Internship project

progress report
company profile
company profile
• The defense logistic main department company was established in
1936 during
the Italian colony.
• From 1936 up to 1941 the company had been served as a
transport and logistics store services for Italians.
• After 1941 up to 1948 it was atechnique training center.
• In 1948 the company was established as a Garage.
• The vehicles like Opie, land rover and American Train Taquatro had been
repaired in this Garage.
• There were well trained the technicians on sectioning and system
accessories up to the decline of Derg.
• Nowadays the company supplies the Ural vehicles for peace, protection
mission. The repairing and other services of cars are accomplished by overall
mechanism. The company invents different machines trailing machines and
converting gasoline vehicles into diesel vehicles.
Goal of the company
Emphasis quality and innovation
Create skilled worker
Reduce human effort
Enlarge a company with modern machine
Deep industry knowledge, experience and high standard of its human
activities

Mission of company
The main mission of defense and logistics is to open many branches all over
the country and create many skilled technicians and be the leading
different military vehicle maintenance and overhaul center in the country.
Main services of company
Services that are given by Defense logistics main department are;
 Periodic Maintenance
 General Repair
 Body & Paint Repair Service.
• Periodic maintenance
Every military purpose vehicle has to be periodically maintained in every 40,000km.
Periodic maintenance will insure mainly reliability, long life and maximum performance.
• Body and Paint Repair
For the vehicles that has problems with body & paint is serviced in body and paint repair
service class. This job is carried out by technicians that are highly trained and skilled.
• Defense and logistic gives maintenance of many different heavy military vehicles such
as.
URAL
Ural is off road military truck
which is manufactured in Russia
and it is manufactured with V8
and V6 engines variations.
UAZ

UAZ is the best known utility vehicle

which has seen wide use as a
military vehicle around the world.
ZILL
The overall organizational structure

General Manger

Management Technique Marketing Finance

manger manager manager manger

Machine Assemble
Engine Power train Electrical
shop and
department department shop
department disassembly
department
department
Internship experience
objectives of the company

According to our company, the internship has the following objectives:

Ø Expansion of knowledge and acquaintance with industry in the field of mechanical engineering.
Ø Consolidation and deepening of existing knowledge in the field of transferring knowledge
.Ø Participation in the development of Ethiopia
Ø Involvement in the maintenance and design of military and civil cars.
Ø Hands-on training in practical skills of students for the situation. Typically, this would be
participation –individually or within a (task) group– in real assignments/projects, which entail the
application of knowledge and skills attained so far during the studies at University –and aiming at
developing special skills related to the industrial practice in our fields.
Beginning of the internship
Our internship started by introduce with students and as well as with technicians and also
safety rules of the company. After that there was a lecture about the repairing of heavy cars
and the science how it is working.

Training introduction

As an introduction we were trained how to identify the problems of cars, based on the
symptoms of the damaged car. And also how to unload and load the spare parts of the cars.
Overall Benefit

In terms of improving our practical skill

² upgrading theoretical knowledge
² Improving practical skill
² improving our team playing skill
² improving our leadership skill
² Improving interpersonal communication skill
• ² Improving entrepreneurship skill
 Components Used
• some componets that are used
• A screwdriver
• Hammers
• Wrenches
• Jack
• Rubber strap wrench
• Gasket maker
• Piston ring installer
 DESIGN OF CYLINDER LINER REMOVER
FOR COMBUSTION ENGINEE

introduction

•In the company where we took our

internships we worked in two different
departments one of them was the Motor
vehicle Department. In this department we
worked on repairing vehicle engine by
disassembling them first and replacing
damaged items. However during our work we
noticed a problem. The problem is in order to
remove the liner inside the combustion
chamber of an engine we had to bit and yank
the liner from the engine block. This was so
hard and difficult to do thus we decided to
design a machine that will make easier
removing process.
 CONCEPT GENERATION
• Concept 1: Permanent Handel Liner
Remover
• The machine operates by pacing the
support at the end of the combustion
chamber and by moving the screw we
can remove the liner. In this concept
the handle of the liner remover has a
handle that is attached with the power
screw by weld. In this design the
• handle has two spherical end for
esyier grip. There is no need of
additional handle required.
CONCEPT GENERATION

• Concept 2: Hand Driven Liner

Remover
• This machine uses hand driven
power screw to remove the liner.
This accomplished using a
spinner and on rod fitted screw.
By rotating the handle on the
spinner, this creates a way to
lower and raise the power screw.
CONCEPT GENERATION

• Concept 3: Extendable Handle Liner

Remover

• This design is considered using other

extendable handle. The top end of the
power screw is hallow so that we can
slide in any handle that can fit inside.
The reason for this is if there is a need
for additional torque a longer handle
can be used. This is heavily important
especially if the linear has high friction
and requires larger torque to remove.
Concept Selection
• Selection criteria are given below:
• Durability
• Easy to Operate
• Easy to Manufacture
• Low cost of Fabrication
• Reliability
• The rating is given using the following metric: 1-bad,2-low, 3-average,
4-good, 5-very good
parameters concept 1 concept 2 concept 3

[Link] 4 3 4

[Link] to Operate 5 3 5

[Link] to Manufacture 4 1 3

4. Low cost of Fabrication 2 2 3

[Link] 3 4 5

TOTAL 18 11 20

Thus based on our rating we have selected CONCEPT 3 as our idea.

 GEOMETRY ANALYSIS:
• Dimension Specification for Liner:
Internal Diameter d: 130mm

External Diameter 170 mm

D:
Depth h : 290mm

• Based on this we can determine the length of the power

screw which must be greater than the depth of the liner.
• lp = 600mm
• We assume the diameter of the power screw and
handle to be 3mm .
• Diameter of power screw: dp = 30mm
• Diameter of bar: dr = 30mm
The dimension of the hinge:
• The length of the hinge: lg = d =
130mm

• We assume the height of the hinge

to : hg = 20mm
• Thus the length of the support bar
would be:
• Hs = Lb − hg
• Hs = 300mm − 20mm
• thus, Hs = 280mm
The dimension of the support :

• The height (Hs) of the support must be less than

length of the power screw for it to be computable,
thus we select it’s diameter to be ds = dr = 30mm

• The length of the support bar(Ls) must be greater

that the diameter of the liner and less than the
distance between two consecutive combustion
chamber thus we have the length of the support
bar to be
• Ls = 245mm

• The thickness of the support bar , t = 20mm

• The length of Support tube: ls = Hs − t = 230mm

 FORCE ANALYSIS:
• Weight of the liner: W = 68.7N , The force exerted
• Thus the force exerted on the :
• F = sin ∗ W
• F = [sin(45) ∗ 68.7]N
• F = 48.6N
• The frictional force exerted by the walls is calculated below:
• Ffr = N∗
• Ffr = [(cos ∗ W)∗]
• Ffr = [(cos(45) ∗ 68.7) ∗ 0.9]
• Ffr = 43.7N
• Thus the total load equals to:
• Ft = F + Ffr
• Ft = 92.3N
The force exerted on the support equals to half of
total force :
• we have;
• F1 = F2 (because the machine is
place at the centre)
• F1 = F2 = Ft/2
• Thus, F1 = F2 = 46.15N
The force exerted on the power screw is the total force Ft :
The torque necessary to raise the load is given by the following
formula:
Tr = Fdm(l + πFfrdmsecα)/2(πdm − Ffrlsecα)
Given the mean diameter for M30 power screw is
dm = 27mm p = 6mm
Tr = 92.3 ∗ 0.0027(1 + π ∗ 43.7 ∗ 0.0027 ∗ sec)/2(π ∗
0.0027 − 43.7 ∗1 ∗ sec)
Tr = 15.83N
Thus the torque required to raise the load equals; Tr = 15.83N
The hinge acts as an anchor the base of the hinge is shaped
with a curvature and its diameter equals the internal diameter
of the cylinder liner. The force exerted on the hinge equals the
the sum of the tangential force and frictional force exerted
between the liner and the cylinder walls.
Fh = F + Ffr
Thus, Fh = 92.3N
 STRENGHT ANALYSIS
• Strength Analysis of Support Structure
• The main function of the support bar is to withstand
the load of the liner and also with stand the twisting
load exerted due to the applied load during
operation on the handle. The bar will fail due to the
bending action. Thus we need to compute the
bending stress exerted on the support bar.
• Material Selections
• Heat Treated Steel 4130 Annealed ( From table A-21
)
• Yield Strength - 361Mpa
• Tensile Strength -560Mpa
• The force exerted on the support bar is shown
below as well as the bending moment exerted on
the bar
• The bending stress applied on the bar is calculated as: • d ≥ Fa/A ⟹ A ≥ fa1/δd
• σb = My/I • A ≥ 92.3N/144.4 ⟹ A ≥ 0.07639m2
• σb = Ft ∗ lb/I • A ≥ 7.06mm2.
• where, I = Iy − momentarea • For design consideration an area of lifting member,
• Iy = [(m/12) ∗ (3r2 + h2)] • (AL) = 7.06mm2 will be chosen.
• Iy = (1.2175 ∗ 10) ∗ 10−4mm
• thus, σb = [(92.3 ∗ 0.0015)/(1.2175 ∗ 10)−4] • Tensile strength,
• σb = 1.0508Kpa • δx = fa1/A = 92.3N/7.0=0.0197N/mm2= 13.7N/m2
• Dimensional analysis of the member is given below:
• Force in a lifting member at minimum raising • Using Maximum Distortion theory we check for
• Design stress, δd = yieldstrength/F.s failure .
• = (361/2.5)Mpa • δmax = [δx2 + δy2 − δxy+ 3τxy2]1/2
• = 144.4MN/m2 • δmax = [(13.7)2 + 0 − 0 + 3(0)]1/2
• δmax = 13.8N/m2

• Checking for safety we have δd> δmax ; thus the

design is safe.
 Design of Power Screw

screws are used to convert rotary motion in to translational motion.

It is also called translational screw. They find use in machines such
as universal tensile testing machines, machine tools, automotive
jacks, aircraft flap extenders, trench braces, linear actuators,
adjustable floor posts, micrometer, and C-clamps. A screw thread is
formed by cutting a continuous helical groove around the cylinder.
These grooves are cut either left hand or right hand. The power
screw is a single Acme threaded screw with collar at both ends, with
one end in contact with Member and the other end having a square
key way to enable the transmission of torque from the gears. The
collar is assumed to be friction less and the power screw has been
designed to be self-locking. A power screw is advice used in
machinery to change angular motion in to linear and usually, to
transmit power. This must have adequate strength to with stand
axial load and the applied torque.
The force acting on the power screw is given above. In our design
we need to check for self-locking condition and the stress on screw
thread.
The Nominal Shear Stress on the Screw Body dew to the Torque to Raise Load:
τ = 16T/πdr3
τ = 16(15.83)/π(0.0024)3
τ = 2.147Mpa

The Axial Stress on Screw Body:

σ = −F/A = −4F/πdr2
σ = −4(92.3)/π(0.0024)2
σ = −20.4Kpa

The Bearing Stress on the Threads:

σB = −F/πdmntp/2 = −2F/πdmntp
σB = −2[0.38 ∗ 92.3]/π(0.0027 ∗ 1 ∗ 6)
σB = −1.378Kpa

The Bending Stress on the Threads:

σb = M/Z = [(Fp/4) ∗ (24/πdrntp2)] = 6F/πdrntp
σb = 6(0.38F)/πdr(1)p
σb = 6(0.38 ∗ 92.3)/π(24 ∗ 1 ∗ 6)
σb = 4.651Kpa
 • The design stress,δd = Tensile strength/F.s
• Material property we need for our power • δd = δst/F.s
screw:
• δd = (560/3)Mpa
• High strength
• δd = 186.67Mpa
• Wear resistance
• Easy to Manufacture
• Total axial force in screw (Fa), Fa = Ft/tanθ;
• For Heat Treated Steel 4130 Annealed:( From • Hence, the axial force (Fa) in a screw is maximum when
Appendix table A-21) (θ) is minimum
• Tensile strength = 56c0Mpa • Fa = Ft/tan
• Yield strength = 361Mpa. • Fa = (93.2/tan9)N
• Dimensional analysis: • Fa = 582.759N
• The allowable stress is calculated as: • The base are of the power screw can be calculated as:
• δall = δy/F.S • δd = Fa/A
• where the yield strength is δy= 361Mpa and we • whereA = Fa/δd
take a factor of safety of 3.
• A = (582.759/186.67)m2
• δall = (361/3)Mpa
• δall = 120.34Mpa
• A = 0.3125m2 = 312.5mm2
• The allowable shear stress is given as • Thus we get A= (π*d2)/4
• τall = δy/2F.S • d= [4*A/ π] 1/2
• τall = (361/2 ∗ 3) • d = (4 ∗ 312.5mm2)
• τall = 60.187Mpa • d = 21.3445mm
The core diameter can be selected on from standard table A-31
Ø core diameter=24mm
Ø outer dimeter =30mm
Ø pitch=6

Stress on the tread of screw:

σx = 6F/πdrntp τxy = 0
σy = −4F/πdr2 τyz = 16T/πdr3
σz = 0 τzx = 0

The von’ Misses Stress can be obtained by:

σ’ = 1/√2[(σx − σy)2 + (σy − σz)2 + (σz − σx)2 + 6(τxy2 +τyz2 +τzx2)]1/2

where,σx = 4.651Kpa τxy = 0

σy = −20.4Kap τyz = 2.147Kpa
σz = 0 τzx = 0

Thus the von’ Misses stress becomes,

σ’=1/√2[(4.651-0 )2+(0-(-20.4))2+(-20.4-4.651)2+6(0+(2.147)2+0)]1/2
σ’ = 16.139Map

The design is safe because the allowable stress is grater than the von’ Misses stress
STANDARD
MATERIAL
SELECTION:
Hinge Connecting Pin
The pins are used to joining a
rotating link axis. The existence of
the machine will depend on the
ability of the pin not to fail under
sudden shear, tensional and
compressive forces. They are used
to hold the hinge part together with
the power screw or limit travel of
moving parts.
Material selection
• The material selection is done by first taking less expensive steel
material, which is to be
• changed depending upon the various outcomes of the design
procedure (Strength analysis)..
• We select steel, a 1045 grade steel material to design bolts because of
• Good heat treatment
• High strength
• Wear resistance
• Ease of producing component parts
• Yield Strength (δy) = 310 MPa
• Factor of safety = 3
• τy = δy/2 = 310/2 = 155MPa
• τall =τy /3 = 155/3 = 51.666MPa

• Shear stress due to maximum applied load force

• τall= w *πd 2 /4
• τall= 4w /πd 2
• d2 = 4w /τall ∗ π
• d = √ 4 ∗ 14715/51.666 ∗π
• d = 19.0428mm
• Thus we select a pin with a diameter D=20mm
TABEL RESULT
Components Length Height Diameter Width

1. Power Screw 600mm - 300mm -

2. Hinge inner-130mm, outer- 20mm - 20mm

170mm

3. Support Bar 245mm 20mm - 20mm

4. Support Frame 280mm - 30mm -

thank you