MIZAN TEPI UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMEENT OF MECHANICAL ENGINEERING

INTERNSHIP REPORT

PURSUED AT: ETHIOPIAN ROAD ADMINISTRATION, NEKEMTE, OROMIA, ETHIOPIA

TITLE: DESIGN AND ANALYSIS OF MULTI NUT REMOVER MACHINE

DURATION: THREE MONTHS

Submission Date: Oct14, 2023

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Declaration
I am here to declare that the work, which is being presented in the report on internship at
Ethiopian construction Work Corporation for the completion of internship program, carried
out from July 10/2023 to October 03/2023 under the supervision of Mr. Nahom A. he is
instructor at department of Mechanical Engineering in Mizan Tepi University. All relevant
resources of information used in this paper have been correctly acknowledged. This is to
certify that the above statement made by the candidate is correct to the best of my
knowledge and belief.
This report has been submitted for presentation with my approval.

Advisor Name Signature Date

Mr. Nahom A. _____________ _________

Name of student ID No. Signature Date

Samuel Lemesa………………ETR/0855/11 ___________ _________

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Acknowledgement
Next to God I would like to express my sincerely gratitude to all “ETHIOPIAN ROAD
ADMINISTRATION” employees for their generous help during the internship period. I am
would like to thank the assistants in every workshop I am were placed. The assistances are well
experienced and as I am are new for such kind of practices. I am would like to thank my adviser
Mr. Nahom A. for his information and guidance during the intern period and our family with
God. Lastly‚ for having successful time of us in the internship period each members of ECWC
have done their best and I am really admire their hospitality and we hope that they will keep on
this good practice for the students next to me.

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Abstract
This report is an outcome of the Internship, which was conducted during I was were stayed at
Ethiopian construction Works Corporation. This was an opportunity for me to put in
practice the theoretical knowledge I has acquired during me study. The Internship also gave
a real opportunity to gain valuable experience to bridge the gap between study and the
beginning of working lives. Moreover, the practical exposure offered an experiential learning
component that can strengthen previous theoretical knowledge and also motivated I am in
perusing with Mechanical Engineering. Additionally, our experiential learning has proven to
be helpful to develop our detail skills about Engine, Transmission, Gear box, steering and
brake. And also we consider that automotive vehicle operation depending upon the company
work like maintenance the car, repair of the car, Annual vehicle checking, Technical Service
and solving different problem of vehicle. I have decided that engine operation vehicle, air
system of the vehicle, electric system of the vehicle, brake system of the vehicle, injection system
etc. In this case I am understand the safety necessary during working on vehicle and machines,
how can I am got power in motor from air and fuel (how power is produced), cooling system to
protect our engine from very hot and burnt, lubrication system to reduce friction, how to start
vehicle using starter, how I am inject (distribute) fuel on the combustion chamber, how power
trains are transfer power to each other, brake system and its assembly, clutch system and their
assembly. Also we decided on measurements and solving problem that obtained in that company
being with workers who have long experience and good skills on the vehicle. For example,
reduce time wastage and force of labor by changing works which done by force of
person to machine. In this case I am understand that how to solve the problem and ability to
communication, learning way of sociable and agree with workers.

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ACRONOMY AND ABBREVIATION

ECWC-Ethiopian construction work corporation

Eng’g-Engineering

Dep’t-Department

ERCC- Ethiopian road construction corporation

EWWCE- Ethiopian Water works construction enterprise

ERA- Ethiopian Road Administration

NOMENCLATURE
PCD- pitch circle diameter

M-module

Np- number of teeth of driven gear

Ng- number of teeth of driver gear b-

Face width

VR- velocity ratio

- pressure angle

J- Geometry factor for spur gear

GR- gear ratio

Fb- beam strength

F- Force

Ft- tangential force

FOS- factor of safety

P- Power

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Pg-power transmitted ring gear

Pp- power transmitted by pinion gear

LH- hand lever δy- yield strength

δu- ultimate tensile strength

Feff- effective load of gear teeth

Y- Lewis form factor

Ka- combined shock and fatigue factor

Km-load distribution factor

Kv- dynamic factor

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TABLE OF CONTENTS
Declaration....................................................................................................................................I
Acknowledgement.......................................................................................................................II
Abstract......................................................................................................................................III
ACRONOMY AND ABBREVIATION................................................................................IV
NOMENCLATURE...............................................................................................................IV
List of figures..........................................................................................................................VIII
List of tables...........................................................................................................................IX
CHAPTER ONE..........................................................................................................................1
Introduction..............................................................................................................................1
1.3. COMPANY INFORMATION..........................................................................................1
1.3.1 Background of The Organization................................................................................1
1.3.2 Main Purposes of The Establishment of ECWC.........................................................2
1.3.3 Location of ECWC......................................................................................................2
1.3.4 Vision and Mission of The Company..........................................................................2
1.3.5 The Main Customers of The ECWC:..........................................................................3
1.3.6 Structures of The Ethiopia Construction Works Corporation......................................3
1.3.7 Competitive Advantage of The ECWC........................................................................4
1.3.8 The Main Branches of ECWC......................................................................................5
1.3.9 Major Businesses of The ECWC..................................................................................5
CHAPTER TWO..........................................................................................................................6
2.1. WORK DONE....................................................................................................................6
2.1.1. Engine Shop....................................................................................................................7
2. Cleaning and Inspection......................................................................................................13
2.1.2. Machine Shop............................................................................................................18
2.1.3. Electrical service shop..............................................................................................21
2.1.4. Body shop.................................................................................................................23
2.1.5. Welding shop............................................................................................................24
2.1.6. Tire shop...................................................................................................................24
2.2. CHALLENGES FACED DURING OUR INTERNSHIP..............................................26
2.2.1. Methods to Overcome These Challenges:................................................................26

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2.3. SKILLS WE HAVE GOT...............................................................................................26

CHAPTER THREE....................................................................................................................29
3.1 INTRODUCTION............................................................................................................29
3.2. PROBLEM STATEMENT.............................................................................................29
3.3. OBJECTIVE....................................................................................................................30
3.3.1. General Objective.....................................................................................................30
3.3.2. Specific Objective.....................................................................................................30
3.4 Scope of study..................................................................................................................30
3.5 Significance of the study..................................................................................................30
3.6. WORKING PRINCIPLE................................................................................................30
CHAPTER FOUR......................................................................................................................31
4.1 LITRATURE REVIEW...................................................................................................31
4.2 MATERIAL AND METHOD..........................................................................................32
4.3 DESIGN OF EACH COMPONENT................................................................................32
4.3.1 Design Calculation......................................................................................................37
4.3.2. Design of Spur Gear..................................................................................................37
4.3.3 Design of Shaft...........................................................................................................38
4.3.4 Design of Casing.........................................................................................................39
4.3.5 Design of Hand Lever.................................................................................................39
4.3.6 Design of Bearing.......................................................................................................40
4.3.7 Design of Box Spanner Socket.................................................................................41
CONCLUSION......................................................................................................................44
RECOMMENDATION..........................................................................................................45
APPENDIXES...........................................................................................................................46

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List of figures
Figure 1.1 Ethiopian construction works corporation ............................................................... 2
Figure1.2 ECWCgarage..............................................................................................................6
Figure 2.1 Engine ...................................................................................................................... 8
Figure 2.2 crankcase .................................................................................................................. 9
Figure2.3 connecting rod .......................................................................................................… 10
Figure2.4 camshaft .................................................................................................................... 11
Figure2.5 bearing ....................................................................................................................... 11
Figure2.6 disassembled engine .................................................................................................. 12
Figure2.8 Transmission system ................................................................................................. 14
Figure2.9 clutch ......................................................................................................................... 15
Figure 2.10 braking system ....................................................................................................... 17
Figure 2.11 Disc brake ............................................................................................................... 18
Figure 2.12 drum brake ............................................................................................................. 18
Figure 2.13 shaper machine ....................................................................................................... 20
Figure 2.14 Features made in machine shop ............................................................................. 21
Figure 2.15 starter ...................................................................................................................... 22
Figure 2.16 Body shop ............................................................................................................... 23
Figure 2.17 Oxy-acetylene and Arc welding ............................................................................. 24

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List of tables
Table 1.1 branches of ECWC .................................................................................................... 5
Table 2.1 Transmission problems with remedies ...................................................................... 16
Table 4.1 material selection procedure ..................................................................................... 32
Table 4.2Parts to be designed .................................................................................…...............33
Table 4.3Properties and parameters for the gear design..............................................…...33
Table 4.4Properties and parameters for the gear design ..................................................…... 41

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CHAPTER ONE
INTRODUCTION
An internship is job training for professional careers. Generally, an internship consists of an
exchange of services for experience between the student and organization. Students can
also use an internship to determine if they have an interest in a particular career, to
create a network of contacts. Internships exist in a wide variety of industries and settings. An
internship may be paid, unpaid, or partially paid (in the form of a stipend).Stipends are
typically a fixed amount of money that is paid out on a regular basis. Usually, interns
that are paid through stipends are paid on monthly basis. Paid internships are common in
professional fields including medicine, architecture, science, engineering and technology. A
typical internship lasts between one and four months, but can be shorter or longer, depending
on the organization involved. Most students apply for internships during their summer and
winter breaks. In some Universities, internships during the college breaks are compulsory and
a part of the curriculum. It is common that previous interns become employees to the
organization once they have acquired the necessary skills and experience. Moreover, many
engineering students also term their training period in certain industrial organization as an
internship.

1.3. COMPANY INFORMATION

1.3.1 Background Of The Organization

The Ethiopian Construction Works Corporation is a newly established public enterprise with
the aim of becoming a leading, preferred and competitive construction contractor. The
corporation was a result of the amalgamation of two formerly independent public enterprises,
namely the Ethiopian Water Works Construction Enterprise (EWWCE) and the Ethiopian Road
Construction Corporation (ERCC).Although it is a new enterprise in its current form, the
Ethiopian Construction Works Corporation (ECWC) has, therefore, accumulated experience in
the construction industry. Currently, the corporation has two operational sectors: the water
infrastructure construction sector, and the transport infrastructure construction sector. The two
sectors in turn have different projects located in different parts of the country. The headquarters
of the corporation is located in the city of Addis Ababa, and situated in the building of the
former Ethiopian Water Works Construction Enterprise, around Gurdi Shola. The Ethiopian

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Construction Works Corporation is newly established on December 18/2015 based on council

of ministers Regulation No 366/2015. This corporation is amended by council of ministers
Regulation No 390/2016, on September 28/2016.

Figure 1.1 Ethiopian construction works corporation

1.3.2 Main Purposes of The Establishment of ECWC
✓ To engage in domestic and overseas construction works as a contractor in constructing,
upgrading and maintaining roads, bridges and other civil works:
✓ To engage in the business of maintaining construction equipment and machinery;
✓ To engage in the rental business of construction equipment and machinery;
✓ To produce and sell construction materials;
✓ To undertake in any other related activities necessary for the attainment of its purposes.
✓ To solve the problem arise related with the road quality in Ethiopia.
✓ To give standardized car maintenance, repair replacement of the parts.
✓ To design and production of the materials for car replacement.

1.3.3 Location of ECWC

The head quarter of the ECWC is located around Gurd Shola, Addis Ababa, Ethiopia. The
corporation has also more than 183 projects and offices around the country. But we were
worked at Nekemte District.

1.3.4 Vision and Mission Of The Company

1.3.4.1 Vision:
✓ To be globally competitive construction works contractor and to take the leading position
in Africa.
✓ To be a worldwide competent construction company by 2025
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1.3.4.2 Mission:
✓ To satisfy the customers and stakeholders of the Corporation by delivering.
✓ Roads and bridges construction, rehabilitation, upgrading and maintenance
✓ Construction equipment and machineries maintenance and lease
✓ Construction materials production and sales,
✓ Services timely, with competitive price and environmentally friendly manner.

1.3.5 The Main Customers of The ECWC:

✓ Ethiopian transportation
✓ Constructions agencies
✓ Ethiopian electric power corporation and others
✓ Ethiopian Road Authority

1.3.6 Structures of The Ethiopia Construction Works Corporation

Ethiopia Construction Works Corporation (ECWC) Nekemte District has the following structure
and department brake down with their overall work flow in the organization in this case the
main customer of Ethiopia Construction Works Corporation is Ethiopian Road Authority
(ERA). Most Activities of ERA are under taken by ECWC.
Among them I had been working in Equipment maintenance staff and under this staff there are
about five main shops for mainly Vehicle maintenance and product service (Bolt and nut)….
For instance If a vehicle need to have service or any maintenance activities (Changing Brake
shoe) 1st the Driver contact equipment maintenance staff Mechanical Engineering then the staff
open shop order and send to the Inspector by giving the key of the vehicle to the Mechanic
Inspector. Finally the Inspector arranges the mechanics and orders them to do the given job in a
given time.

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1.3.7 Competitive Advantage of The ECWC

Thus, the two most important competitive advantages of the corporation are:

1. Its geographical presence:

As indicated in the tables below, the corporation has different projects located strategically
throughout the country. This makes the Ethiopian Construction Works Corporation the most
accessible construction contractor in the country. This geographical presence can be an
advantage even to indulge in different construction projects found in neighboring countries.

2. Its human and material resources:

It is a fact that human resources are among, if not the most decisive factors influencing the
competitiveness of any company. The Ethiopian Construction Works Corporation currently has
more than 15,000 workers among them 800 workers are under Nekemte District. This is in fact
a huge asset if the corporation uses this resource in an efficient and productive manner.

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Therefore, the huge human resources that the corporation has can yield it a competitive
advantage in the industry.

1.3.8 The Main Branches of ECWC

Branches Status
Addis Ababa Head office
Nekemte Operating branch
Adigrat >>
Gondor >>
Jimma >>
Kombolcha >>
Debre-Markos >>
Dire-Dawa >>
Shashemene >>
Alemgena >>
Sodo >>

Table 1.1 branches of ECWC

1.3.9 Major Businesses of The ECWC

The Ethiopian Construction Works Corporation has been established for state-of-the-art
construction solutions. The following are among the major construction businesses that the
corporation renders:
✓ Highways, bridges, railways, and ports.
✓ Surface and subsurface water supply development.
✓ Dam construction.
✓ Hydropower development.
✓ Irrigation infrastructure, river diversions.
✓ Industrial projects and warehouses.
✓ Residential and commercial building construction.
✓ Management of dam and irrigation infrastructure.
✓ Management of bulk water production.

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✓ Construction machinery, equipment and warehouse leasing services.

✓ Civil engineering works.

Figure 1.2.ECWC garage

CHAPTER TWO

2.1. WORK DONE

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. There are
many shops in this company. Those are:-

1. Mechanic or Engine shop

2. Machine shop
3. Body shop
4. Welding shop
5. Electrical service shop
6. Tire shop

Before we described our task in the above shops first lets we describe some tools and
equipment’s that commonly used during maintenances. In ECWC shops there are various tools
used. Most of them are manuals (operated by hands). These tools are:-

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✓ Torque Wrenches,
✓ Sockets and Ratchets,
✓ Screw drivers& Spanners
✓ Combination and box
✓ Hammers, chisel, and Vise

2.1.1. Engine Shop

Engine is a mechanical device that converts chemical energy (fuel) into kinetic energy
(motion). An internal combustion engine is the engine in which combustion (burning of fuel)
takes place in the cylinder of engine by burning of the fuel high temperature and pressure force
generates. This pressure force used to move the vehicle or rotate wheels by use of some
mechanism. In an engine many parts work together and achieve to be a goal of converting
chemical energy of fuel into mechanical energy. These parts are bolted together and the
combination of all these parts is knows as engine.

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Figure 2.1: Engine

2.1.1.1 Stationary Parts of Engine

The stationary parts of an engine include the cylinder block and cylinders, the cylinder head or
heads, and the exhaust and intake manifolds. These parts furnish the framework of the engine.
All movable parts are attached to or fitted into this framework.

2.1.1.2 Engine Cylinder Block

The cylinder block is the basic frame of a liquid-cooled engine whether it is in-line,
horizontally opposed, or V-type. The cylinder block is a solid casting made of cast iron or
aluminum that contains the crankcase, the cylinders, the coolant passages, the lubricating
passages, and, in the case of flathead engines, the valves seats, the ports, and the guides. The
cylinder block is a one piece casting usually made of an iron alloy that contains nickel and
molybdenum. This is the best overall material for cylinder blocks. It provides excellent wearing

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qualities and low material and production cost, and it changes dimensions only minimally when
heated. Another material used for cylinder blocks, although not extensively, is aluminum.
Aluminum is used whenever weight is a consideration. However, it is NOT practical to use for
the following reasons:
➢ Aluminum is more expensive than cast iron.
➢ Aluminum is not as strong as cast iron.
➢ Because of its softness, it cannot be used on any surface of the block that is subject to
wear. This necessitates the pressing, or casting, of steel sleeves into the cylinder bores.
Threaded holes must also be deeper. This introduces extra design considerations and
increases production costs.
➢ Aluminum has a much higher expansion rate than iron when heated. This creates problems
with maintaining tolerances

2.1.1.3 Crankcase
The crankcase is that part of the cylinder block below the cylinders. It supports and encloses the
crankshaft and provides a reservoir for lubricating oil. The crankcase is the basic foundation of
all air-cooled engines. It is made as a one- or two-piece casting that supports the crankshaft,
provides the mounting surface for the cylinders and the oil pump, and has the lubrication
passages cast into it. It is made of aluminum since it needs the ability to dissipate large amounts
of heat. On air-cooled engines, the oil pan usually is made of cast aluminum and is covered
with cooling fins. The oil pan on an air-cooled engine plays a key role in the removal of waste
heat from the engine through its lubricating oil.

Figure 2.2 crankcase

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2.1.1.4.CylinderHead
It covers and encloses the top of the cylinders. Combustion chambers, small pockets formed in
the cylinder heads where combustion occurs, are located directly over the cylinders. Spark
plugs (gasoline engine) or injectors (diesel engine) protrude through holes into the combustion
chambers. Intake and exhaust ports are cast into the cylinder head. The intake ports route air
(diesel engine) or air and fuel (gasoline engine) into the combustion chambers. The exhaust
port routes burned gases out of the combustion chamber.
2.1.1.5.Connecting Rods
Connecting rods connect the pistons to the crankshaft to convert reciprocating motion into
rotary motion. The connecting rods are in the form of an I-beam. This design gives the highest
overall strength and lowest weight. They are made of forged steel but may also be made of
aluminum in smaller engines.

Figure2.3 connecting rod

2.1.1.6.Crank shaft
The crankshaft is located in the bottom of the engine and is the part of the engine that
transforms the reciprocating motion of the piston to rotary motion. It transmits power through
the flywheel, the clutch, the transmission, and the differential to drive your vehicle. Crankshafts
are usually made of cast iron or forged steel. Forged steel crankshafts are needed for heavy-
duty applications, such as turbocharged or diesel engines. A steel crankshaft is stiffer and
stronger than a cast iron crankshaft.

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Figure 2.4 crankshaft

2.1.1.7 Camshaft
The camshaft provides for the opening and closing of the engine valves. The cam shaft is
enclosed in the engine block. It has eccentric lobes (cams) ground on it for each valve in the
engine. As the camshaft rotates, the cam lobe moves up under the valve tappet, exerting an
upward thrust through the tappet against the valve stem or the pushrod.

Figure 2.5 camshaft

2.1.1.8 Engine Bearings

Bearings are installed in an engine where there is relative motion between parts. Camshaft
bearings are called sleeve bearings because they are in the shape of a sleeve that fits around the
rotating journal or shaft, as shown in Figure below View A. Connecting rod or crankshaft
(main) bearings are of the split or half type, as shown in Figure below B. On main bearings, as
shown in Figure, View C, the upper half is installed in the counter bore in the cylinder block.
The lower bearing half is held in place by the bearing cap. On connecting rod bearings, the
upper-bearing half is installed in the rod and the lower half is placed in the rod cap. The piston
pin bearing in the connecting rod is of the full round or bushing type.

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Figure2.6 bearing
Most Engine Problem:
Most engine problem we have seen during our internship time
✓ Engine noises
✓ Low oil pressure
✓ Engine over heating
✓ Loss of power, misfiring
✓ Hard starting
✓ Service year and maintenance time
✓ Sound during operation
✓ Electrical system
✓ Once the problem is identified by the technicians possible solutions is done.
Measurement taken:

1. Disassembling Engine:

Engine disassembly is carried out in a sequence as follows.

✓ Remove the water pump; exhaust manifold, oil filter, thermostat, crankshaft pulley,
oil pump and timing gears.
✓ Remove cylinder head.
✓ Remove oil pan.
✓ Remove piston and connecting rod assembly (give the numbers on pistons and
connecting rods for easy reassembling.
✓ Remove flywheel and crankshaft.

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2. Cleaning and Inspection:

After disassembling all the parts, clean and inspect them carefully, replace the defective parts.
✓ All parts should be cleaned with kerosene and dry them with the compressed air.
✓ The cylinder walls may be inspected for scoring. The cylinder may require re boring
or re honing if scores are present.
✓ To inspect piston for scores, remove the ring without breaking them. In case of deep
scores, replace the piston. While light scores may be polished off. Measure the
clearance between the sides of the piston in the cylinder. In case they are scored.
Replace them.
✓ Inspect the piston ring for damage or wear. If these are defective, replace them.
✓ Inspect the connecting rod small end and big end bearings. If these all scored or
pitted. Service with the rebutting.
✓ Check the valve face and seat. If any part is defective service the valve face with the
valve re facing and cut the valve seat for correct setting of valves.
In this work shop mostly repaired Engines are starting from the smallest to the biggest one. This
engines it`s have different types like V8, D4D, 5L, 3F and etc.

Figure 2.7 disassembled engine

2.1.1.9 Transmission Systems

It is the mechanism through which the driving torque of the engine is transmitted to the driving
wheel of the vehicle. The transmission is a sort of speed and power changing device needed
between the engine of the automobile and its driving wheel. A transmission system includes:

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✓ Clutch, ✓ Final drive, and

✓ Gear box, ✓ Differential system.
✓ Propeller shaft,
The essential parts of the gear box are-the gear case consisting of two halves these are: -
 Drive shaft assembly,
 Counter shaft assembly ,
 Main shaft assembly,
 Synchronizing device assembly
 Reverse speed gear assembly  Gear shifting mechanism.

Figure
2.8 Transmission system

Requirements of Transmission System:-

✓ Provide means of connection and disconnection of engine with rest of power train without
shock and smoothly.
✓ Provide a varied leverage between the engine and the drive wheels ✓ Provide means to
transfer power in opposite direction.
✓ Enable power transmission at varied angles and varied lengths.
✓ Enable diversion of power flow at right angles.
✓ Provide means to drive the driving wheels at different speeds when required.

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2.1.1.9.1 Clutch
A clutch is a mechanism which engages and disengages power from engine to transmission.
When the clutch is engaged, the power flows from the engine to the rear wheels through the
transmission system and the vehicle moves. Clutch is disengaged when:
a. Starting the engine,
b. Shifting the gears,
c. Idling the engine

Figure 2.9 clutch

The clutch principle is based on friction. When two friction surfaces are brought in contact with
each other and pressed they are united due to friction between them. If one is revolved the other
will also revolve. The friction between the two surfaces depends upon:

o Area of the surface, o Pressure applied upon them,

o Coefficient of friction of the surface materials
Here one surface is considered as driving member and the other as driven member.

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Most transmission problem we have been seen:-

Transmission problems with remedies

NO PROBLEM CAUSE REMEDY
1 Transmission Low lubricant level. Refill lubricant
noise Input shaft gear badly worn or Replace input shaft gear
broken. Replace input shaft bearing
Input shaft bearing badly worn or Correct misalignment
broken. Replace countershaft drive gear
Wear in countershaft drive gear Replace the worn gear
Wear in reverse and/or reverse idler Replace countershaft bearing
gear
Countershaft bearings badly worn

2 Transmission Engine clutch not releasing. Detect and repair as necessary.

difficult Distorted or burred output shaft Correct or repair
to splines. Readjust the linkage.
shift Improper adjustment of shift linkage. Re-correct clutch adjustment.
Incorrect clutch adjustment. Use the proper grade of
Incorrect lubricant. lubricant.

3 Transmission Damage oil seals. Replace the oil seals.

leaks oil Damaged or missing gaskets. Replace the O - rings.
Case or cover bolts loose or missing. Replace the gaskets.
High lubricant level. Tighten or replace the bolts.
Loose or broken input shaft bearing Use the proper grade of
retainer. lubricant.
Worn shift lever seals. Replace the seals.

Table 2.1 Transmission problems with remedies

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2.1.1.10 Braking systems

Figure 2.10 braking system

Purposes of braking system:

• Stop the vehicle by converting the kinetic energy of the vehicle to heat energy.
• Heat energy is created in the brakes by friction.
• Friction is created between a moving and a non-moving surface at each wheel to generate
the heat.
• Disc and drum brakes are the most common type of braking systems used.

2.1.1.11 Disc brake:

In a disc brake, the fluid from the master cylinder is forced into a caliper where it presses
against piston’s. Piston in turn squeezes two brake pads against the disc (rotor), which is
attached to wheel, forcing it to slow down or stop.

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Figure 2.11 Disc brake

2.1.1.12 Drum brakes

The drum brake has a metal brake drum that encloses the brake assembly at each wheel. Two
curved brake shoes expand outward to slow or stop the drum which rotates with the wheel
Shoes press against a rotating surface. In this system that surface is called a drum. Drum brake
also has an adjuster mechanism, an emergency brake mechanism and lots of springs. The shoes
are pulled away from the drum by the springs when the brakes are released.

Figure 2.12 drum brake

2.1.2. Machine Shop

A machine shop is a room, building, or company where machining is done. Machining can be
defined as the operation of removing the excess metal by means of a cutting tool, in the
machine tool; to obtain the desired shape, size and surface finish.

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Purpose of machine tools

❖ to improve production rates

❖ to reduce cost of production
❖ to reduce fatigue of workers
❖ to achieve better quality

Machines available in machine shop are:

• Drilling machine • Hack saws
• Shaper machine. • Grinding machines
• Lathe machine • Hydraulic press
• Milling machine
1. Drilling machine: is a machine tool designed for drilling round hole in metallic and
nonmetallic materials. The cutting tool is a multi-point cutting tool knows as drill or drill bit.
Operations done by drilling machine are
✓ Drilling ✓ Tapping
✓ Boring ✓ Counter boring
✓ Reaming
2. Shaper machine: is a machine tool in which the plane and flat surface is produced by a single
point cutting tool by a reciprocating motion. In which the ram moves the cutting tool backward
and forward in a straight line to generate the flat surface. The flat surface may be horizontal or
vertical.

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Figure 2.13 shaper machine

Operations performed on shaper machines are all type of flat surfaces which may be horizontal,
inclined, or vertical.

3. Lathe machine: is one of the earliest machine tools and one of the most versatile and widely
used as a machine tool for performing the machine operations.
The most common operations which can be performed on lathe machine are:-
✓ Facing ✓ Cutting
✓ Drilling ✓ Grooving
✓ Boring ✓ Knurling
✓ Threading ✓ Shaping
4. Milling machine: is a process of metal removal cutting by means of multi teeth of metal
(points) rotating tools called cutter.
5. Grinding machine: is a process of removal by the abrasive action of a revolving wheel
(grinding wheel) from the surface of the blanks, in order to bring it to the required shape and size.
Operation performed by grinder
✓ Surface grinding
✓ Face grinding
6. Power saw: This is just used for cutting different types of metals.

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7. Hydraulic press machine: This machine is used for pressing the material which have high
rigidity or it`s difficult to press by man power. For example; to press the bearing to torque
bushing rod.
The machine shop Services include:
➢ Boring ➢ Washers
➢ Teeth of loader (grader) ➢ Nut
➢ Shafts ➢ Spacer
➢ Bolts ➢ Other spare parts

Figure 2.14 Features made in machine shop

2.1.3. Electrical service shop

This shop is need special attention rather than other shop because there is some acids and
battery cables that may damage our body and need special care. In this shop device maintained
are like stator, alternator, and battery.
Starter:-It is essential to start the automotive Engine. The crank most run fast enough for air
fuel mixture to enter the cylinder. An electronic starter or starting motor does this job. It
convert electrical energy from the battery into mechanical energy that rotates the crank shaft. It

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has two basic parts an armature and a field fram

e.

Figure 2.15 starter

Parts of starter are:- ✓

Main housing (yoke)
✓ Over running clutch, and pinion gear assembly
✓ Armature
✓ Field coils with brushes attached
✓ brush holder and solenoid
Starter motor trouble shouting:-

Possible causes Remedy

Weak or dead battery Charge or replace the battery

Bad starting system cables Replace/repair cables connections

Bad ignition switch or wiring Replace /repair the switch wiring

Bad starter solenoid Replace starter solenoid

Alternator: Alternator is one of the most important electrical components used to charge
automotive battery. The main components of alternator are; Rotor, Stator, Regulator, Rectifier
or diodes, Carbon brush, lending, Pole, Fans, Pulleys belts, Outer cover or casing or housing
This shop is doing so many works, like maintenance of alternator, starter, servicing the battery,

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repairing the construction machine controller, maintenance of the light system, horn, wiper and
any system that is related with electric.

In this shop, most of a vehicle`s electrical systems are maintained and replaced by a new one.
Maintenance of electrical system contains:
✓ Filling the battery with proper proportion of water and acid.
✓ If the battery is either dead or over used, recharging of the battery.
✓ Maintain the wires of display gauges
✓ Preparing the distilled water by purifier to mix with sulphury acid

2.1.4. Body shop

In this shop there are many types of job to be performed but the mains are maintaining body,
forging body and painting, servicing the mirror .In this shop there are a lot of activities
performed. Among thus, washing, grinding, painting and welding are the main activities.

A. Painting shop: different types of cars were painted in this painting room after their body
would be completely finished. And this shop must be cleaned and out of dust .Therefore this
application there is no openings.

B. Body building shop: if the body of the cars were damaged by accident or by any other
reason, their body were changed or repaired in this shop. But there is shortage of some
machines applicable for body reparation like bending machine. Mostly they did by welding
(oxyacetylene and arc welding).

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Figure 2.16 Body shop

2.1.5. Welding shop

In this shop different construction molds and different vehicle components were got welded
and in this shop there are different welding machines like arc welding, oxyacetylene gas
welding machines were available for their work.
It is known that welding is a process of joining similar or dissimilar metal together by
application of heat with or without the application of pressure and filler material. In this shop
most the works are undertaken by Arc welding because it is safer than that of the gas welding.
Welding of broken hose and other activities are undertaken by electric arc welding.

Figure 1.17 Oxy-acetylene and Arc welding

In case of oxy-acetylene it use equipment such as oxygen gas cylinder- which is painted black
and it has pressure regulator (right handed) to regulate flow as well as to lower the pressure of
the gas. The shop is mainly uses oxy-acetylene and arc welding. Most vehicles are welded by
oxy-acetylene because the thickness of the body is very less.

2.1.6. Tire shop

Tires shop is one of the types of workshop which is available Ethiopia construction work
corporation garage. In this shop so many works is doing, those works are:

Checking the pressure of the tires

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Inflating the tires

Maintaining the bump (attaching the bumper) and etc.

In this to perform the above works it uses different types of machines, such
as air compressor, air pressure gauge, grinder, and etc.

Air compressor: in this shop air compressor is used to inflating the tires.
To inflating the tiers first of all the compressor must be filled by the
atmospheric air and the starting to inflating, but the result is reading from
the gauge.

Wheel fixing

Wheel studs and nuts attach the wheel to the hub.

The wheel studs press through the hub or axle flange.

The taper on the wheel nuts secures and centers the wheel.

Wheel studs usually have a right hand thread.

If it is a left hand thread, it can be marked with “L”

Metric threads can be marked with m or metric.

Wheel nut torque

Correct torque of wheel fixing is vital for all vehicles, and nearly all require the use of a torque
wrench

Excessive torque can lead to wheel or hub distortion, causing run out and vibration.

Low torque may allow wheel nuts to work loose and wheels to come off

Nuts should always be tightened in a diagonal pattern.

2.2. CHALLENGES FACED DURING OUR INTERNSHIP

Some of the challenges we had faced during our internship are:
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First time we went there, we were ordered to get safety clothes by ourselves.

Service problem

Technician approach

The technician use Italic language for the materials

2.2.1. Methods to Overcome These Challenges:

We have bought safety clothes by ourselves.

We discussed with manager and they are approved to us to get service.

First time when we enter to the enterprise we afraid the technician, but gradually we related to
each other and discussed as friendly.

We tried to advise them so they may know the vehicles parts by English

2.3. SKILLS WE HAVE GOT

We have got experiences from this company like;

✓ Punctuality and respecting the company rule.

✓ How to keep our safety during work.
✓ How to design and managing of work flow of one company.
✓ We got experiences on investment casting specifically precision casting as well as its work
flow.
✓ We got practical as well as theoretical knowledge on machine and their operation procedure.

In terms of practical skill:

✓ Creativity and solving problems.

✓ The ability to analyze and interpret complex data

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✓ Critical thinking and the ability to evaluate design, plan and project
✓ Awareness of ethical issue
✓ Effective assessment and management of risk, resource and time

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.

In terms of inter personal communication skill:

During our internship program we had able to build up the following interpersonal relationship or
communication skills.

❖ Truthfulness and honesty

❖ Respectful
❖ Inter-dependent
❖ Friendship
❖ We improve our speaking
❖ We improve our communication skill
❖ To give and collect information
❖ To influence the attitude and behaviors
❖ To form contracts and maintain relationship

In terms of teamwork skill:

 active participation
 Listens actively
 Cooperate and Help other
 Demonstrates reliability
 Works as a problem solver
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 Treats other in respectful and supportive manner

 Sharing ideas openly and willingly and
 Clarifying team goals

In terms of Leadership skill:

During our internship time, 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.

In terms of work ethics:

We have developed about moral duties and obligations.

We have developed sincerity, respect for the job, regularity, punctuality, seriousness.

We have developed how to keep certain information confidential, how to maintaining cordial
relation with the clients and agencies that a company has and how to being prepared to take up
new tasks.

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CHAPTER THREE

3.1 INTRODUCTION
An automobile is one of the most basic and fascinating things that one could own. Cars have now
become a need and it is not only the symbol of luxury anymore. Car maintenance, for example, is
one of the key factors in determining its life span. This includes a basic knowledge of changing
the car’s tire. But replacing a punctured tire has always been a difficult task. Every car
manufacturer provides tools such as L wrench and jack but easy and fast removal of nuts using
these tools requires a skilled person. We designed a remover with 110 pitch circle diameter to
replace L-shaped nut removers and jack which allows driver to remove all nuts at once with less
energy consumption and save time. Several static load analyses were performed in order to find
safety factor of design. The fabrication of all wheel nut removers’ tool was completed by milling,
welding and fitting process. [1]
In a day-to-day life there are many problems where there are needs of lot of effort and time to do
that specific work. A little but important work that all people would do often is opening a wheel
of a vehicle. It is a fact that a huge effort is required to open a single nut of a car wheel and it will
become a tedious task to open the wheel in extreme atmospheric conditions. It also creates
problem when there is an emergency situation.

3.2. PROBLEM STATEMENT

During tire removing Operation the person was supposed to remove individual nuts to remove
the tire which has very high fatigue level.
So, Our Intention was to remove all nuts at a time, to reduce human fatigue level.
Multi-nut opener is a device designed at developed for loosening or tightening of wheel hub nuts
for
1. Hilux
2. Land cruiser
3. Toyota

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3.3. OBJECTIVE
3.3.1. General Objective
To design multi nut remover machine for removing five nut at once.

3.3.2. Specific Objective

✓ To reduce time consumption.
✓ To reduce man power.
✓ To design shaft
✓ To design spur gear
✓ To design hand lever

3.4 Scope of study

We have plan to design multi nut remover worked by manual power this tool can be operated by
any one of different ages from young people to old people as it is easy to use and light in weight.
The vehicles multi wheel nuts remover reduces the time in the normal process and also the man
power used.

3.5 Significance of the study

The significance of this study is that it will reduce labor force and used to save our time will
performing nut removing process.

3.6. WORKING PRINCIPLE

Generally, spur gears are used for transmitting power between non parallel intersecting shafts. So
spur gear arrangement is used for actuating the six socket spanners at a time. Six pinion gears
and one ring gear are used. The ring gear is meshing with six auxiliary pinion gears which are in
turn connected to a gear whose axle containing the socket spanners at its end. The auxiliary
pinion gear connected to a hollow shaft (main shaft) which is acting as a guide for follower. A
lock nut arrangement is provided for connecting the main shaft to follower at any desired
position. When the ring gear is rotated the auxiliary pinion gears are also rotated which in turn
gives a rotary motion to the socket spanner.

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CHAPTER FOUR

4.1 LITRATURE REVIEW

In our paper Adjustable Multi nut wheel opener is a special purpose tool made to open/close all
the five nuts of a wheel in one time with less effort. Although various methods are used for
opening nuts, they require a lot of effort to open a single nut. The main objective of work is to
develop a single tool with multiple mechanisms, which can be made use during assembling and
dismantling of wheels in automobiles. It can be successfully used as a standard tool irrespective
of the model of the vehicle. Also it can be used in assembly line of automobiles, garages,
workshops and service stations. In the paper of B. Sivakumar a gear or "gear wheel" is a rotating
machine part having cut teeth, or cogs, which mesh with another toothed part in order to transmit
power. Two or more gears working in tandem are called a transmission and produce mechanical
advantages through a gear ratio and thus may be considered a simple machine. Gears are mostly
used in the mechanical field for power transmission, this project report on stress analysis of spur
gears. Spur gear made of cast iron which is use for high strength. In the paper of A. S.Ud gave
Multiple-spindle drilling machines are used for mass production, a great time saver where many
pieces of jobs having many holes are to be drilled. Multi- spindle head machines are used in
mechanical industry in order to increase the productivity of machining systems. The multiple
spindle drilling machines is a production type of machine. It is used to drill two holes in a work
piece simultaneously, in one setting. The holes are drilled on number of work pieces with the
same accuracy. So we adopt the basic design for over project [2]

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4.2 MATERIAL AND METHOD

The materials used for the design of the various machine components are based on the type of
force that will be acting on them, expected work or function, the environmental
conditions in which they will function, useful physical and mechanical properties, cost and
availability in the local market or the environment.
The working procedures adopted in fabricating the developed machine illustrated as bellow:-

Table 4.1 material selection procedure

4.3 DESIGN OF EACH COMPONENT

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SR.NO. COMPONENTSNAME
QUANTITY
1 Pinion gear 6
2 Shaft 6
3 Spur gears 1
4 Box spanner 6
5 socket
Side plates 2
6 Hand 1
7 lever
Bearings 14
The gear housing accommodates the gear system used for the work and it is supported by the
pillar
guide. The gear housing was designed, and the area was determined based on the length (L) and
breadth of the plate (B),
Table 4.2 Parts to be designed

S/N Design Properties Parameters

1 Ultimate tensile strength(δu) 2
550 N/mm
2 Yield strength (δy) 2
280 N/mm
3 Gear Ratio 1:2
4 Velocity ratio 2:1
5 Nominal shaft diameter 15mm
6 Pitch circle diameter (PCD) 110 mm(for car tyre)
7 Tongue required to remove nuts (T) 480 Nm
8 Average force by human(F) 500 N
9 Pressure angle(Ø) 20°
10 Number of teeth of the driver gear(NG) 40
11 Number of teeth of the driven gear (NP) 20

12 Face width of the gear teeth (b) 30mm

13 Module 2.75mm

Table 4.3 Properties and parameters for the gear design

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The device was designed for 110mm PCD (center distance between the driving and driven gears
is 55mm). The driver (gear) and the driven (pinion) was designed and the torque required for
removal of one (1) nut is 80Nm. Spur gears were selected due to ease in design and
manufacturing. Apart from this, the velocity ratio (V.R) in spur gear is constant. Keeping the
above factors in mind and using medium carbon steel grade for the gear and pinion and the
design calculation were performed. The pitch diameter (Dp) was designed based on the number
of pinion teeth (Np) and diametral pitch (Pd), Eq. (1), [3]
𝑁𝑝
𝐷𝑝 = (1)
𝑃𝑑
Where: Dp- the pitch diameter, Np- the number of pinion teeth, and Pd - the diametral pitch.
Table 1 summarizes the properties and parameters of the material used for the design of the gears
(medium carbon steel i.e. EN 8)
The ultimate tensile strength, yield strength, young’s modulus, and other properties and
parameters are carefully selected before the gear designs for effective performance. The
pitch diameter, together with the number of pinion teeth (Np) was then used to determine the
circular pitch (P), Eq. (2). [4]
𝐷𝑝
𝑃=𝜋∗ (2)
𝑁𝑝

Where: P - the circular pitch, Dp - the pitch diameter, and Np - the number of pinion teeth.

The gear ratio (G.R) and velocity ratio (V.R) was designed using Eq. (3-4).

𝑁𝐺
𝐺𝑅 = (3)
𝑁𝑃

𝑁𝑃 1
𝑉𝑅 = = (4)
𝑁𝐺 𝐺𝑅

Where: 𝐺𝑅 - the gear ratio, 𝑁𝐺- the number of teeth of the driver gear, 𝑁𝑃- the number of teeth
of the pinion, 𝑉𝑅- the velocity ratio.

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The radial force applied and the tangential force was determined using Eq. (5-6).

Fr = FN sin ∅ (5)

Ft = FN cos ∅ (6)

Where: Fr - the radial force applied, Ft- the tangential force applied, and ∅ - the pressure angle.

The stress at the base of the involute profile (δt) was designed using Eq. (7).

sin ∅ cos ∅ 𝐺𝑅
[
𝐽= ] (7)
2 𝐺𝑅 + 2
Geometry factor for spur gear (J) was designed using Eq. (9).

𝛿𝑡 = 𝐹𝑡 × 𝑃𝑑 (8)
𝐹×𝐽
Where: J - the geometry factor for spur gear, δt - the stress, Pd - the diametral pitch, and F -the
face width.
Using the speed of the pinion gear (assume humans can turn the gear at the rate of 30 rpm) (N)
and the torque applied to remove the nuts (T), the power transmitted by the pinion gear (Pg) was
designed, using Eq. (9).
2𝜋𝑁𝑇
𝑃𝑔 = (9)
60
The torque transmitted by the driven gear (Tp) is therefore designed using the gear ratio (G.R),
Eq. (10).

𝑇 𝑝 = 𝐺𝑅 × 𝑇 (10)
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Where: Pg - the power transmitted by the gear, N - the speed of the gear, T – the torque applied
and 𝑇𝑝 −the torque transmitted by the driven gear.
The permissible bending stress (δb) for the gears is given in Eq. (1) [4] based on the ultimate

tensile strength of the gear material (𝛅𝒖). 𝛿𝑏 = 𝛿(11)

Where: δ𝑏- the permissible bending stress, and δ𝑣- the ultimate tensile strength of the gear
material. To design the effective loading on the gear teeth (F eff), the combined shock and fatigue
factor (Ka = 1.25), load distribution factor (Km = 1.2), tangential force applied (F t = 469.85N)
and the dynamic factor (Kv) were considered using Eq. (12).
𝐹𝑒𝑓𝑓 = 𝐾𝑎𝐾𝑚𝐹𝑡 (12)
𝐾𝑣
Where: Feff - the effective loading on the gear teeth, K a - the combined shock and fatigue
factor, Km - the load distribution factor, and F t - tangential force applied, and Kv - the dynamic
factor. The beam strength (Fb) was designed based on the Lewis form factor (Y), face width (F),
permissible bending stress (δb) and module (m), using Eq. (13). [5]
𝐹𝑏 = 𝑚 × 𝑏 × 𝑌 × 𝛿(13)
The available factor of safety (FOS) is then determined by the beam strength (F b) and the
effective loading on the gear teeth (Feff), using Eq. (14).
𝐹𝑏
𝐹𝑂𝑆 = (14)
𝐹𝑒𝑓𝑓
Where: Fb - the beam strength, m - the module, b - the face width, Y - the Lewis form factor, δ b
is the permissible bending stress, FOS - the factor of safety. The design is safe if the available
factor of safety is more than 1.5 and not safe if it is less than 1.5. For shaft design, in actual
practices, the shafts are subjected to shock and fatigue loading. Hence, in design of the shaft, the
shock and fatigue factor are accounted by using the factor knows as combine shock and fatigue
factors. Putting into consideration the speed (N) and the ultimate tensile strength (𝛿𝑢), the
power transmitted by the input shaft to the gear (P i) and the output shaft (Po) are determined
using the input torque (Ti) and the output torque (To) respectively. The diameter of the input
shaft (D) and the output shaft (d) are then determined. [2]

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4.3.1 Design Calculation

4.3.2. Design of Spur Gear
1. Diametral pitch 𝑃𝑑:

𝑁𝑝 𝑃𝑑 = = =
20

𝟎. 𝟏𝟖𝒎𝒎
𝑃𝐶𝐷 110
2. Circular pitch:

𝑃 .𝟐𝟕𝒎𝒎
3. Gear Ratio:
4. Gear Ratio = # teeth of driven gear

20
# of drive gear teeth

𝐺𝑅 = == 𝟏: 𝟐
5. teeth of driven gear

of drive gear teeth 40

6. Velocity Ratio:
𝑁𝑃 1 2
𝑉𝑅 = = = = 𝟐: 𝟏 𝑁𝐺

Fr = FN sin ∅ = 500 sin 20 = 500 × 0.342 = 𝟏𝟕𝟏𝑵

7. Radial Force Applied:

𝐹𝑡 = 𝐹𝑁 cos ∅ = 500cos20 = 𝟒𝟔𝟗. 𝟖𝟒𝟔𝑵

8. Tangential Force Applied:

sin ∅ cos ∅ 𝐺𝑅 sin20cos20 0.5 0.342 × 0.94 × 0.5

9. Geometry Factor for Spur Gear:

𝐽= . 𝟎𝟑𝟐
2 +2 2

𝛿
10. Tensile stress:

𝑡 = 𝐹𝑏𝑡 ××𝑃𝐽𝑑 = 17130 ××0.0107.18 = 30 .78 = 𝟗.

𝟓𝟖𝟗 𝑵⁄𝒎𝒎𝟐 11. Power transmitted by the pinion gear:

2𝜋𝑁𝑇 2 × 3.14 × 30 × 480

𝑃𝑔 = == 𝟏. 𝟓𝟎𝟕𝟐𝑲𝑵
60 60
12. Torque transmitted by the driven gear:

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𝑇𝑝 = 𝐺𝑅 × 𝑇 = 0.5 × 480 =
𝟐𝟒𝟎𝑵𝒎 13. Permissible bending stress:
𝛿𝑏 = 13 𝛿𝑢 = 550 𝑁3⁄𝑚𝑚2 = 𝟏𝟖𝟑. 𝟑 𝑵⁄𝒎𝒎𝟐

𝑭𝒆𝒇𝒇 = 𝐾𝑎𝐾𝑚𝐹𝑡 = 1 .25 × 1.2 × 1 × 469.8

14. Effective loading of the gear teeth:

= 𝟕𝟎𝟒. 𝟕𝑵

15. Beam strength:

𝑭𝒃 = 𝑚 × 𝑏 × 𝑌 × 𝛿𝑏 = 2.75 × 30 × 0.38 × 183.3 = 𝟓𝟕𝟒𝟔. 𝟓𝑵

16. Factor of safety:

𝑭𝑶𝑺 = 𝐹𝑏 = 5746.5 = 𝟖. 𝟐
𝐹𝑒𝑓𝑓 704.7
Our design is safe since the calculated factor of safety is greater than 1.5.

Figure 4.1Driven gear

4.3.3 Design of Shaft

Diameter of input driver shaft=15mm
Length of driver shaft=50mm
Diameter of output driven shaft=20
Length of driven shaft=100mm
Material: mild steel

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3
Figure 4.2, 3D of shaft

4.3.4 Design of Casing

Thickness of the plate=10mm
Length of the plate=width=200mm
Material: steel

Figure 4.3, 3D drawing of plate

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4.3.5 Design of Hand Lever

LH=400mm
Diameter of the lever= 15mm
Material: cast iron

Figure 3.4 3D drawing of hand lever

4.3.6 Design of Bearing

From ANSI metric standard:

Type of bearing: - Radial ball bearing

Sizes of the bearing: 6802

Outer diameter= 32 mm

Bore =8mm

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d D bore Basic bearing

19 5 6800
10 22 6 6900
26 8 6000
21 5 6801
12 24 6 6901
28 7 16001
24 5 6802
15 28 7 6902
32 8 16002
Table4.4 Properties and parameters for the gear design

Figure 4.5, 3D drawing of bearing

4.3.7 Design of Box Spanner Socket

Table 4.5 list of spanner sizes to fit standard metric nuts
Nut size Spanner size

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M3 5.5mm
M4 7mm
M5 8mm
M6 10mm
M8 13mm
M10 17mm
M12 19mm
M14 22mm
M16 24mm
M18 27mm
M20 30mm

Nut size: M10

Spanner size: 17mm

Figure 4.6, 3D drawing of socket spanner

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Fig 3.7 3D assembly drawing

Advantages
✓ Simple in construction.
✓ Less weight
✓ Less cost
✓ It saves time as compared to other devices.
✓ It can operate easily.
Limitations
• It will not use for all type of vehicle
• It requires man power
Applications
✓ Automobile workshops
✓ Automobile Manufacturing units
✓ Garage

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CONCLUSION
To sum up, we successfully managed to design and manufacture an automotive tire changing
mechanism that can unscrew 6 lug nuts of a wheel simultaneously. In addition, this project can
be used in a variety of applications such as tire manufacturing companies and workshops.
Moreover, while working on this project during the semester, we have gained a lot of skills. For
example, we used the theoretical knowledge that we have gained from mechanical engineering
courses and apply it in our project practically to design and manufacture our prototype.
Additionally, this project wouldn’t have been completed, without the equal contribution of each
team member in completing the tasks. Finally, working on this project taught us how to work
under pressure, especially that this semester was short.

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RECOMMENDATION
We recommended ECWC Nekemte district the following points:
✓ This company should work correlation with Mizan Tepi University to support the student
to visit these automobile parts periodically so, they can understand easily what they
learned by theory when they see practically.
✓ In order to increase accuracy and durability of maintained components, the company
should implement the use of CAD software’s like Solid works and Catia.
✓ In order to decrease time consumption on mounting an engine for test after inspection and
maintenance, the company should invest on buying an engine stand.
✓ Using older machines does not make competent, so the company has to use latest
machines such as CNC machines to become successful company regardless of time
management and upgrading its production capacity

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REFERENCES

[1] R. S. Khurmi and J. K. Gupta, “[A Textbook for the Students of B A TEXTBOOK OF A
TEXTBOOK OF A TEXTBOOK OF A TEXTBOOK OF A TEXTBOOK OF Top.”

[2] S. Pruthvi, R. Keval, P. Harsh, P. Dhaval, and M. Pankajkumar, “‘ MULTI NUT

REMOVER ,’” vol. 8, no. 5, pp. 962–965, 2021.

[3] K. B. K. Reddy, “Design & Fabrication Of Multi Nut Removing And Tightening Tool For
A Car Wheel,” pp. 7848–7851, 2018.

[4] S. K. Mondal, “Design of Joint Design of Joint,” pp. 1–263.

[5] R. N. Natarajan, “Machine design,” Handb. Mach. Dyn., no. I, pp. 11–28, 2000, doi:
10.1038/042171a0.

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