FInal Design

DECLARATION
We, in which our name stated below are a fourth year Mechanical engineering student,
have undertaken our internship experience in Ethio-engineering group Akaki Basic Metal
from a period of November 5/ 2020 to January 30/2021 under the guidance of Mr. Bisrat
and Mrs. Bethelem (Academic mentors) and Mr. Kemal Nebil and Mr. Abiy (Company
advisors).
We also declare that this project work entitled “Design Of Inclined Screw Conveyor” is our
own original work. We have carried out it independently with the guidance and
suggestions of the project advisor. and that all sources of materials used for the study have
been duly acknowledged.
Name of student Signature Date

Mulualem worku _____________ ____________
Yared Seyfu _____________ ____________
This is to certify that the above statement made by the candidate is correct to the best of my
knowledge and belief. This report has been submitted for presentation with my approval.
Name of school advisor signature Date
______________ __________
______________ __________
i
Acknowledgement
First of all, we would like to thank GOD for giving the ability and strength to do our
report then we would like to convey our heartiest thanks to Bahir Dar University Mechanical
Engineering Department and Akaki Basic Metals Industry to do our internship program.
The internship opportunity we had in Akaki Basic Metals Industry was a great chance for
learning and professional development. Therefore, we consider our self as very lucky
individuals as we were provided with an opportunity to be a part of it. we also grateful for
having a chance to meet so many wonderful people and professional who led us through this
internship period. Also we would like to use this opportunity to express our deepest gratitude
to our mentors Mr Abiy and Mr Kemal also our advisor Mr Bisrat for their guidance, advice
and good treatment.
Last but not least we would like to thank all Akaki Basic Metals Industry workers and staff
members for their willingness to help us in every section of the company.
ii
Executive summary
This internship report is written based on four months internship program that we were
in Akaki basic metals industry to see an overview of the foundry, mechanical, forging shops
found in akaki basic metals industry. And tries to explain main part of the above shop,
capability of each shop with their main function, the work flow, the process and the method
of work in those shops. And also, it states the main product or main customer of the company
and some of the problem found in those shop with their possible solution. In addition, it states
about design of inclined screw conveyor that used to transfer sand. The background of this
company, discussion, conclusion and pictures of some machine are also stated.
Also this project is written on an overview of the design of screw conveyor for Akaki
basic metal industry especially for foundry section it covers and explain every component of
the screw conveyor with a detailed design calculation. And displays all necessary drawing of
the parts.
iii
List of Figures
Fig- 1.6.1 Some Product of ABMI…………………………………………………….5
Fig-1.7.1 Over all Organization Structure……………………………………………..6
Fig-1.7.2 Quality Section Structure……………………………………………………6
Fig-1.7.3 Marketing and Supplies Department Structure ……………………………..6
Fig 1.7.4 Manufacturing Department Structure……………………………………..…7
Fig- 1.7.5 Administration and HRD Department Structure……………………………8
Fig 1.7.6 Finance Department Structure………………………………………………..8
Fig 2.2.2.1 Sands……………………………………………………………………….12
Fig-2.2.4.2.1 Core Making Section…………………………………………………….14
Fig 2.2.4.1 Spectro Test Machine Print…………………………………………………17
Fig -2.2.5.1 Sand system For Ferrous Foundry…………………………………………18
Fig-2.2.1.1 Gear Hobbing and Die Making unit………………………………………..20
Fig-2.2.2.3 Milling Machine Unit………………………………………………………20
Fig-2.2.3.1 Lathe Machine Unit…………………………………………………………21
Fig 2.2.5.1 Gas Cutting Trollies………………………………………………………....23
Fig-2.2.5.2 Thread Roller Machine………………………………………………….......23
Fig-2.2.7.1 Before and After Galvanization……………………………………………..24
Fig 4.1.1 Types of Screw Conveyor (a) Vertical Screw Conveyor (b) Horizontal Screw
Conveyor (c) Inclined Screw Conveyor (d) Shaftless Screw
Conveyor…………………………………………………………………………………32
Fig 2.1.2 Component of Screw Conveyor……………………………………………….32
Fig 4.7.1 Trough Loading………………………………………………………………..37
Fig 4.7.2 Screw and Shaft………………………………………………………………..38
Fig 4.7.3 Graph of Inclination Factor Vs. Angle of incline………………………………39
Fig 4.7.4 Graph of Corrected HP Vs. Calculated HP…………………………………….39
Fig 4.7.5 Trough………………………………………………………………………….43
Fig 4.7.6 Dimensioning of Trough……………………………………………………….43
Fig 4.7.7 Hangers…………………………………………………………………………44
Fig 4.7.8 Standard dimension of Transmission Flange Bearing………………………….45
Fig 4.7.9 Transmission Flange Bearing…………………………………………………..45
iv
Fig 4.7.10 Standard dimension Trough End……………………………………………..46
Fig 4.7.11 Trough End…………………………………………………………………...46
Fig 4.7.12 Standard dimension of supporting saddle ……………………………………46
Fig 4.7.13 Pulley Center distance…………………………………………………………49
Fig 4.7.14 Power transmission by belt……………………………………………………49
Fig 4.7.15 Cross section Grooved pulley…………………………………………………51
Fig 4.7.16 Speed reducer layout………………………………………………… ……….53
Fig 4.7.17 Graph of Output torque Vs. Center distance…………………………………..57
Fig 4.7.18 Intermediate shaft layout……………………………………………………...57
Fig 4.7.19 Torque Diagram………………………………………………… ……………58
Fig 4.7.20 Vertical Load Diagram………………………………………………………..58
Fig 4.7.21 Shaft Coupling………………………………………………………………...60
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List of Tables
Table 4.7.1 Bulk Material Table ……………………………………………………….36
Table 4.7.2 Capacity Factor table…………………………………………………….…38
Table 4.7.3 Capacity table ……………………………………………………………...38
Table 4.7.4 Hanger bearing factor and Diameter Factor……………………………...…40
Table 4.7.5 Standard dimension of Trough………………………………………………43
Table 4.7.6 Standard dimension of Hanger………………………………………………44
Table 4.7.10 Dimensions of standard V-belts according to IS: 2494 – 1974. …………...47
Table 4.7.11 Standard pitch lengths of V-belts according to IS: 2494-1974…..………....48
Table 4.7.12 Service load factor………………………………………………………… .50
Table 4.7.13 Dimensions of standard V-grooved pulleys according to IS : 2494–1974.…51
Table 4.7.14 Number of reductions ……………….……………………………………….52
Table 4.7.15 Minimum number of teeth on the pinion in order to avoid interference...….53
Table 4.7.16 Standard proportions of gear systems. ……………………………………...55
Table 4.7.17 Standard Key and shaft size…………………………………………………59
Table 4.7.18 Standard Screw coupling size……………………………………………….60
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Contents
DECLARATION........................................................................................................................i
Acknowledgement.....................................................................................................................ii
Executive summary...................................................................................................................iii
List of Figures...........................................................................................................................iv
List of Tables............................................................................................................................vi
1. Introduction.........................................................................................................................1
1.1 Background of the company.............................................................................................1
1.2 Foundry.............................................................................................................................2
1.2.1 Ferrous department....................................................................................................2
1.2.2 Non- ferrous departments..........................................................................................2
1.3 Machine shop....................................................................................................................2
1.3.1 Gear hobbing and Die making Section......................................................................2
1.3.2 Milling Machine Unit................................................................................................2
1.3.3 Lathe Machine Unit...................................................................................................2
1.3.4 Heavy-Duty Machine Unit.........................................................................................2
1.3.5 Fabrication Unit.........................................................................................................3
1.3.6 Hand-tools and Cutlery Unit......................................................................................3
1.4 Forging.............................................................................................................................3
1.5 Laboratories and Quality Control.....................................................................................3
1.6 Main Customers................................................................................................................3
1.6.1 Main Products............................................................................................................3
1.7 Over All Organization Structure......................................................................................6
1.8 Work Flow In Akaki Basic Metal Industry......................................................................9
2 Over all internship experience..............................................................................................10
2.1 Foundry shop..................................................................................................................10
2.1.1 Working Flow Of Foundry Shop In ABMI.............................................................11
2.2.2 Sand Washing..........................................................................................................11
2.2.3 Shot Blast (pang born) Machine..............................................................................12
2.2.4 Main Process Of Foundry Shop...............................................................................13
2.2.5 Non-Ferrous Metal Section......................................................................................17
2.2 Mechanical Work Shop..................................................................................................19
2.2.1 Gear Hobbing and Die making Section...................................................................19
2.2.2 Milling Machine Unit..............................................................................................20
vii
2.2.3 Lathe Machine Unit.................................................................................................21
2.2.5 Cutting and Rolling Section.....................................................................................23
2.2.6 Hand Tool and Cutlery Section...............................................................................23
2.2.7 Electro Plating Section.............................................................................................24
2.3 Forging Shop..................................................................................................................25
2.4 Heat Treatment...............................................................................................................26
2.4.1 Stage of heat treatment............................................................................................26
2.4.2 Types of heat treatment............................................................................................26
3.Overall benefits of internship................................................................................................28
3.1 Improving Our Practical Skills.......................................................................................28
3.2 Upgrading Our Theoretical Knowledge.........................................................................28
3.3 Improving Team Playing Skill.......................................................................................28
3.4 Leader Ship Skill............................................................................................................29
3.5 Working Ethics...............................................................................................................29
3.6 Industrial Problem-Solving Capability...........................................................................29
3.7 Entrepreneurship Skills..................................................................................................30
3.8 Interpersonal Communication Skills..............................................................................30
4. Design of Inclined Screw Conveyor....................................................................................31
4.1 BACKGROUND............................................................................................................31
4.1.1 TYPES OF SCREW CONVEYOR.........................................................................31
4.1.2 COMPONENT OF SCREW CONVEYOR............................................................32
4.2 Statement of the problem & Justification....................................................................33
4.3 Objective.........................................................................................................................33
4.3.1 Main Objective........................................................................................................33
4.3.2 Specific Objective....................................................................................................33
4.4 Literature Review...........................................................................................................34
4.5 Methodology...................................................................................................................34
4.6 Material selection...........................................................................................................35
4.7 General Design of Screw Conveyor...............................................................................35
2.7.1Calculating the Horse power requirement................................................................39
4.7.2Calculating the Total Torque....................................................................................41
4.7.3Design of the Shaft...................................................................................................41
4.7.4 Selection Of Trough.................................................................................................42
4.7.5 Selection of Hangers................................................................................................44
4.7.6 Selection of Transmission Flange Bearing..............................................................44
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4.7.7 Selection of Trough End..........................................................................................45
4.7.8 Selection of supporting saddle.................................................................................46
4.7.9 Design of V-belt Drive............................................................................................47
4.7.10 Design of Speed Reduction Gear Box...................................................................52
Conclusion................................................................................................................................61
Recommendation......................................................................................................................62
References................................................................................................................................63
Appendices
ix
BAHIR DAR UNIVERSITY
INSTITUTE OF TECHONOLOGY
FACULTY OF MECHANICAL AND INDUSTRIAL Ethio-Engineering Group
ENGINNERING Akaki Basic Metals
1. Introduction
1.1 Background of the company
Akaki Basic Metal Industry is a state owned business organization mainly engaged in
manufacturing and sale of spare parts, hand tools, cutlery and so on. It is the largest engineering
company in the country; which has got for different production workshops with multipurpose
machineries. It can be said that the company is achieve industry as it has the capacity to produce
different industrial spare parts and machinery. The company is situated in the south of Addis
Ababa about 25k.m on the Addis Ababa/Nazareth main road and about 3k.m of east of village of
Akaki.
Akaki Basic Metals Industry was established in 1989 G.C, established for the purpose of
producing and supplying spare parts and capital goods and carrying out such related activities
that are deemed important for the attainment of its objectives. This Industry is transferred from
privatization agency to Metals and Engineering Corporation in the year 2010 G.C. ABMI is
formed through amalgamation of six factories. In addition to producing and supplying spare parts
and capital goods it also multiply itself by constructing such factories throughout the country and
transferring to different enterprises.
The company has different shops for different products process and those are:
 Mechanical work shop
 Fabrication Shop
 Foundry shop
 Forging shop
 Heat treatment
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1.2 Foundry
Area: - 5476m2
The foundry has ferrous and non-ferrous department with an annual capacity of 4450 tons in
two shifts. The capacity of the furnaces in the two departments is as follows: -
1.2.1 Ferrous department
Three (3) furnaces --------3.3 tons each.
One furnace ----------250k.g
1.2.2 Non- ferrous departments
Furnace for Aluminum-----------500 kg.
Furnace for Bronze/Brass --------- 500 kg.
Furnace for Aluminum alloys -------500k.g.
1.3 Machine shop

Area: - 11664m2
1.3.1 Gear hobbing and Die making Section
In gear hobbing and die making unit many machines are included that are capable of
producing high quality gears with a desired number of teeth, module, pressure angle, pitch circle
and other stated In the description of design part model.
In this section Spur gears, helical gears, sprockets, worm gears that are up to diameter of
1250mm and module 14mm are produced in different set of machines located in this unit.
Machines that are found in this section are - Pfauter Gear Hobbing Machine, Gleason
Coniflex No. 14 Straight Bevel Gear Generator, Spline Generator, Internal Gear Generator
etc
1.3.2 Milling Machine Unit
In the milling machine unit many milling process are performed based on the required
design of work piece some of the milling operation performed in the unit are Plain milling, Face
milling, Gear cutting, Spline cutting, Drilling, Copy milling and Boring.
Machine found in the milling section are Universal milling, Vertical Milling, Plano
millers etc.
1.3.3 Lathe Machine Unit

Many operation are performed in single engine lathe machine in the machine shop some
the basic operation are Facing, Turning, Drilling, Boring, Tapering, Internal threading,
External threading, Chamfering, Knurling, Necking or Grooving and Parting Operation.
1.3.4 Heavy-Duty Machine Unit

As the name indicate the heavy-duty section is a unit on which large sized work piece are
mounted for machining process on which the workpiece are big enough that they can not be

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machined on the basic milling and lathe machines. Some of the machine founded in the heavy-
duty section are Vertical Lathe machine, Horizontal Lathe machine, Boring machine, Plano
millers.
1.3.5 Fabrication Unit

In this Section machines are included that can do the process of cutting, drilling, welding,
shearing, bending and rolling. Machines that are found in this section are Power hacksaw,
Hydraulic Bending machine, Hydraulic Shearing machines, Gas cutting trollies, Welding
machine, Rolling machines, CNC Plasma Cutter and Radial Drilling machines.
1.3.6 Hand-tools and Cutlery Unit
In this section different machine using; like thread roller machine , piercing
(mechanical and hydraulic presses) and upsetting machine etc
1.4 Forging
Area: - 288m2
Equipped with ; 2 electric motor driven power hammers of 27k.g, one for open and die forging
up to 450k.g and 40k.g respectively and the other one for forging steel balls for cement factories.
1.5 Laboratories and Quality Control
 Metallurgical and mechanical testing
 Laboratories equipped with spectrometer and other lab equipment’s.
1.6 Main Customers
The main customers of Akaki Basic Metal Industry are:-
*, Fincha Sugar Factory
*, Arjio Dedesa Irrigation Dam
*, Kessem Sugar Factory
*, Wonji Sugar Factory
*, Metahara Sugar Factory
*, Mugher Cement Factory
*, Ethiopian Telecommunication Corporation (E.T.C)
*, Ethiopian Electric Power Corporation (E.E.P.CO)
1.6.1 Main Products
Akaki Basic Metal Industry are capable of making:-
Roller; for Sugar Factories (Fincha, Wonji, Metahara and Kessem )- Shafts
Sprocket for chain link drive; for Beshoftu Automotive- Keys
Gear Box Housing; for E.E.P.CO - Steel balls

Inter Mediate Carrier Sprocket; Fincha- Bearing housing
Dust Collector; for Mugher Cement- Sheet and plate parts
Gears (Spur, Bevel, Helical and Worm)- Forged parts
Hand Tools and Cutlery- Hooks and ins pin

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But currently it makes:-

Roller; for Sugar Factories (Fincha, Wonji, Metahara and kessem) Trash plate
Gears Cross arm
Keys Flange roller
Steel balls U-channel (length
2.5 m)
Hooks Scraper Plate

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Fig- 1.6.1 Some Product of ABMI

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1.7 Over All Organization Structure
Board of Management
Internal Audit service

General Manager
Legal Manager Organization and Information

method service
Quality Assurance
Planning and Information
service
technology service
Administration and Marketing and Supplies Finance Manufacturing

HRD department department department department
Fig-1.7.1 Over all Organization Structure
Qualit
y
Inspection Laboratory
section section
Fig-1.7.2 Quality Section Structure
Marketing and supplies

Department
Sales and sales Procurement Market research and

Material
promotion division product development
management
division division
division
Fig-1.7.3 Marketing and Supplies Department Structure

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Manufacturing
department
Design Foundry Mechanical Heat and Maintenanc
production division work shop surface e division
planning and division treatment

Foundry
control division Milling division Electrical
section Heat
PPC method and maintenanc
treatment
section pattern Hand Tool e unit
unit
making and Cutlery
Design section section Surface
and treatment Mechanical
Sand
metho Lathe unit maintenance
preparation,
d section section
mould and
core unit Heavy
duty
Ferrous section Machinery
foundry Surface and
grinding equipment
unit section maintenance
Non- unit
Gear
ferrous
hobbling Vehicle
foundry
section maintenance
Cast
unit Fabrication unit
finishing section
section
Plant service
unit
Forging
shop
Fig 1.7.4 Manufacturing Department Structure

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General Manager
Administration and
HRD department
Clinic
Personnel Administration and General services

Training division division
Fig- 1.7.5 Administration and HRD Department Structure
General Manager
Finance
department
General accounts Cost and

division Budget division
Fig 1.7.6 Finance Department Structure

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1.8 Work Flow In Akaki Basic Metal Industry

The general work flow of foundry shop in Akaki basic metals industry (ABMI) is; -
1, First the customer or the client come to the company with the drawing of the needed material.
If the customer is come without the drawing of the material, they draw but the cost is added for
drawing.
2, Then, the sample seen by sales or the customer speak the needed composition then connect
with PPC (Production Process Control) section.
3, The availability of the raw material and other equipment checked by PPC (Production process
control) After checking the storage and all raw materials are available to produce the product.
4, Next the sales are estimating the cost of product after identify what process the customer need
like heat treatment, addition of alloy, surface finish etc.
5, Then the PPC plan the process and the method of the work.
6, The method of making the runner, getting system, sprue base, riser will design. Then transfer
in to the pattern room.
7, The next step is making the pattern. The pattern will made mostly by wood material.
8, And if core is necessary core will made in core making section.
9, After the pattern made, the molding section will be identified by seeing the size of the pattern.
If the pattern(product) is large hand molding section is selected if it is small or mass production
is needed mechanized section will select and the mold cavity will be formed.
10, The next step is melting the material and pouring the molten metal in to mold cavity by using
pouring cap.
11, After the molten solidify the product will out and if heat treatment is needed it cool by using
water or air medium.
12, The product will grind and also the riser, runner and other unwanted part should remove
13, Next, transfer in to machine shop or other shops.
14, Finally customer will be receptive the product.
But the work flow is not always start from foundry shop sometimes it may start from machine
shop or heat treatment. Which means after PPC plan the process and the method of the work also
after the cost is estimated the work flow start from the needed shops.

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2 Over all internship experience

We select this company: -
Program because it is the main company in the country that work on manufacturing process
of different material by using ferrous and nonferrous metals. Like making of different spare part
materials, casting process. Hand tools and cutlery etc…
Because of we are manufacturing stream student we should see different manufacturing
processes so ABMI is one of manufacturing company. Also in order to develop our practical
knowledge that we learn in campus we select ABMI.
The section of the company we were worked and why
The company mainly consist foundry shop, mechanical work shop, forging shop, heat treatment.
So, we work on those section mainly foundry and mechanical shop because the main
manufacturing process takes place in this section. Also, in order to develop our practical
knowledge of different subject like workshop, handling and equipment, manufacturing, reading
drawing and etc. The shop listed above are selected.
Work piece or work tasks we have been executing
We have been executed in different types of activities in different shop such as in foundry,
mechanical work and forging shop. In foundry shop there are different task like sand washing,
making of pattern, making of core, preparation of mold, melting process, mold transferring
process, sand reclamation process, finishing process and in mechanical work shop gear making,
lath machines, milling machines, cutting process, electrolysis, grinding are the main tasks. And
also forging.
In the process different shop in ABMI ferrous and nonferrous metals are the work pieces that
executed in different process like steel, aluminum, zinc, brass, cast iron, bronze etc...in addition
silica sand is necessary for foundry shop.
2.1 Foundry shop

A foundry is a factory that produces metal casting. Metals are cast into shapes by melting
them into a liquid, pouring the metal in to mold, and removing the mold material after the metal
has solidified as it cools … in this process, parts of desired shapes and sizes can be formed.
Casted metal property
 Density becomes less – due to level of porosity.

 Porosity is high – due to entrapment of slag, oxygen. Hydrogen etc.
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 Minimize conductivity – due to present of porosity
Advantages of casting
 complex shapes of materials can be done easily

 Materials that are not made by plastic deformation is easily made.
 huge (large) objects can be done
 Economically advantage out.
2.1.1 Working Flow Of Foundry Shop In ABMI

The general work flow of foundry shop in Akaki basic metals industry (ABMI) is;-
If the pattern is
Making of
Drawing of Mold large hand mold
pattern and Melting
the material preparation
core If the pattern is process
small
mechanized mold
Then break down Finishing process

Pouring of melt
the mold and out Removing of riser
in to mold cavity
the material ingate and other
unwanted part
2.2.2 Sand Washing
The process of casting done in ABMI is by using sands. Sand casting, also known as sand
molded casting, is a metal casting process characterized by using sand as the mold
material. Mainly we use sand for casting process because it is one of the few available processes
for metals with high melting temperatures such as steels, nickel, and titanium. Because of its
flexibility, heat resistance, and relatively low cost, sand casting is the most widely used
casting process.
When the company start working after its establishment the sand that used for casting process
comes from outside country but one engineer made a research and he conclude we can use sand
from our country this sand comes from Merahabite north Shewa in Ethiopia and the sand is silica
sand (sio2). After it comes it manually purified by water by using two sieves the first sieves used
for removing large unwanted particle it is larger hole than the second sieve the second one is
small hole each of them are 2.5 mm square used to separate the needed sand from impurities by
using pressurized water. After the sand washed it go to hopper.

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a) Sand before wash and dry b) after wash and dry

Fig 2.2.2.1 Sands
ABMI used resin and catalyst for the binders of molding system.
Resin is acted as bonding material and catalyst is used to fast the reaction of resin and sand.
Chemical name of catalyst and resin are:-
For catalyst ………………….. Selphonic acid
For resin …………………..….. Furfural alcohol
2.2.3 Shot Blast (pang born) Machine
Shot blast (pang born) machine is a machine used to reuse the sand ones it works mold cavity.
The sand that reused is called reclaimed sand. This machine work by pneumatic system.
The process of reclamation is as follows; -
First the sand that form the mold cavity should broke after the product out, after the sand broken
in to pieces it insert to the machine by small excavator and this machine spray small ball at high
pressure and those ball broke down the mold sand in to small pieces(original size) and there is
vibrator when it vibrate a very fine sand will remain at the bottom , the medium sized sand take
medium position and the other take upper position. So, a very fine sand and dusts(impurities) are
removed by the machine automatically by pressurized air and the ball is attracted by the magnet.
Finally, reclaimed sand formed and it transfer to three directions.
1. Hand molding section
2. Mechanized section
3. External (reclaimed sand silos)

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2.2.4 Main Process Of Foundry Shop
The main process in foundry shop is making the pattern, making core, forming of mold cavity,
melting of the material, pouring and finishing works.
2.2.4.1 Pattern Making
Pattern is something used as a model to make a copy, is the method to produce the mold cavity
or replica of the final object in pattern shop. Pattern is made from: - wood, plastic, wax, metal
and so on, but in this company made from wood. Because of it is low cost, easy for product, easy
for worked. And ABMI use different allowance those are: -
Pattern allowance
1. Shrinkage allowance
2. Machining allowance
3. Draft allowance
1. Shrinkage allowance
- It is the ability of molten metal to be contract during solidification at solid state.

- Shrinkage allowance is important only during designing of patterns.
2. Machining allowance
- Is the extra amount of metal which is provided on the surface to be machined.

- It is included in the pattern design.
3. Draft allowance
- is required to avoid damage at the sharp edge of the mold during pattern removal.
- Patterns are tapered at some angle along its vertical surface.
After the pattern is made gating system that is conduit network through which liquid metal enters
a mold and flows to fill the mold cavity is prepared that is:- runner, riser and sprue base
Finally; paint the pattern and ready for mold section.

2.2.4.2 Core Section
A core is a device used in casting and molding processes to produce internal cavities or hallow
regions. In ABMI new sand and thermally regenerated sand used for making a core. Thermally
regenerated sand is a sand without chemical done by furnace. But mainly new sand is preferred.

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Core making process
First core making box pattern is prepared and the sand is mixed with resin and catalyst in
measured proportion by using mixer after that the mixed sand added to the core box and
rammed. After some minutes the two-core box separates and the core is made.
Fig-2.2.4.2.1 Core Making Section
2.2.4.3 Mold Section

Depending on the size of pattern there are two type of molding section found in ABMI
Mechanized mold: -use for low size
Hand mold: -used for large size pattern like roller.
Mechanized molding
It called mechanized molding because low amount of man power is needed than hand molding.
The transferring process done by roller conveyor.
The process is: -
o First the prepared pattern come from pattern making section
o Proper flask is prepared
o Set the pattern in the flask in proper place and also set sprue if necessary, riser and air
vent. Dolomite powder added to the pattern material like spraying used for easily separate
of the pattern from the mold cavity.
o Mix the sand with resin and catalyst in proper ratio in the mixer
o Add the mixed sand to the prepare flask

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o After the sand is added to the flask it goes to ramming machine by using roller conveyor
and the sand will ram.
o Then the pattern will remove and go to pattern store and the mold sand goes to drying
machine.
o After the pattern is removed the mold cavity is painted in order to make good surface
finish, to protect the mold cavity and to avoid penetration (making crack) of the molten
metal to the sand. Isomer is used for painting purpose in last time but it comes from
outside country so they develop other thing to locally make this paint they mix
refractories and red soil and to knead the mixture then it paints to the mold cavity mainly.
The locally made mixture used for cast material but the isomer used for steel materials.
o Then it dried by machine (blow air)
o If core is needed place the core in the mold cavity.
o After it dried it go to manipulator to assemble cope and drug
o When cope and drug assemble caustic soda + sodium silicate in baked form are stick
around the mold contact area between cope and drug. This is used to resist leakage of
molten at the contact area.
o Finally, it transfers to pouring area.
Hand molding
It differs from mechanized molding because: -
 It uses large amount of man power and large material done in this section like roller.
The process is the same as mechanized molding the difference is ( riser ,ingate, air vent )is
necessary sometimes it use many flasks and also the flasks does not disassemble until material
out.
2.2.4.4 Melting Section
Melting is a process by which a substance changes from solid phase to the liquid phase. In Akaki
Basic Metal Industry different materials are melted like cast iron and its alloy, steel and its alloy,
copper alloy, bronze, brass and aluminum. There are four furnaces in this section.
The three (3) furnaces melting capacity are: - 3300 kg for each furnace and another one (1)
furnace melting capacity is 250k.g
 Total melting capacity is: - 10150 kg.

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All ferrous metal melting furnace are induction type. When they prepare for melting
process the inside portion of the furnace covered by gasket (amentite) next to the gasket
refractories added by using former for centering purpose. So the former set at the center of the
furnace (it must be at the center). After the former set in right position refractories added
between the refractories and the gasket also at the bottom and it rammed by vibrator or another
ramming machine. Mainly the thickness of the refractories is mostly 3 cm from each side of the
circular cross section. The thickness should be uniform unless when the material melt it may
penetrate to low thickness side. The refractories may be silicate or alumina.
 We use refractories for the purpose of:-
They transfer heat and they do not lose their properties at the melting process
They resist the damage of induction furnace coil by trapping the molten
Refractories’ use for long time once they prepare in the furnace.
The process of melting includes the following steps: -
 First the furnace charge by using pig iron. pig iron is shaped so they do not require large
space which is it occupy small area.
 Then the temperature gradually increases
 The metal start melts from the bottom
 Small scrape material added to the furnace when it melts other added
 Impurities or slag agent added to the molten metal and then the impurities go to upper
part and it removed by slag remover
 Then the small amount of molten metal goes to Spectro test machine and this machine
identify which material is found and measure the composition (amount) of each element
in the melted metal. First a small amount of molten metal pour from the melted metal
then go to the spectro test machine room and it solidify. Then it must grind after it grind
it set on spectro and it measure the amount of element composition.
 After the test, if the amount of carbon is low in order to increase the carbon amount high
carbon element like graphite added to the molten metal.

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 If the carbon amount is high low carbon element is added to the molten metal to reduce
the amount of carbon or sometimes it reduced in the form of smoke.
 Again, we go to the spectro test machine and check the carbon amount is what should be.
 If the required temperature reached then the metal prepared to pouring process
 Then the molten metal pour to the ladle this process is called tapping. The furnace by it
self have hydraulic system to raise the furnace and pour.
 If the molten metal is not enough for the mold it pour to the large ladle for holding
purpose.
 Finally, the liquid molten pour to the mold cavity by using pouring cap.
 If the mold is large it is difficult to pour in to the pouring cap so the mold inserts to the
ground and pour in to the pouring cap.
Fig 2.2.4.1 Spectro Test Machine Print

2.2.4.5 Finishing Section
After the material solidify the sand mold broke down and the final product will out and go to
finishing area then the riser, ingate and sprue are cut from the product and the material will grind
to some extent. If further surface finish, drilling and other process is needed the material go to
mechanical work shop.

2.2.5 Non-Ferrous Metal Section
Nonferrous metal has does not contain iron in appreciable amount. Those are aluminum, copper,
brass, bronze, tin so on. The process of this section is same as the above process only a little

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difference in melting process 3 furnace found in this section and two of them is resistance and
the other one is induction type furnace. The resistant type furnace is used crucible (made of
graphite) instead of refractories in induction type of furnace. And because aluminum has low
melting point it can easily melt and solidify so holding furnace is necessary to hold the molten
aluminum to avoid solidification before it pours to the mold cavity. Different other production
process takes place in this section like piston die casting, centrifugal die casting
Centrifugal die casting is a machine used to make hollow round material
In this casting method different die are found and the die are set in the wheel and the wheel roll.
At first it rotates at 600 rpm then the speed will increase and the molten metal pour in to the
rotating die. Because the die is rotating, the molten metal will have the shape of the die but at the
center it will form constant dimensional hole and then the die should cool and the product will
out from the die.in order to make different size of material different die should needed.
Piston making die casting it used to form piston by using dies from aluminum material.
Once the aluminum is melted in the furnace it goes to the holding furnace and it pour to the die
and after some minuet the die disassemble and the piston will out.
22
24 23 18
20 17
21 16
16
12
13 12
1 14

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8
19
16 15
8 10
5 6 11
25
3 7
4 Fig -2.2.5.1 Sand system For Ferrous Foundry
1. Sand washed 10.Drier 19. Hand Molding Station

2. Sand Transportation 11.Sender 20. Silo
3. Hopper (1) 12. New Sand 21. Sender (3)
4. Vibrator 13.Regenerated Sand 22. Shot Blast
5. Elevator 14. Reclaimed Sand 23.Molds
6. Distribution Belt 15. Sender (2) 24. Pusher
7. Concrete Soils 16. Mixer 25. hopper
8. Jop dog (Power Shovel) 17. Core Station
9. Hopper (2) 18. Mechanized Station
2.2 Mechanical Work Shop

Mechanical Work shop is the main and important part of the company it covers a total area of
11,664 m2 . The mechanical Work shop has different working unit the can do various type
machining process the working units are :-

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 Gear Hobbing and Die making Section

 Lathe machine section
 Milling machine section

 Grinding section
 Cutting and Rolling section
 Heavy Duty section
 Hand Tool and Cutlery Section
2.2.1 Gear Hobbing and Die making Section
A gear is rotating circular machine part having cut teeth or, in the case of
a cogwheel or gearwheel, inserted teeth (called cogs), which mesh with another toothed part to
transmit torque.. Geared devices can change the speed, torque, and direction of a power source.
Gears of different sizes produce a change in torque, creating a mechanical advantage, through
their gear ratio, and thus may be considered a simple machine. There are many types of gears
such as spur gears, helical gears, bevel gears, worm gears, gear rack,.
Production process in gear hobbing and die making unit

In gear hobbing and die making unit many machines are included that are capable of producing
high quality gears with a desired number of teeth, module, pressure angle, pitch circle and other
stated In the description of design part model.

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Fig-2.2.1.1 Gear Hobbing and Die Making unit
In this section Spur gears, helical gears, sprockets, worm gears are up to diameter of 1250mm
and module 14mm are produced in different set of machines located in this unit.
2.2.2 Milling Machine Unit
In the second line of the work shop the milling unit is located with different kind of milling
machine. Milling is the process of machining flat, curved, or Milling machines are basically
classified as vertical or irregular surfaces by feeding the workpiece against a rotating horizontal.
Fig-2.2.2.3 Milling Machine Unit
2.2.2.3Production Process In Milling Machine Unit
In the milling machine unit, many milling processes are performed based on the required design
of work piece some of the milling operation performed in the unit are listed below.
Plain Milling: - Plain milling, also called surface milling or slab milling, is milling flat surfaces
with the milling cutter axis parallel to the surface being milled.

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Face Milling: - Face milling is the milling of surfaces that are perpendicular or at angle to the
cutter axis. Face milling produces flat surfaces and machines work to the required length
Gear Cutting: - Gear teeth are cut on the milling machine using formed milling cutters called
involute gear cutters. These cutters are manufactured in many pitch sizes and shapes for different
numbers of teeth per gear.
Spline Milling: - Splines are often used instead of keys to transmit power from a shaft to a hub
or from a hub to a shaft. Splines are In effect. A series of parallel keys formed integrally with the
shaft mating with corresponding grooves in the hub or fitting.
Drilling:- The milling machine may be used effectively for drilling, since accurate location of
the hole may be secured by means of the feed screw graduations
Copy Milling:- This type of milling uses advanced machine that is capable of copying a sample
product or tracing the shape and profile of the sample product in order to produce output with the
same shape and size of sample product. The machine can function with manual or automatic
feed of the coordinates.
2.2.3 Lathe Machine Unit
Fig-2.2.3.1 Lathe Machine Unit
In the third line of workshop lies a lathe machines unit in which different lathe machine
operations are performed. The lathe is a machine tool used principally for shaping articles of
metal (and sometimes wood or other materials) by causing the workpiece to be held and rotated

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by the lathe while a tool bit is advanced into the work causing the cutting action. The basic lathe
that was designed to cut cylindrical metal stock has been developed further to produce screw
threads. tapered work.
Many operations are performed in single engine lathe machine in the machine shop some the
basic operation are Facing, Turning, Drilling, Boring, Tapering, Internal threading, External
threading, Chamfering, Knurling, Necking or Grooving and Partin Operation.
2.2.4 Heavy-Duty Machine Unit
As the name indicate the heavy-duty section is a unit on which large sized work piece are
mounted for machining process on which the workpiece is big enough that they cannot be
machined on the basic milling and lathe machines. Some of the machine founded in the heavy-
duty section are listed below.
Vertical lathe machine: - is a machine tool that rotates a work piece on a rotating axis and
performs various machining operations vertically. Vertical lathe machines can perform facing,
turning and boring operation up to 1500mm diameter workpiece.
Horizontal lathe machine: -Is the same with basic an engine lathe in which the main difference
is the size the machine and the size of the workpiece that hold. It can perform an operation like
facing, turning, boring, chamfering.
Boring machine: - are two types the single column and the double column boring machine. The
double column boring machine is multi-purposed machine they can be used as a boring and
milling machine as well with a different setup used. The double column boring machine has a
capacity of boring a work piece with 2 meters in length and a weight up to 6 or 7 ton.
Plano Millers: -is a type of metalworking machine tool that uses linear relative motion between
the work piece and a single-point cutting tool to machine a linear tool path. Its cut is analogous
to that of a lathe, except that it is (archetypally) linear instead of helical. (Adding axes of motion
can yield helical tool paths) A planer is analogous to a shaper, but larger, and with the entire
work piece moving on a table beneath the cutter, instead of the cutter riding a ram that moves
above a stationary work piece. The table is moved back and forth on the bed beneath the cutting
head either by mechanical means, such as a rack and pinion drive or a lead screw.

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2.2.5 Cutting and Rolling Section
Fig 2.2.5.1 Gas Cutting Trollies

Fig-2.2.5.2 Thread Roller Machine
In this Section machines are included that can do the process of cutting and rolling are
performed. Machine that are used for Cutting and Rolling process are:
Power hack saw: - work in reciprocatively mechanism by changing the rotation the flywheel
which powered by a motor to cutting transition which is a linear motion the up and down motion
is controlled by the hydraulic piston. They are capable of cutting bar up to 350mm.
Hydraulic Shearing Machine: -is capable of cutting plates up to 16*2500 mm .
Gas cutting trollies: - used to cut plates with high thickness effectively in straight or circular
shape. The motion of the trollies is automatic after being measures the distance and the flame
intensity.
Rolling Machines
are capable of rolling a work piece with dimension of plate’s up to 20*2500 mm.
2.2.6 Hand Tool and Cutlery Section
Thread roller machine
is used to make thread by using different dies. This machine has a roller which is different
shaper and different size of pitches (minimum pitches 1.75 mm and 2m, 2.5mm, 5mm, 6mm, and
maximum are 7mm).

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2.2.7 Electro Plating Section
Electro plating section known as surface treatment plate it has four different plated elements.
1. Nickel 2. Galvanize 3. Chrome 4. Phosphors
Mostly nickel and chrome are not used. Because, this process requires higher costs. Therefore,
Phosphors and Galvanizing are used mostly due to their total low costs.
2.2.7.1 Process of Electro Plating (Galvanization)
First, the material is come by using crane. Then, plate in to storage of hydrochloric acid.
Hydrochloric acid is small cost, high clear, from other materials. After (2-5) minutes get in to
water storage, the material setting in to base bare, and again dipping or soaking in to water
storage. Then, dip into Sodium hydroxide (caustic soda), with electric system that is heat the
chemical (3-5) minutes. Then moving in to water storage by crane and dipping the material by
base bare and wash. Then again dipping into another storage water and wash then moving in to
storage of neutralization by crane and dipping the material, in this stapes not use electric that
means the chemical is cool. Then moving in to storage of water and washing the material. Next,
dip the materials in to storage of Zinc (Zn) plate with electric system. (10-15) minutes in this
steep there are two chemicals. Ammonium chloride and zinc chloride. Ammonium chloride is
closed by bag. It is made from clothe. Zinc chloride is 99.9% is pure zinc.
Then moving in to storage of water and wash the material and dipping the material in to chrome
plate storage without electric system. Finally wash the material three (3) storages of water.
N.B. Hydro choleric acid is used for removed the rust and Sodium hydro-oxide is used for
remove the oil and grease.
Chromic acid is use for hard and smooth material.
Length of storage 1.80m 70-80c.m width and 120cm of height
On other large galvanize electro plate storage in 300cm length, 100cm width and 100cm of
height.

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Fig-2.2.7.1 Before and After Galvanization
N.B- Charges are flow from negative to positive due to this the positive part of electric is
connected to the material to be surface treated and negative part is connected to the Zink
solution. This shows the process is from zinc to metal.
2.3 Forging Shop
Forging section is one of manufacturing department. Today the forging industry covers
wide range of services and technology available to the market. Forging product the material from
steel, aluminum, copper alloy and soon. Those difficult to fabricate alloys typically will demand
slow or controlled deformation rate by forging technique. In order to deform materials like
carbon steel is requires extremely high deforming dynamic load. In this case we need huge and
bulky forging hammers. This type of hammer does not exist for various reasons, instead we heat
the work material to its re-crystallization drop temperature so that it loses its resistance to
deformation, this operation is called hot forging. The main advantages of forging operation are to
get the best material quality and for mass production.
Typical examples of forging products are hand tools. Like knifes, pliers, knives of different size,
steel balls ranging from Ø25mm to100mm, different types of hammers, axes, and so on.
Some of the operation are:-
- Forge shearing bend trim and so on…
- Piercing up-setting roll
In this section different machine are there, such as:-
Self-compress hammer machine
- The machine capacity is 2.8 ton dynamic load and forge by hammer.

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- When the material is large or huge cannot used by human power. Because of it is
difficult. So by using manipulator machine we can forge the material.
Hot shearing machine
- It is using the round bar e.g. 6m, 5m

- It is shearing process. For example, we need 10cm round bar, from 6m so, the round bar
straight to the electrical system furnace adjust the length, and we can cut the round bar by
using stopper.
Drop forging machine it is pneumatic system and mechanical hammer. The blow is not
constant.
Piercing machine it is using puncher and lower die the process is called piercing process and
capacity of 60 ton.
Bending machine, it is used to make bend and the process is called bending process.
Trimming machine, it is used to make trim.
2.4 Heat Treatment
Heat treatment is defined as an operation involving heating and cooling of metals or alloys in its
solid state with the purpose of changing the properties of the material.
Why heat treatment is done
 To soften the material that has been hardened by the previous heat treatment or
mechanical working
 To harden the material and increase its strength
 TO adjust its other mechanical &physical properties like ductility & malleability
 To refine the grain size of the steel and to reduce internal stress
What is the purpose of heat treatment?
 To improve in ductility
 To relieving internal stress
 Grain size refinement
 TO increase of strength and hardness
 To improve in machinability and toughness

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2.4.1 Stage of heat treatment
Heating :-heating must be controlled to the desired temperature using a good insulated proper
heating furnace under a suitable atmosphere to prevent the heat dissipation and the oxidation
process.
Soaking:-soaking is the essential step to ensure that the temperature of component is equated
between its surface and its core. This will depend on the dimensions of the heat-treated
component.
Cooling:-cooling will affect the resulted microstructure and then the obtained properties.
Accordingly, cooling will be done either in the heating furnace (by switch off the furnace) or by
leaving the heat-treated component to be cooled in a certain medium like air, oil or water.
Occasionally, salt-bath and low-temperature melted metals are used as a medium for cooling
step.
2.4.2 Types of heat treatment
1)Annealing:
(i) To reduce internal stresses produced due to cold working, welding etc.
(ii) To reduce hardness and increase ductility.
(iii) To refine the grain size.
(iv) To increase machinability.
2)Normalizing: -The main purpose of normalizing is to obtain a structure that is uniform

throughout work piece and is free from any locked-up stresses. And similar to annealing but the
cooling rate is accelerated by taking the work piece from the furnace and allowing it to cool in
free air.
Normalizing is heating the material to about 30-50 degree centigrade above the upper critical
temperature, holding for proper time and then cooling in still air
3)Hardening:-the hardening treatment for most steels consists of heating the steel to a set
temperature and then cooling it rapidly by plunging it into oil, water, or brine. Hardness of
material is done to increase the strength and wear properties.
4)Tempering:-is done to remove some of the brittleness and hardness of steel after
hardening.
Some tools we have been using while performing our work tasks
The engineering method, tools and techniques are described above but to generalize the main
tool in foundry shop are transferring materials like bucket conveyors, roller conveyors, belt
conveyors, overhead crane, jib cranes, clamping materials (for clamping work piece with the
needed machine), furnaces, flask, pins, trollies, different metals, hammers (to break down the
mold), grinding tools, forklift, welding tools, compressor, fans, motors, flywheel are some of the
tools.

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Major challenges and problems we have been facing and identifying while performing our
work task.
 The major challenge is that there is no work in most of the time.so we cannot see some
the machine while performing the work task.
 Some machine cannot perform their work this leads to the decision of finding alternative
machining operation which could result lack of precision and damage to the other
machine.
 Lack of trained individuals to operate some machines even if these days the production
process is low but the workshop have to occupy well trained individuals.
 Some of the work perform manually that decrease production rate and quality.
 There is no sand transferring system after the sand is washed to the hopper.
 Skilled maintenance is major problem
 Most machine are early they are not Modernize.
And some of the solution are: -
 We recommend the company should modernize some of the machine and a skilled person
is needed for maintaining when they are not work. Also, some part of the shop work
should be performed by using machine like washing the sand, and breakdown of the
mold.
 The better management system is needed
 Fixing broken machine as soon as possible can achieve a great relief for the production
process most of the machine automation and computer guide process are broken it can be
easily fixed with a professional and fixing this machine can boost the record of the
company in the speed and accuracy of production.
 Installment air condition unit or a simple fan and can reduce heat generated in the
machine shop and increase the comfort of the technician.
 Increasing well trained individual for the operation and maintenance some machines.

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3.Overall benefits of internship

Learning process are difficult if it is without practice because we don’t know how to operate the
machine, the mechanisms, the working principles and so on the reason is that there is a gap
between the theoretical and the practical knowledge. So, internship program is very necessary in
order to develop our knowledge in different way not only our practical knowledge. And also, it is
useful to see some problem regarding to our subject and to give recommendations or solutions.
Generally, it is used to develop the following skills
3.1 Improving Our Practical Skills
This internship training used to improve our practical skills and also how to improved our
knowledge in different process. In foundry shop we learn different practical knowledge like
transferring method, casting procedure, melting process, pattern and core making way, mold
preparation, lathe works, milling works, different crane, heavy duty works, surface finishing
process, gear making process, cutting work, tread making roller, rolling process and so on.
And also, we gained the operation of some machines, for example in foundry shop (pangborn
machine, spectrotest machine, band saw, lath machine, milling, mixers and so on), in melting
process (induction and resistor type furnaces) so on. Mainly understand the work flow of
different process. Generally, before this internship we don’t know how to change the theory of
the learning process in to practical process
3.2 Upgrading Our Theoretical Knowledge
This internship training is used to upgrading our theoretical knowledge. Most of the time
universities have not enough laboratory and machineries in order to get full information; this
means the learning process are not detail. So, internship increases the theoretical knowledge with
practices; for example: - how to make the pattern, and different pattern allowances, type of sand
that used for casting methods, melting process, clamping method of workpiece, composition of
different metals, forging type, electrolysis process (zinc, chrome…), heat treatments type,
different cutting methods and so on. Also used in the process of problem-solving process we
develop our theoretical knowledge.

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3.3 Improving Team Playing Skill
This internship training has also essential purpose in team playing skill because in the
company we communicate or work with different others person like different university
internship students, company workers, company mentors, different management bords, security
staffs. For examples we are friend with ambo, welkite and madda walabu university students so
we had share idea to each other in case of our projects, some problems, company background…
In together we were seen some section of the company and we shared idea about the working
principle of some machines. If one of ours is not understand about something we discuss in
groups if we all not know about something, we ask company workers. Generally, team playing
skill played an important role in communication.
3.4 Leader Ship Skill
In some area of the company there is poor leader ship skill that cause a gap between the
leaders or the managers and the workers, that result low production rate and also the workers will
be irresponsible for their work, and make them they work only to get the money rather to
develop the company.so we learn that leadership play a major role in developing of the company
also relationship between the leader and the workers. By filling a gap between the leaders and
the workers we can do better works. And also, some leaders are best, this give better
communication the leader and the employers.
3.5 Working Ethics

All professions have their own working disciplines and work ethics that the professional
must be follow and do on daily working activities. As a mechanical engineer there are many
work ethics that we must remember and respect on job. But, generally almost every organization
defines their ethical approach as a number of discrete components. Such as: Honesty,
Transparency,
Accountability, Confidentiality, Punctuality, Responsibility ,Respectful so on
In this internship program we have gained the most important point for our future lives from role
models engineers and workers who apply the above work ethics characteristics. And also, the
company communication with their customer teach us many things that described in the above.

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3.6 Industrial Problem-Solving Capability

After some weeks of practice, we get opportunities to discuss with more of workers in the
workshop and mentors. This made us a good listener and ideal speaker. Therefore, we realized
that good communication in work place is vital. And this good communication leads to lesson
and gives value to us by other workers and also gets self-confidence to speak any idea that we
want to talk about solution of many problems. Especially we internship students discuss about
some of the problems in the company and their solutions.
We learn that the main reason and the first step to discover something is identifying the problems
next to that a solution should prepare and this leads to problem solving capability. So, problem
solving ability is essential in every section. If you have knowledge, self–confidence and able to
communicative to others workers you can solve problem occurring in industries.
3.7 Entrepreneurship Skills

Entrepreneurship is the process of incorporating innovation in the business or other
organization of which a prime example is to start a business with any innovative idea. In this
internship period we have learned how to use environmental resources and reusing or modifying
any materials from the environment. And also, how to develop a business by using the
appropriate human resource and other acquired resource. In this company there is a lot of waste
material that can used to make different material by making some modification so we can create
a work from different point of view. So we develop our entrepreneurship skills to create a work
from different angle.
3.8 Interpersonal Communication Skills

When we attend our internship program, we gained most of our knowledge from asking
different person which need interpersonal skill and also there were large bond between internship
student so, we learn how to communicate with different person. In ABMI there is a large amount
of worker and they are communicating with each other so they ask each other when there is
difficulty in workplace, also play in groups because they developed their interpersonal
communication. Generally, we conclude this skill is very necessary in each sector.

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4. Design of Inclined Screw Conveyor

4.1 BACKGROUND
The modern screw conveyor is essentially a development of the well-known.
Archimedean screw which was conceived some 2000 years ago as a means of raising water for
irrigation. Applications of this device were naturally very limited until relatively recent
times, and its evolution has consequently been slow. A fundamental feature or the original
pattern of Archimedean screw which distinguishes it from other types of screw conveyor is
that the helical screw (or 'flight') is attached to the inner surface of the cylindrical casing
and rotates with it.
4.1.1 TYPES OF SCREW CONVEYOR

Screw conveyors exists in 4 different type: vertical, horizontal, inclined and shaft less
screw conveyors.
a. Horizontal Screw Conveyor
Horizontal screw conveyors are the most widely used type of screw conveyor .
Used to convey bulk materials from one part of a process to another, horizontal screw
conveyors are available in a wide range of sizes, lengths, configurations and materials
of construction .
b. Inclined Screw Conveyor
Screw conveyors can be operated with the path inclined upward, but the
capacity decreases rapidly as the inclination increases. A standard pitch screw
inclined at 15°with the horizontal has 70 per cent of its horizontal capacity; if it is
inclined 25° the capacity is reduced to 45 per cent; if it is inclined 45° the material
will move along the floor of the trough but at a greatly reduced rate. For steep
inclines the helix may have a short pitch and the trough may be made tubular; then
the capacity loss is less. Thus with a jam feed and 45° incline such a conveyor has a
capacity about 50 per cent of its capacity when horizontal.
c. Vertical Screw Conveyor
vertical screw conveyors are a very efficient method for elevating a variety of
bulk materials at very steep inclines or completely vertical. The compact design allo

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ws for the vertical

screw conveyor to
fit into almost any
plant layout with a
minimum number of
moving parts, the
vertical screw conveyor
is a cost-effective and dependable component of any bulk material handling process.
Fig 4.1.1 Types of Screw Conveyor (a) Vertical Screw Conveyor ((b)d) Horizontal Screw
Conveyor (c) Inclined Screw Conveyor (d) Shaftless Screw Conveyor
d. Shaftless Screw Conveyor

Bulk materials discharged from centrifuges, filter presses or mixers can easily be
conveyed using a Shaftless Screw Conveyor . our shaftless design provides a non-
clogging conveying surface that allows difficult-to-convey materials to become easy-
to-convey . The perfect solution for handling bulk materials with high moisture
content is the Shaftless Screw Conveyor .

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4.1.2 COMPONENT OF SCREW CONVEYOR

The component listed below covers a standard parts
of a screw conveyor parts listed below can be excluded
or additional part might be added depending on the
purpose of the installed screw conveyor.
Fig 2.1.2 Component of Screw Conveyor
4.2 Statement of the problem & Justification

One of the biggest section of Akaki Basic Metals is the foundry section and the basic and
important steps in this section is
the preparation of molding sand
which is a silicate sand. The
silicate sand is supplied
including pits and clay because it
came with impurities directly
from the source, so the sand is
washed and sieved before storing
and ready for mix. And the main
problem obtained in this process
is the mode of transportation to the

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dryer. It is transported using a man power and small excavator on which the excavator has
different purpose so after being washed the sand has to be stored in outer space until it is
conveyed which takes time and make a great gap for the mass need of molding sand. Therefore
designing and inclined screw conveyor that can deliver the constant need for the supplement of
silica sand.
4.3 Objective
4.3.1 Main Objective
The main objective of this project is to design an inclined screw conveyor that can deliver
or convey washed and sieved silica sand to the hopper that drive it to the dryer machine which
reduce the moisture content of the sand.
4.3.2 Specific Objective

 To find the general property of Foundry sand or silica sand.
 To make an general assumption and calculate of the total capacity and speed of the screw
conveyor.
 To calculate the total horse power requirement
 Select the conveyor component
4.4 Literature Review

i. Alan W. Roberts1 has found that the screw conveyors with fully enclosed tubular casings its
torque and power are majorly affect by the vortex motion of the material that is lifted. The
eddy motion, together with the degree of fill, rule the volumetric efficiency and, hence,
the throughput. This, in turn, manipulates the torque, power and conveying efficiency.
A theory is presented to predict the functioning of screw conveyors of any specified
geometry. The influence of the flow properties of the bulk material on the conveyor
performance is exemplified. The performance of screw conveyors is significantly
affected by the eddy motion of the bulk solid being pass on. The eddy motion, composed
with the grade of fill, rule the volumetric competence and, from now, the throughput. This,
in turn, manipulates the torque, power and conveying efficiency. The flow characteristics of
the bulk material being conveyed are demonstrated to have a considerable manipulate on the
functioning.
ii. Alma Kurjak2 suggests that it is examine of how fine particle characteristics and
screw conveyor design influence the flow properties of a vertical screw conveyor. Examine
report show that various bit properties like bit size, bulk density and bit form have a
significant manipulate on screw ability.
4.5 Methodology

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The project starts by identify a problem. This helps to create different question to the design
for improving the product. After identify the problem; we propose an objective to the work,
which lead the path for being success or not. Next, we continue with literature review and
research about our work. This consist a review of the design and works including paper
researches.
Establishing the property of the material to be conveyed which is silica sand is the first and
major step on design on the screw conveyor so we refer different research papers and did some
laboratory investigation with the help of lab technician and decide the final data.
In short, the overall process can be summarized as follow:
1. Establishment of target or statement of the problem
2. Basic conceptual and sketch design as per location outline
3. Selection of components as per suitability
4. Selection of material
5. Design and dimension analysis
6. Part drawing and modeling
7. Assembly
4.6 Material selection

The material selection process of the inclined screw conveyor is dependent on many
factors from them the main factors that affect the selection of the materials are :
1. Type and condition of the bulk material to be conveyed including maximum particle size and
specific bulk density
2. Capacity or feed rate of bulk material to be conveyed expressed in pounds per hour, tons per
hour, or cubic feet per hour
3. required distance and incline the bulk material is to be conveyed
4. design conditions such as materials of construction, inlet feed conditions and operating
temperature
4.7 General Design of Screw Conveyor

The General steps for selecting a screw conveyor in a series of five steps, but additional
design process are to be taken for more miscellaneous components. These steps are arranged in
logical order and are divided into separate sections. The five steps are:
1. Establish characteristics of the bulk material to be conveyed.
2. Determine conveyor size and speed based on capacity in relation with location.
3. Calculate horsepower requirements.
4. verify torque rating of components.

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5. Select conveyor components.

The first step in the designing process is to characterize the bulk material to be conveyed
which is silica sand or foundry sand. The property of this sand is obtained from “Screw conveyor
design catalogue from KWS Engineering ”.
Referring the bulk material table, we can obtain different useful information the can
dictate the whole design process of the inclined screw conveyor, therefore the bulk material is
the major reference of the design process.
 Required information to start the design process:
 Bulk Material: Silica Sand or Foundry sand
 Capacity: Which is the amount of sand required to convey per day or per hour to meet
ton
the requirement which is 5 this information is obtained from rough estimation of
hr
ton
the maximum amount of sand that can be washed per hr and we decide 5 can fulfil
hr
the need.
 Screw Conveyor Length: The total length to be conveyed from the washing section to
the hopper that feed to the drying machine is about 15m.
 Screw Conveyor angle of inclination: The angle of inclination from feeder to the
output is about 5 deg.
 Characteristics of the bulk material
 Bulk Material: Silica Sand or Foundry sand
 Maximum particle Size: minus 1/8-inch 3.175 mm.

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 Bulk Density: 90 lbs/ft or 1441.8 Kg/m3
 Trough loading: 15%

 MF factor: 3.0
 Component/ bearing Series: C4 Hanger bearing made from bronze
 Abrasiveness: iii (Extremely Abrasive)
 Corrosiveness: I (Not Corrosive)
 Table 4.7.1 Bulk Material Table flowability: iii

(Average
Flowability)
Bulk Material lump Size

Bulk material lump size must be considered when designing a screw conveyor . Screw
conveyor diameter not only depends on the capacity of the bulk material to be conveyed, but also
the size and proportion of lumps in the bulk material . Lump size is determined by the maximum

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dimension of the largest lumps . if a lump has one dimension much longer than its transverse
cross-section, then the longer dimension will be used to determine the lump size .
Trough loading
Trough loading is the depth of a bulk material in the trough of a screw conveyor and is
measured in percent when compared to a full trough . a full trough is considered 100-percent
full . recommended trough loadings of 15, 30 and 45-percent were developed based on the
characteristics of bulk materials . The recommended trough loading for a screw conveyor is a
function of the density, abrasiveness and flowability of a bulk material . for a given capacity,
screw conveyor size and speed is determined by trough loading
percentage.
We selected 15% Trough loading because Bulk materials with a

density range of 50 to 120 lbs/ft3 that are extremely abrasive and sluggish
such as alumina, glass cullet or potash are difficult to convey and do
not easily flow through a screw conveyor . The trough loading must Fig 4.7.1 Trough Loading
be kept well below the center pipe to reduce undue wear on the
conveyor components such as screws, hanger bearings, couplings shafts and troughs . The
recommended trough loading for bulk materials with similar characteristics is 15-percent .
Now that the characteristics of the bulk material to be conveyed have been determined,
the next step is to calculate the capacity in cubic feet per hour . always use the lowest bulk
density when calculating capacity in order to get the highest potential volumetric capacity.
Given :- Bulk density=90 lbs/ft3 or 1441.8 kg/m3 , Length= 15m, Required
Capacity=5ton/hr
Selection Capacity (SC) is the capacity adjusted for special pitch or modified flights
used in the process of selecting the screw conveyor diameter for the application .
Calculation of special screw conveyor capacities is as following
Nomenclature: SC = Selection Capacity, CF = Capacity factor
CFH = required Capacity in Cubic feet per Hour (ft3/hr)

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Table 4.7.2 Capacity Factor table Fig 4.7.2 Screw and Shaft
 We have selected capacity factor of 1.5 because of the inclination of the screw conveyor
in order to prevent the back lash of the bulk material we have to increase the rpm of the
screw of decrease the pitch of the screw but increasing the rpm of the screw is not a good
choice, because it increases the wear of the trough because of the abrasiveness of the bulk
material, therefore we have to choose short pitch of 2/3 Diameter.
R .Capcity
The required capacity can be calculated by CFH =
Bulk Density
5 ton/hr
CHF= =3.47 m3/hr or = 122.47 ft3/hr
1441.8 kg/m3
SC= CHF * CF = 122.74 ft3/hr * 1.5 = 183.71 ft3/hr or = 5.205 m3/hr

The Selection Capacity will be used to select the proper screw conveyor diameter and
speed from the Capacity Table . with a recommended trough loading of 15%, the Selection
Capacity must be less than the maximum capacity given in the Capacity Table . a 12-inch or
63.5 mm diameter screw conveyor will convey 323 cubic feet per hour at the maximum
recommended speed of below 50-rpm and at 1 rpm 6.5 ft3/hr.
Table 4.7.3 Capacity table
The actual speed of the conveyor can be calculated by :-

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S=
183.71
= 28.2
6.5
rpm Which is less than the maximum rpm recommended therefore it is safe.
2.7.1Calculating the Horse power requirement

Horse Power is defined as in our case as the power required to safely and feasibly
convey a bulk material a fixed distance in screw conveyor. The horse power required to drive a
screw conveyor is called TOTAL SHAFT HORSE POWER (TSHP).
The horsepower requirements for inclined screw conveyors increase with the degree of
incline . The Horsepower factor (fi) is incorporated into the standard screw conveyor horsepower
calculations to compensate for the additional horsepower required to overcome gravity and bulk
material fall back .
The
incline factor can be obtained by using the graph or the inclination factor graph and drawing
vertical line with respect to angle of inclination of our conveyor and drawing horizontal line
perpendicular to the vertical line to obtain inclination factor.
Based on the angle of incline vs. incline factor graph the incline factor for 5 deg of
inclination is about 1.19 so Fi=1.19

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[Grab your reader’s attention with a great quote from the * If

document or use this space to emphasize a key point. To place
calculated Fig 4.7.3 Graph of Inclination Factor Vs. Angle of incline Material
Horsepower is less than
5HP it should be
corrected for potential overload. We Use the Corrected Material HP Chart.
Fig 4.7.4 Graph of Corrected HP Vs. Calculated HP
 To calculate
Frictional horsepower Conveyor diameter factor
(DF) and Hanger bearing factor (HBF) must be
obtained
from
tables
Table 4.7.4 Hanger bearing factor and Diameter Factor

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DF=55 and HBF=1.7
= 55∗1.7∗49.21∗28.2 = 0.12 HP
1000000
 Next we can calculate the material HP which is a HP required to

move the given bulk material within the given length of conveying.
11023.113∗3∗49.21
= = 1.62HP
1000000
Since the calculated MHP is less than 5HP we have to use the corrected Material HP
Chart and draw a vertical line that intersect the curve and horizontal in order to find the corrected
material HP. And from the chart we have found that
corrected MHP= 2.7HP
 T h e t o t a l s h a f
incline factor(Fi)=1.19 and Drive efficiency (e) which is about 0.88 for belt drive.
0.12+(2.7∗1.19)
= = 3.785 HP
0.88
The total Shat HP (TSHP) is rounded to the nearest common and standard horsepower
rating which is about 5HP, therefore TSHP= 5HP
4.7.2Calculating the Total Torque

Torque is defined as the twisting force exerted by the drive unit on the conveyor screw .
Torque is transmitted through the drive shaft of the drive unit to the screw and converted to force
to convey the bulk material .
full Motor Torque is the maximum torque generated by the
drive unit . The equation for full Motor Torque is shown
below:
HP= 5HP and s=28.2 rpm

5∗63,025
= = 11,174.64 inch-lbs or 1262.564 N-m
28.2

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4.7.3Design of the Shaft

In design of the shaft on which the screw is welded we used a hallow shaft which is a
mild steel shaft with
ultimate shear stress
of 360Mpa.
Based on standard a 12 in. screw
diameter the recommended a pipe or
hallow shaft outer diameter is 2-1/2 in.
and inside diameter 2 in. therefore in
order to make sure it safe to operate
with this rated torque we have to
make a calculation on shaft subjected to twisting moment.
where
Rearrange the equation we can find :-
Where k=Di/Do
Given: T=1262.564 Nm Do= 2.5 in. = 63.5mm or 0.0635m Di= 2in.= 15.875mm
16∗T 16∗1262.564
τ= 4 = = 25Mpa
Π (DO )(1−K ) π (0.06353)(1−0.254 )
3
Taking factory of safety of 8 we found the allowable shear stress =360Mpa/8 = 45 Mpa
Which is greater than the calculated shear stress of 25Mpa.Therefore, it is safe.
4.7.4 Selection Of Trough

The trough is the main part of a screw conveyor on which the bulk material is transported
using the screw which is mounted on the end seal of the trough.

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Trough can be designed in

different shape and size depending on
the purpose they are intended to do. The
main types of troughs are : Double flanged
troughs, Angle troughs, Flared troughs,
Channel troughs and Jacketed troughs.
From different types of troughs we
have selected Double flanged troughs
because, the unique design of the Double
Flanged Trough adds considerably to its strength and structural rigidity without adding to its
weight.
Fig 4.7.5 Trough

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The dimension of the trough is selected based on the size of the screw conveyor with a
little clearance in order to decrease too much interference which might lead to excessive wear
and reduce the work life of the material.
Fig 4.7.6 Dimensioning of Trough
Table 4.7.5 Standard dimension of Trough
From the table listed above we can obtain the total dimension of a double flanged trough
with the diameter of conveyor of 12 inch. The material used
for the construction of the trough is carbo steel : AR-235
which a high abrasion resisting steel and this carbon steel is
an ideal material for bulk material such as silica sand which
is known for its abrasiveness.

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4.7.5 Selection of Hangers

Hangers are used an intermediate support between section of conveyor screw. They
maintain alignment of the conveyor screws and provide a bearing support for the coupling shaft.
Hangers must be placed clear of inlet openings. They can be placed at trough joints as they are
designed with spacer bars wide enough for this purpose. Hangers may be fitted with a wide
variety of bearing materials to suit a diverse range of screw conveyor applications.
Table 4.7.6 Standard dimension of Hanger

Fig 4.7.7 Hangers

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4.7.6 Selection of Transmission Flange Bearing

Transmission Flange Bearings are of fabricated steel with the backing and end faces
machine finished. Additional clearance is provided at the base of the bolt holes for ease of
assembly. The bearings are accurately broached to transmission tolerances and the bore is
concentric to the
flange back.
Fig 4.7.8 Standard dimension of Transmission Flange Bearing
Fig 4.7.9 Transmission Flange Bearing

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4.7.7
Selection
of Trough
End
Trough ends
support the
conveyor
screw and the trough. They incorporate
a bearing assembly to maintain clearance between the trough and conveyor screws, and,
depending on the
direction of material
travel,
incorporate a thrust bearing to maintain clearance between the conveyor screws, hangers and
trough ends. This provides for smoother operation, lower power requirements and less wear on
the hangers, bearings and other vital components.
Figof4.7.10
Internship Report and Design Standard
Inclined dimension Trough End
Screw P a g e | 50
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Fig 4.7.11 Trough End
4.7.8 Selection
of supporting saddle
Saddles are used to support the trough between the trough sections and fasten to the floor
or existing structures. The total height from the floor is the same as for a trough end with feet.
4.7.9 Design of V-belt Drive

A V belt is made of fabric and cord, usually cotton, rayon, or nylon, and
impregnated with rubber. In contrast with flat belts, V belts are used with similar sheaves and
at shorter center distances. V belts are slightly less efficient than flat belts, but a number of
them can be used on a single sheave, thus making a multiple drive. V belts are made only in
certain lengths and have no joints.
The pulleys are used to transmit power from one shaft to another by means of flat belts,
V-belts or ropes.
Fig 4.7.12 Standard dimension of supporting saddle
Since the velocity
ratio is the inverse
ratio of the diameters of driving and driven pulleys. The pulleys may be made of cast
iron, cast steel or pressed steel, wood and paper. The cast materials
should have good friction and wear characteristics. The pulleys made of
pressed steel are lighter than cast pulleys, but in many cases, they
have lower friction and may produce excessive wear.
However, for our design we use cast iron pulleys. The pulleys are
generally made of cast iron, because of their low cost and the cast materials should have
good friction and wear characteristics. The rim is held in place by web from the central boss or
by arms or spokes.

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The motor specification is :

 Power = 5HP or 3.728Kw
 Speed =1500 rpm because we have selected a 4 pole motor, for more torque is
required rather than speed, therefore due to our country voltage and frequency
rating the speed achieved by this electric motor is 1500 rpm.
With the rated power of the electric motor we have selected type B v belt from the
standard table below with:
 Minimum pitch diameter for small pulley =125 mm.
 Top Width =17 mm and Thickness = 11 mm.
Table 4.7.10 Dimensions of standard V-belts according to IS: 2494

– 1974.

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The required rpm for the gear box is about 600 rpm, therefore we can find the pitch
diameter of the larger pulley with the help of the speed ratio.
N 1 1500rpm
Speed ratio (Rs)=
N2
=
600 rpm
=2.5
The pitch diameter of the larger pulley can be obtained from:
Dp= Rs*dp Where Dp - Pitch Diameter of larger pulley
Dp = 2.5*125 mm dp - Pitch Diameter of smaller pulley
= 312.5 mm Rs – Speed Ratio
4.7.9.1Center distance and belt length
Center distance and belt length have relation which is stated in the formula given below
and the center distance between the larger pulley and the smaller pulley is assumed to be 650
mm.
And the exact center distance can be calculated by

Where
Given: C=650 mm Dp= 312.5 mm dp=

125 mm
Lp = 2(650) + 1.57(312.5 + 125) +¿ ¿
= 2,000.3 mm
From the standard table listed below the closest length of the belt is 2,024 mm.
4.7.11 Standard pitch lengths of V-belts according to IS:

2494-1974

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Then we can calculate the exact center distance between the two pulleys as :
b+ √ b2−2(Dp−dp)2
C= b=Lp−1.57 ( Dp+dp )=2024−1.57 ( 312.5+125 )=1337.1
4
Fig 4.7.13 Pulley Center distance
1337.1+ √ 1337.12−2(312.5−125)2
C= =661.9≈ 662 mm
4
2.7.9.2 Power transmitted by Belt

Parameters used : Dp= 312.5 mm dp= 125mm C= 662 mm

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Fig 4.7.14 Power transmission by belt
Dp−dp 312.5−125
For an open belt drive , sin α = = =0.14 α =8.14 °
2c 2∗662
The angle of lap of the smaller driving pulley can be obtained by,
θ=180° −2 α=180 ° −2∗8.14 ° =163.72°∨2.85rad
The weight per meter length of the belt is stated from table 2.7.10 for type B V-belt 1.89 Newton
per length, therefore the mass per length of the belt is
m =1.89 N/m ÷ 9.81 m/s2

= 0.192 kg/m ≅ 0.2 Kg/m
The velocity of the belt can be obtained from ,

π∗dp∗N 1 π∗0.125∗1500 m
v= = =9.81
60 60 s
∴ The centrifugal tension of the belt is
Tc=m v 2=0.2∗9.812=19.27 N
The allowable tensile stress for leather belting is usually 2.0 to 3.45 MPa , for the purpose
of reducing the cost of the belt we have chosen an allowable stress of 2.1 Mpa. The maximum
tension of the belt is,
T =σ∗b∗t=2.1∗17∗11=392.7 N
∴ Tension in the tight side of the belt, T1 = T – Tc = 392.7 – 19.27 = 373.43 N
To find tension of the slack side (T2)of the belt we use the formula of:
2.3 log ( TT 12 )=μ .θcosecβ where μ = friction 0.28 ,θ=2.85 rad,β= groove angle 17°

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2.3 log ( TT 12 )=0.28∗2.85 cosec 17 ° , log ( TT 12 )=1.18

( TT 12 )=15.37 T = 24.3 N
2
To find the number of V-belts required we need to calculate the power transmitted by the
belt as, P= (T 2−T 1 ) v =( 373.43−24.3 ) 9.81=3424.9 W ∨3.4249 Kw
T h e t y p i c a l o v e
1.2 this
value is taken from the table listed below
Since the overload service factor is taken as 1.2 the designed power is 1.2*3.728 Kw = 4.47 Kw
Designed Power 4.47 Kw
Numbers of belt required = = = 1.30 rounded to
Power Transimmited per belt 3.429 Kw
the next whole number the number of belt used is 2.
Face width of the pulleys can be obtained by,
Table 4.7.12 Service load factor B= (n-1) e+2f

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B= (9-1)19 +2(12.5) = 177 mm
Table 4.7.13 Dimensions of standard V-grooved pulleys according to IS : 2494–

1974.
4.7.9.3 Design of driven pulley shaft

Let D = Diameter of the shaft and the shaft is
treated as overhanging since its connected to the
bearing at the end and the distance is taken as 100mm
with
Fig 4.7.15 Cross section Grooved pulley
permissible shear stress of 42Mpa. we know

P∗60 3728∗60
the torque transmitted by the driven pulley is, T = =¿ =59.33 Nm .
2 π∗N 2 2 π∗600
The bending moment of the shaft is calculated as
M =( T 1+T 2+ 2Tc ) 0.1 m∗2 because number of belt is 2.
M =( 373.43+ 24.3+ 2 ( 19.27 ) ) 0.1∗2=87.167 Nm
Therefore the equivalent twisting moment (Te)
Te= √T 2+ M 2 =√ 59.32 +87.167 2 = 105.42 Nm
π
And the equivalent twisting moment is Te= ∗τ∗D 3
16

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π
105.42= ∗42∗D 3 , D=22mm.
16
4.7.9.4 Design of Key
The standard sunk key size and dimension for 22mm diameter shaft is,
Width =8mm and Thickness = 7mm
4.7.10 Design of Speed Reduction Gear Box

As the name indicate the purpose of Gear box is to reduce or increase the input shaft
speed or torque directly from the pulley or motor shaft to the required rated rpm.
For our case the input shaft speed have to be reduce before using directly to the shaft of
the screw conveyor shaft therefore the number of speed reduction is selected based on the
amount of speed ratio between the input and output rpm of the shaft.
N1
Let e be the ratio of speed reduction e= where N1 is the input rpm of the shaft and N2
N3
is the final or output rpm of the shaft N1= 600 rpm N3= 28.2 rpm.
First determining the required the number
Fig 4.7.16 Speed reducer layout
of stages or reduction required this is done by considering the speed reduction ratio in our case it
s about e=21.27.
Table 4.7.14 Number of reduction

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Based on the data obtained from above a double reduction gear box is required for the
speed ratio of 21.27:1 which can be obtained in two stage of 5:1 and 4.5:1 gear mesh.
For the type of gear we have selected a spur gear , because spur gears are the most
commonly used gear type. They are characterized by teeth, which are perpendicular to the face
of the gear. Spur gears are by far the most commonly available, and are generally the least
expensive, easy to find, and efficient.
Determining the center distance between the first pinion and driven gear is the first step
this can done by calculating the output torque of the first step reduction.
30∗p
Tout= ∗e∗Ks Where p= power , e=reduction ratio=5 , Ks= Cs* Kt ; Cs
πN 1
service factor and duty factor Ks= 1* 0.65= 0.65
30∗3.728∗5∗0.65
Tout= =0.192 kNm
π∗600
By using the data listed above we can evaluate the center distance between the two shafts
by referring the chart of output torque vs. center distance.
Fig 4.7.17 Graph of Output torque Vs. Center

distance
Therefore, the center distance for output torque is about 100 mm for the first step of
reduction and which is approximately same for the second step of reduction.

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By selecting a 20 ° full depth involute system of gear teeth we can take a minimum
number of teeth on the pinion of 18.
 The number of the driven gear can be obtained by using the gear ratio e.
Tg=e∗Tp=5∗18=90
2∗a
 For spur gear the module can be estimated by m= where a=center distance, Tp
Tp+Tg
and Tg =Teeth number of pinion and gear respectively.
2∗100
m= =1.85 mmand the nearest modified standard value is equal to 4 mm.
18+90
 For this module the modified center of distance between the gear axis is
m(Tp+ Tg) 4∗(18+90)
a= = =216 mm
2 2
 Therefore, the pitch diameter of both pinion and gear is
Dp=m∗Tp=4∗18=72 mm
Dg=m∗Tg=4∗90=360 mm
 The pitch line velocity of the pinion gear is
π∗Dp∗N 1 π∗72∗600 m
v= = =2.26
60 60 s
 The tangential tooth load taking service factor (Cs)=1 for steady load 8hrs day
p 3728
Wt= ∗Cs= ∗1=1,649.5 N
v 2.26
 The face width of the gears can be taken as b=10∗m=10∗4=40 mm
 The permissible working stress can be calculated by using “Lewis Equation” taking gear
material of cast iron, medium grade which have allowable static stress of 70 Mpa which
is an elastic limit of the material.
σ w =σ o+C v where σ w= permissible working stress , σ o=Allowable Static stress
3
C v =velocity factor = =¿0.42
3+ v
σ w =70 Mpa+0.42=30.9 Mpa
Table 4.7.15 Minimum number of teeth on the pinion in order to avoid interference.

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 Dynamic tooth load
Deformation factor can taken as 342 for 20° full depth cast iron gear for tooth error in
action of 0.04
21∗2.26 (40∗228+1649.5)
W D =1649.5 N + =5,029.25 N
21∗2.26 + √ 40∗228+1649.5
 Static tooth load (also called beam strength or endurance strength of the tooth) is obtained
by Lewis formula by substituting flexural endurance limit or elastic limit stress (σe) in
place of permissible working stress (σw).
0.912
W s=σ e bπmy where y=0.154− can be calculated for both pinion and gear
T
0.912
y=0.154− =0.203∧0.243 for pinon and gear respectively
18
W s=84 Mpa∗40∗π∗4∗0.103=8,571.2 N
 For safety against breakage the static tooth (Ws ) load should be greater than dynamic load
(WD) thus, our design is safe .
 Wear tooth load (Ww) is the maximum load that gear teeth can carry, without premature
wear, depends upon the radii of curvature of the tooth profiles and on the elasticity and
surface fatigue limits of the materials.

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Where
K=1.2 for 20° full depth involute system cast iron gears material.
2∗90
Q= =1.66
90+18
Ww=72∗40∗1.66∗1.2=5,875.2 N
Also wear tooth load should be greater than the dynamic load in order to be safe.
Therefore our design Is safe.
From standard table given above we can calculate the rest parameters of the gears
-Addendum = 1*m = 4 mm -Dedendum = 1.25*m = 5 mm
-Working Depth= 2*m = 8 mm -Minimum total depth= 2.25*m = 9mm
-Tooth thickness = 1.5708*m =6.2832 mm -Minimum clearance=0.25*m = 1 mm
- Fillet radius
at root= 0.4*m = 1.6
mm
4.9.10.1Design of Gear Shaft 1

The pinion gear is mounted on a shaft that is subjected to both bending and twisting
moment. The shaft Table 4.7.16 Standard proportions of gear systems. is mounted on

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ball bearing for smooth rotation. C-45 steel is selected to be the material of the shaft with
ultimate tensile stress of 700 Mpa and ultimate shear stress 500 Mpa.
Given data : Outside diameter of pinion gear= D p+(2*m)=72+(2*4)= 80 mm, power= 3278 W
N=600 RPM, face width= 40 mm, WT=1649.5 N tangential tooth load, φ=20 ° Pressure angle
 The normal load(Wn) acting between the tooth surfaces of the pinion is
Wt 1649.5
Wn= = =1,755.36 N
cosφ cos 20 °
 The weight of the pinion , ℘=0.00118 Tp . b .m 2=0.00118∗18∗40∗16=13.59 N .
 Resultant load acting on the pinion, WR¿ √ ( Wn2 ) ++(℘¿¿ 2)+ 2Wn . Wpcosφ¿
=√ ( 1755.362 ) +(13.59¿¿ 2)+2 ( 1755.36 )∗13.59 cos 20 °=1,768.1 N ¿
Taking the distance between the center line of bearings and gear can be taken as
100 mm we can calculate the twisting moment.
P∗60 3278∗60
T= = =52.17 Nm
2 πN 2 π∗600
 Since the gear is mounted in the middle of the shaft, therefore the maximum
bending force is located at the center of of the shaft.
Wl 1768.1∗0.2
M= = =88.4 Nm
4 4
 The equivalent twisting moment, let d is the diameter of the shaft
T e =√ M 2 +T 2=√ 88.42 +52.172 =102.65× 103 Nmm
 For shafts purchased under definite physical specifications, the permissible shear
stress (τ) may be taken as 30 per cent of the elastic limit in tension (σel) but not
more than 18 per cent of the ultimate
tensile strength (τu). In other words, the
permissible shear stress.
Bearing τ =0.18∗σ ult =90 Mpa
π
T e= ∗τ∗d 3
16
Pinion π
102.65 ×103= ∗90∗d 3 d =17.97 mm
16
From available standard values of shafts, the diameter might be taken as 22 mm with a
standard key of 8x7 mm (width x Thickness).
 The diameter and length of the pinion hub can be calculated as respectively:
d hub =1.8 d=1.8∗22=39.6 mm
Lhub =1.25 d=1.25∗22=27.5 mm

Conveyor-2013/2021
4.9.10.2 Design of Gear Shaft 2(Intermediate shaft)

The intermediate shaft holds two gears pinion for the second reduction and the gear for
the first reduction process since it holds two gears it is subjected to more stress than the first and
third shaft.
Given data: Face width Gear C&D=40 mm RPM=120 rpm Power=3728 W pressure angle=20
 We need Pitch Line velocity of the gear C to calculate the Tangential tooth load( W t ) of the
π∗D g∗N 2 π∗360∗120 m p 3728
driven gear v= = =2.26 and W t = ∗C s= ∗1=1649.5 N
60 60 s v 2.26
 The normal load(Wn) acting between the tooth surfaces of the pinion is
Wt 1649.5
Wn= = =1,755.36 N
cosφ cos 20 °
 The weight of the gear C,
Fig 4.7.18 Intermediate shaft layout
℘=0.00118 Tg . b .m 2=0.00118∗90∗40∗16=67.96 N .
 Resultant load acting on the gear C, WR¿ √ ( Wn2 ) ++(℘¿¿ 2)+ 2Wn . Wpcosφ¿
=√ ( 1755.362 ) +(67.96¿¿ 2)+2 ( 1755.36 )∗67.96 cos 20 °=1,819.3 N ¿
 The weight of the gear D , ℘=0.00118 Tp . b .m 2=0.00118∗18∗40∗16=13.59 N .

 The pitch line velocity of the pinion gear is
π∗D∗N 1 π∗72∗120 m
v= = =0.45
60 60 s
 The tangential tooth load taking service factor (Cs)=1 for steady load 8hrs day
p 3728
Wt= ∗Cs= ∗1=8,240.6 N
v 0.45
 The normal load(Wn) acting between the tooth surfaces of the Gear D is
Wt 8,240.6
Wn= = =8,769.5 N
cosφ cos 20 °
 The weight of the Gear D , ℘=0.00118 Tp . b .m 2=0.00118∗18∗40∗16=13.59 N .
 Resultant load acting on the Gear D, WR¿ √ ( Wn2 ) ++(℘¿¿ 2)+ 2Wn . Wpcosφ¿

Conveyor-2013/2021
=√ ( 8769.52 ) +(13.59¿¿ 2)+2 ( 8769.5 )∗13.59 cos 20 ° =8,782.3 N ¿
Taking the distance between the center line of bearings and gear can be taken as 100 mm
and 40 mm of face width of both gear and center distance between the gears of 150mm the total
length would be 480 mm .we can calculate the twisting moment.
P∗60 3278∗60
T= = =260.85 Nm
2 πN 2 π∗120
 To find the maximum bending moment of the resultant loads of the two gears on the
shaft we must take the reaction force of the bearings RAV and RBV.
Fig 4.7.19 Torque Diagram
 R AV + RBV =10,601.6 N
 Takin
g a
Fig 4.7.20 Vertical Load Diagram
moment at A, R BV∗0.48=( 8782.3∗0.38 ) + ( 1819.3∗0.1 )
0.48 R BV =3519.17 R BV =7,331.6 N R AV =3,269.9 N
 Taking Bending moment at C M C =( R¿¿ BV ∗0.38)+( R AV ∗0.1)−(8782.3∗0.28)¿

M C =( 7331.6∗0.38 ) + ( 3269.9∗0.1 )−( 8782.3∗0.28 )=653.864 Nm
 Taking Bending moment at D M D =( R ¿¿ BV ∗0.1)+(R AV ∗0.38)−(1819.3∗0.28)¿
M D =( 7331.6∗0.1 ) + ( 3269.9∗0.38 )−( 1819.3∗0.28 )=1,466.3 Nm

Conveyor-2013/2021
 Taking the shaft as steeped shaft in order to reduce weight The equivalent twisting
moment for each value of bending moment ,
T eC= √ Mc 2 +T 2=√ 653.8642 +260.852=703.97 ×10 3 Nmm
T eD =√ MD 2+ T 2= √1,466.32 +260.852=1489.32 ×103 Nmm
π
τ =0.18∗σ ult =90 Mpa T e = ∗τ∗d 3
16
3 π 3
 Diameter at Gear C, 703.97 ×10 = ∗90∗d d=34.15 mm
16
3 π 3
 Diameter at Gear D, 1466.3 ×10 = ∗90∗d d =43.61 mm
16
From available standard values of shafts, the diameter might be taken as 38 mm with a
standard key of 12x8 mm (width x Thickness) and diameter of 44 mm with a standard key of
14x9 mm (width x Thickness).
 The diameter and length of the Gear C&D hub can be calculated as respectively:
d Chub=1.8 d=1.8∗38=68.4 mm
LChub=1.25 d=1.25∗38=47.5 mm
d Dhub =1.8 d=1.8∗44=79.2 mm
L Dhub=1.25 d =1.25∗44=55 mm
Table 4.7.17 Standard Key and shaft size

4.9.10.3 Selection of Coupling Bolt
Due to the length of the shaft, the shaft is made in different parts therefore it must be
coupled. We have selected a shaft between the hallow shafts and drilled a hole and couple them
using a bolt as shown in the figure below.

Conveyor-2013/2021
Fig 4.7.21 Shaft Coupling
In order to select the dimension of the shaft and coupling bolts for the pipe we have used
standard table listed Table 4.7.18 Standard Screw coupling size below.
Therefore, for Nominal pipe size of our screw was 2-1/2 in or 63.5 mm the
recommended shaft diameter is 2 in or 50.8 mm and coupling bolt diameter 5/8 in or M16.

Conveyor-2013/2021
Conclusion
The optimal and complete design of inclined conveyor including all the components have
been designed in above documentation. The inclined screw conveyor can give undiminished
purpose at the foundry section by increasing the supply of washed foundry sand or silica sand to
the drier section with feed rate of 5 ton per hour.
The design project can be reference for further studies and can be used for other location
and condition by altering some of the factors assumed on design procedure.

Conveyor-2013/2021
Recommendation
We recommend that Akaki basic metals should use the screw conveyor designed above
because, due to the time and effort applied on designing the screw conveyor shows that this
machine can help the company especially workers working on sand washing section.
Beside the project we recommend that the company should work on employee
management, give an educational training to cope up with modern technology and also harness
the knowledge of experience from senior employees to the beginners or junior employees and
finally scrap management is the major drawback of this company different materials are thrown
out exposed to rust and damage this is resulting the company a major loss of it’s resources.

Conveyor-2013/2021
References
 Shigley's Mechanical Engineering Design 9th Edition.
 A Textbook of Machine Design by R.S.KHURMI AND J.K.GUPTA.
 Hamrock,_Bo_O._Jacobson-Fundamentals_of_Machine_Elements__SI_Version-
CRC_Press_(2014).
 Screw Conveyor catalogue and engineering manual -Continental conveyor LTD.
 Screw conveyor engineering guide – KWS LTD
(https://www.kwsmfg.com/engineering-guides/screw-conveyor/)
 https://powderprocess.net/Equipments%20html/Screw_Conveyor_Design.html
 Standard of materials (https://standards.globalspec.com/std/1626240/vdi-2330-blatt-2)
 https://www.researchgate.net/publication/327931924_Design_and_Analysis_of_Two_St
age_Reduction_Gearbox_for_All_Terrain_Vehicles
 Design of basic of industrial gear box By Andrzej Maciejczyk and Zbigniew
Zdziennicki
 http://cybra.lodz.pl/Content/3714/DesignBasicInd.pdf

Conveyor-2013/2021

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DECLARATION

Name of student Signature Date

1.1 Background of the company

Internship Report and Design of Inclined Screw Page |1

1.3 Machine shop

1.3.3 Lathe Machine Unit

1.3.4 Heavy-Duty Machine Unit

Internship Report and Design of Inclined Screw Page |2

1.3.5 Fabrication Unit

Gear Box Housing; for E.E.P.CO - Steel balls

Internship Report and Design of Inclined Screw Page |3

But currently it makes:-

Internship Report and Design of Inclined Screw Page |4

Fig- 1.6.1 Some Product of ABMI

Internship Report and Design of Inclined Screw Page |5

1.7 Over All Organization Structure

Internal Audit service

Legal Manager Organization and Information

Administration and Marketing and Supplies Finance Manufacturing

Fig-1.7.1 Over all Organization Structure

Marketing and supplies

Sales and sales Procurement Market research and

Internship Report and Design of Inclined Screw Page |6

Design Foundry Mechanical Heat and Maintenanc

production division work shop surface e division

planning and division treatment

Fig 1.7.4 Manufacturing Department Structure

Internship Report and Design of Inclined Screw Page |7

Personnel Administration and General services

Fig- 1.7.5 Administration and HRD Department Structure

General accounts Cost and

Fig 1.7.6 Finance Department Structure

Internship Report and Design of Inclined Screw Page |8

1.8 Work Flow In Akaki Basic Metal Industry

Internship Report and Design of Inclined Screw Page |9

2 Over all internship experience

2.1 Foundry shop

 Density becomes less – due to level of porosity.

Internship Report and Design of Inclined Screw P a g e | 10

 Minimize conductivity – due to present of porosity

 complex shapes of materials can be done easily

2.1.1 Working Flow Of Foundry Shop In ABMI

Then break down Finishing process

Internship Report and Design of Inclined Screw P a g e | 11

a) Sand before wash and dry b) after wash and dry

Internship Report and Design of Inclined Screw P a g e | 12

2.2.4 Main Process Of Foundry Shop

- It is the ability of molten metal to be contract during solidification at solid state.

- Is the extra amount of metal which is provided on the surface to be machined.

Finally; paint the pattern and ready for mold section.

Internship Report and Design of Inclined Screw P a g e | 13

Core making process

Fig-2.2.4.2.1 Core Making Section

2.2.4.3 Mold Section

Internship Report and Design of Inclined Screw P a g e | 14

Internship Report and Design of Inclined Screw P a g e | 15

 We use refractories for the purpose of:-

The process of melting includes the following steps: -

Internship Report and Design of Inclined Screw P a g e | 16

Fig 2.2.4.1 Spectro Test Machine Print

mechanical work shop.

Internship Report and Design of Inclined Screw P a g e | 17

Centrifugal die casting is a machine used to make hollow round material