UNIVERSITY OF GONDAR INSTITUTE

OF TECHNOLOGY SCHOOL OF
MECHANICAL ENGINEERING

INTERNSHIP FINAL REPORT AND PROJECT

HOST COMPANY NAME: -DEFENSE LOGISTIC
MEAN BRANCH AND MAINTENANCE BRANCH
DURATION OF INTERNSHIP:-13/03/2018 TO 01/07/2018

DONE BY
NAME OF STUDENT: TEKALGN MARKOS
STUDENT ID NO: GUR/1076/07

Submission date:22/ October/2018

Submitted To: Inst. ANTENE
University of Gondar institution technology

A
According to the program schedule that is provided from University Industry Linkage
(UIL) office and the agreement which I agreed to work in the company for one full
semester, I started my internship on 21/03/2018, at all times by attending the normal
working hours of the company.
After carried out conscientiously the work in the office and on the site given
by my supervisor, I have completed my internship on 01/07/2018. The supervisor and
the Manager had a good opinion on my tasks. Since they gave me tasks to test how I
perform the work properly. But as my duty in this internship was completing every
task within the time schedule, I have completed and submitted as they needed. So,
they were happy
Name of the intern: TEKALGN MARKOS
Signature:_________________

Date:_____________________

Company Supervisor Name: SHAMBEL SNTAYEW

Signature:__________________

Date:______________________

Mentor name: INS ANTENE

Signature: _______________

Date: ___________________

B
 ACKNOWLEDGEMENT

First and foremost, we want to say thanks to the company supervisors, for
constantly guiding and encouraging us declaration throughout the intern report and
project. Thanks a lot for giving us a professional training, advice and suggestion to
bring this project and report to its final form.
we also would like to express our gratitude to our university advisors and also all
workers of the company for guiding in which part to solve the company problem.
Finally, we would like to say thanks for all our friends, who sharing their knowledge
friendly.

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 CONTENTS OF TITLE
Acknowledgement ......................................................................................................... i
Executive Summery ...................................................................................................viii
Chapter One .................................................................................................................. 1
1.0 Background Of The Company ................................................................................ 1
1.1 Company Brief History ........................................................................................... 1
1.2 Service And Products Of The Company ................................................................. 2
1.3 Main Customers Of The Company ......................................................................... 2
1.4 Work Flow Of The Company .................................................................................. 3
1.4.1 Company Over All Working Flow ....................................................................... 3
1.4.1.1 Structure Of Defense Logistic .......................................................................... 4
Chapter Two .................................................................................................................. 5
2 Overall Internship Experience ................................................................................... 5
2.1 How Did I Get Into The Company? ........................................................................ 5
2.2 The Section I Have Been Working In ..................................................................... 5
2.2.1 Automotive Safety Rules ..................................................................................... 6
2.3 The Section We Have Been Working ...................................................................... 7
2.4. Work Flow Of Shop ............................................................................................... 7
2.4.1. Work Flow In Maintenance Shop ....................................................................... 7
2.4.1.1. Daily Maintenance ........................................................................................... 7
2.4.1.2. Weekly Maintenance ........................................................................................ 8
2.4.1.2.1. 3,000–7,500-Mile Maintenance .................................................................... 8
2.4.1.2.2. 12,000–15,000-Mile Maintenance .............................................................. 10
2.4.1.2.3. 30,000–60,000-Mile Maintenance .............................................................. 10
2.4.2. Work Flow In Engene Shop .............................................................................. 11
2.4.3. Work Flow In Body And Paint Shop ................................................................ 13
2.4.4. Work Flow In Auto Electric Shop ..................................................................... 14
2.4.5. Work Flow In Machine Shop ............................................................................ 14
2.4.6. Work Flow In Gear Shop .................................................................................. 15
2.4.7. Work Flow In Accessory Room ........................................................................ 15
2.5. Work Task We Have Excuted ............................................................................... 15
2.6. Methods Used To Do A Task ............................................................................... 15
2.7. Challenges During This Work Task ..................................................................... 15

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2.8. Measures During This Work Task ........................................................................ 16
Chapter Three.............................................................................................................. 17
3. Internship Project .................................................................................................... 17
3.1. Title Of The Project ............................................................................................. 17
3.2 Abstract ................................................................................................................. 17
3.3 Introduction ........................................................................................................... 18
3.4 Problem Statement ................................................................................................ 20
3.5 Scope Of The Design ............................................................................................ 21
3.5.1 Limitations ......................................................................................................... 21
3.6 Objectives ............................................................................................................ 21
3.6.1 General Objective .............................................................................................. 21
3.6.2 Specific Objectives ............................................................................................ 22
3.7 Assembly Figure Of Machine ............................................................................... 22
3.7.1 Part Of 3d Model ............................................................................................... 23
3.7.2 Disassembly Figure Of The Machine ................................................................ 23
3.8 Methodology ......................................................................................................... 26
3.8.1 Overview ............................................................................................................ 26
3.8.2 Data Collection Method ..................................................................................... 26
3.8.3 Sampling Design ................................................................................................ 26
3.8.4 Data Processing & Analysis ............................................................................... 27
3.8.5 Design Evaluation Of Alternative ...................................................................... 27
3.9 General Design Considerations............................................................................. 28
3.9.1 Materials ............................................................................................................ 28
3.9.2 Material Selection For Each Gear ...................................................................... 29
3.9.3 Material Selection For Power Scrow ................................................................ 29
3.9.4 Material Selection For Floor Jack Wheel .......................................................... 29
3.9.5 Material Selection For The Nut Removal (Shaft) .............................................. 29
3.9.6 Material Selection For The Tool Box................................................................. 30
3.9.7 Material Selection For Tire Removal Saddle ..................................................... 30
3.9.8 Material; Selection For The Gear Box (Housing) .............................................. 30
3.9.9 Material Selection For The Floor Jack (Base Plate) .......................................... 30
3.9.10 Material Selection For The Handle. ................................................................. 31
3.9.11 Selection Of Floor Hydrulic Jack Fluid ........................................................... 31

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3.9.12 Material Selection For Scisser Jack Arm ......................................................... 31
3.10 Design & Operating ............................................................................................ 32
3.10.1 Design & Operating Gear Box ......................................................................... 32
3.10.2 Design & Operating Scissor Jack ................................................................... 32
3.10.3 Design & Operating Floor Jack ....................................................................... 33
3.10.3.1 Basic Components Of Mechanical Jack ...................................................... 33
3.10.4 Design & Operating Tool Box ......................................................................... 34
3.11 Design Of Parts ................................................................................................... 34
3.11.1 Design & Modelling Of Gear Box ................................................................... 34
3.11.1.A. Design Of Gear & Pinion ............................................................................ 35
3.11.1. B. Properties Carbon Steel .............................................................................. 35
3.11.1. C. Beam Strength ............................................................................................ 35
3.11.1. D. Effective Load ............................................................................................ 36
3.11.1. E. Calculation For Available Factor Of Safety................................................ 36
3.11.1. F. Design Of Shaft ........................................................................................... 37
3.11.1.G. Design Of Casing ........................................................................................ 37
3.11.2. Design Details Of Scissor Jack ....................................................................... 38
3.11.2.A. Design Of Screw ......................................................................................... 38
3.11.2.B. Design Of Nut ............................................................................................. 41
3.11.2.C. Design Of Pins In Nut ................................................................................. 41
3.11.2.D. Design Of Links .......................................................................................... 42
3.11.3 Design Details Of Floor Jack ........................................................................... 44
3.11.3.1. Force Analysis For The Saddle .................................................................... 44
3.11.3.2. Force Analysis For The Hydraulic System .................................................. 45
3.11.3.3. Force Analysis Of The Arms ........................................................................ 46
3.11.3.4. Force Analysis Of The Piston ...................................................................... 47
3.12 Literature Review................................................................................................ 47
3.12.1 Literature Review Introduction ........................................................................ 47
3.12.2 Literature Review Terminology ....................................................................... 47
3.12.2.1 Gear Box ....................................................................................................... 47
3.12.2.2.1 Gear Box Design ........................................................................................ 48
3.12.2.2 Floor Jack ...................................................................................................... 48
3.12.2.2.1 Floor Jack Design ...................................................................................... 48

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3.12.2.3 Scissor Jack ................................................................................................... 49
3.12.2.3.1 Scissor Jack Design & Lift ........................................................................ 49
3.13 Conclusions And Recommendation .................................................................... 50
3.13.1 Conclusion ....................................................................................................... 50
3.13.2 Recommendation ............................................................................................. 51
Appendix ..................................................................................................................... 52
Chapter Four ............................................................................................................... 54
4 Overall Benefit Gained ............................................................................................ 54
4.1. Upgrading Theoretical Knowledge ...................................................................... 54
4.2. Improving Practical Skill ..................................................................................... 54
4.3 Improving Interpersonalcommunication Skills..................................................... 55
4.4 Improving Team Playing Skills............................................................................. 56
4.5 Improving Leadership Skills ................................................................................. 56
4.6 Understanding Work Ethics Related Issues .......................................................... 57
4.7. Entrepreneurship Skills ........................................................................................ 57
References ................................................................................................................... 53

Chapter Five ................................................................................................................ 59

5 Conclusion and Recommendation ........................................................................... 59
5.1 Conclusion ............................................................................................................ 59
5.2 Recommendations ................................................................................................. 60
5.2.1 Recommendation for the university ................................................................... 60

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 LIST OF FIGER
fig 1.0 Defense Logistic Industry.................................................................................. 1
Fig 2.0 Maintenance Shop .......................................................................................... 11
Fig 2.1 Engine Assembly ............................................................................................ 12
Fig 2.2 Engine Tester .................................................................................................. 13
Fig 2.3 Paint Shop ....................................................................................................... 14
Fig 2.4 Electric Shop................................................................................................... 14
Fig 3.0 Tier And Wheel All Nut Removal ................................................................. 22
Fig 3.1 3d Model Of Gear Box Front View ................................................................ 23
Fig 3.2 3d Model Of Gear Box Said View .................................................................. 23
Fig 3.3 3d Model Of Gear Box Top View ................................................................... 24
Fig 3.4 3d Model Of Gear Box ................................................................................... 24
Fig 3.5 2d Model Of Gear System Said View ............................................................ 24
Fig 3.6 2d Model Gear System Front View ................................................................ 25
Fig 3.7 Scissor Jack..................................................................................................... 25
Fig 3.8 Tool Box ......................................................................................................... 25
Fig 3.9 3d Model Floor Jack ....................................................................................... 25
Fig 3.9 Combination Wrenches................................................................................... 34
Fig 3.10 Socket Tool ................................................................................................... 34
Fig. 3.11 Geometry Of Screw ..................................................................................... 38
Fig.3 .12 Geometry Of Nut ......................................................................................... 41
Fig.43.13 Geometry Of Link ...................................................................................... 42
Fig 3,14 Saddle Force Analysis .................................................................................. 44
Fig 3.15 Hydraulic System ......................................................................................... 45
Fig 3.16 Arms Analysis .............................................................................................. 46
Fig 3, 17 Piston Analysis ............................................................................................ 47

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 LIST OF TABLE
Table 2.1 Engine Problem And Solution..................................................................... 13
Table 3 Final Design Parameters ................................................................................ 37
Table 3.1: Material Properties ..................................................................................... 43
Table-3.2: Data Analysis Of Scissor Jack .......................................................... 43

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 EXECUTIVE SUMMERY

To come up with this final report different helping techniques and activities has been
done. Interview concerned bodies of the company, company document revision,
machinery manuals and operation sheet format reference and also overall observation
of the company. Using these sources, we have done this final internship report
through detail explanation, supportive picture and table collection. The first part
describes the company background, its main products and customer. The second part
deals about the overall internship experience in work shop of the company for the
past four months.
The third part explains the internship project. This project consists The tier and all
wheel nut removal machine assembly is portable, this machine remove nut by gear
box, using tool put parts by tool box, the tool is moving or lift gear box to upward
and downward by scissor jack or crack and using the same purpose of floor jack base
of the machine using remove tire .tier and all wheel nut removal machine is adding
other parts like scissor jack using support part of the machine. This machine can be
used and transferred to our working place easily. Moreover, if we want to fit gear box
the exact position reciprocate top handle easily. It is able to slide/drive and lock at
any position and will be helpful in many industries due its compatibility, reliability
and efficiency.
We explain in the fourth chapter the benefit of internship in terms of gain knowledge,
improving practical skill, industrial problem solving capability, team playing skill,
leadership skill, entrepreneurship skill and work ethics. The last part includes
conclusion, recommendation and reference.

viii
 NOTATIONS

- Pitch of thread (𝑚𝑚)

- Number of threads in contact with screwed spindle

𝑙- Lead of screw thread (𝑚𝑚)

- Thickness
- Nominal diameter (𝑚𝑚)
𝑑𝑐-Core diameter(𝑚𝑚)
𝑑𝑚- Mean diameter
- Helix angle
𝜇 − Coefficient of friction
- Effort (𝑁𝑒𝑤𝑡𝑜𝑛, 𝑁)
- Torque (𝑁. 𝑚)
𝜂 − Efficiency (%)
𝐹𝑙𝑜𝑎𝑑- The force the jack exerts on the load. (𝑁𝑒𝑤𝑡𝑜𝑛, 𝑁)
𝐹𝑒𝑓𝑓𝑜𝑟𝑡- The rotational force exerted of the jack. (𝑁𝑒𝑤𝑡𝑜𝑛, 𝑁)
-the length of the jack (𝑚𝑚)
𝜋 = 3.141592654
𝐴𝑐- Cross sectional area of the screw shaft

(𝑚𝑎𝑥) -Maximum principal stress

- Maximum shear stress

-Shearing stress of nut collar
- Total torque subjected
𝜎𝑦-Yield stress

𝜎𝑏- Bending stress

𝐼 − Moment of inertia of the cross section.

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x
 CHAPTER ONE
1.0 BACKGROUND OF THE COMPANY
1.1 COMPANY BRIEF HISTORY

DEFENSE LOGISTIC MEAN BRANCH AND MAINTENANCE BRANCH story began in

the heart of Addis Ababa, around the area commonly known as Mexico. The organization was
founded at 1920 initially there were 116 militaries and 75 civil employees. Throughout this
company the overall work is controlled by logistics head office and under it the second in
command is maintenance office which also have a sub department under its control called
light and medium vehicles maintenance s there are, sub store, customer service, planning and
controlling, finance and administrative services.
LOCATION: -DEFENSE LOGISTIC MEAN BRANCH AND MAINTENANCE BRANCHis located in
Addis Ababa city in Lideta sub city area commonly known as mexico woreda 10 Keble 16/17
in front of African Union. In front of defense metal industry and bake of METEC
AREA: -Defense Logistic Mean Branch and Maintenance Branch is built on around 700
square meter area.

Fig 1.0 Defense Logistic Industry (sours to company)

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 1.2 SERVICE AND PRODUCTS OF THE COMPANY

As per the vision of the company, the main services of the company are:
 Maintenance of different medium duty and light duty cars.
 Different types of car part maintenance.And the main maintenance of the company is
abuts 30 car model all parts maintain tier to engine and body to paint
 Those damaged military vehicles are store at this company, and other place and the
mechanics order to select those vehicles for service and decide which vehicle can be
easily serviced and modified.
 After decision run, vehicle come and visual inspection is performed. Then the problem is
identified. During visual inspection which parts must be replaced, which parts are absent
and model of parts are identified. Finally, the supervisor orders the store house to put the
required part.
 Then starting from tire service activities up to final painting stage working schedule is
continued.
 Simple parts can be modified like: body, different hose, cabin chair etc.
 Most parts of the vehicle can be serviced but there is production of parts.
 Damaged parts are replaced with standard one. Make substitution of old gasoline engine
to new and modified import diesel engine.
The company presently gives the following major services:-
 Tire recapping
 Maintenance service
 Assembling and disassembling of old engine by new engine
 Vehicle annual technical examination
 Engine maintenance
 Machine works
 Body building works and maintenance and
 Transport service for military activity in different part of the company

1.3 MAIN CUSTOMERS OF THE COMPANY

DEFENSE LOGISTIC MEAN BRANCH AND MAINTENANCE BRANCH gives

its services and maintenance to different governmental organization, example any defense
company, defense logistic not used (non-governmental organizations, private limited
companies and personal level customers.)
 The customers of the company are government to secure the country‟s peace and
stability. The budget of this company runs by the government. It used for transporting
different material that is used for defense like weapon, food, clothe and any other things.

 Some of the governmental organizations are: the military defense and defense company
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 1.4 WORK FLOW OF THE COMPANY

Like any other company, DEFENSE LOGISTIC MEAN BRANCH AND

MAINTENANCE BRANCH, also has its own structural organization and work flow path
which includes the managing and other departments. The company is organized in such a way
that is leaded by a board of the founding members.
 Following the board the management and the administration offices play important
role in managing the day to day activity of the company.
 The sales department is where the cars, that the company imports, are displayed and
sold.
 The spare parts department is where all the spares for the imported cars are found.
 The finance department is the one which funds all the finance for the day to day
activities of the company according to the yearly budget plan.
In addition to this main structural work flow, the board, the management,
administration offices and each department also have their own work flow structure.

1.4.1 COMPANY OVER ALL WORKING FLOW

Its overall organization and working flow

1. PLANNING AND CONTROLLING: prepares the work plan for the institution and
controls the overall process
2. CUSTOMER SERVICE: provides customer with required information
3. SUBSTORES: is the storage of parts needed for the maintenance and it provides the parts
needed when they are required
4. MACHINE SHOP: prints the license number of all military vehicles also manufactures
parts that can‟t be found on the market
5. CAR BODY ASSEMBELY: is the department that assembles and take part of vehicle parts
6. BODY SHOP: mainly focuses on the maintenance of body of the cars
7. ELECTRIC SHOP: Handles only the electrical components of vehicles
8. INSPACTION: check the cars for any faults and reports the defects to the proper
department
9. FINANCE: Handles the money related works in the office
10. HUMAN RESOURCE: hires, fires and transfers employees
11. PURCHASE DEPARTMENT: Handles the parches of the requested items for the store

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1.4.1.1 STRUCTURE OF DEFENSE LOGISTIC MEAN BRANCH AND
MAINTENANCE BRANCH

RECEPTION :- receives the customers‟ complains on the car they bring for
servicing and inspects the car‟s current condition.

FORMAL
(ENGINEERS :- sends the car to the appropriate workshop according to the
) customers complain and the inspected problems on it.

:-perform the necessary maintenance.

WORK
SHOPS

TEST DRIVER :-inspects the car‟s performance on the road after maintenance.

FORMAL
:- approves the car after maintenance.
(ENGINEER)

RECEPTION :- returns the car to the customer

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 CHAPTER TWO
2 OVERALL INTERNSHIP EXPERIENCE
2.1 HOW DID I GET INTO THE COMPANY?

The internship program allows for students to experience the work place and different
obstacles that they will face after graduation. Students will get the opportunity to see first-
hand how a work place can be harmonies‟ and how to be a team player in a company.
Another aim of this internship program is to provide students with the chance to observe a
working place and identify problems that could be the base for their thesis of the graduation
paper. The institute has a department responsible for arranging and supervising the students
arranged in different industries to do their internship. This department is called university and
industrial linkage (UIL). The institute gave internship request letter at end of third year to
find by ourselves. We had observed different company and request to accept for 2018 second
semester internship program. Among different company I request in their company to
participate for internship program were;
 Metec
 Rise engineering
 Moinco automotive
 Walya automotive
 Ethiopia airline
Most of the companies were not accept the request. Some of them were accept and regent at
the beginning of the program. Finally, I tried to find by my Owen selves and got acceptance
at DEFENSE LOGISTIC MEAN BRANCH AND MAINTENANCE BRANCH then the
head office person gave orientation how the company organize and working rule inside the
work shop and order to bought safety shoe and cloths. I was assigned at maintenance shop.

2.2 THE SECTION I HAVE BEEN WORKING IN

The head office person gave orientation how the company organize and working rule inside
the work shop and order to bought safety shoe and cloths. There are different sections which
are engine shop, defiance shop, gear shop etc.

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 2.2.1 AUTOMOTIVE SAFETY RULES

If basic safety rules are followed, an auto shop can be a safe and enjoyable place to
work.Every year, thousands of technicians are accidentally injured or killed on the job Most
of these accidents result from a broken safety rule while working, constantly think of safety.
1. Do not smoke in the auto shop
2. Read material safety data sheets when in doubt about any dangers
3. Obtain instructor permission before using any new or unfamiliar power tool, lift, or other
shop equipment
4. Use the Right Tools to proper Job Drive slowly when in the shop area
5. Report unsafe conditions to your instructor
6. Stay away from engine fans
7. Respect running engines
8. Clean up spilled water, oil, grease, or solvent immediately.
9. Put dirty rags in the red can with lid by tool room
10. Do not work on engines when supported by a engine hoist.
11. Use adequate lighting
12. Ventilate when needed
13. Always be patient, never rush in the workshop.
14. Always use a guard when working on a machine.
15. Keep hands away from moving/rotating machinery
16. Work like a professional
17. Use of PPE (Personal Protection Equipment)
18. Always ends of class clean working area
19. Horseplay, practical jokes, and fooling around will not be tolerated in the shop or the
classroom
20. Keep tools in good condition by using them properly and storing them properly.
21. Wear appropriate clothing while performing tasks.
22. Proper Footwear Required
23. Do not wear jewelry on your wrists, fingers, ears, or neck while working on vehicles.
24. When doing heavy or awkward lifting, always get assistance and lift with your knees, not
your back

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25. No Cell Phones
26. No Food or Drink
27. No MP3 Players No electronic devices No games ,no Bluetooth No lighters
28. Specified person operating machine
29. Know First Aid Kit location

2.3 THE SECTION WE HAVE BEEN WORKING

DEFENSE LOGISTIC MEAN BRANCH AND MAINTENANCE BRANCH. Those are:
1. Service (maintenance) Shop
2. Engine Shop
3. Body and Paint Shop
4. Gear shop
5. Wood shop
6. Machine shop
7. Electric shop
8. Battery shop
9. Tire shop
The section we were assigned firstly was to the component rebuilding shop commonly known
us service shop. In this service many repairs and maintenance s are performed
2.4. WORK FLOW OF SHOP
2.4.1. WORK FLOW IN SERVICE (MAINTENANCE) SHOP

The work flow in this section is first from the reception all the problem that appear on the
vehicle are written on the job card, then the technician understands the problem and
determine which type of service the vehicle need and maintain it.
2.4.1.1. DAILY MAINTENANCE

In the process of using your car every day, you can make some simple maintenance checks.
These checks can help in early diagnosis of problems that can cause breakdowns.
VISUAL CHECKS
Whenever you approach your car, take a minute or two to critically examine its appearance.
 Check your tires for low air pressure, nails, or other evidence of defects.
 Check to see if the car leans or tilts in any direction from side to side or from front to
back.

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  Look for any puddles of fluid underneath the car. Make these visual checks a part of
your normal routine. If you spot a problem, you can have it fixed before it causes a
breakdown.
DRIVING CHECKS
Try to be aware of the way your car operates. Notice how quickly it starts, the sounds that it
makes, how long it normally takes to warm up, and so on. Permanent changes from normal
operating conditions usually indicate a problem.
2.4.1.2. WEEKLY MAINTENANCE

Gauges and warning lights on the dashboard won‟t indicate that something is wrong until a
problem arises. Rather than risk a breakdown, take a few minutes each week to check under
the hood.
The best time to make these checks is in the morning, before the car has been started, when
the engine and fluids are cool. For all of the following checks except automatic transmission
fluid level, the engine should be off. Procedures for these simple, quick checks are discussed
in the maintenance
2.4.1.2.1. 3,000–7,500-MILE MAINTENANCE
Maintenance to be performed at approximately 3,000 to 7,500 miles, or three to six months,
whichever occurs first, includes the following:
 Change engine oil and oil filter.
 Check fluids.
 Inspect hoses and belts.
 Inspect or change air filter.
 Examine driveline and CV boots.
 Inspect brakes.
 Inspect tire wear and pressure (including the spare).
 Check interior and exterior lights, turn signals, and horn.
 Inspect wiper blades and washer operation.
 Lubricate hinges and latches.
 Inspect air filter.
 Check exhaust system for leaks, damage, and loose parts.
CHANGE ENGINE OIL AND OIL FILTER
To do the oil change, you will need the following tools and supplies:
 An oil drain pan.

8
  A wrench or socket to loosen the drain plug.
 An oil filter wrench to loosen the oil filter.
 Rags or paper towels.
 New oil and filter.
The steps required to perform an oil change. Refer to them as you read the following
procedures.
DIFFERENTIAL LUBRICATION
On FWD cars, the lubricant supply for the differential is included in the transaxle lubricant.
Thus, no further checking is needed for a FWD vehicle. For RWD and 4WD vehicles, locate
the check plug on the front or rear of each separate differential. Follow the procedure
previously outlined for checking and refilling a RWD manual transmission. Refer to the
owner‟s manual for the recommended lubricant.
Also inspect differentials at the front and at the point where the axle housings meet the
backing plates in the center of the drive wheels. Leakage indicates a defective seal or gasket.
When you have finished underneath, raise the car, remove the jack stands, and lower the
vehicle gently onto the ground. To complete a lube job, use a little graphite powder to
lubricate all door locks to prevent the lock cylinders from sticking, and oil the door hinges
and hood hinges.
This simple maintenance will keep these parts from sticking and squeaking.
AIR FILTER
Check the condition of the air filter each time you change the engine oil and filter. Change the
filter if it is coated noticeably with dust and debris or if the paper element is soaked with oil.
Also remember that if you do a lot of driving under dusty conditions, the useful life of the air
filter is reduced. Compare the inner, or clean, side of the filter with the outer side to
determine how much debris has accumulated. A clogged or oiled air filter reduces airflow to
the fuel delivery system. Engine performance and fuel economy suffer. (Oil on the air filter
indicates a clogged positive crankcase ventilation valve (PCV) or a major engine problem.)
CHECKING DISC BRAKES You will be able to see the brake discs and the caliper
assemblies, including the brake pads. Check both the inner and outer sides of each brake disc,
or rotor, for grooving. The surface of the rotor should be very smooth. If there are deep
grooves in the rotor or the surface is rough, it must be turned or replaced. Turning is a process
in which a layer of metal is removed to make the rotor surface smooth again. A rotor should
be turned only if a problem is noted in its surface. Compare the cost of turning the rotor to the
cost of a replacement rotor. Often the cost of the replacement is a little more than turning the

9
rotor. If you want to remove the rotors yourself, consult a service manual for the proper
procedures for your car.
CHECKING DRUM BRAKES Some vehicles have drum brakes on the rear or a
combination of a disc brake with a drum parking brake. The rotor may need to be removed to
inspect the drum-brake portion of the brake system. Consult the manufacturer‟s service
manual should you wish to do this procedure.
Normally, you would have a certified technician check the rear drum brakes in this system.
To remove the rear drums on a FWD car, it may be necessary to remove a dust cover and
disassemble the rear wheel bearings before you can remove the rear drums. If you have a
FWD car, consult a service manual for the proper procedure to remove the rear drums.
On RWD cars, the drums may be held in place with two small bolts or screws or locking clips
on the studs. If small bolts or screws hold the drum in place, use a wrench or screwdriver to
loosen and remove them. If locking clips hold the drum in place, they can be snapped off
with a screwdriver and pliers and then discarded.
New locking clips are not usually required as they are used during vehicle assembly when the
car is new. Release the parking brake lever, and you should be able
2.4.1.2.2. 12,000–15,000-MILE MAINTENANCE

After each 12,000 to 15,000 miles, or one year, additional preventive maintenance should be
done. Remember to consider your own driving habits and driving conditions and to
compensate for the type of driving that you do. The first step in a 12,000- to 15,000-mile
maintenance program is to repeat your weekly check and your regular maintenance program
for the 3,000- to 7,500-mile period.
AIR FILTER REPLACEMENT
Check the condition of the air filter each time you change the engine oil and filter. The filter
should be replaced every year or if it is dirty. Remember that if you do a lot of driving under
dusty conditions, the useful life of the air filter is reduced. Air filter replacement is discussed
earlier in this chapter.
2.4.1.2.3. 30,000–60,000-MILE MAINTENANCE

By the time you have driven your car 30,000 to 60,000 miles, typically over the course of two
to five years, wear has occurred to all moving parts. To maintain reliability, several
preventive maintenance tasks should be performed. Before you start any of the following
procedures, repeat all of the regular maintenance programs outlined earlier. These

10
maintenance tasks include all of the services that were performed at the 12,000- to 15,000-
mile interval.
For the following procedures, you will need a few more tools and supplies.
Fuel Filter Replacement
The fuel filter removes impurities and small amounts of water from the fuel delivery system.
Replace the fuel filter every two to four years or every 30,000 to 60,000 miles, whichever
occurs first. Consult the owner‟s manual for the recommended service interval for your fuel
filter.
CHANGING SPARK PLUGS
With the use of electronic ignition and fuel injection systems, spark plugs may continue to
function acceptably for tens of thousands of miles. Recommended spark plug change
intervals may range to as much as 35,000 miles for standard spark plugs and up to 100,000
miles with platinum plugs.

Fig 2.0 Maintenance Shop (sours to campany)

2.4.2. WORK FLOW IN ENGENE SHOP

Engine maintenance is the removing, tearing down, cleaning, inspection and repairing of the
car or machineries to overhaul the engine. We should use approved factory manual
procedures to taste the engine. This is due to that the engine runs smoothly
In this shop the different tasks are done. Those are
ENGINE ASSEMBLY
1. Before assembly check all parts whether there are damages or not.
2. The assembly ground should be clean.
3. All the disassembled parts should be cleaned and blown with compressed air.
4. For hollow bolts use two asbestos washers on two sides.
5. If any foreign object is on to the crank shaft, intake and exhaust tube remove the objects.

11
 It is the mechanism through which the driving torque of the engine is transmitted to the
driving wheel of the vehicle. The transmission is a sort of speed and power changing device
needed between the engine of the automobile and its driving wheel. A transmission system
includes these are-the clutch, gear box, propeller shaft, final drive, and differential system

Fig 2.1 Engine Assembly (sours to company)

ENGINE DIAGNOSIS AND TEST Engine diagnosis helps to located defects hardly found
or eliminated in a Routine maintenance. Failures may be classified as;
 Abnormal noise or performance
 Unstable idle speed ,break down
Independent and special engine defects in maintenance diagnosis has special *TESTS AND
DIAGNOSIS PROCEDURES.
Information involving special test and diagnosis refers to the following items:
 Cylinder pressure test
 Cylinder combustion pressure release test
 Engine cylinder gasket failure diagnosis
 Gap regulator noise diagnosis
 Inspect engine oil leakage

12
 Table 2.1 Engine Problem and Solution

Phenomenon Possible reason

1/Battery voltage too low 1/Measure battery.charge or
2/Battery connection corroded or loose change
3/Starting motor failure 2/Clean and tighten battery
Engine can Not 4/Starter coil or controller failure wiring
be started up 5/Improper spark plug gap 3/Test starting system
6/Fuel system contaminated 4/Test or change
7/Fuel pump failure 5/Adjust
8/Fuel pump circuit open or short circuit 6/Clean, change fuel filter
9/Engine timing in correct 7/Test fuel pump or change
8/Diagnosis and test
9/Check timing link
1/Improper fuel mixing ratio 1/ Refers to diagnosis document
Engine dies out 2/Inlet manifold leakage 2/Check inlet manifold
Or unstable idle 3/Bobbin failure  Inlet manifold gasket
speed  Vacuum pipe
3/Test or change

Fig2.2 engine tester (sours to company)

2.4.3. WORK FLOW IN BODY AND PAINT SHOP

Malfunction vehicle passes different step of maintenance process starting from tire recapping
to complex engine service. Finally, the vehicle body must be painting with military standard
color. Specifically painting color represents the county (Ethiopia) natural future.
There are different types of works are done those are: -

13
 Repairing damaged parts of the vehicle

 Painting the body of the vehicle

Fig 2.3 Paint Shop (sours to company)

2.4.4. WORK FLOW IN AUTO ELECTRIC SHOP

In this work shop, different car parts wiled and joint deference mechanism used arc welding
or oxy acetyl welding and used deferent machine used to maintain car deferens part example
cheers and any part of the car

Fig 2.4 Electric Shop (sours to company)

2.4.5. WORK FLOW IN MACHINE SHOP

In this shop, different machining activities are done. Lathing, drilling, milling, and Grindings
are the most common. Mechanics from different shops come to this shop and fix any
damaged parts with appropriate machines.

14
 2.4.6. WORK FLOW IN GEAR SHOP (POWER TRAIN SHOP)

Power transferring components like gearboxes, propeller shafts, transfer case and differentials
are maintained in this shop. This shop is owned by the engine room mechanics. The gearbox
and the differential have repair in the engine room by two mechanics. Most problems in this
section are the breakdown of seal, bearing and gear teeth. The problem is identified after the
gearbox or the differential is disassembled. Because there is no inspection machine.
2.4.7. WORK FLOW IN ACCESSORY ROOM (STORE HOUSE)

Since defense logistics heavy vehicle overhaul center is responsible for maintenance rather
than production. Almost all vehicles are manufactured in Russia. No spare parts production in
this company rather importing of every aspect of the part and store in accessory shop.
2.5. WORK TASK WE HAVE EXCUTED

When we working in this company observe different problem, from that problem WE
CONCERNED ON TWO PROBLEMS. THOSE ARE:-
 When assemble and separating Tierand wheel nut from the vehicle needs many man
power and west time. We try to remove this problem by doing a vast project which is
design tier and all wheel nut removal machine
 When mount and separating tire from the vehicle needs so high energy and
dangerous for health. We try to remove this problem by doing a small project which
is tire mount and separating machine by using unwanted material from store. This
device

2.6. METHODS USED TO DO A TASK

As express in the above portion WE do the main project which is tier and all wheel nut
removal machine is done only on the paper because lack of material supply. But company is
so many problem. But problem is used give the solution second and third project is design lift
machine and tool store.

2.7. CHALLENGES DURING THIS WORK TASK

15
 Shortage of automatic material

 Shortage of raw material

 Shortage of tool

 Storage of material strength testing machine

 we have shortage of knowledge to transport material from one place to another place

 shortage of knowledge how to use materials

 Shortage of knowledge how to make safety, during disassembling, during washing,

during welding, during assembling etc.

 There is also a problem in how to use electrical equipment‟s.

 The biggest challenge is to know the behavior of the workers. Since there are many
people, so it is the biggest challenge.

 There is also a challenge in knowing part names because thenames of the parts are in
italic language.

2.8. MEASURES DURING THIS WORK TASK

 Create comfortable working condition

 Using unwanted material from store

 Using other workers tool

 Take experience from company welder

 we will try to understand the behavior of the worker

 We use internet centers, different books, soft copy, hard copy and exercise books that
were taken when we are in campus.

 As we can see in each shop all shops have their own problems. To solve those problems
we made a report for each shop managers and the solution.

16
 CHAPTER THREE
3. INTERNSHIP PROJECT
3.1. TITLE OF THE PROJECT
Our internship project title is “DESIGN OF TIER AND ALL WHEEL NUT REMOVAL
MACHINE”
3.2 ABSTRACT

This project is mainly concerned with the problem of safety in the defense and other shop
especially in the defense shop so the problem is completely solved by using this machine; it is
operated by an hand and electric motor controlled by a switch but using in this project using
mechanical or human hand. The input speed reduced using a gear box to a desired level
The main objective of doing this is to decrease manpower that wanted to this activates, our
precious time and increase production rate, for the hosting company. This machine
(mechanical and hydraulically operated) device used to Gear box during assembly of wheel
nut
For the home mechanic, safety is a very important issue. This is especially true since these
individuals often work alone. However, safety precautions, like jack stands are often
neglected, leaving a floor jack as the only support of the vehicle. The Automotive Floor Jack
Locking Device prevents a floor jack from lowering in the event of hydraulic pressure loss. . .
Automotive maintenance is one of the major parameter for keeping its life span. It includes
mainly changed the punctured tire, has been always a difficult task. Every automotive
manufacture provides tools such as L wrench and jack, but still using these tools requires
skilled person. With the increment of the number of passenger cars on the road, the number of
car‟s problem due to tire failure has increased. Often, the car is provided with tire wheel nuts
remover and jack for instance spare tire replacement. Many passenger cars, heavy vehicles
accessories manufacturer concentrates on producing wheel nut puller using a single tool to
lose the nut one by one. Main problem they have still faced is longer time consumption and
tedious work to do skilled worker. Therefore, it is crucial to have a tool that should be
designed ergonomically, easy to handle, lightweight, requires small space and can perform a
similar task in one time. This paper extending the previous worked done by author and focus
on design, development and simulation work on six nuts wheel remover for automotive like
Chevrolet Tavera, Land cruser, Fortuner, Pajero, patro, duble pickap etc.

17
 3.3 INTRODUCTION

An automobile is one of the most basic and fascinating things that one could own. Cars have
now become a need and it is not only the symbol of luxury anymore. Car maintenance, for
example, is one of the key factors in determining its life span. This includes a basic
knowledge of changing the car‟s tier. But replacing a punctured tier has always been a
difficult task. Every car manufacturer provides tools such as L wrench and jack but easy and
fast removal of nuts using these tools requires a skilled person. MohdAzman designed a
remover in 2013 with 100 pitch circle diameter to replace L-shaped nut removers and jack
which allows driver to remove all nuts at once with less energy consumption and save time.
Several static load analyses were performed in order to find safety factor of design. Here,
torque applied was reduced by 33% and also reduction in time taken is 53%. The fabrication
of all wheel nut removers tool was completed by milling, welding and fitting process. With
support, impact wrench was used of 5.5 HP air compressors. In 2014, M. Mukhtar design and
fabricated four in one (4 in 1) motorized tire nut puller for a car with 100 pitch circle
diameter. This tool can dismantle four nuts simultaneously and power up by a car battery.
With assistance in CAD, CAM, CNC and Rapid prototyping concurrently reduction of time
in part assembly and optimum time in finished product was obtained. Several
recommendations have given by author to improve this product in respect of use of polymers
material for creating the product casing. The bracket holder diameter size should be made in
adjustable type that can be used in various types of cars that have different PCD. Have a
stopper to stop the movement of the gear. Have speed controller to control speed of the gear
movement for an easier operation. Provide hammering mechanism that can give an impact on
loosening the nuts.
In 2006, Azizulrahman and abdaziz developed nut removal with 114 pitch circle diameter to
replace T-nut wrench that can reduce the force and torque needed to open the nuts and open
all four nuts simultaneously. This tool can open four nuts in one time and the force of
utilization has been reduced. This tool used mild steel as the main material to fabricate a
gearing system and the gear ratio is 21.125. AmolBhanage concluded 5 in 1 nut remover with
Pitch Circle Diameter (PCD) 114.3 mm has been designed for 080M40 material for Gear and
pinion. For validation, finite element simulation is performed for better optimized results.
Fabrication of the tool performing various processes, after the overall design the tool was

18
finally seen to meet all the design standards. The results of test proved that the Allwheel nut
remover could efficiently remove all the nuts simultaneously. Time required for nut removal
effectively reduced up to 50% for pneumatic gun, and up to 70% for L wrench. Also, the tool
is efficient and with some required modifications could be efficiently used in future.
For the home mechanic, safety is a very important issue. This is especially true since these
individuals often work alone. Servicing a vehicle often involves raising it off the ground for
better accessibility. This requires the use of a jack and jack stands. The jack is used to raise
the tier and the jack stands are used to support it.
A scissor jack is a device which is used to lift heavy vehicles, partially or fully in the air for
breakdown and maintenance. Scissor jack includes one power screw which is rotating, two
fixed nuts, four links which is connected to nuts, eight pins used to fixed that four links, two
rings provided at screw end and load platform supported by upper two links. Now a days,
different types of car jacks are available for lifting vehicles. However available car jacks are
either manually operated or using external power operated.

19
 3.4 PROBLEM STATEMENT

A Car is a motor vehicle with four wheels; usually propelled by an internal

combustion engine. In general, it has above 120 parts. Those parts are mostly made by using
very heavy materials like steels and the like to create better combustion process and to give
long operating life time for the car. But the negative impact of those heavy materials and joint
parts using bolt and nut but not easy assembles is that the car becomes large and not suitable
for maintenance. Predominately, maintenances that has to be performed for remove tier and
wheel nut. tier heavy and remove to drum and disc by hand difficult .on the other hand wheel
nut are very difficult to remove and mount to disc or drum and wheel
In the company heavy objects especially heavy and medium truck engine, gearbox,
tier and wheel which weighs are remove and mount using human labor or human power
which has different problem
From the problems identified the ones for which engineering solution can be given are
listed below. From these problems we selected the first one and made detailed design analysis
to solve.
 Manually operated means human power or hand
 Remove and mount speed is also low
 Need many man power or not operated female and lass power
 Dangers and risk work
 Using large space
Due to such problems of material handling around the shop, there are some problems which
directly or indirectly affect the work and learning process. Some of these are
 Time taking to change to car tire and check car lug parts, which makes it big problem,
since time is very crucial in our day to day lives.
 Safety hazards to personnel working around there and the students, while moving the car
tire and change car lug part. Because of their clear and the presence of spilt lubricant on
their surface, they might slip off from their hand and cause injury to the personnel
working there.
 It is difficult for a person to work alone on those tire and wheel nut employing such
heavy fixtures and heavy remove.

20
Consequently, some way of mechanical remove and mount mechanism will be required for
use in the maintain shop to improve the efficiency of personnel working in there. In order to
do this, a tire and all wheel nut removal machine where the remove and mount is adjustable is
recommended.

3.5 SCOPE OF THE DESIGN

This project is about the designing and fabricating the tier and wheel nut remove machine.
The types of floor jack and nut removal that we were used in this project were hydraulic and
mechanical system as it is more reliable and easy to operate. The scopes of the design were
on the designing 4KN maximum tier lode capacity of floor jack by using optimization
concept and remove 6 nut one time.
1. The design is based on current company.
2. The scope of design and manufacturing of the machine is based on the material
availability and the application of the knowledge we have acquired.

3.5.1 LIMITATIONS

 The design is done by limit used car by Chevrolet Tavera, Land cruser, Fortuner,
Pajero,patro, duble pikap, etc
 The developed floor jack can only withstand below 4000Kg of load
 The developed Scissor Jack can only withstand below 4000kg of load.
 The design is done by considering the turning force that a normal person can apply at
abnormal condition

3.6 OBJECTIVES

3.6.1 GENERAL OBJECTIVE

The general objective of this project is to:

 Design a tier and wheel all nut removal machine that can be used in the remove and
mount or using automotive Technology
 Determine the various processes to be used in they can be lifting car and tool box
 Identify and list the components which are standard
21
 3.6.2 SPECIFIC OBJECTIVES
The specific objective of the design process is to meet the following conditions and
specifications;
 remove all wheel nut by gear box
 Redesign of current gear box, scissor jack & floor jack in terms of cost and quality
 Design of mathematical model for gear box, Scissor jack & floor jack
3.7 ASSEMBLY FIGURE OF MACHINE

PART 1

Fig 3.0 Tier and Wheel All Nut Rem Oval Machine 3d Model (sours to solid
work)

22
3.7.1 PART OF 3D MODEL
1 Tier Removal (Saddle)
2 Hydraulics Jack
3 Scissor jack base
4 Connector
5 Wheel Nut Removal Gear Box
6 Wheel Nut Removal Handle
7 Scissor Jack
8 Scissor Jack Handle
9 Floor Jack Upper
10 Floor Jack Lower
11 Floor Jack Tier
12 Tool Box
3.7.2 DISASSEMBLY FIGURE OF THE MACHINE

PART 2
ALL WHEELNUT REMOVA MACHINE

Fig 3.1 3d Model Of All Wheel Nut Removal Gear Box Front View (sours to
solid work)

Fig 3.2 3d Model of All Wheel Nut Removal Gear Box Said View(sours to solid
work)

23
Fig 3.3 3d Model of All Wheel Nut Removal Gear Box Top View (sours to solid
work)
PART 3

Fig 3.4 3d Model of All Wheel Multi Nut Removal Gear Box(sours to solid
work)

Fig 3.5 2d Model of Gear System Said View (sours to solid work)

24
 Fig 3.6 2d Model Gear System Front View (sours to solid work)
PART 4

Fig 3.7 Scissor Jack (sours to solid work)

Fig 3.8 Tool Box (sours to solid work)

Fig 3.9 3d Model Floor Jack (sours of solid work)

25
 3.8 METHODOLOGY

Methodology is the basic part of any scientific research because it gives detail about the data.
Methods of data collection and sample size are useful to carry out research activities.

3.8.1 OVERVIEW

The tier and all wheel nut removal machine assembly is portable, this machine remove nut by
gear box, using tool put parts by tool box, the tool is moving or lift gear box to upward and
downward by scissor jack or crack and using the same purpose of floor jack base of the
machine using remove tire .tier and all wheel nut removal machine is adding other parts like
shock absorber using support part of the machine.

3.8.2 DATA COLLECTION METHOD

In this study to collect the necessary data the researcher will use primary sources. Among the
primary sources direct interviews will be used to collect data from prospective mechanics and
supervisors. We will also use direct measurements of the physical available tire and wheel
diameter. Thus, this way we can get a correct and clear data that can help us for the design.

3.8.3 SAMPLING DESIGN

In 2013 with 100 pitch circle diameter to replace L-shaped nut removers and jack which
allows driver to remove all nuts at once with less energy consumption and save time. Several
static load analyses were performed in order to find safety factor of design. Here, torque
applied was reduced by 33% and also reduction in time taken is 53%. The fabrication of all
wheel nut removers tool was completed by milling, welding and fitting process. With support,
impact wrench was used of 5.5 HP air compressors.
In 2014, M. Mukhtar design and fabricated four in one (4 in 1) motorized tire nut puller
for a car with 100 pitch circle diameter. This tool can dismantle four nuts simultaneously and
power up by a car battery. With assistance in CAD, CAM, CNC and Rapid prototyping
concurrently reduction of time in part assembly and optimum time in finished product was
obtained. Several recommendations have given by author to improve this product in respect
of use of polymers material for creating the product casing. The bracket holder diameter size

26
should be made in adjustable type that can be used in various types of cars that have different
PCD. Have a stopper to stop the movement of the gear. Have speed controller to control
speed of the gear movement for an easier operation. Provide hammering mechanism that can
give an impact on loosening the nuts.
In 2016, Azizul rahman and abd aziz developed nut removal with 114 pitch circle
diameter to replace T-nut wrench that can reduce the force and torque needed to open the nuts
and open all four nuts simultaneously. This tool can open four nuts in one time and the force
of utilization has been reduced. This tool used mild steel as the main material to fabricate a
gearing system and the gear ratio is 21.125.
Amol Bhanage concluded 5 in 1 nut remover with Pitch Circle Diameter (PCD) 114.3
mm has been designed for 080M40 material for Gear and pinion. For validation, finite
element simulation is performed for better optimized results. Fabrication of the tool
performing various processes, after the overall design the tool was finally seen to meet all the
design standards. The results of test proved that The All wheelnut remover could efficiently
remove all the nuts simultaneously. Time required for nut removal effectively reduced up to
50% for pneumatic gun, and up to 70% for L wrench. Also, the tool is efficient and with some
required modifications could be efficiently used in future.

3.8.4 DATA PROCESSING AND ANALYSIS

After the necessary data for the study is collected, the processing and analysis of the data will
be done. Thus from this process on wards we will be able to get our design requirements and
start designing accordingly.

3.8.5 DESIGN EVALUATION OF ALTERNATIVE

The evaluation of the proposed alternative of design concept is made depending on the design
parameters. This process involves concept scoring, screening, grading and weight calculation
process.
The main basic design parameters we are considered when designing transmission jack are as
follows;
 Safety
 Easy of operation/ controlling
 Ease of maintenance

27
 Easy of manufacturing
 Efficiency
 size (space utilization)
 Marketability
 Durability
 Stability
 Strength
 Reliability
 Effectiveness
 Wear
 Weight
 Noise
Weight age calculation is done by comparing each of the above parameters with one another
and gives the priority to one parameter over the others.

3.9 GENERAL DESIGN CONSIDERATIONS TIER AND ALL

WHEELNUT REMOVAL MACHINE
3.9.1 MATERIALS

The most important characteristics to be considered when selecting a material of

constructions are:
1 Mechanical properties:
Include the following properties.
1. Strength:- Tensile strength required
2. Stiffness: - The material should have high Elastic modulus
(Young‟s modulus).
3. Toughness: - Fracture resistance needed.
4. Hardness: - high wear resistance required.
N.B: Also the material fatigue and creep resistances are needed.
I. The effect of high and low temperature on the mechanical properties.
II. Corrosion resistance
III. Any special properties required such as thermal conductivity, electrical résistance,
and magnetic properties.
IV. Case of fabrication: forming, welding, casting etc.

28
 V. Availability in standard sizes: plates, sections, tubes etc.
Cost of the material
3.9.2 MATERIAL SELECTION FOR EACH GEAR
The material, we selected for the gear is included characteristics
 High resistance to wear
 High fluidity at casting temperature
 Cheap
 Excellent bearing & damping properties
 Excellent Mach inability and it is available in the market
 SELECT CARBON STEEL EN8
3.9.3 MATERIAL SELECTION FOR SCISSOR JACK POWER
SCROW

The Material we, selected for the shock absorber (supporter) is included characteristics
 High compressive strength to support the load.
 Due to its appreciable hardness.
 Give good surface finish.
 SELECT ALL PART : MILLED STEEL
 SELECT BASE PLATE. CAST IRON
 SELECT SOLID RAM A.LLOY STEEL
3.9.4 MATERIAL SELECTION FOR FLOOR JACK WHEEL

The Material we selected for the floor jack wheel is included characteristics
 High strength,
 harden ability
 toughness
 High creep, & wear resistance.
 Good mechanical property
 SELECT FLOOR JACK FRAME: CAST IRON
 SELECT FLOOR JACK HYDROLIC JACK MANY PART: MILLED STEEL
3.9.5 MATERIAL SELECTION FOR THE NUT REMOVAL (SHAFT)

The material, we selected for the nut removal is included characteristics

 Good strength & ductility

29
 Cheap& available in the market
 Good mechanical properties
 SELECT SHAFT CARBON STEEL EN8
3.9.6 MATERIAL SELECTION FOR THE TOOL BOX

The material, we selected for the tool box is included characteristics

 Ductile
 Strong
 Machinability & available in the market
 cheap
 SELECT CAST IRON
3.9.7 MATERIAL SELECTION FOR TIRE REMOVAL SADDLE

The material, I selected for the tire removal saddle is included characteristics
 Strong & hard
 Heat treatable
 Good mechanical properties
 SELECT CAST IRON
3.9.8 MATERIAL; SELECTION FOR THE GEAR BOX (HOUSING)

The material, we selected for the gear box (housing) is included characteristics
 High ductility
 Good fatigue strength
 Good wear & shock resistance
 SELECT MILLED STEEL
3.9.9 MATERIAL SELECTION FOR THE FLOOR JACK (BASE
PLATE)

The Material, we selected for the base plate is included characteristics

 High resistance to wear
 High fluidity at casting temperature
 Cheap
 Excellent machinability
 Excellent bearing & damping properties
 It is available in the market

30
  SELECT CAST IRON
3.9.10 MATERIAL SELECTION FOR THE HANDLE OF THE GEAR
BOX, SCISSER JACKAND FLOOR JACK.

 Should be hard
 Should be not brittle
 Good resistance to corrosion and rust (for long working life)
 Ease of manufacturability
 SELECT MILLED STEEL

3.9.11 SELECTION OF FLOOR HYDRULIC JACK FLUID

 The fluid in floor hydraulics jack is used to transmit energy as the fluid is pumped
through the system because liquids are virtually incompressible.
 The other functions of hydraulic fluids are to provide lubrication for move parts, and to
protect components from rust and corrosion.
 It is important to use a fluid with the proper fluid viscosity in order to avoid the problems
that may occur if the wrong fluid is used.
 It the fluid is to thin, it can cause
 Increase in internal & external leakage
 Pump slippage
 Reduction in system pressure
 Excessive component wear from inadequate lubrication
 If the fluid is too thick, it may result in
 Increase in internal friction
 More power required for operation.
 Therefore, in order to avoid the above described problem it is better to use medium fluid
viscosity with a grade 20 or grade 30.
3.9.12 MATERIAL SELECTION FOR SCISSER JACK ARM (CRACK)

 High strength,
 harden ability
 toughness
 High creep, & wear resistance.
 Good mechanical property

31
  SELECT METAL
3.10 DESIGN AND OPERATING
3.10.1 DESIGN AND OPERATING GEAR BOX

When the handle is rotate to the left

1 rotate handle to lift force transfer to larger gear, gear is rotate
2 larger gear rotate one time small gear is rotate to four time
3 small gear rotate force transfer to connecter and nut removal part
4 nut removal is rotate wheel nut is remove

When the handle is rotate to the right

1 rotate handle to right force transfer to larger gear, gear is rotate
2 larger gear rotate one time small gear is rotate to four time
3 small gear rotate force transfer to connecter and nut removal part
4 nut removal is rotate wheel nut is mount

TESTING
In order to analyses the efficiency of manufactured all-wheel nut remover, testing was
performed using the various available nut remover tools such as Lug wrench, Pneumatic gun
and all – wheel nut remover tool.

PROCEDURE TO BE FOLLOWED DURING TESTING

1. Firstly, the torque required for each nut using lug wrench will be tabulate using the torque
measuring equipment. Now, the time taken for removal of all nuts using each of equipment
will not down.
2. Then, the nuts are again re-tightening using all the tools mentioned tools and time required
for the same was noted.
3. Finally, all the results were analyzed and conclusion was drawn. The results of test proved
that the all-wheel nut remover could efficiently remove all the nuts simultaneously. Also, the
tool is efficient and with some required modifications could be efficiently used in future.
3.10.2 DESIGN AND OPERATING SCISSOR JACK (CACK)

When the handle is rotate to lift,

1 scissor jack handle is rotate to lift the scissor jack is move upward

32
2 scissor jack is move to upward scissor arm move to upward and support the frame
3 scissor jack move to upward the gear box is move to upward
When the handle is rotate to right,
1 scissor jack handle is rotate to right the scissor jack is move downward
2 scissor jack is move to downward scissor arm move to downward and support the frame
3 scissor jack move to downward the gear box is move to downward
 The main use of scissor jack moves to gear box or flexible wheel nut removal
part case of tire diameter , deferens car is deferens tire diameter
3.10.3 DESIGN AND OPERATING FLOOR JACK

When the handle is moved upward,

1 moved handle of floor jack return spring is relax and mechanical energy change to
hydraulics energy
Means move upward of hydraulic jack piston
2 piston is move to upward to push the floor jack saddle
3 saddle is move to upward tire is mount and remove.
When the handle is moved downward
1 moved handle of floor jack return spring is compress and mechanical energy change to
hydraulics energy Means move downward of hydraulic jack piston
2piston is move to downward to push the floor jack saddle
3 saddle is move to downward tire is mount and remove.

Jack is a device used to lift heavy load or to apply great force.

Generally jack can be classified into two based on the mechanism they used to lift the device:
I. Mechanical jack: uses screw and gear mechanism to lift the device
II. Hydraulic jack: uses a liquid which is incompressible that is forced in to a cylinder by
a pump by a plunger. Oil is used since it is self-lubricating and stable
Mechanical service jack (our concerned project)
It uses a mechanical advantage in order to lift the load. It is easy to assemble and disassemble
because it has no such complicated component.
3.10.3.1 BASIC COMPONENTS OF MECHANICAL SERVICE JACK

Handle: it has a direct contact with the machine operator during the operation
Saddle: it has a direct contact with the load to be lifted.

33
Connecting road: it is used to connect the nut with the lifting arm and allow upward and
down ward motion
Wheel: they carry the whole system
Frame: it changes the rotational motion from the handle to transitional motion by the help of
pin
Lifting arm: it lifts the desire body
Pin: it is used to join the lifting arm with the frame.
3.10.4 DESIGN AND OPERATING TOOL BOX

 The main use of tool box is store and put tool

 Example store tool box

Fig 3.9 Combination Wrenches (sours internet tool of automotive)

Fig 3.10 socket tool (sours internet tool of automotive)

3.11 DESIGN OF PARTS

3.11.1 DESIGN AND MODELLING OF 6 IN 1 ALL – NUT REMOVER

FOR AUTOMOBILE WHEELS

The calculations for the individual component parameters were performed using the standard
design equations. Factor of Safety (FOS) of the design.

34
 3.11.1. A. DESIGN OF GEAR AND PINION

The product was to be designed for 76 PCD, so the center distance between gears had to be
38 mm. The torque required for removal of one nut is 120 N-m. Spur gears were selected due
to ease in design and manufacturing. Apart from this, the velocity ratio in spur gear is
constant. Keeping the above factors in mind and selecting 080M40 for Gear and pinion,
design calculations were performed and the values obtained were as follows.
INITIALLY CONSIDER,

Pitch Circle Diameter of Gear D = 76 mm

Pitch Circle Diameter of Pinion d = 38 mm
Gear Ratio G = 2.00
By using G, Z g = G × Z p
Zp = 18 and Zg = 36 are selected from the Lewis form factor table.
Module m = 3 mm
Face width b = 30 mm
3.11.1. B. PROPERTIES OF THE MATERIAL - EN8 CARBON STEEL

EN8 is an unalloyed medium carbon steel grade with reasonable tensile strength. It is widely
used for applications which require better properties than mild steel but does not justify the
costs of an alloy steel.
Ultimate tensile strength SU = 550 N/mm2
Yield strength SY = 280 N/mm2
Young‟s Modules E = 200000 N/mm2
Poisson‟s Ratio ν = 0.3
Brinell hardness = 255 HB
Permissible bending stress is same for both gear and pinion as the material used is same.
Now, for both gear and pinion,
σb = SU =1 8 3 .3 3 N/ mm2

3.11.1. C. BEAM STRENGTH

The beam strength of both gear and pinion is given by,

fb m b v σb4949.91 N

35
When pinion and gear are made up of same material then at that time pinion is weaker than
gear in bending, so we have to find out Feff for calculating factor of safety.
3.11.1. D. EFFECTIVE LOAD

The effective load must be calculated for precise estimation.

Feff = Ka K m Ft / Kv, where,
For moderate shock and precise gearing, K a =1 .2 5
For face width up to 50 mm, K m = 1 .2
For fine hobbing process, V= 22 m/ s2
Torque required for removal of 6 nuts is 720 N-m,
N = 200 rpm (Since, Pneumatic motor with rpm 200 is used)
Therefore,
P=2ΠNT /60
P=2×3.141×200×720/60
P= 15.076×103 W
Now, tangential force is given by,
Ft =P/V =10×103/22 =685.43N
Kv =5.6 / (5.6 + v1/2) =0.5441
Thus, the effective load is,
Feff = Ka K m Ft / Kv
= 1,25×1.2×685.43/0.5441
= 1889.62N
3.11.1. E. CALCULATION FOR AVAILABLE FACTOR OF SAFETY
(FOS)

Fb=FOS × Feff
FOS =4949.91 /1891.19
FOS =2.619
So FOS= 2.619 >1.5
As the Available FOS of Gear pair is higher than that of required factor of safety, the design
of gear pair is safe. The final gear and pinion parameters are tabulated below.

36
 TABLE 3 FINAL DESIGN PARAMETERS
Parameters Gear Pinion

Teeth 34 17

PCD (mm) 76 38

Module (mm) 2.25 2.25

Addendum (mm) 2.25 2.25

Dedendum (mm) 3.125 3.125

Tooth Thickness (mm) 3.93 3.93

3.11.1. F. DESIGN OF SHAFT

In actual practices, the shafts are subjected to shock and fatigue loading. Hence, in the design
of shaft, the shock and fatigue is accounted by using the factors known as combined shock
and fatigue factor. After performing the standard design calculations for design of shaft as
prescribed in, the material selected is EN8 Carbon Steel and the final dimensions are,
Diameter of input Gear shaft D = 10.076 mm. A diameter of 20 mm was selected for the
provision of lug at the input end of the Gear Shaft. Diameter of output Pinion shaft d = 6.43
mm. A diameter of 12 mm was selected so that the square head for the mounting the lug can
be made. And length of input shaft 500 mm, length of output shaft 24 mm
3.11.1.G. DESIGN OF CASING

The product casing is used to cover the entire assembly. All the gears are mounted within the
casing. The casing was designed according to the standard design procedure mentioned in
and the final casing parameters are listed below.
Cover width = 20 mm
Cover thickness (Sc) = 4 mm
Cover height = 170 mm
Cover length = 500 mm
Bolt diameter = 6 mm
Therefore M6 bolt was selected.

37
 Bolt spacing is 72° around the periphery.
Gear spacing is 600

3.11.2. DESIGN DETAILS OF SCISSOR JACK

Given
1) Load= up to 4 KN
2) Permissible Tensile Stress =100 MPa
3) Permissible Shear Stress = 50 MPa
4) Bearing Pressure =30 MPa
5) Length of Link =100 mm

3.11.2. A. DESIGN OF SCREW

The maximum load on the screw is when the jack is in the bottom most position.

Fig. 3.11 Geometry of Screw (sours internet 2d of screw)

 Pull in the screw,
F =𝑊�/2/𝑡�𝑎�𝑛�𝜃�
Where, F= force exerted on screw
W= load
𝜃��=39.50
 Total force in the screw due to both the nut,
P1 = 2F
Where, p1= total force
 For the screw to be safe in tension,

38
Where, dc = core diameter
σt = tensile stress
 Now, we adopt pitch(p)= 6 mm
 Outside diameter of screw,
do= dc+p
 Mean diameter of screw,
dm=1/2(𝑑�𝑐� + 𝑑�𝑜�)
 Helix angle,

 Angle of friction,
�������∅=tan−1𝜇�
Where, 𝜇�= co-efficient of friction
 Effort required to rotate the screw(P),
P = P1×tan (𝛼� + ∅)
Where, P1= total force
 Torque, T=P × dm/2
 Torsional shear stress in screw,

Where, T= torque
 Direct tensile stress in screw

where, P1= total force;

39
 Maximum principal stress in screw,

which should be less tha

n 100 MPa, hence safe.

Maximum shear stress,

which should be less than 50 MPa, hence safe.

which should be less than 50 MPa, hence safe.

Pull in the screw in KN, F= 2.426219
Total force due to both the nuts in KN, P1= 4.852438
Core diameter of screw in mm, dc= 7.862220
The screw is also subjected to torsion in addition to tension. To account for this, we adopt,
New value of Core diameter of screw, dc= 16.000000
Outside diameter of screw, do= 22.000000
Mean diameter of screw, dm= 19.000000
Helix Angle in degree = 5.745834
Angle of friction in degree = 11.315669
Effort required to rotate the screw in KN, P = 1.488435
Torque required in KN-m, T= 14.140134
Torsional shear stress in screw (MPa) = 17.590732
Direct tensile stress in screw (MPa) = 24.146288
Maximum principle stress in screw (MPa)= 33.408435
Maximum principle stress 33.408435(MPa) is less than permissible stress in tension
100.000000(MPa)
Hence design is safe

40
 3.11.2.B. DESIGN OF NUT

Fig.3 .12 Geometry of Nut (sours to internet 2d of nut)

Let n= number of threads on nut.
Designing the nut in bearing of threads,
 ᵟb= 35.589MPa
 Thickness of threads, t = p/2

We adopt n=4
 Height of nut, h= np
To prevent movement of nuts beyond 200 mm, rings of 8 mm thickness are provided on the
screw on both sides and fixed by set screws.
 Length of screw=200+h+2×thickness of rings+30 mm for spanner
 Length of spanner:
Let the operator apply a force of 50 N to the end of a spanner l mm long.
L=T/50
Number of threads on nut, N = 0.903721
In order to provide stability to jack, we adopt New value of the Number of thread, n=
4.000000
Height of Nut in mm, h =24.000000
3.11.2.C. DESIGN OF PINS IN NUT
 The pins are in double shear. If dp is the diameter of pins then,

 Diameter of pin head=1.5 dp

Thickness of pin head is taken as 3 mm.

41
Split pins are used to keep the pins in position.
Diameter of Pins in mm, dp= 9.372884
Diameter of Pin Head, Dp=14.059325
Thickness of pin head is taken as 3mm
Split pins are used to keep the pins in position
3.11.2.D. DESIGN OF LINKS

Fig.43.13 Geometry of Link (sours to internet draw link)

 Load on each link = F/2
Let b1= width of link= 15.43, and t1= thickness of link=5.144
Assuming b1=3t1
 Area of cross-section of link,
A=3𝑡�1²=79.38
 Moment of inertia,=1575.4

 Least radius of gyration,=4.4549

 For buckling of links in the vertical plane, the ends are considered hinged. Therefore,
using Rankine-Gordon formula,
For critical load,

For design load, P𝑐�𝑟�1 =F.O.S×F

Taking Factor of Safety, F.O.S.= 5.000000
For Design Load,
Actual load on Link in KN = 6.065547
Roots Are:

42
 The First root is: -2.5720
The second root is: 2.5720
Value of the Thickness (t1/2), t= 2.572003
Real value of the Thickness in mm, t1= 5.144005
Width of the links in mm, b1= 15.432015
Critical Load in KN, Pcr= 7.341706
Design Load 6.065547(KN) is less than Critical Load 7.341706(KN)
Hence Design Is Safe.

TABLE 3.1: MATERIAL PROPERTIES

MATERIAL TENSILE YIELD POISSON’S RATIO MODULUS OF
STRENGTH ELASTICITY

Sae J1392 050ylf 344 Mpa 0.3 200000 Mpa

Sae 1018 410 Mpa 0.3 200000 Mpa

TABLE-3.2: DATA ANALYSIS OF SCISSOR JACK

PART NAMES YIELD STRESS FAILURE LOAD TO PLASTIC

(Mpa) STRAIN YIELD STRAIN AT

(%) (Kgs) LOAD (%)

CAP 344 20% 2355 0.0174

BASE 344 20% 1177 0.28
CAP RIVET 410 20% 1577 3.05
20% 1177 1.89
LOWER ARMS 344

UPPER ARMS 344 20% 1577 0.595

43
SCREW 410 20% 2355 0.599

3.11.3 DESIGN DETAILS OF FLOOR JACK

3.11.3.1. FORCE ANALYSIS FOR THE SADDLE

Fig 3,14 Saddle Force Analysis(sours to me )

From ƩFx = 0
Rax-Rbx = 0............. 1
From ƩFy = 0
Let RbX = 9KN
Ray-Rby = 18.75KN……..2
Ray = 9.75 KN
Taking moment at A and B

+ ƩMa = 0
18.75KN * 15mm - Ray * 20mm - Rax * 18mm = 0
20Ray + 18Rax= 281.25--------3
S Rax =10.88KN
+ ƩMb = 0
Rby * 20mm - 18.75kn * 5mm-Rbx * 18mm = 0
20Rby - 18Rbx = 18.75 * 5 = 93.75............4
Rbx = 0.4166 KN

44
 3.11.3.2. FORCE ANALYSIS FOR THE HYDRAULIC SYSTEM

Fig 3.15 Hydraulic System (sours to me)

As said earlier the hydraulic system works with Pascal‟s law multiplies force
Take D2=6D1
D2=60mm
D1=10mm
Fp=1.182KN
From Pascal‟s law
P1=P2
Fp/A1 = F2/A2 hence A1 = (ΠD21)/4 A2= (ΠD22)/4
Fp =F2*A1/A2= F2*D12/D22
Assume
D2=6D1
Fp=F2 *D12/6D12 Fp=1.182

F2 =1.182KN/0.166667
F2= 7.091KN

45
 3.11.3.3. FORCE ANALYSIS OF THE ARMS

Fig 3.16 Arms Analysis (sours to me)

The two arms are symmetrical so only half of Ray, Rax and FZ1 are exerted on each arm
GIVEN
Rax= 2.083KN
Ray= 12.1875KN
Ra‟x= Rax/2 =2.0834KN/2 = 1.0417 KN
Ra‟y=Ray/2=12.1875KN/2= 6.09375KN
From ƩFy=0
Ro‟y + Ra‟y = 0 Ro‟y= Ra‟y = 6.09375KN
Let Ro‟y=6.09375KN
Fz‟2=21.27KN
Ro‟x=20.25KN
Taking moment at 0
+ Mo= 0
LET
L1=464mm
L2 =165.7mm
Fz‟1(L2sin54)-Ra‟y(L1cos16)-Ra‟x(L1sin16)= 0
165.7sin54*FZ‟1 = 464(6.09375cos16 + 1.0417sin16)
Fz‟1=Fz‟2= 2851.2/165.7sin54 =21.27KN
From ƩFx =0
Fz‟1+Ro‟x-Ra‟x = 0
Ro‟x=Ra‟x - Fz‟2
= 1.0417-21.27KN

46
 = -20.23KN
Ro = √Ro‟x2+Ro‟y23
=√6.093752 + 20.232
=21.13KN
δ = tan-1(-20.23/6.09375)
= -73.3
Let Ro = 21.73KN
δ = -73.3
3.11.3.4. FORCE ANALYSIS OF THE PISTON

Fig 3,17 Piston Analysis (sours to me)

F2= 2F21
= 2*21.27KN
= 42.54 KN
F2 = 42.54 KN is the maximum force exerted by the piston
3.12 LITERATURE REVIEW
3.12.1 LITERATURE REVIEW INTRODUCTION

The main purpose of this literature review is to get information about the project from the
reference books, magazines, journals, technical papers and web sites. In this chapter the
discussion will be made base on all the sources.
3.12.2 LITERATURE REVIEW TERMINOLOGY

In this section, all the terminology on this project is presented.

3.12.2.1 GEAR BOX

Gear box the tool used to remove the wheel nuts should be designed for ergonomic, easy to
handle and requires small space for storage. The tool is also function as wheel nuts tightened.

47
Nonetheless, it is difficult for women and the elderly drivers due to high required torque to
remove the wheel nuts. In addition, if the nuts are successfully removed, the problem to
retighten the nuts will follow. If the required torque is not applied in tightening the nuts, the
nuts will lose, and this will
3.12.2.2.1 GEAR BOX DESIGN

The product was to be designed for 139.7 PCD, so the center distance between gears had to
be 69.85 mm. The torque required for removal of one nut is 120 N-m. Spur gears were
selected due to ease in design and manufacturing. Apart from this, the velocity ratio in spur
gear is constant. Keeping the above factors in mind and selecting 080M40 for Gear and
pinion, design calculations were performed and the values obtained were as follows.
3.12.2.2 FLOOR JACK

A floor jack is a device which lifts heavy equipment. The most common form is a car jack,
floor jack or garage jack which lifts vehicles so that maintenance can be performed. Car jacks
usually use mechanical advantage to allow a human to lift a vehicle. More powerful jacks use
hydraulic power to provide more lift over greater distances. Mechanical jacks are usually
rated for a maximum lifting capacity (for example, 1.5 tons or 3 tons).

3.12.2.2.1 FLOOR JACK DESIGN

To design is either to formulate a plan for the satisfaction of a specified need or to solve a
problem. If the plan results in the creation of something having a physical reality, then the
product must be functional, safe, reliable, competitive, usable, manufactured and marketable..
These terms are defined as follows:
I. Functional: The product must perform to fill its intended need and customer expectation.
II. Safe: The product is not hazardous to the user, bystanders, or surrounding property.
Hazards that cannot be „designed out‟ are eliminated by guarding (a protective enclosure); if
that is not possible, appropriate directions or warning are provided.
III. Reliable: Reliability is the conditional probability, at a given confidence level, that the
product will perform its intended function satisfactorily or without failure at a given age.
IV. Competitive: The product is a contender in its market.

48
V. Usable: The product is „user friendly‟ accommodating to human size, strength. Posture,
reach, force, power and control. VI. Manufactured: The product has been reduced to a
„minimum‟ number of parts. Suited to mass production, with dimensions, distortion, and
strength under control.
VII. Marketable: The product can be bought, and service (repair) is available.
It is important that the designer begin by identifying exactly how to recognize a satisfactory
alternative, and how to distinguish between two satisfactory alternatives in order to identify
the better. From this, optimization strategies can be formed or selected.
Then the following tasks unfold:
 Invent alternative solution
 Establish key performance metrics
 Through analysis and test, simulate and predict the performance of each alternative,
retain satisfactory alternatives, and discard unsatisfactory ones.
 Choose the best satisfactory alternatives discovered as an approximation to optimality.
 Implement the design
The characterization of a design task as a design problem can introduce the idea that, as a
problem, it has solution.

3.12.2.3 SCISSOR JACK

A scissor jack is operated simply by turning a small crank that is inserted into one end of the
scissor jack. This crank is usually “Z” shaped. The end fits into a ring hole mounted on the
end of the screw, which is the object of force on the scissor jack. When this crank is turned,
the screw turns, and this raises the jack. The screw acts like a gear mechanism. It has teeth
(the screw thread), which turn and move the two arms, producing work. Just by turning this
screw thread, the scissor jack can lift a vehicle that is several thousand pounds.
3.12.2.3.1 SCISSOR JACK DESIGN AND LIFT

A scissor jack uses a simple theory of gears to get its power. As the screw section is turned,
two ends of the jack move closer together. Because the gears of the screw are pushing up the
arms, the amount of force being applied is multiplied. It takes a very small amount of force to
turn the crank handle, yet that action causes the brace arms to slide across and together. As
this happens the arms extend upward. The car‟s gravitational weight is not enough to prevent

49
the jack from opening or to stop the screw from turning, since it is not applying force directly
to it. If you were to put pressure directly on the crank, or lean your weight against the crank,
the person would not be able to turn it,

3.13 CONCLUSIONS AND RECOMMENDATION TO PROJECT

3.13.1 CONCLUSION TO PROJECT

`
In this project, the design of manually operated tier and all wheel nut removal and assembly
is done for an average load of dies. No external power consumption so it is very cost efficient
for the company. It also avoids the time delay caused by waiting for another time and
removal tool example tube, speed t, l shape removal tool and load the work piece. The
manufacturing of the tier and all wheel nut removal machine is so chip that even the
prototype is made from scrap materials and remove work pieces at nearly coast.
This machine reduce manpower and time during assembly of wheel nut and tier or wheel
and disc by wheel nut
As a result this increases the production of the company.
Here its components of design are depend on the:
 Portability
 Rehabilitee
 Availability of material
 Easily assemble and disassemble
6 in 1 nut remover with Pitch Circle Diameter (PCD) 139.7mm has been successfully
designed using CATIA V5R20. Selecting 080M40 material for Gear and pinion, design
calculations were performed. With calculations, FOS of Gear pair is higher than that of
design factor of safety; the design of gear pair is safe. For validation, finite element
simulation will be performed for better optimized results. In future, Product assembly will be
manufacture and tested.

50
 3.13.2 RECOMMENDATION TO PROJECT

The design in this report is based on some specifications and assumptions. However the
system can be redesigned for any required applications and specifications and Enovation
means new idea are using.
Based on the design specifications of the job, the following are recommended for use:
 It is recommended that the remove and assemble are checked for proper alignment on nut
connecter and nut the at its center before remove and assemble.
 It is also recommended to used tier and all wheel nut removal and assemble to assure
safety and balance during work.
 It is recommended to check the gear box and floor jack after the work

51
 APPENDIX
GEAR BOX

FLOOR JACK

GEAR DESIGN

52
 REFERENCES

1. V. B. Bhandari, Design of Machine Elements, Tata Mc-Graw Hill Publishing House Ltd.,
Second Edition.
2. Dr. N. C. Pandya, Dr. C. S. Shah, Machine Design, Charotar Publishing House Pvt. Ltd.,
Seventh Edition.
3. Khurmi Gupta, Machine Design, Eurasia Publishing House Pvt. Ltd. First Edition.R. K.
Jain, Production Technology, Khanna Publishers.
4. MohdAzman, NurfarahinSulaiman. 2003. Design and Fabrication of Vehicle all Wheel Nut
Remover. International Journal of Computer Science and Electronics Engineering. Volume 1,
Issue 3, ISSN: 2320-401X. pp. 381-384
5. Beers, Ferdinand P and Russel Johnston Jr. Mechanics of Materials. New York, McGraw-
Hall, 1999

53
 CHAPTER FOUR
4 OVERALL BENEFIT GAINED

The internship allowed us to question and work with people who work in our chosen career.
This gave us a good and personal insight in to what the job entails and what has been
developing in our focus area.generally this internship program has enabled as to see solutions
through problems.During this internshiptime we have gained a lot of benefits according to
improving our skills .To mention some of them:-
 Upgrading theoretical knowledge
 Improving practical skills
 Improving interpersonal communication skills
 Improving team playing skills
 Improving leader ship skills
 Understanding the work ethics
 Improving entrepreneurship skills.

4.1. UPGRADING THEORETICAL KNOWLEDGE

IN THEORETICAL KNOWLEDGE We have gained so much interesting knowledge that can boost
to our wisdom in the automotive industry. During this period of internship we are also,
upgrade our theoretical knowledge by relating the theoretical knowledge with practical
activities. For example, we see the condition when the car maintenance fail. At what
conditions the car requires maintenance activities, this can be done by identifying what we
learns theoretically. In addition, we see so many car parts and their application area that we
already know theoretically.

4.2. IMPROVING PRACTICAL SKILL

We were able to practical skills like engine management, failure prevention, body repair and
paint job skills and general car maintenance skills. The internship can be seen as the pinnacle
of our undergraduate education and give us the chance to use the skills that we have learned

54
in the classroom in a real-world setting. It‟s a chance to prove the worth of our qualifications
and to show that we can perform the task we have been given.
This internship period, we are gained different practical skill. Specially, maintenance
management system, So that we able to improve our preventive and maintenance skills. This
can be performed by inspecting the operating machine, identifying, and estimating the
problem and the operating period of the parts of the machines, and also we see at what
interval the maintenance activities takes place for the parts of the machines should. During
this period, we are worked in the workshop room of the company. In these workshop room
different types of formation and maintenance activities takes place,

To improve our practical skill, we make and use the following tasks frequently while we were
in the company:

 Giving special attention to the practice.

 Rising questions

 Creating good relationships within employees

 To be active to get information

 Exchanging information

 Respecting others and keeping the rules and regulations of the company.

4.3 IMPROVING INTERPERSONALCOMMUNICATION SKILLS

This internship program also helps us improving interpersonal communication skills. There
also so many opportunities for improving interpersonal communication skill during the
working period at the company. The workers of company are interested to answer whatever
questions that we want to ask and also their good facial expression which invite us to talk
with them more. This is the main means, which helps us to improve our interpersonal
communication skills. This opportunity helps us know how to introduce our self, how to ask
information and when and where to get it.

55
 4.4 IMPROVING TEAM PLAYING SKILLS

Thanksto defense logistic we are now capable of team working in any kind of job and
situation. In our case most things were performed in team work. Without teamwork it was so
much difficult for us to go much further. So in these types of difficult situations team playing
skills play an important role. In each and every activity the effort put by each and every
individual in the group will result in the better performance of the team. This means if a team
has a good conversation and a better understanding between each other they will have a good
team playing skills. While we work together we were trying to have a better team playing
skills by actively understanding each other and communicating well. By this way were able
to improve our team playing skills. In terms of improving team playing skill we have gained
a lot like:
 Cooperativeness
 Convincing one another
 Developing the habit of group discussion
 Developing a good idea whose ever the ideas are
 Performing tasks together as a team
 Interacting with each other dynamically
 Sharing experiences
 Developing the spirit of group working and brotherhood
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 team work and sharing of
knowledge and responsibility allow us to be more productive in the future.
4.5 IMPROVING LEADERSHIP SKILLS

Our company supervisor was the best leadership example for us in which we are now familiar
with the secret of being a good leader!!! We have got a practical skill that a leadership can
influence others to work towards the achievement of the desired service and it is one of the
functions of management which includes planning, organizing, staffing, leading, and
controlling. From the internship we also improve skills regarding leadership. The overall
benefit that we gained from the internship regarding improving leadership is directing

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successful leadership results in the employee growth and development with new skills and
capabilities that enables to increase the productivity. Us to be more productive in the future.

4.6 UNDERSTANDING WORK ETHICS RELATED ISSUES

During this internship we understand the work ethics and related issues. In this duration we
understand that we have to work hard in addition to working hard it is also to work smart.
This means learning the most efficient way to complete tasks and finding ways to save time
while completing daily assignments. This is important to care about our job and complete all
projects. Doing more than expected on the job is a good way to show that we utilize good
time management skills and don‟t waste valuable company‟s time by attending personal
issues not related to the job.
 Arrive to work at least 15 minutes before the schedules start time this offers the ability to
mentally prepare for tasks.
 Developing a strong work ethic involves taking initiative. Be confident and self-
motivated in your ability to handle job responsibilities.
 Respect what others contribute to the work environment.
 Put a positive spin on negative comments.
 Maintain a professional demeanor at all times.
 Honor Your Commitments

4.7. ENTREPRENEURSHIP SKILLS

This company helps us to improve our entrepreneurship skills. Personal vision and a mission
by means of putting us on top and observing as we are the finder of solution for problems.
This helps us to work hard and to find and analyze a solution for problems of the company.
Characteristics of entrepreneurship:

 Need for achievement

 Willingness to take risks

 Self confidence

 Communication skills and the ability to share ideas and persuade others

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 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 the
competition

 Self-motivated and disciplined

 Adaptable

 Innovative thinking and creative

 The ability to multi-task

 Able to take responsibility and make decisions

 The ability to work under pressure

 Perseverance

 Competitiveness

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 CHAPTER FIVE
5 CONCLUSION AND RECOMMENDATION
5.1 CONCLUSION

Indefense logistic mean branch and maintenance branchour on job training program in this
maintenance industry we were able to see the overall structure, background, the workflow,
and the overall activity of the company. During this time we took part in some of the
assembly, maintenance, and welding activities of the industry and improved our practical
skills. We were able to put our theoretical skills into practice and improved our team playing,
leadership, entrepreneurship, and work ethics related skills. We tried to identify the good
qualities of the company like: -
 Production efficiency means in one day how much cars are service and maintenance
dad
 Good security condition,
 Good management,
 Good workers diligence
 Good workers punctuality.

The limitations and problems are:-

 Storage of material

 shortage of knowledge how to use materials

 Shortage of knowledge how to make safety, during disassembling, during washing,

during welding, during assembling etc.

 Continual interruption of work due to electrical power failure which results in delay
in delivery.
 The spare parts and the vehicles get corroded and damaged due to storage in open
outdoors
 There are no enough safety materials in welding and maintenance shops.

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 5.2 RECOMMENDATIONS

As a suggestion to improve the company‟s ongoing development, I think the following points
are vital:

 The host company supervisors have lack of continuous follow up of the project. So
this should be improved.
 Regarding to provision of safety material and medical facilities; our hosting company
doesn‟t provide enough safety material (safety shoes and cloth) except for project
super visor and site Forman and medical services for every workers of the site. Since
man power is essential for every task anyone who concerns the issue should solve
such type of basic problems.
5.2.1 RECOMMENDATION FOR THE UNIVERSITY

 Another matter that needs change is the teaching system in our opinion which only
focuses on the theoretical aspects of the subject. The attachment program helps in
incorporating the practical knowledge to the educational process and it is a good start
but we don‟t think only 4 months is enough to supply students with sufficient
practical knowledge. Practices have to be all year long process and have to go hand in
hand with the theoretical learning. It will help students to easily visualize what is
being told in class.
 Check and observe the shop before the intern start the practice
 The other recommendation is for UOG We strictly present my thanks for preparing
this internship program for the students to have practical experience. This should be
provided for the for all technology faculty students.

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