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Tire Changing
Dvj,h,l Mechanism 2012
WOLKITE UNIVERSITY
COLLEGE OF ENGINEERING & TECHNOLOGY
Department: - MECHANICAL ENGINEERING

Internship Hosting Company: - UNITED AUTOMAINTENACE SERVICE PLC
Duration:-FOUR CONCICUTIVE MONTHES

PREPARED BY
 Samrawit Mehari…………………………………………………….
 Surafel Solomon…………………………………………………….. 816/08
 Teklu Gebremedhin………………………………………………..... 849/08
DATE OF SUB:-
Adviser Mr.kassahun
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Deceleration
We want to declare that internship practice has been done from march/24/2019-
july/20/2019. We have been working in practical in all workshops of the company.
And do a research on the influence of current maintenance performance in the
production and profit of the company and do a project valve lapping machine.
Approved by
Approval of supervisor: …………………………………………………..
Approval of mentor: ……………………………………………………….
Student signature: ………………………………………………………….
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Acknowledgment
First of all we would like to thank our GOD for being with us in every
Challenge and in our project work. After this we would like to express our
Heartfelt gratitude to united automotive maintenance staff members starting from
the upper management office up to the lower mechanic employers Who helped us
to complete this project and achieve the project objective .And also we would like
to thank our adviser engineer Kassahun who was always with us in every challenge
we had passed. Finally we are very glad to say thanks for all colleagues and those
people who contribute their own hand in our internship.
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Contents
ABSTRACT 6
CHAPTER ONE 8
1 HISTORY & BACKGROUND OF HOSTING COMPANY 8

1.1.1 UNITED AUTO MAINTENANCE SERVICE PLC 8
1.1.2 Service and products of the company 8
1.1.3 Main customers of the company 9
1.1.4 Future Growth Strategies 9
2 OVER ALL INTERNSHIP EXPERIENCE AND WORK SECTION 13
2.1 DESCRIPTION ON HOW WE GET INTO THE COMPANY 13
2.1 Section of the company we have been working 13

2.1.1 Engine section 13
2.1.2. Light vehicle section 15
2.1.3 Heavy duty shop Section 16
2.1.4 Electrical sections 17
2.1.5 Body section 19
3 Overall Internship Benefit 21

3.1 Practical skill 21
3.2 Theoretical knowledge 22
3.3 Interpersonal communication skill 22
3.4 Team playing skill 23
3.5 Leadership skills 23
3.6 Work ethic 23
3.7 Entrepreneurship skills 24
1.1 Statement of the problem 24
1.2 Project objective 25
1.3 Project Specifications 25
1.4 Application 25
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CHAPTER TWO: LITERATURE REVIEW 27
2.1 Project back ground 27
2.2 PRIVIOUS WORK 27
2.3 Similar Mechanism 28
2.4 Comparative Study 31
CHAPTER THREE: SYSTEM DESIGN 33
3.1 Design Constraints 33
3.1.1 Safety 33
3.1.2 Social & Economics 33
3.1.3 Engineering Standards 33
3.1.4 Manufacturability 33
3.1.5 Time 33
3.1.6 Quality 33
3.2 Design Methodology 33
3.4 Design Considerations for a Gear Drive 38
CHAPTER FOUR: SYSTEM TESTING AND ANALYSIS 49
CHAPTER FIVE: SYSTEM TESTING AND ANALYSIS 51
5.1 Project Plan 51
CHAPTER 6: SUMMARY AND CONCLUSIONS 53
Comparison between before and after design 53
CHAPTER 7: CONCLUSIONS AND FUTURE RECOMMENDATIONS 54
RECOMMENDATION 54
REFERENCES 55
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Abstract
In our project we try to identify some problem and tried to solve it. As we all
know tire changing mechanism is a very tired and continuous work in automotive
industry. So in our project we try to reduce the labor force and time consumed in
changing mechanism. In this project we have designed and try to manufacture an
automotive tire changing mechanism using a gear train to unscrew and screw lug
nuts simultaneously. The mechanism simply work by applying power on driver
gear causing, all gears connected to spanners to move at the same time additionally
our design is environmental friendly because the materials we use starting from the
gear most of the materials are spare materials. So our project can be useful and
usable in many places such as simple garages, workshops and tire manufacturing
companies.
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PARAMETERS SYMBOLS UNITS
Pitch circle diameters PCD Mm

Module M Mm
Center distance C Mm
TEETH N Magnitude
Gear materials
Nut sizes Mm
Speed N Rev/s
Power P Kw
Torque T N.M
Catalog C10 KN
Section modules S M
Polar moment of inertia I M
Max shear stress Pa
Stress Pa
Desired life in hours Revolution
Rating life in hours Revolution
Safety of factor SOF Ratio
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CHAPTER ONE
1 History & Background of Hosting Company

1.1.1 UNITED AUTO MAINTENANCE SERVICE PLC
United Auto Maintenance Services Pvt. Ltd. Co. (UAM), a member of the MIDROC Technology Group,
was established in May 2007 and engaged in Auto Maintenance Services and Selling of different type of
spare parts of vehicles. The Company is established to accomplish the following Business Purposes: Body
repairing and painting of Vehicles, Trucks and Trailers; General Preventive Maintenance and repair
including Electrical and Tire repairs; Vehicle washing & greasing; Providing road breakdown services
including wrecker services, lamps, electric machines, appliances and spare parts; Providing Annual
Inspection Services; Importing & Selling spare parts; Providing general metal works in respect to
Vehicles, Trucks & Trailers; Providing consultancy and training services regarding the above business;
Providing fuels and Lubricants dealing services & Tire repair and wheel balancing services.
The company is mainly engaged on maintenance of different type of vehicles product and services are
listed as follow:-
 Automobile Maintenance
 Trucks, Buses & Line Maintenance
 Component Overhaul &Body Repairing
 Tools and Lubricants
 Auto Electric Maintenance
 Injection Pump Calibrating
 Inspection Test Lane Service
 New and Used Vehicles sales
 Towing service
 Agency Service
The overall activates of the company are managed and administrated by Sheik Mohammed Hussein Ali
Al-Amoudi is chairman and owner of MIDROC Ethiopia, Dr. Arega Yirdaw Chief Executive
Officer(CEO) of MIDROC Technology Group and General Manager, MIDROC Gold mine plc and
Mr.Meseret Sgarew General Manager of united Auto maintenance Services. In general United Auto
Maintenance Company is organized to maintain different type of cars for the midroc companies.
1.1.2 Service and products of the company

Production
 ETOS (Engineering and Technical Operation Service )
 Maintenance Control and planning service
 Trucks ,use and Trailer maintenance service
 Automobile maintenance service
 Component overhaul maintenance service
 Body maintenance service
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Service
 Marketing and customer service
 Human resource service
 Financial service
 Quality assurance unit
1.1.3 Main customers of the company

United Auto-Maintenance gives its services and products to different governmental organization,
non-governmental organizations, private limited companies and personal level customers.
 Some of the governmental organizations are: commercial bank of Ethiopia.
 Some of the non-governmental organizations are: Sister companies like Kospi, gold mining
company, and other group of MEDROC companies
 Some of the private limited companies are: king long buses, sun chips company vehicle.
Figure 1.1 Main customers of the company
1.1.4 Future Growth Strategies

Providing quality services to MIDROC Ethiopia Technology Group Companies vehicles with the motto
to be a “Frist class maintenance base”. In the near future Gas station shall be constructed & mobile
inspection test lane service shall be implemented.
1.5 Work flow of the company
Like any other company, United Auto-Maintenance, also has its own structural organization and work
flow path which includes the managing and other departments. Sheik Mohammed Hussein Ali Al-
Amoudi is chairman and owner of MIDROC Ethiopia, Dr. Arega Yirdaw Chief Executive Officer(CEO)
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of MIDROC Technology Group and General Manager, MIDROC Gold mine plc and Mr.Meseret Sgarew
General Manager of united Auto maintenance Services.
MARKETING AND SALES SERVICE

GENERAL MANAGER
Job card for invoice delivery & 17
Marketing & Sales Service
Vehicle get pass approval invoice 16
Invoice 15 invoice
1 2 info. (to give appoint.)

Contract Planning
Administrator Costing
Veh. with mainte. Invoice 14
Request 2 Additional remarks
Work order for approval
Work order + receiving &

Quality
Receptionist Assurance
Delivery from 3 4 Work order + vehicle 12
input
Vehicle delivery Work order + additional
Inspector
To customer 14 Remarks if any 6
inspection
7 repaired vehicle handover 5

before repair
Open job cards 13 & after repair
Job Inspection
Dispatcher lane Inspector
10 Repaired vehicle handover
10 Rework vehicles
Closed job cards summery

ETOS maintenance
Job card to be allocated Control
9
New card Closed Job card 10 11
8 Vehicle to Workshop
Work shops
Closed Job card + invoice summery
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Figure 1.2 work flow of market and sales service
Quality Assurance Unit

GENERAL MANAGER
Report
Quality Assurance unit
9 Report 9 Report Report 9

8
Completed Vehicle 2 Input inspection
Marketin Input/ In-
Inspecti
g & sales 1 output process
on lane
service inspector inspector
Vehicle with work order 7 Output Inspection
Work order + additional 3

Remarks if any
 Any vehicle
Repaired vehicle
coming for  Follows up if every
4 maintenance workshops using
Job card ETOS Rework
will be the necessary
Maintenance inspected by formats for the
control the inspection specific requested
5 lane repairs
Job card  Gives annual  Follows up the
inspection neatness of the
4 Vehicle to Repair Work Shops 6
lane service workshop
for external  Makes sure that
customers the inter-workshop
relation regarding
the requested
repairs is taken
place smoothly
Figure 1.3 work flow of quality assurance unit
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Engineering and Technology Operation Service
GENERAL MANAGER
Reports
DIRECTOR ENGIEENRING & TOS
Reports
Reports
Marketin
g & sales Reports
Veh. With maint. request service

Manager’s
Maintenan
hanger
Reception Job ce
Vehicle to customers maintenance &
Dispatching planning &
workshops
planning costing costing
invoice preparation Reports
Completed Vehicles/ components with
Replaced parts return to the reception/ marketing
Workshops Job card

supervisors analyst &
& senior maintenance
Input supervisors clerks
Output
Inspector
Vehi. For addit. Input
Inspection Maintenance Job card

Inspection
Lane approval
Completed for final inspection/ if not
Ok, rework
Workshop
If remarks found, return to workshop forTechnicians
Approved parts request
Rework
Store raises
Vehicles/ components to be repaired
SIV &
Replenishes
Figure 1.4 Work flow of engineering and technology operation service stock
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1.2 OVER ALL INTERNSHIP EXPERIENCE AND WORK SECTION

1.2.1 DESCRIPTION ON HOW WE GET INTO THE COMPANY
At the end of 3rd year we given an application paper to give to several company we want to intern and we
apply at United Auto maintenance (UAM) and they were happy to accept us in to their company in next
year internship program and we take our acceptance letter to our university. When the time comes we go
back to our host company to start our internship.
The first day we got into the company we joined the company’s human resource department. Then we
were sent to the workshops.
1.2.1 Section of the company we have been working

1. Engine section
2. Light duty vehicle section
3. Electrical section
4. Heavy duty vehicles section
5. Body section
1.2.1.1 Engine section

In this section mainly engine maintenance is performed. When a vehicle has a problem of engine defect a
mechanic tries to inspect external parts of the engine surrounding. If the problem is not solved by
inspection then a mechanic proceeds to dismount the engine from the vehicle and disassembled then
checks internal parts of engine systems. Those systems are
 Cooling system
 Lubrication system
 Ignition system
 Valve timing
 leakage
 Fuel system
 Air intake system and others.
After the above systems have been inspected a mechanic handles a specified problem and takes the
following measurements like washing, maintaining and replacing of damaged parts then assembling is
done.
The work task that we have been executing

We have been staying in this shop for two weeks by visualizing partially how to assemble, disassemble
and repair of damaged parts of the engine
 Removal of an engine from vehicle
 Helping during the Maintenance of an engine
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 Assists the technicians in assembly & disassembled of an engine.

 Cleaning of an engine block, valve spring, cylinder heads & blocks
 Put significant role in the arrangement of valves during the assembly process.
 Preparing working equipment’s during work for the mechanics
 Belt adjustment after the engine assembly completed
 Mounting the engine to the vehicle
Flow charts for engine section

Procedure of Engine Overhaul
 Damaged
parts
 Dissembling  Cleaning  Inspection ordered
 Problems. Received parts from machine

 Parts cleaning for assembling shop
 Start assembling Inspected to problems
 Engine start up.
 Fixing accessory parts for engine run up  Parts cleaning for
assembling
 Engine test
Figure 2.1 work flow of engine shop

Challenges we have been facing in engine shop
 Usage of traditional nomenclature of materials, devices & equipment’s.
 Lack of reference & manuals in that shop.
 Lack of hoist cranes which leads sometimes to convey engine blocks manually which are
sharp edges.
 Manual replacement of engine parts during assembly.
 Waiting till the vehicles engine faced damage to see how they repair.
 The mechanism of insert valve lock and valve lapping is more consume time and
manpower.
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Measures we have been taken in order to overcome challenges

In order to overcome the above & other challenges .we were taken the following measurements
 Try to learn traditional nomenclatures.

 Through asking we improves our understanding about engine system
 Telling them to use hoisting equipment’s rather than manually to reduce labor force.
 We recommend that they should give training to develop awareness for the workers about
material handling and safety
1.2.1.2. Light vehicle section

Work flow in this section
As the name suggested that in this shop light vehicles like Toyota, pickup, Mitsubishi and land cruiser
other vehicles get maintained.at this shop the work flow is takes place by skilled mechanic of the
vehicles. The work includes the whole systems except electrical systems. When a vehicle comes with
some problem a mechanic asks a driver which part of a vehicle is faced a problem or checks by driving
itself. Then visualizes a problem after this a mechanic tries to solve the problem using working procedure
by placing it on a comfortable place.
We were working in this shop for two weeks we were collecting knowledge’s about light vehicles
problem and its solutions. When we having team work with workers. During our stay the following
vehicles problem detection and maintenance performed here.
Some of the works are
 Engine operation and problem
 Brake system
 Cooling system
 Steering system
 Differential
 Fueling system
 Lubrication system
Challenges we have been facing in light duty

The main challenge that we have faced during the internship time
 Safety, no available safety equipment’s are there.
 Nomenclature of parts they call using Italian language. Like kushinet (bearing), Belastira (leaf
spring), selbatiyo (fuel tank), volanno (flywheel), kollo (crank shaft), charke (wheel) ponte (axle
housing) and etc.
 Also during first week when we started our internship it’s difficult to approach technician and
communicate with them.
 Some of tasks are done by experience not according to manual
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Measures we have been taken in order to overcome challenges.

To overcome the challenge with regard to safety we bought safety clothes, shoes and protect ourselves
from hazards. Through gradually we able to know the name of the parts by asking the workers. By
studying the behavior of workers we can commitment clearly with workers.
We try to tell the workers by saying it’s better to use manual in order to get long-life of parts of a vehicle.
1.2.1.3 Heavy duty shop Section

Work flow
In this shop the work flow is takes place by mechanic and those who helps him. When the vehicle needs
repair it comes to this shop then the workers determines the problem happen with vehicle, first the driver
contact the workers and then the workers orally visualize the systems problem. After this immediately he
check the problem what he have visualize. Then the mechanic continue to prove the problem of the
vehicle, by using the tools like wrench, screw drivers, hammers, sockets and etc to operate the work. The
vehicle type repaired here is as a name of shop indicate it large in size like buses, turbo, trucks, trailers,
grader, dozer, excavator etc.
Task we have executed
We have stay at this shop for two weeks in this duration the work task we have observed are. Most
vehicles come with same problems or one vehicle comes most for the time with the same problem. We
stayed here by helping workers.
 Brake system problem

 Suspension system problem
 Transmission problem
 Differential problem
 Cooling system problem
Challenge we faced at heavy duty section

 Because of the huge vehicle part; it needs more power of labor.
 There is lack of machine functioned to lift, hold and load of the heavy duty vehicles
part at this shop.
 Adequacy of safety materials.
 Tire loosing mechanism needs more torques
Measurement we take to overcome the challenge

 We try to protect ourselves from danger by using safety materials and by avoiding to lift heavy
objects alone.
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 We tell them as an idea to design bolt loosening material by using high pressure hydraulic or
pneumatic machine in combination with electric motor.
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1.2.1.4 Electrical sections

Work flow in this section
In this shop electrical part of vehicle detection like the following systems takes place.
1. Starting system
2. Lighting system
3. charging system
4. Ignition system and
5. Accessories
When a vehicle comes in this shop with a problem of an electrical part. The electrician gain information
either from dashboard or from driver (operator). Otherwise the electrician checks all electrical systems
starting from battery and fuse and then proceeds to other parts.
In this shop we have been seen different electrical systems. The work task that we have been executing
includes.
 We differentiates battery is the main electrical power sources of a vehicle.
 Battery charging.
 Identifying the problem from the information listed on the fuse cover.
 Disassembly of starter motor and its parts name.
Challenges we have been facing in electric shop

There are several challenges we faced during our task among them the following challenges takes
our focus. These are
 Lack of Safety equipment’s
 Line or cable identification problem
 Lack of accurate measuring instrument to see whether battery acid is weak or not.
 The other problem that we faced is step of terminal mounting.

 To avoid as much as we can we tried to keep ourselves from acid contact and listening the
workers description.
 Through asking and referring different sources we are able to identify cables through using
conventional colures like
-Red for positive terminal.
-Black for negative terminal
 We also tried to identify the steps of mounting and removing of a terminal.
Step 1:-mounting (connecting) a terminal
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1. First positive terminal is plugged.

2. Second negative terminal is connected.
Step 2:- removal of a terminal
1. Negative terminal removed first
2. Positive is removed next.
All this measure achieved through asking workers, discussing with friends and usage of different sources.
1.2.1.5 Body section

Work task we have been executing
In this shop part of the body of car will be maintained and modified. -, painting room, body grinding and
body welding.
 Body grinding: - the body of car grind by simple grinding machine

 Painting room: -In this room the cars are painted by using a compressor.
 Body welding room:-in this room a body of car is welded if a crash or breaking down is
occurred on the car.
Challenges we have been facing

Challenges are powerful indicator of solution we have been facing different challenges while
performing our tasks. Among the challenges we have facing
 Lack of working material due to this we use un proper metal
 Lack of sacker of welding smoke due to this our eye faced for sick.
 Usage of unbalanced power source
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 Selection of proper electrode

 Some tasks are done by experience, not according to the manual

 Balancing power for the appropriate material to be welded
 We identified both grinding disc and cutting disc for correct purpose
 We also able to identify electrode types and numbers depend on material type to be welded
 Communicate clearly the workers
 discus the problems with my friend
These above measurements are taken collected from different sources like company’s worker working
manual, university books, encyclopedia, from workers and from friends of different university.
NB.There is another subdivision in the company called light maintenance. Here we were servicing several
vehicles due to their traveling kilometer. Service is done every 5000 kilometers. It is used to prevent
problem before it is occured. The first 3 service sessions are called A1, A2 and A3 Service respectively.
The second sessions B1, B2 and B3 Service and the last one is C service.
A1,A2,A3 service Cleaning air filter. Changing engine oil and oil
filter.
B1,B2,B3 service Cleaning air filter. Changing fuel filter.
Checking brake pad or shoe.
C service Changing air filter
Changing gear box oil.
Changing differential oil. Checking suspension
Checking axel. system.
Checking bearings and so Checking ignition or
on. injection system.
Checking sound and
leakage.
Cleaning all parts.
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1.3 Overall Internship Benefit

It is clear that Internship program is useful to the student primarily. It provides and guides to the students
in gaining information, developing their knowledge and skill, being self-confident, punctuation, knowing
future responsibilities after graduation, being competent and developing relationship with
employer/employee during internship program.
1.3.1 Practical skill

Since the education policy is more of deductive, we can say that we had very much listed practical’s. But
after doing the internship, we have improved our practice in work and also technician’s skills.
Some of the practical skill we have improved in the internship program are;-
 Understanding of setting out work for machines(vehicles) maintenance

 Preparation and evaluation of weekly schedule.
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Intern ship has increased our knowledge of machine and man power management which is a crucial thing
in the maintenance work. It help us to know different engine constructions, how the cooling, lubrication,
steering, brake, transmission, clutch systems are working.
1.3.2 Theoretical knowledge

The internship had many benefits in this regards because as we all know our knowledge is mainly based
on theory thus it was necessary by any means to change or interpret the theoretical knowledge to practical
one.
The internship was very help full in upgrading the theoretical knowledge example the knowledge we had
on maintenance work and how UAM PLC manual is used for work on practice.
Additionally the internship had also helped us in how we can relate our knowledge to the working
environment and we think that this is very important for my future in that we won’t be new for working
environment.
1.3.3 Interpersonal communication skill

During the intern program we are trying to develop my interpersonal communication skill i.e. the process
by which we exchange information feelings and face to face communication. We had improved many
communication skill in very good manner which help us to talk any person at the workshop with
confidence and easily as possible. In our experience we had observed that communication between
different sections of the company is vital to attain high efficient on work. Example In every work needs
cooperation. We can take one example of the company the communication between the inspectors, the
engineers, and the mechanics are really great and we learn from three of them. In conclusion the intern
personal communication skill is the vital thing in the quality of work. During these four months we had
been able to upgrade our speaking skill and gained confidence on how to ask different questions, to make
discussion.
Use of interpersonal communication
 To give and collect information
 To influence the attitude and behaviors
 To form contracts and maintain relationship
 To express personals needs and understand the needs of others
 To make decision and solve problem
 To anticipate and predict behavior
 Improving formal communications
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1.3.4 Team playing skill

Team work is important because it can speed up process and make things run more efficiently and allow
goals to be reached in an efficient and timely method. A good team will generate and nurture bond of trust
and confidence, both in themselves and one another. This will positively affect their self-steam,
confidence in their colleagues, and possibly their loyalty to the company increasing productivity and
ultimately, company profit
To achieve good team playing skill team member should develop the following criteria
1. Communication; - it is crucial to be able to communicate openly and honestly.
2. Commitment; - is the ability and desire to commit to a shared team goal. All other team work skill are
useless without a commitment to the team member should be willing to take on any role necessary to
accomplish the required tasks, whether it is a leader ship role or sub ordinate role.
3. Decision making; - the team work skill of effective responsible decision making is rises the decision
making process.
1.3.5 Leadership skills

During the four months in UAM PLC, we have developed our leader ship skills. To achieve leader
ship skills it requires high level commitment to learn from each experience we face. We have
observed that a good leader is well principal individual who is focus on a common goal and eliminate
excess fear and doubt from his employees and work for a common good all. During these times we
have been able to observe that one should have great skills to be a leader these are;
 Communicate effectively
 Take owner ship and responsibility
 Great listener
 Encourage others through positivity
 Good management skill
 Commitment, integrity and passionate
1.3.6 Work ethic

Work ethics include how one feels their job, career and how one does his/her job responsible manner.
This involves attitude, behavior, respect communication, honesty and accountability and interaction.
Company employees who respect their work and work efficiently in the presence or absence of leader
have improved their salary. From this it can be concluded that if one has good work ethics he will
benefited and encourage others to do the same and at last benefits the company
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Characteristics of a good work ethics is

 Reliability
 Dedication
 Productivity
 Cooperation
1.3.7 Entrepreneurship skills

Application of energy and passion towards the creation and implementation of new ideas and creative
solutions is 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
plan; and finally the vision to recognize opportunity where others see chaos, contradiction and confusion.
During our internship experience at United Auto Maintenance PLC, we had developed the five levels of
entrepreneurial development.
 The self-employed mind set
 The managerial perspective
 The attitude of owner (leader)
 The entrepreneurial investor
 The true entrepreneur
Over view of the project

The problem is to remove the nuts of vehicle tire. If the user is required to remove the nut
and fix the problem. It is difficult to remove the nut, especially for female users. It waste time
and energy. Opposition to waste time and decrease the power, then it requires high power to
remove nuts. But our design is safe and it is easy to use. The tire nut removal force is reduced
using gear system. This project is likely to solve and the problem of the use of six nut removal
procedure.
1.1 Statement of the problem

This project try to design and manufacture an automotive tire changing mechanism this
mechanism will help to minimize their time consumption in order to unscrew lug nuts. The
general idea behind this mechanism was to have a power source that is connected through a shaft
to a gear train of 2 driver gear and 6 driven gear that are connected through spanners to unscrew
lug nuts simultaneously. At first we think to do our project with new fabricated materials. But
after we see the economic environment of the market we change our idea and we decide to work
with spare materials. This project is very important to tire manufacturing companies and
workshops, as it can be efficient and time saving.
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1.2 Project objective

In our internship period we saw that most car need a service of the whole body. One of the
most important part to be serviced are the four wheel as it is the main part of automotive. That
means changing bearing, changing clutch, changing the oil (grass) of the wheel and so on. While
the workers use traditional way of changing tire (unscrewing) mechanism. That means this
unscrew the locking lug nuts used one by one. However this way is exhausting and it waste a lot
of time and a labor power so by identifying this problem we came up with idea of this project.
This project has 3 main objective the first is it will help to save time, that means it give us
money. Secondly, it reduces the labor force of the employers (mechanics). Thirdly, it helps to
use our natural resource properly by reusing the spare materials. As we know the materials we
are using starting from the gear to the shaft, bearings and so on are constructed from natural
resource, so we reduce the consumption of that resource.
1.3 Project Specifications
✂ 6 driven gears with a diameter of 71.2mm
✂ 2 driver gears with a diameter of 31.2mm
✂ Module of gears is 2.5mm
✂ 5 shafts with a diameter of 25mm
✂ Pitch Circle Diameter, PCD for wheel hub (mm): 139.7mm
✂ Torque (Nm): An impact wrench with a torque of 426N.m
✂ Power (W): An impact wrench with an output power of 710W.
✂ Speed (rpm): An impact wrench with load speed of 200rpm.
1.4 Application
Now a day’s time and money are directly proportional, so in order to get good profit a
company must use its time properly. So as an engineer we have tried to solve the time
consumption problem by this project. Our design can be used for any kind of automotive
maintenance company starting from simple garage to huge one, workshops and tire
manufacturing companies. Our project not only saves time it will also save the labor force and
make the employers hard working and profitable.
Design consideration for a gear drive
In the design of gear drive the following data is usually given

 The power to be transmitted.
 The speed of the driving gear.
 The speed of driven gear or the velocity ratio and
 The center distance
 The following requirements must be met in the design of gear drive:
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 The gear teeth should have sufficient strength so that they will not fail under static
loading or dynamic loading during normal running conditions
 The gear teeth should have wear characteristics so that their life is satisfactory.
 The use of space and material should be economical.
 The alignment of gear and deflection of the shafts must be considered because the
effect on the performance of the gear
 The lubrication of the gear must be satisfactory
Advantage and disadvantage of gear drive
The following are advantages and disadvantage of the gear drive as compared to other
drives. Example belt, rope and chain drive:
Advantages
 It transmits exact velocity ratio.

 It may be used to transmit large power
 It may be used for small center distances of shaft.
 It has high efficiency.
 It has reliable service.
 It has compact layout
Disadvantages
 Since the manufacture of gears require special tools and equipment, therefore it is
costlier than other drive.
 The error in cutting teeth may cause vibrations and noise during operation.
 It requires suitable lubrication and reliable method of applying it, for the proper
operation of gear drives.
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Chapter two: Literature Review

2.1 Project back ground
As we said earlier the main design of this project is depend on the type and the ratio of the
primary (driver) and secondary (driven) gear so there are three Major categories of gear in
accordance with the orientation of their axes. Parallel. Axes (spur gear, helical gear, gear rack
,internal gear ) intersecting axes ( milter gear Straight bevel gear, spiral bevel gear ) non parallel
non intersecting axes (screw gear Worm, worm gear(worm wheel).this project use the driving of
smaller gear to the Larger gear in order to multiply the force .the main purpose of using gear is to
transfer power from source to application .the modern technology of gear in its current Form age
back to 100 year ago . nevertheless the oldest form of gear can be traced Back to fourth century
B.C Greece as we all know there are different type of gears That can be used such as bevel gear
,helical gear ,spur gear but in this project we use A straight bevel gears that meshed in a way to
achieve the aim of this project. That is design and manufacture an automotive tire changing
mechanism.
2.2 PRIVIOUS WORK
There are many basic work that must be considered before we are going to calculate the
design .as we said earlier the main design of the project is depend on the type and the ratio of
gear. so in our project we decide to use straight bevel gear as the name indicates straight bevel
gear have straight teeth and resemble a spur gear except that they are conical rather than
cylindrical .bevel gear are gears where the axes of the two shafts intersect and the tooth bearing
fact of the gear themselves are conically shaped. Bevel gears are most often mounted on the shaft
that are 90 degree apart .but can be designed to work at other angel as well. This project is based
on gear system where the material provided in the book considered to be reference for gear
system. It help to provide the formulas needed to calculate torque, force acting on gear and
modules more it explain how different type of gear work such as epicycle so it is a basic need to
design this project.
Figure 2.1: Two spur gears in mesh

A bad selection for the motor used in this project leads to poor system performance and an
increase of the cost of installation and maintenance in future. Therefore engineers are required to
avoid bad selection for design in their work .however this article explains procedures in selecting
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the proper size of motors for the design .it also gives more information such as describing the
methods of selecting other associated components in this project to select motor .we have to find
the torque needed to unscrew the 6 nuts at the same time ,so this article shows a good example
of how to calculate the power needed to transmit torque and selecting the right motor for our
system.
The concept and terminology of gears is a requirement to design build and improve gear
drive system to design and build a gear drive system it is necessary to understand all concept of
gear and their mechanical .more over ratio of gear depends on teeth of gear and tells the designer
how much the driver gear rotates to complete one turn for the driven gear for example if the ratio
for the two gears is 1:2 this means that the driven gear to make one complete turn as shown in
figure below.
Figure 2.2: Two gears in mesh that have a ratio of 1:3

2.3 Similar Mechanism
Hammer drills have been used for a long time and they are using a rotating power with the
help of vibration to pulverize the hard material into the surface. Moreover, sometimes the
hammer drill’s bit at the surface of material gets extremely hot, so the tip is made out of carbide
steel to resist the heat.
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Figure 2.3: Components of hammer drill
In figure 2.3 above, it’s showing the main component of a drill hammer. First, the motor of
the shaft is passing through the hammer body where there are bearings to support the shaft.
While the shaft ends in the worm gear that transfers the rotational motion to the large gear. In the
center of the large gear, there is a shaft that is attached to the chuck and drive it. The rotary
switch is located on the top of the drill. It allows the users to select one of two modes of
operation, which are counterclockwise and clockwise. Finally, while the drill is running, the
wedge moves downward and forces the hammer mechanism forward. However, from this
hammer mechanism, the design of impact wrenches was found. The impact wrench is known as
impact gun, air wrench or torque gun. It is a socket wrench power tool that is designed to deliver
torque. An impact wrench is an important tool for automotive repair work and designed to
provide high torque at a medium speed. Therefore, it is different from drill hammer which
designed to provide rotational power at a relatively high speed. But our project is based on the
idea of impact wrench which delivers torque to unscrew the nuts. Moreover, there are two major
types of impact wrenches. There is a compressed air impact wrench known as pneumatic and an
electric impact wrench which uses electrical power. They both deliver the same performance but
air compressed has more power.
In addition, their torque is around 100 Nm to 1400 Nm for heavy duty work. The only
difference between them is that the electric impact can be used anywhere that electric power
source is available. On the other hand, a pneumatic impact is hard to control and adjust the
power. As a result of this high power the bolts can break if the user is not an expert. Moreover, a
pneumatic impact wrench is most commonly used in workshops because it’s half cost the
electrical impact and, also has a smaller size.
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Figure 2.4: Components of impact wrench
In figure 2.4, it shows the main components of pneumatic impact wrench. Firstly, adapter
forces up the air through the handle. Then, the air is forced through channel to rotor cylinder
where air is compressed. After the air is compressed, it passes through the blades which convert
the air compressed into kinetic energy. Then, the rotor turns by using centrifugal force which
moves the rest of the blades partially out of the rotor where they are connected to rotor cylinder.
In addition, rotor has a central shaft which passes through a bearing housing. Finally, there is a
spline that forces a hammer cage and hammer to rotate with the rotor.
As known, one of the uses of impact wrenches is to change tires in workshops. Usually, the
procedure takes around 1 min or more to change only one tire. Moreover, it is much faster than
the traditional way with lug wrench. The lug wrench takes at least 15 minutes and sometimes the
bolts are stuck and not easy to remove. In addition, lug wrench depends on an important factor to
unscrew the bolts which is torque required to unscrew the lug nuts. Therefore, as the radius
increases, the lower forces needed to unscrew the lug nuts. The main issue in using a lug wrench
is that sometimes it takes so much effort to unscrew the nuts. Therefore, workshops use impact
wrenches instead of normal lug wrench.
Detent pin anvil sizes of impact wrench come in different sizes because it depends on power
of impact wrench too. As the torque increases, the Detent pin anvil diameter increases. So, heavy
duty impact wrenches have larger detent pin anvil. Both electrical and pneumatic impact
wrenches use standard sizes such as, 0.25-inch, 0.375-inch, and 0.50-inch as shown in.
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Figure 2.5: Most common sizes for detent pin anvil
2.4 Comparative Study
The objectives of the project are to design a 6-nut removal mechanism and minimize the
cost of it. This project uses one of most common types of gears, which is straight bevel gears, to
reduce the torque and force. The gear system is made of mild steel and has a 1:21.125 gear ratio
and total weight of the product is 5.5 kg. The size of each nut is around 21mm and pitch circle
diameter (PCD) of 139.7mm. Moreover, distance between nuts is 80mm. The gear system is
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supported by power window motor with force of 2436 N to unscrew 4 nuts simultaneously. In
addition, the torque required to unscrew one nut has been measured by using torque wrench and
found the average torque to be around 140Nm. See table 2.1
Tire Nut 1 Nut 2 Nut 3 Nut 4 Nut 5 Nut 6
1 138 143 140 135 142 145
2 150 147 135 136 138 132
3 140 134 142 160 140 140
4 135 133 134 138 145 138
AVERAGE VALUE
Table 2.1: Torque measured at each nut for a normal nuts
The number of nuts and usage of straight (spur) gear to transmit motion to other gears. There
are two type gears used, which are the primary gear (driver) and secondary gear (driven). In this
model, the primary (driver) spur gear is connected to the motor by the shaft, which rotate to
transmit power by using the motor. They used base plate made from cast iron to hold the gears
and to withstand the forces from gears and the shaft extensions to hold the mechanism. This
leads to stability and an increase of weight of mechanism. In addition, gears and the motor
weren’t covered and can be seen. Moreover, they claimed that their electrical motor has a power
of 471 KW and minimum toque of 140 Nm, which seems to be too high for unscrewing lug nuts.
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CHAPTER THREE: System Design

3.1 Design Constraints
3.1.1 Safetys
Safety is considered to be an essential requirement for any project. Therefore, in this project,
we will follow the international standards for choosing types of materials and parts being used
that will lead to prevention of any failures caused by the mechanism.
3.1.2 Social & Economics
As we know, time is money. Therefore, using our project will save a lot of time, because it’s
fast and can definitely unscrew 6 lug nuts simultaneously. In addition, compared to the available
mechanisms to change tires in workshops such as impact wrenches, our project is faster.
3.1.3 Engineering Standards
The project is consisting of many components, which are; gears, bearings, shafts, motor, and
spanners. All of these components were selected based on existing standards such as SKF
catalogue, and American Iron and Steel Institute.
3.1.4 Manufacturability
Our project can be manufactured easily, and it can be used in a wide range of applications
such as tire manufacturing companies, workshops and portable using. On one hand, gears,
bearings, and shafts can be gained from other spare materials from other materials in the market.
On the other hand, the motor will be selected based on the calculations of torque, horsepower
and its availability in the market.
3.1.5 Time
As we all know, time is money, and our project is going to perform efficiently and save time
by screwing and unscrewing all lug nuts simultaneously. Instead of using the normal way to
unscrew nuts such as lug wrench, our prototype will allow the user to unscrew all 6 nuts in one
move by using a gear train system to generate a torque to unscrew the six nuts simultaneously.
3.1.6 Quality
Quality of projects is a very important aspect of any design, and in our design we are
making sure that the quality of materials used in the system and its parts is good and meets the
standards.
3.2 Design Methodology
Our project can be divided into five phases. First phase is brainstorming where we collect
information about the basic design aspects. In addition, using brainstorming method can specify
the features of our design. In this phase, we define the major aspects needed for building the
prototype such as, gears, shafts, bearings and spanners. Also, in this phase we conduct the Gantt
chart, where we divide the tasks and their time durations for the project. Second phase includes
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gathering information about the conceptual design of our project from, books, journals, and old
projects.
Third phase, is analysis and calculation of design. This phase is considered to be an
important phase where manufacturing the prototype depends on it. This phase has a lot of
calculations that include dimensions such as gears centers, pitch diameter, thickness of gears,
size of shafts, number of teeth, and ratio of gears. Moreover, the calculations include the torque
required to unscrew one nut, power transmitted from the motor and factor of safety (FOS).
Additionally, the design of our prototype is made using SolidWorks. SolidWorks includes all
dimensions of the parts, 2D drawing, and assembly of the parts. Fourth phase is we try to get the
needed parts in market but the parts we need are not newly fabricated but they are spare
materials that have a good quality to manufacture our project. Whether there are gears, shafts,
spanner and joints, because some parts need to be made in workshops to get the available size for
our project. Finally, fifth phase includes welding, assembly of parts in workshops and testing our
prototype.
Figure 3.1: Assembly from different sides
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Figure 3.2: Exploded view of assembly
As shown in figures 3.1 and 3.2, our design has three levels because we couldn’t design a
different size of gears at the one level with a 114.3 PCD without avoiding gear interference. So,
we started to build our design on an actual wheel hub, and we designed three levels to avoid the
gear interference problem. See figure 3.3 below.
Figure 3.3: Car hub
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The first level of our design has two driven gears and one driver gear. While the second
level has two driven gears and one driver gear. Lastly, third level has one driven gear and one
driver gear. Therefore, the total number of driven gears is five, and for the driver gears it’s three.
All driven and driver gears are held by 6 shafts. Moreover, gears and shafts are held by a circular
plate and six ball bearings to reduce the rotational friction and support radial loads. Finally, in
top of the shaft there is a wheel spanner to unscrew the lug nuts.
Table 3.1 shows a summary of the design specification for gears, shafts, and the circular
plate.
Driver Gear Driven Gear Circular Shaft

plate
No. of Teeth
(mm)
PCD (mm)
Diameter
(mm)
Module
Thickness
(mm)
Pressure
angle 20
Length
(mm)
Table 3.1: A summary of design specification
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Figure 3.4: Driver and driven gears in mesh

N driven= 31 N driver=15 D driven=71.24 D driver= 31.24
Table 3.2: Driver and driven gears parameters

1 Spur gear Cast iron 06
2 Sun gear Cast iron 02
3 Pin for spur Stainless 06
gear steel
4 Shaft for spur Cast iron 06
gear
5 Shaft for sun Cast iron 01
gear
6 Plate(t=10mm) Mild steel 01
Table 3.1: components of the project
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3.4 Design Considerations for a Gear Drive
(Center to center distance of bolt pattern of the wheel hub) L = 70mm

(Gear ratio) G.R =2
(Speed of pinion gear) Np = 200rpm
Module (m) = 2.5
Assume face width of the gears (f) =30mm
a – Addendum = 0.8*m = 0.8*3= 2.5mm
b– Deddendum = 1*m = 1*3 = 3.125mm
Working depth = 1.6*m =1.6*3 = 4mm
Tooth thickness = 1.5708*m =3.927mm
Minimum clearance = 0.25*m =0.2*3= 0.625mm
Fillet radius at root = 0.4*m = 0.4*3 =1.2mm
C = (𝐷𝑝⁄ 2) + (𝐷𝑔 ⁄ 2)
𝐺.𝑅 =𝐷𝑔⁄ 𝐷𝑝= 2
So Dg = 2Dp
70 =𝐷𝑝 ⁄ 2+ 2𝐷𝑝⁄ 2 = 1.5𝐷𝑝
Dp =57/1.5 = 46.67mm (Pitch circle diameter of pinion gear)
Outside diameter of pinion gear (do) = dp + 2*a =46.67+2*2.5 =51.67mm
Root diameter of pinion gear (dr) = dp -2*b =46.67 – 2*3.125 =40.42mm
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Base diameter of pinion gear (db) = Dp * cosα =46.67 *cos20 =43.85 mm

Pitch circle diameter of gear
Dg=2*dp
Dg =2*46.67 =93.34mm
Outside diameter of gear (Do) = Dg + 2*a =93.34+2*2.4=98.14mm
Root diameter of sun gear (Dr) = Dg -2*b=93.34 – 2*3.125 =87.09mm
Base diameter of sun gear (Db) = Dg*cosα =93.34*cos20=87.71 mm
To calculate the number of teeth on pinion and sun gear
N =𝐷/ 𝑚
dp 46.67
n= = = 18.668 1͌ 9 teeth 𝑎𝑛𝑑
m 2.5
Dg 93.34
N= = = 37.336 ͌ 38 teeth
m 2.5
Note: according to our procedure the minimum number of pinion teeth is 14 in order to avoid
interference.[1]
Note: If D412+2p and Dg are the diameters of the two meshing gears having the teeth Np and Ng
respectively; then for them to mesh correctly.
(Where pc =circular pitch)
Dpπ Dgπ 46.67π 93.34π

Pc= Np = Ng = 18.668 = =7.85mm
37.336
Force and stress analysis

Gears are wheel like machine elements that have teeth uniformly spaced around the outer
surface. Gears can be a fraction of an inch in diameter to a hundred feet in diameter. Gears are
used in pairs and are a very valuable design tool. They are used in everything from clocks to
rockets and have been around for 3000 years. Gears are mounted on rotatable shafts and the teeth
are made to mesh (engage) with a gear on another shaft. Gears deliver force (torque) and motion
(rpm) from one part of a machine to another. Two gears with the driven gear having twice the
number of teeth of the driving gear will rotate at one-half the speed of the driving gear and
deliver twice the torque. Being able to control speed and torque by varying the number of teeth
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in one gear with respect to another makes gears a valuable design tool. An automobile
transmission is an excellent example of how this principle is put to use to control vehicle motion.
3 Types of Gears There are a number of different types of gears. Spur gears are the most
common and the easiest to manufacture. A spur gear has teeth that are uniformly spaced around
the outer surface. The teeth are aligned in a direction that is parallel to the gear axis of rotation.
A spur gear is designed to mesh with another spur gear on a parallel shaft. The profile of the
contact surface of spur gear teeth is in the form of an involute curve. An involute curve is the
path the end of a string takes when it is being unwound from a cylinder. The shape is the easiest
to manufacture and is an efficient way to transmit power between two contacting surfaces
because of the tendency to maximize rolling and minimize sliding. The efficiency of spur gears
is in the high 90% range and approaches that of anti-friction bearings. Spur gears impose only
radial loads (perpendicular to axis of rotation) on shaft support bearings as opposed to other
types of gears which impose radial and thrust loads (parallel to axis of rotation) on bearings.
Gears that impose thrust as well as radial loads require shaft support bearings that are designed to
support both types of loading. Helical gears are like spur gears except that the teeth are
positioned at an angle to the gear axis of rotation. This angle, called the helix angle, is normally
from 10° to 35°. Helical gears are stronger and run more quietly than comparable size spur gears.
Helical gears are less efficient than spur gears and impose thrust as well as radial loads on shafts
making bearing and shaft selection more complex. Double helical or "herringbone" gears can
deliver high power without imposing thrust loads on shafts. Bevel gears are like spur gears
except that the basic tooth configuration is conical in shape resulting in the teeth being smaller at
one end than at the other. Bevel gears are used to transmit power between two shafts that are not
parallel. Two shafts that are at a 90° angle to each other are commonly driven by bevel gears.
Bevel gears, like spur gears, operate at efficiencies in the high 90% range. Bevel gears are used
in vehicles, aircraft, and machine tools. Spiral bevel gears are cut at an angle similar 4 to what
helical gears are to spur gears. Spiral bevel gears can deliver more power but operate at lower
efficiencies than straight bevel gears. Spiral bevel gears whose axes do not intersect are called
hypoid gears.
So the torque is 6* 71= 426N.m is needed to unscrew 6 bolts.
We can calculate the torque of the driver gear by:
426
G.R=Tdriver =2
T=213, so the torque of the driver is 213Nm.
2πNT 2π∗200∗213
𝑃= = = 4461𝑾
60 60
4461
1hp=746 → =5.8 𝒉𝒑 𝒊𝒔 𝒏𝒆𝒆𝒅𝒆𝒅 𝒕𝒐 𝒖𝒏𝒔𝒄𝒓𝒆𝒘 𝒕𝒉𝒆 𝒃𝒐𝒍𝒕𝒔
746
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Since both gears are made of the same material the pinion gear will be weaker so the design
will be based on the pinion gear
Thus, the pitch line velocity may also be obtained by using the following relation, i.e.
Where pitch line velocity
πDN 3.14∗0.046∗200
𝑣= = =0.489m/s
60 60
3
=, for ordinary cut gears operating at velocities up to 12.5 m / s. [1]
3+v
3 3
𝐶𝑣 = 3+v=3+.489=0.86
Since the pitch line velocity is less than 12m/s the velocity factor is given by
Where: Yp for 20° stub involute profile is given by
0.841 0.841
𝑌𝑝 = 0.175 − = 0.175 − = 0.128
Tp 19
𝑊𝑡 (tangential load)
𝑊𝑡 = 𝜎𝑜𝑝 ∗ 𝐶𝑣 ∗ 𝑏 ∗ 𝛱 ∗ 𝑚 ∗ 𝑌𝑝 = 56 ∗ 0.86∗ 30 ∗ 𝛱 ∗ 2.5 ∗ 0.128 = 1452.47𝑵
Table
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Radial force 𝑊𝑟 = 𝑊𝑡 ∗ 𝑡𝑎𝑛20 = 1452.47 ∗ 𝑡𝑎𝑛20 = 528.65𝑵
Dynamic load (Wd)
21v(b.c+Wt)
Wi= 21v√b.c+Wt
21v(b.c+Wt)
𝑊𝑑 = 𝑊𝑡 + 𝑊𝑖 = 𝑊𝑡 + 21v√b.c+Wt
Where WD = Total dynamic load in Newton,
WT = tangential load in newton,

v = Pitch line velocity in m/s,
b = Face width of gears in mm, and
C = A deformation or dynamic factor in N/mm.
A deformation factor (C) depends upon the error in action between teeth, the class of cut of
the gears, the tooth form and the material of the gears. The following table shows the values of
deformation factor (C) for checking the dynamic load on gears.
Table
Where deformation factor for cast iron is given as C =59
21v(b.c+Wt)
𝑊𝑑 = 𝑊𝑡 + 𝑊𝑖 = 𝑊𝑡 + 21v√b.c+Wt
21∗0.89(30∗59+1452.47)
=1732.8 +21∗0.89+√30∗59+1452.47 = 1946𝑵
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Static load Ws =σe*b*𝛱*m*Yp
Note: From the above table we can find the values of flexural endurance limit (σe) for
different materials. In this case our material is cast iron, so (σe) is 84.
Ws =σe*b*𝛱*m*Yp = 84*30* 𝛱*2.5*0.128 =2850.1N
The ratio factor is given by
2∗V.R 2∗2
SQ=V.R+1=2+1= 1.333
𝑊𝑤 = 𝐷𝑝 ∗ 𝑏 ∗ 𝑄 ∗ 𝐾 = 46.67 ∗ 30 ∗ 1.333 ∗ 1.4 = 2612.9𝑵
Where K = 1.4
For safety, against tooth breakage, the static tooth load (Ws) should be greater than the
dynamic load (Wd). Buckingham suggests the following relationship between Ws and Wd.
As Ws > WD (2533.4 > 1946) and Ww > WD (2612.9 > 1946)
So the design is safe.
Design of shaft
 Shafts are commonly made from low carbon, CD or HR steel, such as ANSI
1020–1050 steels.
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 Fatigue properties don’t usually benefit much from high alloy content and heat
treatment.
 Surface hardening usually only used when the shaft is being used as a bearing
surface.
Design Shaft Materials
 Cold drawn steel typical for d < 3 in.
 HR steel common for larger sizes. Should be machined all over.
 Low production quantities ◦ Lathe machining is typical ◦ Minimum material
removal may be design goal.
 High production quantities ◦ Forming or casting is common ◦ Minimum material
may be design goal.
 The material used to design shafts for both pinion gear and sun gear is steel whose
allowable shear stress is 40Mpa.
1. Pinion gear
In order to find the diameter of the shaft for spur gears the following method is used
Find normal force acting on the gear teeth
𝑊𝑁 = 𝑊𝑡/cos∅= 1452.47/ (cos20) = 1545.2𝑵
Load acting on the gear
Weight of the gear
𝑊𝑔 = 0.00118 ∗ 𝑇𝑝 ∗ 𝑏 ∗ 𝑚2 = 0.00118 ∗ 19 ∗ 30 ∗ 2.52 = 4.2𝑵
Resultant load acting on the gear
𝑊𝑅 =√ WN2 + Wg2 ∗ 2WN ∗ WG ∗ cos∅
= √(1545.2)2 + (4.2)2 + 2 ∗ 4.2 ∗ 1545.2 ∗ cos20 = 1613.32𝑵
The gear is overhung on the shaft, then bending moment on the shaft due to the resultant
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𝑀 = 𝑊𝑅 ∗ 𝑋 = 1613.32∗ 100= 161332𝑵.𝒎𝒎
𝑤ℎ𝑒𝑟𝑒 𝑎𝑠𝑠𝑢𝑚𝑒 𝑋 = 100𝑚𝑚

Since the shaft is under the combined effect of torsion and bending, therefore the equivalent
torque, 𝑇𝑒 = √ (𝑀2 + 𝑇2)
𝑤ℎ𝑒𝑟𝑒 𝑇 is twisting moment of the shaft
T = 𝑊𝑡 ∗ 𝐷𝑝/2= 1452.47 ∗ 46.67/2 = 33893.4𝑵.𝒎𝒎
𝑇𝑒 = √ (1613322 + 33893.42) = 164853.8𝒎𝒎
𝑇𝑒 = 𝜋 /16 ∗ 𝜏 ∗ 𝑑p3 = 𝜋 /16 ∗ 40 ∗ 𝑑𝑝3 = 7.85𝑑𝑝 3
𝑇𝑒 = 164853.8= 7.85𝑑𝑝 3
𝑑𝑝 = 𝟐7.6𝒎𝒎
2. Spur gear
Weight of the gear
𝑊𝑔 = 0.00118 ∗ 𝑇g ∗ 𝑏 ∗ 𝑚2 = 0.00118 ∗ 38 ∗ 30 ∗2.52 = 8.4𝑵
Resultant load acting on the gear
𝑊𝑅 = √ (𝑊𝑁2 + 𝑊 𝑔2 + 2 ∗ 𝑊𝑁 ∗ 𝑊𝐺 ∗ cos∅)
= √ (1545.22 + 8.42 + 2 ∗ 8.4 ∗ 1545.2 ∗ cos20) = 1553.1𝑵
The gear is overhung on the shaft, then bending moment on the shaft due to the resultant
𝑀1 = 𝑊𝑅 ∗ 𝑋1 = 1553.1 ∗40 =62124𝑁.𝑚𝑚

M2=WR*X2=1553.1*80=124348Nmm
𝑤ℎ𝑒𝑟𝑒 𝑎𝑠𝑠𝑢𝑚𝑒 𝑋1 = 40𝑚𝑚
X2= 80mm
M1=for the lower driven gear
M2=for the upper driven gear
Since the shaft is under the combined effect of torsion and bending, therefore the equivalent
torque, 𝑇𝑒 = √ (𝑀2 + 𝑇2)
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𝑤ℎ𝑒𝑟𝑒 𝑇 is twisting moment on the shaft

T = 𝑊𝑡 ∗ 𝐷g/ 2 = 1732.8 ∗ 93.34/ 2 = 80869.8𝑁𝑚𝑚
𝑇𝑒1 = √ (621242 + 80869.82) = 101977.04.𝑚𝑚
𝑇𝑒1 =𝜋 /16∗ 𝜏 ∗ 𝑑𝑝3 =𝜋/ 16∗ 40 ∗ 𝑑𝑝3 = 7.85𝑑𝑝3
𝑇𝑒1 = 101977.04 = 7.85𝑑𝑝3
𝑑 = 𝟐3.51𝒎𝒎
𝑇𝑒2 = √ (1242482 + 80869.82) =148248.07N.mm
𝑇𝑒2 = 148248.07= 7.85𝑑𝑝3
𝑑 = 𝟐6.63𝒎𝒎
3. Key design
A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to
connect these together in order to prevent relative motion between them. It is always inserted
parallel to the axis of the shaft. Keys are used as temporary fastenings and are subjected to
considerable crushing and shearing stresses. Types of Keys The following types of keys are
important from the subject point of view:
1. Sunk keys or square sunk keys

2. Saddle keys
3. Tangent keys
4. Round keys
5. Spleens
From the above types of key I select Rectangular Sunk keys for my design. The sunken keys
are provided half in the keyway of the shaft and half in the keyway of the hub or boss of the
pulley.
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From the table above

t=8mm
The length of key is obtained by considering the key in shearing and crushing.
Let l = Length of key
Considering shearing of the key we know that shearing strength (or torque transmitted) of
the key, and assume a factor of safety of 2.5.
According to maximum shear stress theory the maximum shear stress for the shaft,
Ʈ max = σ/2fs=40/2*2.5 =50N/mm2
And maximum shear stress for the key,
Ʈ key = σ/2*fs =340/2 =68N/mm2
We know that the maximum torque transmitted by the shaft and key, T = Ʈmaxd3 = 3
=1.13× 105 N-mm Consider the failure of key due to shearing. We know that the maximum
torque transmitted (T), T =LWƮk 1.13× 105 N-mm =L
L =20.77mm Now considering the failure of key due to crushing, we know that the maximum
torque transmitted by the shaft and key (T),
T=L 1.13× 105 N-mm =Lchi
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4. Plate
Figure Rectangular metallic plate
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CHAPTER FOUR: SYSTEM TESTING AND ANALYSIS

Overall Results, Analysis and Discussion
Each car has its own sizes of nuts that are fixed in the wheel, and there are standards
provided from manufacturing companies for tightening nuts. So, the torque to unscrew the nuts is
different from a car to another, because the torque to tighten depends on several points:
Geometry of lug nuts.
Materials used in manufacturing the nuts such as Aluminum alloys or steel.
We did our tests on standard nuts as shown
TESTING
In order to analyze the efficiency of manufactured all-wheel nut remover, testing was
performed using the various available nut remover tools such as Lug wrench, Pneumatic gun and
Four wheeler multi nut wheel changer.
Procedure to be followed during testing –
1. Firstly, the torque required for each nut using lug wrench will be tabulate using the torque
measuring equipment. Now, the time taken for removal of all nuts using each of equipment will
not down.
Fig .Find Out Torque for Opening a Nut
2. Then, the nuts are again re-tightening using all the tools mentioned tools and time
required for the same was noted.
3. Finally, all the results were analyzed and conclusion was drawn. The results of test proved
that the “Four wheeler multi nut wheel changer” could efficiently remove all the nuts
simultaneously. Also, the tool is efficient and with some required modifications could be
efficiently used in future.
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Type of mechanism Unscrew one nut Unscrew six nut

Lug wrench 50 300
Impact wrench 10 60
Our design 12
As a result, our project managed to unscrew all 6 lug nuts simultaneously in 11 seconds.
Therefore, we achieved our objective of saving time, and it’s better than the other mechanisms
which are the lug wrench and impact wrench.
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CHAPTER FIVE: SYSTEM TESTING AND ANALYSIS

5.1 Project Plan
The table below shows the project’s plan and the tasks required from us to finish the project
successfully from the day we started working on it until the last day of the semester. Moreover, it
helped us to manage our time perfectly, because we also had other courses that required us to do
other projects. In addition, we had the advantage of working together equally in each task, and
that made the work easier for us. So, in the end we managed to go through and finish the tasks
mentioned in our Gantt chart successfully in time.
N Task Assig Start date End date Remark
o ned to
Meeting All April/24/ - It was our first

with group members 2019 meeting.
members After some
discussion we
decided to come with
idea
Discussin All May/1/2 May/3/201 There were so

g on the ideas members 019 9 many choices to
work. Bud we choose
the tire lock nut
remover in
democratic way
without chicanery
Sketch the Some May/4/2 May/14/20 The task was
prototype individuals 019 19 given to some
individuals due to
ability on drawing
Discussin All May/15/ May/20/20 In this discussion

g on the ideas members 2019 19 we choose the
working principle
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Assigning All May/21/ - Tasks were

Tasks to team members 2019 assigned due to
Members ability and
additionally intent
Completin All June/3/2 June/9/201
g the members 019 9
conceptual
design
Working Some June/10/ June/21/20
on calculation individuals 2019 19
Collecting All June/22/ June/27/20

and build up members 2019 19
Refine All July/3/20 July/20/20

and correction members 19 19
Final All July/22/2 August/10/

report and members 019 2019
project build
up
Table 5.1 project schedule
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CHAPTER 6: Summary and conclusions

Comparison between before and after design
Before
There is high time consumption

There is high labor force usage
It will give no good working condition
It did not give any importance for natural resource usage
After
Low time consumption

Low labor force usage
Good working condition
Sum up we successfully manage to design and manufacture an automotive tire changing
mechanism that can unscrew 6 lug nuts of wheel simultaneously. This project can be used in
variety off application such as tire manufacturing companies and workshops. More over
while working on this project during the semester we have gained a lot of skills for example
we used the theoretical knowledge that we have gained from mechanical engineering
courses and apply it in our project practically to design and manufacture our prototype.
Finally we would like to thank our university for giving as this internship program and
make as know what our future work condition look like.
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Chapter 7: Conclusions and Future Recommendations

RECOMMENDATION
From our internship period we went to recommend that the spare materials that are expired
from giving service for some needed purpose are not useless those materials can give an
important usage for some other projects so these materials must put in a good environment that
means we have to protect it from rust and when we extract the materials from the body part they
must remove it properly without damaging the important parts. The other thing we want to
recommend is that internships have a good roll on creating a good student. So it would be better
if there is good governance of student.
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References
1. Childs, P. R. N. (2014). Mechanical Design Engineering Handbook Chapter 8(1st
Ed.). Oxford, United Kingdom: Butterworth-Heinemann.
2. Dal Y. Ohm. Drivetech, Inc. (2017), Selection of Servo Motors and Drives.
3. Spur Gear Terms and Concepts (2017). GEARS Educational Systems 105
Webster St. Hanover Massachusetts
4. Improvement and Optimization of Tire Nut Removal with 114 PCD (2006).
University Malaysia Pahang. Azizul Rahman B Abd-Aziz.
5. Design and Fabrication of Multi Nut Removing Tool (2014). IJSR -
INTERNATIONAL JOURNAL OF SCIENTIFIC RESEARCH
6. Hammer Drill, Impact Wrench, Right-Drill (2017).
7. Richard G. BUDYNAS. J. Keith NI SBETT. “Shigley’s Mechanical Engineering
Design” 10th Ed., Mc Graw Hill Education.
8. Juvinall, R.C. And Marshek, K. M., Fundamentals of Machine Component
Design, John Wiley and Sons, 2000.
9. Nisbett, J. Keith and Budynas, Richard G. Shigley's Mechanical Engineering
Design 9th Edition.
10. Pneumatic Pass-Thru Impact Wrench (2014). Florida International
University. Ryan Lucia, Felipe De La Cruz, Milton Hidalgo Ceotto
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Appendix A: Bill of Materials
Project Bill of Materials and Budget
Item Description Quantity Price

1 bearing 12
2
3 Circular 2
plate
4 Spur gears
5 Spur gears
6 Shafts 7
7 Motor 1
(Impact
wrench)
8 Adaptor
9 Socket 1
wrench
10 7
11
12
Table A: Project Bill of Materials and Budget
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Appendix B: Tables
Specified torque for standard bolts
Table B.1: Specified torque for standard bolts
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Appendix C: SolidWorks Drawings
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61

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Tire Changing

Dvj,h,l Mechanism 2012

COLLEGE OF ENGINEERING & TECHNOLOGY

Department: - MECHANICAL ENGINEERING

Duration:-FOUR CONCICUTIVE MONTHES

Approval of supervisor: …………………………………………………..

Approval of mentor: ……………………………………………………….

Student signature: ………………………………………………………….

1 HISTORY & BACKGROUND OF HOSTING COMPANY 8

2 OVER ALL INTERNSHIP EXPERIENCE AND WORK SECTION 13

2.1 DESCRIPTION ON HOW WE GET INTO THE COMPANY 13

2.1 Section of the company we have been working 13

3 Overall Internship Benefit 21

1.1 Statement of the problem 24

1.2 Project objective 25

1.3 Project Specifications 25

CHAPTER TWO: LITERATURE REVIEW 27

2.1 Project back ground 27

2.2 PRIVIOUS WORK 27

2.3 Similar Mechanism 28

2.4 Comparative Study 31

CHAPTER THREE: SYSTEM DESIGN 33

3.1 Design Constraints 33

3.1.2 Social & Economics 33

3.1.3 Engineering Standards 33

3.2 Design Methodology 33

3.4 Design Considerations for a Gear Drive 38

CHAPTER FOUR: SYSTEM TESTING AND ANALYSIS 49

CHAPTER FIVE: SYSTEM TESTING AND ANALYSIS 51

5.1 Project Plan 51

CHAPTER 6: SUMMARY AND CONCLUSIONS 53

Comparison between before and after design 53

CHAPTER 7: CONCLUSIONS AND FUTURE RECOMMENDATIONS 54

PARAMETERS SYMBOLS UNITS

Pitch circle diameters PCD Mm

1 History & Background of Hosting Company

1.1.2 Service and products of the company

1.1.3 Main customers of the company

 Some of the governmental organizations are: commercial bank of Ethiopia.

Figure 1.1 Main customers of the company

1.1.4 Future Growth Strategies

MARKETING AND SALES SERVICE

1 2 info. (to give appoint.)

Work order for approval

Work order + receiving &

7 repaired vehicle handover 5

Open job cards 13 & after repair

Closed job cards summery

Figure 1.2 work flow of market and sales service

Quality Assurance Unit

Quality Assurance unit

9 Report 9 Report Report 9

Work order + additional 3

Figure 1.3 work flow of quality assurance unit

Engineering and Technology Operation Service

Veh. With maint. request service

Completed Vehicles/ components with

Replaced parts return to the reception/ marketing

Workshops Job card

Inspection Maintenance Job card

Completed for final inspection/ if not

1.2 OVER ALL INTERNSHIP EXPERIENCE AND WORK SECTION

1.2.1 Section of the company we have been working

1.2.1.1 Engine section