Professional Documents
Culture Documents
Declaration
First of all, I express our heartiest grate fullness to Almighty GOD for his countless blessing,
which enabled us to complete this successfully. This final internship document is an independent
work of students that take internship program in the hosting company of Anagaw Getachew
Turno House Enterprise. All writings in this document contain things that are done by our effort
under the guidance of our company supervisor Mr. Eshetu and Mr. Alemtsehay and our adviser
Mr. Ashenafi, family, fried
Acknowledgement
In this document preparation I would like to thank and express my grateful gratitude to DEBRE
BREHAN Institute of Technology for giving this chance to develop my practical skills,
ANGAW GETACHEW TORNO HOUSE for allowing us to work in Motor and Manufacturing
class and their great support in the day-to-day activity by a good respect and appreciation,
faculty and company advisor for their valuable comments, suggestions, constructive criticisms,
and great support for my project work. In addition to these I heartily thank my families and
friends for their financial and moral support.
Abstract
The exponential development in technology and industry boosted the productivity of industries
to such unprecedented level that caused an increase in the number of automobiles produced for
both industrial and personal use.
As the amount of fuel is limited more studies are directed to reduce the fuel consumption of the
automobile. One way of reducing the fuel consumption is the use of efficient and accurate fuel
injector and to ensure that the fuel injector is efficient and accurate the fuel injector tester is quite
handy tool to provide that platform. Another aspect is the environment concern that the emission
of unburn fuel, CO and Co2 can be reduced by using accurate and efficient fuel injector.
The purpose of our project is to construct a design fuel injector tester to verify if a fuel injector is
accurate to the manufacturer standards or not.
Contents
Declaration......................................................................................................................................II
Acknowledgement.........................................................................................................................III
Abstract..........................................................................................................................................IV
CHAPTER ONE..............................................................................................................................1
1 BACKGROUND OF THE COMPANY......................................................................................1
1.1 Company brief history............................................................................................................1
1.2 Vision.....................................................................................................................................1
1.3 Mission...................................................................................................................................1
1.4 How you get into the company...............................................................................................2
1.5 Section of the company I have done......................................................................................2
1.6 Tasks I have been executing...................................................................................................3
1.7 Engine shop............................................................................................................................3
1.8 Service Render Work Shop....................................................................................................4
1.9 Body Shop..............................................................................................................................4
1.10 Maintenance and Repairing Shop.........................................................................................4
1.1.1 Electrical shop..................................................................................................................5
1.1.2 Manufacturing Shop.........................................................................................................6
1.1.3 Machines Found in the Work Shop..................................................................................6
1.1.4 Challenges and Problems I Have Been Facing While Performing Tasks........................7
Measures Have Been Taken to Overcome the Challenges..............................................................7
1.1.5 Work Flow in The Section...............................................................................................8
CHAPTER TWO.............................................................................................................................9
2 OVERALL BENEFITS GAINED FROM INTERNSHIP...........................................................9
2.1. Benefit gained from practice skill.........................................................................................9
2.2. Benefit gained according to theoretical knowledge skills.....................................................9
2.3. Benefit gained in terms of improving my interpersonal communication skills..................10
2.4. Benefit gained in terms of improving my team playing skills............................................10
2.5. Benefit gained in terms of improving my leadership skills.................................................11
2.6. Benefit gained in terms of work ethics looking at Work Ethics Skills...............................11
2.7. Entrepreneurship skills........................................................................................................12
CHAPTER THREE.......................................................................................................................13
3 INTERNSHIP PROJECT...........................................................................................................13
CHAPTER ONE
1.2 Vision
To be one of the open three up to five branch in Amhara region for after 20 years.
• Responsibility
• Transparency
• Giving dynamic service for customer
• Preparing for change
• Working with educated knowledge and transparency
• Safety
• To be the leading Public Transport service provide in the city
1.3 Mission
To ensure satisfaction of the society by maintaining and overhauling different models of
vehicles with better efficiency, quality and at lower cost.
To increase manufacturing capacity and capability for tools, spare parts and auxiliary required
for overhaul and Assembly activity.
• Giving comfortable, modern, active transportation service.
• Working with other means of transportation to give comfortable, active service for people.
• Giving confidential automotive technology service.
• Building company that produce spear part of automotive.
The section I was working is under equipment maintenance room, auto mechanical maintenance
and motor maintenance class. I was working as auto mechanical and Manufacturing for three
months starting from February up to October 30. I try to identify materials which are appropriate
for my intern ship.
Checking the spark of starter plug if it is included and install wires around the starter plug
Maintain connections of wires of display gauges
Checking and maintaining the connection of dynamo meter
Plug lights and fans
sheets to punch out shapes. These shapes may be the desired end product or they may be the
waste product. While shearing metal sheets is most common, other metallic objects may be
processed in one of these machines. A sheep-shearing machine may be anything from a pair
Bending machine, it is a machine used for the hot or cold bending of parts from flat sheet, bar,
tubular, and rolled stock. All-purpose bending machines are of several types, including three-
and four-roll (rotary) machines, roller machines, and machines with a turning traverse, template,
or arm. Three and four roll machines are used for bending sheet stock into cylindrical and
conical shells and arc-shaped components of small clippers similar to ones found in a barber
shop to a large machine that features an external power supply and multiple clipping arms.
1.1.4 Challenges and Problems I Have Been Facing While Performing Tasks
Like most of workshops in Ethiopia, these shops have its own challenges which drag the shops
work quality and productivity. Among these challenges the following can be considered as the
major ones.
• There was a communication problem with mechanics because they often use Italic jargon
words for naming tools. Some manuals are even prepared in Italic since they are
manufacturer there.
I also tried to adapt the working place by taking measurements like communicating with
workers, selecting cloth and shoes which are related to the environment and working
conditions.
Through time I experienced to tie & lose nuts & bolts and assemble & disassemble of
vehicle parts with the help of skilled and experienced technicians who were willing to share
their skills and knowledge’s.
The first work is just visual inspection and looking for the problem from the vehicle and also
checking the oil changed date and also reading the check engine code if any problem is facing
the engine. Since the buses are new and uses ECU, it is easy to see the problems from the dash
board.
After understanding the problem, the mechanics check if the parts can be repaired and solved
without any wastage but if the parts must be changed, they request for the purchase and
warehouse and then assemble the new part and test the bus after assembly.
CHAPTER TWO
Any aspiring Mechanical Engineer should know that the field demands practical skills.
Concerning Practical Skills, being assigned at the motor section was somewhat helpful in
developing this skill. Throughout my stay, we have been assembling and disassembling an
engine and gearbox, and that makes us to gain some practical skill. After this intern ship we
know how to assemble and disassemble.
Assigned in electric section also helpful in developing my practical skill, in electric section also
there is assembling and disassembling an alternator and a starter.
The things that we learn in theoretical makes everything easy to understand everything. In this
intern ship we sow the things that we learn in theoretical and it’s increasing our knowledge.
Theoretically we learn about flywheel, gearbox, bearing, piston, crankshaft, camshaft, clutch etc.
… watching the materials in person makes everything easy. For example, we have a deep
knowledge about a flywheel and know how it works, how it can be assembled and how to use it.
And we sow gearbox also, we sow how every gear are assembled and disassemble also know
how it works and we gained so much knowledge.
This intern ship helps me to learn new things that we haven ‘t learned in theoretical or haven ‘t
seen before. For example, the things that we learn are injection pump, oil pump, cooler and etc.
we know how to assemble them and know what is there uses also where to assemble them. In
electric section also, we learn the things that we didn’t learn in theoretical which are starter and
alternator. We know how to assemble and disassemble both and know the uses and function. In
this intern ship we didn’t gain knowledge only the thing we learn in theoretical, we also gain a
new thing that we didn’t learn in theoretical. So, we can say that this intern ship helps us to
know new things and increase the knowledge that we have been learning in the theoretical
lessen.
When we were enrolled at the company, our first goal was to develop our interpersonal
communication skills. It is obvious that this line of work (Mechanical Engineering) requires such
skill. This would enable us to communicate with people from different walks of life.
In this regard, we had great help from our supervisor. Starting from the first day, he was very
easy to talk to and communicate with. We heard that Supervisors aren’t very welcoming about a
student following them everywhere they go while they work. We were also told they work
racing with time every day so we were very much suspicious about creating a pleasant
communicating environment with our supervisor.
To our surprise, he was more than welcoming. He said we can improve my skills mainly by
focusing on getting familiar with the language used at the section. He highlighted that my
greatest problem would come while communing with the daily workers. The words being used at
the section some of were different from what we know theoretically.
Furthermore, developing a friendly, open personality was also an essential element for a better
understanding between staff members. Our supervisor was a shining example as we closely
followed his daily activities. He treated all those who were lower than him with the same respect
he showed for his boss. We learned even the smallest “hi” in the morning had an effect.
At the end of the day, we are confident to say we have learnt to show respect any employee;
even if it a guard, a daily worker or a Project Manager. Learning some terms and the language a
daily employee uses eased my communication and lifted any communication barriers created
otherwise. we can also safely say we learned to give much emphasis to mutual understanding
with any staff member.
When one develops interpersonal communication skills, it is easier to communicate with a team
and develop team playing skills. Understanding peer groups is all part of the communication
process.
Team play is much more than individual play, because in team play, we can share ideas and if
any one makes mistake, we can correct each other. But in individual no one is perfect so if we
did mistake no one will correct me. Some people went to do individual but we rather do team
play. This thing helps us to develop our team playing skills to some extent. We learn the
different idea comes in many directions. We usually used to do things individual but after
internship we understand working in group ‘s batter than working with individually for gaining
different ideas.
If one chooses to actively take part in what goes on the team, he/she will take active role to serve
and benefit the team. This can be considered as a developed Leadership skill. There were also
opportunities in which we developed my leadership skills one of them is when new interns
joined the company, we were assigned to explain every single detail that we know and control
and guide their work when they were given to see and understand everything. we tried to make
everything as clear as possible by giving examples to avoid confusion.
Problems in the company come in different direction, on different period of time. Thus, a person
who is in the position of leadership seeks optimal solution to problems and should be smart
enough to manage those individuals whom he/she is leading. Here in our every place is occupied
with the right person, this person has a responsibility so they do their work effectively.
Therefore, no one gives us a position to experience this thing. But we learn more from them how
they are good on lieder ship and how to coordinate their team members to solve any problem.
2.6. Benefit gained in terms of work ethics looking at Work Ethics Skills
The first and major responsibility of a disciplined employee is to have work ethics. The benefits
of work ethics go as enormous as organizational levels. Developing work ethics helps for the
creation of a smooth working environment between employees.
One quality of an ethical employee is respecting time and coming to work early. we have been
aware to the time schedules of a school system for over fifteen years so getting to work in the
morning and taking a lunch break to come back to work was a bit hard to adapt. However, one
has to master such skill so that they can carry out tasks and assignments on time and without
interval.
Ethical conduct of workers is very important for developing healthy working environment and
increasing productivity. From this perspective, we‘ve gained a valuable lesson that transparency
and carefulness are two very important work ethics one needs to tolerate and live by. Respecting
the guidelines of an employing company is imperative. This includes mastering the skills of
work ethics. We were never disrespect of Qualities like integrity, commitment and honesty but
we have developed them more at my stay as they are the symbols of a good and efficient
employ.
A wide range of skills are seen as entrepreneurial and useful to entrepreneurs, these include both
personal traits and skills such as: management skills, communication skills and the ability to sell
ideas and persuade others, the ability to work both as part of a team and independently, self-
motivated and disciplined, the ability to multi-task and there are many advantages to develop our
entrepreneurship skill while we are in the intern ship.
To learn new skills and add to our knowledge base while confidence in our
abilities
Can apply some of the ideas learning in universities.
CHAPTER THREE
3 INTERNSHIP PROJECT
3.2 Introduction
Mechanical unit injector tester machine is manually operated machine which used to ensure
proper functioning of injector by testing it. The operation of this machine is manually control and
for batter to convenience this machine is converted into automatic.
This injector tester machine consists of two side, supply side and delivery side. This side consist
of following components and they are pumping system which is used to pump the fuel in to the
injector, fuel tank which used to store fuel into the injector, battery which used to control the
voltage and the current by ECU system, which means it used by harnesses but in this injector
tester there no ECU because this material is expensive so for this machine we used to common
rail.
Leaks
Leak can be through the Tapir internally or usually due to valve unable to fully close which in
both cases cause the leak of fuel from the injector if there is no leak with the fuel injector then
the problem may be in the fuel pump or distributor unable to set the timing.
Spray pattern
If the flow rate is optimized and there is no leak the spray pattern will affect the combustion of
the fuel usually spray pattern is result of change in the fuel injector nozzle projection that change
the shape of the pattern of the spray which result in decrease in the fuel combustion Efficiency
When the current from the battery flow through to the pump it will actuate the pump, then pump
will pump the fuel from the fuel tank and supply it to the fuel gallery at the same time the
electrical motor actuate the distributor that passes current to the fuel injector to actuate the
injector coil and valve that allows the fuel to be injected the amount of fuel that is injected is
collected inside a flasks along with the spray pattern which is seen through the glass of the flask.
The amount of fuel that is collected in the flask is compared with the manufacturer standard
amount of fuel 15second continuous operation; the spray pattern is also compared with the
standard spray pattern provide by the manufacturer of the injector.
Advantage
The fuel injector test has two advantages according to the view of economy and environment.
From economical point of view
A good fuel injector reduces the amount of unburnt fuel thus saves money. By optimizing the
fuel flow rate and spray pattern the combustion is a complete combustion and no residue is
formed in the cylinder than may cause any damage to the engine cylinder or the exhaust system
thus improve their survivability
From environmental point of view
A good injector reduces the emission of harmful gases to the atmosphere such as Co,Co2, and
fuel particle that are harmful to humans and all living being .as people became aware of the
environmental problem that surround our world the contribution of every human is important to
the wellbeing of earth.
Disadvantage
In case of improper implementation of the test in accurate result will be generated that may lead
to improper diagnosis that will be led to costly maintenance in the future and costly time delay.
By logical reasoning, FI being a newer tech should be better, but there are advantages and
disadvantages. The working of the Fuel Injection system is more computerized and works on a
lot of sensors. The fuel injection nozzle is provided directly in the combustion chamber.
In the workshop I perform our internship the system that they use to injector tester is single
injector tester, very old and it not effective and wastage of fuel injector. I think this project uses
in order to solve this problem simply or in order to cheek injector simply and safely. This system
allows us to use the injector for many times.
3.5 Problem solution(justification))
To solve this problem, I have proposed that a fuel injector tester or easily test injector in a short
period of time. This machine minimizes time consumption and man power, from three or four
man power in to only one man power. this machine simplifies the problem by:
Avoid more time
Highly efficient
Not tediouss
Minimise cost
Totally I have justified the problem by introducing a fuel injector tester which having some
3.6 Objective
General objective
The main objective of the project is to protect the fuel injector.
Specific objective
To design fuel injector tester.
To Identify geometrical.
3.7 Scope
The design and construction of these fuel injector tester and easily, efficiently test fuel injector.
3.8 Significance
The design of fuel injector tester is a device for test fuel injector. It comes with various
advantages, namely the following.
3.9 Limitation
There is no computer access to develop the project given by the company and to
prepare this project.
There is no free Wi-Fi access. This creates challenge to get raw data for this project.
CHAPTER FOUR
4 LITREATURE REVIEW AND METHODOLOY
The project describes the design and analysis of manually operated injector tester. This machine
is used to know how well the injector is responding for the given fuel. In old method the injector
is tested by using compressor and with hand. Sometimes it may cause loss more time and dose
not effective. In this case may be the injector to used again but does not use long time forth with
stop. Since it needs more than one person and it will make more time consuming and increases
the cost of reconditioning the injector. The workers strained very due to impracticality to check
the injector.
Also, that is not easy to check which one injector fail or damage. That it was not safe as the
worker time and injector life duration. Also, great care should be taken testing machine not to
damage the injector and loss time. Development of more than two persons to do or make the
injector and then to order from engine block is not only the great loss to the auto mobile
workshops but also the wastage of time and increased material cost resulting to increase the
overhead cost of reconditioning the injector. Most of the times it is difficult to replace or service
injector due to the location size, method of coupling, as a result, it is often times necessary to the
engine entirety to replace or repair the injector. In some instances, the entire machine must be
transported to a maintenance facility to replace the injector. However, it is desirable to replace
injector without
Requiring injector taster assembly
Increased material cost and time duration
Specifically, as we have seen in Anagaw Getachew Turno house service centre the problem
associated with injector tester and installation is not only those explained above but there is also
lack of some required standard sprinkle injector tester. Where these components are very
essential for the job the technicians order these tools from Anagaw Getachew Turno house and
waits until the arrival of the tool. As we know this consumes an additional time and also
increases overall maintenance cost by additional material cost needed to the tool. Additionally,
due to the delay of maintenance the company income will be affected. Significant of the activity
in addressing the problem stated.
Due to above listed problems we decided to design the technology of injector tester and installer
machine. This machine is simple, easy, and safe, take short period time to operate and reduce
man power,
4.2 METHODOLOGY
The project refers to planning and overseeing the tasks necessary to achieve a goal. It is
important because it insures proper expectation is set around what can be delivered. It also helps
to have better control of the variables which contribute to the well-being of the project process.
For these reasons I tried to follow some procedures which will enable the whole project to be
efficient and effective.
I need four Screws and it is the main part of the first stand that experience a tensile and torsional
shear stress due to the load applied.
Identification of a problem
Required
Diameter of the screw
Outer diameter
Core diameter
Mean diameter
The effort required to rotate the screw
Torque required to rotate the screw
In this design I select the square thread (normal series) screw because of:-
Material selection
By considering the above points I select steel alloy ASTM (class a60) for this screw design and it
have these mechanical properties;
Talking factor of safety of 2 due to the nature of the application, then allowable tensile stress and
shear stress will be
σall =σt/F. S
= 431Mpa/2
=215.5Mpa Ans
τall=τt/F. S
=610Mpa/2
=305Mpa Ans
Analysis
A little consideration will show that if one complete turn of a screw thread be imagined to be
unwound, from the body of the screw and developed, it will form an inclined plane as shown.
And by considering that the maximum load on the square threaded screw occurrs when the
frame of an engine block is at the bottom position so I take ϴ is 20°. Then the equation will
come:
Fpull=W/2tanϴ................................................................................................................ [1]
=6000N/2tan20
=8253.094N
Let dc is the core diameter of the screw, we know that the load acts on the screw (FPULL)
F pull=AC×σt.................................................................................................................... [2]
π
AC= 4 (dc)2............................................................................................................................[3]
σall=215.5Mpa
π
F pull= 4 (dc)2×σall............................................................................................................[4]
4∗FPULL
dc=√ π∗σall ......................................................................................................................[5]
4∗8253.094
=√
π∗215.5
=22.68…......................................................................................................................... (Soln,)
The screw is also subjected to torsional shear stress therefore to account for we
approximate to the nearest standard value of core diameter.
dc=23.5mm
by using his value, the pitch is taken as;
p=6mm
Outer diameter will be (do)
do=dc+p.........................................................................................................[6]
=23.5+6
=29.5mm≈ 30 mm….................................................................................. (Soln.)
And the mean diameter of the screw (dm)
P
Dm = do- 2 ...............................................................................................[7]
6
=30-
2
=27mm
Let us check the principal stress. We know that
p
Tanα = π dm ................................................................................................... [8]
6
=
π × 27
=0.0707
And we know that effort required to rotate the power screw
P=F׿)................................................................ [9]
Where, tanα is coefficient of friction between the screw and nut for poor workman
ship or very slow and in frequent motion with indifferent lubrication or newly machined
surface
Use μ = tanϕ
= 0.21 from the standard books.
0.0707 × 0.21
p =8253.094× ( )
1−0.0707 × 0.21
=123.142N……………………………………………………Ans
dm
T=P× 2 ............................................................................................. [10]
27
=123.142×
2
=1662. 417Nmm.....................................................................................Ans
16 T
τ= π ×(dc )2 ................................................................................................[11]
16 ×1662.417
=
π ×(23.5)2
=15. 471Mpa.................................................................................................Ans
Fpull π
σt = …………………. where, AC= 4 (dc)2....................................................[12]
AC
4 × FPULL
σt= ¿ ¿
π ×(dc )2
4 × 8253.672
= =19.0291Mpa............................................................................................[13]
π × ( 23.5 ) 2
σt 1
σt(max)= + √ σt2+4 τ2
2 2
19.029 1
= + √19.9462+4×15.4712
2 2
=127.67Mpa
σall≥ σt(max)
215.5≥ 127.67 ……………....................................................…………...SAFE
1
τmax= √ σt2+4 τ2
2
1
= √ 19.02912+4×15.4712
2
=67.364Mpa
τall≥ τ max
Distortion theory
σd =√ σt2+3τ2
=√19.02912+3×15.4712
=123.663Mpa
σall≥ σD
215.5 Mpa ≥ 123.663 Mpa ……………………………….……....................SAFE
tanα
Efficiency (η)= Where, ϕ=tan-1(μ)=tan-1(0.21)
tan ¿ ¿
Φ=11.86
α=tan-10.036
=2.062
0.036
η=
tan (2.206+11.86)
=0.244≈ 24.4 %
Efficiency of self-locking screw is less than half or 50 % .if the efficiency is more than 50%
then the screw is to be over hauling.
Design of Nut
In this design we have two nuts with different shape and different application but the width, the
thickness, the height, and number of threads for both nuts are the same.
Assumption
The overall dimensions are given by considering the size of the extractor & the size of the
engine block.
Assume that the load F is distributed uniformly over the cross-sectional area of the nut.
Material selection
F
Pb= ( Do 2−Dc 2 ) n .................................................................................. [1]
π
4
8253.094 N
28 = π
( 900−552.25 ) n
4
Also the height of the nut will be considered the product of pitch and number of thread plus some
clearance between the crew and the nut.
H= p×n+some clearance
=6×13+2
F p 6
Τ nut= where: t is thickness of teeth……. t= = =3mm
π × n× Do× t 2 2
8253.094
=
π ×13 × 30× 3
=2.494Mpa
F
Τ screw= ........................................................................................................... [2]
π × n× Dc ×t
8253.094
=
π ×13 × 23.5× 3
=2.866Mpa
Since these stresses are with in permissible limit, therefore design for nut is safe.
Length of the power screw=2×length of the liner+ some clearance between the housing and the
liner; when the liner is fully extracted +the product of pitch and number of teeth of the nut
=2x360+40+13x6
=838
Design of plate
Plate is one part of the stand. It if used to get mechanical advantage roughly speaking it is a rigid
rod moving about some fixed point or axis.
This plate is mounted to upper the bottom of the stand and also to inter the stand with less effort
to facilitate the application of force in a designed direction.
Assumption
There is a limitation of application of force on the plate exerted to and inter someone
Assume that 200N is applied by a person in each handle=400N.
Material selection
We select a gray cast iron AISI 1040 for this design of plate
This material special character, better thermal conductor
Higher level of vibration damping
Damping capacity that is 20-25 time higher than steel
Tensile strength ultimate – 700mpa
Tensile strength yield – 420
Shear stress –400
τ 400
τall= = = 200Mpa
F .S 2
Analysis
First to find the angel between injector and connector
Injector length =8.2
Connector length = 5cm
By Pythagorean theorem
a2 = √ c 2−b 2................................................................................................... [1]
a2=√ 82−42
a2= 6.93
ϴ = tan-1 (opp/adj)
ϴ = tan-1(6.93/4)
ϴ = tan-1(1.732)
ϴ = 600
Or
cosϴ = opp/hyp
ϴ = cos-1(4/5)
ϴ = 600
Design of the bottom plate
The following measurements are what we used but should be confirmed. The best was to make a
bottom plate, or have it made at a machine shop by using the actual new plate for measurements.
The most important is the area of plate they have two plate must be as close as possible to the
injector tester stand it is fit to each other.
Plate 1
Plates are 15 cm thick
Plate hole 12
Injector hole 6
Connector hole 6
Diameters injector hole 4cm
Diameters connector hole 2cm
Total area
AT = L*W.................................................................................................................. [1]
L = 100cm
W = 15cm
AT = 100*15
AT = 1500cm..................................................................................Ans
But the next area is less than the total area because the there are 14 hole, on the plate
= 25.13cm2.....................................................................................................................Ans
A = Aj*6.................................................................................................................. [3]
= 25.13cm*6
= 150,78cm2.........................................................................................................Ans
AB = 2 πr 2∅=2cm r = 1cm N =2
AB = 2π*12N= number of bolt hole
AB = 6.283cm2
The net area of the plate – 1
A1= AT – (Aj+AC+AB)
A1= 1500cm2 – (150.78cm2 + 37.698cm2 + 12.566cm2)
A1= 1298.96cm2
Change in meter
1m = 100cm
1m2 = 102cm2
1cm = 10-4m2
A1 = 1298.96*10-4m2
A1 = 0.1298.96m2
Plate – 2
Total area
AT = L*W.............................................................................................. [1]
= 100cm*15cm
= 1500cm2.................................................................................... (ANS)
Hole – 1
∅=2cm r = 2cm N = 6, number of injector nozzle
AN = 2πr2............................................................................................................... [2]
AN = 2(π*12)
=6.283cm2................................................................................................... (ANS)
The total area of the nozzle hole
A= AN*number of injector nozzle............................................................................................ [3]
A = 6.283cm2*6
A = 37.698cm2...................................................................................................................... (ANS)
Hole 2
∅ = 2cm
N = 2 (the number of bolt)
AB = 2 π r 2 ..................................................................................................................... [4]
AB = 2 π (1 )2
AB = 6.283cm2........................................................................................................ (ANS)
The purpose of pump in the project is to push the fuel from the reservoir to the injector
And the fuel pump is to create adequate pressure, so that the injector with also deriver the correct
amount of fuel, no matter what the operating condition.
For the vehicle they are standard length and weight for battery and fuel pump
The length of battery = 9-10inch
The width of battery = 5-7inch
The high of battery = 8-9inch
Then, the purpose of pump in this project draws the fuel from the tank through fuel lines and
delivers it through a fuel filter to either a carburettor or fuel injector and finally to the cylinder
chamber for combustion.
The standard size of pump
Length of pump = 133,5mm
Diameter [1] of pump = 8mm
Diameter [2] of pump = 8mm
Current strength = 2A (number of connectors 2)
Material selection
Material with less cost but sufficient strength is selected.
By considering the above proses grey cast iron ASTM (class a60) for this screw design and it
have these mechanical properties.
By using allowable tensile stress and the maximum load exerted on the stand which is720KN
Cost Analysis
Cost analysis is one of the basic needs for any material in order to design the material in a
Minimum amount of cost because of cost minimization is one of the basic goals of any
Engineering methods and also it helps to distribute the goods to the customer in easily due to
This. The manufacture and material cost for this machine are estimated as below.
CHAPTER FIVE
RESULT AND DISCUTION
power screw
maximum load applied to the injector is 6KN
core diameter.
dc=23.5mm
Outer diameter will be (do) =29.5mm≈ 30 mm
mean diameter of the screw (dm) =27mm
Nut
Plate 1
Plates are 15 cm thick
Plate hole 12
Injector hole 6
Connector hole 6
Diameters injector hole 4cm
Diameters connector hole 2cm
Total area= 1500cm square
Hole – 1 =6.283cm2
Hole 2 = 6.283cm2
battery
fuel pump
FRONT VIEW
SIDEVIEW
switch
battery
Common rail
Fuel pump
TOP VIEW
FULL
ASSEMBLY
CHAPTER SIX
5.1. Conclusion
The internship period plays a great role to relate student’s theoretical knowledge with
practical skill. This helped us to know my strengths and areas for improvement by
overshooting the future career with respect to my field of study. Also, I know the
application of mechanical machines which are found in industrial environments better
than before.
Generally During our internship period: -
➢I have able to understand that most of mechanical machine maintenance
I have seen maintenance of engine.
➢I have seen the assembling and maintenance shops
➢I have seen practically how-to assembly and disassembly of heavy-duty trucks
➢I have practically checked our knowledge of maintenance and testing section
➢I have seen how electromechanical system and sensors have been used in automation.
➢Generally, I have seen a lot of practical works that I have learned theoretically.
5.3 RECOMMENDETION
During the intern ship period we have got a chance to observe so many interesting knowledge ‘s
that can help us for outside of school life. From those some of them need to be improved, some
are listed below.
The main problem is availability of spare parts in the store room. Some parts will not be bought
on time. This makes delay on finishing time. Parts in the store room will not be stored properly
they may not be found when they needed and they may be damaged from improper storage. Like
bearings, bolts, valves etc.
We observe that the removing of some parts is not safe it takes much more time so if the
company uses our machine, it can solve these types of problem.
REFERENCE
1.Textbook of machine design, R.S Khurmi, 2010
2.Strength of material, 4th edition, William A. Shash, McGraw-Hill.
3.Shingles Mechanical Engineering Design, Eighth Edition, Budynas−Nisbett, McGraw-Hill.
4 https://www.howacarworks.com/basics/how-a-fuel-injection-system-works.