Given data

Table of Contents
1.2 T HE MAIN PRODUCTION OF DEJEN AVIATION I NDUSTRY................................................................................3

5. DISASSEMBLING............................................................................................................................7

7. DISPATCHING OF EQUIPMENTS AND PARTS TO SHOPS: -....................................................7

8. PERFORMING OF ON BOARD MAINTENANCE: -...........................................................................7

9. ACCEPTANCE (RECEIVING) OF EQUIPMENT FROM SHOP AFTER REPAIRING........................8

10. ASSEMBLING OF AIRCRAFT.....................................................................................................8

11. SYSTEM CHECK:-..........................................................................................................................8

2.1.Engine Production Shop......................................................................................................................11

Main Rotor Hub ......................22

Swash Plate...............................................................................................................................................23
2.2.5 Rotary Blade and Propeller Shop......................................................................................................24
1 .transport helicopter shop......................................................................................................................26
2. fighter helicopter shop..........................................................................................................................26
3 .Welding shop.........................................................................................................................................26
4.Hidase and Gyro helicopter shop...........................................................................................................26
3.1.3 Welding shop............................................................................................................................28
3.1.4 Hidase and Gyro helicopter shop.....................................................................................................28

1
Given data

HIDASE(H-77).............................................................................................................................................29
Gyro- plane................................................................................................................................................30
4.Aero Space Production Factory..........................................................................................................34
Lathe machine.......................................................................................................................................35
 Drilling machine.................................................................................................................................35
Shaping machine.......................................................................................................................................35
Milling machine.........................................................................................................................................35
4.3 CONTROL SHOP...................................................................................................................................36
4.4Landing Gear shop...............................................................................................................................37
4. 5 Egress & Parachute system shop........................................................................................................38
4.5.1 EGRESS SHOP....................................................................................................................................38
SPECIFICATIONS OF LIVE SAVING PARACHUTE SYSTEM............................................................................38
4.5.2 OXYGEN SHOP..................................................................................................................................39
4.6 Heat Treatment shop...........................................................................................................................39
Types of furnace........................................................................................................................................39
Professional Ethics.....................................................................................................................................44
HYDRAULIC JACK FOR ASSEMBLY AND DISSASSEMBLY OF MAIN ROTOR HUB......................................45
Pascal ‘slaw................................................................................................................................................45
Force analysis............................................................................................................................................46
Conclusion.................................................................................................................................................60
Recommendation......................................................................................................................................60

1.BACKGROUND OF THE INTERNSHIP PLACEMENT (DAVI)

 The main entrance of Ethiopian air force.

2
Given data

INTRODUCTION

Dejen Aviation Industry one of the known Ethiopian metal and engineering corporation
having eighteen factory and each of the factory has their own shop with different work
benches. The mechanical concerned factories include power plant , rotary wing, fixed wing and
aerospace(aerodynamic) production factory. We have stayed for the first two month in power
plant factory, we have stayed in rotary wing production factory for the third month and for the
last one month we have worked in aerospace and fixed wing production factory.

In addition to the above we would like to add here our problem solving process which is
using hydraulic jack for overhauling(assembling and disassembling) main rotor hub which are
aimed in creating comfortable and safe working condition and replacing fixed and heavy hub
stand, with movable and lighter one.

3
Given data

1.1 Brief History

Dejen Aviation Industry Administrative Office

Dejen Aviation Industry was separated from Ethiopian air force and established as an
organization in 1997 E.C, making its basement in Bishoftu town 47km from east of Addis
Ababa. The total area of Dejen Aviation Industry is 43hctare and having about 1500
employees. The primary goal of this company is solving the technical problem of our federal
air force and saving of millions of dollar as well as advancing the country in aerospace
technology. The main activity of this company are:-

 Maintenance of helicopter both fighter(mi-24 &mi-35) and transport(mi-8& mi-17)

 Maintenance of aircraft like(MIG-23,SU-27,L-39) etc.
In addition to the above this company is maintaining Antonove(AN-12) cargo airplane
by Russian technician. This organization is established with the following vision, mission
core business.

4
Given data

Vision
 Advancing the country and FDRE defense force in Aerospace technology.

Mission
Overhauling, up grading, designing and manufacturing the aerospace machines to
carry out technological development in a view to accelerate our national aviation
engineering industry growth.
To reduce hard currency expense of the country in importing military aircraft by
developing aerospace technology in the direction of sustainable development in
aviation technology.
To penetrate the international aviation market and keeping reasonable market
share.
Core Business of DAVI
Dejen Aviation Industry is engaged in the following core business :

 Manufacture of various aircraft bodies.

 M anufacture of aircraft parts and accessories
 Manufacture of rubber parts for aircraft and other
services
 Production of plexi glass for aircraft and helicopters
 More than nine electro-plating services

 Overhauling, up-grading, designing and manufacturing

military aviation machines that fulfill the requirements
of customers.

The workshops are organized according to the latest Overhaul processing principles in addition
to this what makes this company differ is every activity is according to the manual and also
recorded during assemble and disassemble .

1.2 THE MAIN PRODUCTION OF DEJEN AVIATION INDUSTRY

Designing, developing and manufacturing some aircraft component such as:

 Canopy glass and wind shield

 Flex and helmet
 Hose and tubes

5
Given data

 Repair body aircraft

 Different kinds of fiber product

 Boat
fig1.2 fast attacking boat

SERVICES:

I. Overhauling: - DAVI offers overhaul service for helicopter and aircraft models
with short turnaround times. The airframe overhaul division repairs practically
any aircraft/ helicopter parts, and the fuselage of the air vehicles MI-8, MI-17,
MI-24/35, L-39, MIG-21, MIG23, AN-12 AND SU-27. DAVI Targets to save
maintenance costs improve quality and achieve quick delivery time of aircraft and
helicopters to customers who demand its services. As to become a globally
competitive aviation industry, DAVI manage it from the smallest aircraft Cessna
to the biggest Antonove.

Fig. 1.2
Helicopters for overhauling in DAVI’s
II. Upgrading: - Upgrading of an aircraft/ helicopter and its parts begins with design
work. Design work is believed to determine the goodness or Worseness of
everything, so due consideration is given to this sector, as far as satisfactory result
is needed jets with our huge hangar incorporates a number of helicopters and jets

6
Given data

with qualified assembling and disassembling facilities

Fig. 1.2.1 Crashed, damaged and/or none operational aircrafts for upgrading
III. Designing: - DAVI Implements alternate military aerospace technology through research
and development to design and manufacture Aircraft and related flying bodies.

figure1.2.2 Hidase helicopter

IV. Net working and electrification:-DAVIalso involved in project of Local Area
Network /LAN/ program so as to facilitate fast data transfer within the facility.

7
Given data

1.3 Customer of DAVI's : The customer of Dejen Aviation Industry is mainly Ethiopian air force
and other African countries

 Sudan
 Djibouti
 Mozambique
 Zimbabwe and other African countries

1.4 OVERALL ORGANIZATIONAL WORKFLOW:

1. ACCEPTANCE OF THE AIRCRAFT:-All aircraft documents such as log book, service log,
components certificate & aircraft life history are checked and received by assigned
responsiblespecialists and Engineers followed by Visual inspection and engine run up.

2. PRESERVATION: -engine must be preserved with preservation oil since there is no engine
run up between over haul time & shipment to protect any corrosion on the engine and
engine parts.

3. DEFUELING: -To reduce the load for leveling and to facilitate for disassembling work, fuel
must be defueled from all aircraft fuel tanks with the help of automatic fuel track or by
using manual defueling hoses.

8
Given data

4. LEVELING: -leveling is carried out to know aircraft air-frame condition or to check any
deformation that is occurred during landing or flight.

5. DISASSEMBLING

6. CHECKING THE STOKE FOR MUST CHANGE ITEMS NECESSARY HARDWARE’S AND

SPARE PARTS

7. DISPATCHING OF EQUIPMENTS AND PARTS TO SHOPS: -Every registered (listed)

document for dispatching equipment must available in the set making in addition to
attaching and sending one document to shops with the parts.

8. PERFORMING OF ON BOARD MAINTENANCE: - During on board maintenance the

following work must be performed: Airframe repairing
 Continuity checking of cables

9
Given data

 Repairing of cables

9. ACCEPTANCE (RECEIVING) OF EQUIPMENT FROM SHOP AFTER REPAIRING

10. ASSEMBLING OF AIRCRAFT

11. SYSTEM CHECK:- Electrical power system, Tank pressurization, Canopy pressurization, Air
system, Conditioning system, Mechanical control system and control surface, Retraction
of landing gear and doors, Pilot static system (dynamic and static pressure ) system, Auto
pay let (CAY) system, Radio and navigation system, Radar system and finally Armament
systems are tested at this stage.During the system check process we should recorded all
the results on the document and compare all these results with the data’s that are listed on
the procedure manual .

12. ENGINE RUN UP

10
Given data

13. LEVELING: -After finishing the assembling, system check and engine run up again leveling
is done to identify the difference before overhaul and after overhaul of the aircraft
condition and also is listed and recorded.

14. TEST FLIGHT: -

 Firstly the aircraft is refuel and serviced oil , hydraulic , air, oxygen according to the
procedure manual
 Aircraft shock strut and tire pressure is checked to be within the limit
 Checking all aircraft documents such as Log book and Aircraft preflight inspection must be
done according to procedure manual (check list) and check whether all special lists sign or
not on the log book
 Towing the aircraft to the flight line
 The aircraft high speed taxing and flight is performed with test flight and after high speed or
flight the pilot is listed all the parameters and remarks that he observe during high speed
taxing or flight.

15. DELIVERY: -Delivering the aircraft with full information and documents.

11
Given data

2.Power PlantProduction Factory

For the first two months we have been stayed under this factory. This factory is one of the
known Dejen Aviation Industry's factory because the main component of the air craft
overhauled in this factory. These include: engine, main rotor hub and swash plate, main gear
box and transmission shaft etc. Apart from these shop there are a number of shops under this
factory like: plunger pump test shop. Power plant factory has so many shop relative to other
factory as we have tried to raise some of them above.

Shops under power plant factory are:

2.1.Engine production shop

2.2.Main Gear box and transmission shaft shop

2.3.Fuel aggregate shop

2.4.Main rotor hub and swash plate shop.

2.5.Tail rotor hub, Rotary blade and propeller shop

12
Given data

2.1.Engine Production Shop

fig2.1 engine shop

This shop is one of the major shop of the power plant factory. The maintenance, overhaul and
upgrading of the engine is taken place under this shop. Based on their power production
system engines are categorized into four.These are:

1.turbo jet engine

2 turbo shaft engine.

3 turbo prop engine.

4 turbo fan engine

1.turbo jet engine

The turbojet engine gets its propulsive power from the reaction to the flow of hot gas. So, the
turbojet is the simplest form of gas turbine in that the hot gases generated in the combustion
process escape through an exhaust nozzle to produce pounds of thrust.

Principle of operation system of turbojet engine

Turbojet engine consists of five basic sections as shown in the figure below.

1. In let
2. Compressor (low and high)

13
Given data

3. Combustion chamber (power produce)

4. Turbine (high and low)
5. Exhaust section

Figure 2.2basic components of turbojet engine

Air inters the aerodynamically contoured inlet at ambient pressure and starts
to diffuse, arriving at a compressor at slightly increasing static pressure. The
engine, in this manner, receives its air with minimal turbulence and at a more
uniform pressure. Inlet pressure increases add significantly to the mass
airflow as the aircraft reaches its desired cruising speed.

2 turbo shaft engine.

Turbo shaft engines have a high power-to-weight ratio and are widely used in helicopters. This
engine is an axial-flow turbo shaft engine incorporating the free turbine principle. It is comprised
of a compressor, combustor, gas generator turbine, and power turbine. The engine is equipped
with a control system that modulates fuel flow to maintain constant power turbine output speed
for a given speed selector setting in the governed range. This system maintains the selected speed

14
Given data

by automatically changing the fuel flow to increase or decrease gas generator speed.

The pilot determines the speed by positioning the power lever. The control system
provides automatic protection against compressor stall, turbine over-temperature, over speed of
either turbine assembly, and combustion flameout.

figure 2.3 showing turbo shaft engine

15
Given data

There are many different models of this type of engine.The Mi-8/17 and Mi-24/35 helicopters
are examples of aircraft that use this engine.

figure 2.4 mi-8 transport helicopter

3 turbo prop engine .

The turboprop engine was developed to provide the power requirements for aircraft of greater
size, carrying capacity, range, and speed. The turboprop engine is capable of developing 2 1/2
horsepower per pound of weight.

The turboprop converts most of its gas-energy into mechanical power to drive the
compressor, accessories, and a propeller. The additional turbine stages needed to drive the extra
load of a propeller create the low-pressure, low-velocity gas stream. A small amount of jet thrust
is obtained from this gas stream.

The turboprop engine (fig. ) consists of three major assemblies: the power section, the
torquemeter assembly, and the reduction gear assembly. The propeller assembly mounts on the
reduction gear assembly to provide aircraft thrust.

16
Given data

A turboprop
engine is a turbine engine that drives a propeller through a reduction gear. The exhaust gases
drive a power turbine connected by a shaft that drives the reduction gear assembly. Reduction
gearing is necessary in turboprop engines because optimum propeller performance is achieved at
much slower speeds than the engine’s operating rpm. Turboprop engines are a compromise
between turbojet engines and reciprocating powerplants. Turboprop engines are most efficient at
speeds between 250 and 400 mph and altitudes between 18,000 and 30,000 feet. They also
perform well at the slow airspeeds required for takeoff and landing, and are fuel efficient.

4 turbo fan engine

The turbofan engine has a duct-enclosed fan mounted at the front or rear of the engine. The fan
runs at the same speed as the compressor, or it may be mechanically geared down. An
independent turbine located to the rear of the compressor drive turbine may also drive the fan.

17
Given data

figure 2.5 turbofan engine

The turbofan engine (fig. ) is similar to the turboprop, except a fan replaces the turboprop
propeller. One basic operational difference between the two engines is the airflow. The fan is
inside a cowling, and as a result the airflow through the fan is unaffected by the aircraft's speed.
These factors eliminate loss of operational efficiency at high speeds, which limits the maximum
airspeed of propeller-driven (turboprop) aircraft.

Note: Engine performance affected by different condition like: temperature, pressure and
density depending on the altitude. The performance of an engine is dependent on the capacity

18
Given data

of engine to produce sufficient thrust which is again affected by density, engine speed, air
speed an d altitude.

the process followed in gas turbine engine are as mentioned blow.

1.inlet section

2.compressor section

3.combustion section

4.turbine section

5.exhaust section

1.Inlet Section

figure 2.6 inlet section

The purpose of inlet section is used to enter air at proper angle with maximum and minimum
energy loss due to the drag. The amount of intake air required by gas turbine engine is
approximately ten times(10x) greater than that of the reciprocating engine. The intake section
is made up of magnesium alloy and other corrosion resistance material and it is coated with
chrome plate. Engine thrust can be high only if the inlet duct supplies the engine with the
required air flow at highest possible pressure. This part is mainly the part with which air,
specially oxygen is enter into the engine , combustion chamber and mixed with fuel in order to
make fuel-air mixture. The combustion of fuel -air mixture is taken place by means of ignition
which is in turn made by rotation of crank shaft.

19
Given data

2. Compressor Section

figure 2.7 cmpressor

section

The compressor section has twelve stage which are used to compress the incoming air and
stage one through four(1-4) is to compress the incoming atmospheric air to deliver into
combustion chamber. for compressor there are three types of flow ,which are:

a. centerifugal flow

b. axial flow

c. axial and centerfugal flow

Dejen Aviation Industry is mainly concerned with axial flow since it is mostly used for air craft
propulsion.

3. combustion section

This section is used to convert chemical energy of the fuel into thermal energy by means of
consuming efficient combustion of the fuel in the air flow delivered from the compressor.

4.turbine section

Engine has two kinametically independent turbine, compressor turbine and free turbine.

a/. compressor turbine:-which drive the compressor and engine accessories.

b/. free turbine :-drive the helicopter main rotor blade and tail rotor blade.

5.exhaust section

Engine is assembled in two ways:-whether on the right hand version or on the left hand version
thus the engine exhaust section is intended to discharge gas into atmosphere to the right hand
or left hand of the engine depending on its assembly.

20
Given data

2.2.Main Gear Box and Power Transmission shaft shop

fig 2.2.1 mi 17 - main gear box

Gear and transmission production shop concerned with maintaining and overhauling gear and
transmission system of aircraft/helicopter. The Main gear box are knows as reduction gear box.
There are reduction gear box of turboprop or turbo shaft engines. In addition accessory gear box
of any type of engine of turboprop or turbo shaft engines are also maintained here. The main
uses of gears in the gear box of air craft or helicopter are for speed reduction of aircraft. Speed
reduction in is the most essential activities take place in air craft/helicopter gear box The
mechanism by which gears reduces speed are: 1.Driver and driven mechanism
21
Given data

This mechanism deals with the reality that the gear with small number of teeth drives the gear
with many teeth. speed is reduced when the driver/the one with small number of teeth rotates two
times the driven/the one with many number of teeth rotates only one times. From this reality ,it
takes a long duration for the gear with many numbers of teeth to rotate on its axis even once
time. Since speed and time is inversely proportional ,as time increases sp

θ
is reduced. v=
t

2.2.1 the gear box transmits high load/utilized high load

for rotation as numbers of teeth increases from one to another gear. high load also means high
power, since it is the product of load or force and average speed.P=T ×ω. V =ω ×r&T=F × r
where P is power transmitted through the output shaft rotation which is mounted on the turbine at
the engine exhaust .T is torque of gear .r is radius of gear and v is speed of gear movement.
P=F ×V which implies as the gear transmit high load speed is reduced ,since they are inversly
proportional. Final the average speed needed by helicopter which 192rpm is reached by means
of above methods . Transmission shaft also includes couples or flanges which transmits power
to main rotor and tail rotor blade.

2.2.2 Transmission Shop

The daily function of this shop is: disassemble, assemble, overhaul and checking remark of
Transmission Shaft .As name indicate Transmission Shaft is used to transmit power .

To perform this operation six shafts are used each having their own label.

label number amount in number

1.twenty(20) two(2)

2.fourty(40) one(1)

3.sixty(60) one(1)

4.eighty(80) one(1)

5.hundred(100) one(1)

The path followed to transmit power is as follows: Main Gear Box shaft labeled 20
shaft labeled 40 Accessory Gear Box shaft labeled 80 shaft labeled 60 shaft
labeled 20 Intermediate Gear Box(change angle by 45 degree) shaft labeled 100
Tail Gear Box(change direction by 90 degree) Tail Rotor Hub Tail Rotor Blade.

22
Given data

N. b: Main Gear Box and Accessory Gear Box are connected in horizontal manner while
Intermediate Gear Box and Tail Gear Box are connected through inclination(45degree).

Remark: The remark seen on the shaft are mainly bent and bearing wear. The bent of the shaft is
checked by instrument called Dial Indicator and the wear of the bearing is removed by cleaning
shop.

The other equipment existing in this shop are: cooling fun, car-dial shaft, IMG(intermediate gear
box), AGB(accessory gear box) ,TGB(tail gear box) and others.

 Cooling Fun
Cooling Fun is used to cool engine, main gear box and also for air compressor. Two type of
cooling fun are there: automatic and fixed cooling fun .The difference is that in cold
environment fixed cooling is closed by the pilot while the automatic one is closed automatically
as the name indicate.

 Accessory Gear Box

Accessory Gear Box is used to generate additional power specially for fighter helicopter(mi-24
and mi-35) this additional power is come from two generator on the gear box producing
electrical power

 Tail Gear Box

Tail Gear Box is used to transmit power received from main gear box to the tail rotor blade
changing the direction by 90 degree.

 Car-dial shaft
Car-dial shaft is used to connect main gear box with the cooling fun and transmitting power from
main gear box to the cooling fun.

2.2.3.Fuel Aggregate Shop

Fuel aggregate shop is one of the power plant factory shop concerning with cleaning different
lines and parts like fuel regulating pump containing machine elements including: bearing, ring,
valves/slide valves, nuts, safety wire, filter and others.

speed governor

Speed governor is used to regulate the speed of turbine blade to the shaft connected with the
gear box. components on speed governor are: torsion shaft, spring, ball bearing, valve, leaver
, needle and bush

air sucking

23
Given data

Air sucking is concerned with the regulating or controlling air that enter the combustion
chamber at inlet. the component existing on this part are: -guiding valve

-connecting rod

-cam shaft

2.2.4.Main rotor hub and swash plate shop

This shop is one of the main shop under power plant factory in which the disassembly,
assembly as well checking of main rotor hub and swash plate are take place.

Main Rotor Hub

fig2.2.4 main rotor hub

Main Rotor Hub is one of the important component of air craft having five connecting rod
which is directly locked with the five main rotor blade each and transmitting power received
from main gear box to the main rotor blade. Main Rotor Hub has three hinges and five
connecting rod with hydraulic damper.

a. horizontal hinge: is used to move air craft side way. Horizontal hinge uses normal or non
hypoid oil for lubrication purpose because there is no high load is applied on this position like
others.

24
Given data

b. vertical hinge: is used to join vertical hinge with the feathering hinge and on this part hypoid
oil is used for the lubrication purpose. This is selected for safety purpose as high load is applied
on this position.

c. feathering hinge: is used to move air craft up and down during this movement there is high
load on this position due this hypoid oil is used for lubrication purpose.

NB. hypoid oil is high viscous oil

Hydraulic Damper: is used to damp vibration and joined with the main gear box output shaft .

Swash Plate .
The swashplate consists of a rotating disc (upper), stationary (lower) portion with a scissors and
sleeve assembly separated by a bearing. The swashplate is permitted to slide on the main rotor
vertical driveshaft and mounts on top the main transmission. The entire assembly can tilt in any
direction following the motion of the flight controls.

The hydraulic servo cylinders, swash plate, and adjustable pitch control rods permit
movement of the flight controls to be transmitted to the rotary wing blades.

Test benches and operating tools within the shop:

25
Given data

Hydraulic machine used for assembling and disassembling of hub by pushing/pulling and
revolving action of hydraulic cylinders installed in it.

Damper tester that simulate torsion load on each damper again works hydraulically to press it to
the permissible pressure and check results against the preset rangeof compression. We also did
cleaning and checking anti-icing valve on a separate bench.

fig2.2.4b overhauledswash plate

Swash plate is directly joined with the main gear box with the purpose of transmitting power
from main gear box to the main rotor hub and so called the heart of airplane. Swash plate has
five arms which is connected with the connecting rod of the main rotor hub.

2.2.5 Rotary Blade and Propeller Shop

This shop is one of the known shop under power plant factory. The daily function of this shop is
mainly balancing and maintaining blade , disassembling and assembling of tail rotor hub.

There are two types of blade, which are:

1. Main Rotor Blade

2.Tail Rotor Blade

26
Given data

1.Main Rotor Blade

what makes a Helicopter differ from other is their blade. Main Rotor Blade are five in number
having their own mass each. The balancing is done on two scale each at both end. The range of
mass for main rotor blade is (114-116) in Kg. When each blade is balanced it must be in this
range, if it is less than 114Kg small plate is added until it reaches to the range and if it is above
116Kg the small plate already added is removed from the blade till it comes to the range.

NB. No more than 900g plate is added on the blade for the purpose of safety.

Transport Helicopter's blade is small in area and longer than fighter Helicopter's blade while
fighter helicopter's blade is large in area and shorter than transport blade. The reason is that
for fighter helicopter speed is very important than transport helicopter, this means area and
pressure are inversely proportional while area and speed are directly proportional this

reality makes the difference we have described above on the two blades. The mathematical
proof for what we have mentioned above is as follows:

Pressure=Force/Area P=F/A ................ equation .....1

Force=Mass × Acceleration F=m × a......equation ....2

Acceleration=Velocity/Time a=v/t......equation......3

Then substituting equation (2) and (3) in (1) we get: P=F/A= (m × a)/A = (m × v)/ (t ×A )

(P × t × A)=(m ×v) from this we conclude that if area is increased speed is also increased and vice-versa.

Therefore: as A = v

A =P

A=area F=force m=mass a=acceleration

p=pressure t=time v=velocity

Transport Helicopter: mi-8 and mi-17

Fighter Helicopter: mi-24 and mi-35

2.Tail Rotor Blade

Tail Rotor Blade are three in number and the mass of each blade should 13.75 Kg. The balancing
is done in the same way as that of main rotor blade. The difference we mentioned above for
main rotor blade is also applicable here for tail rotor blade.

27
Given data

Tail Rotor Hub

Tail Rotor Hub is used to transmit power received from main gear box through the tail gear
boxy (change the direction by 90 degree) to rotate tail rotor blade. The tail rotor hub has three
connecting rod which is used to join with and hold the blade.

3.1 Rotary Wing Production Factory

Aircraft existing in this factory are mainly Helicopter including both transport and fighter.
Fighter helicopter are : mi -17 and mi-35 while Transport Helicopter are: mi-8 and mi-24. The
main function performed under this factories are accepting ,maintaining and overhaulling of
rotary wing aircraft.

Flow Chart Of rotary wing production factories are as follow:

Acceptance Visual Inspection Pre-test Disassemble

Dispatch to cleaning, Repair Assembly

NDT ,Plating and

Electroplating shop

Testing Dispatch for Documentation Delivery

final painting & protection

Shops under this factories are:

1 .transport helicopter shop

2. fighter helicopter shop

3 .Welding shop

4.Hidase and Gyro helicopter shop

28
Given data

3.1.1 transport helicopter shop

This shop is concerned with the acceptance ,maintainance and overall of rotary wing transport
helicopter.

Transport helicopter (MI 8and MI 17): generallyboth transportation and fighter helicopter is used turbo
shaft engine. But they are differ according to its performance or power produce. The power from engine
transfer to main gear box 12000RPM. Reduced in main gear box to 192RPM and transmitted to rotary
blade. This means the engine and main gear connected by shaft though bearing system.

fig3.1.1a fig3.1.1b

fig 3.1.1a& b, Mi-8 and mi-17transport helicopter on maintenanc .

The intermediate gear box is used for the direction RPM to 45 degree for tail gear box. The landing gear
of this helicopter is not retracted during flying system therefore has advantage of reducing drag system
on helicopter during system checking on the ground. The main rotary blade used for lift the helicopter
and tail rotary blades change the direction of plane by control pedal system. MI 8 is the oldest version of
helicopter with maximum fuel consumption and low speed of flying. MI 17 is the latest version
helicopter in Ethiopia. The difference MI 17 from MI 8, is low fuel consumption and high speed.

29
Given data

3.1.2 fighter helicopter shop. The main work accomplished in this shop is acceptance
;maintenance and overhaul of fighter helicopter Mi-24 and mi-35

fig.3.1.2 mi-35 fighter helicopter on system check

3.1.3 Welding shop

Welding shop of this company is performing its work from simple to high level of
welding technology ,like aviation welding. welding types existing in this shops are:

 metal arc welding

 tungsten arc welding
 oxy-acetylene welding

3.1.4 Hidase and Gyro helicopter shop.

There are two helicopter are existing in this shop :gyro and hidase helicopter. The main aim of
this shop is just for researchpurpoose.This helicopter is used of transportation system only and the
design of this helicopter designed and manufacture by Ethiopian engineers. But this time it is not on
function because of some fluid likage.

30
Given data

HIDASE(H-77)
The main specification are:

Type: lighter helicopter for commercial Purpose

 tourist transportation and tour purpose

 Arial mapping, primary pilot training
 Can be customized for special commercial utilities
 It has four(4) number of Seat
 max number of passenger are three(3)
 fuel capacity-215.72L

Performance: -max speed 177km/hr

-fuel consumption 49.2L/h

Dimension:
 Height-2.62m
 width-1.52m

31
Given data

fig.3.1.4 hidase light helicopter

Gyro- plane
Type: Light helicopter and commercial version

Purpose- Tourist transportation and tour purpose

 Arial mapping activity

 Primary pilot training
 Can be customized for special commercial utilities
Basic Spacification:-
 Number of seat two(2)
 Max passenger one

Performance:-max speed 120MPH

32
Given data

fig3.1.4b Gyro-plane

3.2 Fixed wing Production Factory

Fixed wing production factory is a factory in which fixed wing air craft are maintained, over
hauled, upgrade and modified. In this factory the type aircrafts overhauled based on service.
 Fighter jet (SU 27, MIG 23 and MIG 21)
 Transport (Antinovel)
 Trainer (L-39)

33
Given data

System induced in those group air craft are:

 Hydraulic system
 Fuel system
 Landing gear system
 Control system
 Engine system

Works performed in under this block are:

 Acceptance of fixed wing aircraft

 Disassembling the system and distributing in to different shops
 Non destructive Testing (NDT) components and body of air craft
 Assembling
 System checking (leveling, Engine test, flight check)

Take off/landing equipments

 Air brake drug Shute

 Vertical fin
 Flapping position indication
 Anti skid control system
 Seat control system

Purposes of hydraulic system are:

 Control wing flap

 Air brake
 Engine jet nozzle flap
 Anti surge shutter, Air intake lower
 Cooling system valve of equipments

Indicators found in fixed wing air craft wing are:

 Angle of attack indicator

 Wing sweep indicator
 Flight indicator
 Flight and navigation indicator
 Range indicator

Electrical equipments system:

 Avionics system
34
Given data

 Radio system

Radio system includes:

 Radial
 Navigation
 Communication

Avionics includes:

 Electrical
 Cairo
 Instrument
 Cable
 Armament (electrical and mechanical)

Shops in fixed wing production factory are:

 Non distractive testing shop

 Applostary and flexing shop
 Structure shop
 Assembling and disassembling shop

3.2.1 Non distractive test (NDT)

NDT is testing for looking crack on different parts of aircraft. this shops perform the fowling
activities:

 Liquid penetrate inspection

 Magnetic inspection
 Ultrasonic inspection
 Eddy current inspection

The testing of cracks by magnetizing the non magnetic materials putting in chemicals and
putting in chemicals, looking cracking, if the crack lines which creased by hand are found, if the
is not creased they are not crack. After testing existence of crack by demagnetizing machine, by
disconnecting AC source. After NDT is performed test materials are taken into powder .

3.2.2Aplostery and flexing shop

Consists of;

 Applostary

35
Given data

 Flexing glass
 Glass cutter
 Polisher
 Sealant
 Accelerator
 Fiber clothes
 Sewing machine

In this shop there are different kinds of mold which is used to make different kinds of canopy
and with required dimension and shape. Flexy glass used for molding purpose, manufacture by
its own furnace using heat and air sack by using vacuum in a necessary mold. Sealant are used
for protecting leakage and Acceleratory used for adding rubber properly to sealant when the
glass are assembled on air craft for protecting entrance of water. Polisher used for polishing
glasses. Generally glasses used in aircraft are molded in to different shape in this shop. The
thickness of glass for different air craft are shown in table blew;

Type of Airplane Thickness of glass

used
MI-8 3mm
MI-35 5mm
MIG-23 8mm
SU-27 12mm
Table 3.2 plane & their glass
Here it is important to notice that thickness of glass used is directly related
with the speed of an air plane i.e the fast is the plane thick is the glass used

4.Aero Space Production Factory

Aero Space Production Factory is a factory under which mechanical work is performed.

Shops Under This Factory Are:

1.Machine Shop

2.Pneumatic Air Conditioning control system shop

3.Landing Gear shop.

4.Egress& Parachute system shop

5.Heat Treatment shop

36
Given data

4.1.Machine Shop
Machine Shop is one of the very known shop of aerospace production factory performing the
following function.

These are:- fabricating

- modifying different parts

-upgrading

Different machine existing in this shop are:

 CNC machine

 Lathe machine
 Drilling machine
Drilling Machine is used to make hole
 Milling machine
 Shaper machine
 Axsaw
A machine used to make thread and to smooth different parts.
Machine shop is established for manufacturing some component of aircraft and of
other related machines .In this shop there are different kinds of machines like: lathe
machine ,universal milling machine ,drilling and shaper machine .The designer design
parts wanted to be manufactured with its part drawing which are the parts of aircraft
and other machine parts.

Lathe machine
Lathe machine is the oldest and the most important machine. Tasks performed under this
machine are: facing, turning, chamfering, boring, knurling and threading (internal, external).

 Drilling machine
The chief purpose of drilling machine is to make holes or enlarging holes by forcing rotating tool
called drill. Operations performed under drilling machine are: reaming boring (counter),
counter sinking, tapping, spot facing and trepanning.

37
Given data

Shaping machine
It is reciprocating type of machine tool intended primarily to produce horizontal , vertical or
include flat surface (up to 1000mm long) cutting in shaper has a reciprocating motion only
during forward strokes the work is bolted to the work table.

Milling machine
It is a machine tool in which metal is removed by means of revolving cutter with many teeth,
each tooth having cutting age which removes metal from a work piece. Works are performed
after they are finished on lathe machine. Operations performed on milling machine are: plane
or slap, straddle, face from gang , jaw and t-slot. On a milling machine the required cutting
speed is given by:-

π DN m
V= where,
1000 min

V cutting speed

D- Diameter

N-revolution per minute(RPM).

 Axe saw is a machine used to cut metal or round bar at required length.
 Milling machine have the purpose of cut, drill to make index by degree.

4. 2 Pneumatic & Air Conditioning control system shop

The air craft air system consists of two system main and emergency .The main system is
operated in

 Pressurizing and lifting of the canopy

 Application of landing wheel brakes
 Closing of fuel system shutoff valve
 Operation of the system serving for engaging the booster pump emergency
 The emergency system provides for;
 Emergency extension of landing gear and the simultaneous retraction of movable
ventral fin
 Emergency application of the brake to the main landing gear wheel.

Both systems are changed from ground source of compressed air .The charged to the system
should be clean and dry. The pressure in the main and emergency system is checked with the

38
Given data

help of two- pointer pressure gauge type 2M-240 positioned in the cabin. The main system
uses the cavities of beam and axles and the emergency system uses the void in the main
landing gear four leg beams.

4.3 CONTROL SHOP

The aircraft or helicopter is controlled by mechanical and electrical systems. The mechanical
system is derived by hydraulic and electric power. Therefore the control shop system can
control the aircraft by mechanical action. The main components of helicopter controlled by
mechanical control system are:

Collective pitch, winch machinery, combined unit, main engine brake, pedal, gear box mount,
booster bracket, engine separator.

COLLECTIVE PITCH

This control system is used for moving the plane up and down .The movement of collective
pitch is transmitted through different units and to top end of power cylinder, attached to the
collective pitch control level by control tube. The most common units which transmit the
movement of collective pitch are: Jack shaft, controlled tubes, bell cranks and power cylinder
(booster).

CYCLIC CONTROL SYSTEM

The cyclic control system is used for the control of forward, longitudinal and lateral flight of the
helicopter. In this movement the pilot or copilot control stick is transmitted by series of control
rod and bell crank to the servo cylinder to automatic flight control system servo cylinder.

DIRECTIONAL CONTROL SYSTEM

This system change of pitch of tail rotor blades, pedal movement through mechanical leakage
servo cylinder and cable to the tail rotor will change tail rotor blades.

AUTOMATIC FLIGHT CONTROL SYSTEM

It stabilizes the helicopter attitude (pitch and roll), heading (jaw) and to permit automatic hands
of flight and hovering.

ENGINE SEPARATOR

39
Given data

Is used to control the engine found on air craft (separating the two engines left and right
position). Stabilizer is used to balance the wing of the aircraft and stabilize the angle when
change in direction.

Generally the control systems are checked for cracks, bend and measuring using visual
inspection or non destructive (NDT) and other instruments.

4.4Landing Gear shop

Landing Gear Shop is a place where landing gear of all type of air craft are developed. The
landing gear of mi-35, mi-8, mi-17, mi-24,andAntonove landing are developed here.

Landing gear uses the airplane to:

 Support aircraft on ground

 Helps an airplane to land safely
 Medium viscous oil is used for landing gear(S6.06H)
 Main Shock strut is used to check the landing gear.
 Anti skid detector machine is used to skid and decreases air by 50% from the
airplane.

4. 5 Egress & Parachute system shop.

4.5.1 EGRESS SHOP

 This shop is also called Parachute system shop. Its function is to get the crew
member system out and away from the disassembled aircraft during its crash. The
system is only found in fighter aircraft such as MIG-23, L-39, MIG-21 and SU-27.
Parachute system is ejection system which is intended for saving life of the pilot
when there is no other choice of saving aircraft .The ejection is through automatic
unit. This system has three stages such as :
 First stage stabilizing parachute
 Second stage stabilizing parachute and
 Third main parachute

 The main components of life saving parachute system are:

 Survival kit
 Instrumental automatic unit
 Harness

40
Given data

SPECIFICATIONS OF LIVE SAVING PARACHUTE SYSTEM

1. First stage stabilizing parachute

It is used for stabilizing ejection seat with the pilot and for deceleration of the rate of descent of
the ejection with the pilot. This stage is common in L-39, MIG-23, and SU-27 types of fighter
aircraft.

Pilot life saving equipments are seat back rest, lock for connecting parachute, main life saving
parachute (pull ring, seat frame).

2 .Second stage stabilizing parachute

It is used for stabilizing the ejection seat with the pilot from high altitude. This stage comprises
of conical canopy, cover, pull link, locking link and head rest.

3. Third main parachute

This parachute is used for the pilot after separation from ejection seat. It consists of parachute
(54m2), cover, pilot Shute cover, back pad flap.

4.5.2 OXYGEN SHOP

The aircraft oxygen equipment consists of pilot oxygen supply system and engine oxygen
supply system the oxygen equipment which is used to provide normal life condition for the pilot
consists of the following system.

 Pilot oxygen supply system

 Pilots high altitude out lift
 The pilot clothing ventilation system
 The anti device system
 The pressure helmet visor heating system
 The parachute packed oxygen set

The total amount of oxygen in pilot oxygen supply system is 12 liters compressed to
150kg/cm2.the engine oxygen supply equipment system consists of oxygen supply system and
electric system used for actuating and monitoring the oxygen supply system. Engine oxygen
supply system is not connected with pilot oxygen supply system. the total amount of oxygen in
the engine oxygen supply system is 2 liters compressed to150k

4.6 Heat Treatment shop

The main objective of heat treatment shop is that:

41
Given data

 For hardening aircraft part

 Softening
 For drying colors painted on aircraft part

Types of furnace
There are two types of furnace based on energy they used:

1. Fuel fired furnace: type of furnace which uses the coal as a form of energy for heat
treatment purpose.
2. Electrical furnace: Is type of furnace which uses electrical power us source of heat
energy for heat treatment .It consists of box furnace, pit furnace, vacuum furnace and
drying furnace.
Note: All furnace in dejen aviation industries are elctrical furnace

Box furnace: is electrical furnace for which heat treatment performance has stone plate in
shape of box (rectangular). This furnace is used for both hardening and softening purpose.

Metal hardening and softening process are take place in this shop

What is differ in this shop is the type of furnace used according to the working dimension of the
material.

Flow Chart Of Heat Treatment Shop is as follow.

Acceptance Assessment of treatment, Cleaning

furnace& cooling media

Pre-treatment test Setting temperature Heat treatment

soaking time Quenching Lab test Documentation Deliv er

There are two types of quenching process are there:-

 Oil quenching furnace(to hard or increase hardness)

 Water quenching(harden the material)

Furnace

42
Given data

There are different type of furnace used for hardening and softening metal.

 box type furnace :- box type furnace have different model

Model 504
working dimension 2200mm*1100mm*700mm
maximum temperature 1200 degCel
weight 1ton
medium air

Model 3502
 working dimension 800mm*400mm*250mm
 max temp 1300 degcel
 weight 0.25ton
 medium air
Model453
 working dimension 1200mm*600mm*400mm
 max temp 1000 degcel
 weight .8ton
 medium air
small size drying furnace
o Model
o working dimension
o weight 80Kg
o max temp 250 degcel

large size drying furnace

model
working dimension 1350mm*1350mm*750mm
max temp 350degc
medium air

PIT furnace

 model3501
 working dimension 1000mm*1000mm
 max temp 1000degc
 weight 0.25ton

43
Given data

 medium air

5.1 General benefit of internship

During we were in Dejen Aviation Industry we have gained so many knowledge that would
helps us in our future professional skills. Even if Dejen aviation have eighteen block , mechanical
concerned works are performed in four of them, These includes power plant , rotary wing
,fixed wing and aerospace(aerodynamic) production factory and we have been working in each
factory. For the first two months we have been working in shops under power plant factory as
well as solving problem for the company, these shops are:-

4.Main rotor hub and swash plate shop :we have studied here how to assemble and
disassemble ,function and how to check rotor hub and swash plate after mantenance

5. Blade and propeller shop: In this shop we have identified type of blade, maintenance of
main rotor blade and tail rotor blade as well as tail rotor hub. there also numbers of of benefits
that

On the third month we have tried to stay under rotary wing production factory and studied
the main activities of this factory. This factory is mainly concerned with:-
 overhaul
 maintenance
 upgrading of rotary wing aircraft
For the last month we have stayed in fixed wing and aerospace
production factory, in fixed wing we have tried to identify fast
attacking jet existing in Ethiopian air force(MIG-23 &su-27), trainer
jet(L-39) and etc. In aerospace we seen different shop with
different purpose like machine shop, hydraulic shop, heat
treatment shop and oters.

Theoretical Knowledge

44
Given data

In terms of improving our theoretical knowledge concerning every coarse of mechanical

engineering department entrepreneurship plays a great role because the worker of the
company specially those have deep knowledge(experienced) on their work bench starts
briefing their work bench with question concerning theoretical coarse that we have took
before. We have seen that how coarse that we taken before are important in practical
work.
. Some of these coarse are as follow:-
Sophomore English
Communication skill
Research methodology
Manufacturing
Pneumatics and Hydraulic system
Auto-cad
Catia
Thermodynamics
Heat
Dynamics
vibration
ICE engine
Design
casting and many other's
Communication Skill
We can see communication skill in two ways
 Personal communication skill
 Communication through the work
Personal communication skill
One of the advantage we gain from internship is improving our
communication skill with the worker of the company starting from the
head office to the team leader as well as with all worker of the company.
What black-shade the communication is that to be absent from work
without permission, not respecting working time and also to brake rule
and regulation of the company, this in-turn help us to guide ourselves in
the future life.
Communication through the work
Every factory of Dejen Aviation Industry have leader and team leader.
Worker of the company are responsible for their work because aviation
works need care apart from other, as a result they brief what to do in the
morning and what they have done in the evening and also plan what to

45
Given data

do for the next day, thus there are weekly and monthly report which are
submitted by team leader to the factory head and then to the overall
administrative office these process teach us our responsibility and how to
lead .

Team Working Skill

Team working is a working system on which DAVI'S worker based on, because it helps
worker to share ideas and helps a new comer worker and students from different
university to learn from experienced worker of the company. In addition to this team
working also improve relationship between the worker and make them friendly , thus it
helps them to accomplish their work on time and

Challenge faced outside of the company

Initially it is obligatory to have identification card to enter Dejen aviation Industry , thus
we stay outside of the company for one week till ID is prepared. The other one is life is
difficult in Bishoftubecuase this town is dominated by government and many private
company worker and tourist from different parts of Ethiopia and abroad came for visit
make life expensive in Bishoftu .
Challenge faced inside the company
 Challenge facing inside DAVI's is concerned with the work area.
 Working time is very long (7am-5pm) thus it is boring
 manuals are written in Russian language and those translated are also not totally
free from Russian hence difficult to understand at some place.
 It is difficult to get any data of the company since mobile, flash, cd and other are
prohibited.
 There is no enough access of computer to use, to accomplish the task we have
given from our superviser of the DAVI.
 Some work area is very overloaded , because of this we could not solve the
problem we have given hundred percent, e.g, machine shop.

46
Given data

Professional Ethics
When we were in DAVI we have developed so many professional ethics that
disciplinary codes allows the employee to follow. these ethics define the
standard of the conduct and ensure that individual entrepreneur fulfil this
standard by giving discipline from concerned body to guide those entrepreneur
accordingly . The main professional ethics that defined by many professional
organizations are mentioned below
1. Loyalty
2. Impartiality
3. Responsibility
4. Honesty
5. Transparency
6. Accountability
7. Confidentiality
8. Objective
9. Respectful
11. Punctuality and & 12. within the law

5.2 PROJECT
HYDRAULIC JACK FOR ASSEMBLY AND DISSASSEMBLY OF MAIN ROTOR HUB
ABSTRACT

Hydraulic jacks are widely used for lifting purpose in garages and aviation industry. However, it
is not assured to be under hydraulic jack during lifting high load, since the leakage may be occur
and cause down movement which is not desired. Hydraulic jack performs lifting event by the
movement of the piston due to the retraction and attraction of double acting hydraulic cylinder.
The hydraulic cylinder retracted and attracted by the hydraulic fluid Power. In order to
overcome the problem that might cause by hydraulic jack when working under it, we have to
lock the valve while lifting the load up and unlock while moving down.

PROJECT DEFINITION

A hydraulic jack is a device used to lift heavy loads. The device itself is light, compact and
portable, but is capable of exerting great force. The device pushes liquid against a piston;
pressure is built in the jack's container. The jack is based on Pascal's law that states the
pressure of a liquid in a container is the same at all point.

Introduction
47
Given data

Hydraulic jacks are a device widely used for lifting heavy loads material like car, aircraft and
heavy machine components.

A hydraulic jack is a jack that uses a liquid to push against a piston. This is based on Pascal’s
Principle. The principle states that pressure in a closed container is the same at all points. If

There are two cylinders connected, applying force to the smaller cylinder will result in the same
amount of pressure in the larger cylinder. However, since the larger cylinder has more area, the
resulting force will be greater. In other words, an increase in area leads to an increase in force.
The greater the difference in size between the two cylinders, the greater the increase in the
force will be. A hydraulic jack operates based on this two cylinder system.

Pascal ‘slaw

Pressure on confined fluid is transmitted undiminished and acts with equal force on equal areas and
at 90 degrees to the container wall .fluid such as oil is displaced when either piston is pushed in ward.
The small piston, for given distance movement, displaces smaller amount of volume than large piston,
which is proportional to the attraction or negative pressure that holds the double acting cylinder is
greater than the retraction pressure that forced the piston to move upwards is self lubricating and if
they may be leakage problem happened they would cause harsh problem on human life. Therefore,
for safety purpose we have designed locking mechanism that locks the hydraulic jack piston and
spline hub shaft together after we rose to the required maximum height. It is simply a steel made
locking key of overall length of 50mm.

Objective of the design

The objective of this project is to replace the fixed and unfavourable main rotor hub stand with
easily movable (up and down since it works with hydraulic system and to from place to place
with the use of wheel) and favourable main rotor hub stand to save working time and man
power with the use of handle of the jack as far as it is manually operated.

Mechanism or synthesis
The design is already available, but it is not favorable for the assembling and disassembling of
the main rotor hub. The main problems with this design is the hub stand that withstand the
main rotor hub that weighs 530kg×10m/s2 is fixed or non movable, hence it is impossible for

48
 Given data

the workers to disassemble and assemble the main rotor hub hinges at the needed height since
the hub stand is fixed and to short for workers with high height of above 1.5m.There fore we
believe that our design will solve the problem mentioned above with the previous design by the
following method mentioned below:-

1. We have replaced the non movable hub stand with the movable hydraulic jack .this enables
the workers to lift up and down the main rotor hub to the required height during disassembling
and assembling the main rotor hub hinges.

2. Our design is also effective in consuming effective force and time during disassemble and
assemble of main rotor hub hinges. It is also efficient in using appropriates force and time to
disassemble and assemble the main rotor hub hinges.

3. It is also possible to use this hydraulic jack for disassembling and assembling of swash plates
by only changing the adapter for main rotor hub and replacing by adapter for swash plates.

Force analysis
There are different kinds of force on the main rotor hub supporter which may affect the main
rotor hub supporter or hydraulic jack.

Those forces we believed to be designed are:

 Bending force

 Compression force

 Fatigue force

5.2.1 Design of components

5.2.2 Design of Spline

MATERIAL SELECTION: alloyed steel with the following property is required

Properties of Material selected Ultimate strength (δsut) Yield strength Torsional/shear

strength,Ƭs
49
 Given data

(δsy)
1020 steel for manufacturing of 448 MP 331 MP
249MPa
spline

Table 5.2.2a properties of steel

Figure5.2.2a part drawing for spline

50
Given data

DAVI has no spline shaft manufacturing machine in there machine shop.

We decided to solve this problem by using non functioned gear shaft.

We also cut the gear shaft with the part on which the spline is made with the
below dimensions:-
Overall length of the spline =175mm
 Round Bar of Steel with the following requirement is
 Diameter=167mm
 Length=250mm
 Number of teeth of the spline is (Z) =42

 addendum =4.25mm
 dedendum =7
 depth of pitch(dp)=4 m=module
 length of each teeth=100mm
t= diametric
 pitch circle diameter(dp)= 150mm
pitch
 degree between each teeth=360/42=8.57degree
 m=d/Z =150/42=3.57mm d =pitch circle
 t=Z/d =1/3.57=0.28 diameter
 pc=π × m=π × 3.57mm=11.215mm
Z= number of
teeth

Pc=circular pitch
During the overhauling the main rotor hub, to disassemble or
assemble each hinges from the hub or to the hub we should turn
(rotate) it by manually power.

Assumption power applied by one person to rotate the spline, ph=200hp

The power transmitted by the spline s

Ph=Tω, where ω=πdsN /60 ds=ds(o)-ds(i)=167mm-156mm=11mm

51
Given data

T=π/16×τall [1− ( dodi ) 4], where, k =di/do=156/167=(0.9341) 4

K=0.7613, where k is the ratio of internal diameter and external diameter of the piston
shaft

By assuming factor of safety for mild steel to be, n=4 then we can calculate the allowable shear
stress hence torque produced.

Yield strength for the steel from which the spline shaft is made by taking value for
δ sy=331 MPa

τall= δsy/n=331MPa/4=82.75×106 N/m2

T=π/16×τall[1-(di/do)4]=π/16×82.75×106 N/m2 [1-(0.9341)] 4

T=16.248× [1-0.7613] =3.876× 106Nm

 When can state that the spline is safe from overload since the allowable stress is less
than the yield strength

There fore we can calculate for the spline shaft turn or revolve to overhaul each hinges per
second.

πdsN
Ph=Tω=T ( )
60

N=60 Ph/T (πds) =60×200hp/ (3.876× 106Nm×π× 0.011)=89,589.04rad/sec

Design of steel rod

Material Selection: Mild Steel with the following description

Properties of Ultimate strength (δsut Yield strength Torsional/shea Bearing

material Selected (δsy) r strength,Ƭ pressure(Pb)
Mild steel for Iron 448 MPa 864Mpa 224MPa 70MPa
52
Rod
Given data

Table 5.2.2b properties of mild steel

Figure 5.2.2b parts drawing of steel rod

ROUND BAR OF MILD STEEL WITH THE FOLLOWING DESCRIPTION IS REQUIRED

Diameter=167mm

Length=420mm

 Note that we required iron rod to join the spline( is used to join with and hold the Main
Rotor Hub) and the Jack

53
Given data

5.2.3 Specification of the design

Typical MIG-23 hydraulic jack

With the following description

HYDRAULIC JACK

Part number MNK-7

Load lifting capacity 7000kgf

Minimum height 1.265m

Maximum height 2.265m

Volume of hydraulic oil 8L

Mass of the hydraulic 130kg

jack

table 5.2.3 hydraulic jack description

54
Given data

figure 5.2.3:-maintained hydraulic jack and spline shaft

Constraints and design target

The hydraulic jack must be less or high as the average human height during li.

The allowable safe minimum height= 1.75m.

The hydraulic jack must be strong enough to support both weight of the main rotor hub and
splines.

The iron rod (round bar) that mounted on the piston at one end and in the spline shaft at
another end must be prepared with the below dimensions.

55
Given data

Diameter of the bar =167mm

Length of the bar =420mm

The round bar has to be faced with different diameter on both sides leaving 20mm thick plate
at the center which has 167mm.

The round bar must have a diameter of 88mm with the length of 250mm at the end which
enters to the splines and at another end the bar which enters the piston has diameter of 40mm
with the length of 10mm into the piston

The hydraulic jack piston is a hollow shaft piston with diameter of 42mm

The product must made of available materials with less cost

The hydraulic jack piston must lock with the splines with the key for safety purposes.

We should have to check for the over load or stress on the hydraulic jack’s piston.

Given data:-

Mass of the main rotor hub, Mh=530kg

Mass of the hydraulic jack, Mj=130kg

Another parameters mass are taken by assumption as below:

Mass of spline shaft and the plate welded on it, Ms=60kg

Mass of iron rod (round bar), MI=60kg

Gravity of the earth g=10m/s2

Compressive load applied on the hydraulic jack by the main rotor hub mounted on the splines
and plates welded on it during disassemble and disassemble calculated like below

Compressive load on the jack, Wj =Wh+ (Ws+wp)×g where Wj= Is the weight of main
rotor spline shaft(ws) and plates which is welded on it(wp)

Wj = ([Mh+ (ms+mp)] ×gWJ= [530kg+ (60kg)] ×10m/s2Wj=5900kgm/s2=5900N

56
Given data

Compressive stress applied on the jack,σc=wj/ Ap where Ap is area of

piston and calculated from diameter dp=66mm
Ap=πd2p/4 =π× (0.0662) /4) =0.00342m2

σc=wj/ Ap

σ c=5900N/0.00342mm2

σ c(compressive stress applied down wards)=1,724,543.92N/m2

Hydraulic jack load lifting capacity

Load lifting capacity of the jack, wl =7000kgf

σc=¿ Wl/AP=7000kgf/ 0.00342m2

σc =2,046,783.63/m2

The jack piston is made of aluminum alloys with ϵ =71.7 Gpa

 G=26.8Gpa
 Therefore, we can conclude that the hydraulic jack can with stand the compressive load
applied on it hence it is safe for workers do their job under it.

We must also calculate for bending stress and deflection that could be on the piston shafts
during lifting up the load.

Torsional bending stress of piston shaft calculated like below

Piston average length, lp =1.765mm

τ =4 × p/ πdp2 , where dp is diameter of the piston

dp =66mm=0.066m
p=wh+(ws+wir )

57
Given data

p = [530kg+ (60kg+40kg)] ×10m/s2

P=6300kgm/s2 =6300N

6300 kgm ❑
τp=4 × π ×0.0662
s2 ❑

τp=121,536.5 N /m2

T=π/16×τ [dp 2]

121,536.5 N
T= π/16× × ¿0.066m2]
m2

T=103.95Nm

Longitudinal deflection on the piston during load lifting also must be

calculated, ∆ s.

∆ s= p× lp / Ap ∈

P=Wh+ (ws+wpl) +wir, where p is average load on the piston shaft

when lifting up wards.

A
P = [530kg+ (60kg) +40kg] ×10m/s2]

58
Given data

A
p=0.0013854 m

∆ s= p× lp / Ap ∈

∆ s=1.12×10-3m =0.112 m

Angular deflection of the piston shaft:-

θp =Tlp/GJ where lp is average length of piston

π
j¿ π /32× dp 4 = 32 × ( 0.042 ) 4=3.055 ×10−4 m4

θ p =Tlp/GJ =1,575.000Nm/26.8×3.055 ×10−4 m4

tan−¿(1,575.000Nm/26.8×1.732× 10−4 m 4 )

θ p=89.9 degree

5.2.4 Design of steel connecting rod

PROCESS FOLLOWED IN MACHINE SHOP :

First the round bar is prepared with the above length

The round bar has to be phased with different diameter on both sides leaving 20mm
thick plate at the center keeping diameter of round bar.
After phasing is completed the product we need is the following one:
On one side the iron rod diameter is 88mm for length of 175mm
At the center 20mm thick plate with original diameter of round bar is needed
On this plate we need five whole each having diameter of 10mm and each whole differ from
each other by 72degree. This hole is used to lock the spline and iron rod together since main
rotor hub has five connecting rod.
On the opposite side the diameter of the iron rod is 66mm for length of685mm
We take the clearance to be 2mm.

By assuming factor of safety to be, n=3 we can calculate allowable stress

59
Given data

σy 864
σall= = =288 N /m2 we can say that the materials selected are safe from overload since
n 3
the allowable stress is less than yield strength of the material

fig5.2.4a Part drawing of hydraulic jack

60
Given data

Figure 5.2.4b :-Assembled drawing

61
Given data

5.3 Conclusion and Recommendation

Conclusion
Generally during we were on internship at DAVI for four months when learned so many things about our
internship hosting company such as, what is the primary goal of our internship hosting company ,from
where raw materials is imported and where does the product of the company is exported and etc.

DAVI is one of the known industries found in Ethiopia and going forward with great vision of developing
countries GDP by selling there products to both foreigners and inland customers like FDRE defense,
and also by making great job opportunities to the people living around the industry and for those people
Skilled in aviation knowledge from different parts of the country in addition to the experts from
Russian and others foreign countries.
We have also upgraded our theoretical knowledge by asking and working with the workers of
company.

The professional ethics is one of the company’s goals to be achieved, so we were guided by those
supervisors signed for the entrepreneur students for different university. There fore we concluded
that we have gained so many things inters of working ethics starting communication agreement with
the workers of company, also another work ethics we believed any entrepreneur can get is being
punctual

Finally, we like to conclude that internship is one program given by so many universities in Ethiopia
which develops the theoretical knowledge they get during there academic learning by there lectures
which cannot be visualized.

Recommendation

DAVI is one of the companies with the huge production, how ever they are so many weak sides
of the company we would like to raise:-

 Safety problems:-there so many problems concerning safety of the workers,

even some times there is no soap provided to worker for washing there
handsafter they finished work, this may cause great problems on healthy of the
worker since they are vulnerable to work with different types of oil, with
different lubrication grades.

62
Given data

Employment:-this also other problems that we have seen in DAVI in which

workers have no great interests towards there job because employment is not
enough and added for them through time, this is one thing that minimizes
product of the company and workers life in the company.

Skilled person:-there is no enough skilled person in the company related to the

company‘s production. Many of the worker’s of the company is those who get certificate from
different technic colleges in the country. This is also one reason why sound creativity work

That may save the company’s income by producing different like gear box casing which costs
them great budget.

Also, we would like to recommend Jimma University to conduct internship program in the
future also, since it is needed for students of the university to upgrade their theoretical
knowledge which is vital in their future professional life.

Finally we recommended that DAVI must look up on the problem we have raised above and
give solution since they are the basic problem we seen there which are left open till know and
one of the draw back for the company’s development

References

1. Textbook of machine design by J.KGUPTA, R.S.KHURMI, First Edition

2 standard hand book of machine design by joseph shigley, Charles R.Mischk and Thomas
H.Brown

63
Given data

3. Manuals prepared the company for there product overhauling guide

4.Internet(https://www.google.com/

64