UNIVERSITY OF GONDAR

INSTITUTE OF TECHNOLOGY
Department of mechanical and industrial engineering
A Internship Report and Project on Design of Wheel Dolly with
Combination of Gearbox Liter

Advisor: Mr. Tesfahun Compiled by:

Abdumalik adem--------0007/09
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 PRESENTATION LAYOUT
PART ONE- INTERNSHIP REPORT
 Background of the company
 Overall organization and Work flow
 Working sections and tasks executed
 Overall benefits of internship
 Conclusion and Recommendation
PARTTWO- Project on design of Wheel Dolly with combination of Gear
Box Lifting
 Introduction
 Methodology
 Design Analyses
 conclusion and recommendation
 PART- ONE
INTERNSHIP REPORT

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 1. Background of the company
1.1Company Profile
 Muna Muhammed garage is an independent The maintenance and repair company that
deals with passenger and light duty vehicles such as, automobiles, jeep, minibus, bus, and
pick up of various brands.
 One of the oldest auto service provider in the city, was founded in 1978 by Mr. Muhammed
birhan with initial capital of 1000 birr.
 located at Bahr dar, situated in a total surface area of approximately 1200 square meters. It
is close to the motorway, and easily accessible from different directions.
1.2 Services of the Company
 Prieodic maintenance service
 General pairs
 Body and paint Repair
 Professional pre purchase used cars inspection service
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1.2 Customers of the Company
 Regional Government Bureaus
 NGO

 Privet Companies
 Individuals

 Hotels

Some of the major fleet Main fleet Customers

 Tiret corporation
 Amhara police Comission
 Ethio-Telecom
 Jacaranda, Unison, Blue nile, Alwaq and Azwa hotels
 Ethiopian catholic church bahirdar branch
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2. Overall Organization and Work flow

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 3.Working Sections and Work Tasks Executed
3.1Working Sections
The maintenance and repair company has mainly two sections where operational procedure
is made by each section to fix the customers vehicle.
1.General services section
• Engine maintenance and repair
• Power Transmission maintenance and repair
• Chassis systems maintenance and repair
• Electrical system maintenance and repair
2.Body and paint repair section
• Denting
• Painting
• Welding
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 3.2 Work Tasks
3.2.1 Cleaning of disassembled parts and equipment
maintenance

• Washing dismantled engine components, drive

shafts, bearings and hub assemblies with diesel and
dry with cotton waste or using air from an air
compressor
• Cleaning brake pads, spark plug, battery terminals,
brake drum, flywheel, wheels etc. with sand paper,
scraper, wire brush and cotton
• Cleaning fuel, oil, air, AC filter with pressurized air
• maintenance of working equipment’s includes
cleaning, adjusting, storing tools safely and accessibly
Washing engine head with compressed air9and diesel
3.2.2 Performing minor Engine tune up
• Adding oil and coolant and Checking their
condition
• Checking state of charge of batteries and
charging them
• Checking belt tensions
• Checking the electric cables and switch for any
loose connections
• Replacing worn filter elements, blown fuses
• Inspecting for any leak
• Check the hoses that connect radiator and engine
• Inspect for any wear and crack in the components
• Tightening bolts and nuts
A technician performing engine tuneups under the hood
 3.2.3Replacing worn parts
Components will usually be removed, inspected and replaced repaired when a defect
has been diagnosed. Many forms of maintenance require replacing worn out parts that
may have taken a beaten over the miles. With assistance from technicians I was
assigned to do the replacements of parts such as
 fuel filter
 oil filter
 shock absorbers
 struts
 brake pads
 spark plug
 rubber boots
 bushes etc.

Inserting a new air filter

 3.2.4Changing lubricants and fluids
Oil is the principal lubricant used in automobiles and its main purpose is to reduce
friction and prevent wear. In engines, differential and transmission systems the oil
performs an additional function, which is to conduct heat away from moving parts
and thus help to keep a system cool. Changing lubricants is a regular routine. I was
also given a task in adding and changing fluids such as brake, power steering,
coolant fluids.

Adding engine oil through oil filler cup 12

3.2.5 Repair works
These tasks are after a component shows malfunction or fails to operate the parts are
diagnosed and repaired for any malfunctions. Together with technicians I solved the
following problems.
 Engine overheating
 Brake binding and overheating
 Fuel leaks
 Engine starting problems
 Suspension issues
 Hard Steering

A technician Resurfacing starter motor housing

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3.3 Procedures, methods and tools Used in performing my task
3.3.1Procedure of Repair work
At this stage it is important to emphasize the need to be methodical. A simple but effective
approach is diagnostic work know as six step approach. I used this six-step approach maybe,
recognized as an organized approach to problem solving in general.
1. Understand the problem.
•Receive the customer and listen carefully to their description of the problem.
•Understand the symptoms and check to ensure that they are understood before
proceeding.
•Make notes of details.
•Carry out checks and make a visual examination.
2. Analyze the evidence - firm up the diagnosis.
3. Locate the fault - carry out tests to confirm the diagnosis.
4. Find the cause of the fault - use test equipment.
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5. Perform the necessary repair - consult the customer if there are alternatives.
6. Carry out thorough tests to ensure that the fault is cured. Ensure that the vehicle is
properly prepared for return to the customer
3.3.2 Tools Required
There are two division of tools based on the source of energy applied on the tools
in the maintenance and service of vehicle. These are hand tools at which we apply
our force to operate with them, and power tools which operate by electric,
compressed air or hydraulic pressure.
The most important hand tools
Wrenches: are used to turn nuts and bolts. Socket wrench, open end, closed end and
combination wrenches
Screw drivers; used to drive or turn screws. it can be flat or Philips head.

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Pliers ; used to grip different size of materials.
Snap ring remover; used to remove rings from the assembly
Hack saw: used to cut metals by replaceable teeth.
Chisel; they are driven by hammer to cut metal by holding it in one hand and
the hammer by the other hand.

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Some of the power tools
• Car jacks
• air Compressor
• Welding machine
• Engine hoists
Measuring and diagnosing tools
• Vernier caliper
• Feeler gauge
• Micrometer
• Scan tools
• Multimeter
• Battery tester
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4.Challenges Faced and Measures Taken to Overcome
The Challenge
Challenges
• There was a communication problem with technicians because they use some Italic nomenclature.
• There was no a safety material for intern students
• Shortage of working tools.
• There is no an engineer who gives scientific analysis
Measures Taken
• fulfilling safety materials by my self
• Reading books, repair manuals
• adapting myself with the working environment
• being patient to get something what I want
• By asking different senior & chief technicians
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 5.THE OVERALL BENEFIT GAINED FROM THE
INTERNSHIP
Improving my practical Skill
Upgrading Theoretical Knowledge
Team Playing Skill
 Solving problems
Developing entrepreneurship skills
Improving Leadership Skill
Understanding about Work Ethics

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 Conclusion and Recommendation
Conclusion
My 4months industrial attachment as a junior technician at muna muhammed
garage was a huge success and a great time of acquisition of knowledge and
skills. My training here has given me a broader view to the importance and
relevance of Mechanical Engineers in the immediate society and the world as a
whole, as I now look forward to impacting it positively after graduation.
Recommendation
1. Regarding the company

2. Regarding the department

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 PART- TWO
DESIGN OF WHEEL DOLLY WITH THE
COMBINATIONOF GEARBOX LIFTING MACHINE

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 2.1 Introduction
In my stay of four month internship in Muna Muhammed Garage as Engineer i
investigate the problem and try to solve. The motive of this project is to design a
machine to solve the company’s problem in lifting and removal of wheel and
gearbox. There for the solution that I proposed for this problem is designing a
machine, which performs the above two tasks easily, with in less time and
requiring low man labor. The system is operated with foot pedal and designed to
lift a weight of 7000N.
A wheel dolly is a machine which is used to remove and assemble the wheel. It is
one of the easier and safer methods to put in and pull out the wheel. Wheel
dollies have two applications. These are
• For Towing service
• For wheel assembly and disassembly
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 2.2 Problem statement and justification
• During my internship stay I faced many problems. There is no wheel dolly which
is used to assemble and disassemble the wheel and No gear box installing and
removing machine. Among these problems, the gearbox lifting and overhauling
device is the severe one. As the gearbox weight is too heavy to lift, six or more
peoples are needed to overhaul or lift the gearbox. So, this way takes more time to
lift the gearbox, it uses more human power, and risky for severe injury. So I have
interested to design is about wheel dolly with combination of gear box lifting
machine.

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 2.3 Working principle
• It contains 3 major components thus are the hydraulic system, lifting arm and
rolling contact bearings. The wheel (tire) is putted on the lifting arm and lifted
using a hydraulic system. The bearing is used to roll the wheel in order to make it
on the right position for removing and installing purpose. The machine is also
used to lift the gear box. During lifting the gear box, I need to use a lifting table
which is assembled and disassembled with the lifting arm of wheel dolly. Both the
wheel and the gear box should not be above 700Kg since, the machine is capable
of handling a weigh up to 7KN.

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 2.4 Objectives
General objective:
The general objective of the project
is to design foot operated wheel
dolly with a combination of
gearbox lifting machine to that can
operate with less time and requiring
low man labor
Specific objective:
To design all the components of a hydraulically
operated wheel dolly & gearbox. That means to
design:-
• To design the hydraulic cylinder components
• To design pump (plunger)and foot pedal
• To design To design helical spring
• To design rolling contact bearing
• To design Lifting arm and fixed frame
• To design upper table and pin
• To select caster wheels
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 2.5Methodology
2.5.2 Data collection
• Direct observation
• Interview concerned people
• Searching internet
• Referring different guide books, manual, written document related to the project.
2.5.3 Material selection
The materials can be selected by considering the availability of the material,
suitability of the material for working condition and cost of the material. The
material selected should be hard enough to withstand the design load and it should
be ductile enough so that it does not fracture under a sudden application of force.
Therefore by considering of the above points I will select the perfect material for
the design components.
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 3.6. Design Analysis
1.Hydraulic Cylinder design
The material selected for cylinder components is mild steel SA36
a. Ram :- Select the ram diameter from the standard table, then calculate
• Length of the ram
• Buckling load and check the stress
b. Ram cylinder :- Using the ram diameter, calculate
• Thickness of cylinder
• Outer diameter of cylinder
• Pressure that acts on the cylinder and
• Buckling load

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c. Reservoir
Calculate
• Volume of the reservoir, outer diameter & thickness of the reservoir.
• Check stress using maximum principal and shear stress theory.
d. Reservoir head
• Using elliptical head equation calculate thickness and height of the head.
• Calculate the stress induced on the head which are:-
• Stress at the center (longitudinal) and stress at the tangent line.
e. Opening
• Calculate the diameter of opening using diameter of ram
• Calculate the hoop stress around the opening area to check whether it is safe or not

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f. End cap of cylinder
• Selectthe value of coefficient ‘K1’ for mild steel from the table and then calculate the thickness
of the plate.
2.Design of Helical spring :By selecting the end materials(Carbon steel) connections calculate:-
• Solid length of the spring
• Free length of the spring
• Spring index (C)
• Spring rate (K)
• Pitch (P)
Check the stress induced in the spring wire:-
• Torsional shear stress
• Direct stress
• Resultant stress

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3.Lever (Foot Pedal)
Taking the effort applied on the lever = 25Kg and Length of lever = 300mm , then
calculate :-
• Spring force (Fs)
• Force acting on the plunger (Fp)
• Bending stress and bending moment
Then using bending moment and bending stress calculate the diameter of lever.
4. Design of Plunger (pump): Using the force applied on the pump calculate :-
• Diameter of the pump
• Length of the pump
5.Design of Pump cylinder: Using plunger diameter and tensile strength of the material
calculate: -Thickness of pump cylinder
-Outer diameter of pump cylinder
Check stress using –Maximum principal stress theory and shear stress theory
6. Design of Rolling contact bearings
Select the standard bearing dimensions from the table and calculate;
• Stress induced in the bearing (σ )
• Equivalent radial load (F)
• Rating life (L)
• Dynamic load (C)
• the maximum working time of the bearing
compare this dynamic load(C) with the basic static and dynamic bearing load
capacity and check whether the bearing is safe for dynamic load or not.

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7.Design of Lifting Arm
Using the given data, dimension of the arm and mechanical properties of the selected
material(Mild steel AISI1018 MILD STEEL/LOW CARBON STEEL). Calculate;
• Deflection and slope of the arm

• Bending moment and bending stress induced on the arm

Check the arm whether it is safe for stress or not using:-

• Maximum principal stress theory
• Maximum shear stress theory
8. Design of Upper table: Using the given data, dimension of the arm and mechanical
properties of the selected material. Calculate;
 Deflection and slope
 Bending moment
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 Bending stress
Compare bending stress with the material strength check also for deflection.
10) Design of Fixed frame
Using the given data (maximum bending moment), dimension of the frame and
mechanical properties of the selected material(Mild steel AISI1018 MILD
STEEL/LOW CARBON STEEL). Calculate;
• Bending moment
• Moment of inertia
• Bending stress
Compare the bending moment and the materials strength.
11)Selection of castor wheel; By considering the load and Floor condition
select caster wheel.

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11)Selection of castor wheel; By considering the load and Floor condition
select caster wheel.

Assembly of the machine

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 Conclusion and Recommendation
Conclusion
• the design helps workers to reduce the man power which will be required to fix and
removing a gear box and also wheel. the design is capable (lifting capacity) up to
7000N This means it can be used for both light and heavy truck. The design included
analysis of 13 parts, checking of failure, complete dimensions of parts, solid work
drawing of parts and assembly. With the design two different application can be
operated with one machine.
Recommendation
The design is good in many ways, but it has the following limitations
• lifting capacity (750 mm)
• the machine is made to move by human force
• absence of tilting mechanism
So, I recommend the design should be improved that were not implemented in this
project 35
My 4months industrial attachment at muna muhammed garage was a huge
success and a great time of acquisition of knowledge and skills. Through my
training I was able to appreciate my chosen course of study even more,
because I had the opportunity to blend the theoretical knowledge acquired
from school with the practical hands-on application of knowledge gained here
to perform very important tasks. I have also been able to improve my
communication and presentation skills and thereby developed good
relationship with my fellow colleagues at work. In general, the internship
program allowed me to grasp practical skills, theoretical knowledge and
management and leadership skills.

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Thank you

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