INTERN Project Final PDF

INTERNSHIP PROJECT 2014
Acknowledgment
It is a great pleasure to thank for all people who helped us while doing our design project here in mesfin
Industrial Engineering (MIE).
Our first thanks goes to our university advisor Ins. Abraha and company advisor production manager
Ato. Kidane for his excellent guidance in our Dish end maker machine design.
And we want to thank to Ato.Meargu from Human resource department for his excellent guidance and
help in taking the overall view of the company MIE and in figuring out problems found in MIE
.
At the finally we want to thank to our company supervisor Engineer Michielle. And to all workers of
MIE for their brotherly and sisterly help in knowing the operation of the machines found in MIE.
At the end we would like to thank to our friends who come from different Universities of Ethiopia for
their teaching experience sharing while our internship time at MIE .
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Abstract
MIE is one of the leading companies in Ethiopia which is found in Tigray region at Mekelle city. The company
is known by producing of Liquid cargo trailers, dry cargo trailers, sugar plant components, cement plant
components, petroleum reservoirs oxyacetylene supply and pre engineering building and others. The for in order
to produce those products MIE uses Different machines, materials, human skills and methods so during the
internship we observed different problems in the company.
The main problems are:
o Dish end preparing machine
o Have not enough roller conveyer for long sheet metals
o Material handling i.e. storage and transporting problems
o Painting mechanism
o Mechanical lift
So to minimize such problems we decided to do our project on designing a machine for manufacturing dish end.
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Contents
CHAPTER ONE .....................................................................................................................................
1. Background of the company .................................................................................................................... 5
1.1.Vission .....................................................................................................................................6
1.2.Mission ....................................................................................................................................6
1.3.Values ......................................................................................................................................6
1.4.Objective of the company .........................................................................................................6
1.5 Main products and sectors……………………………………………………………………………………………..………….7
1.5.1Transport sector……………………………………………………………………………………………………………..7
1.5.2 Energy sector..……………………………………………………………………………………………………………….8
1.5.3 Industrial sector…………………………………………………………………………………………………………….8
1.5.4 Construction sector….……………………………………………………………………………………………………9
1.5.5 Electromechanical and HVAC…..…………………………………………………………………………………….9
1.5.6 Agricultural sector…….…………………………………………………………………………………………………10
1.6 Over all organizational structure of the company …………………………………………………………………..11
1.7. Organizational work flow of MIE ……………………………………………………………………………………………12
1.8. Over all internship time..…....………………………………………………………………………………………………….13
1.9. Over view of the company………………………………………………………………………………………………………14
CHAPTER TWO ....................................................................................................................................

2. Dish end maker machine..……………………………………………………………………………………………………………..20
INTRODUCTION ............................................................................................................................ 20
2.1.Short summry of the project ................................................................................................... 20
2.2.Problem statment ................................................................................................................... 21
2.3.Objective of the project........................................................................................................... 21
2.4.Methodology.......................................................................................................................... 21
2.5.Limitation of the study ............................................................................................................ 22
2.6. Scope of the study ................................................................................................................. 22
2.7. Working mechanism…………………………………………………………………………………………………………………23
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2.8.Design analysis ....................................................................................................................... 24

2.8.1. Design of piston rod ................................................................................................... 26
2.8.2. Design of cylinder ...................................................................................................... 26
2.8.3. Design of flat end cover.............................................................................................. 31
2.8.4. Design of the supporting beam................................................................................... 34
2.8.5. Design of the supporting columns ............................................................................... 47
2.8.6. Design of the table ..................................................................................................... 51
2.8.6.1. Design of the H-beam .................................................................................. 53
2.8.7.Design of the leg ......................................................................................................... 57
2.8.8.Design of welding ........................................................................................................ 62
CHAPTER THREE ..................................................................................................................................
3.Conclusion and Recommendation .................................................................................................. 66
3.1. Conclusion ............................................................................................................................. 66
3.2. Recommendation .................................................................................................................. 67
CHAPTER FOUR ...................................................................................................................................
4.1.Part Drawings ........................................................................................................................ 68
CHAPTER FIVE…………………………………………………………………………………………………………………………………….…
5.REFERENCE ............................................................................................................................... 85
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1. BACKGROUND OF MIE
Mesfin Industrial Engineering PLC was established in 1993 as the engineering wing
of EFFORT (Endowment Fund for the Rehabilitation of Tigray), with a capital of 7 million.
MIE currently is engaged in the manufacturing of
 Liquid and dry cargo bodies

 Low beds
 Trailers
 High beds
 Semi-trailers and
 Various equipment for the construction and energy sectors such as sugar plant, cement
plant components, and hydro power elements.
It is also engaged in electromechanical erection and installation works, which include erection of
machinery and equipment of various industrial projects, civic buildings and fuel storage
facilities. Having grade I electromechanical works license and General Contractor
certificate for civil works, MIE also engages in turn key projects of industrial complex a wide
range of products are manufactured at its industrial complex (35,000 m2) covered area on
the premises on a (120,000M2), found in Mekelle, northern Ethiopia and (35,000m2) premises
found in at Gelan 25 KM south of A.A Which is fully equipped with the state of the art
machinery.
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1.1. Vision
Become a ‘fully-fledged best in class’ engineering company in the electromechanical and
manufacturing sectors.
1.2. Mission
Create superior values to EFFORT, customers and employees and be a pioneer in the
industrialization of Ethiopia.
1.3. Values:
a. We execute all works in a genuine, transparent and accountable manner.

b. We always add value, handle company property with maximum care and ensure
efficient utilization of resources.
c. We give full customer satisfaction and strive to exceed their expectations.
d. We work hard to be best in class and lead the way for quality.
e. We build sustainable, closer, long-lasting relationship with our customers and
partners.
f. We always give maximum respect to our employees, customers and partners.
g. We ensure employment; promotion and reward are based on merit, competence and
performance.
h. We are as good as our employees and our employees are our main sources of
competitive advantage. We therefore create opportunities for continuous employee
development and empowerment.
i. We develop brotherhood among employees.
j. We always ensure safe working conditions to all employees.
k. We provide necessary support to our employees as much as possible.
l. We always observe the law.
1.4. Objectives of the company
 To increase profitability
 To satisfy customers
 To be competitor in the market
 To minimize cost of product
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1.5. MAIN PRODUCTS AND SECTORS
MIE designs, manufactures, assembles and installs equipment & components for the
 Energy . Mining
 Transport . Construction
 Manufacturing . Agricultural
During its existence MIE has shown tremendous growth and expansion.it now acquires net asset
exceeding birr 230million.
 Here below let’s describe the different sectors individually
1.5.1. Transport sector

MIE is the biggest single trailer manufacturing factory in Ethiopia. It designs and manufactures vehicle bodies,
trailers, High and Low-bed semi-trailers as well. MIE has a capacity of manufacturing over 1500 trailers and
semi-trailers per annual. It produces Truck bodies, 2-Axle & 3-Axle trailers & semi-trailers for dry and fuel
cargo transport low beds for transporting heavy duty equipment, bus body, and Tipper bodies.
Some of the products are;
3-Axle draw bar fuel Trailer

Cargo body mounted on truck
Tipper bodies
Low bed Semi trailer Bus body
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1.5.2. Energy sector
With the help of a radiographic, ultrasonic and other testing services provided in its testing laboratory, MIE has
a full capacity of manufacturing and erecting hydroelectric components such as penstocks, steel liners, gates
and reservoirs. Furthermore, it has a unique rolling machine in East Africa that produces very large fuel storage
tanks. The Mega Rolling Plant has a total annual design capacity of producing storage tank of one billion liters.
Some of the products;
Depots at Kombolcha Penstock delivered to TisAbay Hydroelectric

Depots at Sululta
project
1.5.3. Industrial project
With the support of CAD and CAM software MIE designs, manufactures and erects industrial components for
cement, textile, brewery, food, and sugar industry. Moreover, MIE manufactures multi-purpose industrial cranes
and boilers.
In addition to the aforementioned tasks Mesfin Industrial Engineering renders renting services of light and
heavy-duty vehicles, 50 tone mobile crane, 3 to 5 tone forklifts and 15 meter cube dump trucks. It also gives
maintenance service to light & heavy duty vehicles in its well organized Garages in Mekelle and Addis Ababa.
Industrial equipment erected at

Mesebo Cement Factory Conveyer
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Coal-firing equipment installation

at Mesebo Cement Factory
1.5.4. Construction Industry
MIE manufactures a wide range of mobile and stationary crashing plants for the domestic and export market. It
also manufacturers concrete batching plants, trans-mixers, tippers and other similar construction equipment’s.
Furthermore it manufactures steel bridge and constructs steel buildings.
MIE under different construction works
1.5.5. Electromechanical construction and HVAC

MIE is the only local grade 1 electromechanical works licensed company nationwide. It carried out various
electromechanical erection and installation works such as erection of machinery and equipment of various
factories, hospitals, civic buildings, hydropower projects etc. It also carried out a production of air conditioning
equipment’s and erection works (HVAC system).
HVAC system erected at Afar Regional State conference hall
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1.5.6. Agricultural sector

MIE has been engaged in the importing of fuel efficient and suitable to our terrain tractors from India. They are
of 75 and 90 H/Power. Moreover the company manufactures agricultural trailers.
Agricultural Trailer
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1.6. The overall organizational structure of the company
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1.7. Work flow of the company
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1.8. OVER ALL INTERNSHIP time

We know that every company has its own rules and regulations which govern the employees
under the company. Therefore we also govern by the rules and regulations of MIE. And first we
physically contact with training department and we asked permission to pass our internship time
at the company. Then they accepted us and therefore gave us acceptance paper to pass intern
time at MIE from March until June for four months.
Then we come a letter from our university linkage and submitted the letter for human resource
department. After that we made a decision with the training center about their company and how
it can be our intern time. After a few days Ato. Meargu visit all the company for all intern
students. At the next day the training center place intern students in different departments. Such
as
o Design
o Manufacturing
o Maintaince
o Planning
o Quality and
o After seal and soon.
Then we place at the manufacturing department and they gave us one advisor to show the work
flow of the department and to help during designing the problem we identified. Then our advisor
Ato Michiale said us to visit again the company for one week in order to familiarize the company
and to become the problem identification easy.
Therefore after we visit and familiarize to the company and the employees also collect some
problems we report to our advisor and we select our project in designing of a dish end maker
machine. Finally our university advisor is coming and tells us to continue with the way us going.
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1.9. OVERVIEW OF THE COMPANY
The company has different shops for different application. Such of the shops are listed below
 Material Preparation Plant
This plant is equipped with state-of-the-art cutting, shearing, bending and rolling machines.
The machines include the following among others: CNC Oxy-acetylene cutting machine, two NC hydraulic
bending presses of 400 ton capacity, two NC hydraulic Shearing machine, one manually operated hydraulic
shearing machine, one manually operated hydraulic bending press, two rolling machines, one automatic band
saw. All the pre-welding and pre-assembly activities are carried out in this plant.
Band saw shearing machine bending machine
CNC Coordinate Gas Cutting One of the Computerized Bending

Computerized Shearing machine Machines-400 ton capacity
Machine
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 Fabrication Plant
There are two fabrication plants at the company. The first one is the plant which owned by MIE about 51% and AZMIE
is privately owned by MIE.
The fabrication plant consists of
Steel Structure Construction,
Reservoirs/Steel Tank/ Production
truck bodies and Trailer Production shops and
Sugar factory components production.
Steel Structure and Industrial Components construction shop

Is located at AZMIE plant.
 Various steel structures such as antenna masts, transmission towers, steel poles, over-head crane,
pre-engineered buildings etc. are manufactured in this plant.
Structural steel works Overhead crane 3.5, 5, 10 tons

manufactured by MIE
Reservoirs /Steel Tank/ production shop
This shop consists of a heavy-duty Mega Rolling plant, which is used to manufacture reservoir tanks with a
capacity of holding 6 to 10 million liters each. These reservoir tanks can be used for the storage of petroleum,
chemicals, water, grain etc. This work shop has a capacity of producing various size storage tanks with a total
capacity of one billion liters per annum.
Back view front view of the rolling machine

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Truck bodies and Trailer production shop
 Truck bodies and trailer are manufactured at MIE in the former time where as currently are
manufactured at AZIME plant.
 Truck bodies, 2-Axle & 3-Axle trailers & semi-trailers for dry and fuel cargo transport low beds for
transporting heavy duty equipment, bus body, and Tipper bodies are produced in this shop. This shop
has a capacity to produce over 1500 trailers per year.
Sugar factory components
Is the only product which produced at MIE plant that owned privately.
The main components of the sugar project being fabricated are
 Vertical crystallizer (heat exchanger)
 Calanderia
 Tube nest
 Screened juice receiver
 Bagasse tank
 Molasses tank
 Condition keeper
 Tube plate etc.
Some of the products are figure below
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 Machining plant
Various parts are produced in this plant, which are either used by other shops as inputs for further production or
sold to sister companies and customers as finished products. This shop has;
o Very clean work area in which Ensures safe and comfortable work area.
o There are many attractive phrases that motivate workers and
o Equipped with bridge (overhead) crane of capacity 5 ton.
The operations conducted in this shop are;
 Drilling
 Turning
 Facing
 Threading
 Boring
 Cutting
 Shaping and other finishing processes
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 oxy-Acetylene production plant
The oxy-Acetylene production plant produces oxygen and acetylene both for internal consumption and for
external customers like hospitals, vehicle maintenance shops, construction projects and other fabrication shops.
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Chapter two
2. Dish end maker machine
INTRODUCTION
As we discussed above the main products produced in MIE are sugar factory accessories
and liquid cargo trailers but the problem we observed is I liquid cargo trailers, that is in
order to cover at both ends and at the center to resist shocking and to balance the liquid it
needs a dish end. But this dish end is not manufactured here in MIE there for in order to
import these dish ends it needs so much money in foreign currency. Then to save this
foreign currency first we observe how the dish end is manufactured.
After observing all products of the company then we find that the dish end is
manufactured manually, at Workshop 2.
Due to these dish ends are manufactured manually have the following draw backs.
Poor surface finish

Lower mass production
Consumes more time and
Utilizes man power
Then observing and asking the workers who were working on the preparation of the dish
end, we deduce to design a machine which manufacture the dish end that can be
competitive with the imported dish ends in quality.
2.1. SHORT SUMMRY OF THE PROJCT

Our project is designing of a hydraulic punch machine to manufacture the dish end. Then
to design the hydraulic punch machine it has a pump to give the required amount of oil
through the hose in to the cylinder. And there are dies in the upper and lower side. Where
the dies in the upper are two in number and have a shape of the dome end in the major
diameter and minor diameter side. And the dies in the lower side are six in number and can
be slide independently in the case of punching the sheet metal to the center. this is due to
the upper die is mounted at the center therefore instead of moving the upper die we decide
to slide the lower dies to the center in the way which is machined. Which means to punch
the end in the major diameter side of the sheet metal slides the lower die in the major
diameter into center and also the same operation for the other side to give the desired form
of the dish end.
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2.2. PROBLEM STATEMENT

As we know MIE is one of the greatest companies in Ethiopia in the metal work and other
engineering works. The company has about five shops owned by the company individually
and about two shops with china company cooperation called AZMIE. The shops owned
privately are the machine shop, material preparation shop, and fabrication shop. And the
shops with the cooperative are mainly manufactured steel structure, liquid and dry cargo
with trailers and soon.
Then in visiting the company shops there are some problems such as way of transporting,
problems in rolling, shearing and bending long sheet metals and our project the problem in
manufacturing dish end.
Finally due they work a number of liquid cargos with trailer then they demand a number of
dish end. Therefore to solve the problem of machine that makes the head for the liquid
cargo we going to design and manufacture here.
2.3. Objective
General objective
The main objective of our project is in order to press or make dish end for pressure vessel which is
imported from foreign countries and manually made at MIE.
Specific objective
 Good surface finish
 High production compared to manual production of dish ends at MIE.
 Gives better dimensional accuracy than manually made dish ends.
 Minimizes number of labor
 To save from foreign currency
2.4. METHODOLOGY
The machine is designed using different formulas available for the different components of
the machine. And in solving the problems from the beginning of the problem identification
until the solution of the problem collecting data is our primary issue. Then the data’s we
use in our project are collected in different ways of data collection. Such as
 By observing the company
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 By interviewing the work mans of the company and

our company advisor
 By referring different books
 By searching from internet.
2.5. Limitation of the study

 Relevant data collecting was somewhat challenging and hard to get significant
information at right time because there is no documentation
 We have not get help from our advisor about how we can proceed and not give us
corrections on the design analysis at the proper time.
2.6. Scope of the study
The scope of the project is mainly concerned in doing the design analysis of the different
parts of the dish end maker machine. In addition we are going to prepare the part drawing of
each component, assembly drawing of the machine in 2D and 3D models using the available
simulation soft wares. The main simulation soft wares we are going to use is one of them
 AutoCAD 2012
 Catia
 Solid work
We are also ready to prepare the cost analysis of the machine as well as the cost of each
component.
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2.7. Mechanism
Every machine has its own working mechanism. Which means principle of working can be differ
one from the others.
Based on the statement written above also the machine we design has its own working principle.
But before we let see the parts which include on the machine;
 Beam: it supports the combination of the cylinder and piston also the upper dies which
mounted on the piston rod.
 Column: duty of the column is to support the beam.
 Bed: has an obligation to support the table and the lower dies.
 Cylinder: it receives a pressurize fluid in order to push the piston and therefore it press
the sheet metal.
 Piston: it helps to mount the upper die.
 Table: is used to slide the lower dies forth and back in pressing time.
 Upper and lower dies: as we press the sheet metal to give the desired shape and surface
finish.
Then as describe above the machine is operated hydraulically. Which means that primarily we
need to set the lower dies on the table prepared to the dies at four sides. And also we need to
mount the upper dies on the piston with the help of pin. Then as we arranged on this manner the
machine parts. Next we add a pressurized fluid which preferred to operate the machine. That is
from a reservoir a pressurize oil is add in to the cylinder through the hose therefore the pressurize
oil pushes the piston inside the cylinder. But here before the piston goes down we must place the
lower die at the center. This means the lower die slide on the way which prepared on the table.
As we brief, the upper die which is mounted on the piston where the piston is placed at the center
which is 1808mm from south or north and 2529mm from east or west direction. Hence, in
pressing the lower die must slide through the way. Here the die to slide must correspond with the
die mount on the piston rod. (i.e. if the die mounted on the piston has a shape as the shape of a
tori spherical end on the major side shape then the die we slide also need to have similar shape.)
Then the die which slide forth is replaced back to its initial place. Next another die (on the other
direction) is slide forth to the center to the center and it is obvious to change the die which
mounted on the piston rod. This operation is continuing until the sheet metal has a shape of tori
spherical end. (Which is we need to press six times)
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2.8. Design analysis

As we express above the main objective is to design a hydraulic press machine for tori spherical head
making. So, before we proceed to design the machine first calculate the load available in order to shear
the sheet metal.
938 388 750 1876 750 388 938
Development drawing of the tori spherical end.
1976mm
750mm
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Therefore the force is needed to apply at the end of the both end. That is in the minor and major
diameter.
So, load applied to shear is
F=max*A , where max=maximum shear stress
=yt/f.s but yt=y/2
A=cross section where the load applied
=length*thickness
Material used for dished end is
St-52 with properties of

 yt=355Mpa
 t=650Mpa
 Mass=97.2kg
Due to we need to punch the metal with the help of two dies therefore two forces are needed to
calculate
Then, CASE-1 ; Is the load which shear the sheet metal in the major diameter.
Therefore F1=max*A1 , A1=L1*t , max =yt/f.s f.s=3 ,yt=pa/2
=1526mm*4mm =355Mpa/3*2
=6104mm² =59.167Mpa
Then, F=59.167Mpa*6104mm²
=361.15KN in terms of ton it is equal’s to 36.1ton
Approximately the load need to apply to punch is 40 ton in case one.
CASE-2;is the load need to shear in the minor diameter.
F2=max*A2 , A2=L2*t , from above shear max=59.167Mpa
=938mm*4mm
=3752mm²
Then, F=59.167Mpa*3752mm²
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=221.995KN , approximately the value becomes 25 ton.
Therefore from both cases select the maximum load for safe design the of the machine parts and press
the machine for both cases easily. That is FORCE =40 TON.
2.8.1. PISTON ROD DESIGN;

Material selection –ductile cast iron
Grade –SG400/18
Properties –density (ρ) =7100kg/mᶟ - pisson’s ratio =0.275
-tensile strength (σt)=400MPa
-compression strength (σc) =216MPa
-shear strength () =360MPa
-modulus of elasticity (E) =65.9GPa
 We know that the piston rod is applied to compressive load. Therefore we need to calculate the
amount of maximum load which can be beard by the piston.
Assume dp=piston rod diameter
D=piston head diameter
 So, we know that the force acting in the piston rod is
F= (Π*D/4)*(P)……………. (1) where P=pressure acting in the

piston rod
 And the force acting in the piston rod is
F ( ) ( ) ……………………………………………..…………….(2)
where σtp=allowable tensile stress of the piston rod material
 Combine both equation that is equation (1)and(2) we get

dp=D(√ ) ………………………………..………………………………….(*)
But first we need to calculate piston head diameter (D) and pressure acting on the piston.
2.8.2. CYLINDER DESIGN;

Material selection- spheroidal graphite cast iron
Grade –SG 700/2
Properties- density (ρ) =7200kg/mᶟ - poison’s ratio =0.275
 tensile strength (σt) =700MPa
 compression strength (σc) =318MPa
 shear strength () =630MPa
 modulus of elasticity (E) =86.6GPa
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Assume t=thickness of the cylinder
Do=outer diameter of the cylinder
D=Inner diameter of the cylinder
 We know that cylinders are thin and thick walled cylinders.

 Thick walled cylinders are cylinders if the diameter is less than ten times the
wall thickness.
 Thin walled cylinders are if the diameter is greater than ten times of the wall
thickness.
 Thickness of a cylinder is given as
t= * [ √( )
-1 ]…….(**)
Where D= inner diameter of the cylinder
P=pressure acting in the cylinder
σtc =allowable tensile stress of cylinder material
But from the relation above between type of the cylinder and diameter of the cylinder let’s
assume diameter of the cylinder is 10 times of its thickness.
i.e D=10t………………substitute this in to equation(**)and rearranging
Then, t= * [√ ]
–
0.2=√
–
1.2=√ square both sides

–
1.44=
–
0.44tc =2.44P
P=0.18tc is the value of the pressure acting in the piston.
 But we know that material for cylinder is cast iron with permissible tensile stress of
tc f.s=factor of safty t =tensile strength
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=6 =700Mpa
Therefore, p=0.18
P=
P=21MPa
 Then using the pressure calculated above and the force acting in the piston rod let’s find
the inner diameter of the cylinder.
i.e. F= ( )
Where F=40 ton
=400KN
P=21MPa
400*10ᶟ= ( ) solve for D
D² =0.02427
D=155.77mm approximately D=156mm
 Therefore substituting the value of the diameter of the cylinder in to equation (*) we get
that dp=D(√ ) allowable tensile strength
= /f.s
=400MPa/6
=66.67MPa
dp =156mm*(√ )
dp =86.99mm approximately dp =90mm
Generally let’s check the calculated diameter of the piston rod can bear the applied force
That is F= ( ²)/4*( )
( )
= ( )
F=423.92KN this value in terms of ton becomes 42.4 ton
Therefore F=42.4 ton mean is that the piston rod can be withstand a load up to 42.4 ton. But we know
that the maximum load we aim to apply 40 ton. so that the design is safe.
 Calculating thickness of the cylinder

From pervious we have that thickness is expressed as
t= √ -1]
–
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So, t= [√ -1]
t=15.57mm approximately t=16mm
But also using lame’s equation we can also calculate thickness of the cylinder
I.e. lame’s equation
r= and
c=
Where c= circumferential stress
r=radial stress (stress perpendicular to the wall)
b= constant
r=radius
a=constant
 From pervious calculation we know that inner diameter of the cylinder. That is 156mm.now we
have to calculate the outer diameter of the cylinder. Due to thickness is expressed as
 Circumferential stress at inner radius(r)is equal to the maximum tensile stress

of the cylinder material. i.e. 700MPa
Then, c=700MPa=( )
700MPa= ……………………………………………….(1)
 Also radial stress at inner radius is the same as the pressure acting at the inner
radius of the cylinder. i.e.21MPa
r=21MPa=( )
21MPa= ………………………………………………….(2)
 Adding both equations (1)and (2)

Rearranging this we get
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Finding value of the constant (b)

b=2193282N
 Then put value of b in to equation(2) and solve for the value of a
i.e.
( )
a=339.5MPa
Therefore lame’s equation for our case becomes
c=
( )
 The cylinder must be strong enough to absorb all the stress. And the stress at the outer surface
of the cylinder must be zero. This means the stress perpendicular to the wall is zero at the outer
surface.
i.e.
r=0 ……………… (At the outer radius)
Then, r= ( )
=0
339.5MPa= ( )
solve for the value of the outer radius
(ro)²=
(ro)²=6460.33mm
ro=80.376mm approximately ro=90mm
Therefore outer diameter is then becomes Do=2ro
Do=2*90mm
Do=180mm
 Hence from lame’s equation cylinder thickness(t) is

t=
t=
t=
t=12mm
30 | P a g e
Therefore from the relation written above about thickness and diameter of the cylinder we have that
Thin walled cylinder is

D>10t and
Thick walled cylinder is
D<10t
Then using the thickness calculated above we get
156mm<10*16mm for thickness of 16mm
156mm<160mm thick walled cylinder
And, 156mm>10*12mm
156mm>120mm thin walled cylinder
Hence due to the cylinder is acted by a minimum pressure then select a thin walled cylinder. Therefore
select thickness of the cylinder is 12mm.
2.8.3. Design of flat end cover

Let tc=thickness of the end cover
 We know that force acting on the end cover of the cylinder is

F=D*tc*t where, D=internal diameter of the cylinder
t=allowable tensile stress of the cylinder cover material
Therefore, 400KN=156mm*tc*116.67MPa
400KN= mm.MPA
=21.98 mm approximately =22mm
 Also we need to find the total height (length) of the cylinder
That is Hc=lp+tH+allowance where Hc=height of the cylinder
lp=piston rod length
tH=piston head thickness, and
Allowance is the space where the fluid is placed.
 Then let’s calculate length of the piston rod as shown below
31 | P a g e
First we know that length of the piston rod is either small or long. That is if the
slenderness ratio ( ) is less than 40 it is short. Unless if the slenderness ratio ( ) is
greater than 40 piston rod length is large.
Therefore in order to deduce is a short or a long find the value of and column
constant (Cc).
i.e. Solve for slenderness ratio ( ) using rankine formula.
Where =critical load

( )
=F*f.s assume f.s=4
=400KN*4
=1600KN
=compressive yield stress
A=cross sectional area of the rod
l=length of the rod
k=least radius of gyration of the piston rod
a=rankine’s constant
 therefore for cast iron

a= =
Crushing stress or yield stress in compression =550MPa and for circular
cross section of the piston rod area is given as
Hence but diameter of the piston is 90mm

( )( )
( )
( )( )
( )( )
( )( )
32 | P a g e
( )
( ) Is the value of the slenderness ratio
And again find the column constant (Cc)
( )
=56.997 is the value of the column constant. Therefore from the values of the slenderness
ratio and column constant we observe that the value of the column constant is greater than value of the
slenderness ratio then length of the piston rod is small. So, using the J. B. Johnson formula check the
rod for buckling.
()
[ ] Where
( ( ) )
=6358.5mm²
f.s=4
=100MPa
E=65.9MPa
( )
Then
=588.53KN from this we can understand that at this load the rod should just begin to buckle.
 Therefor from the slenderness ratio calculated above we can get length of the piston rod
But √ where, and
33 | P a g e
√
=√ = = =22.5mm
√
Therefore
Length of the piston rod.
 Thickness of the piston head is designed keeping in view of the following consideration.
It should have adequate strength to with stand the straining action due
to pressure inside the cylinder.
So, according to Grashoft’s formula thickness of piston head is
√ Where P=maximum pressure
D=cylinder bore or outside diameter of the piston
Permissible bending (tensile) stress for the

material of the piston.
Therefore piston head thickness is then becomes
( )
` √
Assume thickness of the piston head to be 50mm
2.8.4. SUPPORTING BEAM DESIGN

The supporting beam is fixed at both ends by the supporting columns
and the load is applied at the of the beam. Therefore the beam is need
to check for bending.
Load (W)
Support-A support-B
 But the load applied on the beam or weight (W) is the total weight of the oil (fluid), piston,
cylinder and die weight. Therefore first we to find the total weight.
34 | P a g e
 CYLINDER WEIGHT (Wc)
We know that weight is expressed as

W=m*g therefore cylinder weight becomes
h Wc=mc*g where mc=cylinder mass
g=gravity
Also we know that mass is given as mc=Vc*ρc
Where Vc=volume of the cylinder
ρ=density of the cylinder material
Then,
Therefore mass of the cylinder is
( ) and then
( )
Then we need to find the overall height of the cylinder (h).
A space filled by fluid (allowance)
tH
( ) (Assume length of the piston rod inside the cylinder to be

two third of the length of the piston rod.)
( )
( ) Assume allowance to be 50mm
35 | P a g e
=700mm is over all height of the cylinder.
Therefore weight of the cylinder is become using the equation from above.
 But the cylinder have a cover with a thickness of 22mm and at the upper side of the cylinder it is
approximately fully covered but at the lower side it has a hole with diameter of the piston rod.
Therefore then instead using overall height of the cylinder to calculate the weight we need to
calculate the weight of each cover and body of the cylinder individually.
That is weight of the lower cover
Wl=Vl*ρ*g
Weight of the upper cover
Wu=Vu*ρ*g and the height of the cylinder is h=hc-2tc
h=700-44
h=656mm
Hence the weight becomes
( ( ) ( ) )
( ( ) ( ) )
( ) (( ) ( ) )
(( ) ( ) )
=369.36N
 PISTON WEIGHT (Wp)

 And also piston weight become [piston rod + piston head]
( ) ( )
Material selection for piston is spheroidal graphite cast iron with density of
Then,
36 | P a g e
( ) ( )
]
 DIE WEIGHT (Wd)

 In the upper we have two dies that mounted on the piston rod. Then these dies have influence
over the supporting beam therefore we need to calculate weight of each dies. Then select the
maximum weight for better design.
o DIE-1; is a die having a curve shape with radius of 2831mm and with curve length of
938mm
 Here die thickness is not known. Then assume thickness and width of the die to be 10mm and
500mm respectively.
Therefore weight of die-1 becomes
Wd-1=m1*g
Wd-1=V1*ρ*g , but in order to minimize or simplifying volume
of the die calculating then assume the die have a rectangular shape as shown below.
td
L
w+td+50
Therefore volume of the rectangle is given as
V1=L*td*(w+td+50) where L=938mm
td=10mm
37 | P a g e
w=500mm
Then ( )
Hence weight of the die becomes
Where material used for die is tool steel then its density is
Then
o DIE-2;
Also here let’s draw the die in rectangular shape to simplify Calculation of the volume and due to give
as a maximum Value of weight and this help as safe design.
Therefore
Where
Then
Finally
38 | P a g e
Hence for better design of the beam. Therefor select the maximum value of weight from both weights of
the dies. That is
 Generally now we can design the supporting that supports the hydraulic cylinder, piston, die and
fluid.
SUPPORTING BEAM DESIGN
 As we expressed above the load is applied at the center and we need to design
for bending.
A B
Where weight is equal to the summation of the cylinder weight, piston weight, die weight and
the load applied in order to press the metal.
Mathematically;
 Length of the supporting is beam is two times of the minor diameter of the head and some
clearance in order to easily movement of the sheet metal.
o REACTIONS AT THE SUPPORT
401.35KN
A B
3616mm
From statics course at equilibrium we know that summation of all forces is zero.
i.e. ∑ F=0
Therefore for the beam to find the reaction force
39 | P a g e
∑ =0
Then
………………………………………….. (*)
And also summation of all moments at any reference point is zero.
+ ∑( )=0 then
Rearranging the equation and solve for RB
Where W=401.35KN
Is the reaction force at support-B
And using equation (*) we can also solve the reaction force at support-A.
Where =200.675KN
W=401.35KN
Reaction force at support-A
Hence
W=401.35KN
RA=200.675KN RB=200.675KN
In order to draw the bending diagram let’s take a small segment at section –D
 SECTION-AD
X M1
200.675KN V1
+ ∑
40 | P a g e
+ ∑ =0
Hence @X=0=0 and
@X =
@X =362.82KN.m
 SECTION-AB
A 401.35KN M2
200.675KN X V2
+ ∑
+ ∑ =0
* +
Therefore moment at
@X =725.64KN-200.675KN*1808mm
@X =362.82KN.m
And moment at X=L becomes
41 | P a g e
@X =725.64KN-200.675KN*3616mm
@X =0KN.m
Finally bending diagram of the beam is drawn as follow
401.35KN
200.675KN 200.675KN
200.67KN
362.82KN.m
 Then next we need to find thickness and width of the beam.
t
w
We know that the beam is in bending and have a rectangular shape.
Then  where M=maximum bending moment
42 | P a g e
S=section modulus of the cross section beam
= ,
So
………………………………………..assume w=10t
( )
Therefore
Section modulus in terms of t.
Our aim is to find thickness of the beam. Therefore we know that maximum bending moment from the
diagram is 362.82KN.m and bending moment is get from ratio of the yield strength of the material and
design factor.
 MATERIAL SELECTION – ASTM-36

 PROPERTIES - ρ= - =400MPa
- =250MPa - =145MPa
-E=200Gpa -G=77.2GPa
 
assume design factor to be 2
 
 
Therefore the required is the section modulus and is solved as 
( )
Then value of the section modulus is get so we can calculate thickness of the supporting beam.
i.e.
43 | P a g e
≈56mm
Therefore width of the beam will be
, t=56mm
 Width and thickness of the rectangular beam is calculated above I.e. w=560mm
t=56mm
Then, let’s check section modulus, bending stress, and design factor.
Section modulus
( )
( )
Therefore ( ) >( ) …………………………….OK!!!
Design factor
But,
=( )
Calculated bending stress
Then,
Therefore the design is safe!!!
 Also we to design for deflection at the center.
From strength of materials deflection is finding as follows
o Due to the beam is supported at both ends, then reaction forces are only in the y-
direction.
44 | P a g e
A B
W
L/2
V M
X
W/2
 Using free body diagram of portion AD of the beam, where D is located at a distance X from end
A. now find
+ ∑ =0
i.e. + ∑ =0
( )
…………………………………….(1)
( )
But also we know that , substituting equation (1) into the formula we get that
* +
………is a second order linear differential equation.
 Integrating twice in X, we have

( )
…………………………………(2)
………………………..(3)
 We know that deflection (y) at both fixed ends of the beam is zero.
So, AT X=0 then y=0
Then equation (3) becomes
45 | P a g e
And AT X=L then y=0 so equation (2) becomes

( )
Therefore elastic curve equation of the beam will be
…….. we know that the maximum deflection is at the

center that is at then
[ ( ) ( ) ( )]
* +
* +
| |
Where W=401.35KN
L=3616mm
E=200GPa
* ( ) +
46 | P a g e
[ ( ) ]
Therefore
…………………………ACCEPTABLE!!!
2.8.5. DESIGN OF COLUMNS;

o A column is a structural member that carries an axial compressive load and that tends to
fail by elastic instability, or buckling, rather than by crushing the material.
o The tendency for a column to buckle is dependent on the shape and the dimensions of
its cross section, along with its length and the manner of attachment to adjacent
members or supports.
o There are four types of end conditions
1. Both the ends hinged or pin jointed
2. Both the ends fixed
3. One end is fixed and the other hinged
4. One end is fixed and the other free
o Therefore in our case as we visualize the columns from the assemble drawing it is
fixed at both ends.
Supporting column
 MATERIL SELECTION
-structural ASTM-36
 PROPERTIES
-DENSITY-
-ULITIMATE TENSILE STRENGTH-400MPa
-YEILD STRENGTH IN TENSION-250MPa
-MODULUS OF ELASITICITY-200GPa
 According to Euler’s theory, crippling or buckling load (Wcr) under various end conditions is
represented by the equation.
47 | P a g e
Where
( )
young’s modulus for the material of

the column.
A=area of cross section
K=least radius of gyration of the cross
Section.
L=length of the column
C=constant, or end fixity coefficient
 We know that crippling stress is given
, and crippling stress for column cannot be more than the
crushing stress of the column material. Then because the material for the column is steel, and
then crushing stress is 330MPa.
Therefore , from this let’s find the selendress ratio
( )
i.e.
( )
( ) Where C=constant, for both ends fixed value

of the end fixity coefficient is FOUR (4)
Then ( )
( )
( )
( )
Therefore due the column have a slendreness ratio more than 80, then the column is long.
 And then let’s calculate thickness of the columns.

CASE-1;using Euler’s formula
( )
Where C=4
√
 The vertical columns have two moment of inertias (i.e ).since the column will tend to
buckle in the direction of least radius moment of inertia; therefore the least value of the two
moment of inertia is to be used in the relation.
Therefore
48 | P a g e
And
 For a column that has a rectangular cross section the expected buckling axis is y-y because both
are much smaller for that axis than for the x-x axis.
 But let’s first find the actual length of the column. That is we know that the relation between
equivalent length and actual length for both ends fixed is
Then
( )
We know that the force at the supporting columns is half of the weight applied at the center.
Therefore the load applied to the supporting column is W=401.35KN and half of the weight of
the supporting beam.
Therefore
Where W=401.35KN
=beam weight
Then beam weight is get as follows
( )
( )( )
………….. Weight of the beam.
Then
So, crippling load will be
Assume f.s=6
49 | P a g e
Hence
( )
But
≈7mm
CASE-2 ; using rankine formula
( )
Then
( )
( )
50 | P a g e
 Taking the maximum value of thickness from both case’s that from Euler’s and rankine formula.
Therefore supporting column thickness is
 And length of the supporting beam can get from the value of the selendreness ratio which
calculated above.
i.e.
But √
Then
Is the length of the supporting column. But we know that length of

the supporting column is to be the summation of the length of the piston rod, length of the
difference of the cylinder and cylinder cover, height of the table and thickness of the upper and
lower die.
Mathematically
Thickness of the upper die is 20mm and thickness

of the lower die is the length of the sheet metal need to shear plus some allowance. Assume the
allowance to be 20mm.then thickness becomes 70mm.therfore,
( )
But in order to know the height of the table first we need to design the table
2.8.6. Design of the table

MATERIAL SELECTION
Mild steel (A-36)
PROPERTIES
i. Ultimate strength=400MPa
ii. Yielding strength=250MPa
iii. Compressive strength=125MPa
51 | P a g e
The table is designed to in order to support the lower die and also to with stand the force applied on it
to shear the sheet metal. And is supported by several legs.
 But due to the lower die is movable in order to give the required shape in punching therefore to
reduce the difficulty of the flat table for machining the rail way of the die let’s use four beams
and machining the beams before assembled. Then know we can design one the beams which
can represent the left beams.so after machining the beam have a H-shape.
Drawing
 The H-beams are supported on two sides and the force applied is.
F’=
Where F=force applied
=0.504KN
 And weight of the lower die is calculated as follows

o We know that thickness of the die is to be 70mm and for the die in the major diameter
side width is 326.5mm and length of 1658mm, also for the die in the minor diameter
side width of 500mm and length of 938mm.therfore we can calculate the weight
Then
=( )
( )
But due to we have two dies in the major diameter side and then the total weight is
o And weight of the die in the minor diameter side is
Drawing
So,
( )
52 | P a g e
And also the die in the minor diameter side there are four dies with similar shape. Therefore total
weight becomes
Therefore
And then the maximum load applied is at the middle beam and the total load becomes
2.8.6.1. Design of the H-beam

The reaction forces at the support leg is
Hence W=416.78KN
RA=208.39KN RB=208.39KN
In order to draw the bending diagram let’s take a small segment at section AC
 SECTION-AC
X M1
208.39KN V1
+ ∑
+ ∑M1=0
53 | P a g e
Hence M1@X=0=0 and
M1@X =
M1@X =527.02KN.m
 SECTION-AB
A 416.78KN M2
208.39KN X V2
+ ∑ =0
* +
Therefore moment at
@X =1054.04KN-208.39KN*2529mm
@X =527.02KN.m
And moment at X=L becomes
@X =1054.04KN-208.39KN*5058mm
@X =0KN.m
Finally bending moment diagram of the beam is drawn as follow
54 | P a g e
416.78KN
208.39KN 208.39KN
208.39KN
527.02KN.m
Then from the bending diagram above we can understand that the maximum bending moment is
 The beam is in bending and have an H-shape
h H
Then  where M=maximum bending moment
S=section modulus of the cross section beam
= ,
So
Where H=width of the beam
=829mm
And assume
55 | P a g e
h=629mm
Therefore section modulus is become
[ ( ) ( ) ]
The material used for the beam is A-36 then its yield strength is 250MPa
So,  
assume design factor to be 2
 
 
Therefore the required is the section modulus and is solved as 
( )
Then value of the section modulus is get so we can calculate thickness of the supporting beam.
i.e.
Let’s relate Band b to solve the equation that is assume B=3b
Therefore
Since B=3b and b=15mm
B=3*15mm
56 | P a g e
B=45mm
Then finally let’s check.

Section modulus
[ ( ) ( ) ]
[ ]
Therefore ( ) >( ) …………………………….OK!!!
Design factor
But,
=( )
Calculated bending stress
Then,
Therefore the design is safe!!!
And also we need to design the leg of the table or the column supporting of the beam. Therefore the
force applied is half of the load applied on the H-beam.
208.38KN
Therefore let’s design the leg as a column.
2.8.7. DESIGN OF THE LEG

 MATERIL SELECTION
-structural ASTM-36
 PROPERTIES
-DENSITY-
57 | P a g e
-ULITIMATE TENSILE STRENGTH-400MPa

-YEILD STRENGTH IN TENSION-250MPa
-MODULUS OF ELASITICITY-200GPa
 According to Euler’s theory, crippling or buckling load ( ) under various end conditions is
represented by the equation.
Where
( )
young’s modulus for the material of

the column.
A=area of cross section
K=least radius of gyration of the cross
Section.
L=length of the column
C=constant, or end fixity coefficient
 We know that crippling stress is given
, and crippling stress for column cannot be more than the
crushing stress of the column material. Then because the material for the column is steel, and
then crushing stress is 330MPa.
Therefore , from this let’s find the selendress ratio
( )
i.e.
( )
( ) Where C=constant, for one end fixed and one

end free value of the end fixity coefficient is one fourth (0.25)
Then ( )
( )
( )
( )
Therefore due the column have a slenderness ratio less than 80, then the leg is short.
 And then let’s calculate thickness of the leg.

CASE-1;using Euler’s formula
( )
Where C=0.25
58 | P a g e
√
 For a leg that has H cross section the expected buckling axis is x-x because both are
much smaller for that axis than for the y-y axis.
 But let’s first find the actual length of the column. That is we know that the relation between
equivalent length and actual length for both ends fixed is
Then
( )
We know that the force at the supporting leg is half of the weight applied at the center of the H-
beam. Therefore the load applied to the supporting leg is 208.39KN
So, crippling load will be
Assume f.s=6
Hence
( )
But where width of the leg is equal to H of the H-beam
w=H=829mm
CASE-2 ; using rankine formula
( )
59 | P a g e
Then
( )
( )
 Taking the maximum value of thickness from both case’s that from Euler’s and rankine formula.
Therefore assume supporting leg thickness is
 And length of the supporting beam can get from the value of the slenderness ratio which
calculated above.
i.e.
But √
Then
Is the length of the supporting leg
Generally we need to check for buckling the design parameters
( )
60 | P a g e
And
Due one end is fixed and one end free
Therefore
[ ]
( )
Then
And at the previous design of the column we say that the total length is .where
height of the table is 230.8mm.
Therefore
Checking
( )
Therefore 2850KN>926.49KN ………………………..acceptable!!!!
61 | P a g e
2.8.8. Design of welding

 Welding joint is a permanent joint, which is obtained by the fusion of the adages of two
parts to be forced together, with or without the application of pressure and filled
materials.
 Welding is extensively used in fabrication as an alternative method for casting or forging and are
replacement for bolted and riveted joints.
Advantages of welding joint over riveted joint
 Welding joint provide maximum efficiency which is not possible in riveted joints
 Alternations and additions can be easily made in the existing structure
 Tension members are not weakened as in the case of riveted joint
 Welding provide very rigid joint
 The process of welding takes less time than riveting.
Type of welding
There are two types of welded joints
 Lap joint or fillet joint, and

 Butt joint
 Lap joint: obtained by over lapping the plates and then welding the ages of the plats.
 Butt joint: obtained by placing the plates edge to edge and then welding. And also have other
types of welding
i.e. T-joint, Edge joint and Corner joint
The main considerations involved in the selection of weld type are:

1. The shape of the welded component required,
2. The thickness of the plates to be welded, and
3. The direction of the forces applied.
Therefore we select corner joint due the supporting beam and supporting column are welded by placing
perpendicularly.
 In our design welding is encountered on the supporting column supporting beam.

 As understand from the figure maximum stress can accrue if the load is applied eccentrically
from the welded joints.
 We will conceder metal A as supporting beam which is eccentrically loaded from the welded
joint therefore having checking the safe condition of the member under given eccentric load we
can conclude that metal A supported by a metal B(supporting column) should never fail under the
applied load.
 Considering a corner joint fixed at one end subjected to an eccentric loaded P at a distance e.
a) The joint will be subjected to direct shear stress due to shear force (P)
62 | P a g e
b) The joint will be subjected to bending stress due to a bending moment (Pe)
tc F
tb
Lb
Lc
ANALYSISS
The maximum shearing and normal stress accrue with the member due to the applied load are
max= .......................................................................................... (1)
b= .......................................................................................... (2)
Where:
b= bending stress
shearing stress
A=throat area
t=throat thickness
L=length of the weld
Z=sectional modulus
P= maximum load to be lifted
S=leg of the weld
Assumptions
 We use fillet weld
Given data
L=56mm
63 | P a g e
S=4mm
F=401.5kN
Therefore shear Stress in weld is
 .......................................................................................... (3)
For fillet weld A=
  
 
MPa
The bending moment in the weld is
b= ......................................................................................... (4)
But the sectional modules is given by
( )
Z= * ( ( )
+
Where b is the height from end of the supporting column up to the weld part. That is length of the
supporting column minus the thickness of the supporting beam.
Mathematically
Therefore
Z= ( ) ( ( )
( )
* +
64 | P a g e
Substituting on equation (4)
b= =
b=
b= 48.04Gpa
Substituting the value of equation (3) & (4) on to equation (1) & (2) respectively
The maximum shearing stress will be
max=
= √( ) ( )
max =24.15Gpa
But the maximum strength of the material for shear is
y=35Mpa
I.e. max < y ......................................................................................... …safe!!!
The maximum normal stress will be
max=
= √( ) ( )
=
max=
But the maximum strength of the material for bending stress is
y=
I.e. max < y ......................................................................................... …safe!!!
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3. Conclusion & Recommendation

3.1. Conclusion
After all we have reached to the point of conclusion to our design project, in our four month
internship time here at MIE.
Our project is specifically designed to minimize the problems that are challenging MIE in
domestic production of tore spherical dish ends.
Then after all our analysis of the problem we have designed hydraulic dish end maker machine.
All the group member concluded that it is possible to produce tore spherical dish end using this
machine, then MIE can minimize the labor cost, foreign currency and save time in domestic
production of the tore spherical dish ends.
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3.2. Recommendation
Our recommendation for further information on this machine goes as following.
 This machine operate hydraulically

 It is specifically designed to make tore spherical dish ends but we can use this machine
for other application by changing the lower die and the upper punch base on the required
application and design of the work piece need to be worked at.
 The dies are slide manually through the grooves provided on the support bed.
 Generally we recommend to our host company MIE it is possible to construct (produce)
this kind of machine using readily available materials that are found here at MIE.
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4. Part drawing
Assemble drawing
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Front view
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5. References
 Text book of Machine Design ……………………………………Gupta
 Machine Elements text book …………………………………….shigly
 Mechanical Design text book …………………………………….
 Strength of Materials ………………………………………………Beer & Immam.
 Manuals of different machines ………………………………….hydraulic press machines.
 Questioning the advisors ……………………………………………………Ato.Kidanemariam
 Internet ……………………………………………………………………. Gobooks.com, YouTube videos &
different websites.
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INTERNSHIP PROJECT 2014

1.5.2 Energy sector..……………………………………………………………………………………………………………….8

1.5.3 Industrial sector…………………………………………………………………………………………………………….8

1.5.4 Construction sector….……………………………………………………………………………………………………9

1.5.5 Electromechanical and HVAC…..…………………………………………………………………………………….9

1.5.6 Agricultural sector…….…………………………………………………………………………………………………10

1.6 Over all organizational structure of the company …………………………………………………………………..11

1.7. Organizational work flow of MIE ……………………………………………………………………………………………12

1.8. Over all internship time..…....………………………………………………………………………………………………….13

1.9. Over view of the company………………………………………………………………………………………………………14

CHAPTER TWO ....................................................................................................................................

2.8.Design analysis ....................................................................................................................... 24

MIE currently is engaged in the manufacturing of

 Liquid and dry cargo bodies

a. We execute all works in a genuine, transparent and accountable manner.

 To minimize cost of product

1.5. MAIN PRODUCTS AND SECTORS

 Here below let’s describe the different sectors individually

1.5.1. Transport sector

Some of the products are;

3-Axle draw bar fuel Trailer

Low bed Semi trailer Bus body

Depots at Kombolcha Penstock delivered to TisAbay Hydroelectric

Industrial equipment erected at

Coal-firing equipment installation

1.5.5. Electromechanical construction and HVAC

1.5.6. Agricultural sector

1.6. The overall organizational structure of the company

1.7. Work flow of the company

1.8. OVER ALL INTERNSHIP time

1.9. OVERVIEW OF THE COMPANY

Band saw shearing machine bending machine

CNC Coordinate Gas Cutting One of the Computerized Bending

Steel Structure and Industrial Components construction shop

Structural steel works Overhead crane 3.5, 5, 10 tons

Back view front view of the rolling machine

Sugar factory components

2. Dish end maker machine

Poor surface finish

2.1. SHORT SUMMRY OF THE PROJCT

2.2. PROBLEM STATEMENT

 By observing the company

 By interviewing the work mans of the company and

2.5. Limitation of the study

2.6. Scope of the study

2.8. Design analysis

938 388 750 1876 750 388 938

Development drawing of the tori spherical end.

So, load applied to shear is

F=max*A , where max=maximum shear stress

=yt/f.s but yt=y/2

A=cross section where the load applied

Material used for dished end is

St-52 with properties of

Therefore F1=max*A1 , A1=L1*t , max =yt/f.s f.s=3 ,yt=pa/2

=361.15KN in terms of ton it is equal’s to 36.1ton

Approximately the load need to apply to punch is 40 ton in case one.

CASE-2;is the load need to shear in the minor diameter.

F2=max*A2 , A2=L2*t , from above shear max=59.167Mpa

=221.995KN , approximately the value becomes 25 ton.

2.8.1. PISTON ROD DESIGN;

Assume dp=piston rod diameter

D=piston head diameter

Therefore F1=maxA1 , A1=L1t , max =yt/f.s f.s=3 ,yt=pa/2

F2=maxA2 , A2=L2t , from above shear max=59.167Mpa

F= (ΠD/4)(P)……………. (1) where P=pressure acting in the