in all
directions. The load acts on the surface where the engine is mounted on the adaptive engine
connector. Since we have 4 engine connectors, we can find the force acting on the single engine
connector by dividing the total force on a connector by 4,
𝑏 7626.9
𝐶F = 4 = = 1906.7𝑁
4

where, 𝐶F is the force acting on each connector.

The horizontal component of this force is,

𝐶FH = 1635𝑁

The vertical component of this force is,

𝐶FV = 981𝑁

Figure 4.6 Mounting Arm

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4.11.3 Design of Bolt for Holding Engine
Material for bolt is mild steel with [σt] =100 MPa
[τ] =50 MPa
A) Considering the bolt is subjected to direct shearing loads, it should be located in such a
way that the shearing load comes upon the body (i.e., Shank) of the bolt
Let d = Major diameter of the bolt, and
n = Number of bolts
Assuming shearing load carried by bolt is 25 KN
We know that permissible shear stress for mild steel is, 50 MPa n = 4
∴ Shearing load carried by the bolts,
π
PS=4 × d² × τ × n

π
25000 = × d² × 50 × 4
4

d=12.6mm

B) Considering the bolt is subjected Bending stress when the outside surfaces of the parts to
be connected are not in the same axis with bolt, and then the bolt will be subjected to
bending action. The bending stress (σb) induced in the shank of the bolt is given by
32M
σb= πd3

weight of engine
We know that the bending moment, M = × length of bolt
4

400×9.81
M= ×40 mm=39240 Nmm
4

And bending stress, σt or σb=100 MPa

32×39240
σb = πd3

3 32×39240
d=√
π×100

d=15.8 mm

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Table 4.2 Design dimentions of screw theared, bolts and nuts according to IS:4218

Taking the larger value 15.8 mm, from Table 4.2 (coarse series), we find that the standard
nominal diameter of the bolt is 16 and the corresponding size of the bolt is M 16.

4.11.4 Design of Nut and Bolt for Fastening Mounting Arm

 Material for bolt and nut is mild Steel with [σt] =100 MPa; [τ]=50 Mpa
Design of Bolt

 Assuming the size of bolt to be designed is M 16, (the bolt diameter is based on the size
of the plate on the back side of the mounting arm. When the size of the bolt increase it
does not hold the bolt attaching the mounting arm)
 If the bolt is not initially stressed, then the maximum safe axial load which may be
applied to it is given by
 P= Permissible stress × Cross-sectional area at bottom of the thread (i.e., stress area)
 From Table 4.2, for M16 bolt the stress area is 157 mm2, dc=13.835 mm and pitch, p = 2
mm
 P = 100 × 157 =15700 N
 Checking for Shear stress across the threads.
 The average thread shearing stress for the bolt (τs) is obtained by using the relation:
P
τs = ≤ [τ]
πdc ×b × n

 Where b = Width of the thread section at the root; n= number of treads

 Assuming width of thread section b=3 mm and height of bolt is 10 mm, from this

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Jimma University, JIT, Faculty of mechanical engineering
 h 10
n=P= =5
2

15700
τs = π×13.835×3×5 ≤ [50MPa]

τs = 24.6 ≤ [50MPa]

 therefore, the design is safe

Tosional shear stress caused by the frictional resistance of the threads during its tightening may
be obtained by using the torsion equation
𝑇 𝜏 𝜏×𝜋×(𝑑𝑐 3 ) 24.6×𝜋×(13.835)3
=𝑟 → = = 479.94Nm
𝐽 16 16

Figure 4.7 Design of Bolt

Design of nut
 Let; h= Height of nut
n= number of treads in contact with bolt
d = nominal diameter
 When a bolt and nut is made of mild steel, then the effective height of nut is made equal
to the nominal diameter of the bolt; h = d = 14mm
 We know that; h = n × p
h 14
n = p = 2 = 7mm

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Jimma University, JIT, Faculty of mechanical engineering
 Figure 4.8 Nut

4.11.5 Design of Worm, Worm Gear, Shafts and Key

Available Data,
 Self-locking
 ɳ < 50%
 Single threaded worm ( n = TW = 1 )
 Velocity Ratio (V.R) > 36, take 100
 Pressure angle (ɸ) = 14.5°
 Right angle Shafts
 Speed of worm gear (NW) = 60rpm
Material Selection
 Steel worm
 Phosphor bronze worm gear

Assumption;
Since there is no way to know the center distance, taking into consideration the space
available and also maintaining standard center distances, we assumed the center distance
to be x = 100. The maximum mass the engine stand can hold is 400Kg.

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 Figure 4.9 worm gear and worm thread dimension
A) Design of Worm
0Let 𝑙𝑁 = Normal lead, and
𝜆 = Lead angle

The center distance may be expressed in terms of the axial lead(𝑙), lead angle (𝜆) and velocity
ratio (V.R.), as follows:

𝑙
𝑥 = 2𝜋 (𝑐𝑜𝑡𝜆 + 𝑉. 𝑅 )

In terms of normal lead (V.R), the above expression may be written as:
𝑙
𝑁 1 𝑉.𝑅 𝑋 1 1 𝑉.𝑅
X= 2𝜋 (𝑠𝑖𝑛λ + 𝑐𝑜𝑠λ) or = 2𝜋 (𝑠𝑖𝑛λ + 𝑐𝑜𝑠λ )
𝑙𝑁

Since the velocity ratio (V.R.) is given, therefore the above equation contains three variables 𝑖.𝑒,
𝑥, 𝑙𝑁and 𝜆. The right hand side of the above expression may be calculated for a given value of
velocity ratio and the lowest point on the curve gives the lead angle which corresponds to the
minimum value of 𝑥/𝑙𝑁.This minimum value represents the minimum center distance that can be
used with a given lead or inversely the maximum lead that can be used with a given center
distance.

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Jimma University, JIT, Faculty of mechanical engineering
 The lowest point on the curve may be determined mathematically by differentiating the above
equation with respect to 𝜆 and equating to zero, 𝑖.𝑒,

⇒ 𝑉. 𝑅 = Cot3𝜆 ……………………………………………………………..(1)
Cot3 𝜆 = 50 ⇔ 𝜆 = 15.20

100 1 1 50
⇒ =2π [𝑠𝑖𝑛15.2 + 𝑐𝑜𝑠15.2 ] …………………………………………………..(2)
𝑙𝑁
⇒ 𝑙𝑁 = 11.4𝑚m
⇒ Axial load, 𝑙 = 𝑙𝑁 𝑐𝑜𝑠𝜆 = 11.8𝑚𝑚 ………………………………………(3)
Table 4.3 Number of starts to be used on the worm for different velocity ratios
Velocity ratio (V.R) 36 and 12 to 36 8 to12 6 to12 4 to10
above
Number of stars or thread Single Double Triple Quadruple Sextuple
on the worm (n =Tw)

From the above table, we find that for a velocity ratio of 100, the number of starts or threads on
the worm, 𝑛 = 𝑇𝑊 = 1
⇒ 𝑃𝑎 = 𝑛 × 𝑙 = 1 × 11.7 = 11.7𝑚𝑚 ………………………………………………………………….(4)

𝑃𝑎
⇒𝑚= = 11.7 𝜋 = 3.72𝑚𝑚 …………………………………………………………………….(5)
𝜋
Let us take the standard value of module, 𝑚 = 4𝑚𝑚

Now from the table of standard dimensions of worm gearing, for standard module of 4mm and
self-locking characteristics we can have the following data,
𝜆 = 3.41670, 𝑃𝑎 = 𝑚 × 𝜋 = 12.566𝑚𝑚, 𝑙 = 𝑃𝑎 = 12.566𝑚𝑚,
𝑙𝑁 = 𝑙 × 𝑐𝑜𝑠3.4167 = 12.566 × 𝑐𝑜𝑠3.4167 = 12.544𝑚𝑚

We know that the center distance,

𝑙𝑁 1 𝑉.𝑅 12.544 1 50
𝑥 = 2π [𝑠𝑖𝑛λ + ]= [ + ] = 133.5𝑚𝑚 …………………….(6)
𝐶𝑂𝑆 λ 2π 𝑠𝑖𝑛3.4167 𝑐𝑜𝑠3.4167

𝐿𝑒𝑡 𝐷W = Pitch circle diameter of the worm.

We know that,
𝑙
𝑡𝑎𝑛𝜆 = 𝜋×𝐷𝑊

𝑙 12.566
𝐷𝑊 = π x tanλ = π x tan3.4167 = 67mm ………………………………………………(7)

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Since the velocity ratio is 50 and the worm has single thread, therefore number of teeth on the
worm gear,
𝑇𝐺 = 𝑛 × 𝑉. 𝑅. = 1 × 50 = 50 …………………………………………(8)

Table 4.4 Proportion for worm thread

From the above table, we find that the face length of the worm or the length of threaded portion
is

Face length (𝐿𝑤) by using eq 4

𝐿𝑤 = 𝑃𝑐 (4.5 + 0.02𝑇𝑤) ………………………………………………….(9)
= 𝑃𝑎 (4.5 + 0.02 × 1) …………………………… [ 𝑃𝑐 = 𝑃𝑎 ]
𝐿𝑤 = 56.8mm
This length should be increased by 25 to 30mm for the feed marks produced by the vibrating
grinding wheel as it leaves the thread root.
∴ 𝐿𝑤 = 85mm
Depth of tooth (h) by using eq 4
ℎ = 0.686𝑃𝑐 = 0.686𝑃𝑎 = 0.686 × 12.566 = 8.62mm
Addendum (𝑎)
𝑎 = 0.318𝑃𝑐 = 0.318𝑃𝑎 = 0.318 × 12.566 = 4mm
Outside diameter of worm (Dow)
𝐷𝑜𝑤 = 𝐷𝑤 + 2𝑎 = 67 + (2 × 4) = 75mm ……………………………………(10)
C) Design of Worm Gear
What Is Worm Gear?
A worm gear is a gear consisting of a shaft with a spiral thread that engages with and drives
a toothed wheel. It changes the rotational movement by 90 degrees.
How Worm Gears Work?
An electric motor or human force applies rotational power via to the worm. The worm
rotates against the wheel, and the screw face pushes on the teeth of the wheel. The wheel is
pushed against the load.

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Why we use Worm Gear?
There are a few reasons why we would choose a worm gear over a standard gear.
The first one is the high reduction ratio. A worm gear can have a massive reduction ratio
with little effort.
A second reason to use a worm gear is the inability to reverse the direction of power.
Because of the friction between the worm and the wheel, it is virtually impossible for a
wheel with force applied to it to start the worm moving.
Table 4.5 Properties for worm gear

Diameter of worm gear (𝐷𝐺 ) from eq 8

𝐷𝐺 = m𝑇𝐺 = 4 × 50 = 200mm ……………………………………(11)
Throat Diameter (DT)
𝐷𝑇 = 𝐷𝐺 + 0.636𝑃𝑐 = 𝐷𝐺 + 0.636𝑃𝑎
= 200mm + 0.636 × 12.566mm
𝐷𝑇 = 208mm
Face width (𝑏)
𝑏 = 2.38𝑃𝑐 + 6.5mm = 2.38𝑃𝑎 + 6.5mm
= (2.38 × 12.566mm) + 6.5mm
= 36.4mm 𝑏 ≈ 37mm
Outside Diameter (𝐷𝑂𝐺 ), from eq 4 and 11
𝐷𝑂𝐺 = 𝐷𝐺 + 1.0135𝑃𝑐 = 𝐷𝐺 + 1.0135𝑃𝑎 ………………………(12)
= 200mm + (1.0135 × 12.566mm)
𝐷𝑂𝐺 = 212.73mm

Let us know check the designed worm gearing from the standpoint of tangential load, dynamic
load, static load or endurance strength and wear load.

Check for the tangential load

We know that velocity ratio of the drive, 𝑉. 𝑅. = 50 and the speed of the worm is 𝑁𝑊 = 60𝑟𝑝𝑚
then we can find the speed of the worm gear using the following relation.

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 Nw 60
NG = V.R = 50 = 1.2 rpm ……………………………………………………(13)

A mean power that a man can apply on the working handle of a crank lever, off and on for a full
working day is 80W. Now the torque transmitted to the axis of the worm shaft can be found by
applying the following equation,
p×60 80×60
Torque transmitted, T=2𝜋×𝑁 = 2π×60 = 12.7 N-m …………………(14)
𝐺

Tangential load acting on the gear,

2×Torque 2×12.7
WT= = = 127.3 N …………………………………..(16)
DG 0.2

We know that pitch line or peripheral velocity of the worm gear,

π.DG.NG π×0.2×1.2
V= = = 0.01 m/s ……………………………………(17)
60 60

Therefore, Velocity factor

6 6
CV=6+V = 6+0.01=0.99 …………………………………………….(18)

And tooth form factor for 14.5° involute teeth,

0.684 0.684
Y=0.12− =0.124 − =0.11 …………………………………(19)
TG 50

Since the worm gear is generally made of phosphor bronze, therefore taking the allowable static
stress for phosphor bronze, σo = 84 MPa or N/mm2.

We know that the designed tangential load,

WT = (σo, Cv) b. π m .y= 84×0.99×37×π×4×0.11N = 4253.23 N

Since this is more than the tangential load acting on the gear (i.e., 127.3 N), therefore the design
is safe from the stand point of tangential load.

Check for dynamic load

We know that the dynamic load,

𝑊𝑡 4253.23
WD = 𝐶𝑣 = = 4296.2N
0.99
Since this is much more than 𝑊T = 127.3𝑁, therefore the design is safe from the standpoint of
dynamic load.

Check for static load or endurance strength

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We know that the flexural endurance limit for phosphor bronze is, 𝜎𝑒 = 168 𝑀𝑃𝑎 𝑜𝑟 N/mm2
∴ Static load or endurance strength,
𝑊S = 𝜎𝑒. 𝑏. 𝜋. 𝑚. 𝑦 = 168 × 37 × 𝜋 × 4 × 0.11
𝑊S = 8592.4N
Since this is much more than 𝑊T = 127.3𝑁, therefore the design is safe from the standpoint of
static load or endurance strength.
Check for wear
Since the material we select for worm is hardened steel, therefore from the following Table we
find that for hardened steel worm and phosphor bronze worm gear, the value of load stress
factor, 𝐾 = 0.55𝑁/𝑚𝑚2
Table 4.6 Load stress factor for different materials
S.NO. Material Load stress factor (K)
Worm Worm gear N/mm2
1 Steel (B.H.N.250) Phospher bronze 0.415
2 Hardend steel Cast iron 0.345
3 Hardend steel Phospher bronze 0.550
4 Hardend steel Chilled phospher 0.830
bronze
5 Hardend steel Antimony bronze 0.830
6 Cast iron Phospher bronze 1.035
Note: The value of K given in the above table are suitable for angles up to 100. For lead angles
between 100 and 250, the values of K should be increased by 25 per cent for lead angles greater
than 250, increase the value of K by 50 per cent.

Limiting or maximum load for wear, from eq 11

𝑊w = 𝐷G. 𝑏.𝐾 = 200 × 37 × 0.415 = 1073𝑁
Since this is more than 𝑊T =127.3N therefore the design is safe from the standpoint of wear

Check for heat dissipation

First of all, let us find the efficiency of the worm gearing (𝜂).

We know that the rubbing velocity, from eq 1 and 7

π × Dw × Nw π× 0.067× 60
𝑉r = = = 12.65m/min
𝑐𝑜𝑠λ Cos 3.4167

Coefficient of friction for rubbing speed below 10m/min is 𝜇 = 0.15,

𝜙1 = 𝑡𝑎𝑛-1 𝜇 = 𝑡𝑎𝑛-1 0.15 = 8.30

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We know that efficiency,
tanλ tan 3.4167
𝜂 = tan(λ + ϕ) = tan(3.4167 + 8.3) = 28.8%
Note: Since the efficiency of worm gearing is less than 50%, then the worm gearing is said to be
self-locking, i.e. it cannot be driven by applying a torque to the wheel. This property of self-
locking is desirable in this case.
Assuming 25% overload, heat generated
𝑄g= 1.25𝑃 (1 − 𝜂) = 1.25 × 80(1 − 0.288) = 71.2W
We know that projected area of the worm, from eq 7
π 𝜋
𝐴W = 4 (𝐷W) 2 = (67)2 = 3525.65𝑚𝑚2
4
And projected area of the worm, from eq 11
π π
𝐴G = 4 (𝐷G) 2 = (200) 2= 31415.93𝑚𝑚2
4
Therefore, the total projected area of the worm and worm gear.
𝐴 = 𝐴W + 𝐴G = 3525.65 + 31415.93 = 34941.6𝑚𝑚2
= 34941.6 × 10-6 𝑚2
We know that heat dissipating capacity.
𝑄d = 𝐴 (𝑡2 – 𝑡1) 𝐾 = 34941.6 × 10−6 (𝑡2 – 𝑡1) 378 = 13.21(𝑡2 – 𝑡1)
The heat generated must be dissipated in order to avoid over heating of the drive, therefore
equating 𝑄𝑔 = 𝑄𝑑, we have
13.21(𝑡2 – 𝑡1) = 71.2
(𝑡2 – 𝑡1) = 5.4 0C
Since the temperature difference between the housing surface and surrounding air, 5.4 0𝐶 did not
exceed the maximum temperature difference (𝑡2− 𝑡1) = 38 0𝐶 that can be allowed, the design is
safe from the standpoint of heat dissipation.

Figure 4.10 worm and worm gear

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Jimma University, JIT, Faculty of mechanical engineering
 C) Design of worm shaft
Material selected for worm shaft is carbon steel of grade 45C8 (Indian standard designation) and
it has a Yield strength of, 𝜎𝑦 = 200𝑀𝑃𝑎. When the worm gearing is transmitting power, the
forces acting on the worm are similar to those on a power screw.
Since the efficiency of the worm reducer gearbox is found to be 28.8%. But we know that,
Poutput
𝜂= ⇔ 𝑃output = 𝜂 × 𝑃input = 0.288 × 80𝑊 = 23.04w
Pinput

We know that torque acting on the worm gear shaft,

P × 60 23.04× 60
𝑇gear = = = 382.45 ×10 3mm
2πNG 2π × 0.8

Torque acting on the worm shaft,

Tgear 382.45 × 103
𝑇worm = V.R.× η = = 27× 103 𝑁mm
50 × 0.288

We know that tangential force on the worm,

𝑊T = Axial force on the worm gear.
2 × Tworm 2 × 27 × 103
𝑊T = = = 806N
Dw 67

Axial force on the worm,

𝑊A = Tangential force on the worm gear.
2 × Tgear 2 × 382.45× 103
𝑊A = = = 3824.5N
𝐷𝐺 200

Radial or separating force on the worm

𝑊R= Radial or separating force on the worm gear
= 𝑊A 𝑡𝑎𝑛𝜙 = 3824.5𝑡𝑎𝑛14.5 = 989.1N
Let us take the distance between the bearings of the worm shaft (X1) equal to 230mm,
𝑋1 = 220𝑚m
Bending moment due to the radial force (WR) in the vertical plane
𝑊𝑅 𝑥 𝑋1 989.1 𝑥022
𝑀WR = = = 54.4𝑁m
4 4

And bending moment due to axial force (𝑊A) in the vertical plane
𝑊𝐴 𝑥𝐷𝑊 3824.5 𝑥0.067
𝑀WA = = = 64.1𝑁m
4 4

Total bending moment in the vertical plane,

𝑀1 = 𝑀WR + 𝑀WA = 54.4𝑁𝑚 + 64.1𝑁𝑚=118.5𝑁m

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We know that bending moment due to tangential force (𝑊T) in the horizontal plane,
𝑊𝑇 𝑥𝐷𝐺 806 𝑥 0.2
𝑀2 = = = 40.3 𝑁m
4 4

Resultant bending moment on the worm shaft,

𝑀worm= √𝑚1 2 + 𝑚2 2 = √118.52 + 40.32 =125.2𝑁m

We know that equivalent twisting moment on the worm shaft,

𝑇eq = √𝑇𝑤𝑜𝑟𝑚 2 + 𝑀𝑤𝑜𝑟𝑚 2 = √272 + 125.22 = 128.1Nm

For 45c8 of, yield strength, 𝜎𝑦 = 200𝑁/𝑚𝑚2 and considering a safety factor of 2, according to
maximum shear stress theory,
σy 200
𝜏𝑦 = = = 100𝑁/mm2
2 2

Now permissible shear stress will be,

We also know that equivalent twisting moment (𝑇𝑒𝑞),
π π
𝑇𝑒𝑞 = 16 τ (𝑑𝑤) 3 ⇔ 128100 = × 50 × (𝑑𝑤) 3 ⇔ 𝑑𝑤 3 = 9167.3mm3
16

𝑑𝑤 = 23.5𝑚𝑚
Taking the standard value, 𝑑𝑤 = 25 mm
Let us know check the maximum shear stress induced.
We know that the actual shear stress,
16Teq 16 × 128100
𝜏= = = 42𝑁/mm2
π(dw) 3 π(25) 3

And direct compressive stress on the shaft due to the axial force,
𝑊𝐴 3824.5𝑁
𝜎𝑐 = π\4(dw) 2 = = 8𝑁/mm2
π\4(25) 2

Maximum shear stress,

1 1
𝜏max = 2 √(σc) 2 + 4τ2 = √82 + 4 ∗ 422 = 43𝑀𝑃𝑎
2

Since the maximum shear stress induced is less than 50MPa, therefore the design of worm shaft
is satisfactory.
Deflection of Worm-Shaft
In a worm and worm-wheel drive system, the worm is subjected to bending and deflection. Since
perfect contact relations and tooth action are possible only in case of precise bearing mountings

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and accurate too thing, and since such a conditions are not practically attainable, some amount of
deformation during service has to be allowed.
It is desirable to have comparatively large diameter of the worm-shaft, and the distance between
the bearings, should be kept as small as possible commensurate with the other design number of
worm.
The following relations are relevant for calculations of defections.
From mechanics, we can establish the following formula.
𝐹𝑅𝐼 3
𝛿= 48EI

Where 𝛿 (mm) = the deflection of worm shaft

𝑙 (mm) = the distance between the bearings holding the worm shaft.
Here the worm is mounted at the center from the two bearing.
FR (𝑁) = the vector sum of the tangential force WT and radial force WR.
This resultant force (FR) which deflects the worm shaft, is given by
𝐹R = √𝑊𝑡 2 + 𝑊𝑟 2 = √8062 + 989.12 = 807N
Symbol 𝐸 (𝑁/mm2) is the modulus of elasticity of the worm material and 𝐼 (mm4) is the area
moment of inertia of the cross-section of the worm shaft. Here, 𝐼 is taken to be approximately
constant throughout the length of the shaft. Since the material of the shaft is selected to be C 07
steel, we can have
𝐹𝑅𝐼 3 807 × 2203
𝛿= = = 0.044𝑚m
48EI 48×210000×19175

Permissible deflection is given by,

𝐷𝑊 67
𝛿𝑝 = = = 0.067𝑚m
1000 1000

The following factor of safety against deflection (𝑆d) should be adhered the design
𝛿𝑝 0.067
𝑆d = = = 1.523 ≥ 1
𝛿 0.044

The above design, therefore, is safe against all the conventional failures as the above check
method shows.
D) Design of worm gear shaft
Material selected for worm gear shaft is carbon steel of grade 45C8(Indian standard designation)
and it has a yield strength, 𝜎𝑦 = 207𝑁/mm2
We have calculated above that the axial, tangential and radial force on the worm gear to be 𝑊A =
3823.5𝑁, 𝑊T = 806𝑁, 𝑊R = 989.1N respectively.

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We know that bending moment due to the axial force on the worm gear
𝑊𝐴×𝐷𝐺 3823.5×200
𝑀GA = = = 191.175𝑁m
4 4

The bending moment due to the axial force will be in the vertical plane.
Let us take the distance between the bearings of the worm gear shaft (𝑋2) as 120mm. Bending
moment due to the radial force on the worm gear
𝑤𝑅× 𝑋2 989.1×0.12
𝑀GR = = =29.67 𝑁m
4 4

The bending moment due to the radial force will also be in the vertical plane.
Total bending moment in the vertical plane
𝑀3 = 𝑀GA + 𝑀GR = 191.175𝑁m + 29.67𝑁m = 220.85𝑁m
We know that the bending moment due to the tangential force in the horizontal plane
𝑊𝐴×𝑋2 3824.5×0.12
𝑀4 = = = 114.74𝑁m
4 4

Resultant bending moment on the worm gear shaft,

𝑀gear = √𝑀3 2 + 𝑀4 2 = √220.8452 + 114.742 = 248.9𝑁m

We have already calculated that the torque acting on the worm gear shaft, 𝑇𝑔𝑒𝑎𝑟 = 384.45𝑁𝑚
Equivalent twisting moment on the worm gear shaft,

𝑇eq = √𝑇𝑔𝑒𝑎𝑟 2 + 𝑀𝑔𝑒𝑎𝑟 2 = √384.452 + 248.92 = 458 × 10 3 𝑁mm

For mild steel, yield strength, 𝜎𝑦 = 207𝑁/𝑚𝑚2 and considering a safety factor of 2, according to
maximum shear stress theory,
σy 207
𝜏𝑦 = = = 103.5𝑁/mm2
2 2

Now permissible shear stress will be,

τy 103.5
𝜏= = = 51.75𝑁/mm2
FoS 2

We know that equivalent twisting moment (𝑇eq)

𝜋
𝑇eq = 16 𝜏 (𝑑G) 3
𝜋
1025450 = × 51.75 × (𝑑G) 3
16

𝑑G = 46.56mm
Taking the standard value, 𝑑G = 50mm
Let us now check the maximum shear stress induced.

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We know that actual shear stress,
16Teq 16×458000
𝜏= = = 18.66𝑀𝑃a
𝜋(𝑑𝐺)3 𝜋(50)3

And direct compression stress on the shaft due to the axial force,
𝐴𝑊 3824.5
𝜎𝑐 = 𝜋(𝑑𝐺) =
2 𝜋
= 1.95 𝑀𝑃a
(50)2
4

Maximum shear stress,

1
𝜏max = 12 √𝜎𝑐 2 + 4𝜏 2 = 2 √1.952 + 4 × 18.662 = 37.4𝑀𝑃𝑎

Bearing Worm gear

Mounting arm

120mm
250mm
3823.5N
989.1N

248.9Nm

There for the maximum beanding moment is Mb = 248.9 Nm

Can the gearbox produce enough torque to rotate a mass of 400kg?
The torque produced by the worm gear must exceed the torque that weight of an engine
produces to rotate the engine. But we have already calculated that the torque produced by the
worm gear to be,

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 𝑃×60 23.04×60
𝑇gear =2𝜋×𝑁 = = 183.34 𝑁mm
𝐺 2𝜋×1.2

Now let us calculate the torque the weight of an engine produces and check that the torque
produced by the worm gear exceeds this value.
Torque transmitted to the axis of the shaft is, the resultant of the horizontal torque, 𝑇H and the
vertical torque, 𝑇V.
The horizontal torque is given by,
𝑇H = 𝐵𝑋 × 𝑦 = 6540 × 0.18 = 117.2𝑁m
And the vertical torque is given by
𝑇V = 𝐵𝑦 × 𝑙 = 3924 × 0.06 = 235.44𝑁𝑚
Where l is the horizontal distance between the bearing and the point B. Now the resultant
torque, 𝑇R will be,

𝑇R = √𝑇𝐻 2 + 𝑇𝑉 2 = √1172 + 235.442 =120.5Nm

𝑇gear > 𝑇R 859.43 > 750.32

Therefore, we can conclude that our gearbox has the capacity to rotate the given weight
E) Design of Key

Figure 4.11 Sunk Key

A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to connect
these together in order to prevent relative motion between them. It is always inserted parallel to
the axis of the shaft. Keys are used as temporary fastenings and are subjected to considerable
crushing and shearing stresses. A keyway is a slot or recess in a shaft and hub of the pulley to
accommodate a key.

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Jimma University, JIT, Faculty of mechanical engineering
The type of key chosen for the worm reducer gearbox is a rectangular sunk key. The sunk keys
are provided half in the keyway of the shaft and half in the keyway of the hub or boss of the
pulley and the material selected for the key is mild steel and it has a yield strength of,
𝜎𝑦 = 207𝑁/mm2 and by considering a factor of safety, n = 2, we can get the following,
Allowable yield strength (Crushing stress),
𝜎𝑦 207𝑁/𝑚𝑚2
𝜎𝑐 = = = 103.5𝑁/mm2
𝑛 2

Allowable Shear stress,

𝜏 = 0.5 × 103.5 𝑁/mm2= 51.75 𝑁 mm2

Table 4.7 Proportions of standard parallel, tapered and gib head keys
Shaft Key cross-section Shaft Key cross section
diameter diameter
Thickness(mm) Thickness(mm)
(mm) up to (mm) up to
Width(mm) Width(mm)
and and
including including
6 2 20 85 25 14
8 3 3 95 28 16
10 4 4 110 32 18
12 5 5 130 36 20
17 6 6 150 40 22
22 8 7 170 45 25
30 10 8 200 50 28
38 12 8 230 56 32
44 14 9 260 63 32
50 16 10 290 70 36
58 18 11 330 80 40
65 20 12 380 90 45
75 22 14 440 100 50
I) Worm key
For the worm the diameter of the shaft is 25mm and the torque transmitted by the shaft is 𝑇worm
= 27 × 10 3 𝑁mm. Thus from the standard table of keys we can have the following data,

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 Width of key, 𝑏 = 10mm
Height of key, ℎ = 8mm
Length of key, 𝑙 = 1.5𝑑 = 37.5mm

Check for shearing of the key

𝑇worm = 𝜎𝑐 × 𝑙 × d\2
2𝑇𝑤𝑜𝑟𝑚 2×27×103
𝜏= = = 18 𝑁/mm2
𝑙×ℎ×𝑑 37.5×8×10

Which is less than the allowable strength, hence the design is safe and acceptable from the
stand point of shear.
Check for crushing stress of the key
ℎ 𝑑
𝑇𝑤𝑜𝑟𝑚 = 𝜎𝑐 × 𝑙 × 2× 2
4𝑇𝑤𝑜𝑟𝑚 4×27×103
𝜎𝑐 = = = 36𝑁/mm2
𝑙×ℎ×𝑑 37.5×8×10

Which is less than the allowable strength, hence the design is safe and acceptable from the
stand point of crushing.
Therefore, as the above check method shows, the key chosen for the worm is safe.
II Worm gear key
For the worm gear the diameter of the shaft is 50mm and the torque transmitted by the shaft is
Tgear = 384.45×103 𝑁mm. Thus from the standard table of keys we can have the following data,
Width of key, 𝑏 = 16mm
Height of key, ℎ = 10mm
Length of key,
𝑙 = we should adopt a length of at least equal to the shaft diameter,
𝐿 = 𝑑 = 50mm
Check for shearing of the key
𝑇 = 𝜏 × 𝑙 × 𝑏 × 𝑑 /2
2𝑇 2×384.45×103
𝜏 = 𝑙×𝑏×𝑑 = = 12.8𝑁/mm2
75×16×50

Which is less than the allowable strength, hence the design is safe and acceptable from the stand
point of shear.
Check for crushing stress of the key

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 𝑇 = 𝜎𝑐 × 𝑙 × ℎ 2 ⁄ × 𝑑 /2
4𝑇 4×383.45×103
𝜎𝑐 = 𝐼×ℎ×𝑑= = 40.9𝑁/mm2
75×10×50

Which is less than the allowable strength, hence the design is safe and acceptable from the stand
point of crushing.
Therefore, as the above check method shows, the key chosen for the worm gear is safe

Figure 4.12 Worm gear assembly

4.11.6 Bearing Selection
A) Bearing selection for worm shaft
From table of life of bearings for various types of machines which is mentioned in the Appendix
II, for a machine working 8 hours per day and not always fully utilized, the life of the bearing
will range between 12000 – 20000 hours, so we choose 16000 hours in this case.
We have already calculated the speed of the worm shaft to be 60rpm, the axial force acting on
the bearing to be 1.8KN and the radial force acting on the bearing to be 1.5KN.
We have also determined the diameter of the shaft to be, d = 25mm.
Table 4.8 Service factors for bearings carrying geared shafts
Applications Service factor
Rotary machine with no impact 1.1 – 1.5
Reciprocating machine 1.3 – 1.9
Machine with pronounced impact, hammer 1.6 - 4
mills etc.
Since, the engine stand is a rotary machine with no impact, we took a safety factor of 1.4.
Since the diameter is already determined to be, d = 25mm

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Jimma University, JIT, Faculty of mechanical engineering
Selections of dimension for radial ball bearing
Thus from the standard table of be principal dimensions for radial ball bearings, single row
angular contact ball bearing No. 305 with Bore = 25mm, Outside diameter = 62mm and
Width = 17mm is chosen. Now let’s check if this bearing is capable of withstanding all the
loads.

The static and dynamic load for this bearing is, 𝐶𝑜 = 12.5𝑘𝑁 and 𝐶 = 19.3𝑘𝑁 respectively.

The value of e, for single row ball bearing, e = 1.14

Thus,
𝐹𝑎 1.8𝐾𝑁
=1.5𝐾𝑁 = 1.2
𝐹𝑟

𝐹𝑎
> 𝑒 ↔ 1.2> 1.14
𝐹𝑟

Thus from the table of Values of X and Y given in the Appendix II,

Thus for single row angular contact bearing with the radial load factor, X = 0.35 and axial
or thrust load factor, Y = 0.57.

Equivalent load, 𝑃 = (𝑋𝐹𝑟 + 𝑌𝐹𝑎) 𝑆 = (0.35 × 1.5 + 0.57 × 1.8) × 1.4 = 1.98𝑘𝑁
From table of loading ratio given in Appendix II, for bearing life of 16000hrs and rotational
speed of 60rpm, we get

Since the dynamic load rating of the singles row, bearing No. 305 is more than the required
dynamic load capacity, 𝐶 = 17𝑘𝑁 > 16.69𝑘𝑁 the selected bearing is safe.
B) Bearing Selection for worm gear shaft
From table of life of bearings for various types of machines which is mentioned in the Appendix
II, for a machine working 8 hours per day and not always fully utilized, the life of the bearing
will range between 12000 – 20000 hours, so we choose 16000 hours in this case.
We have already calculated the speed of the worm gear shaft to be 1.2rpm, the axial force acting
on the bearing to be 2.78KN and the radial force acting on the bearing to be 2.2KN.
We have also determined the diameter of the shaft to be, d = 50mm.
From table, since the engine stand is a rotary machine with no impact, thus we took a safety
factor of 1.4.
Since the diameter is already determined to be, d = 50mm

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Thus from the standard table of be principal dimensions for radial ball bearings, single row
angular contact ball bearing No. 310 with Bore = 50mm, Outside diameter = 110mm and
Width = 27mm is chosen. Now let’s check if this bearing is capable of withstanding all the
loads.

The static and dynamic load for this bearing is, 𝐶𝑜 = 40.3𝑘𝑁 and 𝐶 = 53𝑘𝑁 respectively.

The value of e, for single row ball bearing, e = 1.14

Thus,

Thus from the table of Values of X and Y given in the Appendix II,

Thus for single row angular contact bearing with the radial load factor, X = 0.35 and axial
or thrust load factor, Y = 0.57.

Equivalent load, 𝑃 = (𝑋𝐹𝑟 + 𝑌𝐹𝑎) 𝑆 = (0.35 × 2.22 + 0.57 × 2.78) × 1.4 = 3.31𝑘𝑁
From table of loading ratio given in Appendix II, for bearing life of 16000hrs and rotational
speed of 0.8rpm, we get

Since the dynamic load rating of the singles row, bearing No. 306 is more than the required
dynamic load capacity, 𝐶 = 40.5𝑘𝑁 > 17.56𝑘𝑁 the selected bearing is safe.

Figure 4.13 Bearing house

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4.11.7 Design of Handle

Figure 4.14 lever dimension

Specifications
• Length of handle, 𝑙 = 100𝑚𝑚
• Length of lever arm, 𝐿 = 120𝑚𝑚
• Overhang of the journal, 𝑥 = 70𝑚𝑚
• The lever is operated by a single person exerting a maximum force of 100N at a distance
of 1⁄3𝑟𝑑 of the handle from its free end.

 The material selected for the Handle is 30C8 grade of carbon steel ( IS standared
designation) with σy = 200MPa. Taking,
And by considering a factor of safety, 𝑛 = 2, we can get the following,

Allowable yield strength (Bending stress),

𝜎𝑦 200𝑁/𝑚𝑚2 2
𝜎𝑏 = = = 100𝑁/𝑚𝑚
𝑛 2

Allowable Shear stress,

𝜏 = 0.5 × 100𝑁⁄𝑚𝑚2 = 50 𝑁⁄𝑚𝑚2

Diameter of the handle
Let 𝑑 = Diameter of handle in mm.
Since the force applied acts at a distance of 1/3rd length of the handle from its free end, therefore
maximum bending moment,
1 2 2
𝑀 = (1- 3 ) P× 𝑙 = 3 × 𝑝 × 𝑙 = 3 × 100 × 100 = 7 × 10 3𝑁𝑚 … … … … … (1)
𝜋
Section modulus, Z = 32 × 𝑑 3 =0.0982d3
Therefore the resisting bending moment,

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 𝑀 = 𝜎𝑏 × 𝑍 = 100× 0.0982𝑑3 = 9.82𝑑3 … … … … … … … … … … … (2)
From equation (1) and (2), we get
8×103
d3= 9.82𝑑3 ⇔ d = 11.34mm

Say d = 12mm
Cross-section of the lever arm

Let,

𝑡 = thickness of the lever arm in mm, and

𝐵 = Width of the lever arm near the boss, in mm
Since the lever arm is designed for 25% more bending moment, therefore maximum bending
moment,

𝑀 = 1.25𝑃 × 𝐿 = 1.25 × 100 × 100 = 12.5 × 103𝑁𝑚𝑚

Section modulus,

𝑀 12.5×103
We know that bending stress (𝜎𝑏), 50= 𝑧 = 0.667𝑡 3

Let us now check the lever arm for induced bending and shear stress.
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 = 100 × 120 = 31.25 × 103𝑁𝑚𝑚

And section modulus,

Induced bending stress,
𝑀 31.25×103
𝜎𝑏= 𝑍 = = 46.9𝑀𝑃𝑎
666.67

The induced bending stress is within safe limits.

We know that the twisting moment

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 2 2
𝑇= × 𝑃 × 𝑙 = × 100 × 100 = 8 × 103
3 3
We also know that the twisting moment (T),
2 2
8 × 103 = 9 × 𝐵 × 𝑡 2 × 𝜏 = 9 × 20 × 102 × 𝜏 = 444.44𝜏

𝜏=18MPa
The induced shear stress is also within safe limits.
Let us now check the cross-section of lever arm for maximum principal or shear stress.
We know that maximum principal stress,
1
𝜎𝑏(𝑚𝑎𝑥) = 2 (𝜎𝑏 + √𝜎𝑏 2 + 4𝜏 2 = 43.4𝑀𝑃𝑎

And maximum shear stress,

1
𝜏𝑚𝑎𝑥 = 2 √𝜎𝑏 2 + 4𝜏 2 = 24.6𝑀𝑃𝑎

The maximum principal and shear stresses are also within safe limits.
Diameter of the journal
Let

𝐷 = Diameter of the journal.

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,
2𝑙+𝑥 2
𝑇𝑒 = 𝑃√( ) + 𝐿2 = 27.73 X 103 Nmm
3

We know that equivalent twisting moment (𝑇𝑒),

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 Figure 4.15 Handle
4.11.8 Design of Base
Material for support is mild steel:σc = 320MPa , τ = 400MPa
Assumption
Length=1000mm
Thickness= 40mm
Width= 40mm
The base is made up of
Permissible compressive stress of (𝜎𝑐) =320MPa
Compressive area of the base =1200× 30=36000mm2
Load acting on the base = 19620
Checking for compressive strength
𝑙𝑜𝑎𝑑 19620
𝜎𝑐 = 𝐴𝑟𝑒𝑎 = = 0.545𝑁/𝑚𝑚2
36000

Figure 4.16 Base

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4.11.9 Design of Wheels for Front and Rear Legs
From geometrical analysis Diameter of rear leg =100mm Diameter of front leg=100mm Total
stress of the wheel can be calculate as
𝐹
𝜎=𝐴 where 𝜎= stress at wheel F is force=19620N
A=Area of wheel= 𝜋d²/4
𝜎1 =19620N ×4/П×0.1² (for rear)
𝜎 =2.5 MPa
Since the number of wheels is two at rear leg the stress in induced on each the stress in the front
leg is the same as the stress of rear wheel because the wheels have the same diameter
(𝜎=2.5MPa).
Material selection for caster wheel
The material that used for caster wheel must have high compression ratio, high wear resistance,
excellent machine ability also must have low cost, good casting characteristic. Due to this cast
iron selected for caster wheel.
Tensile strength = 100 to 200MPa
Compressive strength = 400 to 1000 MPa
Shear strength = 120 MPa
Base Legs and casters: The base of engine stand consists of legs, casters and base tube. Engine
stands usually come with 3-6 casters. The most common wheel count for engine stand is four.
Four wheeled stands are stable and do not take as much space as six wheeled stands. Same stands
have three casters, these stands are good for engine with weight less than 2270N, but usually are
unstable with heavier engine. Five and six wheeled stands are used for larger and heavier engine
and will support load over 18140N. Stand with two legs are more stable and usually can be used
with large engines. Due to this we selected engine stand with four casters and two legs. There are
two casters on the front post and two on the back post of the stand. Front casters can be turned
360 a round to increase the maneuverability of the stand, while rear casters cannot be turned
around allow to move the stand only forward and back. This engine stand rolls very easily, even
when it is holding a load. Four-wheel designs not only allow moving the stand easier, but also
provide better stability than three wheeled engine stands.

Figure 4.17 Design of Caster Wheel

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 4.11.10 Selection of Bearing
A bearing is a machine element which supports another moving machine element (known as
journal). It permits a relative motion between the contact surfaces of the members, while
carrying the load.
From table 4.8, Since the engine stand is a rotary machine with no impact, thus we took a safety
factor of 1.4. Since the bore diameter of wheel is – 70mm
Thus from the standard table of be principal dimensions for radial ball bearings, single row
angular contact ball bearing No. 207 with Bore = 35mm, Outside diameter = 70mm and
Width =17mm is chosen. Now let’s check if this bearing is capable of withstanding all the loads.
The static and dynamic load for this bearing is, 𝐶𝑜 = 15.3𝑘𝑁 and 𝐶 = 21.2𝑘𝑁 respectively. The
value of e, for single row ball bearing, e = 1.14 Thus,

Thus from the table of Values of X and Y given in the Appendix II,

Thus for single row angular contact bearing with the radial load factor, X = 0.35 and axial
or thrust load factor, Y = 0.57.

Equivalent load, 𝑃 = (𝑋𝐹𝑟 + 𝑌𝐹𝑎) 𝑆 = (0.35 × 2.22 + 0.57 × 2.78) × 1.4 = 3.31𝑘𝑁

Since the dynamic load rating of the singles row, bearing No. 207 is more than the required
dynamic load capacity, 𝐶 = 40.5𝑘𝑁 > 17.56𝑘𝑁 the selected bearing is safe.

Figure 4.18 Bearing

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Figure 4.19 Assembly of Engine Repair Stand

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 CHAPTER FIVE
Result and Discussion
The design is safe
 Reduce human force or energy requirement
 provide safe working area
 prevent parts from damage
 reduce time waste

Figure 4.20 Maximum principal stress analysis of engine repair stand

Figure 4.21 Maximum principal elastic strain analysis of engine repair stand

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Figure 4.22 Total deformation analysis of engine repair stand

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Cost Analysis
Table 4.9 Cost Analysis
Part Quantity Material Dimension
(mm)
Support 1 Mild steel 40×40×1500
Base 1 Mild steel 40×40×1000
Handle 1 30c8 carbon D=12, l=120
steel
Shaft 2 Carbon steel DW=25, DG=50
Mounting plate 1 Mild steel 450×400×50
Mounting arm 4 Mild steel 15×5×140
Worm gear, 1 Phosphor DG=200, DW=67
worm bronze, steel
Bolt 4 Mild Steel D=14
Nut 4 Mild Steel D=7
Bearing 4 Steel N0.208
Wheel 4 Rubber + steel D=100, t=40
1$=53 birr and 1Kg=0.001 tone
Materials Cost of Cost of Cost of material Density of
material in material in in birr / kg materials in
$ /tone $/ kg kg/m3
Mild steel 1500 1.5 72 7850
Steel 1670 1.67 80.16 7880
45c8 steel 1480 1.48 71.04 7800
30c8 steel 1440 1.44 69.12 7790
Phosphor bronze 1980 1.98 95.04 8500
πd2
Formula used V= ×L or H for circular parts
4
V=L×W×H
M = ρ×V

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  V – volume
 d - diameter
 L – Length
 W – width
 H – height or thickness
 M - mass
 ρ – density
Table 4.10 Material cost for each part
No Parts Quantity Unit cost Total cost
in in (ETB)
( ETB)
1 Support 1 1200 1200
2 Base 1 1080 1080
3 Bolt and nut for 4 50 200
bearing cup and
mounting arm
4 Bolt and nuts 4 60 240
which holds the
engine
5 Bearing 4 450 1800
6 Hand wheel 1 120 120
7 Shaft 2 400 800

8 Mounting plate 1 205 205

9 Mounting arm 4 65 260
10 Worm gear 1 1500 1500
11 Bearing house 2 120 240
12 Bots and nuts for 4 80 320
wheel
13 Bolts and nuts 1 70 70
for post
14 Wheel 4 120 480
Total material cost ……………………………………………………8115 ETB
Table 4.11 Machining cost
No Process Total cost in (ETB)

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1 Milling 1800
2 Drilling 50
3 Turning 100
4 Facing 70

5 Other machining process 150

Total Machining cost…………………………………………2170 ETB
C. Electric power cost
Cost……………………………………………………………………………250 ETB
D. Labor cost
Cost………………………………………………………………………….2500 ETB
Total cost =13035 ETB
Main total cost =Total Cost +10% (Total Cost) =14833.5 ETB

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 CHAPTER SIX
CONCLUSION AND RECOMMENDATIONS
5.1 Conclusion
Generally the whole internship time in Johnny general auto service is great. The main objective
of the internship program is to enable the intern to experience the practical activities carried out
on working environment and correlate it with the theoretical background gained through
learning. Other objectives include if problems exist to identify its cause and take engineering
measures to solve it, to get accustomed to the working environment, to be governed by the rule
and regulation of the employer, to be more of team player. It is also important for applying job
placement in the hosting company after graduation. Different work division in are there to
facilitate good working environment and check and balance the work activities that takes place.
It is necessary this check and balance for the smooth running of the project, meeting schedules,
flow of ideas, and create a working environment that helped to accomplish the commencement
of the maintenance. The work we could complete here was very satisfactory. We tried to develop
as many as possible for the company by converting our theoretical knowledge and even got very
encouraging results as much as we can with help of our team. We hope our designs will help the
company to achieve its goals if they will work hard on the implementation process.

5.2 Recommendation

As internship program gave an opportunity to change the student to change theoretical

knowledge into practical or real world and exposes the student to exercise the real world life, we
strongly recommended to be continue in a manner that it achieves its goal.

During our intern months, we have seen a lot of problem which are the main cause for
manufacturing delays and wastage of resource. Now we want to recommend the company:
 The company should have to manufacture or buy such like engine repair stand or other similar
machines for the reason that:
 It can reduce human force and time.
 Prevent easily broken parts of engine from crushing or damage.
Provide easy working area.
 Can easily transfer or move the engine from one place to another.

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 REFERENCE
1) R.S. Khurmi & J.K. Gupta, a Text book of machine design, Fourteenth edition, 2005.
2) R. C. Hibbeler, Mechanics of Materials, Pearson Prentice Hall, 2011.
3) Shigley’s, Machine design text book, eight editions, 2006.
4) G. M. Maitra, Handbook of Gear Design, McGraw Hill Publishing, 2001.
5) S. Timoshenko, Strength of Materials,D. Van Nostrand Company, Inc, 1998.
6) Daniel kitaw, Material handling equipment, Addis Ababa university press, 2003.
7) Addisu kidanemarm, Design of machine element II, Jimma University, 2018.
8) Erik Oberg, Franklin D. Jones, Holbrook L. Horton, and Henery H. Ryfel, Machinery's
Handbook, Industrial Press Inc., 2004.
9) R. Hibbeler, Engineering Mechanic, Statics, Pearson Prentice Hall, 2004.
10) Ferdinand P. Beer, E.Russell Johnston, John T. Dewolf, David F. Mazurek, Mechanics of
Materials, McGraw Hill, 2012.

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 Appendx I

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 Appendx II
Standard table of bearing
Table1 Principal dimensions for radial ball bearings

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Table 2 Life of bearing for various types of machines

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Table 3 Values of X and Y for dynamically loaded bearings

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Table 4 Basic static and dynamic capacities of various types of radial ball bearing

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