ASSOSA UNIVERSITY

COLLEGE OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
AUTOMOTIVE STREAM
INTERNSHIP REPORT
PROJECT TITLE: - MECHANICAL WHEEL DRUM PULLER
(EXTRACTOR)
HOSTING COMPANY: - ABEBE GIRMA GENERAL CAR
MAINTENANCE
STUDENT NAME: - 1) LAMESEGN BIRARA
2) TSEGAZEAB SISAY

ASSOSA, ETHIOPIA
 ASSOSA UNIVERSITY
COLLEGE OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
AUTOMOTIVE STREAM
INTERNSHIP REPORT
PROJECT TITLE: - MECHANICAL WHEEL DRUM PULLER
(EXTRACTOR)
HOSTING COMPANY: - ABEBE GIRMA GENERAL CAR
MAINTENANCE
STUDENT NAME: - 1) LAMESEGN BIRARA
2) TSEGAZEAB SISAY
ADVISOR NAME: - MR.TILAHUN
SUBMITTED TO: MECHANICAL ENGINEERING
DEPARTMENT

DURATION MAY 27-JUNE 27; 2013 E.C

SUBMISSION DATE: - FEBRUARY 26, 2014 E.C

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DECLARATION
This is to declare that we are 4th year student of mechanical engineering department, we have
been working as internship in Abebe girma general car maintenance from May 27 to June 27
2013 E.C, through In these 2 months we tried a lot to achieve the internship objectives and
we were able to do the tasks according to the guide line as much as we can. After all, we do
our best project prototype to solve the Specific problem of the company.
We also declare that this project entitled Design and manufacturing of mechanical wheel
drum puller (extractor) is our original work, which has not been presented from any
internship students.

Name of student Signature Date

Lamesegn Birara __________ _____________
Tsegazeab Sisay __________ ______________

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APPROVAL SHEET
To the best of our knowledge and as we understood by Abebe girma garage workers as well
as by our friends this designed project will solve a lot of problems in different garages or
other companies in the world.so the project design is completed and Can be presented to the
internship report evaluation juries.

Advisor __________ Sign __________ Date ________

Examiner 1 __________ Sign __________ Date ________
Examiner 2 __________ Sign __________ Date ________
Chair Person __________ Sign __________ Date _________

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EXECUTIVE SUMMARY
This Internship report mainly consists of the historical background of Abebe Girma general
car maintenance. Including services, its main customers or the end users of its services and
its overall organization and workflow and activity of each department. We have seen
different kinds of working procedures and applications of more basic theoretical knowledge.
Moreover, we have got practical and communication skills during team working, identifying
remark and team playing skills. Finally, we have tried to link our knowledge to theoretical
into practical skills. So, in this report we have included the detail description of organization
and its work flow structure, vision and its mission, customers and products of industry,
problems are identified and solving of problems like the Design and manufacturing of
Mechanical Wheel Drum Puller. Major activities in each department, conclusion with
suggested recommendation are also part of this report.
Generally, this report includes all activities that we performed during our period internship
and challenges that we faced. It also includes overall benefit and background of internship
itself.

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ACKNOLEDGEMENT
First of all our deepest thanks goes to our GOD who helps us to carry out this project. The
internship opportunity we had with Abebe Girma Garage was a great chance for learning and
professional development. Therefore, we consider our self as very lucky individual as we
were provided with in an opportunity to be a part of it. We are great full for having a chance
to meet so many wonder full people and professionals who lead as through this internship
period. Secondly, we would like to thank our families to help us by as we want and fulfill our
needs up to completing our practical work.We would like to express our sincere appreciation
and special thanks to our advisor Mr. Tilahun for his continuous advice throughout the
report and to the company supervisor Mr. Abebe Girma who were helped as to accomplish
this report. Also we want to say thanks for all Abebe Girma Garage workers and operators
who were willing to share their machinery experiences to us.Finally, we would like to thank
our university, which paves way for this internship program and its contribution to have this
kind of opportunity.

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 TABLE OF CONTENTS
DECLARATION...........................................................................................................................................
APPROVAL SHEET...................................................................................................................................
EXECUTIVE SUMMARY.........................................................................................................................
ACKNOLEDGEMENT................................................................................................................................
ABBREVIATION AND SYMBOL..............................................................................................................
CHAPTER ONE............................................................................................................................................
INTRODUCTION..........................................................................................................................................
1.1 Definition of internship................................................................................................1
1.2 Background of the company........................................................................................1
1.2.1 History of the company.............................................................................................1
1.3 Objectives of the company...........................................................................................2
1.4 Vision of the company.................................................................................................2
1.5 Mission of the company...............................................................................................2
1.6 Values...........................................................................................................................3
1.7 Service operation..........................................................................................................3
1.8 Service Reception.........................................................................................................3
1.9 Organizational structure...............................................................................................4
1.10 The main services of the company.............................................................................4
1.11 Major customers.........................................................................................................5
1.12 Companies workflow.................................................................................................5
CHAPTER TWO...........................................................................................................................................
THE SELECTION OF THE COMPANY.....................................................................................................
2.1 The way of selection of the company..........................................................................6
2.2 The section of company we have been working in......................................................6
2.3 The work tasks we have performed in each section.....................................................6
2.4 The work tasks that we have been executing.............................................................11
2.5 Engineering methods, tools and techniques...............................................................14
2.6 Challenges and problem we have been faced while performing work tasks.............16
2.7 Measure we have taken in order to overcome these challenge..................................17
CHAPTER THREE......................................................................................................................................
THE OVERALL INTERNSHIP EXPERIENCE.........................................................................................
3.1 In terms of improving our practical skill....................................................................18
3.2 In terms of updating our theoretical knowledge........................................................18
3.3 In terms of improving team skill................................................................................18
3.4 In terms of improving our leadership skills...............................................................19
3.5 In terms of understanding about our work ethics issues, industrial psychology and
related issues....................................................................................................................19
3.6 In terms of improving entrepreneurship skills...........................................................20
3.7 In terms of improving our interpersonal communication..........................................21
CHAPTER FOUR........................................................................................................................................
PROJECT: MECHANICAL WHEEL DRUM PULLER............................................................................
4.1 Summery of the Project..............................................................................................22
4.2 Statement Of The Problem.........................................................................................23
4.3 Objective....................................................................................................................24
4.4 The scope of the study................................................................................................24

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 4.5 Research Methodology...............................................................................................24
4.6 Literature Review.......................................................................................................25
4.7 Research Gap.............................................................................................................26
4.8 Method and Material..................................................................................................26
CHAPTER FIVE..........................................................................................................................................
DESIGN OF MECHANICAL WHEEL DRUM PULLER PARTS............................................................................
5.1 Design of screw..........................................................................................................29
5.2 Design of nut..............................................................................................................33
5.3 Design of handle........................................................................................................34
5.4 Design of holding arms..............................................................................................35
5.5 Design of cross arm....................................................................................................40
5.7 Cost Analysis.............................................................................................................42
5.3 Result and discussion.................................................................................................44
CHAPTER SIX............................................................................................................................................
CONCLUSION AND RECOMMENDATION...........................................................................................
6.1 Conclusion..................................................................................................................45
6.2 Recommendation........................................................................................................45
REFRENCES...............................................................................................................................................
APPENDICES..............................................................................................................................................

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 LIST OF FIGURE
Figure 1.1 Over view of the company……………………………………………….. 2
Figure1.2 Overall organizational structure ………………………………. ………….4
Figure1.3 Workflow of the company …………………………………………………5
Figure2.1 Repair and general service section ………………………………………...7
Figure2.2 Engine overhauling section ………………………………………………..8
Figure2.3 Differential Overhauling section …………………………………………..9
Figure2.4 Transmission and transfer case overhauling section ……………………….9
Figure 2.5 Surfacing of the vehicle ………………………………………………….10
Figure2.6 The machine found in the company ……………………………………...15
Figure 2.7 Hand tool shop………………………………………………………….. 17
Figure 4.2: People Facing Problem on Existing Drum and Bearing ………………...23

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LIST OF TABLE
Table 4.1mechanical properties of carbon steel and stain less steel………………….....….28
Table 4.2 Money spent before using the drum puller…………………………………..…...44
Table 4.3Money spent after using the drum puller…………………………………………..44

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ABBREVIATION AND SYMBOL
A …………………….…… Cross-sectional area
b…………………....Base
D …………………….…… Major diameter
d …………………….…..… Nominal diameter
dc …………………….…… Core diameter
DI…………………..Distance from the centre of curvature to the inner fibre
dh …………………….…….. Diameter of handle
DO………………….Distance from the centre of curvature to outside fibre
dm …………………….…… . Mean diameter of the screw
dp …………………….……. Diameter of pin
𝑒………………...… .Distance between centroid axis and neutral axis
Ff….………………. Frictional force
Ft …………………..….…… Torsional shear stress
h……………………...…….… Height
I …………………..….…… Moment of inertia
L ………………………...…… Length of screew
l h …………………..….…… Length of handle
l…………………… Lead
M…………………...Bending moment
N …………………….…… Normal reaction
n……………………………… Number of internal thread
Pb………………………...……Bearing pressure
P …………………………… Pitch
R…………………… Radius of curvature for centroid axis
Ra………………….... Reaction forces at a
Rb…………………… Reaction force at b
Rn…………………….Radius of curvature for neutral the axis
s……………………... Safety factor
SYC/SYT…………….Yield stress in compression/tension
T …………………….…… …..Torque
t …………………….…………. Thickness

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Uts……………………Ultimate tensile strength
W …………………….………. Load
w……………………...width
X…………………….. distance between the load and the centroid axis
Yi…………………… The distance from the neutral axis to inside fibre
Yo………………..…. distance between the neutral axis and the outside fibre
α…………………….…………… Helix angle
σc………………………………...Compressive stress
(max)………….…….Maximum shear stress
σt ………………………….…… Tensile strength of material,
τ …………………….……….… Shear strengths of material.
μN …………………….……..… Frictional force
η …………………………....…… Efficiency
θ …………………………….…… Friction angle.
σc(max) …………………….…… Maximum principal shear stress
μ ………………………….…… Coefficient of friction
𝞃ₐ………………………Allowable shear stress
Ϭbi ………………..….Maximum bending stress of the inside fibber
Ϭbo ……………….….Maximum bending stress of outside fibre

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 CHAPTER ONE
INTRODUCTION
1.1 Definition of internship
An internship is a period of practical training, carried out by a student within a company or
organization. Simply put, through internships or experiential education, students learn by
doing.
A structured experience relates to a student’s major and career goal. It enhances a student’s
academic, career and personal development
1.2 Background of the company
1.2.1 History of the company
In north Wollo capital city of Woldiya, have some general car maintenance companies in
these of companies Abebe Girma general car maintenance is one of the private garage in
Woldia city. Itis established in 1998 E.C in order to maintain the cars. Before this year as
micro enterprise starts simple maintenance service to the society in some hand tools and
small working area. At that time, the initial capital was 6000 ETB. The workers were three in
number. After four years i.e. in 2002 E.C to increase the ability to satisfy the customers, open
new varies overhauling shops. Still now using this shop. In this short period of time, the
company has a great recognition in Woldiya and round of neighbour city.
The main target to establishment this private company is accessible the maintenance service
for the society in quality and the company get their profit from the customer. Although from
the profit and customer suggestion, develop the quality suitable to the customer and their
employers in order to create suitable working area. In this company above, 30-man power is
deployment and prevents the idleness in Woldiya city in their capacity. It has a capacity to
development in overhauling technique to satisfy the customers in time-to-time change in
company. The company has their own rule and regulation to manage the employers and
working system.
The garage popularity in engine service, gearbox service, axel and wheel service, suspension
changing and service, welding, vehicle body maintenance …. Etc. These services are
supplied for the customers. It is coordinated with the known companies, NGO and
governmental organizations such as MOENCO, Woldiya poly Technique College, Woldiya
University, Red Cross, and Wereda burro and zone burro and also there is individual
customer. Mainly the garage related with the companies or organizations with the tender

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annually service program, mainly organizational costumers related with the company to
service the car in tender program.[7]

Figure 1.1 Over view of the company

1.3 Objectives of the company

 The objective of the car maintenance is to renewed inoperative car into perky car
qualified for wanted purpose.
 To get profit from the customer in quality work.
1.4 Vision of the company
The vision of the company is to satisfy the customer and altering into a huge car maintenance
company.
 To be competent in market with better efficiency
 To be the most respected and successful enterprise
 Delighting the customers
 Wide range of maintenance
 The best people with the best maintenance
1.5 Mission of the company
The mission of the company is
 To repair the car.
 To improve competent mechanic substitute to the new generation to the society.
 To provide safe and sound journey.
 To developing various new technologies energy saving and diversifying energy
sources.

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  Providing excellence service and many magic moments by customer friendly service,
advisor, and sales people.

1.6 Values
 Winning together
 Treating every coin as own
 Integrity without compromise
 Pioneering new ideas
1.7 Service operation
The type of service provided by service operation ranges from repairs conducted at their
workshop their fleet customers. The full explanations of service given below.

Free service Check-up: all customers are entitled for free inspection check-ups at 1,000 km
and 5,000 km except for replacement of lubricants and filters. By this type of maintenance
check-ups, they are able to confirm that customers are satisfied with their new vehicles and
the vehicles are in good condition.
Periodic Maintenance: Proper maintenance will ensure maximum performance, greater
reliability, longer life and higher resale value for vehicles. Hence, to ensure safety they
recommend that all customer car owners bring in their vehicles to their service shop every
5,000 km or 3 months (whichever comes first). In tender deal, the customers come to the
company to periodic maintenance.
Component Repairs and Overhauls: Their company service shop provides component
repairs and overhauls for all sophisticated general mechanical and electrical service to the
fleet customer.
1.8 Service Reception
Abebe Girma general car maintenance has a service reception that is convenient and
comfortable to the customers. The customer ordered the defilations of the car and then
transferred into the chief mechanic.
Comprises of units overhauling (like engines, automatic and manual transmission/transaxles,
differentials, steering gearboxes, starters, alternators, etc. In addition, repairing of any
malfunctions on the vehicle using the state-of-art equipment and tool available.

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1.9 Organizational structure
Abebe Girma general car maintenance has their own organizational structure to facilitate the
working system to the costumer and employers. As a private company, its structure is used to
control the profits and their incomes from the costumer so this structure is play great roll for this
company in check and balance work.

The owner of the

company

Human resource Service manager Finance and

and management administration

Security

Service
manager
Repair Body
shop and
Shopkeeper
Forman paint
shop
Forman
Figure1.2 Overall organizational structure

1.10 The main services of the company

The main services that Abebe Girma general garage are gives
 Motor service
 Oxy-acetylene and electric arc welding
 Vehicle body maintenance and painting
 Gearbox service
 Modification work

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  Electrical work
 General repair service
 Car rent service in different programs like wedding
1.11 Major customers
The company has a lot of customers from all sections of economy the governmental
organizations, NGOs, private companies and individuals. Some of fleet customers includes
Wereda and Zone bureaus, Woldia poly Technique College, Woldia University and Red Cross…
1.12 Companies workflow
The general workflow of the company includes the whole processes done while one car is being
serviced. Most of the time governmental and NGO’s cars are serviced at the company, which
need a fastest service time. For this reason, the work is divided into different sections. The figure
below shows the general work flow diagram of the company.

Vehicle Vehicle Cost

Reception Inspection
Estimation

Vehicle delivery Service section

Quality control
 Mechanical
Repair
 Body and Paint
 Engine
Figure1.3 Workflow of the company maintenance
 Gearbox
maintenance

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 CHAPTER TWO
THE SELECTION OF THE COMPANY
2.1 The way of selection of the company
Most people’s said way you inter your internship paper in this company to disvalued car
maintenance company but the reality was we were mechanical students especially (automotive
stream) we were inferior our self to relief the challenge of the automotive work by this case we
prefer Abebe grima general garage. In addition, this company is short distance to travel arrived
being on time as well as without any stress and we can get full internship practice any economic
crisis so we can strengthen our theoretical concept in to practical in this real world about an
automotive engineering.
. The reason that we select this company is :-
 It is found near to our living area.
 We can spend full time within practice.
 When we spend full time within practice we will get knowledge and skill in practical
works.
 The weather condition adapted and comfortable to work
 To save the economy
2.2 The section of company we have been working in
The sections of work in this company are the following
 Repair section
 General service section
 Unit rebuilding service section
 Body and painting section and
 Electric system servicing section
 Express service section
2.3 The work tasks we have performed in each section
2.3.1 Repair and general service section
In both sections we have been perform the same activity, but the vehicles that encounter to the
accident are the concern of repair section.
 Oil and filter change in specification manual program.

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  Brake shoe and brake pad change when its fades up.
 Brake fluid change
 Brush, pin and washer change

Figure2.4 Repair and general service section

2.3.2 Unit rebuilding section
A. Engine Overhauling
In the company, we have been disassemble the removed engine from the vehicle, wash the
disassembled parts by diesel and inspect the defective parts. Such as cylinder head, valves, valve
lifter, valve shim, valve spring, camshaft, crankshaft, crankshaft bearing, timing belt, piston ring,
piston, connecting rod, short block, cooling system components and lubrication system
components. If the above parts are defective, they should be reconditioned or replace.
When the vehicle has one of the following problems, it will be overhauled
 If the oil consumption is high
 If there is overheating
 If the engine rpm is greater or lower than specification
 If there is high knock and noise with bad smoke
After overhauling then reassemble the engine. Then after the engine will be assembled and tested on
test bench. If everything is good, the engine will be mounted on the vehicle and road test will follow. If it
is out of specification, replace it.

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Figure2.5 Engine overhauling section

B. Differential Overhauling
We have been disassembling the removed differential and wash the disassembled parts by petrol.
Then surfacing the gears by the sand paper. Inspect the defective parts. Such as drive pinion
gear, ring gear, side gear, side pinion gear, front small and large bearing, collapse, side bearing
and backlash adjusting nut. If the above parts are defective, they should be replaced and
reassemble the differential.

Figure2.6 Differential Overhauling section

C. Transmission and transfer case Overhauling

We have been disassembling the removed transmission and transfer case; wash the disassembled
parts by diesel and after washing the transmission housing wash by laundry again we inspect the

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defective parts such as input shaft and its gear, countershaft gear, output shaft and its gears,
synchronizers, sleeves, hub, forks, and shifting liver shafts and the transfer shaft and gear. If the
above parts are defective they should have reconditioned or replace.

Figure2.7 Transmission and transfer case overhauling section

D. Alternator overhauling
We have been disassembling the alternator and inspect the abnormal parts, if there is replace or
recondition to specified condition, Depending on the service manual.
E. Starter motor overhauling
We have been disassembling the starter and inspect the abnormal parts, if there is replace or
recondition to specified condition, Depending on the service manual.
2.3.3 Body and Paint Shop
Body and paint shop has its Owen Forman and workshop. They have also their Owen procedures
and techniques to repair the vehicle. There are two sub sections. These are body surfacing and
painting section. The work of the two sections almost the same goal. The work we have been
performed in these shops can be
Repair body; the damaged body part repair by off dolly, on dolly and washer welding.
Repair chassis: preparing the chassis for measuring, measuring the chassis bendiness, repair
depends on the measured value by pulling and pushing.
Painting: This shop is divided in three shops. One is the chemical to be mixed shop which is the
different color fixation is being done from their store in this shop by using the appropriate
software and technician.

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Figure 2.8 Surfacing of the vehicle
2.3.4 Electric system servicing section
In this shop, most of a vehicle`s electrical systems are maintained or replaced by a new one.

The work we have been executing in this shop was: -

The Automotive Company have three parts of work section.

 The express servicing section and
 The repair section
 Vehicle body and painting section
The repair section divided into three sub sections.
 Engine overhauling section
 Mechanical system repair section
 Electrical system repair section
2.3.5 The express servicing section
The service that is given in this section is periodic maintenance, which is performed in every
5,000km (also called A service), 10,000km (also called B service), 20,000km (also called C
service) and 40,000km (also called D service). Some parts have to change in order to make the
engine and other part to long last. This section is important in cars safety some costumer transit

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the maintenance period. This develop into complex problem in gearbox, engine and in
mechanical parts.
These parts are: -
 In 5,000km
Changing Engine oil
Changing Oil filter

Inspect the overall system

 In 10,000km
Changing Fuel filter
Changing Air cleaner

Changing Engine Coolant

Changing Timing belt and the wheel knuckle have to be cleaned in kerosene and replace with
new grease.
 In 40,000km
Inspect and replace fuel system, ignition system, steering system, brake fluid, transmission fluid
and all bearings
2.4 The work tasks that we have been executing
In the first week, we just start our work by learning safety rule of the company and all of rule and
regulation that we should follow. Safety is denoted as duty that helps to keep us from injury. The
word safety also refers to the precondition people take to prevent accidents and harm damage.
The Cause of accident may be unsafe condition, unsafe act and Personal failure.
So we learnt how to protect and keep ourselves from any accident while working on the different
area of the company especially performed work on the machines.
It took only one week to know more about the workers, hand tools and supervisor (owner) of the
company so this creates good opportunity to know more about the working principal, its
components, working tools and process. After we observe and knowing the company rule and
regulation, we start to participate in different activities like employer.
These activities are:
 Servicing
 Mounting and un mounting engine

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  Changing clutch
 Inspect and repair electrical system
 Grinding
 Overhauling engine etc.
Actually, we was working in all sections of the company periodic Service and inspection room,
general maintenance room, engine room, injection pump room and electric work room; in those
work shop proceeds, different kind of process and steps. Under this team’s mechanical and
electric maintenance; there are three maintenance procedures are practiced
 Service
 Replacement
 Inspect
Servicing
In this element of maintenance technology cleaning, lubricating, repair action is performed
Cleaning: the cleaning action can be done by using appropriate cleaner depending on the way to
be cleaned such us by kerosene, gasoline, diesel and anti-rust (penetrate oil), the parts need to be
clean are bearing back plats, axle, washers, brake valve splines, shaft, some electric board, lock,
brush, alternator battery plugs.
Lubrication: after the part has been cleaned the dust very well, the lubricating action can and
possibly have applied this means not including electric materials.
Repair: this kind of service can be takes place whenever the parts of component failed to
perform its predetermined function so if the component is not completely failed it can be
repaired or recondition to its function.
Replace:
This step is take place when the commonent of the mechanical part damaged and the new one
were implmented. When this step is not done without the manualy and in prodice time it may
occur failerity of the parts such as engine parts, gear box,
 replace engine oil more frequently
 replace oil filter every 5,000 km (3,000 Miles)
 replace air cleaner filter every 20,000 km (12,000 Miles) or 12 months
 replace fuel filter every 20,000 km (12,000 Miles) or 12 month

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  check brake pads, discs and brake components every 5,000 km (3,000 Miles) or 3
months
 replace ventilation air filter more frequently
 check steering gear and linkage, axle and suspension parts, and exhaust system every
10,000 km (6,000 Miles) or 6 months
 replace automatic transmission oil every 40,000 km (24,000 Miles) or 24 months
 replace limited slip differential gear oil every 40,000 km (24,000 Miles) or 24months
 check brake pads, discs and brake components every 5,000 km (3,000 Miles)or 3 months
 check propeller and drive shafts every 10,000 km (6,000 Miles) or 6 months
Inspect:
 engine oil level
 engine coolant level
 brake fluid level
 windshield washer fluid level(wiper)
 battery fluid level
 Drive belts.
 engine oil filter.
 clutch and auto transmission fluid levels and for leakage
 power steering fluid levels and lines for leakage
 braking systems
 clutch system
 exhaust system
 manual transmission, front and rear differentials and transfer case oils for levels and
leakage
 steering gear and linkage
 axle
 suspension parts
 propeller shaft
 drive shafts
 wheel alignment, rotation and balance of wheels

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  brake pads, discs and associated brake components
 Foot brake, park brake and clutch for free play, stroke and operation.
 seat belt, buckles, retractors, anchor
2.5 Engineering methods, tools and techniques
These related things identified the personal working behaviour of the mechanical engineering
student without these things could not have successful work is done. The engineering methods
There are different tools that are used in work tasks some of them are
 Grinding machine
 Hydraulic press machines
 Modified Injector nozzle tester machine
 Air compressor machine
 Bench vice
 Drilling machine
 Electric arc welding machine
 Oxy acetylene

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Figure2.9 The machine found in the company
Tools we have been performing our work in the servicing shop
In working section, there are various tools such as,
Hand tools: - Socket, Universal Joint (Socket W4rench Set), Extension Bar (Socket Wrench
Set), Ratchet, Boxed Wrench, Opened Wrench (Spanner), Adjustable Wrench, Screwdriver,
Needle-Nose Pliers, Slip-Joint Pliers, Cutting Pliers (Nipper), Hammer, Gasket Scraper, Centre
Punch and Pin Punch are hand tools.
Wrenches: are used to turn screws, nuts, and bolts with hexagonal heads. There are three types
of wrenches. Open end, box (closed) and combination
Adjustable wrench: is often used where the exact size wrench is not available or when a large
nut, such as a wheel spindle nut, needs to be rotated but not tightened.
Socket: fits over the fastener and grips the points and/or flats of the bolt or nut. The socket is
rotated
Ratchet: used to rotate a socket. A ratchet makes a ratcheting noise when it is being rotated in
the opposite direction from loosening or tightening. A knob or lever on the ratchet allows the
user to swot
Filer gauges: used to adjust the valves & to measure the air gap between assembled parts
specially to measure the clearance of the cylinder block.

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Screwdriver: a flat-tip (straight blade) screwdriver. The width of the blade should match the
width of the slot in the fastener being loosened or tightened. Phillips screwdriver: Due to the
shape of the crosshead screw and screwdriver, a Phillips screw can be driven with more torque
than can be achieved with a slotted screw.
Hammers: are used to force objects together or apart. The shape of the back part of the
hammerhead (called the peen) usually determines the name.
Snap ring remover: is used to remove rings from the assembly.

Figure 2.10 Hand tool shop

2.6 Challenges and problem we have been faced while performing work tasks
During our internship period we have been faced some problems. The major challenge in
practical time is the covid19 pandemic disease. This pandemic disease creates the gap in
internship practical schedule periodic time, this makes to us confuse and loose of time in some
weeks and reinterred to the company, and we worked the practice with in safety way but not
more safe as the danger property of the virus. And the other is the language misunderstanding in
the filed language of the company is italic and the international language is English this is the
challenge occurred in first weeks. The company has no information about internship. In this case,
we have been faced in economic problem. Another challenge that we have been faced during our

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internship period was working without safety material like without safety boots and faced with
the problem of internet other gadding material like working manual books and also this problem
limits me to upgrade my theoretical knowledge. There is no any machine working for vehicle
body maintenance and the loose of power caring of engine and gearbox, differential, etc.
2.7 Measure we have taken in order to overcome these challenge
We asked the rule and regulation of the company and we just try to understand and implement
effectively. We discussed with supervisor about lack of safety material and he told us this
company is private company so there is no any budget that the company proposed for this
material for intern students and any employers then, we just bought safety material like gloves,
safety glass and safety shoes in the case of covid19. In this company, there is the shortage of
hand tools and improper use of tools at that time the material is damaged not used in longer time.
Due to this reason, we design and fabricate the Mechanical Wheel Drum Puller (Extractor).

17 | P a g e
 CHAPTER THREE
THE OVERALL INTERNSHIP EXPERIENCE
This part contains about the overall experience of the internship that means available work
sections we have been working in the company, work of tasks executing, engineering methods,
tools and techniques, using
3.1 In terms of improving our practical skill
Working with experienced technicians gives us many skills about automotive maintenance,
repair and use of machines. Since we are mechanical engineering student we asked different
questions that are not clear for us depending on what we learn, the technicians answered our
question briefly, and so we gained more knowledge In improving of our practical skills such as :-

 Designing by AutoCAD
 We learn what the workflow looks like during designing and manufacturing
 How the machineries are actuated i.e. we learn the mechanism
 We learn management of time and how to work with different plans.

3.2 In terms of updating our theoretical knowledge

In addition to the practical skill this program helps to us to be good in practical skill as well as in
theoretical knowledge to reading mechanical books and bethinking last year courses. The
practice depends first on theory; it is easy to work for the one having good theoretical base.
Theoretical knowledge is dependable on principles, logic and calculations. Upgrading theoretical
knowledge of courses like IC engine, machine elements, modern automotive engineering, engine
over hauling, refrigeration and Ac, instrument and measurements, heat transfer, maintenance,
and others.
3.3 In terms of improving team skill
During the internship time we were working with in a group which helps us to discuss problems
we faced in the company and to adapt ourselves to the new environment fast. There were
students from different universities like Adigrat, Arbaminch and so on. While, we were
observing different section of the company together, we discussed what we have seen in the
section relating it with what we have learnt before and we also discussed on new ideas which
raised between us. Also after we identified problems we were trying to solve the problems and
prepare our project helping to each other.
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There are a number of benefits that we gained from a team work. From these

 To do work in the scheduled time.

 To distributes the work load.
 To develop individual skills by sharing individual experience.
 To create participation and involvement.
 To make better decision.
 To develop a friendship.

So, we believed that team work plays a very important role in our staying in the internship
program.

3.4 In terms of improving our leadership skills

The internship experience helps us how to improve an effective leadership skill. Through
patience, persistence and hardworking we can be an effective leader this help us to develop good
leadership qualities. During internship period we just take an advice and experience from our
workshop supervisor, he told us the way to develop leadership skills. The internship had offered
us to grasp leadership virtues such as self-confidence, accountability and fair assignation of
tasks. We have seen how important the concept of leadership in any work area. Hence, we tried
to learn:
 How to control the resource and material of the company
 How to develop operational plan
 How to monitor and review operational performance
 Review and evaluate work performance
 How to apply managing the employees of the company
 How the leaders interact with employees in smooth and understandable way

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3.5 In terms of understanding about our work ethics issues, industrial
psychology and related issues
We have understood work ethics being on time to work and by working for our responsibilities
and also recognized the role of responsibility in keeping and performing particular work in a
good manner. Work ethics and related issues are important in every working area. Work ethics
that we develop in the internship program are:
 Respecting the rules of the company
 Respect all the employees of the company
 Punctuality
 Commitment
 Accountability
 Responsibility and
 Good leadership skill
3.6 In terms of improving entrepreneurship skills
An entrepreneur is an important sector even for the countries development because it creates job
opportunities to the society. In our internship experience, we have observed the sense of self-
confidence and self-esteem in order to develop entrepreneurship skill by developing our
classroom knowledge and practical skills we have understood how to be an entrepreneur in
different aspects. The more we work on practical application; the better that we create an
entrepreneur that means the internship experience will improve our entrepreneurship skills.
Wide ranges of skills are seen as entrepreneurial and useful to entrepreneurs, these include both
personal traits and skills:
Management skills - the ability to manage time and people (both yourself and others)
successfully
Communication skills and the ability to sell ideas and persuade others
The ability to work both as part of a team and independently
Able to plan, coordinate and organize effectively
Financial literacy
Able to research effectively, for example available markets, suppliers, customers and other more
specific or business-related skills, will be of use to entrepreneurs, these may include:

20 | P a g e
  Being able to draw up a business plan for a new venture
 Being able to market and sell a new product or idea
So, the other things we should do to improve our leader ship skills are

 Have a clear vision

 Know and utilize your strengths and gifts
 Be passionate
 Live in accordance with your morals and values
 Serve as a role model
 Set definitive goals
 Maintain a positive attitude
 Improve communication skill

3.7 In terms of improving our interpersonal communication

The other thing we improved is our interpersonal communication skills which involve both
personal as well as professional communication skills. Those collection of abilities enable a
person to interact optimistically and work efficiently with other. Developing interpersonal skills
is very essential. Interpersonal communication skills are those which we need in our everyday
life.
There are some of the most important skills that we learnt we need to focus on as large
percentage of our life involving interacting with people; friends, colleagues, relations or our boss
during communication. Those are;
 Don’t show negative body language
 Don’t interrupt the other person
 Think before you speak
 Listen well
 Don’t be defensive or attacking- be neutral
 Don’t deviate
 Be confident of your ideas
 Be open to receiving feedback

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  Use the right communication method
 Shake hands firmly…

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 CHAPTER FOUR
PROJECT: MECHANICAL WHEEL DRUM PULLER
4.1 Summery of the Project
A mechanical wheel drum puller is a device used to take out a stuck wheel, drum and bearing
from the hub or a shaft.

The wheel drum puller is a tool intended for professional use in mechanical service shop to
remove the bearing, brake drums and disks. Its functional handles enable to operate most original
brake drums and disks in automobiles and delivery trucks like trailer, cargo truck, dump truck
and body of semi-trailer. The puller enables the removal of fastened parts without any damage to
the disks during the removal with the impact tool. Tool is delivered in a metal case. Any wheel
or bearing will stuck to its shaft or hub due to working for a long period of time without
replacing. This device has a great advantage in solving thus kinds of problems.

Perversely peoples were used to different methods to pull a stuck wheel from its hub like by
means of kicking the rim using a hummer or other force with drawl methods. Despite this fact,
the mechanical wheel drum puller will reduce these kinds of difficulties by a great amount.

This device operates like a screw jack but has a reverse application, that means in this design the
screw jack used for lifting purpose is applied for pulling out a wheel with some additional part
assemblies.

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4.2 Statement Of The Problem
Now days in this country, most of the car wheels and drums that are stuck to their hub are
separated by kicking the rim by a hammer or using another object. However, this method might
not overcome the problem completely and it would have further accidents, damage the standard
material of the cars or trucks and labour consumption.

In this case, the Abebe Girma Garage repairs lots of heavy-duty trailers and semi-trailers, which
are used to give for long transportation system. These trailers and semi-trailers have a wheels and
drums, which were used for a long period of time. Due to a long period service, the wheels and
drums were stuck to the hub and it is difficult to take out using hammer or other methods. Our
wheel drum puller is a tool intended for professional use in mechanical service shop to. Its
functional handles enable to operate most original brake drums and disks in automobiles and
delivery trucks like trailer, cargo truck, dump truck and body of semi-trailer. The puller enables
the removal of fastened parts without any damage to the disks during the removal with the
impact tool. Despite this fact, the mechanical wheel drum puller remove the bearing, brake
drums and disks will reduce these kinds of difficulties by a great amount.

Figure 4.2: People Facing Problem on Existing Drum and Bearing

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4.3 Objective
4.3.1 Main Objective

The main objective of this project is to design a mechanical wheel drum puller with the required
parameters.

4.3.2 Specific Objective

Specifically the aim of this project is

 To know how to use the wheel drum puller and where used to be.
 To design power screw
 To design holding arms
 To design cross arm
 To design net
 To design pin
 To design handle

4.4 The scope of the study

There were various problems we worked with, we have seen them work harder and less accurate
to remove the bearing, brake drums and disks in automobiles and delivery trucks like trailer,
cargo truck, dump truck and body of semi-trailer, which can be easily and efficiently solved, as
well as it takes many hours to take out the materials . To solve this problem, we have developed
this simple mechanical wheel drum puller to take out these stacked materials and move them
around the yard as needed. In order to make this design, we was able to organize the documents
that would help us first and then develop detailed theories to better coordinate the data we found
with our own ideas in a month.so this design will reduce these kinds of difficulties by a great
amount.
4.5 Research Methodology
In this design the following methods are being used
 Observing information by referring previous documents, manual and reports, which are
connected to this project.
 Making basic assumptions and taking in account design consideration.

25 | P a g e
  Selecting the appropriate materials for the design.
 Design the required parts of the wheel drum extractor.
 Making the detail drawings and assembly drawing using auto cad software.

4.6 Literature Review

An industrial extractor can be the solution to one of the most frustrating and time consuming
Maintenance, repair and Operations tasks: removing frozen bearings, drums & wheels from
shafts.

Choosing the right capacity starts with knowing what size of shafts the puller will be working on.
A good, industry-wide rule of thumb for hydraulic pullers is 8-10 tons of capacity for every inch
of the shaft’s diameter. This means that an application with a shaft 2 inches in diameter requires
a 16-20 ton capacity puller, while a larger shaft of 8 inches in diameter would need a much
bigger machine. For manual pullers, the rule is that the central puller screw be at least half as
wide in diameter as the shaft it is working on.

Reach refers to the length of the extractor arms. Obviously, they need to be at least as long as the
work piece is deep, in order to grip the object securely, but not so long that they become
cumbersome. Extractor models with arms arranged in a claw formation have one set reach per
machine, meaning you may need to buy multiple machines to get the range you need. The
machines manufactured by Industrial wheel Puller are set apart by the fact that their reach is
adjustable. Unlike claw-arrangement models, the Industrial wheel Puller’s two rigid, straight
arms run parallel to each other, and can be secured farther forward or backward on the machine,
increasing and decreasing the machine’s reach to accommodate a wider variety of jobs.
Adjustable adapters will also help to achieve more reach.

Spread is the distance between the puller arms when they are extended as far apart as possible.
The puller’s spread must be at least as wide as the diameter of the work piece. When looking at
product specs, spread information is usually written as a range, indicating the minimum spread
(the closest the arms ever come to each other, or their distance from each other when the
machine is at rest), and the farthest distance apart they can be. Some companies’ literature may
only indicate a maximum measurement; however, in this case, it is necessary to find out the

26 | P a g e
entire range of the machine spread to know if it will suit your application. You will want to find
a puller that can accommodate the fullest possible range of work piece sizes in your plant.

Capacity and reach/spread measurements aside, extractors are broken into three main groups,
according to how they are powered: manually, mechanically, and hydraulically. The choice
between them will depend on your application, preferences, and price range: hydraulic power is
quickly becoming the preferred option, because of its convenience and high ease of use. On
higher-capacity pullers, it is now difficult to find anything less. Hydraulic extractors are powered
by a high-pressure hydraulic pump, which may be hand-operated or electric. Smaller pullers
(used to remove objects under six to eight inches in diameter, for example), are the best
candidates for hand pump operating, whereas larger, higher-capacity pullers will demand the
added efficiency and force of an electric or gas-powered pump (gas powered pumps can be a
great solution for puller use in situations where electricity is unavailable).[7]

4.7 Research Gap

As we observe in our company and other garages perversely peoples were used different
methods to pull a stuck wheel from its hub like by means of kicking the rim using a hummer or
other force with drawl methods. Our wheel drum puller is a tool intended for professional use in
mechanical service shop to remove the bearing, brake drums and disks. Its functional handles
enable to operate most original brake drums and disks in automobiles and delivery trucks like
trailer, cargo truck, dump truck and body of semi-trailer. The puller enables the removal of
fastened parts without any damage to the disks during the removal with the impact tool.

Despite this fact, our mechanical wheel drum puller design will reduce many kinds of difficulties
by a great amount compared to the previous methods also it;

 Reduces cost
 Saves time
 Have high working productivity
 Reduces skilled power... etc.

4.8 Method and Material

4.8.1 Material Selection

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 A typical mechanical wheel or drum puller has the following basic components.

1. Screw

2. Nut

3. Holding Arms

4. Cross arms

5. Handle

6. Pin

The screw is subjected to torsional moment, compressive force and bending moment from the
strength consideration material: EN8 carbon steel is selected because it have:-

• High strength
• High hardness
• Wear resistance and
• Low ductility
There is a relative motion between the screw and the nut, which results in friction. The friction
causes wear at the contacting surfaces. When the same material is used for these two
components, the surfaces of both components get worn out, requiring replacement. This is
undesirable. The size and shape of the screw make it costly compared with the nut. The material
used for the nut, jaws and cross arm stainless steel because it have:-

• Corrosion resistant
• High tensile strength
• Very durable
• Easy formability and fabrication
The handle is subjected to bending moment plain carbon steel is selected as the material for the
handle because it have:-

• Good toughness

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 • Good ductility
• Relatively good strength, may be hardened by quenching
• Low cost

Physical parameter Carbon steel Stainless steel

Average density 7850 Kg/m³ 8000 Kg/m³

Yield strength 325 Mpa 280 Mpa

Tensile strength 460 Mpa 450 Mpa

Elastic modules 2100 Gpa 1900 Gpa

4.11mechanical properties of carbon steel and stain less steel.

4.8.2 Specification

Maximum height of Pull = 400mm

Weight of payload (applied load) =100kg
Weight inherent in the system=100kg
Length of cross arm = 500mm
Length of handle= 300mm
The handle is subjected to bending moment plain carbon steel is selected with

=700-850 Mpa, Yield stress= 465Mpa, Hardness 201-255 Mpa

Length of screw =500mm
Length of holding arm= 346mm

Material for screw, (EN8 carbon steel (Indian Standard).With = 300Mpa ,τ = 350 MPa,
=465Mpa

Material for nut,jaws and cross arm is stainless steel with, = 450 Mpa MPa, τ = 480 MPa, =
520 MPa

Where, = tensile strength of material, τ=shear strengths of material. = crushing stress.

29 | P a g e
 CHAPTER FIVE
Design of Mechanical Wheel Drum Puller Parts
A wheel drum puller is a portable device consisting of a screw mechanism to extract a stuck
wheel or bearing from its shaft. The load acting on the screw is a compressive load which is
equal to the frictional force acting on the mating surface between the hub and the wheel. In
addition to this load, there is also a force at the handle to rotate the screw and a twisting moment,
which induce shear stress between the threads of the screw and the nut. Mechanical extractors
can be either hand operated or power driven. In this type of extractor, the hazards are dropping;
slipping of mechanism of their parts during operation .Proper size, strength and stability are
essential requirements for the design of this extractor.

5.1 Design of screw

5.1.1 Terminology of Power Screw

(i) Pitch: The pitch is defined as the distance, measured parallel to the axis of the screw, from a
point on one thread to the corresponding point on the adjacent thread. It is denoted by the letter
“p” [6].

(ii) Lead: The lead is defined as the distance, measured parallel to the axis of the screw that the
nut will advance in one revolution of the screw. It is denoted by the letter “l”. For a single
threaded screw, the lead is same as the pitch, for a double-threaded screw, the lead is twice that
of the pitch, and so on [6].
(iii)Nominal diameter: It is the largest diameter of the screw. It also called major diameter. It is
denoted by letter “d” [6].

(iv)Core diameter:
It is the smallest diameter of the screw thread. It is also called minor diameter. It is denoted by
the letters “dc” [6].

(v) Helix angle:

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It is defined as the angle made by the helix of the thread with a plane perpendicular to
the axis of the screw. Helix angle is related to the lead and the mean diameter of the screw. It is
also called lead angle. It is denoted by α [6].

From the selected material specification

 𝑦𝑖𝑒𝑙𝑑 𝑠𝑡𝑟𝑒𝑠𝑠 𝑖𝑛 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛/𝑡𝑒𝑛𝑠𝑖𝑜𝑛 (SYC / SYT = 210Mpa)

 𝑢𝑙𝑡𝑖𝑚𝑎𝑡𝑒 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ (𝑢𝑡𝑠) =380M𝑝𝑎
 Factor of safety =6
𝐴𝑙𝑙𝑜𝑤𝑖𝑏𝑙𝑒 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑠𝑠 (𝜁𝑎) = 0.75∗𝑢𝑡𝑠

= 0.75∗380

= 285M𝑝𝑎

The weight of the wheel acting on the hub is 100kg, which is equal to the normal force acting on
it, but here we want the frictional force acting between the hub and the wheel.

Hence, we know that,

𝐹𝑓 = 𝐹𝑛∗μ

= 1000N*0.1

= 100N...Which is the required amount of load to be pulled.

Considering only compressive stress, we have a relation

4∗W
Ϭc=
π d2

syc
Where, Ϭc=
f.s

= 210/6

= 35M𝑝𝑎

From this, we can get the core diameter

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 d=
√ 4∗w
π∗Ϭ c

¿
√ 4∗100
π∗35

= 24 𝑚𝑚

The diameter only consider compressive stress but screw is subjected to bending moment for
that we increase a diameter to a higher values we will use a screw with 10mm and 2mm pitch
from table of basic dimensions for square threads.

𝐷 = 24 𝑚𝑚

𝑝 = 3 𝑚𝑚

𝑑 = 24−3 = 21 𝑚𝑚

𝑑𝑚𝑒𝑎𝑛 = 𝐷−0.5∗𝑝

=22.5 mm

Find the torque required to rotate the screw and the shear stress due to torque

We know that,

P
tan α=
π∗d (m)

−1 p
α =tan
π∗d (m)

3
α =tan−1 =2.5
π∗22.5

And 𝜇 = tan𝛽

Assume μ = 0.19 for bad lubricating

−1
β=tan ( 0.19 )

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 = 10.75

Hence, β>α the screw is self-locking

The torque required is given by
w∗d ( mean )
T= ∗tan (α + β )
2
= 100*(22.5/2)*tan (2.5+10.75)

= 265 N mm

Now compressive stress due to axial load

W
σc=
A

4∗100
σc= 2 = 288Kpa
π∗d

Which is less than the permissible compressive stress =35Mpa so, it is safe.

Shear stress due to the torque is given as

16∗T
ζ= 3
π∗d

16∗265
ζ= 3
=146 Kpa
π∗21

The shear stress also less than the allowable shear stress 285Mpa their fore it is safe.

Maximum principal stress

σc (max)=1/2 ¿ ¿

σc (max) ¿ 0.5(288+ √ 288 + 4(146¿ ¿2¿))¿ ¿

2

= 350K pa

Maximum shear stress

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 ζ ( max)=0.5∗¿ ¿

ζ ( max)=0.5∗¿ ¿

= 205K pa

As we can see from the above results the maximum stresses are below the allowable stress, their
fore design of screw is safe.

5.2 Design of nut

The nut of the main screw is a part of a puller in which the screw rotates for its desired
function. Considering the bearing pressure between the screw material and nut material is
17Mpa.

The bearing pressure is given by:

Pb=w/¿

W
Or Pb=
π∗d∗n∗t

Where d (m) = Mean diameter of screw,

t = Thickness or width of screw = p / 2, and

n = Number of threads in contact with the nut

Height of the net h

= =
Pitch of threads p

D = outer diameter of the screw

d = core diameter of the screw

Using the first equation:

100∗4
17=
π∗( 242 −212 )∗n

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𝑛 = 9.6 say 10

ℎ = 𝑛∗𝑝

= 10*3

= 30 mm

𝑡 = 𝑝/2

= 3/2 = 1.5mm

Now let us check the stress induced in the screw and nut when they are in contact.

w
ζ ( screw)=
π∗n∗d∗t

100
¿
π∗10∗22.5∗1.5

= 94.4Kpa

And the shear stress on the nut

w
ζ ( nut)=
π∗n∗D∗t

100
¿
π∗10∗24∗1.5

= 86.7kpa

Hence, the stresses are within the permissible limit stresses 36Mpa and 285Mpa their fore
design for the nut is safe.

5.3 Design of handle

Handle is a part of wheel extractor in which a person applied a direct pulling activity in order to
rotate the screw for the required function. From design consideration there is a little force applied
at the end of lever, which will cause bending of handle.

35 | P a g e
The bending moment on the handle is given as:

M=force applied by human hand * length of handle.

Here the force applied by human can be taken as half of average human weight around 30kg and
length of handle can be taken as 300mm.

Their fore M = 300N*300mm

= 90000Nmm

sy
From the selected material for the handle we have, Ϭ=
f .s

220
¿
6

= 34.67Mpa

π
We know the bending moment, M = ∗Ϭ∗DH
32

From this, we can find the diameter of handle (DH), DH =

√
3 32∗M
π∗Ϭ

= 29mm say 30

Calculating the induced stress using the new diameter we got

32∗M
Ϭ= 3
π∗DH

32∗90000
¿ 3
π∗30

= 34Mpa

Which is less than the permissible stress, 35Mpa their fore the design for the handle is safe.

36 | P a g e
5.4 Design of holding arms
This is the main part of a wheel extractor, which actually pull the wheel from the shaft one end.
The holding arm has a hole so as to mount in on the cross arm using a pin so as to provide it
rotating degree of freedom in two direction other than the axis of the pin plane in which it is
attached. The other end of the holding arm has a wider cross section and a curved jaw in the end
so as to claw one end of the wheel rim and to remove the wheel out with the force created on it.

Force analysis

The arm is supported at an angle of 30 degree assuming the position of arm while pulling the
wheel from the shaft

Ra RB

A 100 B

Taking the summation of forces in the y direction

∑ fy=Racos 30+ Rbcos 30−100 N=0

Taking the summation of forces in x direction

∑ fx=Ra sin 30−Rb sin 30=0

Solving the equations simultaneously we got that,

𝑅𝑎 = 𝑅𝑏 = 58𝑁…...In to the given direction.

37 | P a g e
Stress analysis

Considering the end of the holding arm (jaw) as a curved beam. We have the following known

parameters and standard dimensions.

Direct load on the jaw (W) = 58𝑁

Distance from the centre of curvature to the inner fibre (RI) = 25mm

Distance from the centre of curvature to outside fibre (RO) = 50𝑚𝑚

High t (h) = 25mm

Width (w) = 10mm

We know that the area,

𝐴 = 𝑏∗ℎ

= 25∗10

= 250𝑚𝑚^2

The radius curvature of neutral the axis,

h
Rn=
Ro
loge
Ri

25
Rn=
50
loge
25

= 36mm

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Radius of curvature of centroid axis

h
R=Ri +
2

25
R=25+
2

= 37.5mm

Distance between centroid axis and neutral axis

𝑒 = 𝑅−𝑅𝑛

= 37.5−36

= 1.5𝑚𝑚

And distance between the load and the centroid axis

𝑋 = 𝑅 = 37.5𝑚𝑚

Bending moment about centroid axis

𝑀 = 𝑊∗𝑋

= 58∗37.5

= 2175𝑁𝑚𝑚

The holding arm jaw is subjected to a direct tensile load and a bending moment. We know that

the direct tensile stress is given by:

39 | P a g e
 W 58
Ϭt= ¿
A 250

= 232K𝑝𝑎

The distance from the neutral axis to inside fibre

𝑌𝑖 = 𝑅𝑛−𝑅𝑖 = 36−25 = 11𝑚𝑚

And distance between the neutral axis and the outside fibre

𝑌𝑜 = 𝑅𝑜−𝑅𝑖

= 50−25 = 25𝑚𝑚

∴Maximum bending stress of the inside fibber

M∗Yi
Ϭbi=
A∗e∗Ri

2175∗11
¿
250∗1.5∗25

= 2552K𝑝𝑎 (𝑡𝑒𝑛𝑠𝑖𝑙𝑒)

And maximum bending stress of outside fibre

M ∗Yo 2175∗25
Ϭbo= =
A∗e∗Ro 250∗1.5∗50

= 2900K𝑝𝑎 (𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒)

∴The resultant stress at the inside fibre

= Ϭ𝑡 + Ϭ𝑏𝑖

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 = 232 + 2552

= 2784K𝑝𝑎

The resultant stress at the outside fibre

= Ϭ𝑡 – Ϭ𝑏𝑜

= 232 – 2900= 2668K𝑝𝑎

Hence, the maximum bending stresses at the outside and the inside the fibres are less than that of

the permissible stress the design is safe.

5.5 Design of cross arm

This is basically a base in which the components of wheel puller attached to the desired purpose.

Determining the length of the cross arm the holding arms tilt to 30 degree for the maximum

griping of the wheel rim, Their fore geometrically

Cross arm

CA B

ϕ=500mm

Using sin law

sin 30 sin 60 sin 90

= = Where; 𝑏 = 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 = 300𝑚𝑚
a b c

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 Also we get
𝑎 = 173𝑚𝑚
𝑐 = 346𝑚𝑚
∴ 𝑇ℎ𝑒 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑐𝑟𝑜𝑜𝑠 𝑎𝑟𝑚 = 𝑑𝑖𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑟𝑖𝑚 – 2 ∗ 𝑎
= 500𝑚𝑚 – 2 ∗ 173𝑚𝑚
= 154𝑚𝑚

Force analysis

Considering the cross arm as a horizontal beam we have the following forces acting on it.

Cross arm

𝑅𝑎sin 30 A B 𝑅𝑏 sin 30

𝑅𝑎 cos30 100 N 𝑅𝑏 cos30

∑ fy=Racos 30+ Rbcos 30−100 N=0

𝑀 (𝑏) = 𝑅𝑎 cos30 ∗ 154𝑚𝑚 − 100𝑁 ∗ 77𝑚𝑚=0

Solving the equations simultaneously we got

𝑅𝑎 = 58𝑁

𝑅𝑏 = 58N

The maximum bending moment,

𝑀𝑚𝑎𝑥 = 58𝑁 ∗ 154𝑚𝑚 − 100𝑁 ∗ 77mm = 1232𝑁𝑚𝑚

Stress analysis

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The bending stress on the beam is given by:

MY
Ϭb=
I

Consider standard dimension for the cross arm under the given load we have,

𝐻𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑟𝑜𝑠𝑠 𝑎𝑟𝑚 = 𝐻𝑖𝑔ℎ𝑡 𝑜𝑓 𝑛𝑢𝑡 = 30𝑚𝑚

𝑊𝑖𝑑𝑡ℎ 𝑜𝑓 𝑐𝑟𝑜𝑠𝑠 𝑎𝑟𝑚 = 2 ∗ 𝐷

= 2 ∗ 24.5𝑚𝑚

= 49𝑚𝑚

∴The moment of inertia along x-x section

bh3
Ixx=
12

3
49∗30
¿
12

=110250𝑚𝑚^4

h
And Y =
2

30
Y= =15 mm
2

MY 1232∗15
∴ Ϭb= =
I 110250

= 167.6K𝑝𝑎 which is less than the allowable stress their fore the design is safe.

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5.6 Design of pin

The pins are in double shear conditions. The diameter of pin (d p) is given by,

W
Where, F=load on pins F= =50 N
2

¿
√ 4∗100 = 2.7mm say d = 5mm
2 π∗265
p

The diameter of pinhead is taken as 1.5dp (i.e. 15mm) and its thickness is 4mm.
5.7 Cost Analysis
In this project, we have estimated the cost spent before and after using the mechanical drum

puller.

No. Activity Persons Duration Salary per Salary per

assigned time month year

1 To take out a 2.mechanic I 1:20Hr 6800 birr 81600 birr

Stuck Drum

2 Mechanic II 4000 birr 48000 birr

Sum 10,800 birr 129,600 birr

Table 4.2 Money spent before using the drum puller

N0. Activity Persons Duration of Salary per Salary per

assigned time month year

1 To take out a stuck Mechanic I 10min 3,400 40,800

drum

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Table 4.3 Money spent after using the drum puller

Calculating the profit Abebe girma garage can get using this drum puller

Profit (P) =total cost spent before using this drum puller-total cost spent after using this drum

puller

Monthly

P=10800birr-3400 birr

P =7400birr

Yearly

P=129,600 birr-40,800 birr

P=88,800 birr

Or P=monthly profit *total months in a year

P=7400 birr*12

P=88,800 birr

N.B: considering the time required to pull out a stack drum using this project is more efficient

than it used to be before because, they were taking a lot of time and applying a lot of power to

take out, but using this drum puller they can extract as many as greater than eight (8) times than

the previous one. Considering these cost analysis values and time taken, we conclude that using

this mechanical drum puller Abebe girma garage can benefit by minimizing the dangers and
45 | P a g e
consumption of high power to extract without damaging any parts of the trailers and reducing the

time required and manpower to pull out the stacked drum.

5.3 Result and discussion

In this design of a mechanical wheel hub puller, the engineering materials selected for the parts
of the puller where easily available and have low cost. The direct applied forces on the cross arm
and the holding arms are shown graphically accordingly with their respected line of action .Basic
assumption and design consideration were taken for the design purpose and applied accordingly
throughout the process.

The different types of stresses, which are expected to have an impact during the operation of the
tool, were calculated and analysed accordingly. From all out comes of the design analysis and
results of the wheel hub puller, we can surely say that it would have a great advantage in
consuming time and cost not only for the Abebe girma garage but also for other companies
which needs this kinds of tool.

CHAPTER SIX
CONCLUSION AND RECOMMENDATION
6.1 Conclusion
In this four month we have gained more knowledge especially on improving our personal skills,
we can easily see the difference b/n theory and Practical work; when we do practical work, we
can easily see each and Individual things. So, this makes better to improve our personal skill.

And when we see in terms of up grading our theoretical knowledge, the Knowledge that we
knew only in theory is not enough, but when we see the theory in practical, it is unforgettable.
So, this helps us to upgrade our theoretical knowledge and when we look in terms of work ethics,
we learn to be punctual and work properly. The activities which have done on each section helps
to see and Knows different things, like working with machines which got new technologies and
knowing the working principle of some machines which we learned in theory with practice.

Generally, we conclude that this internship program gives to us a lot of things, such as:-

46 | P a g e
  We get the opportunity to know a real world situation and experience.
 We add a lot of practical skills from the companies training activity to the theoretical

Knowledge learned from university.

 We can realize the importance of quality, safety, hygiene and cleanness for every job.
 we know how to develop our playability skills, communication skill team work, problem

Solving, self-management, planning, organizing and so on.

6.2 Recommendation
Since this internship program is our first real practical work experience, we earned a lot of
knowledge and we can surely say that it fills us with a great values and new ideas. The program
allows us to meet different peoples, which have a real experience and knowledge of solving
problems, however beside this fact there are problems, which we observed throughout the
internship period, which needs a great concern. First of all our recommendation to company
office should be to communicate with the host companies and provide information for the
students and advisors what kind of the company is and sector industry it works on. The office
should have a full profile about the company before the beginning of the internship for
minimizing the confusion of students before starting the internship. Secondly, our
recommendation goes to our hosting company, the company should provide well-educated
supervisors and give a full support for the students.

Generally, the company should;

 Build well structure engineering department

 Important data should be provided as a standard base, the information given by the
mechanic Should be clear and accepted
 Those old machines should be changed with new and modernize machine to facilitate the
Service and profitable.

At the end, we suggest that every section of the company should contain a well skilled
manpower to increase the profit of the company and the company should provide necessary
manuals.

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REFRENCES
[1] Documents and Oral datas from Abebe girma garage.

[2] Shigley-S-Mechanical-Engineering-Design-9th -Edition, Mcgraw –Hill, New York, USA

[3] R.S Khurmi and J.K Gupta, 2005 Text Book of Machine Design Eurasia Publishing House
(Pvt.) Ltd. Ram Nagar, New Delhi-110 055
[4] http//www.google.com
[5] J.E Shigley- Ch.R.Mischke, Mechanical Engineering Design, Mc Graw-Hill international
Edition, 1989, Singapore.
[6] J.E Shigley- Ch.R.Mischke, standard handbook of machine design, second edition, Mc Graw-
Hill, 1996, New York
[7] http://www.wikipedia.com
[8] M.F. SPOTTS- T.E. SHOUP-L.E.HORNBERGER, Design of machine elements, Eighth
edition, PEARSON Prentice Hall, 2004
[9] P.N. RAO, Manufacturing Technology, Second Edition, Tata Mc Graw-Hill, 1998 New Delhi
[10] Marshek, Fundamentals of Machine Components Design, Third Edition, John Wiley and
Sons, 2000, New York.
[11] R.S Khurmi-J.K. Gupta, A Text Book Of Machine design
[12] http://www.industrial extractor.com

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49 | P a g e
APPENDICES
Part Drawing

φ10

346

50

DR ASSOSA UNIVERSITY COLLEGE OF ENGINEERING

BY:LAMESEGN.B DEPARTMENT OF MECHANICAL
:TSEGAZEAB.S ENGUNEERING(AUTOMOTIVE STREAM)
CH BY: Mr.
TILAHUN

ID:RU 0957/10 HOLDING ARM SCALE:1:2

:RU0959/10

DATE: 27/5/2017 DR NO:1

All in: mm

50 | P a g e
 ASSOSA UNIVERSITY COLLEGE OF ENGINEERING
DRBY:LAMESEGN.B DEPARTMENT OF MECHANICAL
:TSEGAZEAB.S ENGUNEERING(AUTOMOTIVE STREAM)

CHBY: Mr.
TILAHUN.

ID:RU0957/10 SCALE:1:2
: RU0959/10 HANDLE
DATE: 27/5/2017 DR NO:2

All in: mm

51 | P a g e
 DRBY:LAMESEGN.B ASSOSA UNIVERSITY COLLEGE OF ENGINEERING
:TSEGAZEAB.S DEPARTMENT OF MECHANICAL
ENGUNEERING(AUTOMOTIVE STREAM)
CH BY: Mr. TILAHUN

ID:RU0957/10 SCALE:1:2

:RU0959/10 SCREW

DATE: 27/5/2017 DR NO:3

ALL IN:MM

52 | P a g e
 φ24.5 R17.5

30

DR BY: LAMESEGN.B ASSOSA UNIVERSITY COLLEGE OF ENGINEERING

: TSEGAZEAB.S DEPARTMENT OF MECHANICAL
ENGUNEERING(AUTOMOTIVE STREAM)
CH BY: Mr. TILAHUN

ID:RU0957/10 SCALE:4:1

: NUT
RU0959/10

DATE: 27/5/2017 DR NO:4

ALL IN: MM

53 | P a g e
 DR BY: LAMESEGN.B ASSOSA UNIVERSITY COLLEGE OF ENGINEERING
: TSEGAZEAB.S DEPARTMEN OF MECHANICAL
ENGUNEERING(AUTOMOTIVE STREAM)
CH BY: MR. TILAHUN

ID:RU0957/10 CROSS SCALE:1:2

: RU0959/10 ARM

DATE: 27/5/2017 DR NO:5

ALL IN:MM

54 | P a g e
 DR BY: LAMESEGN.B ASSOSA UNIVERSITY COLLEGE OF ENGINEERING
: TSEGAZEAB.S DEPARTMEN OF MECHANICAL
ENGUNEERING(AUTOMOTIVE STREAM)
CH BY: MR. TILAHUN

ID:RU0957/10 PIN SCALE:1:2

: RU0959/10

DATE: 27/5/2017 DR NO:5

ALL IN:MM

55 | P a g e
 ASSEMBLY DREWING

1 Screw Carbon steel 1

2 Holding arm Stainless steel 2

3 Cross arm Stainless steel 1

4 Nut Stainless steel 1

5 Handle Carbon steel 1

6 pin Stainless steel 2

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