Internship Report

Declaration of Originality
I, Nasir Sa’ed Mohamed, declare that this report is originally mine; it is a true record
of the work I undertook during my industrial training at Disaster Risk Management
Bureau Fleet Project in Jijiga and, to the best of my knowledge, has never been
submitted as an internship report in Mechanical Engineering or any other academic
qualification to Wallaga University or any other university or academic institution of
higher learning.

Signature: ………………. Date: …………………

Nasir Sa’ed Mohamed

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Approval
This industrial training report was submitted to Wollega University, Department of
Mechanical Engineering after the approval of the following:

Signature: ……………………… Date: ……………………………

Mr. Osman Ali
Training Coordinator
DRMB

Signature: ……………...... Date: ……………………

Ms. Sololo K.
Academic Advisor
Department of Mechanical Engineering
Wallaga University

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Dedication
This report is dedicated to my precious mother for all her unconditional love and
eternal wisdom to me growing up. May you be in the highest places of paradise,
Mom. You will always be in my heart.

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Acknowledgements
First and foremost, I express my sincere gratitude to God for His generosity, guidance
and protection; and for making the training a success. It is entirely by His grace that I
have reached this far in life in general and the academic journey in particular. Praise,
glory and honor be to Him!
I extend my heartfelt gratitude to the management and staff of DRMB Fleet Project
for granting me the valuable opportunity to train at their institution. In particular, my
appreciation goes to the Deputy Manager Mr. Mahad for admitting me and
welcoming me and my fellow interns to the institution with great enthusiasm, and my
training supervisor, Mr. Osman Ali, for his precious guidance and support rendered
to me throughout the training.
Special thanks also goes to the Mechanical Engineering Department of Wallaga
University and the university administration at large for availing me with this study
time so as to apply the theoretical skills learned in class into real life problem-solving
situations and understanding of the Mechanical Engineering profession at large.
With great honor and in a special way, I thank my university advisor Ms. Sololo K.
for her tremendous support and guidance rendered to me during the writing of this
report,
Sincere gratitude is also expressed to my fellow interns, Habon Mohamed, Saed Bile,
Deik Omar, Rukia Yimir, Mas’ud Mohamed, Abdirizak Abdilahi, and Amen Muktar,
with whom I shared valuable ideas; for their support, company and continued team
work exhibited during the entire industrial training period.
I am greatly indebted to my two friends, Shaafi Abdirashid and Kedir Abdirahman,
for the critical role they played in securing internship place for me at this prestigious
institution.
I would like to acknowledge and express my heartfelt thanks and love to my father for
his tremendous assistance, support, love, encouragement and inspiration, and for
always being there for me. You are one of a kind and the greatest of all fathers.
Finally, to all those who have supported my academic journey yet whose names are
not mentioned here, I am truly grateful and very much appreciate all your
contributions. May the ever-good God immensely reward you all!

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Abstract
Industrial attachment is an industrial based practical training experience which is
included in the program of Mechanical Engineering to create an opportunity of pre-
exposure to the industry, where students will exercise their future profession after
graduation. This will allow them to see by themselves the application of the theory
they learned during the first seven semesters and will also facilitate the learning-
teaching process after return from the internship. Exposure to the industry will also
help them identify possible industrial problems on which they could work for their B.
Sc. thesis.
The program is planned in such a way that students will have sufficient background to
follow and understand most of the industrial activities after completion of the 7th
semester. Each student will therefore be sent to an industry at the beginning of the 8th
semester and will stay there during all the working hours and for the whole period.
They will closely follow the industrial activities (both technical and managerial),
participate in the activities in reach of their capacities and, in the process, acquire
knowledge and skill relevant to their future profession as mechanical engineers.
Industrial training is one of the requirements for Bachelor Degree in Mechanical
Engineering. As such, students are required to write and submit reports at the end of
the training.
This report is the record of what I personally did during my industrial training at Disk
Risk Management Bureau (DRMB) from April to July, 2022. It consists of seven
chapters which altogether entail background information about the institute I was at,
present various daily activities I carried out at the institute, view how my academic
background was of value during the internship, give a detailed personal critique of
self, and finally end with recommendations and a conclusion.
This report also presents design and analysis of car screw jack with the aim of
increasing safety of mechanics at DRMB. A screw jack serves to give mechanical
advantage by changing rotational force to linear force thus allowing one to lift a load
and support it at a given height. The aim of the project was to come up with a design
procedure for a simple screw jack. The technical chapter is divided into various
sections that describe parts of screw jack, material selection and design analysis.

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Table of Contents
Contents Pages
Declaration of Originality...............................................................................................I
Approval........................................................................................................................II
Dedication....................................................................................................................III
Acknowledgements......................................................................................................IV
Abstract.........................................................................................................................V
List of Figures..............................................................................................................IX
List of Tables.................................................................................................................X
Acronyms.....................................................................................................................XI
Chapter One.................................................................................................................1
Introduction to Disaster Risk Management Bureau.................................................1
1.1 History of DRMB.................................................................................................1
1.2 Location of DRMB...............................................................................................1
1.3 Main Services of DRMB......................................................................................1
1.4 Vision and Mission Statements of DRMB...........................................................1
1.4.1 Vision.............................................................................................................1
1.4.2 Mission...........................................................................................................1
1.5 Organizational Structure of DRMB......................................................................2
1.6 Work Flow Structure............................................................................................3
1.7 Clientele of DRMB...............................................................................................4
1.8 Department of DRMB and Their Tasks...............................................................4
Chapter Two.................................................................................................................8
Interesting Case Studies, Events and Experiences....................................................8
2.1 Major Activities During Internship......................................................................8
2..1.1 Diagnosis and Correction of Failure of a Car Battery..................................8
2.1.2 Replacement of Water Pump.......................................................................10
2.1.3 Replacement of Leaf Springs.......................................................................11
2.1.4 Replacement of a Tire..................................................................................12
2.1.5 Adjusting the Clutch....................................................................................14
2.2 Memorable Experiences.....................................................................................17
Chapter Three............................................................................................................18
View on How My Academic Background Was of Value during Internship.........18
Chapter Four..............................................................................................................19

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Detailed Personal Critique of Self............................................................................19

4.1 Individual Growth..............................................................................................19
4.2 Experience Gained/Achievements from the Internship......................................19
4.2.1. In Terms of Improving Practical Skills.......................................................19
4.2.2 In Terms of Upgrading Theoretical Knowledge..........................................19
4.2.3 In Terms of Improving Interpersonal Communication Skill.......................20
4.2.4 In Terms of Improving Team-Work Skills..................................................20
4.2.5 In Terms of Understanding About Work Ethics Related Issues..................20
4.2.6. In Terms of Entrepreneurship Skills...........................................................21
4.3 Individual Performance and Some Challenges Faced During the Training.......22
Chapter Five...............................................................................................................24
Usefulness of My Internship for Future Career......................................................24
Chapter Six.................................................................................................................25
Project Done on Screw Jacks....................................................................................25
6.1 Introduction........................................................................................................25
6.2 Working Mechanism of Screw Jacks.................................................................25
6.3 Statement of Problem.........................................................................................25
6.4 Objectives...........................................................................................................25
6.4.1 General Objectives.......................................................................................25
6.4.2 Specific Objectives......................................................................................25
6.5 Review of Literature...........................................................................................26
6.5.1 Introduction to Literature Reviews About Design of Screw Car Jack........26
6.5.2 Illustrations of Literature Reviews About Design of Screw Jacks..............26
6.6 Components, Material Selection and Specification............................................27
6.6.1 Components of Screw Jack..........................................................................27
6.6.2 Material Selection........................................................................................27
6.6.3 Design Specification....................................................................................28
6.7 Design and Modeling of Screw Jack..................................................................28
6.7.1 Design of Screw Spindle..............................................................................28
6.7.2 Designs of Nut.............................................................................................30
6.7.3 Design of Head and Cup..............................................................................33
6.7.4 Design of Body............................................................................................36
6.8 Conclusion and Recommendation......................................................................37
6.8.1 Conclusion...................................................................................................37
6.8.2 Recommendation.........................................................................................38
Chapter 7.....................................................................................................................39
Overall Recommendations and Conclusion.............................................................39

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7.1 Recommendations..............................................................................................39
7.2 Conclusion..........................................................................................................40
References....................................................................................................................41
Appendices...................................................................................................................42

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List of Figures
Figures Pages
Figure 1: Organization Structure of DRMB...................................................................3
Figure 2: Work Flow Chart of DRMB...........................................................................4
Figure 3: Spare Parts Department..................................................................................5
Figure 4: Some Tools.....................................................................................................5
Figure 5: Open-end Wrenches.......................................................................................6
Figure 6: Ratchets, Extensions and Sockets...................................................................6
Figure 7: Workshop Department....................................................................................7
Figure 8: Replaced Batteries........................................................................................10
Figure 9: New Battery..................................................................................................10
Figure 10: Replaced Pressure Plate..............................................................................15
Figure 11: New Pressure Plate.....................................................................................15
Figure 12: Replaced Clutch Disk.................................................................................16
Figure 13: New Clutch Disk........................................................................................16
Figure 14: Screw Spindle.............................................................................................28
Figure 15: Nut..............................................................................................................30
Figure 16: Head............................................................................................................33
Figure 17: Handle.........................................................................................................34
Figure 18: Body............................................................................................................36

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List of Tables
Tables Pages

Table 1: Mechanical properties of cast iron.................................................................28

Table 2:Mechanical properties of carbon steel............................................................27

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Acronyms
Symbol Meaning
σt Tensile strength
σc Compression strength
τ Shear strength
Le Endurance limit
W Load
Ac Cross sectional area
Dc Core diameter
f.s Factor of safety
T Torque
Dm Mean diameter
do Outer diameter
μ Coefficient of friction
Ј Polar moment
σmax Maximum principle stress
τmax Maximum shear stress
pb Bearing pressure
n Number of thread in contact
with screwed spindle
h Height of the nut
σt Tearing strength of the nut
D1 Outer diameter of nut
D2 Outer diameter of collar
D3 Diameter of head screw
D4 Diameter of pin
D5 Diameter of the body
D6 Inside diameter at the bottom
D7 Outer diameter at the bottom
σc Crushing strength of the nut
t1 Thickness of the nut collar
L Length of the handle
M Bending moment
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σb Bending stress
H Height of head
Leff Effective length of screw
σy Yield stress
C End fixity coefficient
K Radius of gyration
Wcr Critical load
I Moment of inertia
E Bulk modulus
t2 Thickness of the body
T3 Thickness of the base
Hb Height of the body
η Efficiency of the screw jack
TO Torque required rotating screw with no friction
T Total torque subjected to handle
T1 Torque required rotating the screw
T2 Torque required overcome friction

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Chapter One
Introduction to Disaster Risk Management Bureau
1.1 History of DRMB
DRMB is a governmental enterprise which was established in 2016 G.C (2008 E.C). It
was found necessary to obtain adequate machineries in quality that are competent usage
for the various development activities being carried out in the region as well as for the
managements and utilization of vehicles. It’s found necessary to organize one
administration of maintenance of heavy machineries owned by Somali Regional State and
it was necessary to establish a public body responsible for maintenance and inventory of
government.
1.2 Location of DRMB
DRMB is located on Jijiga Highway before reaching Jijiga University and after passing
the Ethio Telecom’s main branch.
1.3 Main Services of DRMB
 It provides food assistance for those in the region who are affected by droughts.
 It solves the problem of transportation in and around Somali Regional State.
 It gives vehicle services for customers with fair prices.
 It gives proper maintenance and renewal of vehicles.
 It manufactures spare parts of the machineries.
 It engages in any other activities necessary for attainment of its purpose.
1.4 Vision and Mission Statements of DRMB
1.4.1 Vision
 To be the leading and commendable Somali Regional State urban transport
provider.
 To obtain adequate machineries and garage service in quality and that are
competent its usage various development activities year of 2025.
1.4.2 Mission
Providing, modern, suitable, sustainable, and speedy urban transport service to the
enterprise beneficiary community with an affordable price expressively. The enterprise
shall perform the following activities:
 Undertaking re-engineering of works which can grow up its institutional capacity
in light of the procedure, organization and human resources.
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 Undertaking performance centered activity, which enhances discharging its

capacity in adequate manner.
 Establishing service Improvement system for handling customer complaints
suggestions; working in close collaboration with shareholders and collaborator.
1.5 Organizational Structure of DRMB
As per the current structure of DRMB, there are seven divisions and two services each of
them containing its sub sections:
Divisions
 Operation Division
 Technical Division
 Service Researching, Designing and supervision Division
 Property purchasing and provision Division
 Property purchasing and provision division.
 Finance and Human resource division
 Audit and inspection service
Service
 Plan and data processing service
 Legal service

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Figure 1: Organization Structure of DRMB

1.6 Work Flow Structure
Work flow Structure of DRMB is as follows:

General Manager

Administrator

Marketing Manager

Mechanics

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Welders

Store and tool

management

Guards

Figure 2: Work Flow Chart of DRMB

1.7 Clientele of DRMB
The customers of DRMB are governmental and non-governmental organizations which
include:
 People of Somali Regional State for transportation maintenance.
 Many insurance companies when accidents face their customers’ cars.
 Save the Children Organization for their car maintenance.
 World Vision’s and other non-governmental organizations.
1.8 Department of DRMB and Their Tasks
DRMB has five departments. They are listed as follows:
1. Management Department
The first department is the department of administration. It’s the governing body of
DRMB and it contains the manager, the deputy manager and several other organs. When
there is a vehicle to be maintained, the driver firstly notifies the management department,
and after that this department commands the responsible personnel to execute the task.
Tasks this department performs:
 Managing and overseeing the staff.
 Estimating the capacity of the task to be performed and assigning workers as such.
 Conducting research and development activities.
 Conducting automotive capacity building training.

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2. Spare Parts Department

The spare part department contains all the spare part materials that could be needed for
the vehicles. The department contains two stores: one store is for removed parts which
could be needed later after repairing. The other store is for new parts which would be
used to replace the broken or removed parts. This department is run by its own person and
is very accessible mostly.

Figure 3: Spare Parts Department

3. Tools Department
Of course without tools, no task is ever possible. This department governs all the tools
needed to perform the given task on
vehicles. Tools like wrenches, ratchets,
breaking bars, jacks and etc. were all
sitting in this department. Like the spare
part department, this department has also
its own responsible personnel. Some of
the tools found in the tools department
are these:
 Wrench
 Pliers
 Cutting tools
Figure 4: Some Tools
 Chisel
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 Hammer
 Snap ring
 File
 Screw driver
 Flexible extension
 Socket
 T-handle
 Oil filter wrench
 Lug wrench
 Extension
 Pipe wrench
 Caliper

4.

Figure 6: Open-end Wrenches Figure 5: Ratchets, Extensions and Sockets

4. Workshop Department
This is the department where metals are manufactured, modified, joined or cut using
different tools and machines. It contains welding (arc welding and gas welding), grinders
and others.
Workshop is divided into these sections:
 Welding section
 Machining section
 Electric section
 Accessory room
This department executes these tasks:

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 Manufacturing of bolts and nuts for the vehicles

 Joining metals
 Cutting metals

Figure 7: Workshop Department

5. Vehicle Maintenance Department
This is arguably the most important department in DRMB. It’s where vehicles are
actually maintained. Engine, gearbox, body parts and all other parts of the vehicle are
fixed here. It is the most congested place in the company and it’s where always the work
is being carried out.
This department performs the following tasks:
 Maintenance of engine
 Maintenance of gearbox
 Maintenance of body parts
 Checking the vehicle and searching for faults
 Lubricating the vehicles
 Other services like washing and cleaning

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Chapter Two
Interesting Case Studies, Events and Experiences
2.1 Major Activities During Internship
During my training at DRMB, I participated in different practical activities where I
applied the theoretical knowledge and skills acquired in class into real world problem
solving situations. The activities included among others: clutch adjustment, diagnosis and
correction of battery failure, tire replacement, diagnosis and correction of power steering
faults of a car and replacement of hydraulic oil of a truck. They are detailed below.
2..1.1 Diagnosis and Correction of Failure of a Car Battery
Battery failure is often reported and is one of the major causes of vehicle breakdowns.
With modern vehicles full of complex and sensitive electrical equipment that constantly
draw current from the battery, an ever-increasing number of mechanical faults from new
and older vehicles alike are battery related. However, the expense and inconvenience of
battery failure could be heavily reduced by regular battery maintenance.
Common Faults of the Car Battery, Their Causes and Remedies
The following are the common faults associated with the car battery; their causes and
corrections.
A. Low Charge
This is caused by leaving the battery in uncharged condition for a long time and also
when battery usage exceeds battery capacity.
Solution: The best solution for this problem is to recharge the battery. A jump start as
well as a trickle charger can be used for this operation. A trickle charger is most
commonly used. It delivers electricity to the battery from a power outlet in a slow, steady
stream. It has an electric cord with a plug and two jumper cables with alligator clips.
B. Sulphation
If the battery is allowed to stand in a discharged state either on or off the vehicle for a
long period of time, a chemical reaction takes place which permanently impairs the
performance and life of the battery. It can be seen as a fine white/grey coating of the
positive plate. This is called sulphation.
Solution: Clean the battery terminal.

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C. Wear and Tear Due to Ageing

As the battery is charging and discharging, the active materials within the battery plates
are in motion in order to release electricity stored by the battery. This leads to the wear
and tear of the battery when used for a long period of time.
Remedy: Replace the battery.
D. Incorrect Application
This is when the battery is not correctly applied or installed. Therefore, it cannot function
properly on the vehicle.
Remedy: Ensure that the correct battery in the right condition has been used in the right
application.
E. Low Acid Stratification
This is when the electrolyte on the stratified battery concentrates on the bottom causing
the upper half of the battery to be poor.
Remedy: Replace the electrolyte.
F. Low Acid Level
This is when the level of the acid in the battery is not enough as required.
Remedy: Refill the battery to required level.
H. Overcharging
If the alternator regulator is not set properly, an alternator voltage control circuit fails.
Then the battery can be subjected to an excessive charge. If left unchecked for a long
time, the battery will overheat and will start to evaporate the electrolyte.
Remedy: Replace regulator with another.
I. Electrical Faults
These are caused by excessive use of electric consumers for example air conditioning,
long standing time without recharge, vehicle lightings and hazard flashers left on.
Remedy: Recharge the battery; lightings and flashers should not be left on.
Fault Found with the Battery
After the diagnosis, it was found that the battery was too old. The problem was corrected
by replacing the battery.
Technical Procedures Followed
The following procedures were followed to recharge the battery;
A. The battery terminals were checked and cleaned using a manual sand paper.
B. The cell caps were removed.
C. The charger cables were attached with the car turned off.
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D. The charger was turned on for the battery to charge itself.

E. The battery was checked to find out whether it worked after charging and it didn’t
function.

Figure 8: Replaced Batteries

Figure 9: New Battery

2.1.2 Replacement of Water Pump
The engine of a vehicle needs coolant just as much as it needs oil. Engine coolant helps
protect against high heat. It is cycled from the radiator throughout the engine, absorbing
heat from engine operation and then allowing that heat to wick away into the atmosphere
at the radiator.

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The water pump is the key to making the entire system work. It is an impeller pump,
buried under the timing belt cover on the side of the engine. The pump is operated by the
drive belt of the engine – as the belt turns, the pump turns. Blades on the pump force the
coolant to flow through the engine.
When the water pump fails or is beginning to wear out, it can lead to complete engine
failure. The water pump is the key to making the entire system work. Like any other
mechanical device, they will produce a few warning signs that they are wearing out.
Fault Found with the Water Pump
The water pump was worn out which could lead to complete engine failure. This
prompted its replacement.
Technical Procedures Followed
A. The radiator was drained.
B. The fan belt was removed, carefully noting how it was routed before removing it in
order to reinstall it correctly afterwards.
C. Any other accessories that were blocking access to the pump were removed. This
included the fan, fan shroud, timing belt cover, or any brackets.
D. The water pump was unbolted from the engine.
E. The pump mounting surface was cleaned to remove all traces of old gaskets. The
mounting surface must be clean and dry before installing the new pump.
F. The gasket was positioned on the new pump using gasket sealer or adhesive as
required, and then the new water pump was bolted to the engine.
G. The cooling system was refilled.
2.1.3 Replacement of Leaf Springs
The rear suspension under some vehicles is supported by a pair of leaf springs made up of
multiple leaves (strips) of spring steel. A leaf spring is a component of suspension
systems of some vehicles. They are composed of several (or occasionally just one) thin
strips of metal, called leaves, arranged on top of each other to form a single curved piece.
Typically, they have three or four individual leaves that make a set of springs. Leaf
springs have a specific curvature, and this curvature and the number of leaves in the
spring pack; determine the load capacity and the ride height of the vehicle. The curvature
also helps the spring absorb impact. The bending of the leaves and the friction between
them as they slide slightly over each other while bending, absorb the weight of the vehicle

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as well as any bumps. Leaf springs should be replaced when they are worn out, flattened
out, cracked or broken.
Maintenance of Leaf Springs
Multi-leaf springs occasionally get “sticky” as dirt works its way in between the leaves;
the effect can be to make the ride slightly stiffer, but this is rarely a significant problem.
The attachment points will need to be checked periodically and lubricated in some cases
as specified by the manual of the manufacturer, and regular maintenance should be
carried out. If the body of the car seems to sit too low over the wheels, this sagging is
usually due to the leaf springs having bent slightly over time, and the solution is to have
them replaced.
Fault found with the Leaf Springs
The leaf springs were broken as depicted by inspection. This necessitated their removal
and replacement.
2.1.4 Replacement of a Tire
Tires are often the most neglected components on vehicles, but better care should be
taken of them, our lives on the ride depend on them. They support the overall weight of
the vehicle and thus must be in good conditions to function properly. They are one of the
most important components of the vehicle. The tire tread area making contact with the
road is relatively small– only about the size of the palm of the hand - so if tires are worn
or damaged it can seriously affect the safety and handling of the vehicle. Figure 19 below
shows the operation.
Minimizing Tire Problems
Tires are the only point of contact that the vehicle has with the road and as such, they
need to be in good working condition at all times to ensure the safety of the users. To
minimize tire problems and thus maximize the life of tires and achieve optimal
performance from the vehicle, observe the following:
A. Ensure that tires are correctly inflated. Driving with incorrect tire pressures can
affect handling and braking of a vehicle, particularly in wet conditions, and can seriously
compromise safety of users. In some cases, tires are over-inflated which inhibits vehicle
handling and causes excessive wear on the center strip of a tire. Driving on severely
under-inflated tires can cause heat build-up and eventually a premature failure. Check tire
pressure regularly and before every long trip.

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B. Observe the load capacity. Do not exceed the load capacity relative to the load index
of the tires. Overloading a vehicle increases strain upon the tires which raises
temperatures, causes rapid wear and significantly heightens the risk of receiving impact
damage that leads to premature failure. Consult the vehicle handbook to find pressures
should there be need to fully load the vehicle.
C. Manage the speed of the car. Driving at very high speeds over long and short
distances causes tire temperatures to increase, which in some cases can lead to tire
damage. If tires are not correctly inflated, driving at high speeds also increases the
likelihood of sudden tire failure and rapid loss of air. To maximize the life of tires,
observe speed limits and avoid aggressive acceleration/deceleration.
D. Make use of spare tires. If any damage to a tire or wheel is seen, replace tire with
spare tire and have tires checked by a professional.
E. Inspect the tires. It may not always be noticed if one of the tires has been damaged.
Inspect tires regularly for wear and any damage to avoid any sudden problems. Also, have
a professional inspect the tires every year.
Note: Unfortunately, many tire problems are unavoidable. Tires can be checked regularly
but still fall foul of an errant nail, piece of metal or a pesky pothole. However, if the
guidelines are followed and tell-tale signs of potential problems are looked out for;
longest life possible out of tires can be got.
Fault Found with the Tire
Inspection of the tire indicated that it was worn out; this prompted its removal and
replacement.
Technical Procedures Followed
A. The truck was parked on a flat surface.
B. The parking brake was applied and the truck put in to park position.
C. Rocks were placed in front of the front and back tires.
D. The jacks were placed under the frame near the tire that was to be replaced.
E. The jacks were raised until they were supporting but not lifting the car.
F. The hubcap was removed and the nuts loosened by turning them counterclockwise. G.
The jacks were pumped to lift the tire off the ground.
H. The nuts were removed by turning them counterclockwise until they loosed.
I. The tire was then removed.
J. The spare tire was placed on the hub, its rim aligned with wheel bolts and lug nuts put
in positions.
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K. The nuts were tightened using the wrench in a star pattern.

L. The truck was lowered without applying full weight on the tire, and the nuts were
tightened further.
M. The truck was fully lowered to the ground.
N. The jacks were removed.
O. The nuts were tightened finally and the hubcap replaced.
P. The truck was road-tested and the new tire was found to be functioning well.
2.1.5 Adjusting the Clutch
If the clutch is maintained properly, it can be good for the life of the vehicle. Most
modern vehicles with manual transmissions have self-adjusting clutches that require no
adjustment, but models without self-adjustment should be properly adjusted.
Faults Found with the Clutch System
Inspection of the clutch system revealed the following faults that prompted the operation.
A. The clutch was getting worn out.
B. There was difficulty shifting, the shifter was not moving freely.
Technical Procedures Followed
A. The parking brake was engaged, the gear shifter put in neutral, and the clutch pedal
pressed to the floor.
B. The access opening for the clutch assembly was located under the truck just behind the
oil pan. A torch light was used to see where the adjustment plate was.
C. With the clutch pedal depressed, a large flathead screwdriver was used as a lever to
rotate the flywheel assembly till the adjustment plate was at the bottom and fully
accessible.
D. Using a socket, only the left-hand bolt which secures the retaining strap was removed.
E. The retaining strap was removed and set aside.
F. Using a wrench, the adjusting bolt on the splined shaft was rotated clockwise (handle
towards the side of the driver) until the proper amount of clutch adjustment was achieved.
G. Reassembling was done and the car was road-tested and found to be functioning
properly.

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Figure 10: Replaced Pressure Plate

Figure 11: New Pressure Plate

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Figure 12: Replaced Clutch Disk

Figure 13: New Clutch Disk

2.1.6 Brake Service

Brakes are one the most important elements in the vehicle. Not caring for the brakes leads
to dangerous situations in which they could be not functioning properly, or worse not
functioning at all. Most common brake problems are dirt getting in the brake system or
brake shoes fading.

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When we disassembled the brake system, we found there was a lot of dirt and we washed
it.
Technical Procedure Followed
A. Car was jacked.
B. Wheel was removed.
C. Drum was removed.
D. Springs, retainers and shoes were removed.
E. Brake system components were washed.
2.2 Memorable Experiences
One memorable experience which I am proud of is the day we were uninstalling a battery
from a vehicle and the mechanic asked me how to tell between the two terminals of the
battery. Since the signs were torn off, I couldn’t’ see them. From my Automotive
Electrical and Electronic Systems course teacher I remembered that the positive terminal
is always bigger than negative terminal and quickly told him which terminal was the
positive one and which terminal was the negative one.

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Chapter Three
View on How My Academic Background Was of Value during
Internship
Much of my first seven semesters of my academic journey was very helpful and came in
handy during my internship. Taking courses like IC Engines, Basic Workshop,
Maintenance of Machineries, Motor Vehicle Engineering, Basic Electricity,
Manufacturing, and many more made me quite skilled and equipped with enough
knowledge to know what was going on at the field of the internship, especially when it
comes to the maintenance of vehicles. My knowledge of the systems of vehicles and their
components was helpful in decoding the complicated language of mechanics and
mechanical engineers.
In addition to that, my knowledge of Machine Element, Machine Design, Theory of
Machines and Machine Drawing helped me identify design faults in the company and
eventually construct the complex of screw jack. Without this knowledge I wouldn’t have
been able to achieve the project I did.
Nonetheless, I wouldn’t say that all the courses and all the knowledge I consumed in class
was implemented on my internship. Unfortunately, some of what I studied were left
unused during my internship. My tremendous knowledge in courses like
Thermodynamics and Turbomachinery were not much needed on the field.
Some coursework I would like to have completed before going to the internship is some
engine maintenance or engine breakdown. This is one of the most important works that
any automotive company does, so it is very essential for the student to have some solid
ground there. I also wish there were some industrial or garage visits in our curriculum
before the internship. This would have given me an insight of what to expect before
internship. It would have made me not feel about my internship as new and difficult task
like I did in my first days of internship.
In general, my academic background was very valuable to me in my internship and
without it my entire internship would not have been as successful and enjoyable as it has
been.

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Chapter Four
Detailed Personal Critique of Self
4.1 Individual Growth
Four months of being in Jijiga and having to pay for my own rent and food, having to
work many hours in the day, meeting and conversing with new people, working with staff
and other interns, those things taught me hard work, time management, perseverance,
using money efficiently, and looking many things from many angles. There was also
much wisdom which I have learned from the senior mechanics and engineers at DRMB.
Listening to the stories from their education in the past which was comparatively difficult
taught me to be grateful to what I have now. So it’s no doubt that the internship helped
me grow as an individual.
4.2 Experience Gained/Achievements from the Internship
From the industrial training, I acquired a number of skills and knowledge through the
application of the theoretical knowledge learnt in class into the practical operations which
led to an improvement and widening of my engineering knowledge. All activities were
carried out while taking note of all the safety precautions necessary to prevent accidents
and produce the desired results accurately and in time while using the right tools and
following the correct procedures.
4.2.1. In Terms of Improving Practical Skills
After spending four months at the company I have gained the practical skills on how to
repair vehicles and find problems. In the engine section I have learned the process that
should be taken to overhaul an engine which is disassembling and assembling. In each
step there are tools that are used specially made for the case and I have familiarized
myself with them.
Also, I have learned the steps to repair, and as well as maintaining of heavy-duty
machines and trucks. The most important skill that I acquired from my four months of
stay in this company is the skill of reading manuals and interpreting them.
4.2.2 In Terms of Upgrading Theoretical Knowledge
In terms of upgrading my theoretical knowledge, the practical knowledge has helped me
to understand more about vehicles, like:
 how they work
 what their components are

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 what their differences are

 how to inspect them
 how they are repaired and maintained
And also, the internship program gave me the opportunity to apply my theoretical
knowledge in real world environments. There are so many courses like IC Engine, Motor
Vehicle Engineering and Machine Design which I have come to understand more. Due to
this fact my stay at the company has helped me upgrade my theoretical skills a lot.
4.2.3 In Terms of Improving Interpersonal Communication Skill
A task might be appointed to two or more persons. In this case interpersonal
communication skills are essential. Dividing the task and assigning it to different peoples
is more suitable. This will also ensure faster completion of the task. The most important
part of communication skills is listening and being open-minded. The other main thing in
interpersonal skills is the ability to accept criticism. One may not see a problem that the
other sees. Just because one did not see the problem does not mean that one is less good
than the other, it just means that two different people see one problem from two different
angles. So, if some major problem occurs, everyone should be able to accept criticism and
be open-minded. This was a lesson.
4.2.4 In Terms of Improving Team-Work Skills
During the internship program I have acquired valuable team-work skills. In terms of
team playing I have learned the ability to work cooperatively and share tasks. Working
among a team, I learned sharing responsibility, understanding others’ ideas and working
together. By working together on one wider task I learned how to handle responsibility,
working diligently, and finishing the task on time. Above all I learned the significance of
the contribution an individual makes to the success of the team.
4.2.5 In Terms of Understanding About Work Ethics Related Issues
The benefit of my internship program was interesting in the development of strong ethical
work since work ethics is vital to a company achieving its goals. So, every employee
must have a good work ethic to keep the company functioning at its peak. The work
ethics of the workers of this company is what I took from this internship. Younger
mechanics should have respect for their elderly colleagues even if they disagree with
them sometimes.
Some of the work ethics I learned are the following:

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 Reliability - the worker should be qualified for the part he/she is supposed to be
performing. He/she must have appropriate skills and knowledge for the task
assigned.
 Honesty: regarding this value each worker regardless of its status should abstain
from bad behaviors such as cheating, bias, corruption etc.
 Cooperation: each worker should be interacting and cooperating with others while
working. That is because it is the only way problems could be easily solved.
 Punctuality: means keeping the companies work time from the beginning to
ending time and to complete a given task within the given period. It was
challenging to come punctual for the first days of work. But gradually I began to
start and end my task on time.
4.2.6. In Terms of Entrepreneurship Skills
The benefits I gained from the internship in terms of entrepreneurship is the willingness
to take risks and develop, organize and manage a business venture in a competitive global
market place that is constantly evolving.
During this four-month internship program I developed entrepreneurship skills such as:
 management skills: the ability to manage time and people (both yourself and
others) successfully;
 the ability to work both as part of a team and independently;
 the ability to plan, coordinate and organize effectively.
Overall, the following were the achievements from the training:
A. Maintenance of vehicles and equipment.
B. Exposure to the demands and challenges of the workplace.
C. Appreciation of the professional and therefore better work ethics.
D. Improved confidence in problem-solving.
E. How to relate to different categories of people likely to be met in real-life situation.
F. Opportunity to meet and work with potential employers.
G. Gained first-hand experience working as an engineering professional.
H. I learnt how to work with other engineering professionals and the value of teamwork
in engineering.
I. I was able to increase my technical, interpersonal and communication skills, both oral
and written.

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4.3 Individual Performance and Some Challenges Faced During the

Training
My individual performance was very good during the internship. I would always come in
time, engage with staff and other interns, accomplish the given tasks, think creatively and
ask questions to the engineers. Nevertheless, during the training, a number of challenges
were faced which without them, my performance could have improved. Some are listed
below:
A. Most technical words used in motor vehicle work were not familiar to me and were in
Somali or in Amharic contrary to the university which I learned in English, but with more
research and inquiries with the senior mechanics and through reading of vehicle manuals
to get acquainted with them, I eventually overcame it.
B. In the earlier days of the training, several accidents and injuries were sustained for
example cuts on fingers and legs; however, with time, vigilance on work was increased
which reduced on injuries.
C. Language barrier. The language used at the work place by some of the engineers and
the staff was Amharic which I am not good at but I usually requested my fellow interns to
kindly translate for me and also efforts were made to learn the key words normally used
while carrying out operations.
D. While making inquiries from the senior mechanics on the operations being carried out,
different reactions would be received from different people; some were welcoming while
others were tough. So most of the research and inquiries were made with the friendly
mechanics and serious efforts were made to befriend everyone at the workshop.
E. Delay of some spare parts of the vehicles which made some work not to be completed
in time.
F. Most of the work needed use of heavy tools and machine components which made the
work difficult, tiresome and time consuming. In such cases, help was sought from other
people in the workshop to help especially in lifting the heavy machine components and
tools.
G. Inadequate tools and lack of some equipment caused delay of the work hence creating
work backlogs.
H. Unfavorable weather conditions like heavy rainfall often disrupted activities at the
workshop. In such cases, operations were carried out under an erected structure, which
however could only accommodate small vehicles.

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I. Relating theoretical knowledge to practical situations was a great setback. However,

through continuous research and persistent inquiries from the workshop technicians, it
became easy.
J. Limited time to share knowledge with all engineers and technicians due to tight
schedules at the workshop.
K. Inadequate financial support to cater for my daily expenses like transport, meals and
others.
L. Limited working space due to congestion in the workshop.
M. Inadequate safety guards during operation of some machines like air compressor
which blows dust from air cleaners.
N. Lack of a well-designed training program and an immediate person who is responsible
for the affairs of the trainees. This made trainees not to fully exploit some of the most
important engineering aspects of the institution as there was no serious monitoring and
also access to some of the sections was either not easy or prohibited without the
permission of a supervisor.
O. Some unprofessionalism in workplace from younger mechanics who didn’t listen to
senior mechanics caused a bit of frustration and disagreement among the staff.
P. Sometimes lack of a defined procedure to solve the problem made me become lost
about what step will be taken next.

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Chapter Five
Usefulness of My Internship for Future Career
As I have written above, my internship was very helpful in clearing my future vision for
me. Before going to the internship, I had no good idea what mechanical engineers do and
what their life revolves on. But after engaging with mechanical engineers and seeing how
their lives is, it made me realize what my future profession looks like. With the tasks that
DRMB executes, the way it runs the business, the way that operations like vehicle
maintenance and manufacturing are performed, it increased the choices I had for future
career which I could pursue. It inspired me to work hard for what’s left of my education
so that I can work like them one day. Also, my internship was very beneficial in building
my confidence for later when I get a job. It made the work that mechanical engineers do
become familiar with me.

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Chapter Six
Project Done on Screw Jacks
6.1 Introduction
Screw jack is also called jackscrew in other terms. A screw jack is an example of a power
screw and referred to as a mechanical device that can increase the magnitude of an effort
force. Screw jacks are used for raising and lowering platforms and they provide a high
mechanical advantage in order to move moderately heavy and large weights with
minimum effort. They function by turning the lead screw when raising or lowering of
loads.
6.2 Working Mechanism of Screw Jacks
The jack is raised and lowered with a metal bar, which is inserted into the jack. The
operator turns the bar with his/her hands in a clockwise direction. This turns the screw
inside the jack and makes it go up. The screw lifts the small metal cylinder and platform
that are above it. As the jack goes up, whatever placed above it will raise as well, once the
jack makes contact. The bar is turned until the jack rises to the required level. To lower
the jack, the bar has to be turned in the opposite direction.
6.3 Statement of Problem
The great problem that I have seen in my DRMB is poor safety condition during
maintenance. As we know, the weight of the vehicle is very heavy and no proper
condition was there to carry it. This may cause dangerous working condition, unwanted
cost and injury of mechanics. The solution, which made before now, but most garages
including my hosting company didn’t do, is screw jack.
6.4 Objectives
6.4.1 General Objectives
 To design a screw jack
 To improve safety condition of mechanics at DRMB

6.4.2 Specific Objectives

 To design a simple and portable screw jack using Machine Design concept
 To design durable and free-of-buckling screw jack using the suitable materials
 To draw the 3D model of components of screw jack
 To draw the assembly of screw jack

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6.5 Review of Literature

6.5.1 Introduction to Literature Reviews About Design of Screw Car Jack
In this section project papers are discussed related to the present work. Published papers
are highlight in this section. The main purpose of this literature review is to get
information about the project from the reference books, magazines, journals, technical
papers and web sites. In this chapter the discussion will be made based on all the sources.
After going through various literatures on screw jacks, some of the selected papers are
cited below and which are considered as basis for developing structural analysis
methodology for screw car jack.
6.5.2 Illustrations of Literature Reviews About Design of Screw Jacks
"Experimental Investigation of the performance of a Laboratory Screw Jack' and
concluded it has been established that the relationship between the loud and efficiency,
and between the loud and effort applied is linear and was also discovered that decrease in
load means decrease in effort and decrease in load causes increase in efficiency. [1]
In this paper a lifting device is a system that allows small force (effort) to overcome a
large force or load. There are practically hundreds of uses for lift tables in manufacturing,
warehousing and distribution facilities. The addition of this device (lift table) makes job
faster, safer and easier. Some typical applications include; machine feeding and off-
loading, product assembly, inspection quality control repair, feeding and offloading
conveyor levels. The commonest method for operating a scissors lift is the use of a power
screw. [2]
The manually operated screw jack lift is a device that makes use of a horizontally placed
power screw to overcome large load through less effort applied on the power screw. One
of the most important factors of lift platform is its stability. Knowing that stability is a
source of concern for a lift platform, as positioning should be on a flat surface and the
load should be place or concentrated at the center of gravity of the table. Other constraint
to be considered is the deflection of the unit. Deflection in the lift can be defined as the
resulting change in elevation of all parts of a screw jack lift assembly, typically measured
from the floor to the top of the platform deck, whenever load is applied to or removed
from the lift. [3]
Safety requirement for industrial scissor lifts states that "All industrial screw jack lift will
deflect under load. The Shop standard goes on to outline the maximum allowable
deflection base on platform size and number of scissor mechanism within the lift design.

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Screw jack lift deflection becomes more critical in material handling applications where
the lift must interface with adjoining, fixed elevations, especially when transferring
rolling load.
In these cases, it is important that any difference in elevation between adjoining surfaces
during material transfer be minimized if not totally eliminated. [4]
6.6 Components, Material Selection and Specification
6.6.1 Components of Screw Jack
1. Body
2. Screw spindle
3. Counter sunk screw
4. washer
5. Nut
6. Cap
7. Tommy bar
6.6.2 Material Selection
Materials for body, screw spindle, counter sunken screw and cup
Over all load subjected on those the material for those selected to carbon steel, since the
load applied on these components is high the material used to make these components
should be strong and hard, thus the best material suited is steel which has carbon content
of up to 1.5% which results in an increased strength and hardness.
Table 1: Mechanical properties of carbon steel

Material Carbon steel

Maximum section size, mm 63
Yield strength 385Mpa
Tensile strength 550-700Mpa
Compressive strenght 700
Elongation n% 13
Hardness number 152-207(HB)

Material for nut and washer

Thus, the nut and the washer are subjected to tensile and compressive stress so cast iron
selected for it, because it is malleable and ductile material.

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Table 2: Mechanical properties of cast iron

Mechanical properties British standard specification

Tensile strength (Mpa) 150

Compressive strength (Mpa) 125

Shear strength (Mpa) 105

Endurance limit (Mpa) 96

Young’s modulus (Gpa) 89-114

Modulus of rigidity (Gpa) 36-45

Hardness number (HB) 196

6.6.3 Design Specification

Since the vehicles that DRMB firm deals with are heavy duty, I chose this specification
for the screw jack I am designing.

Maximum load to be lifted is 2460 kg

Maximum lifting height is 200 mm

6.7 Design and Modeling of Screw Jack
6.7.1 Design of Screw Spindle

Figure 14: Screw Spindle

Core Diameter
The core diameter is determined by considering the screw to be under pure compression.
That is;
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𝑤=𝜎𝑐𝐴𝑐 (6.1)
Where
σc = Pure compression stress = 700MPa
Ac=Cross sectional area of the screw shaft = π/4𝑑𝑐2
dc=Core diameter
Hence,
𝑊 = σc ×π/ 4(dc)² (6.1a)
4W
𝑑𝑐 = √ (6.1b)
σc × π
Taking factor of safety 𝑓. 𝑠=5
𝑑𝑐 = √4W×f.s/σc×π (6.1c)
4 × 2460× 9.81 ×5
𝑑𝑐 = √
700 ׿ ¿
dc = 0.0148147m= 14.8147mm
The core diameter 𝑑𝑐 = 16𝑚𝑚, 𝑑𝑜 = 18𝑚𝑚 and pitch 𝑝 = 𝑙 = 2𝑚𝑚.
Torque Required Rotating the Screw
We know that torque required to rotate the screw is the same torque required to lift the
load that given by:
𝑇1= P ×dm/ 2= [Wtan (α+θ)] dm/ 2 (6.2)
We know that
𝑑𝑚= (do + dc)/ 2= (18 + 16)/ 2= 17mm
And
tanα =l/ πdm=2 /π × 17= 0.03745
Assuming coefficient of friction between screw and nut, μ =tanθ=0.1 then
[24132.60 tan(2.1447+ 5.71)]0.017
T1 = =28.298Nm
2
Screw Stresses
Compressive stress due to axial load using the new core diameter is:
4 × 24132.60
σc=4𝑊/Ac= 4W /π(dc)²= =120.025MPa
π ×(0.016) ²
In addition, the shear stress due to this torque using the new core diameter is given by:
T 1× dc
τ=
2J
(6.3)

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Where
J =𝑝𝑜𝑙𝑎𝑟 𝑚𝑜𝑚𝑒𝑛𝑡=πdc 4 /32 (6.4)
Hence,
τ =16T1dc 3=16 × 28.298 π × 0.0163= 35.186MPa
Principal Stresses
Maximum principal stress is as follows:
√ σc ²+ 4 τ ²
σmax= σc+
2
(6.5)
√ 120.025²+ 4(35.186)²
Substituting the stresses, we get. σmax = 120.025 +
2
σmax =129.579MPa
The design value of compressive stress and maximum shear stresses as follows:
σc=700/5= 140MPa
τmax= √σc² +4τ²/2 (6.6)
τmax= √ 120.025²+4(35.186)²/2
τmax= 69.567MPa. The design value of τ = 450/ 5= 90MPa
These maximum shear and compressive stresses are less than the permissible stresses.
Hence, the spindle or shaft is safe.
6.7.2 Designs of Nut

Figure 15: Nut

Height of the Nut
We find the height of the nut (h) by considering the bearing pressure P b on the nut. The
bearing pressure on the nut given by;

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4W
Pb = ¿
π [(do)²−(dc )² ]n ¿
(6.7)
Where
𝑛 = Number of threads in contact with screwed spindle
Material specification for the nut is phosphor bronze which has tensile stress = 150MPa,
compressive stress = 125MPa, shear stress = 105MPa, safe bearing pressure not exceed
17MPa and a coefficient of friction of 0.1.
Assuming the load has uniformly distributed over the entire cross section of the nut and
substituting for the known values, we get the number of threads in contact:
6
17 ×10 π [(0.018) ²−(0.016) ²]n
24132.60 = =907.92 n
4
n =26.58
Say n=27
Then height of the nut is as follows:
h=n×p (6.8)
h=27 × 2 = 54mm
Check: For a safe nut height h ≤4dc = 64mm
Stresses in the Screw and Nut
Shear stress in the screw is as follows:
W
τ (screw) = (6.9)
πn . dc .t
Where
t = Thickness of screw =𝑝/2= 1mm
24132.60
τ (screw) = = 17.782MPa
π × 27× 0.016 ×0.001
In addition, shear stress in the nut is as follows:
τ (nut) =W/πn.do.t (6.10)
Where,
t = Thickness of screw =𝑝/2= 1mm
τ (nut) = 24132.60/π × 27 × 0.018 × 0.001= 15.806MPa
The given value of τ =1055= 21MPa
Check: These stresses are within permissible limit; hence, design for the nut is safe.
The Outer Diameter of Nut

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Outer diameter 𝐷1 is found by considering the tearing strength of the nut.

σt= 4W/ π[(D1)² − (Do)²] (6.11)
Where,
σt =Tearing strength of the nut = Tensile stress
σt =150/5= 30MPa
Then we get D1 as follows:
4 × 24132.60
30=
π [[(D 1)²−(18)²]]
D1=36.718mm
Say D1 = 37mm
The Outside Diameter of Collar
Outside diameter, 𝐷2 is found by considering the crushing strength of the nut collar.
σc =4W/ π[(D2)²−(D1)²]] (6.12)
Where,
σc=Crushing strength of the nut = Compressive stress σc=125 /5= 25MPa
Then we get 𝐷2 as follows:
(24132.60)/ ¿
25=4 ¿
π [(D 2) ²−(37)² ]
D2 =50.971mm,
Say D2 = 51mm𝜋𝑟2
Thickness of the Nut Collar
The thickness of nut collar 𝒕𝟏 is found by considering the shearing strength of the nut
collar.
t1 =W/πD1.τ (6.13)
Shearing strength of nut collar =105/5=21MPa
Therefore
t1=24132.60 /π × 37 × 21
t1=9.88mm
Say t1 =10mm

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6.7.3 Design of Head and Cup

Figure 16: Head

Dimensions of Diameter with Head on Top Screw and for the Cup 𝑫𝟑
Assuming
D3 =1.75do (6.14)
Then
D3 =1.75 × 18=31.50mm
Say D3=32mm
The seat for the cup has made equal to the diameter of the head and then chamfered at the
top. The cup prevents the load from rotating and is fitted with pin of diameter 𝐷4=𝐷3/4
approximately (Gupta, 2005). Therefore, D4=8mm.
The pin should remain loose fit in the cup
Take length of pin to be 9mm.
Other dimensions for the cup have taken as:
Diameter at the top of the cup = Diameter of the head=52mm
Height of cup =9mm
Thickness of cup =3mm
Fillet radii =1mm
Torque Required to Overcome Friction
We know that by assuming uniform pressure condition torque required to overcome
friction given as follows:

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1 ( D 3 ¿ ¿ 3−D 43 )
𝑇2 = ×𝜇1 ¿
3 2
( D3 −D 4 )
2

(6.15)
Where 𝐷3=Diameter of head=32mm 𝐷4=Diameter of pin=8mm
Substituting for the known values, we get:
(0.023 ¿ ¿ 3−0.008 )
3
1
T2= × 0.1 × 24132.60 ¿=27.0285Nm
3 2
(0.023 −0.008 )
2

Total Torque Subjected to the Handle

Figure 17: Tommy bar

Total torque to which the handle subjected given by
T=𝑇1 + 𝑇2 (6.16)
T=28.298 + 27.0285 = 55.326Nm
Activity Professional use Domestic use Pushing 200N (20.4kg) 119N (12.1kg) Pulling
145N (14.8kg) 96N (9.8kg) Table 5.2: Maximal Isometric Force by General European
Working Population for Whole Body Work in a Standing Posture
Therefore, taking the force of 96N then the length of the handle required is
L=𝑇/96
Then
L=55.326/96 = 0.5763m = 576.30mm
𝑆𝑎𝑦 L=580mm
The length of the handle may be fixed by giving some allowance for gripping 70mm.
Therefore, the length of the handle/lever is 646.30mm

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Diameter of Handle (Lever)

The diameter of the handle/lever may be obtained by considering bending effects. We
know that bending moment:
3
π × σb × D
𝑀= (6.17)
32
While σb=σt=σc=700/5=140MPa
And maximum bending moment on the lever/handle
M=Force applied × Length of lever
M=96 × 0.6463=62.0448Nm
Then
π ×140 × 106× D3
62.0448 =
32
D =16.5269mm
Say D=17mm
Height of Head
The height of head is usually taken as twice the diameter of handle.
H =2𝐷 (6.18)
Therefore, H=2 × 17=34mm
Design Check against Instability/Buckling
Effective length of screw,
Leff= Lift of screw + 1/2 of height of nut
Leff= H1+1/2𝐻2 (6.19)
Leff= 200 +54/2
Leff =227mm
When the screw reaches the maximum lift, it regarded as strut whose lower end is fixed
and the load end is free. Therefore, buckling or critical load for this given condition is as
follows (Gupta, 2005):
−σy
¿
Wcr=¿Ac [1 L (6.20)
4 c π ²E( )²
K
Where σy =Yield stress=385MPa

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𝐶 = End fixity coefficient. The screw considered to be strut with lower end fixed and load
end free. Therefore, C =0.25
I
k=the radius of gyration=√ =0.25dc=0.004
A
𝐼 = Moment of inertia of the cross section.
The buckling load as obtained by the above expression and must be higher than the load
at which the screw is designed
Substituting for the known values:
σy L
Wcr=4dc².σy [1− ( )² ] (6.21)
4 c π ²E K
385× 106 0.227
Wcr=4π ×0.016²× 385 × 106[1 – − 9 ( )²
4 × 0.25 π ² × 200× 10 0.004
Wcr=28784.55N
While W =24132.60N
𝑊𝑐𝑟 >W, hence there is no chance for the screw to buckle.
6.7.4 Design of Body

Figure 18: Body

Dimensions for the Body of the Screw
The dimension of the body may be fixed.
1. Diameter of the Body at the Top
D5=1.5D2 (6.22)
D5=1.5 × 51=76.50mm
2. Thickness of the body
t2 =0.25do (6.23)

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t2 =0.25 × 18=4.5mm, t3 =5mm

3. Inside Diameter at the Bottom
D6= 2.25D2 (6.24)
D6=2.25 × 51

4. Outer Diameter at the Bottom

D7=1.75D6 (6.25)
D7=1.75 × 114.75=200.8125mm
5. Thickness of Base
t3 =2t1 (6.26)
t3 =2 × 10=20mm
7. Height of the Body 𝐻𝑏
Height of the body =Max.lift + Height of nut + Extra 50 =200 + 54 + 50=304mm
Finally, the body tapered in order to achieve stability of the jack.
Efficiency of the Screw Jack
Efficiency of screw jack given as follows:
¿ ¿
η=Torque required ¿rotate screw withno friction Total torqure output = T

(6.27a)
¿
η= T (6.27b)

But
Wtanα × dm
To=
2
24132.60× 0.03745 ×0.017
To=
2
To =7.682Nm
And
T =55.326Nm
Therefore
7.682
η= = 0.1388 or 13.88%
55.326

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6.8 Conclusion and Recommendation

6.8.1 Conclusion
The screw car jack is successfully designed so that it withstands all the mechanical
stresses acting on it. The screw car jack is analyzed under various conditions of operation.
The stresses in above-mentioned conditions are found out and thickness and diameters of
various parts are calculated such that the stresses produced in each member are within the
maximum allowable range. All the calculated dimensions have been successfully verified
and hence the design of screw jack is safe.

6.8.2 Recommendation
For the project, I concentrated on the design of a simple mechanical screw jack where the
nut is fixed in a cast iron frame and remains stationary while the spindle is being rotated
by the lever.
This design can work for light loads and heavy loads but when the screw jack is needed
for heavy load application long lifts should be avoided since they can cause serious
overheating and generate a large amount of heat. It should therefore be used under
ambient temperatures with the use of the required lubricants. Design and manufacturer's
instructions such as speed, load capacity and recommended temperatures must be
followed to avoid accidents. Always keep the mating surfaces clean after use and check
for wear and damage on the surfaces.

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Chapter 7
Overall Recommendations and Conclusion
7.1 Recommendations
Following what transpired during my industrial training especially the challenges I
encountered, I recommend the following to the management of DRMB, to Wollega
University, especially Mechanical Engineering Department, and to future interns:
To DRMB Management:
A. Proper waste management should be frequently carried out at the workshop. Rubbish
should be collected together and either burnt or disposed of to keep the workshop clean
every time.
B. There should be a well-designed training program for trainees and an immediate
person responsible for their affairs.
C. All the necessary tools should be availed and close supervision carried out by
registering all the tools and the corresponding workers using them so that in case of any
tool loss, the particular worker is responsible and replaces them.
D. More safety gadgets should be acquired especially for air compressing and panel
beating
E. More air compressors should be acquired so that more air filters can be cleaned within
a short time.
F. Cleaning air filters should be carried out from an open space where there is free
circulation of air to protect the person carrying out the operation from dust and other
harmful fumes.
G. Scraps should be removed from working areas to give more working space as well as
for safety purposes.
H. There should be a scrap yard where scraps are collected and stored.

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I. Management should consider expanding the workshop so as to accommodate the ever-

increasing volume of work at the workshop.
J. Training duration should be extended since the mechanical engineering field is a very
wide one and therefore cannot be fully exhausted within the allocated weeks of training.
K. Materials should be acquired timely and availed immediately upon requisition, to
avoid delay in carrying out work in the workshop.
L. There should be a training for junior mechanics about some fundamental theory about
mechanical engineering so that they can better get along with interns
M. There should be stricter rules on junior mechanics so that they show more
professionalism and listen to their seniors.
To the Department of Mechanical Engineering of Wallaga University:
A. Studies should focus more on the practical side of education rather than the theoretical
side.
B. Courses which are directly related to the internship should be taken in the semesters
close to the internship semester.
C. There should be an orientation about internship right before students go for the
internship semester.
D. The department should be in constant contact with the students and their hosting
companies so that any challenge faced by the student can be quickly solved by the
responsible party.
E. There should be some industrial or garage visits in the curriculum.
To Future Interns:
A. Future interns should revise the important courses right before going to the internship.
B. Future interns should do some visits to industries or garages before internship.
C. Future interns should search or ask more about internship so that they fully know what
to expect
D. And finally, future interns should ask many question during internship and be creative
as much as they can.
7.2 Conclusion
The internship was a fruitful experience. Through the application of the theoretical
knowledge into real-life problem-solving situations, I gained a lot of experience
especially in the automotive field. I also got insight into professional practice, learnt how
life can be fruitful as well as challenging under employment; and how to face and deal

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with these challenges. It was also a great opportunity for developing personal networking
activities and making contacts with influential people; which is of great value to me as far
as my career is concerned. The training also enabled me to discover my strengths and
weaknesses. This further helped me to identify areas to improve on. It helped me check
where I stand as a person, as a student, and as a soon-to-become engineer. Generally, I
achieved most of my learning objectives from the training and I will do my best to fill the
voids which I felt during my internship.

References
[1] Investigation of the Performance of a Laboratory Screw Jack", IOSR Journal of
Mechanical and Civil Engineering (IOSR-JMCE), Volume 12, Issue 4. 4) JJ. Ferreira, M.
B. M. G. 2004. Review of the risks associated with pushing and pulling heavy loads. First
ed. Sheffield: Health and safety Laboratory.
[2]. Michael-Adel, 2008 Material Selection for a Manual Winch Rope Drun. Volume 1
[3] ANSI MH29.1 screw jack Design for Use in the Automotive Industry New Jersey,
2004
[4] KIRIK T. V ANGELDER Fundamental of automotive technology principles and
practice second edition
[5] Auto Repair & Maintenance by DAVE STRIBLING
[6] Gupta,R.k.& .J,2005.theory of machines .revised edition .
[7] ASHRAE 2005 duct design textbook (3rd edition)
[8] A.V. Rasu turbo machinery text book (2nd edition)
[9] Andrew Parr hydraulics and pneumatics (3rd edition)
[10] KMPF magazine (2013) products catalogue
[11] R.S Kuhrmi and J.K Gupta, (2005) A textbook of machine design .Ram Nagar, New
Delhi
[12] Mikell P. Grover fundamentals of modern manufacturing (4th edition). Lehigh
University

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Appendices
Appendix A: Drawing of Screw Jack Parts

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Appendix B: Drawing of Screw Jack Assembly

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Appendix C: Mechanical properties of cast iron

Mechanical properties British standard specification

Tensile strength (Mpa) 220

Compressive strength (Mpa) 766

Shear strength (Mpa) 284

Endurance limit (Mpa) 96

Young’s modulus (Gpa) 89-114

Modulus of rigidity (Gpa) 36-45

Hardness number (HB) 196

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Appendix D: Mechanical properties of carbon steel

Material Carbon steel
Maximum section size, mm 63
Yield strength 385Mpa
Tensile strength 550-700Mpa
Elongation n% 13
Hardness number 152-207(HB)

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