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Declaration
I, Yidenek Nigussie is a 4th year students of electromechanical engineering department in jimma
University institute of technology, I have been working as an intern in Marathon motors engineering
PLC. As required in the curriculum, I have prepared this report and project from what I have
observed and practiced during my stay.

I hereby declare my internship report works I presented here is certify the best of my contribution
and knowledge that I have.

Name of student Signature Date

Approval

I declare that this final internship report is not a copy of somebody's document and I approve it is
completely own work.

Name of Advisor Signature Date

Supervisor's Name Signature Date

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Executive Summary
This paper was formally written document that explains what I have done, learned and
experiences I have gained in the four months i stayed in the company during the
internship session. In this report I try to explain in detail almost all things related to my
internship experience starting from the time I join into Marathon Motors up to the July
15. For sake of simplicity and easily understood for the reader, it was divide into two
different chapters.
Chapter one mainly focuses on describing the brief history of the company, the service
that the company gives to the costumers, its aim, mission and goals of the company. chapter
two, explain about the overall internship experience that includes: how I get into the
company, the section that we have worked in which describe the electrical workshop
section, workflow and the works implemented in this work shop such as motor repairing,
maintenance and rewinding three phases induction motor.

The primary purpose of this project is to develop an engine stand for a construction vehicle engine
that is capable of holding the engine at a comfortable height to work and give access to all the
various areas of the engine including its rotation giving full access to the underside, topside and the
various ends. This engine stand will be designed for Marathon Motors Engineering PLC in order to
provide safe and easy working conditions for engine assembly. The engine stand is going to be
designed using low cost and locally available materials. The mechanism involves using gears that
mesh at the same axis of rotation. One gear is rotated using a lever arm which will drive the other
gear attached to a shaft which is welded to a plate which supports the engine. This project will solve
the problem with the current uncomfortable and potentially dangerous working condition in the
workshops and add value to the productivity of the industry.

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CHAPTER ONE
1. Background of the company
Marathon Motor Engineering PLC (MME) was founded in 2008 and officially
inaugurate in February 2009 as importer and distributor of Hyundai passenger,
commercial vehicles and genuine parts in Ethiopia.

2009 was year of inception to MME and it starts by importing parts for existing
Hyundai cars, provide services and support current owners of Hyundai to earn their
confidence and to use their reference. On the same time there was a challenge of
shortage of hard currency. It was the commencement of the global financial crisis
that led to the economic recession and ultimately created the social crisis that
changes the lives of millions in number of countries. Major institutions that have
been successfully in business for years, even decades, had started losing revenue,
downsizing and many of them even closed down. Transactions slowed down,
businesses shrank, economies crumbled, and families struggled to survive.

2010 was year of earning. Despites its brief existence, MME started crating a
positive image for Hyundai and building a name as a strong competitor in the
automotive market of the country. Parallel to this there were challenges of lack of
local market trust. The Ethiopian car market has been dictated for decades solely by
car brokers and also dominated by only one brand. Even if the competition is
tougher MME starts winning tenders to supply fleets for big government and non-
government projects.

MME’s commitment, competency and noteworthy success won the confidence of

Hyundai. After three years of venture with only letter of intent, Hyundai granted
MME a distributorship of agreement. Through diligent and outstanding
performance in customer care in sells, parts and service MME’s turnover has
increased considerably. Our target ‘’Bigger, Better and Stronger’’: Bigger
investment, Better facilities and services, Stronger performance. It reinforced

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mobile workshops, intensive care as well as roadside assistance; it laid the

foundation of 3S facilities Sells, Spare-parts and Services.

MME would like to reassure that the future is more brighter with Hyundai’s New
Thinking New Possibilities. Hyundai strongly believes that its distributors across
the globe to be lifetime partners. Similarly, MME would like to establish a lifetime
partnership with its customers.

MME is also exclusive agents of SAME Tractor from Italy Since, 2016 and we
import different type of tractors Explorer3 115, Especial Explorer 95 and Laser
tractor 130.

On 25th May, 2017 MME signed SKD assembly technical assistance agreement
with Hyundai motor company. The assembly plant will produce 5000 in one shift,
and 10,000 at full capacity assorted models of cars per year. Our 3 fully equipped
facilities are

 Saries, Nifas silk lafto sub city

 Megenagna Infront of diaspora round about , Yeka sub city

 Haile road Haile building

 Hawassa, SNNPRS
Marathon Motor Engineering signed an assembly technical assistance agreement with
Hyundai cementing the company’s plans to start assembling vehicles in Ethiopia. The
agreement was signed on Monday May 29, 2017 and a manufacturing plant is set to
be constructed at a cost of half a billion birr.

“Globally, Hyundai is among the top five car makers so the fact that this elite brand
will be assembled here will give confidence to others who have plans to invest in the
country,” said Melkamu Assefa, CEO and Managing Director of Marathon Motor
Engineering Plc who signed the agreement with Mike Song, Head of the Africa and
Middle East Department for Hyundai.
The manufacturing plant will be based in Addis Ababa Lafto sub-city on 30,000

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square meters of land. It is expected to rollout cars by the first quarter of 2018 and
will provide jobs to 200 people. The plant will have the capacity of assembling 2,000
to 2,500 vehicles annually and will have six to eight different models. “Though this,
there will be skill and technology transfer, the plant will be very modern, most of the
machines will be imported from South Korea and Hyundai will monitor all the
technical aspects to maintain the brand’s high standards,” Melkamu said.
Hopes are that this assembly plant will reduce the price of cars in Ethiopia. “There
will be a 15 to 18 percent reduction in the selling price over imported cars, since
people will be able to afford new cars there will be less accidents and it will also have
a significant effect on the environment,” Melkamu said.

According to Marathon Motor Engineering, the company currently controls 30 to

35 percent of the market share in the country and once its assembled cars hit the
market, it estimates controlling a 40 percent share. The company was inaugurated
May 22, 2016 with two facilities: a six storey building that includes a mega show
room, a service center and a training center in Addis Ababa with an investment of
80 million birr and another facility in Hawassa with an investment of over 37
million birr, also equipped with a service center for trucks and buses, as well as a
technical training facility

1.2Main products of Marathon Motors

i. GRAND STAREX (H-1)
Category Commercial
Product label : Theta 2.4 MPi (EU3/4) 5-Speed Manual RWD (3 seats)
Model name : H-1
Seats : 12
Performance
 Engine Label : 2.4 Theta MPi
 Displacement (cc) : 2,359
 Max. Speed (kph) : 178

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 Max. Power (ps / rpm) : 175/6,000

 Max. Torque (kg·m / rpm) : 23.2/4,200
 Acceleration (0 - 100 kph) (sec) : 17.3
 Braking Distance (100 - 0 kph) (m) : 44.6
 Number of Cylinders : 4
 Valves of Cylinder :16
 Transmission Type : 5-Speed Manual RWD
 Fuel Type : Gasoline
ii. TUCSON
 Category SUV
 Product label Smartstream Gasoline 2.0 (EURO 3/4/5/6/6D) 6 Speed Manual
FWD
 Model name The all-new TUCSON
 Seats 5
 Performance:-
• Engine Label - 2.0 NU MPi
• Displacement (cc) - 1,999
• Max. Speed (kph) - 186
• Max. Power (ps / rpm) - 156/6,200
• Max. Torque (kg·m / rpm) - 19.6/4,500
• Acceleration (0 - 100 kph) (sec) - 10.8
• Braking Distance (100 - 0 kph) (m) - 42
• Number of Cylinders4
• Valves of Cylinder - 16
• Transmission Type - 6-Speed Manual FWD
• Fuel Type - Gasoline

iii. ELANTRA

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 Category Cars
 Product label; Gamma 1.6 MPi 6 Speed Manual FWD
 Model name; ELANTRA
 Seats 5
 Performance:-
• Engine Label-1.6 Gamma MPi
• Displacement (cc) - 1,591
• Max. Speed (kph) - 200
• Max. Power (ps / rpm) - 127.5/6,300
• Max. Torque (kg·m / rpm) - 15.77/4,850
• Acceleration (0 - 100 kph)(sec)-12.5
• Number of Cylinders - 4
• Valves of Cylinder - 16
• Transmission Type ;6-Speed Manual FWD
• Fuel Type ;Gasoline
iv. SANTA
Category SUV
Product label Theta 2.5 III MPI 6 Speed Automatic FWD (5-Seater)
Model name Santa Fe
Seats 5
Performance:-
• Engine Label : 2.5 Theta III MPi
• Displacement (cc) : 2,497
• Max. Speed (kph) : 195
• Max. Power (ps / rpm) : 180/6,000
• Max. Torque (kg·m / rpm) : 23.7/4,000
• Acceleration (0 - 100 kph) (sec) : 10.1
• Braking Distance (100 - 0 kph) (m) : 43.1

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• Number of Cylinders : 4
• Valves of Cylinder : 16
• Transmission Type : 6-Speed Automatic FWD
• Fuel Type : Gasoline

v. KONA
Category SUV
Product label Smartstream G1.0 6 Speed Manual FWD
Model name KONA
Seats 5
Performance
• Engine Label 1.0 Kappa GDi
• Displacement (cc) 998
• Max. Speed (kph) 181
• Max. Power (ps / rpm) 120/6,000
• Max. Torque (kg·m / rpm) 17.5/1,500~4,000
• Acceleration (0 - 100 kph) (sec) 11.5
• Braking Distance (100 - 0 kph) (m) 35
• Number of Cylinders 3
• Valves of Cylinder 12
• Transmission Type 6-Speed Manual FWD
• Fuel Type Gasoline

vi. CRETA
Category-SUV
Seat – 5

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Performance
 Engine Label -1.5 Gamma II MPi
 Displacement (cc) - 1,497
 Max. Speed (kph) - 170
 Max. Power (ps / rpm) - 115/6,300
 Max. Torque (kg·m / rpm) -14.7/4,500
 Acceleration (0 - 100 kph) (sec) - 12.2
 Braking Distance (100 - 0 kph) (m) - 42.1
 Number of Cylinders - 4
 Valves of Cylinder – 16
 Transmission Type – 6-Speed Manual FWD
 Fuel Type – Gasoline
HD170
Model HD170
Performance
• Displacement (cc) 9960-12740
• Max. Speed (kph) 181
• Max. Power (ps ) 220-410
• Max. Torque (kg·m ) 75-188
• Acceleration (0 - 100 kph) (sec) 20.5
• Braking Distance (100 - 0 kph) (m) 15
• Number of Cylinders 6
• Valves of Cylinder 24
• Transmission Type 6-Speed Manual FWD
• Fuel Type Gasoline
It used for the purpose of Mixer, Cargo, Dump and Tractor

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Category : Commercial
Model : HD36L
Performance
 Engine Label -1.5 Gamma II MPi
 Displacement (cc) – 2,497
 Max. Speed (kph) - 130
 Max. Power (ps / rpm) - 130
 Max. Torque (kg·m / rpm) - 26
 Acceleration (0 - 100 kph) (sec) - 12.2
 Braking Distance (100 - 0 kph) (m) - 42.1
 Number of Cylinders - 4
 Valves of Cylinder – 16

Its main customers or the end users of its products and services

Marathon Motors Engineering PLC most of its customers are governmental and
non-organizations are the main costumers of the company

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Overall Internship Experience

How I get into the company

As a mechanical engineer it is a big dream to join Marathon Motors Engineering

PLC, As we know Marathon Motors Engineering PLC is one of the biggest
company in Ethiopia which import and give service for automobiles and heavy
vehicles, when i got my internship paper, i went directly to the Hawassa branch and
submitted to the human resource, then they gave me an appointment for a week
then they told me that they are going to accept me. Next join the company on June
20/07/2022 G.C and we stayed for three months and fifteen days.

WORKING SECTIONS

Marathon Motor engineering PLC have two main sections: -

 Sales In this section several automobile’s and buses are imported and
assembled
 Maintenance
The following are the sections found under maintenance;
1. Body Workshop
2. Basic service Workshop
3. Motor Workshop
4. Electrical Workshop

1. Body Workshop - is where the cars body maintenance takes place. Basically,
the things that are done in body shop are welding, grinding, painting, drilling
and modification of the trucks part.

2. Basic service Workshop- there are four types of service:-

 Type-A Service
 Type-B Service
 Type-C Service

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 Type-D Service

3. Motor Workshop- is the workshop where important parts of the automobiles trucks
and buses maintenance takes place. These includes maintenance of gear box, steering
gearbox, differential, engine parts (cylinder head, oil sump), valve adjustment
(clearance), gear timing, clutch etc.

4. Electrical Workshop- As the name indicates it is a workshop where every electrical

related problem is repaired. The tasks that are performed under this workshop is
mainly diagnosis of problems on automobiles, trucks and buses using a special
diagnosis tool. Sometimes when there is a part that has to be removed from the cars
for other maintenance, they remove the parts that are electrical such as Dashboard.
And this workshop also tests the batteries. Electrical shop is the one responsible for
any electrical related problems.

Task performed by the company

The following tasks are performed by the company

Work performed by the company on last month's presented as follow. Most of

the work on service area; vehicle service is a series of maintenance procedures
carried out in a certain time. The service type is depending on the vehicle travel
distance

Steps that is ordered to carried out the vehicle service and any maintenances

First the company receive the type of maintenance they went to order
anything specific about why the service or the maintenance are needed.
This all give it to the service advisor ( my Mentor) then the service advisor
and receptionist write customer request on the company form. The
mechanic receive the vehicle and the company form depending on paper
the mechanic maintain and when he have to submit back any spare part he
need for the maintenance. Finally, the vehicle has been tested by the
Forman then the Forman have been tested the car and the service advisor
calls to the customers to get their cars.

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Marathon motor cars serviced based on the kilometre of car travel

Type A service: - is type of service that is performed on cars that travel 5000km,
15,000km, 25,000km, etc. It keeps going on adding 10,000 and the types of
service are listed in the table.
 Inspect brake pad and discs
 replace engine oil with filter
 check air cleaner and battery
 inspect steering wheel linkage, steering and gear box oil
 inspect front and rear suspension
 inspect external leakage if any

Type B service: - is type of service that is performed on cars that travel

10,000km, 30,000km, 50,000km, etc. It keeps going on adding 20,000 and the
types of service are listed.
 Check Brake pad, discs brake, drums brake
 Steering link centre arm linkages (grease)
 Replace Engine oil with filter
 Check Brake fluids and clutch fluids
 Drive shaft boots
 Check Brake pedal and parking brake
 Check Ball joints and dust covers
 Check Brake pipes and hoses
 Inspect All light, horn and wiper/washer
 Check and replace Fuel filter and fuel line
 Check and replace air cleaner element
 Inspect spark plug (gasoline)
 Check front and rear suspension
 Inspect oil leakage and water leakage

Type C service: - is type of service that is performed on cars that travel

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20,000km, 60,000km, 100,000km, etc. It keeps going on adding 40,000 and the
type of service are listed : -
 Check Brake pad, discs brake, drums brake
 Change air filter elements if the car is diesel and hand brake cable.
 Check steering linkage arms
 Inspect drive belts
 Inspect brake disk and drum run out
 Inspect air filter if the car is gasoline
 Inspect valve clearance
 Check battery and battery connection
 Check spark plugs if the car is gasoline
 Check any external leakage
 Checks ball joints
 Tighten all bolt and nut (including propeller shaft bolt)
 Inspect brake, clutch and power steering oils
 Check all light, horn, wiper and washer
 check wheel bearing grease Replace engine oil with filter
 Change fuel filter if the car is diesel
 Check front and rear suspension
 Check differential and gear box oil
 Check exhaust pipe

Type D service: - is type of service that is performed on cars that travel

40,000km, 80,000km, 140,000km, etc. It keeps going on adding 40,000 and the
types of service are listed in the table. Most of service work includes checking,
cleaning and changing of the parts, if any part of the vehicle needs
 Check Brake pad, discs brake, drums brake
 Check ball joints and hand brake cable.
 Inspect Steering knuckle, linkage and arm

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 Check fuel line

 Inspect brake disk and drum run out
 Check radiator coolant
 Replace differential and gear box oil
 Inspect valve clearance
 Check brake and parking brake cable
 Check any external leakage
 Tighten all body and exhaust pipe bolts
 Check front and rear suspension
 Check brake pipe, line and hose s
 Check all light, horn, wiper and washer
 Change fuel filter
 Check front and rear suspension
 Replace spark plugs
 Change engine oil with filter
 Inspect and replace drive belts
 Check all light, horn, wiper and washer
1. The work piece or work tasks we had been executing
In three and half months of internship period participating in different tasks of
different shops of the company, by observing, asking and taking notes on the
procedures, operation/working principle of the machines. In addition to this,
we were executing some simple tasks such as for type-A service . But, we
spent most of our time by observation and used different materials when
executing the tasks.

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How good I have been in performing my tasks During my internship program

I work my tasks in enthusiasm, as well as my supervisor is such a sincere man
when I ask a question he answered courteously. This internship program helped me to
improve my practical skills, leadership skills, upgrading interpersonal and
communication skills and best of all how to work with peoples peacefully. During the
duration of the internship I have been practicing some electrical and mechanical tasks
mentioned before like:
• Maintenance of breaking system
• Replace filters and shock absorber
• Repair and replace lighting system
• Testing and Maintenance of charging system
• Testing and maintenance of starter motor
During performing my work task, some employers had good practical skills so,
when we ask theemployers about something part they share about that thing clearly
and I have got good things frommy hosting organization.

2.6 Challenges faced me while performing my tasks and Measures I

have taken in order toovercome challenges

2.3 Challenges we have faced while performing our work task

The main challenges we have faced while we were performing our work task are: -
 Lack of working clothes and shoes.
 Technicians were considered us; we are outstanding automotive professional men.
 Our hand got injured many times because we were not experienced on handling the tools.
 It takes time to know the mechanics and work efficiently with them.
 Because of the work really needs high energy it was difficult for the first month.
 Many mechanics call spare parts of the auto motives by other language such as Italy so, it
is difficult to understand at the first time.
2.4 Measurements taken to overcome challenges
 We tried to buy our own from the market.

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 Apparently share our experience with the technicians.

 We try to handle the tools carefully as much as possible.
 We try to be watchful while they are performing tasks.
 Doing physical exercise in the weekend.
 I made close relationship with each mechanic and electrician of the company to get full
the information
3. Over all benefits I gained from internship

This internship training is very important for Ethiopia. It generate skill full generation to
create the new technology on the future. This internship is used to solve the problems and to
make the project. To know how to change theoretical knowledge in to practical. From this
internship improve the following things.

Improving practical skill

In spending our internship in Marathon motors for a semester provides me the opportunity to
gain practical skill on work experience that i just can’t get by attending in the class room.
This internship training is very important for Ethiopia. It generate skill full generation to
create new technology on the future and It gives the chance to use my theoretical knowledge
on the real world. It is a great chance to prove the work of my qualification and to show my
performance in real world and getting experience in the real working environment is a great
way to build confidence.
Here is some other skill i develop in my internship period :-

 I have seen the real practical world and understood the work flow and interaction
between different levels of the organization.

 I try to operate machines

 I have developed working on heavy machines without fear and the ability of to
maintaining machines.

 I understand the working mechanism and the required materials of machines found in
the workshop.
 I also improved my sociability with the employs to adapt the working environment

3.1 Improving Theoretical knowledge

Everything that i learned in school are not there in the company. However, I have got a lot of

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knowledge that upgraded what i have been learned in the campus. The following are
practically noticed, that i learned in the campus.
 breaking system, axle shaft, and bearing
 Fastening: - like bolting, riveting and welding (electrical art, metal inert gas and oxygen)
 Thread, screw, gear, and differential
 Combustion process, crank shaft, connecting rod, and cylinder
 Lubrication system: like different type of oil and greases
 cooling of engine: like oil, coolant water and air (for radiator)
3.2 Improving my interpersonal communication Skill
When I was joined to the first time in MOENCO, it was very hard to communicate with the
compound because of the rule and the regulation of the staff, working language, age variation
But after a week later it was become fine for communicating with workers and applying the
rule and the regulation of the industry and reach in to the common agreement with workers
and I begins exchanging life sharing experience. In the case of internship training
communication skill is the core thing. As we know, for different person have different
behavior. In our working area, there are different workers with their different behavior. So
that, this was one of the problem that i have been faced, but i decided to have a confidence to
communicate them. I started by greeting and asking question about a vehicle. This situation
make them tired of that is asking question about the vehicle and machineries every day. So ,
we planned something, that keep the continuity of our relation, since the workers are not
much aged .we started raising ideas and try to have fun by talking about ladies ,jokes ,football
and other stuffs which , helped us to get a nice feedback and they started to share their
knowledge.

Generally, i have developed communication skills through:

 Adaptation of those different workers

 sometimes our supervisor and us talked about the whole situation about the compound

3.3 Improving Team playing skills

Team playing skills are one of the basic requirements for the proper working of a good
company, regardless of its size and its service. A company with properly functioning
dedicated working team will always have a graph going up wards with different workers,
working as different team. However, they contribute to a single goal the progress of the

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company.
For the proper functioning of a team, each member must be sure of his mission, vision,
behavior, working style, and goal. They must personally and organizationally dedicate to the
team. Team members must believe in one another and must be ready to work hand to hand in
both adverse and favorable situation.
General skills such as; good communication skill, concentration, fast decision making, self-
confidence and a well being feeling are important for all team members engaged. So, in our
company any work or problems are accomplished with the co-operation of each other. Thus,
situation makes us to develop a team playing skill, since we were one of the members of
them.

Improving leader ship skills

A leader is a person who has strong principles, courage and dedications to a clear vision.
Developing a power full vision, building strong team and bringing out the best in those you
lead are key facts to experience success as a leader. People follow their leaders because they
are representative of their believe. Those persons have to focuses on common benefits and
goals.
Leader ship is critical management; skill is being the ability to motive a group of people
toward a common goal. It shows the skill, as a manager must master to be successful and
shows this management skills build on each other to wards success .The leader person, first
have to eliminate fear and behave knowledge or an idea about what he going to do with a
confidence. A leader ship person must have a communication skill that helps him to persuade
his follower. In four month duration of the internship, we learn some skills and techniques of
leader ship
.Among the skills we developed are ;how to decide a management carrier is appropriate for
us and how to get the train and develop large projects, how to lead, motive, inspire and
encourage workers, develop work ethics, values; like accountability , which is answerable to
the decision and acts we took and transparency , which is our openness of activities that we
done to the customers and works of the company.
we have observed that, during a meeting/a conference of, the branch and service manager
discuses about the work, food preparation in company for the workers, salaries and other
related agenda. During this time, the managers are listening the workers problems and
complain politely. The managers then negotiate with the workers about the problems politely,
and decide the solution with respect to a common benefit. The situation between them is like

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brothers and every worker likes them. Clearly, we can see that, this is the result of how the
managers treat their workers. From these situations, we captured how lead a team or a people.
Remember, the creation of opponent/uprising is a result of bad leading system.

3.5. Improving Work ethics skills

If one have strong love to his work we call it, he has work ethics habit. Instruction to develop
strong work ethics are:-
 Arrive to work on time
 put a positive spin on negative comments, a positive attitude is crucial to have a
strong work ethics. Bring a fresh perspective to problems at work.
 be confident and self- motivated in your ability to handle job responsibility
 Honor your commitment, being independent and creates confidence in your working
capacity. Seek to serve the interests of the company’s goal, objectives and missions.
Do your part to create a productive place to work.

 The quality and quantity of work is a direct reflection of personal characters and
integrity.

 Respect what others contribute to the work environment. Concentrate on your job and
commitment to proactive attitude.
 Eliminate or reduce absent

 Respect yourself, yours work and others with their work, in addition to these respect
other’s religion, race, language and customs.
Work ethical employee is a key to productive. All of the employees have to disciplined and
ethical in their working environment. The employees can be considered as a work ethical
when they are:-
 Punctual
 Not absent
 Commitment for work
 Accountable and responsible for my work etc…
3.6. Improving Entrepreneurship skills
It is defined by their habit of innovation and redefines markets. It can be realized that when
someone engages or creates profitable job, which is/are significant for the society. From
entrepreneur principle, the following are some of them. Therefore, we have three

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alternations:-
 If you have enough money, even if you have neither talent nor profession, you can
make a business by employee those educated or talented persons. To do this first, you
have to study the most needed thing in the community, in the country, or in the world,
that are not or les available.

 If you are not educated/have no profession and money, you may have talent.
Therefore, you can start a business about your talent.

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4.1 Design concept generation

Design concepts were generating by referring to previously used engine assembly techniques
and mechanisms. There are different design concepts according to the need and
specifications. For this project three design concepts of the engine stand were generated. The
difference between these concepts is the driving and gear box mechanisms. These are listed
as follows:

Design concept one

An engine stand with two columns which is going to be operated manually without having
gear box. This concept will surely be inexpensive but require more effort from operators.

Figure 6 Engine stand without gear box

Design concept two

This engine stand will also have two columns which is going to be operated manually with a
gear box mechanism. This concept will surely be more expensive than the first but will
decrease the amount of effort needed by the operator.

Figure 7 Engine stand with gear box

Design concept two

This engine stand is the same as the one on concept two, but instead of manually operating
the gear box it will be operated by an electric motor. It is believed to be expensive but it will
be effort less and guarantee smooth operation.

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Figure 8 Engine stand with electric motor drive

Design concept evaluation

The three design concepts are compared and contrasted by using weighted mean method
using different criteria as follows. (Scores are given out of 10, total value is the sum of the
product of score and weight)

Concept One Concept Two Concept Three

Criteria Weight Score Weight Score Weight Score Weight

Ease to 0.1 10 1 9 0.9 7 0.7

manufacture

Availability of 0.2 9 1.8 9 1.8 8 1.6

materials

Reliability 0.2 7 1.4 9 1.8 10 2

Cost 0.4 9 3.6 8 3.2 6 2.4

Ease to use 0.1 6 0.6 8 0.8 10 1

Total 1 8.4 8.5 7.7

Rank 2 1 3
Table 1 Design concept evaluation Therefore,
according to the above table Design concept two is selected.

4.2 Product Definition

The engine stand which is going to be designed in this project has different members. These members are
discussed as follows.
4.2.1 Worm and worm gear
Worm and worm gear drive is used to drive the shaft which is connected to the engine mounting plate. The
worm gear arrangement will provide 90-degree power transmission and helps reduce the operator effort.

4.2.2 Caster
A caster is wheeled device which can be mounted at the bottom of the engine stand to enable relatively easy
rolling movement of the engine stand. It is important for the engine stand to move around the workshop easily

.
.

and casters will provide that ability.

4.2.3 Mounting plate and arms

These are the parts of the engine stand where the engine is going to be bolted and held. The arrangement can
be rotated 360-degree with the help of a handle which makes every part of the engine easy to reach.

4.2.4 Solid Shaft

Shaft is a rotating member which is used to transmit rotating power or torque. It will transmit the
rotation from the worm-gear arrangement to the plate where the engine is held.

4.2.5 Hollow shaft

This is the member in which the solid shaft passes through. It will act as hub for the solid shaft and guide its
motion.

4.2.6 Bearing
It is a machine element which supports another moving machine element and guide its motion. It will support
the worm and worm wheel. The two main types of bearing are sliding contact bearing and rolling contact
bearing. The type of bearing used for this project is rolling contact bearing because of availability.

4.2.7 Key
It is a machine element which is used to connect rotating machine element to a shaft. It prevents relative
motion between two parts and enable torque transmission. In this case a key is used to connect shaft to the
worm gear.
4.2.8 Main Frame
Rectangular hollow steel is used for the horizontal and square hollow steel for vertical members. The
horizontal and vertical members are the main building blocks of the engine stand. Two vertical members will
hold the engine from the two ends axially. The horizontal members will connect the vertical members and act
as the base of the engine stand. Also, casters will be fixed on the horizontal members.

4.2.9 Lever arm

It is an arm keyed at right angle to the end of the worm shaft, by which motion is imparted to the worm gear.
It mainly suffers from torsional stresses so medium carbon steel is used as it combines merits of malleability
and sufficient torsional strength.
4.2.10 Bolts
A bolt is s form of threaded fastener with an external male thread. Bolts are used to hold the engine through
the mounting arm. They are fitted on the engine through the fly wheel mounting internal threads.

4.3 Design Calculation

Materials selected for the design calculation:

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.

Worm = hardened steel

Worm gear = Alloy cast iron,
Endurance limit, 𝜎𝑒 = 210 𝑀𝑃𝑎
Ultimate strength, 𝜎𝑢 = 420 𝑀𝑃𝑎
Allowable static stress, 𝜎𝑜 = 140 𝑀𝑃𝑎
4.3.1 Design of Worm

Initial assumptions taken for the design calculation process:

 Distance between the shafts, 𝑥 = 180 mm

 Velocity ratio = 5

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.

Let, 𝑙N = Normal lead, and

𝜆 = Lead angle.
The value of 𝑥 / 𝑙N will be minimum corresponding to

cot3 𝜆 = 𝑉. 𝑅 or cot 𝜆 = 3
√𝑉. 𝑅
cot 𝜆 = 3
√5
cot 𝜆 = 1.7099
𝜆 = cot−1 1.7099
𝜆 = 30.319 0
1
We know that 𝑥 1 𝑉.𝑅
𝑙𝑁 = 2𝜋 (sin + cos 𝜆)
𝜆

180 1 1 5
= ( + )
𝑙𝑁 2𝜋 sin 30.319 cos 30.319 0
0

180 1
𝑙𝑁 = (1.9809 + 5.7922)
2𝜋

∴ 𝑙𝑁
180 = 145.49 mm
= 1.237
𝑙𝑁 145.49
and axial lead, 𝑙 = =
= 168.55 𝑚𝑚
cos 𝜆 cos 30.3190

From Table 2, we find that for a velocity ratio of 5, the number of starts or threads on the
worm,
𝑛 = 𝑇𝑊 = 6

Table 2 Number of starts to be used on the worm for different velocity ratios
∴ Axial pitch of the threads on the worm, 𝑝𝑎
𝑙 168.55
𝑝𝑎= 𝑛= 6

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.

𝑝𝑎 = 28.09 𝑚𝑚

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.

𝑝𝑎 28.09
∴ Module, 𝑚= = m∜∜m
𝜋 𝜋

𝑚 = 8.942 𝑠𝑎𝑦 9 𝑚𝑚 (standard value of module)

∴ Axial pitch of the threads on the worm, 𝑝𝑎
𝑝𝑎 = 𝜋𝑚 = 𝜋 𝑥 9 = 28.27 𝑚𝑚 Ans.

Axial lead of the threads on the worm,

𝑙 = 𝑝𝑎. 𝑛 = 28.27 𝑥 6 = 169.65 𝑚𝑚 Ans.

and normal lead of the threads on the worm,

𝑙𝑁 = 𝑙 cos 𝜆 = 169.65 𝑥 cos 30.3190 = 146.44 𝑚𝑚 Ans.
We know that the center distance,
𝑙𝑁 1
𝑥= ( 𝑉.𝑅
2𝜋 sin 𝜆 + cos 𝜆)
146.44 1 5
𝑥= ( + )
2𝜋 sin 30.319 cos 30.319 0
0

𝑥 = 23.307(1.9809 + 5.7922) = 181.168 say 182 𝑚𝑚 Ans.

Let 𝐷𝑊 = Pitch circle diameter of the worm.

𝑙
We know that tan 𝜆 =
𝜋𝐷𝑊

𝐷𝑊
= 𝜋 tan = 𝜋 tan 30.3190 = 92.34 𝑚𝑚 Ans.
𝑙 169.65

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.

Since the velocity ration is 5 and the worm has sextuplet threads (i.e. 𝑛 = 𝑇𝑊 = 6),
therefore number of teeth on the worm gear,
𝑇𝐺 = 𝑉. 𝑅 𝑥 𝑛 = 5 𝑥 6 = 30
Length of the worm or length of threaded portion is,
𝐿𝑊 = (4.5 + 0.02𝑇𝑊) = 28.27(4.5 + 0.02𝑥6) = 130.6074 𝑚𝑚
∵ 𝑝𝑐 = 𝑝𝑎
This length should be increased by 25 or 30 mm for safety. Say 𝐿𝑊 = 155 𝑚𝑚 Ans.
We know that depth of tooth,
ℎ = 0.623 𝑝𝑐 = 0.623 𝑥 28.27 = 17.6122 𝑚𝑚 Ans.

and addendum,

𝑎 = 0.286 𝑝𝑐 = 0.286 𝑥 28.27 = 8.085 𝑚𝑚 Ans.

∴ Outside diameter of worm,
𝐷𝑂𝑊 = 𝐷𝑊 + 2𝑎 = 92.34 + (2 𝑥 8.085) = 108.5 𝑚𝑚 Ans.

4.3.2 Design of worm gear

Pitch circle diameter of worm gear,

𝐷𝐺 = 𝑚. 𝑇𝐺 = 9 𝑥 30 = 270 𝑚𝑚 Ans.
Therefore, outside diameter of worm gear,
𝐷𝑂𝐺 = 𝐷𝐺 + 0.8903 𝑝𝑐 = 270 + 0.8903(28.27) = 295.2 𝑚𝑚 Ans.
Throat diameter,
𝐷𝑇 = 𝐷𝐺 + 0.572 𝑝𝑐 = 270 + 0.572(28.27) = 286.2 𝑚𝑚 Ans.
Face width of worm gear,
𝑏 = 2.15 𝑝𝑐 + 5𝑚𝑚 = 2.15(28.27) + 5 = 66 𝑚𝑚 Ans.
Let us now check the designed worm gearing from the standpoint of tangential load,
dynamic load, static load and wear load.

 Check for the tangential load

Let 𝑁𝐺 be speed of worm gear in rpm
𝑁𝑊
Velocity ratio of drive, 𝑉. 𝑅 =
𝑁𝐺

.
.

𝑁𝑊 10
= 2 𝑟𝑝𝑚
𝑁𝐺 = = 5
𝑉. 𝑅
∴ Torque transmitted,
𝑃 𝑥 60 15.7 𝑥 60
𝑇= = = 74.96 𝑁. 𝑚
2𝜋𝑁𝐺 2𝜋 𝑥 2
Tangential load acting on the gear,
2 𝑥 𝑇𝑜𝑟𝑞𝑢𝑒 2 𝑥 74.96
𝑊𝑇 = = = 555.27 𝑁
𝐷𝐺 0.27

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.

Pitch line or peripheral velocity of the worm gear,

𝜋. 𝐷𝐺. 𝑁𝐺 𝜋 𝑥 0.27 𝑥 2
𝑣= = = 0.028 𝑚/𝑠
60 60
∴ Velocity factor,
6 6
𝐶𝑣 = = = 0.995
6+𝑣 6 + 0.028
Tooth form factor,
0.912 0.912
𝑦 = 0.154 − = 0.154 − = 0.1236
𝑇𝐺 30
Since the material selected for the worm gear is alloy cast iron, allowable static stress is
𝜎𝑜 = 140 𝑀𝑃𝑎
Designed tangential load,
𝑊𝑇 = (𝜎𝑜. 𝐶𝑣). 𝑏. 𝜋𝑚. 𝑦 = (140 𝑥 0.995)66 𝑥 𝜋 𝑥 9 𝑥0.1236 = 32129.6 𝑁
since the value is more than the tangential load acting on the gear, 𝑊𝑇 = 555.27 𝑁,
therefore the design is safe from the stand point of tangential load.

 Check for dynamic load

Dynamic load,

𝑊𝐷 = 𝑊𝑇 32129.6
= = 32291.1 𝑁
𝐶𝑣 0.995

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.

Since this is greater than 𝑊𝑇 = 555.27 𝑁, therefore the design is safe from the standpoint of
dynamic load.

 Check for static load or endurance strength

Flexural endurance limit for cast steel is
𝜎𝑒 = 210 𝑀𝑃𝑎
∴ Static load or endurance strength,
𝑊𝑆 = 𝜎𝑒. 𝑏. 𝜋. 𝑚. 𝑦 = 210 𝑥 66 𝑥 𝜋 𝑥 9 𝑥 0.1236 = 48620.15 𝑁
Since this is greater than 𝑊𝑇 = 555.27 𝑁, therefore the design is safe from the standpoint of
static load or endurance strength.

 Check for wear

Assume material for worm as hardened steel. Load stress factor for hardened steel and
alloy cast iron 𝐾 = 0.345
∴ Limiting or maximum load for wear,
𝑊𝑊 = 𝐷𝐺. 𝑏. 𝐾 = 270 𝑥 66 𝑥 0.345 = 6147.9 𝑁
Since this is greater than 𝑊𝑇 = 555.27 𝑁, therefore the design is safe from the standpoint of
wear.

4.3.3 Design of worm shaft

Let 𝑑𝑊 be diameter of worm shaft

Torque acting on worm gear shaft, (taking 25% overload)
1.25 𝑃 𝑥 60 1.25 𝑥 15.7 𝑥 60
𝑇 = = = 93.7 𝑁. 𝑚 = 93.7 𝑥 103 𝑁. 𝑚𝑚
𝑔𝑒𝑎𝑟
2𝜋𝑁𝐺 2𝜋 𝑥 2
∴ Torque acting on worm shaft, (taking 89% efficiency)
𝑇𝑔𝑒𝑎𝑟 93.7
𝑇𝑤𝑜𝑟𝑚 = = = 21.056 𝑁. 𝑚 = 21.056 𝑥 103 𝑁. 𝑚
𝑉. 𝑅 𝑥 𝜂 5𝑥 0.89
Tangential force on the worm, (equal to axial force on the worm gear)

2𝑥 2 𝑥 21.056 𝑥 103
𝑊𝑇 = = = 456.057 𝑁
𝑇𝑤𝑜𝑟𝑚 92.34
𝐷𝑊
Axial force on the worm, (equal to tangential force on the worm gear)
𝑊𝐴 =

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.

2 𝑥 𝑇𝑔𝑒𝑎𝑟 103
2𝑥 = = 694.07 𝑁
𝐷𝐺 93.7 𝑥 270

Radial or separating force on the worm and worm gear,

𝑊𝑅 = 𝑊𝐴. tan 𝜙 = 694.07 𝑥 tan 250 = 323.65 𝑁
Assume distance between bearing of worm shaft equal to the diameter of the worm gear, i.e.
𝑥1 = 𝐷𝐺 = 270 𝑚𝑚
∴ Bending moment due to radial force in the vertical plane,
𝑊𝑅 𝑥 𝑋1
= 323.65 𝑥 270
4 = = 21846.38 𝑁. 𝑚𝑚
4
Bending moment due to axial force in vertical plane,
𝑊𝐴 𝑥 𝐷𝑊
= 694.07 𝑥 92.34
4 = = 16022.6 𝑁. 𝑚𝑚
4

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.

∴ Total bending moment in vertical plane,

𝑀1 = 21846.38 + 16022.6 = 37868.98 𝑁. 𝑚𝑚
Bending moment due to tangential force in horizontal plane,
𝑊𝑇 𝑥 𝐷𝐺 456.057 𝑥 270
𝑀2 = = = 30783.84 𝑁. 𝑚𝑚
4 4
∴ Resultant bending moment on the worm shaft,

𝑀𝑤𝑜𝑟𝑚 = √𝑀12 + 𝑀22 = √37868.982 + 30783.842 = 48802.71 𝑁. 𝑚𝑚

Equivalent twisting moment on the worm shaft,

𝑇𝑒𝑤 = √𝑇𝑤𝑜𝑟𝑚2 + 𝑀𝑤𝑜𝑟𝑚2 = √(21.056 𝑥 103)2 + 48802.712 = 53151.29 𝑁. 𝑚𝑚

Also, equivalent twisting moment is, (assume 𝜏 = 50𝑀 )

𝜋 𝜋
𝑇𝑒𝑤 = 𝑥 (𝑑𝑊 ) 3
, 53151.29 = 𝑥 50 (𝑑𝑊 )3, 53151.29 = 9.8174(𝑑𝑊 )3,
16 16
(𝑑𝑊)3 = 5413.945 𝑜𝑟 𝑑𝑊 = 17.6 𝑚𝑚 𝑠𝑎𝑦 20 𝑚𝑚 Ans.
Let us now check for the maximum shear stress induced. Actual
shear stress,
16𝑇𝑒𝑤 16 𝑥 53151.29
𝜏=
𝜋(𝑑𝑊 )3 = (20)3
= 33.837 𝑀𝑃𝑎

Direct compressive stress on the shaft due to the axial force,

𝑊𝐴
𝜎𝑐 = 𝜋 (𝑑 694.07
=𝜋 = 2.209𝑀𝑃𝑎
4 𝑊 )2 4 (20)2
∴ Maximum shear stress,
1 1
𝜏𝑚𝑎𝑥 = √𝜎𝑐2 + 4𝜏2 = √2.20922 + 4𝑥33.8372 = 33.853 𝑀𝑃𝑎
2 2
Since the maximum shear stress induced is less than 50 MPa (assumed), therefore the
design of worm shaft is safe.
4.3.4 Checking for self-locking of the worm
1 tan2 𝜙 1 tan2 25
𝜂= − = − = 0.3913 = 39.13%
2 2 2 2
Since the efficiency is less than 50% the worm is self-locking.

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4.3.5 Design of worm gear shaft

Let 𝑑𝐺 be diameter of worm gear shaft We

have calculated above that,
Axial force on the worm gear = 456.057 N
Tangential force on the worm gear = 694.07 N
Radial or separating force on the worm gear = 323.65 N
Bending moment due to axial force on the worm gear in vertical plane,
𝐴𝑥𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 𝑥 𝐷𝐺
= 456.057 𝑥 270
4 = = 30783.85 𝑁. 𝑚𝑚
4

Let us take the distance between bearing of worm gear shaft is X2 = 200 mm

∴ Bending moment due to radial force of the worm gear in vertical plane,
𝑅𝑎𝑑𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 𝑥 X2
= 323.65 𝑥 200
4 = = 16182.5 𝑁. 𝑚𝑚
4
∴ Total bending moment in vertical plane,
𝑀3 = 30783.85 + 16182.5 = 46966.35 𝑁. 𝑚𝑚
Bending moment due to tangential force in the horizontal plane,
𝑇𝑎𝑛𝑔𝑒𝑛𝑡𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 𝑥 X2 694.07 𝑥 200
𝑀4 = = = 34703.5 𝑁. 𝑚𝑚
4 4
∴ Resultant bending moment on the worm gear shaft,

𝑀𝑔𝑒𝑎𝑟 = √𝑀32 + 𝑀42 = √46966.352 + 34703.52 = 58396.67 𝑁. 𝑚

We have already calculated torque acting on worm gear shaft, 𝑇𝑔𝑒𝑎𝑟 = 93.7 𝑥 103 𝑁. 𝑚𝑚

∴ Equivalent twisting moment on the worm gear shaft,

𝑇𝑒𝑔 = √𝑇𝑔𝑒𝑎𝑟2 + 𝑀𝑔𝑒𝑎𝑟2 = √(93.7 𝑥 103)2 + 58396.672 = 110407.7 𝑁. 𝑚𝑚

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.

Also, equivalent twisting moment is, (assume 𝜏 = 50𝑀 )

𝜋 𝜋
𝑥 (𝑑𝐺 ) , 110407.7 =
3
𝑇𝑒𝑔 = 𝑥 50 (𝑑𝐺 )3, 110407.7 = 9.8174(𝑑𝐺 )3,
16 16
(𝑑𝐺)3 = 11246.12 𝑜𝑟 𝑑𝐺 = 22.4 𝑠𝑎𝑦 30 𝑚𝑚 Ans. (because of engine load) Let
us now check the maximum shear stress induced.
Actual shear stress,
16𝑇𝑒𝑔
16 𝑥 110407.7
𝜏=
𝜋(𝑑𝐺 = = 20.215 𝑀𝑃𝑎
)3 (30)3
Direct compressive stress on the shaft due to the axial force,
𝐴𝑥𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 456.057
𝜎𝑐 = 𝜋 =
( )𝐺2 𝜋 = 0.6452𝑀𝑃𝑎
4 4 (30)2
∴ Maximum shear stress,
1 1
𝜏𝑚𝑎𝑥 = √𝜎𝑐2 + 4𝜏2 = √0.64522 + 4𝑥20.2152 = 20.217 𝑀𝑃𝑎
2 2

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Since the maximum shear stress induced is less than 50 MPa (assumed), therefore the
design of worm gear shaft is safe.

4.3.6 Bearing selection of the worm

From the above calculation we have,

𝑊𝑅 = 323.65 𝑁
𝑊𝐴 = 694.07 𝑁
𝑁𝑊 = 10 𝑟𝑝𝑚
Since the average life of the bearing is 5 years at 300 days a year 10 hour per day,
therefore life of the bearing in hours,
𝐿𝐻 = 5 𝑥 300 𝑥 10 = 15000 Hours
Life of bearing in revolutions,
𝐿 = 60𝑁 𝑥 𝐿𝐻 = 60 𝑥 10 𝑥 15000 = 9 𝑥 106 rev
Basic dynamic equivalent radial load,
𝑊 = 𝑋. 𝑉. 𝑊𝑅 + 𝑌. 𝑊𝐴
𝑊𝐴
In order to determine the radial load factor, 𝑋, and axial load factor, 𝑌, we require
𝑊𝑅
and 𝑊𝐴. Since the value of basic static load capacity 𝐶 is not known, therefore let us
𝐶0 0
assume 𝑊𝐴
= 0.5. Now from Table 3, we find that the values of 𝑋 and 𝑌 corresponding
𝐶0
694.07
to 𝑊𝐴 = 0.5 and 𝑊𝐴 = = 2.1445 (which is greater than e = 0.44) are,
𝐶0 𝑊𝑅 323.65

𝑋 = 0.56 and 𝑌 = 1

Table 3 Values of X and Y for dynamically loaded deep groove ball bearing
Dynamic equivalent radial load (V= 1 for most bearings),

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.

𝑊 = (0.56 𝑥 1 𝑥 323.65) + (1 𝑥 694.07) = 875.314 𝑁

From Table 4, we find that for uniform and steady load, the service factor (𝐾𝑠) for ball
bearings is 1. Therefore, bearing should be selected for 𝑊 = 875.314 𝑁.

Table 4 Values of service factor (𝑲𝒔)

Basic dynamic load rating, (k = 3 for ball bearings)
𝐿 1 9 𝑥 106 1
𝐶=( 6
) = 875.314( )3 = 1820.726 𝑁
10 106

From Table 5, let us select bearing No. 200 with the following basic capacities,
𝐶𝑜 = 2.24 𝐾𝑁 and 𝐶 = 4 , then

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𝑊𝐴 694.07
= = 0.309
𝐶𝑜 2240

Table 5 Basic static and dynamic capacities of various types of ball bearings
From Table 3, the values of 𝑋 and 𝑌 are, 𝑋 = 0.56 and 𝑌 = 1.2
Substituting these values, we have dynamic equivalent load is,
𝑊 = (0.56 𝑥 1 𝑥 323.65) + (1.2 𝑥 694.07) = 1014.128 𝑁
∴ Basic dynamic load rating,
𝐿 1
9 𝑥 106 1
𝐶 = ( 6) = 1014.128( )3 = 2109.47 𝑁 = 2.1 𝐾𝑁
10 106
From Table 5, for shaft fitting the bearing number 204 having 𝐶 = 10 𝐾𝑁, may be
selected. Therefore, Bore diameter = 20 mm
Outside diameter = 47 mm
Width = 14 mm Ans.

4.3.7 Bearing selection of the worm gear

From the above calculation we have,

𝑅𝑎𝑑𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 = 323.65 𝑁
𝐴𝑥𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 = 456.057 𝑁
𝑁𝐺 = 10 𝑟𝑝𝑚

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.

Since the average life of the bearing is 5 years at 300 days a year 10 hour per day,
therefore life of the bearing in hours,
𝐿𝐻 = 5 𝑥 300 𝑥 10 = 15000 Hours
Life of bearing in revolutions,
𝐿 = 60𝑁 𝑥 𝐿𝐻 = 60 𝑥 10 𝑥 15000 = 9 𝑥 106 rev
Basic dynamic equivalent radial load,
𝑊 = 𝑋. 𝑉. 𝑊𝑅 + 𝑌. 𝑊𝐴

In order to determine the radial load factor, 𝑋, and axial load factor, 𝑌, we require 𝑊𝐴

𝑊𝑅
and 𝑊𝐴. Since the value of basic static load capacity 𝐶 is not known, therefore let us
𝐶0 0
assume 𝑊𝐴 = 0.5. Now from Table 3, we find that the values of 𝑋 and 𝑌 corresponding
𝐶0
456.057
to 𝑊𝐴 = 0.5 and 𝑊𝐴 = = 1.409 (which is greater than e = 0.44) are,
𝐶0 𝑊𝑅 323.65

𝑋 = 0.56 and 𝑌 = 1
Dynamic equivalent radial load (V= 1 for most bearings),
𝑊 = (0.56 𝑥 1 𝑥 323.65) + (1 𝑥 456.057) = 637.301 𝑁
From Table 4, we find that for uniform and steady load, the service factor (𝐾𝑠) for ball
bearings is 1. Therefore, bearing should be selected for 𝑊 = 637.301 𝑁.
Basic dynamic load rating, (k = 3 for ball bearings)
𝐿 1
9 𝑥 106 1
𝐶 = ( 6) = 637.301( )3 = 775.238 𝑁
10 106
From Table 5, let us select bearing No. 200 with the following basic capacities,
𝐶𝑜 = 2.24 𝐾𝑁 and 𝐶 = 4 , then
𝑊𝐴
456.057
𝐶𝑜 = = 0.203
2240
From Table 3, the values of 𝑋 and 𝑌 are, 𝑋 = 0.56 and 𝑌 = 1.4
Substituting these values, we have dynamic equivalent load is,
𝑊 = (0.56 𝑥 1 𝑥 323.65) + (1.4𝑥 456.057) = 819.7238 𝑁
∴ Basic dynamic load rating,
𝐿 1
9 𝑥 106 1

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𝐶=( ) = 819.7238( )3 = 997.145 𝑁 = 0.997 𝐾𝑁

106 106

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From Table 5, because this bearing supports the load of the engine, the bearing number
206 having 𝐶 = 15.3 𝐾𝑁, may be selected.
Therefore, Bore diameter = 30 mm
Outside diameter = 62 mm
Width = 16 mm Ans.

4.3.8 Design of key for worm gear

Material selected for key is low carbon steel with,

𝜎𝑦 = 370 𝑀𝑃𝑎

𝜎𝑢 = 440 𝑀𝑃𝑎
Assumption, Factor of safety = 4
From Table 6, we find that for a shaft diameter of 30 mm,
Width of key, 𝑤 = 10 𝑚𝑚
Thickness of key, 𝑡 = 8 𝑚𝑚

Table 6 Proportions of standard parallel, tapered and gib head keys

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Let length of key be 𝑙 and is obtained by considering the key in shearing and crushing.
Considering shearing of the key, shearing strength is,
𝑑
𝑇 = 𝑙 𝑥 𝑤 𝑥 𝜏𝑘 𝑥 ,
2
𝜎𝑦 370
= 46.25 𝑀𝑃𝑎
𝑎𝑛𝑑 𝜏𝑘 = = 2𝑥4
2𝐹. 𝑆
30
∴ 𝑇 = 𝑙 𝑥 10 𝑥 46.25 𝑥 = 6937.5 𝑙 𝑁. 𝑚𝑚 𝑖
2

Torsional shearing strength of the shaft,

𝜋 𝜋
𝑇= 𝑥 𝑑 3
=
16 𝑥 𝜏𝑠 𝑥 50 𝑥 303 = 265071.9 𝑁. 𝑚𝑚, 𝑖𝑖
16
𝜎𝑦𝑠
∵ 𝜏𝑠 =
2𝐹. 𝑆
From equations i and ii,

265071.9 = 6937.5 , 𝑙 = 265071.9

= 38.21 𝑚𝑚
6937.5
Considering crushing of the key, crushing strength is,
𝑡 𝑑
𝑇=𝑙𝑥 𝑥 𝜎𝑐 𝑥
2 2
𝜎𝑦 370
= 92.5 𝑀𝑃𝑎
𝑎𝑛𝑑 𝜎𝑐 = = 4
𝐹. 𝑆
8 30
𝑇=𝑙𝑥 𝑥 92.5 𝑥 = 5550 𝑙 𝑁. 𝑚𝑚 𝑖𝑖𝑖
2 2
From equations ii and iii,

265071.9 = 5550 , 𝑙 = 265071.9

= 47.76 𝑚𝑚
5550
Taking the larger value,
𝑙 = 47.76 𝑚𝑚 say 50 mm Ans.

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4.5.9 Design of bolts

Material selected for the bolt is 304 stainless steel with yield strength:
𝜎𝑦 = 215 𝑀𝑃𝑎

Safety factor assumed is F.S = 2

Number of bolts, 𝑛 = 8
Engine weight 𝑃 = 2000𝑙𝑏 = 8900𝑁
The internal thread found on the engine for fitting the bolt is 12mm. Therefore, diameter of
bolt d = 12mm.
Considering shearing of the bolt, shearing strength is,
𝜋𝑑2𝜏𝑏𝑜𝑙𝑡
𝑃𝑙𝑜𝑎𝑑 =
4
Load on each bolt
𝑃 8900
𝑃𝑙𝑜𝑎𝑑 == = 1112.5 𝑁
𝑛 8
Therefor shearing strength will be,
𝜋122𝜏𝑏𝑜𝑙𝑡
1112.5 =
4
4 𝑥 1112.5
𝜏𝑏𝑜𝑙𝑡 = = 9.84 𝑀𝑃𝑎
𝜋122
But allowable shear stress is,
𝜎𝑦
𝜏𝑎𝑙𝑙 = = 215
2𝐹. 𝑆 = 53.75 𝑀𝑃𝑎
2𝑥2
Since 𝜏𝑏𝑜𝑙𝑡 = 9.84 𝑀𝑃𝑎 is less than 𝜏𝑎𝑙𝑙 = 53.75 𝑀 , the design is satisfactory.
Considering crushing of the bolt, crushing strength is,
Torque transmitted
𝑇 = 𝑘 𝑥 𝑑 𝑥 𝑃𝑒𝑎𝑐ℎ = 0.2 𝑥 12 𝑥 1112.5 𝑁 = 2670 𝑁. 𝑚𝑚
k = 0.2 for non-lubricated bolts
∴ crushing strength is,
2𝑇
𝜎𝑐 𝑏𝑜𝑙𝑡 = 𝜋 2 𝑥 2670

= 𝜋 3 = 3.934 𝑀𝑃𝑎
4 12
3
4𝑑
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But allowable crushing stress is,

𝜎𝑦
𝜎𝑐 𝑎𝑙𝑙 = = 215 = 107.5 𝑀𝑃𝑎
𝐹. 𝑆 2
Since 𝜎𝑐 𝑏𝑜𝑙𝑡 = 3.934 𝑀𝑃𝑎 is less than 𝜎𝑐 𝑎𝑙𝑙 = 107.5 𝑀 , the design is satisfactory.

4.5.10 Design of column

The column is the vertical supporting member for the engine stand which supports the
engine load.
The material selected for the column is mild steel with crushing stress 𝜎𝑐 = 320 𝑀𝑃𝑎
The ideal working height for most humans on engine repair is 130 mm. Therefore, the
length of the column is assumed to be L = 100 mm.
The steel is square section b = h and thickness of column is assumed to be 4 mm.
Now let us check whether the column is safe or not by using Rankine’s formula.
𝑓 𝑐𝐴
𝑃=
1 + ( )𝑙𝑒 2

Where, P = critical load

fc = Crushing stress

A = Cross-sectional area of column

le = Equivalent length of column

a = Rankine’s constant
k = Least radius of gyration

h t

b
Since the column is fixed at on end the effective length, Le = 2L = 2000 mm
Load coming at the column is, P = Pengine / 2 = 4450 N
1
Rankine’s constant for mild steel, 𝑎 =

.
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7500

.
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Area of cross-section, A = (bh)-[(b-2t) x (h-2t)] = 4bt + 4t2 =1664 mm2, since b = h

𝑏ℎ3
Moment of inertia, 𝐼 = (𝑏−2𝑡)(ℎ−2𝑡)3
12 −[ ] = 2363392 mm 4
12

Radius of gyration, 𝐾 = √ = √ = 37.686 𝑚𝑚

𝐼 2363392

∴ Crushing load 𝐴 1664

𝑃=
𝑓𝑐𝐴 = 320 𝑥 1664
𝑙𝑒 1 2000 = 387.1 𝐾𝑁
1 + ( )2 1+ ( )2
7500 37.686

Since the load coming at the column is much less than the crushing load, the design is
safe.

4.5.11 Design of lever arm

The lever arm has L-shape and the length of this lever is selected as, l = 180 mm.
Let d = Diameter of handle in mm.
The load applied by the operator is assumed to be 50N. And 𝜎𝑏 = 100 𝑁/𝑚𝑚2
The force applied acts at a distance of one-third of the length of the handle from its free
end. Therefore, maximum bending moment is
1 1
𝑀 = (1 − ) 𝑥 𝑃 𝑥 𝑙 = (1 − ) 𝑥 50 𝑥 180 = 6000 𝑁. 𝑚𝑚
3 3
Section modulus,
𝜋
𝑍= 3 3
32 𝑑 = 0.0982𝑑
Therefore, twisting moment is
𝑀 = 𝜎𝑏 𝑥 𝑍 = 100 𝑥 0.0982𝑑3
𝑑 = 8.485 𝑚𝑚 𝑠𝑎𝑦 10 𝑚𝑚 Ans.
Cross-section of the lever arm
Let t = thickness of lever arm in mm
b = width of lever arm in mm
Assume width is twice the thickness.

.
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The lever arm is to be designed for 25% more bending moment.

.
.

Therefore, maximum bending moment is

𝑀 = 1.25 𝑥 𝑃 𝑥 𝑙 = 1.25𝑥 50 𝑥 180 = 11250 𝑁. 𝑚𝑚
Section modulus,
1 1
𝑍= 𝑥 𝑡 𝑥 𝑏2 = 𝑥 𝑡 𝑥 (2𝑡)2 = 0.667𝑡3
6 6
𝑀
11250
σ𝑏 = 100 =
𝑍 0.667 t3
𝑡 = 5.53 𝑚𝑚 𝑠𝑎𝑦 6 𝑚𝑚 Ans.
𝑏 = 2𝑡 = 12 𝑚𝑚 Ans.
Let us now check the lever arm for induced bending. Bending moment on the lever arm near
the boss (assuming that the length of the arm extends up to the center of shaft) is given by,
𝑀 = 𝑃 𝑥 𝑙 = 50 𝑥 180 = 9000 𝑁. 𝑚𝑚
Section modulus,
1 1
𝑍= 𝑥 𝑡 𝑥 𝑏2 = 𝑥 6 𝑥 (12)2 = 144 𝑚𝑚3
6 6
𝑀 9000
σ = = = 62.5 𝑁/𝑚𝑚2
𝑏
𝑍 144
Therefore, the induced bending stress is within safe limits.

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