Project On Hydraulic Telescopic Transmission Jack

UNIVERSITY OF GONDAR
INSTITUTE OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
HOISTING ORGANIZATION: MOENCO ADAMA BRANCH
TITLE: - DESIGN OF CLAMP FOR TELESCOPIC

TRANSMISSION JACK AND INTERNSHIP REPORT
DURATION OF INTERNSHIP: THREE MONTHS
PREPARED BY: ID No
1. KALEB MERGA 03505/11

2. BIRUK AYNE 03360/11
UNIVERSITY SUPERVISOR: Mr. YESHAMBEL.D
COMPANY SUPERVISOR: Mr. MELES.T
DATE: 01/02/2023
GONDAR, ETHIOPIA
Declaration
We hereby declare that our work, which is being presented in the report after working in
MOENCO Adama branch This internship was done from October 31 to January 27. This is the
result of our own report and all the writings in this document are done by our effort. And we
assure that it was not presented before.
All relevance resources of the information used in this paper have been duly acknowledged
STUDENT SIGNATURE DATE
1. KALEB MERGA ------------------ ------------------
2. BIRUK AYINE ------------------ ------------------
Design of clamp for hydraulic telescopic transmission jack
This is to certify that the above statement made by the candidate is correct to the best of my
knowledge and belief. This report has been submitted for presentation with my approval.
ADVISOR SIGNATURE DATE
1. Mr. YESHAMBEL. D ---------------------- -------------------
i
Acknowledgment
First and for most, we would like to thank Gondar University, Department of Mechanical
Engineering for handing us this opportunity and M O E N C O C o m p a n y A d a m a b r a n c h
for allowing us to do an internship within the organization. We have taken efforts in this project.
However, it would not have been possible without the kind support and help of many
individuals and organizations. We would like to extend our sincere thanks to all of them.
We are highly indebted to all workers in the organization for their guidance and constant
supervision as well as for providing necessary information regarding the report/ the project and
also for their support in completing the report and to our advisor Mr. Yeshambel. D for his
consultancy in our project.
We would like to express our special gratitude and thanks to each and every industry personnel
for patiently giving us their time and guidance. Our thanks and appreciations also go to our
colleague in developing the project and people who have willingly helped us out with their
abilities. It is really difficult to list all individuals who kindly helped us during the work of our
internship project.
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Table of Content
Declaration........................................................................................................................................i
Acknowledgment.............................................................................................................................ii
Table of Content...............................................................................................................................i
List of Figure..................................................................................................................................iii
List of Table....................................................................................................................................iv
Abbreviations...................................................................................................................................v
Abstract...........................................................................................................................................vi
PART ONE; INTERSHIP REPORT...............................................................................................8
CHAPTER ONE..........................................................................................................................................8
BACKGROUND OF THE COMPANY.......................................................................................................8
1.1. Brief History of the company....................................................................................................8
1.2. Objective of the Company........................................................................................................8
1.2.1. Lead In Customer Experience.............................................................................................8
1.2.2. Become The OEM's Partner of Choice...............................................................................9
1.2.3. Deliver Full Potential from All Our Revenue Streams.........................................................9
1.2.4. Leverage Our Global Scale.................................................................................................9
1.2.5. Invest To Accelerate Growth..............................................................................................9
1.3. Mission and Vision Statements.................................................................................................9
1.3.1. Mission...............................................................................................................................9
1.3.2. Vision.................................................................................................................................9
1.3.3. Values................................................................................................................................9
1.4. Services of the company.........................................................................................................10
1.4.1. PDI Service (pre delivery Inspection):..............................................................................10
1.4.2. Free service Checkup:......................................................................................................10
1.4.3. Periodic maintenance:.....................................................................................................10
1.4.4. Express maintenance.......................................................................................................10
1.4.5. Body and Paint Repair......................................................................................................10
1.4.7. Annual vehicle inspection................................................................................................10
1.4.8. Towing Service.................................................................................................................11
1.5. The sale service provides those machines and Vehicles.........................................................11
1.6. Customer of the product (service)..........................................................................................11
1.7. Staffing and facility.................................................................................................................11
1.8. Work flow...............................................................................................................................12
CHAPTER TWO.......................................................................................................................................13
2. Internship experience...................................................................................................................13
2.1. How we get into this company?..............................................................................................13
2.2. Auto- service department maintenance schedule for periodic service...................................13
2.2.1. Power transmission..........................................................................................................14
2.2.2. Auto Electricity.................................................................................................................14
2.2.3. Engine maintenance........................................................................................................15
2.3. Automotive Fuel System service.............................................................................................15
2.4. Contamination Control Procedures........................................................................................16
2.5. Automotive Tire & Wheel Service...........................................................................................17
CHAPTER THREE.......................................................................................................................................1
3. OVER ALL INTERNSHIP BENEFIT.......................................................................................................1
3.1. Upgrading Theoretical Knowledge............................................................................................1
3.2. Improving Our Practical Skill.....................................................................................................2
3.3. In terms of improving problem-solving capability....................................................................2
3.4. Improving Team Playing Skills...................................................................................................3
3.5. Improving Leadership Skills.......................................................................................................4
3.6. Understanding about work ethics and related issues...............................................................4
3.7. Entrepreneurship Skills.............................................................................................................5
CHAPTER FOUR........................................................................................................................................6
4. Conclusion & Recommendation......................................................................................................6
4.1. Conclusion................................................................................................................................6
4.2. Recommendation.....................................................................................................................7
Part two: Project Report...................................................................................................................8
Abstract...................................................................................................................................................9
1. Background of the project.............................................................................................................10
1.1. Introduction...........................................................................................................................10
1.2. Background.............................................................................................................................10
1.3. Problem Statement................................................................................................................11
1.4. Justification.............................................................................................................................11
1.5. Objective................................................................................................................................12
1.5.1. General objective.............................................................................................................12
1.5.2. Specific objective.............................................................................................................12
2. Literature Review...........................................................................................................................13
3. Methodology.................................................................................................................................15
3.1. General procedure in machine design....................................................................................15
3.2. General design considerations................................................................................................16
3.3. Components of clamp.............................................................................................................16
4. Modeling and System Design.........................................................................................................17
4.1. General Design Considerations...............................................................................................17
4.1.1. Material selection............................................................................................................17
4.2. Design of plate........................................................................................................................17
4.3. Design of Clamp arm...............................................................................................................18
4.4. Design of Clamp Bolt...............................................................................................................20
4.4.1. Stress Analysis of Bolt......................................................................................................21
4.5. Design of Clamp adjuster nut.................................................................................................22
4.6. Design of Adjuster leaver.......................................................................................................22
4.6.1. Stress Analysis of adjuster leaver.....................................................................................23
4.7. Design of Clamp Support.......................................................................................................23
4.7.1. Stress Analysis of support................................................................................................24
4.8. 3D part and Assemble drawing of clamp of a telescopic transmission jack...........................25
4.8.1. 3D part drawing..............................................................................................................25
4.8.2. 3D Assembly of clamp support....................................................................................................31
4.9. Cost estimation.......................................................................................................................32
4.9.1. Cost of plate.....................................................................................................................32
4.9.3. Cost of support................................................................................................................33
4.9.4. Cost of other materials....................................................................................................33
5. Result and Discussion....................................................................................................................34
5.1. Result......................................................................................................................................34
5.2. Discussion...............................................................................................................................35
6. Conclusion and recommendation..................................................................................................36
6.1. Conclusion..............................................................................................................................36
6.2. Recommendation...................................................................................................................36
Reference..............................................................................................................................................37
APPENDIX..............................................................................................................................................38
Appendix A........................................................................................................................................38
Appendix B.........................................................................................................................................39
Appendix C.........................................................................................................................................41
List of Figure
Figure 1: Work flow of MOENCO---------------------------------------------------------------------------------
Figure 2:Three-Dimensional View of the plate-------------------------------------------------------------------
Figure 3: Three-dimensional View of the clamp arm------------------------------------------------------------
Figure 4: Three-dimensional View of the clamp support-------------------------------------------------------
Figure 5 Plate---------------------------------------------------------------------------------------------------------
Figure 6: Clamp arm-------------------------------------------------------------------------------------------------
Figure 7: Clamp bolt-------------------------------------------------------------------------------------------------
Figure 8: Clamp adjuster nut----------------------------------------------------------------------------------------
Figure 9: Adjuster leaver--------------------------------------------------------------------------------------------
Figure 10: Support----------------------------------------------------------------------------------------------------
Figure 11: Assemble drawing of Clamp---------------------------------------------------------------------------
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List of Table
Table 1: Design specification for plate----------------------------------------------------------------------------
Table 2: Design specification for clamp arm---------------------------------------------------------------------
Table 3: Material selection for bolt design------------------------------------------------------------------------
Table 4: Standard bolt and nut dimension-------------------------------------------------------------------------
Table 5: Design specification for clamp support-----------------------------------------------------------------
Table 6: Result--------------------------------------------------------------------------------------------------------
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Abbreviations
N Newton
Ft Total force
t Thickness
dc Core diameter
mm Milimeter
Mpa Mega Pascal
dp Pitch diameter
n Number of bolt
Lt Length of threaded
Lut Length of unthreaded
Ab Area of bolt
Ap Area of plate
σall Allowable stress
σtb Tensile strength of bolt
mt Mass of transmission
Wt Weight of transmission
d/D Major diameter
σ Normal stress
FS Factor of safety
MOENCO Motors and Engineering company
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Abstract
Internship the core of new curriculum is one of the main changes that were introduced to help
students to integrate a thought and to provide dynamic linkage between the industry and the
universities institutions of technology to meet the demands of the ever-growing economy of
Ethiopia. As being one of the beneficiaries of this program we were able to incubate new ideas
and meet the demands of the internship we were assigned for. Internship is also without a
shadow of doubt will place the students a dynamic environment and make students test and smell
a new working environment. This strange environment shines a new light on our life to cultivate
our theoretical backgrounds and made us to know the hidden secretes of this world. The final
internship report is designed for the accomplishments of fourth year second semester Mechanical
Engineering internship program. This program takes about 90 days in the motors and engineering
company of Ethiopia Adama branch. In this final report the background main activities in the
organization, responsibilities of intern the qualities developed by the intern, the design of clamp
which used to assemble and disassemble transmission case manually, conclusion,
recommendation and references are included.
Keyword; MOENCO, Car, Industry, Clamp, Transmission
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UNIVERSTIY OF GONDAR, IOT
PART ONE; INTERSHIP REPORT

CHAPTER ONE
BACKGROUND OF THE COMPANY
1.1. Brief History of the company
MOENCO is a subsidiary company of Inchcape PLC, a London based company engaged in global
distribution & retail leader in the premium and luxury automotive sectors. Moenco is the largest
automotive company in the country, representing over 20 brands. MOENCO has grown both in terms
of size and in terms of the modernization of its service shops and parts distribution centers, which
display a passion for creating the ultimate customer experience. Moenco has over 871highly skilled
and professional employees, 7 branches in Ethiopia, 12 sub-dealers and more than 10 brand partners.
[10]
In the heart of Addis Ababa, around the area commonly known as Mexico, a small garage with a
capital of 200, 000 Ethiopian birr was founded by Mr. Y. D. Lappine on January 1959 in a small
rented house. His far-sighted vision became reality with the help of other resourceful people, such as
Ato Menasseh Lemma, the Governor of the National Bank of Ethiopia, and the boss of Imperial
Insurance Company.[10]
Nine years later, MOENCO took over the TOYOTA franchise business for Ethiopia when Inchcape, a
London based international organization, became a major shareholder and injected a considerable
amount of capital. This was a milestone moment in the firm’s journey to become the MOENCO of
today.[10]
In addition to the TOYOTA business, at different times MOENCO used to represent General Motors
for various types of American vehicles and trucks; Ingersoll-Rand; WABCO, Pettibow; Universal;
Dupont; General Tire; Frigidaire; Zanussi; and Thomas De La Rue & Co. of England.[10]
MOENCO Adama is one of the branches of MOENCO that we spent our internship program. It is
initial investment of birr 30 million rests in area of 20,000 m2 in good location of Adama. This branch
gives a quality service to customers in Adama and surrounding area.[10]
1.2. Objective of the Company
MOENCO's strategy is built around our Vision to become the world’s most trusted automotive
Distributor and Retailer
1.2.1. Lead In Customer Experience
We will invest to maintain our position as leader in customer service innovation in automotive
distribution and retail, with digital a key priority. Through a program of global research, we will build
on our insights into the customer journey in an omnichannel world and create stand-out customer
experiences combining data-driven personalization with a human touch.
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1.2.2. Become The OEM's Partner of Choice

We will build and strengthen our working relationships with our OEM partners by investing time in
understanding their needs, seeking greater opportunities for collaboration with the aim of becoming a
consistent strategic business partner.
1.2.3. Deliver Full Potential from All Our Revenue Streams
We will increase our management focus on our Used vehicle and Aftersales activities at all levels of
the organization, enhancing their perceived status within the business and deepening further reporting
and analysis.
1.2.4. Leverage Our Global Scale
We will allocate more resources to innovation, sharing and benefiting even more effectively from the
proven ideas generated throughout the global organization. We will sharpen further our business
processes, management skills, creativity and strategic planning across the Group, focusing on talent
management and shared services to boost performance and reduce costs.
1.2.5. Invest To Accelerate Growth
We have increased our business development resources to ensure we have the management
capabilities to participate in industry consolidation. Furthermore, we will involve the CEOs of our
market-specific operations, and leverage their knowledge and insight more directly in delivering our
growth agenda.
1.3. Mission and Vision Statements.
1.3.1. Mission
Providing vehicle sales, parts and service in the world-class purpose-built center. Providing Excelling
service and many magic moments by customer friendly service, Advisor, sales people, Toyota
certified technician and support staff. Minimizing time for the service of Toyota vehicle by using
special service Shop, genuine spare parts and sophisticated equipment.
1.3.2. Vision
To be the most customer-centric distributer of vehicles and equipment for the construction, agriculture
and industry sectors in Ethiopia with unparalleled after sales services supported by state of the art
technology and skilled manpower.
1.3.3. Values
MOENCO being an affiliate company of INCHCAPE PLC, shares same set of values stated
hereunder.
 Respect for each other
 Passionate about customers
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 Caring for environment

 Winning together
 Integrity without compromise.
1.4. Services of the company
MOENCO represents TOYOTA one of the great Automobile Company of this world. The main
reason that makes MOENCO the great organization is its providing of different service for the
customers. Service that are given by MOENCO are PDI Service, Free Service Check-up, Express
Maintenance Service, Periodic Maintenance, General Repair, Body & Paint Repair Service,
Annual Vehicle Inspection, Towing Service.
1.4.1. PDI Service (pre delivery Inspection):
Before delivering a new vehicle to the customers the pre delivery inspection is done. The job of PDI
staff includes removing the protective materials applied to prevent possible damage on the vehicle
during transportation from the supplier to the distributor, inspection of mechanical status, body parts.
1.4.2. Free service Checkup:
In MOENCO there is free service checkup for vehicles that are purchased from MOENCO in every
1,000 km & 5,000 km this makes the customers feel safe with their properties and satisfy with their
new vehicle. Only the customers have to pay replacement of lubricant and filters.
1.4.3. Periodic maintenance:
Every TOYOTA, DAIHATSU & LEXUS vehicles have to be periodically maintained in every
5,000km or by the intervals of 3 months. Periodic maintenance will insure reliability, high resale
value, long life and maximum performance.
1.4.4. Express maintenance
the express maintenance service is done for vehicles with mile age up to 50,000km. The service is
given by using the best and most advanced automotive equipment’s and the service provided by their
qualified technicians enable them to deliver TOYOTA’s quality service to their customers.
1.4.5. Body and Paint Repair
MOENCO by teaching the proper fundamentals of Body and Paint through a continued in-house and
overseas training program and using the state-of-the-art equipment manages to develop full-fledged
Body and Paint technicians who can correctly trouble shoot and carry out major and minor Body &
Paint repairs to mint condition.
1.4.6. General Repairs
MOENCO’s Service Centers also provide General Repair Service. Their General Repair Service
comprises of units overhauling (like engines, automatic and manual transmissions/transaxles, fuel
injection pumps, differentials, steering gearboxes, vane pumps, starters, alternators, etc.), and
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diagnosis & repair of any malfunctions on the vehicle using the state-of-art equipment and tools
available in the Service Centers.
1.4.7. Annual vehicle inspection
The Ethiopian Transports Authority decides for all vehicles have to be annually inspected for safety of
the human life and economic disaster.
1.4.8. Towing Service
MOENCO also provide towing service (dragging of a car) to assist the customers in the event of
vehicle collapse or malfunction.
1.5. The sale service provides those machines and Vehicles
Automotives
 TOYOTA HIULUX - TOYOTA LAND CRUISER
 TOYOTA RAV 4 - TOYOTA PRADO
 TOYOTA HAICE - TOYOTA RUSH
Constriction
 KOMATSU EXCAVATOR
 KOMATSU DOZER
Agriculture
 NEW HOLLAND TRACTOR
1.6. Customer of the product (service)

MOENCO provides genuine parts for the vehicles and machinery it supplies genuine parts and
accessories. Its objective is to deliver the right quality at the right time and the right place. When
they say “the right quality”, they mean genuine parts for trouble free performance, long life and safe
environment. When they say “At the right time”, they mean an optimum availability of parts,
ensuring continuous supply based on customer demand. A fully computerized sales, stock control and
electronic parts catalogue system has enabled to achieve a very high supply of parts resulting in
remarkable customer satisfaction. When they say “the right place”, they are referring to their dealers
in different parts of the country and their branches in Awassa, Bahirdar, Adama, and other branches.
They are committed to serve their customers with quality service, wherever they are.
Their parts operation is one of their primary value chain systems. It is based on “JIT” operation
system (Just in time) which in turn is based on “sell one buy one” philosophy. In effect, their parts
operation is backed up by extensive inbound and outbound logistic activities. Recent trends show that
the market in the motor industry is characterized by increasingly fierce competition in after sales. The
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value of the after sales market is increasing due to longer vehicle ownership and diversification of
customer needs.
1.7. Staffing and facility
Staff: There are total of 60 staff on permanent and contractual basis working in the different sections
of parts department – Parts office, main counter, service counter, data control, customer relation and
tender section, ordering officials.
Warehouse Facility: Their warehouse is one of the best among similar African Toyota distributors.
Its storage capacity is 10,000 m2. It is well organized and equipped with sufficient storage and
handling materials. They also have satellite stores in their Awassa and Bahirdar branches with a
capacity of 5,000m2 each.
Parts Counter: Their parts counter is designed in such a way that their customers can be served
comfortably and conveniently.
1.8. Work flow
Vehicle Reception vehicle inspection Cost estimation
service section
Mechanical Repair
- Body and Paint quality control vehicle delivery
Engine maintenance
Auto electric service
Figure 1: Work flow of MOENCO
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CHAPTER TWO
2. Internship experience
2.1. How we get into this company?
We send our application letter to MOENCO through our university by email and after 2 weeks they
told us they will accept us with warm face and good sense of humor. Next, we joined the company
and stay there for about three months.
In our four-year mechanical engineering experience, we began to realize that this world is only can go
far in innovation and creating things that uses to provide for humans best need to achieve their needs
energy is must. Especially mechanical energy. In the study of mechanical engineering many problems
are solved and if the study widens its horizon students are able to solve many problems related to
industries in the future. In our world of competition vehicles provide a best track to let everyone do
what he/she want and to win the race. We are one of the competent we prefer to win our race by
studying the track provider (vehicles) this motivation encouraged us to know more about designs of
the cars and their systems.
In Ethiopia there are many companies that relate their job in servicing of vehicles and automobiles
like Rise engineering, Nyala motors, MOENCO, National Motors, marathon motors, belayab motors.
From these companies we get the one which has many services, facilities and well-organized company
that is MOENCO branch in Adama.
Gondar University 4th year mechanical engineering student’s internship program is appropriate for
increasing student’s practical knowledge. The letters that ask for internees to do their internship
program in the MOENCO is given to us. The latter is accepted by the company HR and they allow as
joining the Moenco staffs and workers after 3 weeks of application.
2.2. Auto- service department maintenance schedule for periodic service
The service is given for the vehicles of HILUX 2L,3Land 5L engine, Condor 5L Engine, Land
Cruiser, Station Wagon, Pick-Up and Hard Top (diesel 1HZ Engine) (Appendix C)
 Service type A = 5/15/25/35/45/55/65/75,000 km
 Service type B = 10/30/50,000 and 70,000km
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 Service type C = 20,000 and 60,000 km
 Service type D = 40,000 and 80,000 km
In addition to this, the activities that are performed in this shop can be classified into three main parts.
They are: -
1. Power Transmission
2. Auto Electric
3. Engine Maintenance
2.2.1. Power transmission

This is where all parts of the car, which are used for the power transmission system, are checked and
repaired. Some of the main daily activities are-
 Check and replacement of Tires
 Check and repair of front and rear housing
 Check and repair of Propeller Shaft
 Check and repair of gear box
 Check and repair of Transfer Gear Box
 Check and repair of joints, like Universal Joint
 Check and repair of pumps such as Vain Pump, Vacuum Pump, Water Pump
 Check and repair of timing belt
 Check and repair of cleaners such as Air Cleaner, Fuel Filter, Oil Filter
 Refilling of hydraulic oils such as brake oil, clutch oil, power steering fluids.
 Check and repair of knuckle components such as bearing, spacer, hub and etc
 Check and repair of hand brake, pad, shoe
In those days we got deep knowledge about the mechanics of the automobile & its system &sub
system in simplified manner. In addition, we deal with the essential description of the construction &
principal operation of various components as a part of total vehicle system. Until now, we tried to get
proper knowledge, skill & attitude that are necessary & sufficient in order to maintain modern
automobile. Let see some of the duty and tasks in detail that we discover from the 3-month experience
in Repair & maintenances shop.
Repair & maintenances shops one of the biggest shops, which accomplish different big duty & tasks
for the customer as well as for the company. In this class, there is different service person, which
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accomplishes the work. Such as fuel system serviceperson, lubricating system service person, cooling
system service person, power train service person, tire & wheel person, hydraulic brake system
service person& steering system service person.
2.2.2. Auto Electricity
This is where the electrical part of the car is checked and repaired. Some of the activities are:
 Check and maintenance of all the lighting system
 Check and replacement of car battery
 Check and repair of alternator and starter
 Check and repair of Air conditioning system
 Check and maintenance of all the electrical system inside the car.
2.2.3. Engine maintenance
This part is where the engine, gearbox, and differential of the car is checked and maintained. The
general main activities that are performed here are as follows.
 Check and replacement of engine and its accessories including:
o Check and installation of the crank shaft
o Check and installation of all bearing
o Check and installation of camshaft
o Check and maintenance of cylinder head
o Check and installation of piston with its rings
o Check the diameter of cylinder
o Check cylinder blocks
o Lapping the valve with its valve seat
o Check and repair of front and rear differential
o Check and repair of gear box
2.3. Automotive Fuel System service

In MOENCO Adama. Everything seems nice we quickly adapt the environment of the organization.
We get nice friends in there. They told us everything about the life of industry, they also advise us a
lot of things. Since they are experienced, they told us what they know without hesitation. Now we
have some knowledge about automobile & vehicle.
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For this week, our supervisor Ato Tadese told us to work in automobile fuel system service area. In
this class, there are different duties & task to be done. Those are: -
 servicing air cleaner
 servicing fuel tank
 servicing fuel line
 servicing gasoline engine fuel pump
 servicing carburetor
 servicing fuel filter
 Servicing transfer pump service etc. these are some of duties.

When we are dealing with automotive fuel system, we must have fundamental understanding of
engine design & operation. Fuel is a major combustion control system. The system has many major
parts such as intake manifold, fuel pump, fuel return line; fuel tank etc. the fuel tank stores the
gasoline or diesel fuel. Steel lines & rubber-hoses connect the tank to the fuel delivery parts on the
engine. One or more fuel pumps move fuel from the tank to the carburetor or fuel injection system.
One or more fuel filter removes water, dirt, & other impurities from the fuel before it enters the
engine. If the impurities mix with the fuel, they cause contamination. Contamination will be dealt with
further explanation in the next page. Another filter at the engine air inlet removes dirt from the
incoming air evaporative emission controls keep fuel vapors from escaping into the atmosphere from
the tank, the carburetor & other fuel system parts. The carburetor or fuel injection system atomizes &
vaporizes the fuel & mixes it with air in ratios that satisfy engine’s operating needs from light to full
load.
2.4. Contamination Control Procedures
 Housekeeping
 Sweep floors daily
 Clean up spills immediately
 Keep work benches uncluttered and free of debris
 Limit use of floor storage
 Oil storage and transfer
 Filter new oil
 Use drum covers
 “Kidney loop” system oil

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 Parts handling and storage
 Keep components packaged until ready to install
 Return parts to storage in packaging
 Clean in-process components
 Hose assembly and storage
 Protect bulk hose with caps and plugs
 Clean assembled hoses
 Protect assembled hoses with caps and plugs
 Component repair and assembly
 Establish a “clean repair” process
 Use cylinder washer after honing
 Separate welding and cleaning operations
 Keep fuel injector rooms closed
 Field service
 Keep exchange parts and components packaged until ready to install
 Filter new oil
 Stock vehicles with High Efficiency Filters
Contamination Control Will
 Require a cultural change
 Reduce redo
 Enhance value of rental fleet
 Improve machine performance
 Improve customer satisfaction
Success Formula
Clean Oil+ Clean Components+ Clean Assembly Processes = Clean Machines
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2.5. Automotive Tire & Wheel Service

Purpose of tires
Tire is the only element that connects a vehicle with the road. The tire supports the vehicle in all
condition of load and on its proper speed. Tire is air-filled cushions that absorb most of the shocks
caused by road irregularities. The tires the road to provide good traction that enables the car to
accelerate, brake and turns without skidding.
Tire Construction
The carcass prevents the tire from stretching under the force of internal air pressure. The carcass
forms the supporting framework of the tire The tire casings, and tubeless tires, are made in about the
same way. Layers of cord, called plies, are shaped on a form and impregnated with rubber. The rubber
sidewalls and treads are then applied. They are vulcanized into places to form the completed tire. This
process molds the rubber into the desired form and gives it the proper wear characteristic and
flexibility. The tire quality mainly depends on the cord fabric strength.
Tire wear
Tire wear depends on several factors:
 Rapid tire wear can be caused by layout irregularities
 The speed any style of driving can also cause rapid tire wear
 The distribution of car’s weight on tires
Changing Tire Assembly
There are three common duties, which are to be done are: -
 changing tire assembly
 servicing tire assembly
 servicing wheel bearing.
In changing tire assembly there are three main tasks which is to be done by the mechanic i.e.
 Removing tire assembly
 installing tire assembly
 Correcting tire pressure.
When we are removing the tire, assembly there is procedures that are to be done.
 Set the parking brake
 Remove the spare tire, jack &wrench from the car

18
 Set jack in its stand & attach the saddle to the bumper
 Break lose all the lug nuts
 Raise the car by jack, until the tire lifts off the ground
 Finish the lugs & pull of the vehicle.
This is the first task during removing the tire then the next task is installing tire assembly. The
procedure is reverse
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CHAPTER THREE
3. OVER ALL INTERNSHIP BENEFIT
The internship is defined as, ―work experience with clear learning objectives‖. Internship programs can
lend support to academic programs and to institutional initiatives involving student recruitment and
retention. Internship programs can assist with skill development, such as writing skills, oral
communication and computer skills, initiative, time management skills, dependability, professional
skills, interaction with others, ability to contribute, the overall quality of work and attitude. Studies have
found that internships are typically completed while a student is enrolled in other academic courses.
Enrollment in an internship course can provide students the additional benefits of earning course credit,
as they connect classroom theory to the workplace.
Our internship was: -
 A structured work experience related to our major and/or career goal
 An experience that should enhance our academic, career, and personal development
 supervised by a professional in the field
 An experience that can be one academic term (one semester term in length)
 It was unpaid
 An experience that is mutually agreed upon by us, the supervisor and/or faculty member
 Depending on the field the experience might also be called a practicum or coop
3.1. Upgrading Theoretical Knowledge
There is a slight difference between what we have learned in class and the practical work around
companies. However, having a deep knowledge about the practical work makes us more intensive for
the theoretical knowledge.
 It enhances our theoretical knowledge by integrating academic principles to practical work. Gave
us a better understanding of the concepts we learned in class. It allowed us to practice the
theories we learned.
 Theory wise we learned how to read manuals and have better understanding. It also allowed us to
have more exposure to different machine drawings and manuals.
Moreover, we have upgraded what we have learned in class. Among these are:
 All chapters we take under IC engine course
 all Chapters we take under motor vehicle course
 Thermal unite system. Like; compressor, condenser, evaporator.
1
 Pumps. Like, hydraulic pump and vacuum pump
 About heat transfer and fins
 Mechanical power transmission (belt, gear, chain, sprocket) and so on.
3.2. Improving Our Practical Skill

The internship program develops our practical skills and improves our attitude towards knowledge
formation. We admit that practical knowledge is different from the theoretical knowledge and it was a
great opportunity to have a test of how the working world is.
We were able to learn great skills like:
 How to handle machines.
 Take down small parts of machines and repair and put them back
 The ability to work under pressure.
 Effective technical skills.
 Problem-solving skills.
 Creativity.
 Interpersonal skills.
 Verbal and written communication skills.
 Commercial awareness.
 Team working skills.
3.3. In terms of improving problem-solving capability

Problem solving skills help you to determine the source of a problem and find an effective solution.
Although problem solving is often identified as its own skill, they contribute other related skills to this
ability. Some of these key problem skills include
 Active listening
 Analysis
 Research
 Creativity
 Communication
 Dependability
2
 Decision making
 Team building
3.4. Improving Team Playing Skills

Teamwork is defined as a series of activities where two or more people work collaboratively towards a
common aim. Team playing skills are a vital requirement to manage people in a company.
In this internship program we were working with different persons like machine operators, maintenance
planners, mechanists, managers, students and labor workers. Therefore, we are able to improve our team
playing skills and we are able to understand:
 How to develop collaboration with a group of people
 Different team playing skills such as
 Working cooperatively
 Contributing to groups with ideas, suggestions, and effort
 Communication (both giving and receiving)
 Sense of responsibility
 Healthy respect for different opinions, customs, and individual preferences
 Ability to participate in group decision-making
 Strike off the habit of complaining
 Conflict management
 The importance of team playing skills
 More people mean more efficiency:
 Quick functioning:
 Work never suffers in a team:
 Healthy competition:
 Improves employee relationships:
 Teammates gain from each other:
 Increased accountability:
Generally, this program helps us to improve our teamwork skills to work with groups in our future
workplace.
3
3.5. Improving Leadership Skills

Leadership skills are the tools, behaviors, and capabilities that a person needs to in order to be successful
at motivating and directing others. Yet true leadership skills involve something more; the ability to help
people grow in their own abilities. It can be said that the most successful leaders are those that drive
others to achieve their own success. We certainly know that we have grown and learned many effective
leadership skills from the internship. We understood that what skills all the people had that made them
effective leaders.
Some of those effective skills are:
 Committed to mission and vision of the organization
 Understand individual’s role
 Demonstrate integrity
 Understand how to motivate the behaviors of others
 Communicate effectively
 Willing to take risks
 Adapt Problem solving methods
3.6. Understanding about work ethics and related issues
Work ethics include not only how one feels about their job, career or vacation but also how one does
his/her job or responsibilities. This involves attitude, behavior, respect communication and interaction,
how work ethics break down to what one does or would do in particular situation. The basic goal of any
business is to make profits and the people working is organizational depends on how much he/she
contributing towards this goal of business, so employee for their personal benefits as well as mutual,
they overlook work ethics in the company. The benefit off the internship program was interesting in the
development of ethical work habit. We gain a lot of benefits from the company according to work
ethics. Some of these are;
 Punctuality
 Accountability Teamwork
 Attitude
 Organizational Skills
 Honesty
 Respect
 Loyalty
4
3.7. Entrepreneurship Skills

An entrepreneur is an individual who organizes, manages and operates any enterprise, specifically, a
business, usually with considerable initiative and taking on financial risk. There are many skills that
entrepreneurs develop over time, but they are a few skills that every entrepreneur must have before
opening ―the door‖ for business. Successful entrepreneurs have skill which increases productivity of the
organization products.
These skills are:

 Creativity and innovative thinking
 Self-motivation
 Time management
 Leadership ability
 Risk taker
5
CHAPTER FOUR
4. Conclusion & Recommendation
4.1. Conclusion
The internship is defined as, ―work experience with clear learning objectives. Internship programs can
lend support to academic programs and to institutional initiatives involving student recruitment and
retention. Internship programs can assist with skill development, such as writing skills, oral
communication and computer skills, initiative, time management skills, dependability, professional
skills, interaction with others, ability to contribute, the overall quality of work and attitude. Studies have
found that internships are typically completed while a student is enrolled in other academic courses.
Enrollment in an internship course can provide students the additional benefits of earning course credit,
as they connect classroom theory to the workplace.
During internship period we tried to work and learn some of the duties and tasks in repair and service
shop. We have acquired adequate knowledge about the mechanics of automobile, its systems and sub-
systems in a simplified manner. We have also dealt with the essential construction and principles of
operation of various components as a part of total vehicle system. Moreover, we tried to grasp basic
knowledge and skill that are necessary and sufficient to maintain and provide service for modern
automobiles. While working with our coworkers we gained many experiences and habits like Respect for
each other, Caring for environment, Winning together, integrity without compromise and other
beneficiary habits.
6
4.2. Recommendation
We recommended MOENCO to improve and soften the challenges that may be faced. Far too little
attention is paid by the company on addressing the problems. We have a lot to recommend but few of
them are only mentioned here.
The delays of hours being counted by computer, as a result the customer have to pay for the delay. The
power ranch and the sockets used must be maintained or replaced by new in order to increase the
efficiency of work. And also arc welding and MIG welding machines which are not operating should be
maintained and used as an alternative. Most Importantly the company must focus on quality work rather
than time it takes to maintain a car in giving efficiency to the workers which eliminates come back and
improve quality working. Also, we recommend that the company must give motivational speeches to the
workers for good mind set. Safety materials for all the welding types, sanding, and grinding such as
gloves, goggles and others are not enough. Otherwise, the workers that are carelessly doing their job
may face a series internal and external injury and may lose his precious life. The main issues about
washing engine by benzene and cleaning air filter by using pressurized air is also have to be addressed
well.
The rigidity of the company is not limited but extended to not to provide resource and facilities such as
library, internet access, physical fitness center and other reference materials for the intern students and
workers to progress for any type of intended project for further insight should be fulfilled.
On the other hand, neither no pocket money is given by the company nor the pocket money given by the
university to the internship students is enough. It may be difficult to survive for students from poor
background. The serious of sense of punctuality and team working in the company should be admired
and promoted for further success.
7
Part two: Project Report

_________________________________________________________________________
_____________________________________________________________________________
Project title: Design of Clamp for Hydraulic Telescopic

Transmission jack
8
Abstract
Telescopic Transmission Jack allows you to remove, install, and transport transmissions and transfer
cases on vehicles supported by lifts.in case of maintenance and service time. some issue or problem
occur to change or service the transmission (gear box) when replace of clutch disk, some of the issues
like time consumption, safety of the workers. The objective of this project is to design clamp for
hydraulic telescopic transmission jack. In this process, selection of characteristics of material,
components and calculation has been mainly carried out to determine a rage of parameters, such as
clamp arm, clam support, clamp adjuster bolt and nut, capacity of holding the load, length of the plate.
Several measurement techniques, formulas and selection component have been used to select the clamp
performance and reliably. After all tasks has been design properly, we have worked a three- dimensional
drawing of the clamp has been done in solid work software.
Key word: Transmission, Clutch disk, Telescopic, Jack, Clamp, solid work
9
1. Background of the project

1.1. Introduction
Telescopic Transmission Jack allows you to remove, install, and transport transmissions and transfer
cases on vehicles supported by lifts. Its universal saddle plane has two adjustable arms that adjust to the
transmission weigh direction. Wide base legs with swivel casters keep the jack stable, steady and easy to
maneuver.[3]
Transmission jacks lift, lower, and position a transmission to safely and easily remove, repair, or install
it. They have an adjustable head for aligning with transmission bolts patterns and pins. These heavy-
duty jacks have casters for mobility and straps or chains to secure equipment when moving.[3]
1.2. Background
A jack is a mechanical lifting device used to apply great forces or lift heavy loads. A mechanical jack
employs a screw thread for lifting heavy equipment. A hydraulic jack uses hydraulic power. The most
common form is a car jack, floor jack or garage jack, which lifts vehicles so that maintenance can be
performed. Jacks are usually rated for a maximum lifting capacity (for example, 1.5 tons or 3 tons).
Industrial jacks can be rated for many tons of load. Before the invention of weight lifting device such as
screw jack, hydraulic jack, crane, etc., the early man applies a crude way of lifting objects to great
heights through the use of ropes and rollers, which was mostly applied in the construction area, where, it
was used to raise mortar (cement, sand & water). In 1838 William Joseph Curtis filed a British patent for
a hydraulic jack. In 1851, inventor Richard Dudgeon was granted a patent for a "portable hydraulic
press" – the hydraulic jack, a jack which proved to be vastly superior to the screw jacks in use at the
time.[4]
Hydraulic jacks are typically used for shop work, rather than as an emergency jack to be carried with the
vehicle. Use of jacks not designed for a specific vehicle requires more than the usual care in selecting
ground conditions, the jacking point on a vehicle, and to ensure stability when the jack is extended.
Hydraulic jacks are often used to lift elevators in low and medium rise buildings.[5]
After the industrial revolution, with the advent of Machine, the Machine Shop was also faced
with the challenge of load lifting, because of the bulkiness of some Machine parts. The Machine
Shop deals with various components made of metal, rubber, ceramics, polymers, etc., assembled
mechanically to move people and goods from one place to the other. Because of the interface
between the Machine and human lives, there is need for standardization of its component parts to
improve its performance and efficiency and to reduce failure.[5]
10
1.3. Problem Statement

In Adama MOENCO (Motor and Engineering Company) during a service. time and energy consumption
are occurring in the company by means of all worker in that area leave their works to lift up or down the
transmission (gear box) from the car engine to change a clutch disk, and also it hazards for safety. But
all of these things happen under hydraulic telescopic transmission jack device with the help little unsafe
support to the transmission to put on it. This able to affect the company productivity level and workers
safety condition. To overcome the above problem, we design clamp for the hydraulic telescopic
transmission jack.
1.4. Justification
Clamp for hydraulic telescopic transmission jack is an important piece of machinery that can be very
useful in any modern mechanical workshops because it can facilitate the easy, safe and efficient work.
This is significant because: -
I. It uses more man power (labor force): most of time it takes more than two individuals to
perform this work and this kind of work process is not economical at all.
II. It is quit risk full to the mechanic: during the disassembly of gearbox there is high risk that
the gear box may fail on the mechanic leg and can cause different accidents.
III. The time lapse wasted during oil exchange: this especially happens on C-type and D-type
service of vehicles where the clutch is changed and gearbox maintenance. doing this
operation old way can take a long time.
IV. Damage on the part: the gearbox can be damaged due to unsafe disassembly and
installation.
V. It highly affects the profile of the company: if the company does not have good safety on
work area because of this problem the workers will not have good working condition and
affect their safety.
11
1.5. Objective
1.5.1. General objective
The general objective of this project is to design clamp for hydraulic telescopic transmission jack.
1.5.2. Specific objective

To design clamp for hydraulic telescopic transmission jack that is safe, reliable and able to raise and
lower the height level and to save energy. The specific objective of this project is:
Conduct different analysis for the designed and selected components.

To select a material with desired properties for the design of clamp for a hydraulic telescopic
jack.
To analysis cost of the components
To design plate
To design clamp arm
To design bolt clamp
To design clamp adjuster nut
To design clamp bolt
To design clamp support
To draw 3D drawing of each component of the clamp
To draw 3D Assembly drawing of the clamp
12
2. Literature Review
An inbuilt lifting and safety arrangements for a Four-Wheeler with a hydraulic cylinder jack system is
attached to automobile vehicle on front and rear part of the chassis. During puncture or some repairs
without lifting externally drop the hydraulic cylinder jack with a single button. For heavy vehicles like
truck, lorry etc., [6]
Hydraulic cylinder jacks are versatile because their horizontal position makes it possible to place them
in tight spots and provides good leverage. Hydraulic cylinder jacks have proven useful in search and
rescue missions following earthquake damage. As a result, Hydraulic cylinder jacks are standard
equipment in firehouses and for search and rescue teams. They are also used for elevating, thrusting,
weighing, or forcing requirements. The base of bottle jacks is welded for strength. All models of bottle
jacks are capable of working in erect, angled, or horizontal positions. JACKS became popular in the
early 1900s when the automobile industry began to take off. Also called hand jacks, bottle jacks
provided an easy way for an individual to lift up a vehicle for roadside inspection or service and now a
day in large company jacks are used for lift up and down transmission from the car. Generally, jacks are
weight to offer a lifting capability ranging from one hundred to several tons. Bottle jacks feature a
vertical shaft, which supports a platform (called a bearing pad) that directly bears the weight of the
object as it is lifted. Although they are most commonly used in the automobile industry (1.5-to-5-ton)
jacks are frequently used to lift cars), bottle or cylindrical jacks have other uses as well. In the medical
industry they can be used in hydraulic stretchers and patient lifts.[6]
Hydraulic jack works on the principle of ―Pascal ‘s law. When the handle is operated, the
plunger reciprocates then the oil from the reservoir is sucked into the plunger cylinder during
upward stroke of the plunger through the suction valve. The oil in the plunger cylinder is
delivered into the ram cylinder during the downward stroke of the plunger through the delivery
valve. This pressurized oil lifts the load up, which is placed on top plate of the ram. After the
work is completed the pressure in the ram cylinder is released by unscrewing the lowering screw
thus the pressure releases and the ram is lowered, then the oil is rushed into the reservoir.it
consists of plunger cylinder on one side and ram cylinder on the other side. These two cylinders
are mounted on base which is made of mild steel. Plunger cylinder consists of plunger which is
13
used to build up the pressure by operating the handle. Plunger cylinder consists of two non-returns
valves i.e., one for suction and other for delivery. Ram cylinder consists of ram which lifts the
load. The ram cylinder connected to delivery valve of plunger cylinder. It is also consisting of
lowering screw this is nothing but a hand operated valve used for releasing the pressure in the
ram cylinder for get down the load. This project will build a prototype of hydraulic telescopic
transmission jack with for the maximum load (rated load) of 1000 Lbs. (1,000,000 kg) lifting capacity
that could be used in lifting. [5]
The advent of the industrial evolution which saw the major transition in history of manufacturing and
engineering process. All of this culture developed strong skill through century to ease the way of lifting
equipment had not fast progressed, although cranes, hoist and other equipment were limited use by their
default design manufactured, this created many problems to move heavy loaded material from place to
place because of the material to be moved were unable to fit with the hoist equipment. From decent
days, the hydraulic transmission telescopic jack fabricated in many loads capacity to lift, as we
discussed in the above generally about jack, we have found some gap relative to their design to lift the
load material they have lack of enough support to the material to be lifted. Now a day or currently
hydraulic telescopic transmission needs well-functioning clamp support to hold the transmission. [5]
14
3. Methodology
Data collection
Primary
Secondary
- Interview
- Reference used
- Observation
Observation
When we were in the company, we observed different problems related to vehicle maintenance sections.
We observed that the assembling and disassembling of the transmission
Interview
From the company we have seen some problems. So, we asked different company workers that what
their main problem in vehicle maintaining process and many of them said while changing the clutch
more than four people leave their post and help to assemble the transmission and they suggested that if
the telescopic jack can grab and move the transmission. So, we are forced to design this project
Reference Used
As a reference we used from internet pdf, some text books, videos related to the assembly and
disassembly of the transmission.
3.1. General procedure in machine design

The methodologies implemented to achieve this project as follows:
i) Synthesis (Mechanisms): - select the possible mechanism or group of mechanisms which will
give the desired process.
ii) Material selection: - select the material best suited for each member of the machine.
iii) Analysis of force: - find the forces acting on each member of the machine and the energy
transmitted by each member.
15
iv) Design of elements: - find the size of each member of the machine by considering the forces
acting on each member and the permissible stresses for the materials used.
v) Detail drawing: -A detailed drawing of each component and the assembly of the machine with
complete specification for the manufacturing processes suggested.
3.2. General design considerations
 Type of load and stresses caused by the load. The load, on the machine components, may act
in several ways due to the way the stresses are set up.
 Motion of the parts or kinematics of the machine. The successful operation of any machine
depends largely up on the simplest arrangement of parts which then gives the motion required.
 Form and size of the part. The form and size of the part are based on our judgment. The
smallest practicable cross section was used.
 Convenient and economical feature. Designing the operating feature of the machine should be
undertaken after careful study.
 Safety of the operation. Some machines are dangerous to operate especially machines which are
sped up to insure the production at maximum rate.
 The working environment.
 Total cost of the project.
 Assembling
3.3. Components of clamp
Since a project is a combination of different components & mechanisms, this clamp has its own
mechanical components. Those are:
1. Plate
2. Clamp arm
3. Clamp Bolt
4. Clamp adjuster nut
5. Adjuster leaver
6. Clamp Support
16
4. Modeling and System Design

4.1. General Design Considerations
4.1.1. Material selection
The plate and the clamp arms are works to ensure that the transmission is safe and has a complete rest on
it. The purpose of the plate is to support the transmission and it withstand compressive load exerted on it
by the weight of the transmission.
For this reason, grey cast iron- as a material is selected for the frame (Appendix 1). Cast iron is cheap
and it can give any complex shape without involving costly machining operations. Cast iron has higher
compressive strength compared to steel. Therefore, it is technically and economically advantageous to
use cast iron for the plate. Graphite flakes cast iron with an ultimate tensile strength of 220MPa is
considered suitable for the design of the plate and clamp arms. The graphite flakes improve the ability to
resist compressive load.
4.2. Design of plate

Table 1: Design specification for plate
Design specification of plate

Parameter Value Unit
Width of the plate 200 mm
Length of the plate 300 mm
Design ultimate strength 220 MPa
The weight of the transmission (Gear box)
approximate mass mt = 500kg
Wt = mt*g ------------------------------------------------------------(eq 4.1)
Wt = 500kg * 9.81 kg/s= 4,905N
17
Figure 2:Three-Dimensional View of the plate
By considering load type and material take factor of safety is 4;

So, we can calculate allowable stress from selection material property;
σt
σall = ------------------------------------------------------------(eq 4.2)
FS
220 Mpa
σall= = 55Mpa
4
Total force applied on the plate is 4,905N

Ft¿4,905N
Ft
σall= =55Mpa; A=200mm*t mm
A
Ft=4,905N
Ft 4905 N
σall= =55Mpa=
A 200∗tmm
4905 Nmm
t= =0.45mm
55 Mpa × 200 mm
So we can take t=30mm.

Ft
σ= ------------------------------------------------------------(eq 4.3)
A
4905 N
= = 0.8175Mpa
200 mm∗30 mm
σ = 0.8175Mpa; allowable stress is greater than induced stress. So; our design is safe.
4.3. Design of Clamp arm
The purpose of the clamp arm is to hold (grab) the transmission and it withstand compressive load
exerted on it by the weight of the transmission. For this reason, we use the same material as the plate
which is Graphite flakes cast iron with an ultimate tensile strength of 220MPa.
Transmission weight = 4905N

Tensile strength = 220Mpa
Table 2: Design specification for clamp arm
18
Design specification of Clamp arm

Width of the clamp arm 40 mm
Length of the clamp arm 200 mm
40mm
Figure 3: Three-dimensional View of the clamp arm
A=40*tmm2
By considering load type and material take factor of safety is 4;
By using equation 4.1
220 Mpa
σall = = 55Mpa
4
Total force applied on the clamping arm is 4905N

Ft¿4905N
By using equation 4.3
σall = 55Mpa; A = 40mm*t mm
Ft=4905N
4905 N
σall=55Mpa=
40∗tmm
4905 N
t= = 2.23mm
55 Mpa × 40 mm
19
So, we can take t= 10mm.

4905 N
σ= = 12.2625Mpa
40 mm∗10 mm
4.4. Design of Clamp Bolt
We select Mild steel type C material to design clamp bolts because of easily workable, very hard, yet
malleable, good for construction, easy to shape and machine and very flexible and can be harden.
Table 3: Material selection for bolt design
Steel grade Measured direction Yield strength (Mpa) Tensile strength (Mpa)
HT50 A 542 591
HT80 A 693 830
Mild steel A 452 497
HT50 B 501 562
HT80 B 657 799
Mild steel B 439 471
HT50 C 531 587
HT80 C 665 811
20
Mild steel C 447 478
In our design we select the material for the bolt is Mild steel type A. So, σ tb = 478N/mm2 the core
diameter is from the appendix A by taking standard M16 size.
From the table we take dc = 20.32mm
Nominal or major diameter of nut and bolt (d=D) = 24mm and
The number of bolts we used is 2.
Table 4: Standard bolt and nut dimension s

ource:
Frederick
C. Nash
(2010)
Automotive Technology
The total length of bolt and thread length of bolt can be calculated as follows:
Let us take L<320mm, d<60mm
Length of threaded part from geometric analysis is;
Lt =100mm
Lunthreaded =L−Lthreaded
Lunthreaded = 320mm – 100mm
21
Lunthreaded = 120mm
4.4.1. Stress Analysis of Bolt

F = 4905N is the total force acted in the 2 bolts. Then in single bolts can be calculated as follow:
F 4905 N
Fi= F i= =2452.2 N
n 2
Then we will calculate the stress on the bolt. Let us take standard bolt size of M24
Fi 2452.2 N 2
but since Abolt = π D i = π 24 =452.16 mm2
2
Stress on a bolt = =
A bolt 452.16 mm2 4 4
= 5.423MPa
The tensile strength of M24 bolts is σtb = 478N/mm2
Since 5.423Mpa<478MPa hence our design is safe.
4.5. Design of Clamp adjuster nut

We select Mild steel type C material to design clamp adjuster nut the same as bolt because of easily
workable, very hard, yet malleable, good for construction, easy to shape and machine and very flexible
and can be harden. And the number of nuts is equal to the number of bolts.
By reading from appendix A, we get:

 minor or core diameter of nut (dc) = 20.32mm
 effective or pitch diameter of nut (dp) = 22.051mm
 nominal or major diameter of nut and bolt (d=D) = 24.00mm
clamp adjuster nut length is 100mm from geometric analysis
4.6. Design of Adjuster leaver

The adjuster leaver is the same as a bolt which has full thread so we like to assume the adjuster leaver as
a bolt and use the same material as the clamp bolt.
In our design we select the material for the bolt is Mild steel type A. So, σ tb = 478N/mm2 the core
diameter is from the appendix A by taking standard M16 size.
From the table we take dc = 20.32mm
Nominal or major diameter of nut and bolt (d=D) = 24mm and the number of adjuster leaver we used are
2.
22
The total length of bolt and thread length of bolt can be calculated as follows:
Let us take L<130mm, d<60mm
Length of threaded part from geometric analysis is;
Lt =120mm
Lunthreaded =L−Lthreaded
Lunthreaded = 130mm – 120mm
Lunthreaded = 10mm
4.6.1. Stress Analysis of adjuster leaver

F = 4905N is the total force acted in the 2 bolts. Then in single bolts can be calculated as follow:
F 4905 N
Fi = F i= =2452.2 N
n 2
Then we will calculate the stress on the adjuster leaver. Let us take standard bolt size of M24
Fi 2452.2 N π D i2 π 24 2
Stress on adjuster leaver = = but since Abolt = = =452.16 mm2
A bolt 452.16 mm2 4 4
= 5.423MPa
The tensile strength of M24 bolts is σtb = 478N/mm2
Since 5.423Mpa<478MPa hence our design is safe.
4.7. Design of Clamp Support

The purpose of clamp support is to support and hold the plate, clamp arm, and adjuster leaver. And it has
different types of pins in order the plate move on it at a fixed pivot.
The purpose of the plate is to support the transmission and it withstand compressive load exerted on it
by the weight of the transmission. For this reason, grey cast iron as a material is selected for the frame.
Cast iron is cheap and it can give any complex shape without involving costly machining operations.
Cast iron has higher compressive strength compared to steel. Therefore, it is technically and
economically advantageous to use cast iron for the plate. Graphite flakes cast iron with an ultimate
23
tensile strength of 220MPa is considered suitable for the design of the plate. The graphite flakes improve
the ability to resist compressive load.
Table 5: Design specification for clamp support
Design specification of Clamp arm

Width of the clamp support 50 mm
Length of the clamp support 200 mm
The dimension of the clamp support is found from geometric analysis.
50 200mm
50mm
Figure 4: Three-dimensional View of the clamp support

A=50 mm× 50 mm
A=2500 mm2
4.7.1. Stress Analysis of support

By considering load type and material take factor of safety 4;
σt
σall =
FS
220 Mpa
σall = = 55Mpa
4
Total force applied on the clamping arm is 4905N

24
Ft¿4905N
Ft 4905 N
σ= = = 1.962Mpa
A 2500 mm2
4.8. 3D part and Assemble drawing of clamp of a telescopic transmission jack

4.8.1. 3D part drawing
1. Plate
Figure 5 Plate
25
2. Clamp arm
Figure 6: Clamp arm

26
3. Clamp bolt
Figure 7: Clamp bolt
27
3. Clamp adjuster nut
Figure 8: Clamp adjuster nut
28
4. Adjuster leaver
Figure 9: Adjuster leaver
29
5. Clamp Support
Figure 10: Support
30
4.8.2. 3D Assembly of clamp support
31
Figure 11: Assemble drawing of Clamp

4.9. Cost estimation
After careful design of the clamp, we analyze the cost of each component in order to determine the
capital needed to build the clamp. Since this clamp made of various types of metals and metal alloys, all
with different costs, we need to analyze the cost of each component individually. We consider current
market values of currency exchange in which 1 dollar is 53.43 birr. (In the volume analysis of the
components, all dimensions are in millimeter)
4.9.1. Cost of plate

The plate is made Graphite flakes cast iron which is about 1.26$ per kg. First, we need to calculate the
volume of the plate.
Volume of plate
V p=200 mm× 300 mm× 30 mm
3 3
V p=1,800,000mm =0.0018 m
m p= ρ p ×V p
kg 3
m p=2260 3
×0.0018 m where, density of graphite flake cast iron = 2260 kg/m3
m
m p=4.068 kg
Cost of plate = 4.068 kg * 1.26$/kg
= 5.12$ = 5.12 * 53.43 birr = 273.86 birr
4.9.2. Cost of clamp arm
The clamp arm is made Graphite flakes cast iron which is about 1.26$ per kg. First, we need to calculate
the volume of the plate.
Volume of clamp arm
V c =10 mm ×200 mm × 40 mm
V c =80,000mm 3=0.00008 m3
mc =ρc ×V c
kg 3
mc =2260 3
× 0.00008 m where, density of graphite flake cast iron = 2260 kg/m3
m
32
mc =0.1808 kg
Since there are four clamp arms
mc =0.1808 kg × 4=0.7232 kg
Cost of clamp arm = 0.7232 kg * 1.26$/kg
= 0.91$ = 0.91 * 53.43 birr = 48.68 birr
4.9.3. Cost of support
The support is made Graphite flakes cast iron which is about 1.26$ per kg. First, we need to calculate the
volume of the support.
Volume of support
V s =50 mm ×50 mm ×200 mm
V s =500,000 mm3=0.0005 m 3
ms =ρc × V c
kg
ms =2260 3
×0.0005 m3 where, density of graphite flake cast iron = 2260 kg/m3
m
ms =1.13 kg
Cost of support = 1.13 kg * 1.26$/kg
= 1.4238$ = 1.4238 * 53.43 birr = 76.0736 birr
4.9.4. Cost of other materials
Cost of other materials like adjustable leaver, clamp bolt, clamp adjuster nut, welding, labor, and other
assistants for the design of clamp be 601.3864 birr.
Total cost of clamp(T)= cost of plate + cost of clam arm + cos of support + cost of other material
T = 273.86 birr + 48.68 birr + 76.0736 birr + 601.3864-birr T = 1000 birr
33
5. Result and Discussion

5.1. Result
The following table shows the overall geometry of clamp support for telescopic hydraulic jack.
Table 6: Result
Components Material Type Dimensions of the component
1. Plate Gray cast iron Wp=200 mm
Lp= 300 mm
t= 0.45 mm
Ap= 60000mm 2
Ft= 4905 N
2. Clamp arm Gray cast iron Wca= 40 mm
Lca = 200 mm
t= 2.23 mm
Ft= 4905 N
3. Clamp bolt Mild steel type C dc= 20.32 mm
d=D= 24 mm
n= 2
Lt= 100 mm
Lut= 120
4. Clamp adjuster nut Mild steel type C dc= 20.32 mm
dp = 22.051 mm
d=D= 24.00 mm
5. Adjuster leaver Mild steel type A dc = 20.32

34
d=D= 24 mm
Lt= 120 mm
Lut= 10 mm
Ab= 452.16 mm2
6. Support Gray cast iron A= 2500 mm2
Ws= 50 mm
Ls= 200 mm
ts= 50 mm
5.2. Discussion
For this internship project, we have design a clamp support for hydraulic telescopic jack for
transmission(gear box) can withstand of hold average mass transmission of 500 kg a having plate area
of 60000mm2 and clamp arm with the thickness of 2.23, made from gray cast iron which gives a better
strength to the support, and also we have selected a good material for clam bolt and adjuster nut
sufficient for holding the transmission load, we were able to get good result of different stress on the
component of the clam support of the telescopic jack. In this process we have design plate, clamp arm,
clam bolt and adjuster, adjuster arm and support. All of these components are designed by using
appropriate formulas. In order to protect failure on the pressure vessel we have selected proper material
for each of the components and also, we have checked safety of the components by comparing stress of
the component with design stress to complete our design.
35
6. Conclusion and recommendation

6.1. Conclusion
At the end it can be conclude that the result of this project is in accordance to its predetermined
application. The solution that we provided in this paper is one answer that we believe addresses the very
real problem we expressed in our problem statement. where the design of clamp for telescopic hydraulic
transmission jack has been studied in time consumption of the company and safety of the worker when
maintenance of service of the vehicle(transmission), this design enhances the company key role in
reducing time conception and energy loss of the worker in every station, the design of this machine is
the heart of our understanding but the availability of resource and materials to develop this machine
create difficulties. we have worked this design in slid work software relative to our time.
6.2. Recommendation
The project can be further modified by using sensors and electric devices in order to reduce the man
effort used on the object. The capacity for a process was confidential and some other information’s were
kept secret because of the company’s policy so if this data were known the project would be very
clearer. The internship time given was very short due to some factors. Also, this affected our project so if
this can be corrected in the next Bach. Most importantly the internship cost sharing was late which drown
as back in beginning aur project. Our cost is based on the manufacturer selling price.
36
Reference
[1]. A Mechanical Engineering Department professor @Sreyas Institute of Engineering &
Technology, Nagole, Hyderabad-500068, bStudent,Mechanical Engineering department,
Sreyas Institute of Engineering & TechnologyNagole, JNTUH, Hyderabad-500068, INDIA
International organization of Scientific Research 16 | P a g e
[2]. Romesh Chandra Khanna (2006) automobile mechanics, 8thth ed.Khanna Publishers 2-B,
NaiSarakDelhi( India).
[3]. Ellinger, H Robert E. (1977) Automechanics, 2ndnd ed., Prentice – Hall Inc., USA.
[4]. William H. Course and Donald L. L. Anglin (19993) Automotive Manual Transmission and Power
Trains, McGraw – Hill publishing Company, USA
[5]. William K. Toboldt (1993) Automotive Encyclopedia Fundamental Principle, Operation,
Construction, Service Repair, The Good Heart WillcoxCo.Inc, USA.
[6]. Frederick C. Nash (1979) Automotive Technology, 2ndnd ed., McGraw – Hill Ryerson Limited,
Canada.
[7]. http://www. www.automotivecrossing.com/.../Automotive-Internship-Jobs
[8]. http://www. www.internships.com/employer/resources/setup/benefits
[9]. http://www. www.i-to-i.com/benefits-of-internship.html
[10]. Moencoethiopia.com/about
[11]. MOENCO workers manual
37
APPENDIX
Appendix A
Mechanical Properties of Cast Iron.[1] Mechanical Properties
Grade Designation (British Standards)

150 180 220 260 300 350 400
Tensile 150 180 220 260 300 350 400
Strength
(MPa)
Compressive 587 663 766 868 970 1097 1225
Strength
(MPa)
Shear 176 222 284 346 407 484 562
Strength
(MPa)
Endurance 71 82 96 111 125 143 161
Limit (MPa)
Young’s 71-96 70-104 89-114 100-135 110-135 124-147 137-160
Modulus
(MPa)
Modulus Of 29-40 32-42 36-45 43-51 48-55 53-58 53
Elasticity
(GPa)
Hardness 160 176 196 236 236 261 286
(HB)
38
Appendix B
Standard bolt and nut dimension
39
40
Appendix C
Source: MOENCO workers manual
41
42
43
Source: MOENCO workers manual [11]
44
Source: MOENCO workers manual [11]
45
Fig: Hydraulic Telescopic Transmission jack (at this time on selling

device)
46

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UNIVERSITY OF GONDAR

DEPARTMENT OF MECHANICAL ENGINEERING

HOISTING ORGANIZATION: MOENCO ADAMA BRANCH

TITLE: - DESIGN OF CLAMP FOR TELESCOPIC

DURATION OF INTERNSHIP: THREE MONTHS

1. KALEB MERGA 03505/11

UNIVERSITY SUPERVISOR: Mr. YESHAMBEL.D

COMPANY SUPERVISOR: Mr. MELES.T

STUDENT SIGNATURE DATE

1. KALEB MERGA ------------------ ------------------

2. BIRUK AYINE ------------------ ------------------

Design of clamp for hydraulic telescopic transmission jack

ADVISOR SIGNATURE DATE

1. Mr. YESHAMBEL. D ---------------------- -------------------

MOENCO Motors and Engineering company

PART ONE; INTERSHIP REPORT

1.2.2. Become The OEM's Partner of Choice

 Caring for environment

 TOYOTA HIULUX - TOYOTA LAND CRUISER

 TOYOTA RAV 4 - TOYOTA PRADO

 TOYOTA HAICE - TOYOTA RUSH

 NEW HOLLAND TRACTOR

1.6. Customer of the product (service)

Vehicle Reception vehicle inspection Cost estimation

Figure 1: Work flow of MOENCO

 Service type A = 5/15/25/35/45/55/65/75,000 km

 Service type B = 10/30/50,000 and 70,000km

 Service type C = 20,000 and 60,000 km

 Service type D = 40,000 and 80,000 km

2.2.1. Power transmission

 Check and replacement of engine and its accessories including:

o Check and installation of the crank shaft

o Check and installation of all bearing

o Check and installation of camshaft

o Check and maintenance of cylinder head

o Check and installation of piston with its rings

o Check the diameter of cylinder

o Check cylinder blocks

o Lapping the valve with its valve seat

o Check and repair of front and rear differential

o Check and repair of gear box

2.3. Automotive Fuel System service

 servicing air cleaner

 servicing fuel tank

 servicing fuel line

 servicing gasoline engine fuel pump

 servicing fuel filter

 Servicing transfer pump service etc. these are some of duties.

 Sweep floors daily

 Clean up spills immediately

 Keep work benches uncluttered and free of debris

 Limit use of floor storage

 Oil storage and transfer

 Filter new oil

 Use drum covers

 “Kidney loop” system oil

 Parts handling and storage