JIMMA INSTITUTE OF TECHNOLOGY (JIT)

DEPARTMENT OF MECHANICAL ENGINEERING

N.A METAL INDUSTRY & ENGINEERING P.L.C

Duration: March /01/2015 – June/30/2015

Submission date June 22/09/2015

Submitted by:

HENOK ADMASU……………….02139/04
DECLARATION

Internship program is newly adopted in the educational curriculum of Ethiopia for engineering
students. It is given to students of fourth year and above for one semester (four months).I have
done this internship program for four months in N.A Metal Industry & Engineering company. I
decelerate that the following report paper of the internship period is my original works has not been
presented earlier after completion of the period and that all sources of material used for report have
been duly acknowledged.

Student name Henok Admasu Signature .

Date Month Year .

Mentor name signature .

Date Month year .

Supervisor name Signature .

Date Month Year .

I
ACKNOWLEDGEMENT

First and foremost, I would like to express my sincere appreciation to Jimma University Institute
of Technology which prepare this internship program. Next I would like to express my deepest
gratitude to NA Metal Industry& Engineering that allowed joining and working my internship
program in the company. Thanks a lot to my supervisor Mr. Henok and all workers of N.A for
giving a professional training, experience and good practical skill.

I am extremely thankful to my advisor Mr. Ahemed Mohamed for his invaluable guidance,
motivation, constant inspiration and above all for his ever co-operating attitude that enabled me in
bringing up this thesis in the present form.

In particular, my sincere thankful is also extends to all my colleagues and others who have provided
assistance at various occasions. Their views and tips are useful indeed. I am also obliged to express
my appreciation towards my parents and also my family members for their enduring patience,
moral and financial supports. Unfortunately, it is not possible to list all of them in this limited
space. Thank you to all. Thank you for everything. May God bless all of you.

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EXECUTIVE SUMMARY

N.A Metal Industry & Engineering is a private sector manufacturing company in Addis Ababa
Ethiopia. N.A since its foundation at 2007G.C has been engaged in Engineering, International
Procurement, Project Management and Service Station Construction services for Oil Storage
Tanks, Pipelines, related to oil, gas and metal industries of Ethiopia. This company is known by
manufacturing and supply of steel fabricated products for industrial and transport application. For
transport application it manufactures and supplies of 3-Axle Drawbar Trailers, 3-Axle Semi-
Trailers, 2-Axle Semi-Trailers for dry and fuel cargo. It has material preparation, metal fabrication,
and machine and compressor shops with their respective functions. It has foreign supplies as well
as local end users/customers.

The process to engage in this company was very difficult since it has their own broad beruicracy.
I have attended in fabrication shop of Hana Mariam branch. I have done bending, rolling, cutting,
and welding tasks as well as quality control of products. I have been followed some procedures
and guides while performing any task in the company. I have also faced to some challenges and I
have taken my own measurements to overcome them. During the internship program I have been
benefited with improving practical skills, theoretical knowledge, interpersonal communication
skills entrepreneurship skills, team playing and leadership skills.

The welding jig to cargo body increases productivity by eliminating individual positioning,
marking and frequent checking. The main advantage of the jigs is interchangeability. The need of
selective assembly is eliminated. The parts of the jig will fit properly and in the assembly and all
similar components are interchangeable. Also a jig reduces the repetitive nature required for
welding the cargo body, because the locating, clamping and guiding of the part is done by the jig
itself. The part guiding element is used whose chief work is to guide the part in to the correct
position. Hence the requirement of skilled laborers is eliminated. Detail analysis of the design is
presented with the help of tabulated data, graphs, some standards and equations and CAD/CAM
drawings. The required cost to manufacture this jig is minimum since it is produced with in their
own workshop and material.

III
TABLE OF CONTENTS

Title page

Declaration…………………………………………………………………………………………I

Acknowledgement……………………………………………………….………...………...…… II

Executive summary…………………………………………………………………………...…. III

Table of contents …………………………………………………………..……...……...……... IV

List of figures…………………………………………………...………….…………….………VII

List of tables…………………………………………………………………………………….VIII

CHAPTER ONE: BACKGROUND, HISTORY AND OBSERVATION

1.1.Introduction…………………………………………………..………………………….…….1
1.2.Historical background of the company………………………..…………………….………….2
1.3.Company’s core values……………………………………………………………...…………3
1.3.1. Vision…………………………………………………………………………………..3
1.3.2. Mission……………………………………………………………………………...…3
1.3.3. Corporative values……………………………………………………………….…….3
1.3.4. Objective of the company………………………………………………..……………..4
1.3.5. Competitive advantage……………………………………………….………………..4
1.4. Product and services of the company………………………………………….………………5
1.4.1. Transport sector…………………………………………….………………………….5
1.4.2. Industrial project……………………………………………..………………………...7
1.5. Plants and workshops of the company………………………………….……………………...8
1.5.1. Material preparation shop………………………………..…………………………....8
1.5.2. Machine shop……………………………………...………………………………….9
1.5.3. Fabrication shop………………………………………………………………………9
1.5.4. Compressor shop………………………………...…………………………………..10
1.6. Customers of the company…………………………………...………………………………11

IV
1.7. Foreign supply……………………………………………….………………………………11
1.8. The overall organizational structure…………………………….……………………………12

CHAPTER TWO: OVERALL INTERNSHIP EXPERIENCES

2.1. The process to engage in the company……………………………….……………………….13

2.2.1. Manufacturing of cargo body………………………...………………………………14

2.2.2. Manufacturing of fuel truck body…………………………………………………….16

2.2.3. Manufacturing of underground tanks………………………………………………...17

2.2.4. Manufacturing of vertical tankers………………………………………………….…18

2.3. Work flow in my working section…………………………………………………………....19

2.4. Tasks I have been executed…………………………………………………………………..20

2.5. Procedures and methods I have been following …………………………………………..….21

2.6. How good I had been in performing work tasks……………………………………………....22

2.7. Challenges I have been facing while performing ………………………………………….....23

2.8. Measurement I have been taken to overcome the challenge……………………………….…24

CHAPTER THREE: OVERALL BENEFITS FROM THE INTERNSHIP

3.1. Practical skill………………………………………………………………………………....25

3.2. Theoretical knowledge…………………………………………………………………….…26
3.3. Interpersonal communication skill…………………………………………………………...27
3.4. Benefit I have gained from improving team paying skill ……………………………………28
3.5. Benefits I have gained from improving leadership skill………………………………………29
3.6. Benefits I have gained in terms of understanding work ethics………………………………..30
3.7. Benefits I have gained from entrepreneurship skill…………………………………………...31

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CHAPTER FOUR: DESIGN OF WELDING JIG TO CARGO BODY

4.1. Introduction ………………………………………………………………………………….32

4.2. Back ground of the study……………………………………………………………………..33
4.3. Statement of the problem ………………………………………………………………….…34
4.3.1. Major point problem…………………………………………………………………..34
4.3.2. Sub problem…………………………………………………………………………...34
4.4. Objective…………………………………………………………………………………..…34
4.4.1. General objective…………………………………………………………………...…34
4.4.2. Specific objective……………………………………………………………………..34
4.5. Scope and limitation …………………………………………………………………………34
4.6. Presentation and design analysis………………………………………………………….….36
4.6.1. Design specification and assumption ………………………………………………....37
4.6.2 Tabulated data………………………………………………………………………….38
4.6.3 Design of part one……………………………...………………………………………39
4.6.3.1. Design of beam one…………………………..………………………………39
4.6.3.2. Design of beam two…………………………………………………………..47
4.6.3.3. Design of beam three………………………………………………………....50
4.6.3.4. Design of beam……………………………………………….………………51
4.6.3.5. Design of column…………………………………………………………….52
4.6.4. Design of bolt and nut…………………………………………………………………54
4.6.5. Design of welding……………………………………………………………………..56
4.6.7. Working principle of the designed equipment…………………………………...……56
4.6.8. Cost analysis………………………………………………………………………..…57
4.7. Detail drawing………………………………………………………………………………..58
Conclusion ……………………………………………………………………………………….61
Recommendation…………………………………………………………………………………62
References...............................................................................................................................…...63

VI
LIST OF FIGURES
Fig 1.1: Partial view of N.A Metal Industry and Engineering ……………………………………..1
Fig 1.2: Axle drawbar fuel trailer ……………………………………………………………….…5
Fig 1.3: Cargo body mounted on truck…………………………………………………………..…6
Fig 1.4: Low bed semi-trailer ………………………………………………………………….…..6
Fig 1.5: Tipper bodies ………………………………………………………………………...……6
Fig 1.6: Coal firing equipment……………………………………………………………….…….7
Fig 1.7: Material preparation shop…………………………………………………………………8
Fig 1.8: Machine shop…………………………………………………………………………..….9
Fig 1.9: Material fabrication shop……………………………………………………………..….10
Fig 1.10: Compressor shop………………………………………………………………………..10
Fig 1.11: Overall organizational structures………………………………………………….……12
Fig 1.12: Work flow of the company…………………………………………………………...…12
Fig 2.1: (a) Production of cargo body………………………………………………………..……15
Fig 2.1: (b) Movable crane………………………………………………………………………..15
Fig 2.1: (c) Cargo body assembly………………………………………………………………....15
Fig 2.2: Fuel truck trailer………………………………………………………………………….16
Fig 2.3: Manufacturing of underground tanker…………………………………………………...17
Fig 2.4: Vertical tanker………………………………………………………………………...….18
Fig 2.5: Work flow in my working section………………………………………………………..19
Fig 4.1: Manufacturing cargo body without using jig……………………………………………..35
Fig 4.2: Isometric view of welding jig…………………………………………………………….36
Fig 4.3: Isometric view of part one……………………………………………………………..…39
Fig 4.4: Isometric view of beam one………………………………………………………………39
Fig 4.5: Distributed load on beam one………………………………………………………….…40
Fig 4.6: Shear force and bending moment diagram of beam one…………………………………46
Fig 4.7: Isometric view of beam two…………………………………………………………...…47
Fig 4.8: Distributed load on beam two…………………………………………………………….48
Fig 4.9: Shear force and bending moment diagram of beam two……………………………….…49
Fig 4.10: Isometric view of beam three…………………………………………………………...50
Fig 4.11: Applied load on beam three……………………………………………………………..50

VII
Fig 4.12: Isometric view of beam four………………………………………………………….…51
Fig 4.13: Distributed load applied on beam four……………………………………………….…52
Fig 4.14: (a) Isometric view of column…………………………………………………………....53
Fig 4.14: (b) Maximum applied load on column……………….………………………………….53
Fig 4.15: Isometric view of bolt and nut assembly…………………….………………………….55

LIST OF TABLES
Table 4.1: Size of each component of the cargo body……………………………………………..37
Table 4.2: Indian standard designation of steel according to IS…………………………………...38
Table 4.3: Dimensions of screw thread according to IS…………………………………………..38
Table 4.4: Moment distribution iteration for beam one………………………………………...…41
Table 4.5: Material costs…………………………………………………………………….……57

VIII
 CHAPTER ONE

BKGROUND, HISTORY AND OBSERVATION

1.1. Introduction
N.A Metal Industry & Engineering is a private sector manufacturing company in Addis Ababa
Ethiopia. The company is a sole proprietor owned and operated in Ethiopia. N.A Metal Industry &
Engineering (N.A) since its foundation in 2007 has been engaged in Engineering, Procurement,
Project Management and Service Station Construction services for Oil Storage Tanks, Pipelines,
and General Engineering Markets as well as all other industrial projects related to oil, gas and metal
industries of Ethiopia. It has also been engaged in manufacturing and supplies of 3-Axle Drawbar
Trailers, 3-Axle Semi-Trailers, 2-Axle Semi-Trailers for dry and fuel cargo.

Fig 1.1: Partial view of N.A Metal Industry & Engineering in Addis Ababa (Hana Mariam branch.

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1.2. Historical background of the company
N.A Metal Industry & Engineering since its foundation at 2007G.C has been engaged in
Engineering, International Procurement, Project Management and Service Station Construction
services for Oil Storage Tanks, Pipelines, related to oil, gas and metal industries of Ethiopia. N.A
metal industry & Engineering in the past years has been supplying Tankers, Shades /Canopy and
various display tools to all most all sector players including industry movers like TOTAL, NOC
and YBP.

N.A Metal Industry & Engineering is a sole-proprietorship owned and managed by an Ethiopian
personnel. It has given a fulltime employment opportunity for about 60 citizens. Its product
offerings are positioned as cost effective, reliable, operational solutions to the current and future
needs of the fuel and lubricants retail industry. N.A Metal Industry & Engineering is known for
its market scanning capability as it introduces timely product into the market. In this regard, the
newly lunched Double Envelope Tanks (DET) aimed at import substitution, received
acceptance from industry and is expected to significantly contribute to market dominance
strategy of the company.

Recently, as part of pursuing its product line diversification strategy, N.A Metal Industry &
Engineering has recruited an Italian consultant that conducted the feasibility study to a ascertain
demand for Cargo Body and Trailers manufacturing. In line with this, N.A plans to introduce
Cargo & Fuel trucks to the Ethiopian market by June 2012. This will make N.A to be the
third company formally engaged in heavy duty vehicle manufacturing sector here in Ethiopia
Model Service Station (EMSS).

2
 1.3. Company’s core values
1.3.1. Vision
Our vision is to become an industry leader in quality designing, engineering, fabricating
and installation services in the areas of Tanker, Canopy and Vehicle products by offering
competitive price and delivering whilst upholding quality and skilled workmanship whose
products and services are most looked for here in Ethiopia. We envisage our activities to
demonstrate adequate health, safety, quality and environment standards.

1.3.2. Mission
Our mission is to strive to provide our clients’ with the highest quality products and services timely
and on budget. Our approach to working with clients as partners also extends to our entire
employee ensuring timely completion of projects and high quality execution. The prevention
of environment polluting activities, death, injury and ill health to those at work and those affected
by work activities is the primary attentions of our company

1.3.3. Corporative Values

 We are Unswerving to Safe Working Environment.
 We are committed to the Surrounding Community
 We believe in Collaborative relationship.
 We Mind meeting Customer contentment
 We Dare to Keeping High Quality
 We believe in Collaborative relationship.

3
 1.3.4. Objectives of the company
1. To design, manufacture vehicle’s trailer as well as low and high bed cement trailers more over
heavy-duty tracks are assembled.
2. To design manufacture and erect industrial components for cement, textile, brewery, food
industry, storage tank and sugar plants etc.
3. To provide service renting of vehicle and machinery.
4. To provide maintenance of vehicle.
5. To satisfy customers.
6. To be competitor in the market.
7. To minimize cost of production …etc.

1.3.5. Competitive advantage

 Professional, highly and skilled and committed work force excellent reputation.
 Being partner of first choice.
 Investment in employee up to dated equipment and technology.

4
1.4. Product and services of the company

The product and services of N.A Metal Industry & Engineering is categorized as:

 Transport sector and

 Industrial project.

1.4.1. Transport sector

NA Metal Industry & Engineering is one of the biggest single trailer-manufacturing factory in
Ethiopia. It designs and manufactures vehicle bodies, trailers, high and low bed semitrailers as
well. NA Metal Industry has a capacity of manufacturing over 800 trailers and semi-trailers annual.
It produces truck bodies 2axele, 3axele trailers, semi-trailers for a dry, and fuel cargo transport low
beds for transporting heavy-duty equipment bus body and taper bodies. Generally N.A Metal &
Engineering Company manufacture the following vehicles such as:

 Truck Cargo Bodies 12-15tons payload.

 Truck Cargo Bodies 12-15tons payload.
 Cargo Semi-trailers two axle 22tons payload.
 Cargo Semi-trailers three axle 30tons payload.
 Water and or Fuel tankers from 200-12000 litter capacity.
 Truck dumper bodies from 8tons to 20 tons payload.
 Cargo trailers with two axle’s 15 tons payload.
 Fuel Tanker Trailers two and three axles from 12000-25000 litter.
 Semi-trailer low bed two/three axle 40/50 tons payload.

Fig 1.2: Axle drawbar fuel trailer.

5
 Fig 1.3: Cargo body mounted on truck.

Fig 1.4: Low bed semi-trailer

Fig 1.5: Tipper bodies

6
 1.4.2. Industrial project
With the support of CAD and CAM software N.A Metal Industry & Engineering designs,
manufactures and erects industrial components for cement, textile, brewery, and food and sugar
industry. Such as:
 Designing, Fabricating, & Installation of Fuel and Service Station
Canopies.
 Designing, Fabricating, Engineering & Installation of Steel Structure.
 Fabrication of Underground & overhead fuel tanks

Fig 1.6: Coal firing equipment.

7
1.5. Plants and workshops of the company
This company is the biggest and most productive of mechanical parts such as, machine component,
sugar component, and different factory component. It is clear that the biggest corporation, which
contains any workers, has many working sections and sub sections. However, the main sections of
corporation of the company are:
I. Material preparation shop
II. Machine shop
III. Fabrication shop
IV. Compressor shop

1.5.1. Material preparation shop

This is the plant where all raw materials for the fabrication process are prepared in the
multiplication shop. In this shop, all the pre welding and assembly activities are carried out. The
quality of product in the material preparation plant determines the precession and functionality of
the final product. Therefore, NA metal industry has acquired and has been using state of the art
machining for metal preparation that is equipped with-
 Shearing
 small rollers
 Bending
 Cutting
 NC operated hydraulic and bending machine etc.

Fig 1.7: Material preparation shop

8
 1.5.2. Machine shop

Machine shop is a shop in which a number of machinery operation are undergoing. The N.A Metal
Industry & Engineering machine is equipped with-

 Conventional (parallel) lathe, vertical lathe, radial drill, universal

milling, press machine, bench drill machine, shaping machine,
cylindrical grinding etc.

Fig 1.8: Machine shop.

Purposes of this shop are-

 Cutting operation, treading operation, turning operation, surface finishing,
boring operation, facing operation.
 Bending of circular future of small diameters of solid rods.

1.5.3. Metal fabrication shop

The metal fabrication is equipped with welding equipment (MAG, TIG, arc and submerged arc
welding machines and overhead crane for transportation system). In all workshops the welding
process are completed.

9
 .

Fig 1.9: Material fabrication shop

1.5.4. Compressor shop

The electrical powered compressor is available in each branch of N.A Metal Industry &
Engineering. And it is used for spray different inks to paint various products of the company. It
also used for powering the tire of different vehicles.

Fig 1.10: Compressor shop

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1.6. Customers of the company or end-users
The capacity of production for the company is increase time to time. The main customers for this
company are as follow.
 Trance Ethiopia
 Tikur Abay
 United alpha
 Shebelle
 Ministry of national defense.
 Messobo building material
 Tendaho sugar factory
 Various private costumers.

1.7. Foreign supply of the company

N.A Metal Industry & Engineering purchase its raw material from the following foreign countries.
Such as:

 Italy
 Germany
 China and other countries.

11
1.8. The overall organizational structure

Fig 1.11: overall organizational structures

Fig 1.12: work flow of the company

12
 CHAPTER TWO

OVERALL INTERNSHIP EXPERIENCE

2.1. The process to engage in the company

The University Industry Linkage (UIL) office and department of mechanical engineering is the
main role player to have a chance to work in to spend the internship semester of four months. On
July, 05, 2014 I have addressed my petition paper to N.A Metal Industry & Engineering main office
in Addis Ababa Bole. Then since September, 11, 2014 the company have requested an acceptance
paper to me. Since March, 15, 2015 I have engaged in the company at Hana Mariam branch. At
that time there was a big challenge regard to my involvement into the company. The general
manager of this company have said that, you have to request an insurance paper from your
University, otherwise we didn’t take any responsibility of you. After those challenges I have fully
engaged in N.A Metal Industry & Engineering.

On March, 15, 2015 I did contact Mr. Henok who was assigned as a general coordinator and
supervisor of the four months internship period. For the first time I have involved in a fabrication
cost for 20 days. Since the company is beginner it has little sections/branches. Among those I have
spent my internship period in Cargo body, Canopy, Casony, Fuel truck trailer manufacturer section.
I have good relationships with my supervisor and other workers of the company. However, I
haven’t my own office all office owners are volunteer to use their offices together.

13
2.2. My working section in the company

I have spent most of my internship period in manufacturing section particularly in fabrication shop.
At this section many products are completely fabricated. In fact, there are number of customers
available in the other sections but maximum number of costumer is covered in this section. Thus
there were more working load to satisfy the costumers with in short period of time. In this section;

 Cargo body
 Fuel truck trailer
 Cargo body trailer
 Underground tank
 Vertical tank
 Canopy and other products were manufactured.

2.2.1. Manufacturing of cargo body

Cargo body production is the main task in my working section since most customers ordered us to
accomplish it. The procedure cargo body production are:

1. Preparation of frame, upper omega, and lower omega, chancy and side
cover pieces by using bending, rolling and bending machine. Each piece
covers 3 meter length.
2. Settling each piece at the required position on the floor/ground.
3. Measurement and checking the position of each component.
4. Welding each joint by using tungsten welding.
5. After the floor is accomplished then vertical frame is welded on four
frames.
6. Then the prepared sheet metal is attached with the lower frames as a side
cover by using hinge joints.
7. Painting of ant-rust and desired color inks.
8. By using crane the prepared cargo body is put on the vehicles chancy.
9. Finally the cargo body chancy and truck chancy is joined by nut and bolts.

14
 (a) (b)

(c)

Fig 2.1: (a) Production of cargo body, (b) Movable crane and (c) cargo body assembly

15
 2.2.2. Manufacturing of fuel truck body

Manufacturing of fuel truck body requires more precision than the other production since leakage
of fuel is the critical problem on it. This company produces both of fuel truck body and fuel truck
trailer in fabrication shop. In order to produce fuel truck the following procedure is used:

1. Bending of hallow rectangular bar to the circular shape.

2. Preparing the circular frame with the bar by using tungsten welding.
3. Rolling each flip of sheet metal.
4. Welding of rolled sheet metal on the frame by using oxy-acetylene.
5. Preparing each ladder by using bending machine.
6. Welding of each ladder on the chancy.
7. Welding of the circular tanker on each ladder.
8. Preparation of each partition by using welding jig.
9. Inserting and fixing each partition into the tanker.
10. Painting of ant-rust and white color inks.
11. By using crane lift and putt on the truck.
12. Attach the tanker chancy with the truck chancy by using bolt and nut.

Fig 2.2: Fuel truck trailer

16
 2.2.3. Manufactures of underground tanker

Underground tanker is used for store gasoline, diesel, and various oils in fuel and oil stations. Thus
the production of this tanker requires highest precision due to leakage and external applied load.
N.A Metal Industry & Engineering manufactured various sized tankers regard to customers order.
The procedure to manufacture this tanker are:

1. Bending of hallow rectangular bar to the circular shape.

2. Preparing the circular frame with the bar by using tungsten welding.
3. Rolling each flip of sheet metal.
4. Welding of rolled sheet metal on the frame by using oxy-acetylene.
5. Preparation of each partition by using welding jig.
6. Inserting and fixing each partition into the tanker.
7. Preparation of lids to both mouths of the tanker.
8. Painting of anti-rust chemical

Fig 2.3: Manufacturing of underground tankers

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 2.2.4. Manufacturing of vertical tankers/canopy

Vertical tankers are used for Sugar Company, cement industries and other industries. At the recent
time N.A Metal Industry & Engineering Company was manufactured some vertical tankers to
Tendaho sugar industry. The steps to manufacture this tanker are:

1. Bending of hallow rectangular bar to the circular shape.

2. Preparing the circular frame with the bar by using tungsten welding.
3. Rolling each flip of sheet metal.
4. Welding of rolled sheet metal on the frame by using oxy-acetylene.
5. Preparation of each partition by using welding jig.
6. Inserting and fixing each partition into the tanker.
7. Preparation of lids to both mouths of the tanker.
8. Preparation of vertical frames as a ladder.
9. Attach the tanker with the vertical frame.
10. Painting of anti-rust chemical white color inks.

Fig 2.4: Vertical tanker/canopy

18
2.3. Work flow in my working sections

In fabrication section there is different types of welding process. Such as, arc welding, tungsten
welding and gas welding. There is also a smooth work flow between customers and workers of this
company. All accomplished tasks of this section requires a mechanical work alone.

Fig 2.5: Work flow in my working section

19
2.4. Tasks I have been executed

During the internship period, I have been executing a number of works in different areas, which
are relevant to our field of study/department. Manufacturing process is the back bone of other
technologies. Hence manufacturing of cargo body, canopy, casony, and fuel truck trailer requires
various machining and welding process. Among those:

 Cutting
 Bending
 Rolling
 Drilling
 Threading
 Grinding
 Tungsten welding
 Oxy-acetylene welding and
 Arc-welding are major manufacturing process performed in my
working section.

Thus as a mechanical engineering student I have accomplished various tasks in my working section
according to supervisor’s order and my initiation to work. Those are:

 Quality control and supervision of the work as a formal.

 Measuring and checking of each component before production/assembling.
 Consulting and advising of workers regard to the design and manufacturing of
products.
 Welding of various products by using different welding process.
 Drilling desired holes to the production.
 Preparing and evaluating of process plan to cargo body and fuel truck trailer.
 Preparing weekly report together with my supervisor.
 Investigating and solving minor problems in the company through discussing
with my supervisor (measurement, safety, and quality problems ).
 Design welding jigs to cargo body.

20
2.5. Procedures and methods I have been following

while performing tasks

I have been following company’s rule and regulations and supervisor’s order to perform any task
during my internship period. At the beginning of any working day I have prepared myself to work
and requesting work order from my supervisor as well as from other workers. The following are
the procedures when I have been followed to perform any task. Such as:

I. Receiving work order from the worker or the supervisor.

II. Identifying weather the task can be carried out by myself or not.
III. Accepting and collecting required materials and equipment to perform the
task.
IV. If the task is complex I have asked help from others.
V. Perform the task carefully according to engineering views.
VI. Presenting and/or showing the completed work to my supervisor.

21
2.6. How good I had been in performing work tasks

I were good enough while performing my work tasks in the company. I did read manuals of
different machines, ask engineers, technicians, operators and everybody around the machine about
the machines working principle, processes, and ask everything I get confused this helps to improve
my skills. I involved in the manufacturing and work supervision carried in the company which
enables me to improve my practical skills.

22
2.7. Challenges I have been facing while performing work tasks

During my internship period I come across a number of pleasant and wonderful times in terms of
upgrading my practical skills of welding and other machining process. Hence having good practical
skill is very essential to my future work. In contrary, a number of problems have been challenging
me during the study. The following are the major problems that has been challenging me:

 In the first time it was difficult to introduce myself with the department particularly with
the engineers, mechanics, guards and other office holders. Hence I were not feel good to
ask them to introduction.
 The workers of the company are not interested when I touch any materials and equipment
in order not to take the responsibility when the materials are get damaged.
 I haven’t my own specific office to accomplish my design project and other assignments.
And also there is not enough space to take rest when I was tired.
 Reliable manuals and archived instructions have not available in each section. Even the
available manuals weren’t easily understandable.
 Most of the time mechanics and engineers were busy at work. Hence, there wasn’t enough
time to discuss with them.
 Technical and documentary library weren’t available in the company which results lack of
practical knowledge.
 Most of the mechanics do not have a plate specification and life time span. Hence adaptation
of new mechanics with in short period is difficult.
 Safety materials were not fully provided to me during work in each workshop.
 Reliable maintenances of machines weren’t adopted in each section of the company which
results delay time to work.
 There weren’t enough materials to do my design project.
 Workers lack of knowledge to help and order me during work. Hence I have taken long
period of time to understand one task.
 Lack of fair management system and bureaucracy around section managers since those
weren’t interested good response to any kind of my question.
 Pocket money from the company weren’t provided so I have faced to financial problem.

23
2.8. Measurements I have been taken to overcome the challenges

Since before I have engaged in to company, I have gathered full information about internship period
from our senor students and teachers. I have asked them, what is the internship period look like in
the company? , what difficulties can I will face and how can I over come when those challenges
are occurred?.Thus answers of those question were help to take good measurements when the
challenges are occurred.

However, it does not mean that I am fully aware, passing of those challenges have created good
experience to work. There were a dozen of challenges during my work. In order to overcome these
challenges and achieve my goal it was critical to take the right measurements as the challenges
were happen. Among those some of them are listed below. Such as:

 I have been clearly communicate with my supervisor Mr. Henok and quality
control manager Mr. Yishak about my problem. Then they were access desired
materials and equipment which are essential for me during work.
 I have collected useful manuals of available machine from individual
mechanics and engineers.
 I have discussed from my partners that were works from other companies
physically, with phone and with different social media.
 I have decided to read and refer various documents which are essential to
manufacturing and mechanical engineers.
 Even if the workers are busy I have asked them after they have finished their
tasks. Hence it helps me to done that work in the next time.
 I have referred required information to my work from different web sites.
 I have done my project at home and at various public library.
 When I was tired, I have gone to nearest café & restaurant to take rest and
recreation.
 I have respected any person who were working in the company.
 I have distributed my money effectively to required tasks and services.

24
 CHAPTER THREE
OVERALL BENEFITS FROM THE INTENSHIP
3.1. Practical skill

The main aim of internship is providing and developing practical skills with a practical real world
experience in the public or not profit sector. So the following points are mentioned in terms of
improving practical skills.

 Improving my practical skills to the operation of different machines.

 It enables me to improve my practical skills in metal works.
 It enables me to improve my measurement and accuracy skills.
 It enables me to improve maintenances of various machines.

25
3.2. Theoretical knowledge

The internship program have many benefits in this regard. Because, as we know our knowledge is
mainly based on the theory. Thus, it was necessary by any means to change or interpret the
theoretical knowledge to practical one .and it is the information, understanding and skills concerned
with ideas and principles on which a practical subject it based on the internship up grades
theoretical knowledge through:

 Working mechanism of different machineries.

 Knowing the general safety rules of each operation.
 Referring different manuals of machines.
 Improving my design knowledge.
 In enables me to have good knowledge about different types of welding.
 It enables me to have good knowledge about different types of machining process.

The internship program was very help full in up grading the theoretical knowledge. Example the
knowledge I have on manufacturing department work and how N.A Metal Industry and
Engineering manual is used for work on practice. Additionally the internship program had also
helped me how I can relate my theoretical knowledge to the working environment. Thus I think
this is very important for my future in that I will not be new for working environment.

26
3.3. Interpersonal communication skill

During the inter program I were trying to develop my interpersonal communication skill with the
process by which we exchange information feelings and face-to-face communication. I had
improved my communication skills in very good manner which I could talk to any person at the
site with confidence and easily as possible in our experience I had observed that communication
between different sections of the project is vital to attain high efficient on work

Example:

In every work needs cooperation. As I take one example of the company the
communication between the supervisor, engineers and the mechanic are
greatened. Thus I was learned from three of them. During these four months I
had been able to upgrade my speaking skill and gained confidence on how to
ask different questions to make discussion.

As a result, interpersonal communication used for:

 To improve formal communication skill.

 To make effective decision and solve problem.
 To regulate power that comes from others.
 To form contracts and maintain relationship.
 To give and gather information.
 To express personals needs and understand the needs of others.
 To attract customers toward me through good oral and written
promotion.
 To speak my idea in public and other meetings freely.
 To make good relationships with my colleagues.
 To improve my social life.

27
3.4. Benefits I have gained from improving team playing skills

Team playing skills means the activity of working well together as team to solve or shear the ideas
and challenges. When I stay in N.A Metal Industry & Engineering, I have learned that it is difficult
to go ahead with the manufacturing works without having a strong team. Teamwork is important
because, it can speed up process and make things run more efficiently and allows goals to be reacted
in an efficient and timely method. A good team will generate and further bond of trust and
confidence both in themselves and one another. This was positively affecting their self-steam,
confidence in their colleagues, and possibly their loyalty to the company increasing productivity
and ultimately, company profit. I have developed the following values after improving team plying
skills when I stay in N.A.

1. Commitment:
I have improve the ability to take commitment towards something weather it is good or
not. This helps to improve my encouragement and initiation to accomplish any task with
in the given period of time. And also I have a commitment to work any tasks with team.
2. Communication:
After improving team plying skill, I have shared and discussed my idea freely with others.
Hence it is crucial to be able to communicate openly and honestly.
3. Decision-making:
I can make any decision effectively with regard to my and other circumstances. The
teamwork skill of effective responsible decision-making is arises the decision making
process.

4. Punctuality:
Being punctual is the first element while we perform any tasks with in a team. Thus after
improving team plying sill, I have respect any appointment with anyone. Whenever the
time is not suitable for me, I will adjust and compromise it during the appointment.
5. Tolerance of diversity:
I have tolerate any idea and behavior which arises from various persons.
6. Respecting others:
I have respect anyone since he is man alone.

28
3.5. Benefits I have gained from improving leadership skills

Leader ship means the position being a person who lead/guide and group of people in an
organization. Therefore, during the internship period in N.A I have developed my leadership skills.
To achieve leader ship skills require a high level of commitment to learn from each experience. I
have observed that a good learner is well principal individual who is focus one common goal and
eliminate excess fear and other doubt from his employer and work for a common goal. During
these time I have been able to observe that one should have great skills to be a leader ship, these
are:

 Great listener.
 Take owner ship and responsibility.
 Communicate effectively.
 Commitment, integrity and passionate.
 Good management skill.
 En courage others through positively.
Thus I have improved the following values after improving leadership skills.

1. Taking responsibility:
I have taken any responsibility which are essential to my work. Hence leadership
requires taking a responsibility of tasks, agreements and protocols.
2. Loyalty:
I am being loyal to serve my customers, servants, companies and country since
am employed through those elements.
3. Self-confidence:
Good leadership by itself requires very confidence educated person. Thus I have
good self-confidence to achieve my goal and manage others.
4. Confidential/keeping secret/
I have kept companies secret when I will employed.
5. Unbiased decision maker

29
3.6. Benefits I have gained in terms of understanding Work ethics

Work ethics are standards, principles or values that are generally based on conscientious. Mostly
work ethics are thought to a benefit of a person morally, thereby improving their character. Work
ethics is the core idea when you are in some staff, sounder standing of work ethics is crucial, the
internship program helps to me:
 To respect the entrance and working time in the company being punctuality.
 To respect others in the work place.
 To prevent any kind of corruptions.
 To respect any kinds of job.
 To prevent me from addicted drugs in the workplace.
Additionally I have gained a good work ethics, such as:
 Reliability
 Dedication
 Productivity
 Cooperation
In fact, I am not sure ta say I understand all of work ethics, I will respect the above work ethics.

30
3.7. Benefits I have gained from entrepreneurship skills

Application of energy and position towards the creation implementation of new idea and creative
solutions essential in gradients includes the willingness to take calculated risks. In terms of time,
equity or career, the ability to formulate an effective venture team, the creative skill of building
solid business plans and finally the vision to region opportunity where others see chaos,
contradiction and confusion. During internship program at N.A Metal Industry & Engineering I
have developed the following levels of entrepreneurial development.

 The self-employed mind set.

 The attitude of owner(leader)
 The entrepreneurial investor.
 The true entrepreneur.

31
 CHAPTER FOUR

DESIGN OF WELDING JIG TO CARGO BODY

4.1. Introduction

Jigs are special purpose tools which are used to facilitate production like machining, assembling
and inspection operations. The mass production of work-piece is based on the concept of
interchangeability according to which every part produced within an established tolerance. Jigs
provide a means of manufacturing interchangeable parts since they establish a relation with
predetermined tolerances, between the work and the tool. Once the jig is properly set up, any
number of duplicate parts may be readily produced without additional set up.

Increasing the productivity and accuracy are the two basic aims of mass production. As we know
the solution to this is by reducing the set up cost of the machine and also reducing the manual
fatigue. In this case the device that caters our needs is the use of jigs. Let us take one example. Let
us consider that one gets an order of say 1000 products. There need to be three holes drilled on this
product. In such a case the designer tries to draw out every single hole with the help of square,
straighteners, scribers and center hole. In order to align the axis of the hole with the axis of the drill
we generally go for trial and error method. Accuracy is the main problem in such cases. In doing
so it increases the work load on the operator. Hence using of jig to position and guide the tool to
its right path is preferred rather than using scribers, square, straighteners or center punch etc.

In NA Metal Industry also cargo body assembly was performed on the ground alone without the
help of clamping tool. Thus to assuring workers safety, accuracy, to reduce manufacturing time
and labor fatigue using jig is essential. Thus the productivity is increased which is done by
eliminating individual positioning, marking and frequent checking. Interchangeability is the chief
advantage here. All the parts fit in properly except only the similar components are interchangeable.
One does not need to repeatedly clamp and unclamp the object for various purposes like positioning
as the locating, clamping and guiding of the part is done by the jig itself.

32
4.2. Background of the study

Starting from the time of mass production beginning in manufacturing industry until now, how to
manufacture with in less time and low cost? Is the major question of all manufacturing industries?
Thus to answer those questions manufacturing engineers have been design and manufacture
various type of jig and fixture at different time.

Before the birth of JUSES CHRIST in civilized state and town fixtures made from wood and rock
is used to manufacture ceramics and mica household equipment. This fixture was used as a pattern.
Countries like Egypt and Roman states were employed those type of technology.

After the birth of JUSES CHRIST around 18th and 19th century various type of jig and fixture are
started to make from metal and other materials. Those jigs and fixtures used for different
manufacturing process like drilling, milling, welding, boring and treaming.

Now a days also jig and fixture are designed and manufactured to maintain mass production. In
China many things are produced with the help of jig and fixture to maintain safety and to decrease
time wastage. In NA Metal Industry also jig is available to produce botti alone.

33
4.3. Statement of the problem
4.3.1. Major problem

Unavailability of applicable jig to produce cargo body in NA Metal Industry workshop.

4.3.2. Sub problems

 The absence of tool guiding elements to ensure correct positioning of the part during assembly of
cargo body in NA Metal Industry.
 More time wastage during the assembly of the cargo body in NA Metal Industry.
 Labor fatigue during positioning, adjusting and checking the proper orientation of the part
during assembly of cargo body in NA.
 Higher manufacturing cost of cargo body in NA.

4.4. Objective
4.4.1. General objective

To design a welding jig that holds a cargo body assembly in N.A Metal Industry & Engineering.

4.4.2. Specific objectives

 To minimize manufacturing cost of the cargo body.

 To address workers safety.
 To avoid time wastage for repetitive poisoning and checking of part.
 To maintain product quality.
 To increase production quantity.
 To increase design and manufacturing potential of local company.

4.5. Scope and limitation

All cargo bodies which have 7000mm length and 2500mm width is assembled on this jig. Due to
its flexibility the jig is used for produce a cargo body at anywhere and anytime. Hence the jig can
assembled and disassembled easily through its screwed joint. All the required parts and accessories
of the cargo body is settled and punted on this jig. And then the desired machining /welding/
process is accomplished easily. All workers who can produce a cargo body in N.A is beneficial.

34
 (a)

(b)

Fig 4.1: Manufacturing of cargo body without using welding jig.

35
4.6. Presentation and design analysis

Fig 4.2: Isometric view of the jig.

36
4.6.1. Design specifications and assumptions
 The weight of jig components are negligible with relative to cargo body weight.
 Geometrical size of each component was selected based on its cost and compactness.
 Thermal effect due to welding is neglected minimize design complexity.
 Maximum total masses of cargo body assembly / frame ,chancy, upper omega, lower
omega, and twist lock/
𝑀 = 3000𝑘𝑔
 Maximum length of the cargo body.
𝐿 = 7000𝑚𝑚
 Maximum width of the cargo body.
𝑊 = 2500𝑚𝑚

Table 4.1: Size of each component of the cargo body

In (mm) Front Back Side Chancy Upper Lower
frame frame frame omega omega
Length 2500 2500 7000 7150 2500 7000
(L)
Width 90 90 90 90 150 120
(w)
Height 150 150 150 230 90 90
(h)

 Cross-section of beam and column of the jig.

𝐿 = 100𝑚𝑚 𝑡 = 100𝑚𝑚

𝑤 = 100𝑚𝑚

 Cross-section of side supporter.

𝐿 = 30𝑚𝑚

𝑤 = 100𝑚𝑚

37
4.6.2. Tabulated data

Table 4.2: Indian standard designation of steel according to IS.

Indian standard Tensile strength Yield stress Uses as per IS

Designation (minimum in (minimum in
N/mm2) N/mm2)
Fe 290 290 170 It is used for plain drawn or enameled
parts, tubes for oil well, casing, steam,
water and air passage, motor cycle,
cycle and automobile tubes, rivet bars
and wires.
Fe 310 310 180 Used for locomotive carriages and car
structures, screw stock and other
general engineering purposes.
Fe E 230 310 230 Locomotive carriage and car
structures, screw stock and other
general engineering purposes.
Fe 540 540 320 Used for locomotive carriage, wagon
and tramway axles, arches for mines
bolts, seamless and welded tubes.

Table 4.3: Dimension of screw threads, bolts and nuts according to IS.

Designation Pitch Nominal Minor Minor Pitch Depth Stress

(mm) diameter(mm) dia. dia.(mm) dia. of area
(mm) (nut) (mm) thread mm2
(bolt) (nut and (bolt)
bolt) mm
M14 2 14 11.546 11.835 12.701 1.227 115
M16 2 16 13.546 13.835 14.701 1.227 157

38
4.6.3. Design of part one

This is the first section of the jig which covers 2362mm. it also consists different sized beam,
column and auxiliary side supporter.

Fig 4.3: Isometric view of part one

4.6.3.1. Design of beam one

Fig 4.4: Isometric view of beam one.

This is the major beam of part one and it is permanently joined on the side of this part. It has
supported with four vertical columns.

Total weight of the cargo body, 𝑊 = 𝑚𝑔

𝑊 = 3000𝑘𝑔 × 9.81𝑚/𝑠2 = 29430𝑁

39
Thus weight applied on part one is one-third of the total weight applied on the jig.

1 1
Average weight applied on part one,𝑊1 = 3 𝑊 = 3 (29430) = 9810𝑁

Average total weight of the frame, 𝑊𝑓 = 1000𝑘𝑔 × 9.81𝑚/𝑠2 = 9810𝑁

𝑊𝑓 9810𝑁
Distributed load on four side’s beams of the jig is , = = 2452.5𝑁
4 4

Thus distributed load on beam one is, 𝑤1 = 2452.5𝑁/2362𝑚𝑚 = 11038𝑁/𝑚

Fig 4.5: Distributed load on beam one

Thus by using moment distribution method:

Stiffness of each span:

𝐼𝑎𝑏 1 𝐼𝑏𝑐 1
KAB = 𝐿𝑎𝑏 = 0.355 =2.82 KBC = 𝐿𝑏𝑐 = 0.619 = 1.62 , KCD = 1.62 , KDE = 1.62

Relative stiffness of each span:

𝐾ab 2.82 1.62

K’AB = min(𝐾𝐴𝐵,𝐾𝐵𝐶,𝐾𝐶𝐷,𝐾𝐷𝐸) , K’AB = 1.62 = 1.74 , K’BC = 1.62 = 1 , K’CD = 1, K’DE =

KAB 2.82
DFBC = = =0.635
KAB+KBC 2.82+1.62

𝐾𝐶𝐵 1.62
DFCB = 𝐾𝐶𝐵+𝐾𝐶𝐷 = 1.62+1.62 = 0.5

DFCD = DFDC = DFDE = 0.5

40
Table 4.4: Moment distribution iteration for beam one

41
Section AB

∑ 𝑀A = 0

0.355
25.69 + 𝐵1(0.335) − 3.5 − 1038 (0.355)( )=0
2

25.69 + 𝐵1(0.355) − 3.5 − 65.4 = 0, B1 = 121.7

∑ 𝐹𝑦 = 0

𝐴 + 𝐵1 − 1038(0.355) = 0 , 𝐴 = 246.79

Section BC

∑ 𝑀B2 = 0

35.26 − 25.69 + 𝐶1(0.619) − 1038(0.619)2 = 0, C1 = 305.8N

∑ 𝐹𝑦 = 0

𝐵2 + 305.8 − 642.522 = 0 , 𝐵2 = 336.7, thus, 𝑩 = 𝐵1 + 𝐵2 = 121.7 + 336.7 = 458.4𝑁

42
Section CD

∑ 𝑀C2 = 0

(0.619)2
35.26 − 32.61 − 1038 + D1 (0.619) = 0, D1 = 316.98N
2

∑ 𝐹𝑦 = 0, 𝐶2 = 458.4

C = 305.8 + 458.4 , 𝑪 = 764.2𝑁

Section DE

∑ 𝑀D2 = 0

(0.619)2
33.4 − 32.61 − 1038 + 𝐸(0.619) = 0, 𝐸 = 319.98 𝑁
2

∑ 𝐹𝑦 = 0

𝐷2 + 319.98 − 642.522 = 0, 𝐷2 = 322.54𝑁

D = 316.98 + 322.54 , 𝑫 = 639.52

43
 Internal reactions

Section AB: (𝟎 ≤ 𝒙 ≤ 𝟎. 𝟑𝟓𝟓)𝒎

∑ 𝐹𝑦 = 0

247 − 1038𝑥 − 𝑉 = 0, 𝑉 = −1038𝑥 + 247

∑𝑀 = 0

𝑀𝑏 = −519𝑥 2 + 247𝑥

Section BC: (𝟎. 𝟑𝟓𝟓 ≤ 𝒙 ≤ 𝟎. 𝟗𝟕𝟒)𝒎

∑ 𝐹𝑦 = 0 , 𝑉 = −1038𝑥 + 705

∑ 𝑀 = 0 , 𝑀𝑏 = −519𝑥 2 + 705𝑥 − 162.6

44
Section CD: (𝟎. 𝟗𝟕𝟒 ≤ 𝒙 ≤ 𝟏. 𝟓𝟗𝟑)𝒎

∑ 𝐹𝑦 = 0 , 𝑉 = −1038𝑥 + 1469

∑𝑀 = 0 , 𝑀𝑏 = −519𝑥 2 + 1469𝑥 − 907

Section DE:(𝟏. 𝟓𝟗𝟑 ≤ 𝒙 ≤ 𝟐. 𝟐𝟏𝟐)𝒎

∑ 𝐹𝑦 = 0

𝑉 = −1038𝑥 + 2132

∑𝑀 = 0 ,

𝑀𝑏 = −519(2.362 − 𝑥)2 − 320𝑥 + 756

45
Fig 4.6: Shear force and bending moment diagram of beam one

Thus the maximum moment, 𝑀𝑚𝑎𝑥 = 161𝑁𝑚

46
 Area moment of inertia of the cross-section

1
𝐼 = 12 [(0.13 × 0.1) − (0.093 × 0.09)]

= 2.86 × 10−6 𝑚4

0.1
𝐶= = 0.05𝑚
2

𝑀𝑚𝑎𝑥 ×𝐶 161𝑁𝑚 ×0.05𝑚

Thus σ𝑎𝑙𝑙 = = = 2.8𝑀𝑃𝑎
𝐼 2.86×10−6 𝑚4

σ𝑚𝑎𝑥 = σ𝑎𝑙𝑙 × 𝐹𝑂𝑆 = 2.8𝑀𝑃𝑎 × 4 σ𝑚𝑎𝑥 = 11.2𝑀𝑃𝑎

Therefore from Table 4.2 Fe 290 Indian standard steel is used. Which has:

Minimum yield stress σy = 170MPa

Minimum tensile strength σt = 190MPa

4.6.3.2. Design of beam two

This beam is available in the front side of the jig. It supports the load of front frame and some loads
of upper omega and chancy.

Fig 4.7: Isometric view of beam two

47
 2452.5𝑁
Thus distributed load on beam two is , 𝒘2= = 2692𝑁/𝑚
0.911𝑚

Fig 4.8: Distributed load on beam two

∑ 𝑀𝑏 = 0 , thus RA = RB

∑ 𝑀𝑐 = 0 , RA (0.911) + RB(0.455) − (2452)(0.455) = 0 thus RA = RB = 559N

∑ 𝐹𝑦 = 0 559 + 559 + 𝑅𝑐 = 2452 Thus, 𝑹𝒄 =1118N

Internal reactions

Section AB: (𝟎 ≤ 𝒙 ≤ 𝟎. 𝟒𝟓𝟓

∑𝐹 = 0 , 𝑉 = −2692𝑥 + 559

∑𝑀 = 0 , 𝑀 b= −1346𝑥 2 + 559𝑥

48
 Bending moment diagram

Fig 4.9: Shear force and bending moment diagram of beam two

Thus 𝑀𝑚𝑎𝑥 = 24.3𝑁𝑚 and 𝐶 = 0.05𝑚

24.3𝑁𝑚 ×0.05𝑚
σ𝑎𝑙𝑙 = 2.86×10−6 𝑚4
= 4.2𝑀𝑃𝑎 And 𝛔𝒎𝒂𝒙 = 4.245 × 4 = 17𝑀𝑃𝑎

49
Therefore from Table 4.2 Fe 290 Indian standard steel is used. Which has

Minimum yield stress σy = 170MPa

Minimum tensile strength σt = 190MPa

4.6.3.3. Design of beam three

This beam is also available on the front side of the jig and it carries the load of the chancy.

Fig 4.10: Isometric view of beam three

Average load applied by the chancy which applied on beam three is, Wc1 = 𝟐𝟎𝟎𝑵 = Wc2

Fig 4.11: Applied load on beam three

∑ 𝐹 = 0 , thus by symmetry, RA= RB = 200N

50
Therefore 𝑴𝒎𝒂𝒙 = 200𝑁 × 0.105𝑚 = 21𝑁𝑚

21𝑁𝑚 ×0.05𝑚
σ𝑎𝑙𝑙 = = 3.7𝑀𝑃𝑎 And σmax = 3.7 × 4 = 14.8𝑀𝑃𝑎
2.86×10−6 𝑚4

Therefore from Table 4.2 Fe 290 Indian standard steel is used which has:

Minimum yield stress σy = 170MPa

Minimum tensile strength σt = 190MPa

4.6.3.4. Design of beam four

This beam carries the total weight of upper omega and some weight of lower omegas.

Fig 4.12: Isometric view beam four

Average distributed weight of upper omega, Wu= 500𝑁/𝑚 and load from lower omega is
negligible relative to load from upper omega.

51
Fig 4.13: Distributed load applied on beam four

Thus by symmetry, RA = RB= 𝟐𝟐𝟖𝑵

Maximum moment is occurred at the mid span of the beam. Which is

0.911 0.9112
𝑀𝑚𝑎𝑥 = 228 ( ) − 500 ( ) = 35𝑁𝑚
2 6

35𝑁𝑚 ×0.05𝑚
σ𝑎𝑙𝑙 = = 6.1𝑀𝑃𝑎 And σ𝑚𝑎𝑥 = 6.1 × 4 = 24.4𝑀𝑃𝑎
2.86×10−6 𝑚4

Therefore from Table 4.2 Fe 290 Indian standard steel is used. It has

Minimum yield stress σy = 170MPa

Minimum tensile strength σt = 190MPa

4.6.3.5. Design of column

There are 43 columns in this jig to overcome all types of load which come from the weight of the
cargo body assembly. All of them are a fixed ends type of column. They are designed based on the
maximum load applied on them and the longest column. The marketing /purchasing/ process is
simplified by manufacturing them with similar material. Therefore all columns have similar cross-
section.

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 (a) (b)

Fig 4.14: (a) Isometric view of column and: (b) maximum applied load on column

Cross-sectional area 𝐴 = (0.1 × 0.1) − (0.09 × 0.09), 𝑨 = 1.9 × 10−3 𝑚2

𝑃 764𝑁
Thus normal stress σ = 𝐴 = 1.9×10−3 𝑚2 = 0.4𝑀𝑃𝑎 and σmax = 0.4 × 4 = 1.6𝑀𝑃𝑎

Therefore from Table 4.2 Fe 290 is used. It has

Minimum yield stress σy = 170MPa

Minimum tensile strength σt = 190MPa

Design to buckling:

Effective length for fixed ends column 𝐿𝑒 = 0.5𝐿 = 0.5 × 0.5𝑚 = 0.25𝑚

1
Area moment of inertia 𝐼𝑥𝑥 = 𝐼𝑦𝑦 = 12 [(0.13 × 0.1) − (0.093 × 0.09)], 𝑰 = 2.86 × 10−6 𝑚4

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Modulus of elasticity for steel 𝐸 = 200𝐺𝑃𝑎

𝐼 2.86×10−6 𝑚4
Radius of gyration 𝐾𝑥𝑥 = 𝐾𝑦𝑦 = 𝐾 = √𝐴 = √ 1.9×10−3 𝑚2 = 0.039𝑚

𝐿𝑒 0.25𝑚
Slenderness ratio = = 6.4
𝐾 0.039

𝜋 2 𝐸𝐼 𝜋 2 ×200×103 ×2.86×10−6 𝑚4
Critical load; 𝑃𝑐𝑟 = = = 90.3𝑀𝑁
𝐿𝑒 2 (0.25)2

𝜋2 𝐸 𝜋 2 ×200×103
Critical stress; 𝜎𝑐𝑟 = (𝐿𝑒/𝐾)2 = = 48𝐺𝑃𝑎
(6.4)2

Therefore buckling is occurred after the material yields. Hence its critical stress is greater than its
yield stress. So the column is safe to buckling. Fe 290 is used.

Thus the other column and beam is manufactured from similar materials of beam one, beam two,
beam three, beam four and column one. Since the load applied on them is similar with the other
beams and columns. Therefore part one is similar with the other part.

4.6.4. Design of bolt and nut

The bolt and nut is used for joined each parts together. There is no external applied on the bolt and
nut rather than internal forces (screwed up forces). Hence, the design is based on the effect of
screwed up forces alone.

Regarded to manufacturing cost, material cost, and compactness of the stand, from Indian standard
of coarse series M16 bolt is used.

Thus; initial tension in bolt∶

𝑷𝒊 = (1420𝑑)𝑁 , Where d is nominal diameter of the bolt in mm.

= (1420 × 16)𝑁 = 22720𝑁

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 From Table 4.2 for M16 bolt, stress area = 157mm2

𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑡𝑒𝑛𝑠𝑖𝑜𝑛
Therefore; safe tensile stress = 𝑠𝑡𝑟𝑒𝑠𝑠 𝑎𝑟𝑒𝑎

𝑃𝑖 22720𝑁
𝛔𝐬 = 𝐴𝑠 = 157𝑚𝑚2 = 144MPa

Allowable tensile stress = 144MPa× 4 = 578MPa

Thus from Table4.1: Fe540 steel is used:

Which has:

Minimum yield stress = 320MPa

Minimum tensile strength = 540MPa

Fig 1.15: Isometric view of bolt and nut assembly

Then shear stress on the nut due to initial tension is:

𝑷𝒊
 = 𝝅𝒅×𝒃×𝒏 Where b and n are width of thread section at the root and number of threads

engaged respectively.

22720
 = 𝜋×14×1.6×7 = 46𝑀𝑃𝑎

According to maximum shear stress theory of failure,max = 0.5σy

max = 0.5 × 320MPa = 160MPa ; It is also safe

Therefore the bolts and nuts are made up of Fe540 Indian standard steel of M16.

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4.6.5. Design of welding

All the welded joints formed with square butt joint since the joint is formed at its edge without
requiring overlapping.

4.6.7. Working principles of the designed equipment

This jig doesn’t required neither mechanical nor mechanical energy rather it requires safety. It used
as a guide to maintain each piece of the cargo body on its desired place. The working procedures
are:

 Measure and cut required size and shape of frame, chancy, upper omega and lower
omega.
 Putt each piece of chancy on its guide.
 Putt each piece of frame on each side of the jig beam.
 Putt each piece of upper omega on its guide beam.
 Putt each piece of lower omega on its guide.
 Weld each joint of the cargo body assembly.
 Weld other accessories of the cargo body (twist lock, winch and hooks).
 Pick up the assembly with overhead crane and putt it on the cargo body truck.
 Repeat this process to produce mass production of the cargo body.

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4.6.8. Cost analysis

Table 4.5: Materials costs

Thus, total material cost= 16028.15𝑏𝑖𝑟𝑟

Labor cost = 1400𝑏𝑖𝑟𝑟

Machining cost = 1200𝑏𝑖𝑟𝑟

Total cost = 1000𝑏𝑖𝑟𝑟 + 980𝑏𝑖𝑟𝑟 + 2165.1𝑏𝑖𝑟𝑟

= 𝟏𝟖𝟔𝟐𝟖. 𝟏𝟓 𝒃𝒊𝒓𝒓

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4.7. DETAIL DRAWING

Part one

Part two

58
Part three

Nut and bolt assembly

59
Assembly drawing

60
CONCLUSION

N.A Metal Industry & Engineering is one of interesting company in Ethiopia since it manufactures
various products. It is a well-organized and well-equipped as result of this it has a lot of customers
in a short period of time. The working environment of its branch is suitable for heavy duty vehicles.
Hence any products of this company are well-transported to everywhere. Every activity in the
company is accomplished based on its scheduled plan. The plan is based on working time and
credits of task. Thus heavy duty work takes more credit than simple tasks. Every work order is
delivered from the design center and implemented in its respective workshop.

N.A Metal Industry & Engineering didn’t have welding jig to cargo body. Thus designing of
welding jig is very essential in the fabrication work. It increases production quantity of the cargo
body in short period of time. Workers safety and quality of production are achieved with this
welding jig. Welding jig to cargo body is manufactured from local products of steel in fabrication
shop of N.A Metal Industry & Engineering Company. The design analysis of this jig is based on
cargo body assembly weight. This project minimizes manufacturing cost, time and labor with high
precision. Fabrication of this welding jig requires low material cost and it is manufactured by using
arc welding alone.

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RECOMMENDATIONS

The opportunity to engage in this interesting company should be broad since there is various
practical activities. The applied bruicracy should be minimized to maintain higher workers life
span in the company. Internship student should be count as one worker during any task. All required
facilities should be full filed to implement students’ theoretical knowledge on practical activities.
Pocket money to internship student should be earned since it increases students’ work interest.

Working environment should be clean and fresh which maintain workers safety and production
quality. Measurements error shouldn’t be compromised because it has greater impact on the
production. Advanced welding method should be implemented in fabrication shop to produce huge
frames and structures. All mass productions should be manufactured by using their appropriate
jigs.

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REFERENCES

Text book of machine design, R.S. Khurmi and R.J. Gupta, 2005………………………………….1

Shigley’s mechanical engineering design, Budynas Nibett, 8th edition………………………….....2

http://engineeringhut.blogspot.in/2010/11/types-of-drilling-jigs.html ......................................................3

http://chestofbooks.com/crafts/machinery/Shop-Practice-V1/Jigs-And-Fixtures.......................................4

http://mechanicaldatahelp.blogspot.in/2011/04/clamping-fixtures............................................................5

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