Asegid Intern

BAHIR DAR UNIVERSITY
BAHIR DAR INSTITUTE OF TECHNOLOGY
FACULTY OF MECHANICAL AND INDUSTRIAL ENGINEERING

INTERNSHIP REPORT
HOSTING COMPANY: BISHOFTU AUTOMOTIVE MANUFACTURING

INDUSTRY
PROJECT TITLE: DESIGN AND MODELING OF MECANICALLY OPERATED

WHEEL REMOVAL AND HANDLER MACHINE
Internship Duration: -Jun 08, 2022 – Oct 10, 2022
By: Asegid Amare
ID No. BDU 1103092
Mentor: Mr. Atrsaw J.
Company Supervisor: Mr. Hubtamu
Date: Nov, 9, 2022

DECLARATION
I declare that this internship report and project paper is my original work except some references and
manuals used. The References used are fully cited. The paper has been submitted to Bahir Dar institute of
technology department of automotive engineering.
Name of student Signature Date
1) Asegid Amare __________ ________________
Advisor approval
This is to certify that the above statement made by the candidates is correct to the best of my Knowledge
and belief. This paper has been submitted for presentation with my approval.
Name of Advisor Signature Date
Mr. Atrsaw.J _________ _________
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ACKNOWLEDGEMENT
First of all, I would like to thank almighty GOD for helps me in all aspects from the start to the
end and for leading me throughout my life and keep me safe and healthy. Secondly, I would like
to thank my adviser Mr. Atrsaw J. helps me on selecting my project title and he gave as
information on how to write a report, so many thanks to Mr. Atrsaw J.
My acknowledgement also extends to Bishoftu Automotive Engineering Industry because the

company for allowing me to practice my internship program which had lasted for about four-
months. During my stay the staffs of the maintenance service department were very encouraging,
helpful and supportive. My special thanks go to my company supervisors, Mr. Habtamu, Mr. Beker
and to all of the fellow workers for their concern, support and encouragement.
I am grateful to my relatives and friends for their encouragement and wishes of successful
accomplishment.
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EXECUTIVE SUMMARY
This internship report document is based on the four-month long internship program that I had
successfully completed in Ethio-engineering group in Bishoftu Automotive Engineering industry
branch. It includes brief history of the company, main services, main customers, organizational
structure, work flow, mission, vision, objectives of the company. From the report I have also
included the section of the company I have been working with, work flow and work tasks and,
methods and techniques are stated briefly. The report includes major problem while performing
the work task and their proposed solution and then result & discussion with recommendation for
the identified problem. Finally, the report talks about the overall benefits I have gained from the
internship and then the report concludes with recommendation.
The report also includes the project on design and modeling mechanically operated tire removal
and handler machine. It starts by short summary of the project and then followed by identified
problem and their justification. Then describes the objective & methodology and then finalizes by
giving a conclusion with supported recommendation. The result & conclusion is done by taking
the analysis of each component and assembly from the software solid work. By using this software,
solid work, makes the project simpler.
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Contents
DECLARATION .................................................................................................................................. ii
ACKNOWLEDGEMENT .................................................................................................................... iii
EXECUTIVE SUMMARY .................................................................................................................... iv
LIST OF FIGURE .............................................................................................................................. vii
CHAPTER ONE .................................................................................................................................. 1
BACK GROUND................................................................................................................................. 1
1.1 BACKGROUND OF THE COMPANY .................................................................................. 1
1.2 ORGANIZATION AND MANPOWER ................................................................................... 2
1.2.1 Vision ........................................................................................................................................................... 3
1.2.2 Mission ........................................................................................................................................................ 3
1.2.3 Core Activities ............................................................................................................................................. 3
1.3 EQUIPMENTS UTILIZED DURING THE INTERNSHIP .................................................... 4
1.3.1 Engine hoists ............................................................................................................................................... 4
1.3.2 Hand Chain Hoists ....................................................................................................................................... 4
1.4 BASIC COSTUMERS OF THE COMPANY .......................................................................... 5
1.5 ORGANIZATIONAL STRUCTURE ....................................................................................... 6
1.5.1 Design and development ............................................................................................................................ 6
1.5.2 Power train .................................................................................................................................................. 6
1.5.3 Vehicle production factory .......................................................................................................................... 7
1.5.4 Vehicle system production factory ............................................................................................................. 8
1.5.5 Construction machinery production factory ............................................................................................... 9
1.5.6 Tank production factory .............................................................................................................................. 9
1.5.7 Body and frame production factory .......................................................................................................... 10
1.6 WORK FLOW OF THE COMPANY .................................................................................... 10
CHAPTER TWO ............................................................................................................................... 12
2.1 INTERNSHIP EXPERIENCE .............................................................................................. 12
2.1.1 Working section ........................................................................................................................................ 12
2.1.2 Challenges and measures taken ................................................................................................................ 13
2.2 BENEFITS OF INTERNSHIP .............................................................................................. 14
2.2.1 Purpose of internship ................................................................................................................................ 14
2.2.2 Overall benefits of internship ................................................................................................................... 14
2.3 Recommendation and Conclusion ....................................................................................... 18
CHAPTER THREE............................................................................................................................. 19
DESIGN OF MECHANICALIY OPRATED WHEEL REMOVAL AND HANDLER .................................... 19
3.1 ABSTRACT........................................................................................................................... 19
3.2 STATEMENT OF THE PROBLEM AND JUSTIFICATION ............................................... 20
3.3 SCOPE OF THE STUDY ..................................................................................................... 21
3.3 OBJECTIVE OF THE PROJECT ........................................................................................ 22
3.3.1 General objective ...................................................................................................................................... 22
3.3.2 Specific objectives ..................................................................................................................................... 22
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3.4 METHODOLOGY ................................................................................................................ 23
3.5 LITERATURE REVIEW ....................................................................................................... 25
3.6 MATERIAL SELECTION ..................................................................................................... 26
3.7 DESIGN ANALYSIS ............................................................................................................. 27
3.7.1 Design Considerations ............................................................................................................................... 27
3.7.2 Design of lever arm ................................................................................................................................... 28
3.2.3 Design of Tire Lifter (movable frame) ....................................................................................................... 29
3.2.4 Design of the Ram ..................................................................................................................................... 31
3.2.5 Design of lifter supporter Frame ............................................................................................................... 32
3.2.6 Design of Main Base Frame ....................................................................................................................... 33
3.2.7 Design of tire Support Plate ...................................................................................................................... 35
3.2.8 Design of the Power Screw ....................................................................................................................... 36
3.2.9 Design of Nut............................................................................................................................................. 38
3.2.10 Selection of Caster Wheel ....................................................................................................................... 39
3.2.11 Assembly of the drawing ......................................................................................................................... 40
3.8 Cost Analysis and Estimation .............................................................................................. 42
3.8.1 Labor cost .................................................................................................................................................. 42
3.8.2 Machine and power cost ........................................................................................................................... 42
3.8.2 Material Cost ............................................................................................................................................. 42
Conclusion ................................................................................................................................. 44
Recommendation ........................................................................................................................ 44
CHAPTER FOUR .............................................................................................................................. 45
RECOMMENDATION AND CONCLUSION ....................................................................................... 45
Reference/Bibliography ................................................................................................................. 46
Appendices .................................................................................................................................... 47
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LIST OF FIGURE
Figure 1-1 Logo of Ethio EngineerinGroup.................................................................................... 1

Figure 1.2 Engine hoist ................................................................................................................ 4
Figure 1-3 Hand Chain Hoists ..................................................................................................... 4
Figure 1-4 personal tool sets and collection....................................................................................5
Figure 1-5 Engine on engine seat.................................................................................................... 6
Figure 1-6 Different productions of the company………………………………...........................7
Figure 1-7 Electrical system assembly........................................................................................... 8
Figure 1-8 Construction machinery.................................................................................................8
Figure. 1-9 Tank production factory ..............................................................................................9
Figure 1-10 Body and frame............................................................................................................9
Figure 1-11 Service Repulsion.......................................................................................................10
Figure 1-12 Market repulsion for purchase...................................................................................10
Figure 3-1 Methodology cycle .................................................................................................. 21
Figure 3-2 Removal of tire............................................................................................................ 22
Figure 3-3 lever arm...................................................................................................................... 23
Figure 3-4 Tire lifter..................................................................................................................... 27
Figure 3-5 Ram..............................................................................................................................28
Figure 3-6 Tire handler..................................................................................................................29
Figure 3-7 Main base fram.............................................................................................................31
Figure 3- Support plate..................................................................................................................34
Figure 3-9 Nut................................................................................................................................35
Figure 3-10 Caster.........................................................................................................................36
Figure 3-11 Assembly of Drawing…............................................................................................37
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List of tables
Tables
List of tables
Table 1.1 material selection…………………………………………..28
Table 3.1 cost analysis ………………………………………………...43
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CHAPTER ONE
BACK GROUND
1.1 BACKGROUND OF THE COMPANY
Ethio-Engineering Group is a government owned industrial enterprise established under the laws
of the Federal Democratic Republic of Ethiopia (FDRE) by the decree of the council of ministers.
Ethio-Engineering Group is working under a free market norms and standards with special
commitments that enables a domestic and foreign investor to enjoy partnership and cooperation.
Figure 1.1 Logo of Ethiop Engineering Group
Ethio-Engineering Group is a vast organization that includes a number of companies underneath

itself. These companies include: Ethiopia Plastic Industry, Bishoftu Automotive Manufacturing
Industry, Ethiopian Power Engineering Industry, Akaki Basic Metals Industry, Adama Agro-
Machinery Engineering Industry, High Tech Engineering Industry, Hervey Manufacturing and
Machine Building Industry, Ethiopia Power Engineering Industry, Metals and Fabrication Industry
and other sub-industry factories and workshops.
Ethio-Engineering Group Bishoftu Automotive Manufacturing Industry is one of the industries

under FDRE Metals and Engineering Corporation. The industry is located at about 48 km From
Addis Ababa, at Bishoftu town. The company started as Project 40720(currently named as Ethio-
engineering group Bishoftu Automotive Manufacturing Industry) was originally constructed to
render maintenance service for tanks, armored vehicles military vehicles, artillery weapons, optical
devise, small arms, communication and control equipment. Implementation of the project began
in February 1984 and was interrupted in May 1991 following, the fall of Derg regime. From 1991
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up to 2008 the project work finalized and overhauling of Tanks and Ural military trucks started.
Again in 2008 project 40720 re-organized under defense industry sector by the name of Bishoftu
Motorization Engineering Complex. Bishoftu Motorization Engineering Complex (2008 to 2010)
carried out overhauling of Tanks Armored personal carriers (APCS), artillery materials, optical
devices, communication equipment, military trucks and generator. In 2010, the defense industry
sector re- organized by the name of METALS AND ENGINEERING CORPORATION separated
from defense. From then; Bishoftu Motorization Engineering Complex was renamed as Bishoftu
Automotive Engineering Industry under metals and Engineering Corporation. (Minister, 2008)
Today under Ethio-engineering group Bishoftu Automotive Manufacturing Industry is the single
largest vehicle manufacturer in Ethiopia, from light vehicle to heavy duty commercial trucks,
buses, special purpose vehicles, military trucks and APCS. In addition, the industry works
overhauling and upgrading of Tanks and APCS. The company occupies at total area of 32.5
hectares, out of which 87000m^2 area is covered by various building. (Abdella, 2010)
1.2 ORGANIZATION AND MANPOWER
Project 40720 is organized under the defense industry and infrastructure sector, DIIS, of the
ministry of national defense, which is highest authority of the project. The general manager, who
is accountable to DIIS, is responsible to ensure that the project is carrying out its operation
efficiently and effectively. The units responsible to perform the core activities are organized under
the operation and engineering department, while those responsible for supporting activities are
organized as staff units under the General Manager and under the administration and financial
D/G/Manager. The project has about 1001 workers, of which 498 are civil and 503 are military
personal. amount these workers there are highly qualified and skilled workers with many years of
experience, including eight the second degree, 46 first degree and 212 diploma holders.
(Information Department, 2021)
DESIGN AND MODELING MECHANICALLY OPERATED WHEEL REMOVAL AND HANDLER MACHINE
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1.2.1 Vision
The vision of industrial of the project 40720 phase was to be self-reliant on the providing
maintenance and over all service for the military hardware and materials of the ground force and
ensure repulsion easiness of the army.
1.2.2 Mission
The mission of the industry of the project phase was to ensure the combat readiness of the army
by maintaining and over hauling military hard work and equipment of the ground force with better
efficiency, quality and at lower cost. To increase manufacturing capacity and capacity for tool,
spare part and auxiliary required for the maintenance and overhaul activities. engineering market
as a result the industry being to maintain over haul and assemble different types of civil and
commercial engineering equipment like that of city busses, construction and locomotive
machineries and different types of field vehicles. Therefore to include the basic customers of
Bishoftu Automotive Manufacturing Industry are ministry of defense, federal and regional
government offices, non-governmental organizations, private firms and others.
1.2.3 Core Activities
The Bishoftu Automotive Manufacturing Industry at the project phase 40720was equipped with
appropriate technology, machinery and equipment that enable it to provide efficient services in the
following specialized areas :-
✓ Tank and APC overhaul and maintenance services

✓ Military Automotive and engineering vehicles overhaul and maintenance service
✓ Armament overhaul and maintenance services
✓ Communications equipment overhaul and maintenance service
✓ Generator maintenance and much more.
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1.3 EQUIPMENTS UTILIZED DURING THE INTERNSHIP
1.3.1 Engine hoists
Engine hoists are also known as engine cranes, shop cranes, floor cranes, or portable cranes and
are specialty required for safe lifting of engines, transmissions and other bulky and heavy parts
and is a common repair tool, and we used in repair shops to remove or install a load in small and
crowded compartments. It is considered a valuable tool in every field as it is being used to move
heavy objects and has a heavy cantilevered support structure to hold the load with defined lifting
load capacity.
Figure 1.2 Engine hoist
1.3.2 Hand Chain Hoists
The hand chain hoist model is designed using the latest technology and manufactured with quality
materials. This chain hoist is compact with low headroom and light weight for easy installation.
This hand chain hoist is made with heat treated reduction gears, top hook pivots and swivels for
easy rigging. Sealed, pre-lubricated ball bearings provide long service life with low maintenance.
Figure 1.3 Hand Chain Hoists
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All capacity ratings are metric (1 ton). This hand chain hoist is an efficient means of lifting freely
suspended material loads within its load rating. The cast hand chain wheel and load activated break
will provide smooth, precise spotting of loads.
Figure 1.4 personal tool sets and collection
This personal mechanic’s tool sets contain SST comprehensive collection of the most used
automotive and mechanic’s tools, including adjustable wrenches, pliers, hammer and sockets
1.4 BASIC COSTUMERS OF THE COMPANY
Bishoftu Automotive Manufacturing Industry which was founded as Bishoftu motor fixation
engineering about 20 years ago and the umbrella of the Federal Democratic Republic Ethiopia
ministry of defense ,so that to fulfill the different types of needs of the mission military equipment
to make armies ready for its basic international regional and global mission given by the Peoples’
of Federal Democratic Republic of Ethiopia and through that of the question of the international
societies specially in the peace keeping missions.
Therefore the basic and sale customer of the industry was:-
➢ The federal democratic republic of Ethiopia ministry of defense

➢ Anbesa public service
➢ Public service
➢ City administrations
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➢ Government hospitals
➢ Adama university.
➢ Oromia police commotion.
1.5 ORGANIZATIONAL STRUCTURE
Bishoftu Automotive Manufacturing Industry is organized under different departments having

different purpose. Which are listed as the following.
1.5.1 Design and development
The main function of design and development in Bishoftu Automotive Manufacturing Industry is
provide a design and developing a job training for workers based on the demand of Bishoftu
Automotive Manufacturing Industry factories and other industries.
✓ Design and manufacturing proto type of new product and transfer the proto type to mass
product on job.
✓ Library service for the factories and staff departments. Preparing on job training for
workers in the department to improve their knowledge.
✓ Preparing on job training facility following manner industry factories for government on
private universities, colleges, technical staffs, and vocational schools.
1.5.2 Power train
The main activities of power train production factory are listed in the following manner.
✓ Over hauling of engine, gear box, propeller shaft transfer case differential
✓ Design of power train parts, manufacturing and assemble.
✓ Overhaul of various commercial vehicles.
✓ Recondition and grind of crankshafts.
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Figure 1-5 Engine on engine seat
1.5.3 Vehicle production factory
The main activities of vehicle production factory in Bishoftu Automotive Manufacturing Industry
is-Assembling of various military and non-military commercial vehicles. For example, since last
year factory is assembled 500 city buses for Addis Ababa city administration. Upgrading,
designing and others is the other activities of the factory for both military and commercial customer
needs.
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Figure 1-6 Different productions of the company
1.5.4 Vehicle system production factory
The main operational activities of vehicle system production factory is assembling of vehicles
injection pump, steering system, cooling system, electrical system and others.
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Figure 1-7 Electrical system assembly
1.5.5 Construction machinery production factory
This department includes the following.
✓ The construction machinery production factory compresses the following four different
production section dozer, grader, loader, excavator production section.
✓ The construction production factory has been receiving machineries such as dozer, grader,
loader and excavator from different local customers, and performing repair, assemble as
well as well overhaul tasks.
✓ This factory future intends will be to design and fabricate different types of construction
parts and machinery.
Figure 1.8 Construction machinery
1.5.6 Tank production factory
The main operational activities of tank production factory are maintenance, overhauling,
modifying and upgrading of various model tanks and tank accessories.
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Figure 1-9 Tank production factory
1.5.7 Body and frame production factory
Overhaul products tank hull, tank turret, various vehicles fender, plat form, frame and chassis.
Armored vehicle body new products bus bodies, armored bodies heavy truck cab, heavy truck plat
form, different production of sheet metal. Armored personnel carriers vehicles production factory
perform tasks such as: BROM, BTR armored personnel carriers is BTR commend personnel
carriers mission car, wheeled armored vehicle, special purpose vehicles and others.
Figure 1-10 Body and frame
1.6 WORK FLOW OF THE COMPANY
Bishoftu Automotive Manufacturing Industry which is a governmental development organization

is now a profit-making industry follow different types of operational job flow cycles such as:
(Abdella,2010)
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Figure 1-11 Service Repulsion
Figure 1-12 Market repulsion for purchase
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CHAPTER TWO
2.1 INTERNSHIP EXPERIENCE
Bishoftu automotive manufacturing industry is one of the biggest industries in our country under
FDRE Ethio-engineering Group. There are many students joining this company almost from all
universities. Among these students, I am one of those who wants to join this company. To give
equal chance to all university students it concerns the number of students comes from each
university. While joining the company the following things are told before proceeding to work:
✓ Orientation about rule and regulation of the company

✓ General overview of company
✓ Grouping all internship students
✓ Orientation about safety, maintenance and related
✓ Procedure Assigned responsible person for each group.
2.1.1 Working section
I was assigned at a garage where both heavy duty and light duty vehicles are serviced. In the garage
all the following parts of the vehicle are maintained. These are body and chassis, drive transmission
and steering parts, suspension and brake parts, engine parts and electrical parts. In the garage I
have been executing different tasks assigned to me by the chief mechanics and other mechanics
and technicians. I have been mainly working on:
✓ Checking car tires

✓ Checking wheel alignment
✓ Checking engine parts
✓ Inspecting electrical systems
✓ Testing of serviced vehicles
✓ Overall inspection the vehicles
✓ Lubrication of the parts
✓ Aligning the parts at previously calculated angles
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During my stay though I have been assigned to the garage I got a permission from the supervisor
to work and participate at different department of the company.
These tasks includes:
✓ Bus manufacturing workshop

✓ Small vehicle manufacturing workshop
✓ Painting workshop
✓ Power train inspection workshop
2.1.2 Challenges and measures taken
2.1.2.1 Challenges
At the time of my admission to the company there is a problem related with the arrangement and
satisfaction of the students as the market is very low. Due to this I do not get the chance to work
as expected. Then somehow specific placement in the company is carried out after I join, but
challenges are not overcome at all some of this are listed below.
✓ Lack of supervisor to follow our daily activities and to order us for work step by
step in all station.
✓ Some worker has no interest to tell some activities and the components.
✓ It’s difficult to gain information about company/background/ from worker and
doctrinarian department (that collect data of company).
✓ There is lack of material supply.
2.1.2.2 Measures taken
The basic way to overcome these challenges is mainly depends on my interests to know some
things and need to add additional knowledge. Then depends on my interest I try to take a measure
to overcome the challenge faced me in many ways. Some of them are:
✓ I ask permission individually as well as in group to visit and to take some action in other
factory.
✓ I ask negotiable and interested advisor (employee) to guide way.
✓ I use material that used as replacement or have similarity.
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2.2 BENEFITS OF INTERNSHIP
2.2.1 Purpose of internship
The purpose of internship is to update practical knowledge of students in the Universities. It was
aimed at bridging the gap between the theoretical knowledge acquired in classes and technical
knowledge in the industry by providing students with the opportunities to apply their educational
knowledge in real work situations.
It gives student the opportunity to blend the theoretical knowledge acquired in the classroom and
with practical hands on application of knowledge required to perform work in the industry. Also
it prepares students for employment and makes the transition from school to the world of work
easier after graduation.
2.2.2 Overall benefits of internship
2.2.2.1 Gain practical experience
Many people learn best by things on hand but everyone can benefit from seeing the things that
they have been learning in class, put to action. Students learn about their strengths and weaknesses
by creating learning objectives and receiving feedback from their mentor.
This is a unique learning opportunity that students may never have again as a working adult.
Embracing the mistakes that they will make and the many things that they do not know. This is a
prime opportunity to ask questions, observe, and take risks.
2.2.2.2 Improving practical skills
The internship program helps me to improve my theoretical knowledge by implementing it

practically. It is so interesting to face the real world. Using this internship program, I tried to relate
the theoretical knowledge with the practical part, technical, subject -specific knowledge and
understanding. I know that it is better to show some things rather than teaching it theoretically.
Psychologically I gain confidence on how to practice something and how to change ideas
practically.
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Generally, this program made me skilled man power and give qualities nurtured by studying
mechanical engineering and other related things like;
• Creativity and an innovative approach to solving problems practically;

• The ability to analyze and take different, difficult works;
• Effective opinion and supervision of team working ;
• Awareness of ethical issues and the wider impact of work;
Related to the area where we took the internship program we gained skill in these areas listed
below:
• Skills on independency and reliability in the world.

• Understanding of the disassembling and assembling of vehicles and their parts in specific.
Generally, the practically gained knowledge are base for one’s future life, because, without
practical skill a person may not be able to show the theoretical knowledge on the field.
2.2.2.3 Improving theoretical knowledge
The following are some points that help to improve my theoretical knowledge:
✓ How the component of vehicle are assembled.

✓ How the assembled components work together.
✓ How to cheek when the assembling parts are not work properly Gain an increased
awareness about the department and departmental courses like; mechanism of machinery,
heat transfer, vibration, machine element and electrical machine.
✓ Learn how and where to use courses we are taken theoretically like design, thermal and
motor vehicle, so this used for more understanding of our courses.
2.2.2.4 Improving interpersonal communication skill
This internship program helped me in improving our interpersonal communication skills. There
were opportunities for improving interpersonal communication skill during the working period in
the company. The intended workers of company are interested to answer whatever questions that
I asked and also their good facial expression helped me talk with them more. This is the main
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means, which helps me to improve our interpersonal communication skills. This opportunity helps
us to know how to introduce ourselves, how to ask information and when and where to get it. I
also develop my interpersonal communication skills.
2.2.2.5 Improving teamwork skills
In terms of improving teams playing skills I have gained a lot like:
✓ Cooperativeness
✓ Convincing one another
✓ Developing the habit of group discussion
✓ Performing tasks together as a team
✓ Interacting with each other dynamically
✓ Sharing experiences
Above all each team member has a responsibility to contribute equally and offer their unique
perspective on a problem to arrive at best possible solution, such teamwork and sharing of
knowledge and responsibility allow me to be more productive in the future.
2.2.2.6 Improving leadership skills
The main point I gained during this internship for improving my leadership skills is to have the
confidence in the position I was and the ability to make a decision on the issues that concerns me.
Getting experience is a great way to build my confidence after I have done an internship. If an
interviewer asks, I know how to do something. During this period I gained, the way of improving
my leadership skills by the help of my supervisor by means of observing how he leads his workers
and how he solves a problem comes from the workers.
2.2.2.7 Understanding about work ethics
Work ethics: There are two common types of ethics.
• Personal
• Professional ethics.
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During the internship program I understood the work ethics related issues. I understood how to
work hard in addition how to work smart. This means learning the most efficient way to complete
the tasks and finding ways to save time while completing daily assignments. It is also important to
care about my job and complete the project. Doing more than expected on the job is a good way
to show management that I utilize good time management skills and not wasting valuable company
time attending to personal issues that are not related to the job.
These ways are:
• Being independent and responsible

• Possessing a positive attitude
• Honesty and integrity
2.2.2.8 Entrepreneurship skills
This company helps me to improve my entrepreneurship skills. Personal vision and mission by
mean of putting me on top and observing as creator of solution for problems. This helped us to
work hard and find and analysis a solution for problems of the company. The project stated and
solved is best example for this entrepreneurship skills.
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2.3 Recommendation and Conclusion
Ethio-engineering group Bishoftu Automotive Industry is one of the giant industries organized
under the former Metals and Engineering Corporation. This industry thrives to alleviate the burden
of foreign expense allotted to import vehicles. This industry does receive students and assist to the
sharing of the knowledge and experience. By using this goal I participated in departments of the
company and I have been practicing to know more about what I have been learning in theory.
During our stay I have faced different problems during the program and I have taken approaches
on how to solve these problems. I was able to solve some problems by asking the parts involved
and taking responsibility of by myself. There are also some problems that are related to managerial
skills, team work skills, psychological skills, and others that may not be easily solved by one part.
On these types of problems, I recommended the company itself along with other students from
different universities on how to take care of its properties, employees, customers. I also thrived to
solve the problem they faced as much as I can, the project solved could be taken as an example.
Generally, internship is the best opportunity to know in order to test patience and skill of a person.
I have already discovered and adopted how the working life looks like in the real world. From this
internship, I have seen the work ethics and related things like how to communicate with others and
the interaction between leaders and workers as of teamwork. In the other word, it is the best place
to improve practical skill from my background theoretical skills, interpersonal communication
skills and others. I also improved my skill in the way of identifying problem and solve by
producing related project practically.
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CHAPTER THREE
DESIGN OF MECHANICALIY OPRATED WHEEL REMOVAL AND

HANDLER
3.1 ABSTRACT
Mechanically operated wheel removal and handler machine is designed to modify the way a tire
is removed and installed. The mechanism of the mechanically operated tire removal and handler
is by using small human force that is applied on the lever arm to install and remove the tire during
maintenance of vehicle tire. When an arm is rotate the tire lifter is move up and down which is
attached to the ram by menace of welding mechanism. It hold the tire to remove it from wheel
bolts during servicing of the vehicles. This project mainly used for reducing human force required,
to reduce the technician effort, reducing the time needed to install and remove a tire, reducing the
number of employers required, increasing the production rate, performing two operation with
single part and with a minimum cost. This project is mainly used for the company and also can use
for heavy truck drivers as the projects movable and flexible. It can be used for different place and
environment. To design this tool, we follow different procedures and we considered the time,
efficiency, availability of the material, safety to the professional and cost of material.
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3.2 STATEMENT OF THE PROBLEM AND JUSTIFICATION
There are many problems occurring in the automotive workshops. The main problem is related to
The wheel. This problem includes removing and installing of the wheel. In these cases, it is
difficult to get the exact position of the wheel bolts in short period of time due to its high weight.
It also needs high human power to carry the wheel as long as we get the exact position. The services
related to these kinds of services occur daily in automotive shops hence the way to perform better
is needed rather than the traditional way. The project has to be formulated as the demand for the
service is high and it allows the company and the consumers to achieve the work needed in the
greatest satisfaction. The mechanics face the tiresome work during tire assembling and
disassembling. In addition, this kind of operation needs a number of man power to perform the
operation. It is so hard to move tire from place to place and remove from vehicles. Hence based
on these observable facts and working environment the machine is needed to operate the foregoing
problems stated.
Justification: - The Company that I’m engaged in has many works connected with tire
removing process but the way they are doing it is tedious. So that, I planned to design and construct
a mechanical operated wheel removal and handler for the company and I discus with my instructors
of the company and I get a positive reward than I work on it.
Therefore, I need to design a tool that is easy to construct, cheap, which use low energy to complete
the mission that we can use it for a long time with low cost and able to bring a long life for design
and modeling mechanically operated wheel removal and handler machine. We decided to do this
project from the cheapest and easily available material.
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3.3 SCOPE OF THE STUDY
This project is about the Design and modeling mechanically operated tire removal and handler
machine. These types of machine are applicable for pick up car’s which have 40cm radius and
26cm width of tire that I was used in this project it is more reliable and easier to operate. In order
to develop new concept of these design, I do some research. The scopes of research were on the
designing 25cm lifting capacity of tire by using small human force. For optimizing the human
power, the concepts that will be used in this product by multiplying the force with mechanically
operated machine. Therefore, by this, the mechanical advantage while removing and lifting tire
can be reducing. In our design we were using machine drawing instrument to draw out the detailed
and assemble drawing of each component of our product the project cost can be analyzed based
on material cost in kilogram, labor cost which can be take time off manufacturing of part and
standard material cost.
Figure 2.2 pickup car and its wheel
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3.3 OBJECTIVE OF THE PROJECT
3.3.1 General objective
The main objective of the project is to design and modeling mechanically operated tire removal
and handler machine.
3.3.2 Specific objectives
➢ To design a lever arm.

➢ To design the tire lifter.
➢ To design lifter supporter frame.
➢ To design the ram.
➢ To design power screw.
➢ To design main base frame structure.
➢ To design nut.
➢ To select caster wheel.
➢ To modeling the machine.
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3.4 METHODOLOGY
In this project I collected the data with two perspectives of data collection method, primary data
collections and secondary data collection.
My primary data collection includes an interview with the people involved and our own
observation of the problem. The secondary one includes visiting different sites of internet and
referring to different books.
The cycle involved in the methodology is shown as below.
Problem
Identification
Evaluation Literature
and
Conclusion Review
Modeling Data and

of the Design
machine Study
Date Materials
Analysis Selection
Figure 3-1 Methodology cycle
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Problem
Literature review Data collection
identification
Choosing Citing the

Primary data
the main project
collection
prepared
problem Secondary
globally and
Data
giving credit
collection
Tire Support
Evaluation and Producing 3D Tire removal Analysis
Conclusion model Analysis
Data
analysis
Solid work
Finite Analytical
Preparing Element Mathematic
Model for
the final Analysis for al Analysis
the parts and
proposed parts.
assembly
solution. Dimensionin
Checking g the model
the design.
Finite Element
Analysis and
Mathematical
Analytical cross
checked
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3.5 LITERATURE REVIEW
Vehicles are a result of engineering evolved over a century. From the beginning of the
manufacturing process these machines need a great care and observation to operate well. Every
part of the machine has their own unique way of designing and way operation.
Vehicle of any kind have one property that makes them similar, all vehicles got tires. These parts
of the vehicle are the most at disposal part of the machine. They need special care and attention
when it come to their way of performance otherwise great damage to the machine and to people’s
life follow.
These parts are parts which needs maintenance and observation before and after every time they
have to be used. The service is available almost at every vehicles garage. As it is a common service
the way of maintaining and servicing these parts have been in use in different countries which
comes in different forms and different ways.
These parts are handled manually using high human force in many countries including Ethiopia.
In garages these kinds of services are given and because of the man power needed the number of
services garages give is limited at a time. In the following pages there are photos and descriptions
show how tires are removed both in a traditional and modern way.
Mohawk lifts model TD1000AH is air/hydraulic tire lifting machine. It is able to lift heaviest tires.
(Nottingham, 2021)
Figure 3-3 Mohawk tire lifting machine
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Electric lift stacker for lifting tires which is used to lift tires to the needed place.
Figure 3-4 Electric lift stacker
TSI
So those materials that are listed above work electrically or mechanically. So they contain a lot of
sophisticated structures. And these structure may be affected during the maintenance. So we are
interested to do the project by reducing the structure, removing electric power need and make it
easy for use, production and maintenance at a lower cost.
3.6 MATERIAL SELECTION
Selection of suitable material must to be considered in account. The suitable of material with the
process of machined as well as the compatibility of the material with the environment. Different
manufacturing factor have been consider selecting material is the first target for designing or
manufacturing one machine. Selecting material must consider the requirement or the material
properties, sufficient strength and easily workable.
For the project different materials have been selected for different parts of the machine. The
material selection for the part is based on:-
✓ The strength,
✓ Corrosion resistance,
✓ Hardness,
✓ Roughness,
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✓ The machine ability,

✓ Heat treatment properties,
✓ Resistance property, and other properties of the material is considered.
No Part Material type
1 Lever arm Low alloy Steel
2 Tire Lifter Mild Steel
3 Lifter supporter frame Cast iron
4 Main base frame Low alloy Steel
5 Ram Low alloy Steel
6 Plate Low carbon
7 Nut Mild steel
8 Power Screw Cast steel
Table 1.1 material Selection
3.7 DESIGN ANALYSIS
In this section I will be designed the mechanically operated tire removal and handler each part
including lever arm, ram, tire lifter, base and handler fame. All these parts attached with welding
mechanism. I also select the part like caster.
3.7.1 Design Considerations
• Total weight of the tire 30kg

• Diameter of the tire 40cm
• Ground clearance of vehicle 5cm-10cm
• Maximum lift range of the device. 20cm
• Overall length of the device 1.25m
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• Overall Width of the device 1.02m

• Arm length of the device 20cm
• Source of power manual operated(hand)
3.7.2 Design of lever arm
The material chosen for the lever arm is high strength, low alloy of grade A440 steel having the
yield strength of 𝜎𝑦 = 290Mpa and taking Fs = 2 and the allowable stress will be
𝜎𝑎𝑙𝑙 =𝜎𝑦/𝐹. 𝑆= 145𝑀𝑃𝑎
Let us draw a FBD diagram and calculate the force and bending moment.
Fb
20cm
B A
Fa=5N
From the above FBD the value of the momentum
At point B M= -Fa∗x = -5N∗0.2m = -1Nm
At point A M=-Fb∗x = Fb*0.2m= -0.2FbNm
But M at A and at B are equal so
-0.2FbNm=-2Nm
Fb=1Nm
From above given moments the maximum moment is M=1Nm
To calculate the diameter of the lever arm we use the formula of:
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𝑑
𝑀𝑚𝑎𝑥 ∗ 𝑦 𝑀𝑚𝑎𝑥 ∗ 2 32
𝜎𝑎𝑙𝑙 = = ⁄ 𝑑4 = 𝑀𝑚𝑎𝑥
𝐼 ⁄64 d3
𝑑 𝑑4
Where y is 𝑦 = and 𝐼 = and the given 𝜎𝑚𝑎𝑥 = 50𝑀𝑃𝑎 and 𝑑 = 10𝑚𝑚.
2 64
Checking for the safety of the design
𝑦
Using shear stress analysis of the lever at the critical points 𝜏 =𝑇∗ J
𝑑4
Where 𝐽 =32= 312𝑚𝑚4, 𝑇 = 𝐹𝐻 (200 − 40) = 40(200 − 40) = 6400 𝑁𝑚𝑚, 𝑦 =𝑑2= 5𝑚𝑚
Hence the shear stress will be
𝜏 =6400∗ 5312= 103𝑀𝑃𝑎 and 𝜏 = 103𝑀𝑃𝑎 < 𝜎𝑎𝑙𝑙 = 145𝑀𝑃
Therefore, as the shear stress produced is less than the allowable stress of the material the design
Of the part is safe.
3.2.3 Design of Tire Lifter (movable frame)
The Tire lifter is attached to the ram and power screw by means of welding attachment mechanism. It
is located in handler frame. It made from the mild steel like other components of the tire removal. The
Tire lifter is constructed with welding of the solid linear bar and enclosed by other hallow linear bar
designed to move in up and down freely in one direction.
The Tire lifter bar is subjected to bending moment due to shear force and tensile load. The Tire lifter
bar is considered as both ends are fixed beam and the type of load is point load which is due to the
lever arm push load in to power screw during removing the tire.
The length of the screw is 25mm and the length of the Tire lifter bar L is 90mm.
Then the shear stress load is given by Where;
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P=τ∗ 𝐴
P is the maximum vehicle load

τ is the stress available in the selected material (P=8550N)
A is cross sectional area of the bar
Let the cross-sectional area A of the bar is given by
A=l∗W
=900mm∗5mm
450mm2
To check the design is whether safe or not we have to calculate the maximum shear stress which is
given by
𝑃 85500𝑁 𝑁
τmax = 𝐴 = 450𝑚𝑚2 =19𝑚𝑚2
Therefore; the allowable shear stress is greater than the maximum shear stress
𝑁 𝑁
i.e. τall > τmax , 20 >19 ,the above design is safe.
𝑚𝑚2 𝑚𝑚2
Figure 3.3Tire handler
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3.2.4 Design of the Ram
The material selected for the ram is high strength, low alloy steel AISI/SAE Grade A440 which
have a yield strength of 290MPa and by assuming 𝐹. 𝑆 = 2 its allowable tensile strength
σy 290
𝜎𝑎 = = 2 = 145Mpa
𝐹.𝑠
The load on the ram is 300N. And the diameter of the ram is calculated as:
𝜋𝑑𝑟2∗𝑝𝑖 𝑤∗4
𝑊= = 𝑑𝑟 = √ =4cm
4 𝜋∗𝑝𝑖
Checking for the design: We check if our design is safe or not by using the Rankine’s formula for
buckling or crippling load which is calculated as below.
𝜎𝑎𝑙𝑙𝐴
𝑊𝑐𝑟 =
1 + 𝑎(𝑙|𝑘)2
Where: l is length of the ram rod (Khurmi & J.K, 2005)
k is radius of gyration of the material
E is Modulus of Elasticity of the material
a is Rankine’s constant=1/7500 for steel
Given values: 𝜎𝑎 = 145𝑀𝑃𝑎, W= 300𝑁, 𝑑𝑟 = 4𝑚𝑚,
𝐸 = 210𝑀𝑃𝑎, C = 1, l=160mm, since
Both ends are hinged ends, k = 0.25*d=1
𝜎𝑎𝑙𝑙𝐴
𝑊𝑐𝑟 = = 3570,
1 + 𝑎(𝑙|𝑘)2
𝑊 = 1000𝑁 < 𝑊𝑐𝑟 = 3570𝑁
Hence the crippling load is greater than the total load on the ram the design is safe.
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Figure 3.4 Ram
3.2.5 Design of lifter supporter Frame
The tire lifter supporter frame support base is the support which handles a tire also it helps the
device as a counterweight. It is where a tire is placed during assembling and disassembling process.
It is connected and welded to the handle and the base frame.
The material selected for this part is ductile cast iron of Grade ASTM A536 having yield strength
of 𝜎𝑦 = 483𝑀𝑃𝑎 and its allowable stress is calculated as below where 𝐹. 𝑆 = 2
𝜎𝑦 483𝑀𝑝𝑎
𝜎𝑎𝑙𝑙 = = = 242𝑀𝑃𝑎
𝐹.𝑆 2
𝑀𝑚𝑎𝑥
𝑀𝑚𝑎𝑥 = 𝑊 ∗ 𝐿 and 𝜎𝑚𝑎𝑥 =
𝑍
𝐼 bt3 ⁄12 1
𝑍= = 𝑏𝑡2
𝑦 t⁄2 6
Where 𝑀𝑚𝑎𝑥 is the maximum moment produced in the part, 𝜎𝑚𝑎𝑥 is the maximum stress
produced in the part, 𝑍 is the section modulus of the part, is the moment of inertia of the part
𝑦 is the distance to the point from the material’s neutral axis
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𝐼 bt3 ⁄12 1
𝑀𝑚𝑎𝑥 = 𝑊 ∗ 𝐿 𝑍= = 𝑏𝑡2
𝑦 t⁄2 6
1
𝑀𝑚𝑎𝑥 = 600 ∗ 400 𝑍 = 600 ∗ 152
6
= 240000𝑁𝑚𝑚 = 22500𝑚𝑚3,
𝑀𝑚𝑎𝑥
𝜎𝑚𝑎𝑥 =
𝑍
𝜎𝑚𝑎𝑥 =240000/33750
=11𝑀𝑃𝑎
Hence as the maximum stress produced in the material is much less than the allowable strength of
the material the design is safe.
Figure 3.5 Tire lifter supporter Frame
3.2.6 Design of Main Base Frame
A main base frame is a bed base that supports overall load of the above parts. The total load acting
on the base is the sum of the individual parts of the mechanically operated tire removal and handler,
the tire, the support base and other additional parts.
We take: -
the length of the base, 𝑙 = 1300𝑚𝑚
width of the base, 𝑤 =1000𝑚𝑚,
thickness of the base, 𝑡 = 50𝑚𝑚,
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The material selected for the part is high strength low alloy steel of AISI A633 Grade E having a
yield strength of, 𝜎𝑦 = 552𝑀𝑃𝑎 assigning a factor of safety is 2.
We get:
σy 552𝑀𝑃𝑎
𝜎𝑎𝑙𝑙 = = 2
= 276MPa
F.S
From the given total load acting base frame the stress produced on the base will be calculated as
𝜎 =𝑤𝐴, 𝑊 = 1602𝑁, 𝐴 = 𝑙 ∗ 𝑤 = 1000 ∗ 1300 =1300000𝑚𝑚2,
𝜎 =1602𝑁∗1300000𝑚𝑚2 = 2.082𝑀𝑃𝑎.
Hence the stress produced in the base is very small compared to the allowable stress for the
material hence the design is safe.
Shear load design
Consider the cross-sectional area of the one side of bottom base member and the shear load is
given by
P=n*t*τ
Where
P is the total tire load
n is number of beam
A is the cross sectional area of the one side of bottom base member
is shear stress of the selected
τ is shear stress of the selected material (τ=5𝑚𝑚2

𝑁
)
p=n*w*t* τ
p 300
t= = =3mm
w∗n∗τ 10∗2∗5
Say 5 mm for safe design and use hallow base member for attractiveness of the device. Hence it
holds all the parts.
Calculating the materials deflection to check the design as: (Richardson’s, 2005)
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FL3 1602 ∗ 13003

𝛿= = = 0.5𝑚𝑚
48𝐸𝐼 48 ∗ 210000 ∗ 651042
Figure 3.6 Main Base Frame
3.2.7 Design of tire Support Plate
The part is a part where the hydraulic bottle jack is welded on and the part is in turn welded on the
main base frame. The material selected for the part is plain low carbon steel of Grade AISI 1010
having yield strength of 180MPa and its allowable strength will be , by considering the factor of
safety 2,
σy 180𝑀𝑃𝑎
𝜎𝑎𝑙𝑙 = F.S = = 90MPa
2
The dimensions are taken as the length of the plate l = 800mm, the width of the part w = 102mm
and the thickness of the plate, t = 20mm.
Checking for the design the material is subjected to the load from above and the plate is considered
as a simply supported beam welded at both the ends.
Calculation for the part will be:
𝑊∗𝐿 yMmax
Mmax= , 𝜎max= , I=𝑏𝑡3/12 and y=𝑡/2
4 𝐼
Where Mmax is= the maximum moment produced in the part
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W Is the total load acting on the part, 𝜎max is the maximum stress produced in the part, I is the
moment of inertia of the part, y is the distance to the point from the materials neutral axis.
1600∗1200 10∗48000
Mmax = = 48000Nmm, 𝜎max= = 12Mpa
4 41666
Maximum stress produced in the material is less than the allowable strength of the material, hence
the design is safe. In addition we can calculate the materials deflection to check the design as:
(Richardson’s, 2005)
FL3 1602 ∗ 1203
𝛿= = =0.03mm
48𝐸𝐼 48 ∗ 210000 ∗ 41666
Hence the deflection produced is negligible therefore the design is safe.
3.2.8 Design of the Power Screw
Power screws are used to convert rotary motion in to translational motion. It is also called
Translational screw. They find use in machines such as universal tensile testing machines, machine
tools, automotive jacks, vises; aircraft flap extenders, trench braces, linear actuators, adjustable
floor posts, micrometers, and C-clamps. A screw thread is formed by cutting a continuous helical
groove around the cylinder. These grooves are cut either left hand or right hand. The power screw
is a single threaded screw with collar at both ends, with one end in contact with Member and the
other end having a square key way to enable the transmission of torque from the gears.
The collar is assumed to be frictionless and the power screw has been designed to be self-locking.
A power screw is advice used in machinery to change angular motion in to linear and usually, to
transmit power. This must have adequate strength to with stand axial load and the applied torque
The Material selected for screw is GS -52.3 cast steel material to design bolts because of:-
✓ High level of ductility
✓ High strength
✓ Wear resistance
✓ Ease of producing component parts
For GS -52.3 cast steel:
Tensile strength = 250MN/m 2
Yield strength = 160 MN/m 2 .
Factor of Safety = 2
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Dimensional analysis
𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ
The design stress,δd = 𝐹𝑠
𝑊
Total axial force in screw (F), F =tanθ Hence, the axial force (F) in a screw is maximum when;
(θ) is minimum.
300𝑁
F = 𝑡𝑎𝑛9 = 1894.12N
𝛿𝑦𝑡 250
Design stress, δd = 𝐹.𝑠 = =125MN/m
2
1894.12N
δd = F⁄A = ⟹ A =1894.12⁄125𝑀𝑁/𝑚=15.15mm2
𝐴
𝜋𝑑𝑐 2 4𝐴 4∗15.15
A= ⟹ dc = √ 𝜋 =√ =19.26mm
4 𝜋
dc=19.26mm
From appendices, Table A.1, say dc = 23.4mm standard size.
Core diameter (dc) = 20mm
Outer diameter (do) = 26mm
𝑑𝑜+𝑑𝑐
Mean diameter (dm) = =23mm
2
Pitch (p) = 6mm
Where P= pitch of the screw

d= mean diameter of the screw
α=helix angle
P = Effort applied at the circumference of the screw to
Lift the load,
W = Load to be lifted, and
μ = Coefficient of friction, between the screw and nut
= tan φ, where φ is the friction angle
𝑙𝑒𝑎𝑑
Helix angle, tan (α) == πd
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Lead=p; since the screw has a single start square thread

6
tan(α) =∏∗29 Helix angle α = 3.7678◦
for square thread take μ from 0.1 − 0.15; take μ = 0.14

Friction angle, (ϕ) = tan −1 (μ) ⟹ ϕ = tan −1 (0.14) = 8
4𝑊 4×14715
The direct tensile stress in screw body, (δt) =πdc 2= = 27.71556MN/m
π26 2
16𝑇𝑟 16×45352.665
Shear stress due to torque, (τs) =πdc 3 = = 13.141MN/m 2
π×26 3
𝛿𝑡 1⁄
Maximum principal stress theory, (δmax) =2 + 2 √δt 2 + 4 × τs 2 =
27.7⁄ +1 √27.7 2 + (4 × 12.88 2 ) =37.8268MN/m
2 2
The design is safe, because δmax < δall,i.e 37.8268MN/m2 < 80.83N/m2
δt 27.7
Maximum shear stress theory, (τmax) = √( )2 + τs 2 = √( ) 2 + (12.88 2 )
2 2
= 18.91MN/m
The design is safe, because τmax < τall, i.e. 18.91MN/m 2 < 80.83MN/m2
Figure 3.7 Power Screw
3.2.9 Design of Nut
The material chosen for the nut is mild steel Syt =400N/mm, Force exerted =10N
Factor of safety = 2 and Number of nuts = 3
𝑆𝑦𝑡 ⁄ 400⁄ = 200N/mm 2

So σall = f. s = 2
Allowable shear stress (τall) = 0.5S yt /f.s = 400x0.5/2=100N/mm 2
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The load exerted on the bolt is given by;
P = (π×d c 2 ×τall×n) ÷4
Then dc = [4P/π× τall×n] 1/2 = [4×19620/π×100×16] 1/2 = 5.7mm
Approximately dc =6mm D=d c /0.84=7
From Kurmi text book table 11. ; pitch=1 Major diameter =7 depth of thread =0.613
Nut dc= 6 Coarse series M7
But for safety take the larger diameter;
Pitch = 2 Major diameter =14 depth of thread = 1.2
Coarse series M14
Length of thread (l) =1.3dD=1.3x14=18.2 head of bolt t (h) =0.8D=0.8x14=11.2
Figure 3.8 Nut
3.2.10 Selection of Caster Wheel
Many varying and individual factors must be considered to make the selection of the good wheel caster
that will do the best job for our design. The weight of the load is influence on the mobility of the wheel.
By considering the load and Floor condition we select caster. From the bottom base design the two
reaction force helps to select the caster.
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We need four casters two at rear which are served as leader. For this we select Swivel caster . This type
of caster allows for movement in multiple directions. They can have one or two sets of raceways that
allow the caster to swivel 360 degrees under a load.
We need also two rigid caster casters at front which are simply follower the rear caste. This style of
caster only allows forward and backward movement. Rigid casters tend to be stronger than swivel
casters. They are rated at the same capacity as the swivel casters for safety reasons.
Figure 3-9 Caster Wheel
3.2.11 Assembly of the drawing
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Figure 3.10 Assembly of the Drawing
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3.8 Cost Analysis and Estimation
Cost analysis is an estimation of the total cost of the machine. It includes cost of labor that
participate in the design, material cost, machine cost, power cost and manufacturing cost. The cost
of the materials are based on the current cost of the fabrication of the cost of the materials
worldwide. We have used cast iron and steel for our design and we estimated the cost as follows
based on the materials density. Two types of cost are included in the project they are: labor cost,
machine and power cost.
3.8.1 Labor cost
This type of cost is at disposal for labor from the very beginning of the sheet metal bending up to
the finishing time of the project. Two person participated in this machining process. Workshop
technician with a payment of 125 ETB per hour Laborer with a payment of 60 ETB per hour with
eighth working hour per day manufacturing of the machine is estimated to take a day and half to
finish. Hence the total cost will be:
Workshop technician 125*8=1000 and laborer 60*8=480; Hence the total is 1480ETB.
3.8.2 Machine and power cost
The manufacturing process includes welding, drilling, machining and other related processes that
are done on the lathe machine, welding machine, drilling machine and related machines intended.
These kinds of machines usually uses around 4 kW per hour. The Ethiopian Electric Utility price
for 1kWh is 2ETB.Overall machine we take the average power consumption of 50 kW per hour.
Hence the manufacturing will consume 50*12=600kW of power. Hence the total cost will be
600*2=1200. With a miscellaneous cost of 800 ETB.
3.8.2 Material Cost
The cost is calculated based on the mass of the parts. The mass of these parts are calculated based
On their volume. Volume calculation is showed below.
Ram: V=Πr2
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Lever arm, V=Πr2
Support Plate, Tire Support Plate: V=A*t=b*w*t
Handle Frame: V= (b*w*l) out - (b*w*l) hole
Main Base Frame: V= (b*w*l) out - (b*w*l) hole
No Parts Material type Density Mass Vol Cost per Actual Unit Qu Overall
kg Cost
1 Ram Low alloys 7850 0.025 1.4*10^(-4) 1.25 1.35 53 1 230.56
2 Lever arm Low alloys 7300 0.02 1.2*10^(-3) 2.5 1.65 53 1 148.55
3 Main Base Low alloy 7850 1.4 1.4*10^(-6) 3 4.25 53 1 220.5
4 Handle frame Cast iron 7500 0.89 1.5*10^(-5) 1.8 2.8 53 1 485.96
5 Power screw Cast steel 7850 0.03 1.3*10^(-5) 1.6 1.56 53 1 274.6
6 Nut Mild steel 7300 0.01 1.5*10^(-7) 0.9 1.59 53 1 95.3
7 Plate Low carbon 7890 0.9 1.5*10^(-7) 0.99 1.89 53 1 1480
8 Labor cost 2200
9 Machine cost 2500
Table 3.2 material Cost
From the Spreadsheet file above table above we see that the actual cost for the project is around
12,927ETB. Hence the total grand cost to manufacture the machine is estimated to be around
13000ETB
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INTERNSHIP REPORT
Conclusion
During this internship program we have seen many problems or draw backs that should be solved
to avoid injuries during work, to save time, to perform specific task and also unnecessary cost
expenditure.
Generally, I can conclude that this mechanically operated tire removal and handler machine will
solve the existing problem encountered in greater amount as we have tried to show by the above
design calculation and consideration.
Finally, this project has improved my technical design and also thinking ability on how to solve
the problem.
Recommendation
The duration of the internship is not enough to us in solving the problem of the company.
The time given for internship is not much enough to full fill a good experience
knowledge required from us.
In addition to this the company has no new budget to me to finish this project us per the
requirement.
Due to this problem project has been retarded.
What I recommend for the new comer is to develop the problem definition as such us we
start.
I recommend that the new comer should finish this project in good manner.
45
INTERNSHIP REPORT
CHAPTER FOUR
RECOMMENDATION AND CONCLUSION
Ethio-engineering group Bishoftu Automotive Industry is one of the giant industries organized
under the former Metals and Engineering Corporation. This industry thrives to alleviate the burden
of foreign expense allotted to import vehicles. This industry does receive students and assist to the
sharing of the knowledge and experience. By using this goal, we participated in departments of
the company and we have been practicing to know more about what we have been learning in
theory.
During our stay we have faced different problems during the program and we have taken
approaches on how to solve these problems. We were able to solve some problems by asking the
parts involved and taking responsibility of our own. There are also some problems that are related
to managerial skills, team work skills, psychological skills, and others that may not be easily solved
by one part. On these types of problems, we recommended the company itself along with other
students from different universities on how to take care of its properties, employees, customers.
We also thrived to solve the problem they faced as much as we can, the project solved could be
taken as an example.
Generally, internship is the best opportunity to know in order to test patience and skill of a person.
We have already discovered and adopted how the working life looks like in the real world. From
this internship, we have seen the work ethics and related things like how to communicate with
others and the interaction between leaders and workers as of teamwork. In the other word, it is the
best place to improve practical skill from our background theoretical skills, interpersonal
communication skills and others. We also improved our skill in the way of identifying problem
and solve by producing related project practically.
46
INTERNSHIP REPORT
Reference/Bibliography
1. Abdella, A. (2010). Bishoftu Automotive Manufacturing Industry. Bishoftu.

2. Aser, J. (2012). Wikipedia. Retrieved from Wikipedia.org.
3. Callister, W. P. (2008). Material Science and Engineering (Vol. Seventh Edition). John Wiley
and Sons,Inc.
4. Digital, R. (2022). sunextools.com. Retrieved from sunextools.com/products/tire handler
ethioengineering.com.
5. Information Department. (2021, February). Ethio Engineering Group. Retrieved from
6. Khurmi, R., & J.K, G. (2005). Textbook of Machine Design. New Delhi, India: Eurasia
Publishing House.
7. Minister, F. D. (2008, May). Wikipedia. Retrieved from en.m.wikipedia.org.
8. Nottingham, A. (2021). Mohawk Industries. Retrieved from www.mohawkindustries.com.
9. Shigley. (2010). Mechanical Engineering Design (Vol. 8 Edition). McGraw Hill Publication.
ShinnFuCompany of America, I. (2022). omegalift.com. Retrieved from www.omegalift.com:
47
INTERNSHIP REPORT
Appendices
Maximum shear stress………………………………………………………………………. 𝜏𝑚𝑎𝑥 .
Allowable shear stress………………………………………………………………………...𝜏𝑎𝑙𝑙

Crushing stress…………………………………………………………………………………...𝜎𝑐
Tensile stress……………………………………………………………………………………..𝜎𝑥
Bending stress……………………………………………………………………………………𝜎𝑏
E.E.G………………………………...……………………...…………… Ethio engineering group
B.A.E.I…………………………………………..……..Bishoftu automotive engineering industry
Steel metal properties
48
INTERNSHIP REPORT
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BAHIR DAR UNIVERSITY

BAHIR DAR INSTITUTE OF TECHNOLOGY

FACULTY OF MECHANICAL AND INDUSTRIAL ENGINEERING

HOSTING COMPANY: BISHOFTU AUTOMOTIVE MANUFACTURING

PROJECT TITLE: DESIGN AND MODELING OF MECANICALLY OPERATED

Internship Duration: -Jun 08, 2022 – Oct 10, 2022

By: Asegid Amare

ID No. BDU 1103092

Mentor: Mr. Atrsaw J.

Company Supervisor: Mr. Hubtamu

Date: Nov, 9, 2022

Name of student Signature Date

1) Asegid Amare __________ ________________

Name of Advisor Signature Date

Mr. Atrsaw.J _________ _________

My acknowledgement also extends to Bishoftu Automotive Engineering Industry because the

Figure 1-1 Logo of Ethio EngineerinGroup.................................................................................... 1

1.1 BACKGROUND OF THE COMPANY

Figure 1.1 Logo of Ethiop Engineering Group

Ethio-Engineering Group is a vast organization that includes a number of companies underneath

Ethio-Engineering Group Bishoftu Automotive Manufacturing Industry is one of the industries

1.2 ORGANIZATION AND MANPOWER

1.2.3 Core Activities

✓ Tank and APC overhaul and maintenance services

1.3 EQUIPMENTS UTILIZED DURING THE INTERNSHIP

1.3.1 Engine hoists

Figure 1.2 Engine hoist

1.3.2 Hand Chain Hoists

Figure 1.3 Hand Chain Hoists

Figure 1.4 personal tool sets and collection

1.4 BASIC COSTUMERS OF THE COMPANY

Therefore the basic and sale customer of the industry was:-

➢ The federal democratic republic of Ethiopia ministry of defense

1.5 ORGANIZATIONAL STRUCTURE

Bishoftu Automotive Manufacturing Industry is organized under different departments having

1.5.1 Design and development

1.5.2 Power train

Figure 1-5 Engine on engine seat

1.5.3 Vehicle production factory

Figure 1-6 Different productions of the company

1.5.4 Vehicle system production factory

Figure 1-7 Electrical system assembly

1.5.5 Construction machinery production factory

This department includes the following.

Figure 1.8 Construction machinery

1.5.6 Tank production factory

Figure 1-9 Tank production factory

1.5.7 Body and frame production factory

Figure 1-10 Body and frame

1.6 WORK FLOW OF THE COMPANY

Bishoftu Automotive Manufacturing Industry which is a governmental development organization

Figure 1-11 Service Repulsion

Figure 1-12 Market repulsion for purchase

2.1 INTERNSHIP EXPERIENCE

✓ Orientation about rule and regulation of the company

2.1.1 Working section

✓ Checking car tires

These tasks includes:

✓ Bus manufacturing workshop

2.1.2 Challenges and measures taken

2.1.2.2 Measures taken

2.2 BENEFITS OF INTERNSHIP

2.2.1 Purpose of internship

1) Asegid Amare ______

Mr. Atrsaw.J _ _