DEBRE BERHAN UNIVERSITY

COLLEGE OF ENGENEERING

DEPARTMENT OF MECHANICAL ENGINEERING

Internship Report and Project

Hosting Company: DAWIT AUTOSHOP

Project Title: TWO POST AUTOMOBILE CAR LIFT

Advisor: Mr. Amanuel (MSc.)

Prepared By: ID NO.

SALEAMLAK MIHIRETIE…………………….2650/11
GETACHEW ………………….
GIRMAW ALEM……………………………….. 2646/11
ABEBE BEYENE………………………………..
TAKELE EWNETU…………………………….
BOGALE ………………………………
MELAKU …………………………………

SUBMISSION DATE
 Declaration

We are a 4th year mechanical engineering student in DEBRE BERHAN UNIVERSITY, college of
Engineering, Mechanical Engineering department. The institute declares that this report is our own
original work based on the past four month’s internship program with DAWIT AUTOSHOP.
Approval of the mentor

our advisor Mr.amanuel contribute a lot of things in our training program By advising and telling the
working position of our work .

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 ACKNOWLEDGMENT
After all, we want to specially thank the ―almighty god‖ for giving ours the inspiration to start
and patience to finalize this internship work report and providing the sensational internship. we
really thank you to say for Dawit auto shop company office managers, operators, daily laborers
for their encouraging to do more and give moral in addition to give information about the
company how everything is it. And also, we running out of ink to express we gratitude for ours
work shop supervisor and advisor MR. Amanuel for guiding us. at last but not list, we glad to
say ―thank you so much‖ to all our family members and friends for their invaluable support
during and after our intern ship.

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 TABLE OF CONTENTES
DECLARATION ............................................................................................................................................
....i
ACKNOWLEDGMENT..................................................................................................................................
...ii
NOMENCLATURE ....................................................................................................................................ix
ABBREVIATION ........................................................................................................................................x
ABSTRACT................................................................................................................................................xi
PART 1......................................................................................................................................................xiv
CHAPTER ONE ......................................................................................................................................xiv
OVERALL INTERNSHIP
REPORT .....................................................................................................xiv
1. Background history of company.........................................................................................................xiv
1.1 Its brief
history ...............................................................................................................................xiv
1.2 Vision and mission of company......................................................................................................
xv
1.2.1 Vision of the company..............................................................................................................xv
1.2.2 Mission of the
company ...........................................................................................................xv
1.3 Main product or services ...............................................................................................................
xv
1.4 Main customers or end user of the company ...............................................................................
xv
1.5 Overall organization and work flow of the company .................................................................
xvi
CHAPTER TWO ...................................................................................................................................xviii
2. Overall internship
experience ............................................................................................................xviii
2.1 Section of company we have been working ................................................................................
xviii
2.1.1 Engine service .......................................................................................................................xviii
2.1.2 Brake service ...........................................................................................................................xxi
2.1.3 Battery service ......................................................................................................................xxiii

III
 2.1.4 Body maintenance and painting ...........................................................................................
xxv
2.2 Engineering methods, tools and techniques we have been using while performing our work
task ................................................................................................................................................... xxvii
2.3 Challenges and problems, we have been facing and identifying while performing our work
task .....................................................................................................................................................xxviii
2.4 The measurement we taken for the challenges and problems ................................................ xxviii
CHAPTER
THREE ..............................................................................................................................xxviii
3. Overall benefits of internship ..........................................................................................................
xxviii
3.1 Objective of the internship ................................................................................................xxviii
3.2 Upgrading theoretical knowledge .........................................................................................xxix
3.3 Improving practical skills ......................................................................................................xxix
3.4 Improving interpersonal communication skill ....................................................................xxix
3.5 Improving team playing
skill ..................................................................................................xxix
3.6 Improving leadership
skill .......................................................................................................xxx
3.7 Understanding about work ethics issues, industrial psychology and related issues. ............... xxx
3.8 Entrepreneurship skills .................................................................................................................
xxx
CHAPTER FOUR ..............................................................................................................................xxxi
4. Conclusion and Recommendation in about above report ..........................................................
xxxi
4.1 Conclusion ....................................................................................................................................xxxi
PART. 2...................................................................................................................................................xxxii
PROJECT TITLE: DESIGN TWO POST AUTOMOBILE CAR LIFT ........................................ xxxii
ABSTRACT ..........................................................................................................................................xxxiii
CHAPTER ONE ..................................................................................................................................xxxiv
1. INTRODUCTION ............................................................................................................................xxxiv
1.1 BACKGROUND OF THE
PROJECT ................................................................................xxxiv
1.2 Problem statement and justification ....................................................................................xxxv

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 1.3 Objective of the
project .........................................................................................................xxxvi
1.3.1 General objective........................................................................................................xxxvi
1.3.2 Specific objective ......................................................................................................xxxvii
1.4 Scope and limitation ............................................................................................................xxxvii
1.4.1 Scope .........................................................................................................................xxxvii
1.4.2 Limitation ..................................................................................................................xxxvi
i
CHAPTER TWO ............................................................................................................................xxxvii
2. LITERATURE REVIEW ...........................................................................................................xxxvii
CHAPTER THREE ..............................................................................................................................xli
3. Methodology ..........................................................................................................................................xli
3.1 MATERIAL SELECTION .............................................................................................................xlii
3.1 Analyzing each component ...........................................................................................................xliii
CHAPTER FOUR ..................................................................................................................................xlvii
4. Modeling and system design (system analysis) ..............................................................................xlvii
4.1 Design of Power Screws .........................................................................................................xlvii
4.2 Motor selection ..........................................................................................................................lii
4.3 Design of Shaft ............................................................................................................................lii
Material selection .............................................................................................................................lii
4.4 Design of the fork .......................................................................................................................
lv
4.5 Design of frame ..........................................................................................................................lv
4.6 Key design ................................................................................................................................ lvii
4.7 Design of Base ..........................................................................................................................lix
4.8 Bolt design for the base ............................................................................................................ lix
4.9 Design of Fork Holder ...............................................................................................................lxi
4.11 Design of Pulleys ...........................................................................................................................lxii
CHAPTER FIVE ....................................................................................................................................lxiv
5. Result and discussion ..........................................................................................................................lxiv
5.1 Result ...................................................................................................................................... lxiv
5.2 Discussion.................................................................................................................................. lxv

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6. Conclusion and Recommendation in about project .......................................................................lxvi
6.1 Conclusion .............................................................................................................................. lxvi
6.2 Recommendation ....................................................................................................................lxvi
REFERNCE.......................................................................................................................................lxvii
Appendix ...........................................................................................................................................lxviii

LIST OF FIGURE
Figure 1. view of
company ..........................................................................................................................xiv Figure 2 brake
service ...............................................................................................................................xxiii
Figure 3 Battery
service ............................................................................................................................xxiv Figure 4 .Body
maintenance ....................................................................................................................xxv Figure 5.Lifting
method in company ................................................................................................xxxvi Figure 6Air motor
power jack .................................................................................................................xxxix Figure 7 worm
gear jack ......................................................................................................................... xxxix
Figure 8.Worm gear screw jack [1] ...........................................................................................................
xlix
Figure 9 Force diagram. A, Lifting of the load, Lowering the load [1] ....................................................
xlix
Figure 10.FBD of the frame [1] ..................................................................................................................
lvi Figure 11.Effictive length of the various conditions [3] ............................................................................
lvii Figure 12.Force acting on sunk key
[4] .....................................................................................................lviii
Figure 13 2D and 3D power screw ....................................................................................................lxviii
Figure 14 2D and 3D fork .........................................................................................................................
lxix Figure 15 2D and 3D fork
holder ............................................................................................................... lxx Figure 16 2D and 3D
Base ........................................................................................................................ lxxi Figure 17 2D and
3D Worm gear ............................................................................................................. lxxii Figure 18 2D

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and 3D Gear .....................................................................................................................lxxiii Figure 19 3D
Assembly ..........................................................................................................................lxxiv

LIST OF TABELE Table 1 US GVWR classifications....................................................................... xlii

Table 2 Diameters and Area of course pitch and fine pitch metric threads Threads .................................... xlviii
Table 3 Coefficients of friction f for threads and pairs .................................................................................. xlix
Table 4 Property of the 40 C8......................................................................................................................... liii
Table 5.Material property of steel alloy........................................................................................................... lxi
Table 6 Standard width of pulley................................................................................................................... lxiii
Table 7 Result each components.................................................................................................................... lxiv

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NOMENCLATURE
PR - Raising load power screw N
PL - Lowering load power screw N
- Bending stress Mpa (N/mm2)

VIII
 T1 - Tension in tight side of the belt in pulley N mm
T2 - Tension in slack side of the belt in pulley N mm
MH - Bending moment along horizontal N mm
Me - bending moment along vertical N mm
Te - equivalent twisting moment N mm
Me - equivalent bending moment N mm
Ixx - second moment of area mm 2
Pcr - critical load of frame N

- Allowable shear stress Mpa (N/mm2)

- Bending tensile stress Mpa (N/mm2)
- Density of the rim material kg/mm 3
µ=f - Coefficient of friction
Dc - core diameter of screw mm
Do - outer diameter mm
P - Pitch of screw thread mm
K - Least radius of gyration mm

n - Number of thread
F .s - factor of safety
E - Modulus of elasticity (N/mm²)
V - Pitch line velocity (m/s.)
L - unsupported length mm C

- end fixity coefficient

ABBREVIATION

…………………..American society of mechanical engineers

GVWR.........................Gross vehicle weight rating

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ABSTRACT

This paper mainly composed of a four month internship report. We concerned about ours
internship program in Dawit auto shop Company and it includes the brief history of the industry,
the main products or service, main customers, overall organization, work flow, section of the
company we have been worked, the work task we have been executing, the problems we have
been identified, solutions to overcome the problems, and over all benefits gained from internship.
In general, the company’s main services are: maintenance of the car components. In those
workshops there are different problems from those one is maintain and repair the vehicle
underground. This needs more space for maintain and high functionality.

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 PART 1
CHAPTER ONE
OVERALL INTERNSHIP REPORT
1. Background history of company
1.1 Its brief history
Dawit auto Shop Company found in Debre Berhan city which is 130km far from Addis Ababa.
It established in 1993 E.C by two persons with initial capital not more 100,000 birrs. The
company cover an area of 1890 m2 i.e. 0.189 hectares. Currently the number of workers becomes
more than 30. This Company gives different services like brake service, battery service
bodypainting.

Figure 1. view of company

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1.2 Vision and mission of company
1.2.1 Vision of the company
To reduce or minimize car accident that comes through causes of poor maintenance. And to
reduce internal and external break of car body.

1.2.2 Mission of the company

• To advert their work quality internationally.
• To competitive with other auto shop companies and becoming a selected company from
those companies.
• To engage the person how to develop the entrepreneurship skills.
• To aware the workers that they understand the work ethics and related issue.
• By giving a good service to reduce accidents and to safe human lives.
• To advert their work quality internationally.
• To competitive with other auto shop companies and becoming a selected company from
those companies. .

1.3. Main product or services

Dawit auto shop company almost done all types of automotive services such that
• Brake service including, disc brakes, drum brakes, emergency brakes, and anti-lock
brakes.
• Engine service including; cylinder head, valve seat, gasket, cam and crank shaft, piston
• Battery service including celd and non celd.
• Body maintenance and painting including; color painting of body and repair the body.
Other services like Check Tire Air Pressure, Wash the Car, Check the Air Filter and so
• Gives training for junior technicians and poly technic student, in addition to this, gives
orientation and COC tests for college students those come from different collages from
level 1 up to level 5 in auto engine and level 1 in auto electrical system.

1.4. Main customers or end user of the company

There are many customers that use the service of this company for their automobile maintenance
such that: -
• Governmental organization automobiles
• Non-governmental organization automobiles and

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 • Private cars
1.5. Overall organization and work flow of the company
The overall organization and work flow of the company is shown by the following flow chart.

Manager

Security Supervisor

Administra
tion and Accountant Body and
finance Engine Power panting
supervisor supervisor supervisor

 Manager
The main functions of a manager are including controlling a workflow, overseeing a group of
employees, analyzing performance against goals, setting internal goals, and communicating

results to upper-level management and company executives.

 Supervisor
Supervisors are defined as members of management; therefore, they must perform these four
general functions. It includes
 planning
 Organizing,
 Directing, and
 Controlling the work and the activities of subordinates or employees.

 Security
The primary function of a security guard is to ensure that a property and all of its occupants
remains safe in the company.

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  Administration and finance
The Finance and Administration Associate is responsible for establishing and maintaining
efficient administrative systems and procedures to support the smooth running of the operations
and ensure compliance.

 Engine supervisor
This is supervisory work involving responsibility for the operation of a garage which services
and repairs automobiles, trucks, heavy equipment and machinery, etc.  Body and painting
supervisor
Plans, schedules and assigns repair and automotive paint jobs of automotive body workers
/painters. Supervises and participates in the repair and painting of damaged vehicles and
equipment, including frame straightening and alignments.  Power supervisor
To supervise the City’s fleet repair services; provide skilled mechanical work in diagnosing,
repairing and maintaining a variety of mechanical, hydraulic and electrical systems on City light
and heavy gasoline and diesel power-driven vehicles and equipment; to perform preventive
maintenance duties; to schedule daily work priorities, maintain inventory and records for
mechanic shop; and to perform a variety of technical tasks relative to assigned area of
responsibility.

 Accountant
The main function of the accountant is to maximize cash flow, manage capital needs and remain
compliant with ever-evolving tax laws.

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 CHAPTER TWO
2. Overall internship experience
2.1 Section of company we have been working
When we work in the company we try to work in all available and permitted section like;
 Engine service
 Brake service
 Battery service
 Body maintenance and painting
 Other services

2.1.1 Engine service

The engine is the power plant of a vehicle. Automotive engines have gone through tremendous
changes since the automobile was first introduced in the 1880s, but all combustion engines still
have three requirements that must be met to do their job of providing power – air, fuel, and
ignition. The mixture of air and fuel must be compressed inside the engine in order to make it
highly combustible and get the most out of the energy contained in the fuel mixture. Since the
mixture is ignited within the engine, automobile power plants are called internal combustion
engines.

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  Process Flow of Engine Repair Shop
In engine repair shop there are many tasks could be done. These tasks have their own steps.
These are disassembling, washing, inspection, maintenance and assembly.
 Disassembling
In this stage’s engines disassembled into components and parts. All parts of engines will be
disassembled and small parts such as bolts, nuts, etc. put in a dish. Similarly, crank shaft, piston
head, and other heavy parts will be hosted by the crane and sit on washing machine. There is no
different method or unique machine to disassembling process simply uses a number of wrenches

 .Washing
After disassembling, parts and components of engines will be washed. This washing machine
initially used steam to wash. But now it is not working and instead of steam it uses hot
water.
 Inspection
After parts have been washed, the next stage will be inspection. The first part of the inspection
process will be the visual inspection. Through this process we will recognize if there are any
problems like, crack and breakage on the engine housing and the other parts.
Inspection of the valve will be accomplished by checking whether the valve gained is usable or
not and if the valve head fits with the engine head opening.

 Maintenance
After the parts of engine (mainly the crank shaft, camshaft and engine cylinder) have been
inspected, if there is a faulty part it will have to be maintained to suitable value.
There are different maintaining methods that will be used for different parts.

 Assembly
Unlike disassembling work group, the assembly section follows a set of procedures as set by
manufacturer on the manual.
Special tools may be used in assembly specific to the part that will be assembled. Most of these
tools are custom made to lessen the difficulty and reduce the time that the assembly process
causes. But even with the special tools the assembly process is tire some and time consuming.
The main cause to this problem is the engine time setting process. On the tank engine the engine
time seating process may take up to one or more days.

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Engine mechanical problems can have many causes. Component wear is both normal and
inevitable. Anything with moving parts will wear with prolonged operation. This wear can occur
sooner than expected if an engine is abused or is improperly maintained. Sealing gaskets can split
or leak, internal engine parts such as piston rings, bearings, and valve train components can wear,
and intake and exhaust valves can burn, just to note a few common examples.

Improper service can cause engine mechanical problems and increased wear as well. For
example, cleaning gasket surfaces with surface conditioning disks is NOT recommended by
vehicle manufacturers. The use of such surface conditioning discs dislodges Aluminum Oxide
(from the disk) and metal particles, which can lead to premature engine bearing failure. In some
cases, this failure occurs in as little as 1,000 miles (2,200 km) after the repair has been made.

Unusual noises can be indicators of engine damage or wear. Pinpointing and evaluating engine
noise is a very difficult diagnostic job. It is important to attempt to locate the area where the
noise appears to be coming from before tearing the engine apart. Noise is sometimes transmitted
to other locations, and can often be difficult to isolate. Practice and experience will make this
process easier over time. A technicians’ stethoscope, or probe, can be helpful in successfully
locating and evaluating engine noise. The stethoscope can be moved around until the exact
location of the noise is determined. If a stethoscope is not available, a long, thin screwdriver, or a
piece of hose can sometimes be substituted.

 The following section is designed to show common causes of abnormal engine sounds.

Rod Knock:
A worn, loose connecting rod bearing causes the big end of the rod to hammer on the rod journal
of the crankshaft as the piston moves up and down. This hammering makes a knocking sound.
Piston Pin Knock:
Excessive clearance at the other (small) end of the connecting rod can cause a knock as well. A
knock at the piston (wrist) pin sounds somewhat like a rod bearing knock but will be located
much higher in the engine than the rod knock. It also may or may not be sensitive to changes in
engine speed, load, or temperature. In some cases, the location of the knock may be the only way
to determine if it is coming from a rod or from a piston pin. In other cases, the rod bearing and
piston pin produce two different types of noise.

Piston Slap:

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Piston slap is a knocking sound caused by a piston rocking in a worn cylinder bore and
contacting the cylinder wall. Piston slap sounds much like a wrist pin knock. However, unlike a
wrist pin knock, a piston slap generally quiets down as the engine warms up and the piston
expands. Sometimes killing fuel or spark to one cylinder at a time will temporarily make the
piston slap get louder or change its sound. Correction of the piston slap also requires engine
disassembly and measurement.
Main Bearing Knock:
A main bearing knock sounds more like a dull thud than a knock. A main bearing knock comes from
lower in the engine. The knock is loudest when the engine is under a moderate to heavy load. The cause is
usually worn crankshaft main journals and/or worn main bearings allowing the crankshaft itself to flex
under load. This in turn makes the crankshaft move up and down inside the cylinder block.
Non-engine related sounds:
If the noise occurs only when changing gears or going into or out of gear, the engine itself may
not be the problem. The engine mounts, transmission, torque converter flex plate or clutch should
be checked for wear or breakage.

Eight signs and symptoms of engine damage

The engine is the heart of your vehicle, giving your car the necessary power, it needs to operate
correctly. When the engine is damaged, it will significantly affect your car’s performance.
Fortunately, you can save yourself time and money by quickly diagnosing engine problems
before them because more harm to your vehicle.
1. The Check Engine light turns on.
2. Your car is making strange noises.
3. The engine is running roughly or inconsistently.
4. Your car produces oil patches.
5. You can smell odors from inside the car.
6. Your car is using more gas than normal.
7. You experience a loss of engine power.
8. There is smoke coming from your exhaust.

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2.1.2. Brake service
Brakes are one of the main safety components in your vehicle. So, in the event that you notice
any of the following common warning indications of brake issues Complete/partial brake failure,
Bouncing or recurring stoppage when braking suddenly, Burning smell when brakes are applied,
Car tugging in a direction when braking, Wooden or soft brake pedal, Visible leaking fluid,
Vibration or squealing while braking, Grinding sound when brakes are applied, Metallic squeal
when in motion, and Dashboard Warning Light
Keep your car in perfect condition during springs. A damping brake System responsible for an
increase of 10% in the distance necessary to restrain. Keep an eye on the state and the pressure of
your tires because they determine the effectiveness of the braking since one of its missions is to
convey the power and braking
The brakes for automotive use may be classified according to the following considerations:
1. Purpose
2. Location
3. Construction
4. Method of actuation
Purpose
From this point of view the brakes may be classified as the service or the primary and the
Parking or the secondary brakes. The service brakes are the main brakes used for stopping the
Vehicle while in motion, whereas the parking brakes are meant to hold the vehicle on a slope.
Location
The brakes may be located either at the transmission or at the wheels. In case of automobiles, the
wheel brakes are used universally
Construction
From construction point of view, the two categories are the drum brakes and the disc brakes
Method of Actuation
The following brake types are the most frequently used ones: a.
Mechanical brakes
b. Hydraulic brakes
c. Electric brakes
d. Vacuum brakes

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e. Air brake
Procedures of brake system maintenance

Figure 2 brake service

1. Loosen the lugs.
2. Jack up the car.
3. Remove the wheels.
4. Locate the brake caliper.
5. Remove the brake caliper as a single unit.
6. Inspect the brake pads for wear or damage.
7. Make note of any damage on the calipers.
8. Take a close look at the brake rotor.
9. Replace or Upgrade Brake Par

2.1.3 Battery service

A battery is a source of electric power consisting of one or more electrochemical cells with
external connections for powering electrical devices such as flashlights, mobile phones, and
electric cars.Inspect the battery’s terminals and cables to make sure they are securely attached,
with no corrosion. If the battery has removable caps, check its fluid level every few months—
especially in warmer climates. (See our car battery ratings and buying advice. Regular
Maintenance for Every Two to Four Years.

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 Figure 3 Battery service

Procedure of battery service

1. Turn power off and allow battery to cool before removing.
2. When water/electrolytes are needed, be sure to water battery after and
Disconnecting. Charging
3. If battery is overfilled, clean battery immediately following overflow.
4. Clean battery with a neutralizing detergent solution on a regular basis.

Battery testing
Battery testing has changed in recent years; although the three areas are basically the same, the
equipment has improved.
1) Visual Inspection;
2) State of Charge;
 Specific Gravity;
 Open Circuit Voltage;
3) Capacity or Heavy Load Test

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2.1.4. Body maintenance and painting

Figure 4 .Body maintenance

Important of painting
 Preventing Structural Problems
 Preventing Corrosion
 Improving Resale Value
Body maintenance and painting procedure
1. Auto Body Technicians Will Disconnect Components and Remove the Bumper
2. Auto Body Repair Technicians Then Repair Any Bumper Imperfections
3. Once a Bumper Is Properly Shaped, Technicians Can Reinstall and Paint Look for
these 5 signs that you look for auto body painting services.
1. Accidents
Having any kind of accident can be a perfectly good reason to examine the exterior of your car.
Any sort of ding or scratch from a minor bump to a full-on collision could open your car up to
serious issues.
If you want to get your cars looking like new, have an auto body painting specialist look at your
car. Waiting could result in an exterior that chips, cracks, and leaves your whole exterior up for
massive deterioration.

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2. Paint Is Fading
If your paint job is noticeably fading, it means its beginning to wear. This is probably the number
one reason people talk to an auto body painting expert.
There are lots of that your paint job might not look as new as it used to. If you’ve left your car
out in the sun, it could lead to fading. If you’re considering buying a new car, you might want to
find a place to store it.
3. The Clear Coat Is Peeling Back
Your first line of defense against your paint starting to chip off is your clear coat. Once you lose
that, your car is vulnerable to the elements and anything else that life throws at it.
If you think you’re seeing paint peeling from your car, it’s probably just the clear coat separating
from the base coat. But once that clear coat is gone, the base coat could lift from the body and
expose your car to all kinds of damage.
4. Deep Scratches
If you get sideswiped on the highway, scratched up in a parking lot, or ended up having someone
key your car, your paint job is going to need to be treated. Have a pro take a look at any scratches
and see what they recommend. An auto body professional will take you through their process and
talk through the options.
Some scratches can be buffed out. Some can be buffed out in a DIY manner. Others need a little
more work.
5. Rust Issues
If you live in a colder climate, you know there are lots of things that can attack your car through
the winter.
If your car survived a tough winter, you’ve still got some work to do. Always be sure you get the
underside of your car wiped of any salt that can eat away at your car. Once winter’s over, you
might have some scratches or rust that’s accrued.
we performed my work on the above sections to know different automobiles problem and give
service to them.
Other services Check the Engine Oil
Do it regularly—monthly for a vehicle in good condition; more often if you notice an oil leak or
find you need to add oil routinely.

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Check Tire Air Pressure
Once a month and before any extended road trips, use an accurate tire-pressure gauge to check
the inflation pressure in each tire, including the spare. Do this when the tires are cold (before the
vehicle has been driven or after no more than a couple of miles of driving pounds.
Wash the Car
Try to wash the car every week, if you can. Wash the body and, if necessary, hose out the fender
wells and undercarriage to remove dirt and road salt
Check the Air Filter
Remove the air-filter element and hold it up to a strong light. If you don’t see light, replace it.
Regardless, follow the recommended service intervals.
Check the Constant-Velocity-Joint Boots
On front-wheel-drive and some four-wheel-drive vehicles, examine these bellows like rubber
boots, also known as CV boots, on the drive axles. Immediately replace any that are cut, cracked,
or leaking. If dirt contaminates the CV joint it can quickly lead to an expensive fix.
Inspect the Exhaust System
If you’re willing to make under-car inspections, check for rusted-through exhaust parts that need
replacing. Also tighten loose clamps. Do this while the car is up on ramps. If a shop changes
your oil, have them make these checks
Look at the Brakes
For most people it makes sense to have a shop check and service the brakes. If you handle your
own brake work, remove all wheels and examine the brake system. Replace excessively worn
pads or linings, and have badly scored rotors or drums machined or replaced. The brakes should
be checked at least twice per year; more often if you drive a lot of miles.
Clean the Radiator
Prevent overheating by removing debris with a soft brush and washing the outside of the radiator
with a detergent solution.

2.2 Engineering methods, tools and techniques we have been using while
performing our work task
 we use different jacks and safety stands to perform brake service
 we use millimeter and hydrometer to perform battery service
 we use oxyacetylene welding method to perform body maintenance

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  we use different tools to separate different automobile parts like
 different size sockets
 speed handling

2.3 Challenges and problems, we have been facing and identifying while
performing our work task
• Lack of safety shoes
• Lack of company supervisor who advise and guide us.
• Transport problem
• Not safe working environment (sunny, dirty, and formless)
• Working tools were not fully available (hand tools and lifting mechanisms)
• Lack of required materials to perform our project
• Repeated and same works for long time

2.4 The measurement we taken for the challenges and problems

In order to reduce and avoid those problems and challenges mentioned above we take the following
actions by collaborating the other groups of our friends and even including the company workers.

• doing different especially focusing on those materials that are not available but still necessary for
the work
• arranging those formless work areas using kaizen principles
• cleaning and keeping the hygiene of the work areas after work
• enforce the administrator to fulfill the necessary tools and materials
• by communicating with our faculty advisor we try to do our project in the institute work shop

15
 CHAPTER THREE
3. Overall benefits of internship
3.1 Objective of the internship
 To maximize or develop theoretical knowledge by practical
 To be creative and problem solving
 Identify the problems
 To strengthen interpersonal skill
 For participating social life and any others

3.2 Upgrading theoretical knowledge

In this internship program we get a better understanding rather than theoretical knowledge
additionally and it help to expand our intellectual and practical skill which is related to
automotive service.

3.3. Improving practical skills

The internship program helps for improving our theoretical knowledge to implement practically
when we get the theoretical part in practically; we tried to observe the automotive service of our
host company very well. It is so interesting to face the real world. By this internship program we
have try to relate the theoretical knowledge with the practical part, technical, subject – specific
knowledge and understanding.

3.4 Improving interpersonal communication skill

To develop our communication skill, we try to communicate with operator, daily laborers or
worker, mechanic, and high-level managers. So that we find ourselves good enough in personnel
interactions. Now we know in what way, we should speak to the person in the company to gain
what we want. Therefore, the communication skill in company has a significant role to exchange
information.

3.5. Improving team playing skill

Among the most important skills that we develop during the internship program are
communication and working together /team sprit/ skill. In our company all of the workers are
sociable. Most of the time we discus about the work and other related issues wisely.
Therefore, we have learned the following points from them.

16
  Listening the idea of others whatever it is.
 Be patient and wise and respect fullness of the voice of others.
 Open minded to other point of view
 Able to share information freely
 Able to celebrate the successes and learn the set backs
 Focus on the positive and take the negative in stride not let them down
 Understand complains of others and make sure that the communication
channel flow is free.

 Be flexible rather than rigid for new concepts and changes

3.6 Improving leadership skill

Leadership is a skill to guide, control and monitors the peoples. For effective leadership we
understood that personal values like confidence, effective communication and devotion are very
important role.
We have actually observed the method of the working time, the amount of work done by each
worker so that the work proceeds according to the work plan.
Generally, we have noticed the following important points from the leaders.
 Ability to encourage and motivate workers to do their best
 The ability to communicate with all workers without any force
 The ability to listen problems and focus on its solution
 As leader to have clear and defined goals missions and vision.
 Be willing to admit and learn from failures and weaknesses

3.7 Understanding about work ethics issues, industrial psychology and related
issues.
We have been guided and obeyed by the rule and regulation of the company. Some of the work
ethics include;
 Office disciplines
 Punctuality
 Reliability
 Honesty and
 Cooperation

17
From these perspectives, we have gained a valuable lesson that transparency and carefulness are
two importance work ethics one needs to abide and live by.
These statements of intended conduct are expected of every member (permanent members,
associated members and students’ members) of the company.

3.8 Entrepreneurship skills

Emphasizing the growth of entrepreneurship would not only lead to a new robust of its own but
also is a basis for improving the social and economic capability of the country. we had a wide
range of interpreter skills from above skills including personal trails and management skill.

 How to improve self-motivation & discipline

 Able to plan, coordinate & organized effectively
 The ability to work both as part of a team and independently.

18
 CHAPTER FOUR
4. Conclusion and Recommendation in about above report
4.1 Conclusion
The internship program has helped to improve all our personalities like inter personal
communication skills and our team playing skill. Generally, we conclude that this internship
program helped to improve and develop our;
 Practical and theoretical knowledge
 Interpersonal communication skill
 Team playing ability skills &
 Work ethics related issues etc.
we also get the chance of working with automotive engineers. This chance enables us to have a
broad overhauling maintenance skill and work ethics. In our stay we contribute project to solve
the problems of truck loading unloading conveyor system.

4.2 Recommendation
During internship period we observe many good things beside to this there are some problems. Among
good things of accompany punctuality, respect each other, communication, social interaction and
members are freely flow their knowledge for us. Up on this, we recommend them to keep up these good
things. Besides, we have seen some problems. Among these: Lack of resource, Low payment for
mechanics per month, Internship students prohibited by managers to drive cars for training, Lack of tool
and equipment. Regarding above problems, we recommend accompany to take the following action.

• A company should full fill maintenance resource materials, tools and equipment’s for mechanics
to keep customer happiness and Increase Company’s profit.
• A company should maintain private vehicles with appropriate payment.
• A company should pay for mechanics adequate salary relative with market

19
 PART. 2
PROJECT TITLE: DESIGN TWO POST AUTOMOBILE CAR LIFT

ABSTRACT
This paper mainly composed of on the project of a design and modeling of two post automobile
car lift. We concerned about ours internship program in Dawit auto shop Company and this
needs more space for maintain and high functionality. The aim of this paper work is to get
desired space and function at every condition using the method of collecting different parts,
which consists of frame power screw fork, fork holder, worm gear belt gear pulley and different
types of bolt with nut are selected parts of the machine.
The system is operated in automated and the machine design to lift the mass below to 3856kg
and with a weight is 39000N load.
The parts are design in detail according the design consideration parameters using engineering
formulas and preparing their respective 2D and 3D drawing and drawing views using solid work
software. We conclude the design is safe as we have seen from the result. All stresses that we
have calculated using the given data are less than the allowable stress of the selected material.

20
 CHAPTER ONE
1. INTRODUCTION
1.1 BACKGROUND OF THE PROJECT
Two post lifts are not all for general repair of cars but also for light trucks, and they're great for
working on the brakes, wheels, suspension, exhaust systems, grease points, oil changes, and
much more. For heavier types of vehicles or specialized work, you may want to look into other
auto lifts but in the main, the two-post lift is a great lift to have in any shop.
Some people like using two-post lifts for most jobs because they give free access to all parts of
the vehicle. A two post above ground lift is designed to raise cars and trucks for easy access to
wheel assemblies and the underside of the vehicle [1].
Most two post above ground lifts are powered by an electric/hydraulic power unit. The power
unit is an assembly of the following main component parts: Electric motor (usually 220 Volt
single phases 60 HZ). The preferred electric motor should offer maximum torque while drawing
the least amount of amperage. That being said, post car lifts differ from scissor lifts in that they
allow full- accessibility to the underside of the car. While scissor lifts are useful for things like
tire rotations and brake service (because they get all 4 wheels off the ground), they all but block
the entire under side of the vehicle, making things like transmission work (and even oil changes
on some cars) out of the question. The lift is exclusively designed for lifting passenger cars or
vehicles where the total weight is not above the maximum permitted carrying capacity of the lift
and where stipulated acceptance points lie within the acceptance area of the lift. The lift is
designed to lift motorized vehicles; it is not meant to transport persons [2].
Working principle
When the power button on the electric motor is pressed, the electric/hydraulic power unit delivers
the rotation to the gear, and the gear transfer the torque as well as the speed to the twopower
screw (one is located in each of the opposing columns). The rotation of the mechanism we used
controlled by the electric motor. (Important: The weight of the vehicle to be lifted must be evenly
distributed on the four arm pads).

21
1.2. Problem statement and justification
During maintenance and repairing the components of the vehicle there is no enough lifting machine
of the car for diagnostic, repair, brake service, transmission work and maintenance work in the
company. There is low functional for all condition, and it is blocked the entire side of the vehicle,
and not free access to all parts of the vehicle.
The solution for this problem is design two post (column) automobile car lift is the best that they
allow full- accessibility to the underside of the car.

Figure 5.Lifting method in company

22
 1.3 Objective of the project
1.3.1 General objective
 The general objective of this project is to design and modeling of the two-post
automobile car lift.

1.3.2. Specific objective

 Design bevel gear with their shaft
 Selecting of a motor
 Design and modeling of the column(frame)
 Design and modeling of the base
 Design and modelling power screw
 Design and modeling of the fork
 Design and modeling of the belt, pulley, and key.
 Design and modeling of the different types bolt with nut.
 Modeling of the two post automobile car lift
1.4 Scope and limitation
1.4.1 Scope
This project mainly focuses on design and analysis of two post car lift machine using electrical
motor. The design will includes material selection part design, dimensional, force analysis,
strength analysis, power required, components selection and 3D model. Design report giving
necessary calculations of the design of components.

1.4.2 Limitation
Since there are certain types of limitation to design and analysis of the two post car lifting
machine. Due to the lack of time we have not done the project broadly and different parts which
useful for the machine has not designed but we take and select some of them. Loads and certain
types of installation mechanisms with different input forces, there should have been alternate
designs for the raising and lowering of a certain load. But due to the following restrictions or
restrains possible design is contained in this project.

23
 CHAPTER TWO
2. LITERATURE REVIEW
Bhandari et al.(2010) [3] have studied and investigated about a motorizing jack which is a device
that used to lift vehicles. The application of force depends upon the type of jack. Motorizing jack
has higher capacity to lift loads.. Pascal’s law is used in the operation principle. Hydraulic jacks
depend on this basic principle to lift heavy loads: they use pump plungers to move oil through
two cylinders. The plunger is moved forward which opens the suction valve and draws oil into
the pump chamber. As the plunger is pushed forward, the oil moves through an external
discharge check valve into the cylinder chamber, and the suction valve closes, which results in
pressure building within the cylinder.
Oduori (2016) [4] an enterprising Mississippi river boat captain named Josiah Barrett had an idea
for a ratchet jack that would pull barges together to form a „tow‟. The idea was based on the
familiar lever and fulcrum principle and he needed someone to manufacture it. That person was
Samuel Duff, proprietor of a local machine shop. 3 Together, they created the Duff
Manufacturing Company, which by 1890 had developed new applications for the original
„Barrett Jack‟ and extended the product line to seven models in varying capacities. Over the next
30 years the Duff Manufacturing Company became the largest manufacturer of lifting jacks in
the world, developing many new types of jack for various applications including its own version
of the ball bearing screw jack. It was only natural that in 1928, The Duff Manufacturing
Company Inc. merged with A.O. Norton to create the Duff-Norton Manufacturing Company.
Both companies had offered manually operated screw jacks but the first new product
manufactured under the joint venture was the air motor-operated power jack that appeared in
1929.
Ravi Kumar et al... (2012)[5]. A screw jack that has a built-in motor is now referred to as a linear actuator
but is essentially still a screw jack. Today, screw jacks can be linked mechanically or electronically and
with the advances in motion-control, loads can be positioned to within microns. Improvements in gear
technology together with the addition of precision ball screws and roller screws mean the applications for
screw jacks today are endless and a real alternative to hydraulics in terms of duty cycles and speed at a
time when industry demands cleaner, quieter and more reliable solutions

24
With the aid of the relatively new portable compressor technology, users now could move and
position loads without manual effort. The jack, used predominantly in the railway industry,
incorporated an air motor manufactured by The Chicago Pneumatic Tool Company.

Figure 6Air motor power jack

There was clearly potential for using this technology for other applications and only 10 years
later, in 1940, the first worm gear screw jack, that is instantly recognizable today, was offered by
Duff-Norton, for adjusting the heights of truck loading platforms and mill tables. With the ability
to be used individually or linked mechanically and driven by either air or electric motors or even
manually, the first model had a lifting capacity of 10 tons with raises of 2‖ or 4‖.

Figure 7 worm gear jack

25
 Since then the product has evolved to push, pull, lift, lower and position loads of anything from a
few kilos to hundreds of tonnes. One of the biggest single screw jacks made to date is a special
Power Jacks E-Series unit that is rated for 350 tonnes –even in earthquake conditions for the
nuclear industry. More recent developments have concentrated on improved efficiency and
durability, resulting in changes in both lead screw and gearbox design options for screw jacks.

2.1. Conclusion from the above literature

 From the above I conclude that it cannot access all part of the underside.
 There low functionality it can be work for all condition.
 There is low space for utilization of activity
Finally I would going to design of the two (column) post automobile car lift.

26
 CHAPTER THREE
3. Methodology
The methodology followed during the development of this project which starts from project title
selection up to the complete project submission is presented in this section.
During my design I have followed a series of methods. The major ones are described as follows;
 By observing the company
 By interviewing the work mans of the company and my company advisor
 By referring different books
 By searching from internet
 Identifying part components which are needed for the machine
 Checking availability and manufacturability of those components

27
 Material selection

Literature reviewing by gathering information from different published

source

Performing conceptual design generation evaluation solution

Numerical analysis

Software modeling drafting parts

and assembly drawing

3.1 MATERIAL SELECTION

The best material is one which serves the desired objective at the minimum cost. The following
factors should be considered while selecting the material:
• The cost of the materials

• Availability of the materials.

• strength of material

• Suitability of the materials

Truck classification
Truck classifications are typically based upon the maximum loaded weight of the truck, typically
using the gross vehicle weight rating (GVWR) and sometimes also the gross trailer weight rating
(GTWR), and can vary among jurisdictions.

28
In the United States, commercial truck classification is determined based on the vehicle’s gross
vehicle weight rating (GVWR) from table 1.Trucks are also classified more broadly by the
Federal Highway Administration (FHWA), which groups classes 1–2 as light duty and 3
medium trucks.
US Duty classification Weight limit Examples
truck
class

Class Light truck 0-2722kg Chevrolet,Colorado,ford,nissa

1 n frontier and Toyota

Class Light truck 2722-3856kg Chevrolet

2a siverado,ford,dodge, and
tundra
Class Light/medium truck 3856-4536kg Nissan Tita XD,ford F-250
2b
Class 3 Medium truck 4536-6350kg Isuzu, PR
Table 1 US GVWR classifications

The design project works for the class 1 and class 2a which is approximately the mass 3856kg
and with a weight is 39000N.

Material selection plays a key role in designing a machine and also influence on several factors
such as: durability, strength, resistance which finally leads to increase the life of machine.
 Availability (easy available).
 Resistivity for corrosion (high).
 Durability.
 Strength.

3.1 Analyzing each component

1. Design and modeling of the power screw
To design the power screw we used the following analytical formula
Design load can be calculated as follow: where is twisting effect, and
F is force applied on the screw in

To find core diameter of the screw Fdesign is design load in N

To find torsional moment to be transmitted by the nut and screw for raising and lowering the

29
load respectively are
TR is raising the load in
TL is lowering the load in
dm is mean diameter in mm
For Check Buckling in the absence of column action for a short column the J. B. Johnson

buckling formula is given by Sy is yield strength in N/mm2

 Check maximum normal stress

 The bearing stress σb is, with one thread carrying 0.38F is

 The thread-root bending stress with one thread carrying 0.38F is

 The body shear stress τ due to torsional moment T R at the outside of the screw body is

 Finally check the maximum stress induced on screw using the formula
2. Motor selection
What is the typical power you need? In other words, what is a typical speed and torque operating
point for your system? Choose a motor that is capable of providing this much mechanical power.
3. Design of the shaft for the pulley
Design on basis of strength
Given from previous design
 T1= Tension in the tight side of the belt on pulley
 T2= Tension in the slack side of the belt on pulley Horizontal load acting on
the shaft is
WT=T1+T2
 We know that torque acting on the pulley
T=(T1-T2)d/2
Let RAV and RBV be the reactions at the bearings A and B respectively. We know that
Rav+Rbv=WT
Taking moments about at end
RBV*C=WT*d/2

30
Bending moment along vertical the will be
MH= Rav*d/2
The resultant bending moment will be M= MH
Effective twisting moment or torque (Te is the equivalent twisting moment may be defined as
that twisting moment, which when acting alone, produces the same shear stress (τ) as the actual
twisting moment. Since the shaft is subjected to twisting moment (T) and bending moment (M)
the equivalent twisting moment will be. Where Te is the equivalent twisting moment.

M is bending moment.
T is twisting moment.

√
Then Where Where d is diameter of the shaft
Allowable shear stress
F.s is factor of safety ꝺy
is yield strength
 Me Effective moment torque is the equivalent bending moment may be defined as that
moment which when acting alone produces the same tensile or compressive stress (σ b) as
the actual bending moment.

Now let find Me will be

We know that bending stress But

From the above two equations solve for d and we will get as follow:

 Finally take the larger diameter for the safety.

4. Design of the fork

 Second moment of area

 Maximum bending moment

 The bending stress will be

 Finally compare the bending stress with yield stress

31
 5. Design Analysis of the frame (column)
 Maximum bending moment, M due to the fork Where D is distance from the
applied to the center of

 The column the critical load the frame can withstand is

Where P cr maximum force that the column supports load
Leff effective length=4m

I second moment inertia

 Finally compare critical load with weight the vehicle.
6. Design of Base
 Crushing of the base due to shear stress

 First calculate allowable shear stress:

 Solve from this the thickness t

7. Design of Fork Holder
Maximum bending moment M = w*L where M is maximum bending moment
W is weight applied on the fork older
L is distance between force applied
Where weight applied on the fork holder and the distance between force applied force to end.
The bending tensile stress

From this calculate thickness of the t

Finally we would achieve the result and conclusion to our project

32
 CHAPTER FOUR
4. Modeling and system design (system analysis)
In machine design we can use two methods. The first one is specifying the size of our machine
components then we will calculate the maximum stress which will be induced on the
components. Based on the values we’ll select a material that is able to resist the maximum
induced stress. The second method is the reverse one. I.e. first, we select the material then we
will determine the size. For the sake of simplicity, preferred one of the methods to this machine
component.

4.1. Design of Power Screws

A power screw is a device used in machinery to change angular motion into linear motion, and,
usually, to transmit power.
The design of power screw used in scissor jack decreases the intensity of force required to drive
the mechanism by the user.
Material selection We choose Steel, C-45 type from strength
 σy=360 MPa σy is yield strength in N/mm2
 σut= (630-710) MP σut ultimate tensile strength in N/mm2
 E =210 GPa E -Young’s modulus for the material of the in N/mm2

 Caring capacity of the power screw is up to 39000N. There for one power screw caring
capacity is 19500N.
 Load =19.5KN
 Lifting height, H=1300mm
 Effect of twisting moment, β =1.3
 Coefficient of friction for nut and screw, µ=f=0.15

33
  Factor of safety = 2.25
Design Analysis power screw
Design load can be calculated as follow:

To find core diameter of the screw

…………………………………………………………………………equation 4.1

where evaluate for dc

Choosing square thread, reading from table 2 the standard outer diameter, core diameter and
pitch of the thread is: -
Nominal Course pitch serious Fine pitch serious
major
diameter Pitch Tensile Minor Pitch Tensile Minor
d[mm] p[mm] stress area p[mm] stress area
diameter diameter
Ar[mm ] 2
Ar[mm2]
area area
AR[mm2] AR[mm2]
16 2 157 144 1.5 167 157
20 2.5 245 225 1.5 272 259
24 3 353 324 2 384 365
Table 2 Diameters and Area of course pitch and fine pitch metric threads Threads

dc=20 mm do=21.5mm p =1.5 mm

do is outer diameter in mm dc is core diameter in mm dm is mean diameter in mm p is
pitch in mm
To find torsional moment to be transmitted by the nut and screw
First let’s find and υ

………………………………………………………………………… equation 4.2

Solve for
The material has been selected was steel, machine oil table 3 with Coefficients of Friction f is
0.15. Then can be calculated as follow:
l= * =4.71

34
Nut material
Screw material Steel Bronze Brass Cast iron
Steel, dry 0.15-0.25 0.15-0.23 0.15-0.19 0.15-0.25
Steel, machine 0.11-0.17 0.10-0.16 0.10-0.15 0.11-0.17
oil
Bronze 0.08-0.12 0.04-0.06 … 0.06-0.09
Table 3 Coefficients of friction f for threads and pairs

Figure 8.Worm gear screw jack [1]

35
Figure 9 Force diagram. A, Lifting of the load, Lowering the load [1]
In Fig. above a square-threaded power screw with single thread having a mean diameter dm, a
pitch p, a lead angle l, and a helix angle c is loaded by the axial compressive force F.
The system is in equilibrium under the action of these forces, and hence, for raising the load, we
have o

In a similar manner, for lowering the load, we have

o o

We eliminate it from each of these sets of equations and solve the result for P. For
raising the load, this gives

……………………………………………………………….. Equation 4.3

And for lowering the load,

…………………………………………………………………. Equation 4.4

Both equation 4.3 and 4.4 divide by and we know the relation we get

, and

36
 To get torque multiply by mean diameter dm/2.

……………………………………………………………….….. Equation 4.5

=4333.9*20.75/2 =44964.2 N mm

……………………………………………………………………………. equation 4.6

The axial stress s in the body of the screw due to load F is

…………………………………………………………….. equation 4.7

Check Buckling
In the absence of column action for a short column the J. B. Johnson buckling formula is given

by, …………………………………………… equation 4.8

Where L = unsupported length = 1800mm
C = end fixity coefficient = 1, rounded – rounded
K = least radius of gyration of the section = 0.25 dc =0.25*20 = 5

Where A = area =314.15 mm2

Fcr=3.1415*10-4*359997974 Pa =113096.699 =113.03KN
Therefore: - Fcri= 113.03KN >19.5KN
 Therefore, the power screw is quite safe
Check maximum normal stress
• The bearing stress σb is, with one thread carrying 0.38F

……………………………………………………………………….. equation 4.9

• The thread-root bending stress with one thread carrying 0.38F is

37
 ………………………………………………………………………… equation 4.10

The body shear stress τ due to torsional moment TR at the outside of the screw body is

……………………………………………………..…………………….. equation 4.11

…………………………………….………………. equation 4.12

Therefore, it is safe design in case

stress on the teeth of the screw is less than yields shear stress therefore it is safe design.
4.2. Motor selection
To choose a motor and gearbox appropriate for your application, consider the following issues:
 What is the typical power you need? In other words, what is a typical speed and torque
operating point for your system? Choose a motor that is capable of providing this much
mechanical power. (Most motors are classified according to their power.) Usually you will
choose the smallest, lightest, most inexpensive motor that meets your specifications.
You have chosen a motor, based on the gearbox for the motor so that the speed plus torque
Combinations you want from it (including the maximum speed and maximum torque you need)
are under the speed combination.
By using the given torque and speed we select the standard Motor. Therefore, reading from table
the corresponding power is Tg =606Nm and the overall dimensions and parameters will be: -
Speed =120 r .p.m.
Therefore power is 7.6KW.

4.3 Design of Shaft

A shaft is a straight, mostly round bar, which is designed to have other rotating parts of a
mechanism mounted on it or to transmit power from one place to another. The power is delivered
to the shaft by some tangential force and the resultant torque (or twisting moment) set up within
the shaft permits the power to be transferred to various machines linked up to the shaft. Stress
in the shaft

38
In shaft the following stresses may be induced,
• Shear stresses due to the transmission of torque
• Bending stresses (tensile or compressive) due to the forces acting upon gears as well as due
to the weight of the shaft itself (but the mass of the shaft is negligible so in my design we
consider only bending due to loads on the gear)
Material selection Figure 3.4 Motor
The material used for shafts should have the following properties:
• It should have high strength
• It should have good machinability.
• It should have low notch sensitivity factor.
• It should have good heat treatment properties.
• It should have high wear resistant properties.

 Modules o Modules of Ultimate tensile Yield strength Density i

f strength in Mpa in Mpa Mg/m3 n
elasticity rigidity in Gpa
i
Gpa (E) n (G)
207 79 560 320 7.7
Table 4 Property of the 40 C8

Based on those criteria’s we select carbon steel with ultimate tensile strength of 560 N/mm2 and
yield strength of 320 N/mm2 Specific code of the material is 40 C 8 (Indian code). Property of
the material is listed table 4

Design analysis
Assumptions The shaft mass is negligible
Take factor of safety of 1.5
Uniform stress is induced
Shear stress is 42Mpa
Bending stress is 63Mpa
 Given from previous design
T1= Tension in the tight side of the belt on pulley =261.968N
T2= Tension in the slack side of the belt on pulley =102.02N

39
 Diameter of the pulleys are d1=d2=38mm
Horizontal load acting on the shaft is
WT=T1+T2=261.968N+102.02N=363.988N
We know that torque acting on the pulley
T=(T1-T2)d/2=(261.968-102.02)*0.019=3.039Nm
 Let RAV and RBV be the reactions at the bearings A and B respectively. We know that
Rav+Rbv=363.968N
Taking moments about at end RBV*0.2245=WT*d/2
RBV=30.81N and Rav=333.16N
Bending moment along vertical the will be MH= Rav*d/2=333.16*0.019=6.33N
The resultant bending moment will be M= MH=6.33N
 Effective twisting moment or torque (Te is the equivalent twisting moment may be defined as
that twisting moment, which when acting alone, produces the same shear stress (τ) as the
actual twisting moment. Since the shaft is subjected to twisting moment (T) and bending
moment (M) the equivalent twisting moment will be

……………………………………………………………equation 4.13
Then

…………………………………………………… equation 4.14

Where

Where d diameter of the shaft

allowable shear stress
Me Effective moment torque is the equivalent bending moment may be defined as that moment
which when acting alone produces the same tensile or compressive stress (σ b) as the actual
bending moment. Now let find Me will be

………………………………………… equation 4.15

40
 We know that bending stress
……………………………………………………… equation 4.16 But
…………………………………………………… equation 4.17
From the above two equations solve for d and we will get as follow:

The diameter of the shaft that is obtained by using effective torque is(d=11.7mm) lower than by
using effective moment(d=15.88mm). I.e. the shaft will fail by bending first. And in order to
make the design safe we need to take the larger d = 15.88=16 mm

4.4 Design of the fork

Material selection
Steel, C-45 σy =360 Mpa
σ ut =(630-710)Mpa
E =210 GPa
Assumption Its acts as a cantilever beam. It is rectangular section.
Factor of safety = 2
Given F = 9.75kN L = 0.3 m b = 30mm h=30mm
Design Analysis of the fork

The height from the lower base to the centroid is Let h=30mm
Second moment of area

……………………………………………………………. equation 4.18

Maximum bending moment …………………………………………. equation 4.19

= 9750*0.03 = 292.5N.m

The bending stress will be ………………………………………….... equation 4.20

41
Conclusion it’s safe design i.e.

4.5 Design of frame

Material selection Steel, C-45 σy =360
Mpa σut = (630-710) Mpa E =210 GPA
Assumption
 The frame act as cantilever beam but the force is applied on the inside part of the frame.
 The column only considering buckle effect Given L = 2m (height of the column)
w = 19.5KN
b = 100mm (width)
t=80mm (depth of the column)

Design Analysis of the frame (column)

From the above assumption the force is not apply directly in the all frame rather it acts on the one
side of the rectangular part.
 Maximum bending moment, M due to the fork
Where D is distance from the applied to the center of the
column assume 1.2m.
M = (19.5*1.2) KN m =23.4KNm
F

Calculate the reaction forces as follow:

M
•
•
•
RX MO

RY

Figure 10.FBD of the frame [1]

For my design is free end is and which is effective length (Leff) with 2L i.e. 4m.

……………………………………………………………………… equation 4.21

Where Pcr maximum force that the column supports load=19.5kN
Leff effective length=4m

42
 I second moment inertia

Figure 11.Effictive length of the various conditions [3]

Conclusion It’s safe design because Pcr is greater than the applied load F. i.e.
350KN>19.5KN

4.6 Key design

A key is a part inserted between the shaft and hub to connect these together in order to prevent
relative motion between them. It is always inserted parallel to the axis of the shaft. Keys are used
as temporary fastenings.

. Stress in the key

There is two type of stresses induced in the key while it transmits a torque or power. Those are
 Shear stress and
 Crushing stress
Material selection
we select carbon steel AISI 1020 material for the key because the material retains good ductility
as indicated by a percent elongation value greater than about 10%, particularly when shock or
impact loads could be encountered. It also has an adequate strength for ours application. Design
analysis the key
Assumptions

43
Forces due to fit of the key are neglected and it is assumed that the distribution of forces along
the length of key is uniform

Take factor of safety F.S = 2

We select sunk type of key for our system. Sunk keys are provided half in the keyway of the
shaft and half in the keyway of the hub or boss of the pulley. Since the diameter of the shaft is
12mm we can know the cross section of the key.

Figure 12.Force acting on sunk key [4]

a) Design of key for gear and pinion

From previous design d = 15 mm select standard diameter from the above table 7 which is
d=17mm w = t =6 mm
In order to find the length of the key to transmit full power of the shaft, the shearing strength of
the key is equal to the torsional shear strength of the shaft.
The shaft is made of 45 C 8 steel having ultimate tensile stress of 700 Mpa and a ultimate shear
stress of 500 Mpa.
We know that the shearing strength of key,

…………………………………………………………………………equation 4.22
And torsional shear strength of the shaft,

………………………………………………………………………… equation 4.23

Equate the above two equation and we get as follow,

44
Where Shear stress for the shaft material
Shear stress for the key material from table 6
Key for pinion gear will be as follow:

Key for bevel gear is the same as pinion gear we are considering the material that we have
selected before for the gear.

4.7 Design of Base

Material selection
The properties of cast iron which make it a valuable material for engineering purposes are its low
cost, good casting characteristics, high compressive strength, wear resistance and excellent
machinability. The compressive strength of cast iron is much greater than the tensile strength.
Following are the values of ultimate strength of cast iron:
Tensile strength = 100 to 200 Mpa
Compressive strength = 400 to 1000 Mpa
Shear strength = 120 Mpa
Assumption
The only failure that happens in the base is crushing because of the given load.
Assume that the depth will be d=75mm.
Factor of safety is taking 3.
Design Analysis the base
Crushing of the base due to shear stress First
calculate allowable shear stress:

Solve from this the thickness

45
4.8 Bolt design for the base
Tap bolt is screwed into a tapped hole of one of the parts to be fastened without the nut.we select
screw (Tap bolts) as fastener to join the housing with the base because Screwed joints are highly
reliable in operation, convenient to assemble and disassemble, adapted to various operating
conditions and Screws are relatively cheap to produce due to standardization and highly efficient
manufacturing processes.

Stresses on the power screw

In our design the screw will face only initial stresses due to Screwing up Forces. I.e. there is no
Stress due to External Forces unless there is any eccentricity. Smaller diameter screws (less than
M 16 or M 18 bolts) may fail during tightening. Design analysis the bolt frame
Assumption
There is no eccentricity (the load of the car is concentrated at the center of the cap).
To remove the uncertainty due to the above assumption,
Factor of safety is equal with 1.5
The initial tension in a bolt, based on experiments, may be found by the relation
……………………………………………………………….. equation 4.24

Where Pi is Initial tension in a bolt d is Nominal diameter of bolt, in mm

Here likes the power screw, specify the size of the bolt then we select a material that can support
the induced initial stress.
we considered the M 7 bolt so that its core diameter and pitch will be 5.773 mm and 1 mm
respectively.

Then the induced initial tensile stress will be

……………………………………………………………………………. equation 4.25

Where

There fore
To remove uncertainties let take a factor of safety

46
Material of bolt
We select a stainless steel for producing this bolt, Specifically AISI 303 Austenitic stainless
steel. select stainless steel because; stainless steels can be cut, formed, machined and fabricated
easily. And it also has good strength. It has the following properties
Yield strength
Ultimate strength 770 M.pa, and
Elongation present is equal to 22 %

4.9 Design of Fork Holder

Material selection
Indian standar Tensile strength Yield strength(minimum) Remark
designation d (minimum) in N/mm2 in N/mm
2

Fe E 230 310 230 Used for

Fe 330 330 200 locomotive

carriages and car
Fe E 250 330 250 structure

Table 5.Material property of steel alloy

From the table 8 is select Fe E 250 with the following property: Tensile
strength=330N/mm2

yield strength=250N/mm2
Assumption It acts as a cantilever beam and it is a rectangular section.
Factor of safety = 2 W = 19.5 KN
Design Analysis the fork holder
For the back side
Here we have: - L =80mm b = 60mm
Maximum bending moment M = w*L = 19500*260 = 50.83Nm
Section modulus

……………………………………………………………………..equation 4.26
The bending tensile stress

From this calculate thickness of the t

47


4.11 Design of Pulleys

The pulleys are used to transmit power from one shaft to another by means of flat belts, V-belts
or ropes. Since the velocity ratio is the inverse ratio of the diameters of driving and driven
pulleys, therefore the pulley diameters should be carefully selected in order to have a desired
velocity ratio. The pulleys must be in perfect alignment in order to allow the belt to travel in a
line normal to the pulley faces.
The pulleys may be made of cast iron, cast steel or pressed steel, wood and paper. The cast
materials should have good friction and wear characteristics. The pulleys made of pressed steel
are lighter than cast pulleys, but in many cases they have lower friction and may produce
excessive wear.
Types of Pulleys for Flat Belts
Following are the various types of pulleys for flat belts:
1. Cast iron pulleys
2. Steel pulleys
3. Wooden pulleys
4. Paper pulleys, and
5. Fast and loose pulleys.
From the above listed types of belts, we select the cast iron type of belt because of it is
 easily available
 less costly
 easy to manufacture
The following procedure may be adopted for the design of cast iron pulleys.
Dimensions of pulley

(i) The diameter of the pulley (D) may be obtained either from velocity ratio consideration or
centrifugal stress consideration. We know that the centrifugal stress induced in the rim of the
pulley, σt = ρ.ν2 where ρ = Density of the rim material

48
 = 7200 kg/m3 for cast iron
ν = Velocity of the rim
= πDN / 60, D being the diameter of pulley and N is speed of the pulley.
 centrifugal stress consideration
…………………………………………………………………….. equation 5.33

√
solve for D=0.14m.

The following are the diameter of pulleys in mm for flat and V-belts.
20, 22, 25, 28, 32, 36, 40, 45, 50, 56, 63, 71, 80, 90, 100, 112, 125, 140, 160, 180, 200, 224, 250,
280, 315, 355, 400, 450, 500, 560, 630, 710, 800, 900, 1000, 1120, 1250, 1400, 1600, 1800,
2000, 2240, 2500, 2800, 3150, 3550, 4000, 5000, 5400.
The first six sizes (20 to 36 mm) are used for V-belts only.
(ii) If the width of the belt is known, then width of the pulley or face of the pulley (B) is taken
25% greater than the width of belt.
B = 1.25 b = 1.25*0.4857 m =0.6063 m Where
b = Width of belt.
According to Indian Standards, IS: 2122 (Part I) – 1973 (Reaffirmed 1990), the width of pulley is
fixed as given in the following table 6 :
Belt width in mm Width of pulley to be greater than belt width
by (mm)

Up to 125 13
125-250 25
250-375 38
475-500 50
Table 6 Standard width of pulley

49
 CHAPTER FIVE
5. Result and discussion
5.1. Result
Component Material type Design of the components
s
Dc =107.5mm
1.Power Steel C -45 L =1300mm
screw

H = 30mm
L = 150mm
2.Fork Steel C- 45 W = 25mm

T = 13mm
3,Base Cast iron L = 2000mm
W = 100mm

4.Fork Steel C- 45 L =80mm

b = 60mm t=
holder
6.778mm

L = 2m (height of the column)

5.Frame Steel C- 45 b = 100mm (width) t=80mm
(depth of the column)

M 7 bolt dc = 5.773 mm
6.Bolt Stainless steel pitch = 1 mm

7.Pulley cast iron D=0.14m.

w=0.6063 m

8.Shaft carbon steel D = 11.7mm for Te

D = 15.8mm for Me

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Table 7 Result each components
5.2 Discussion
The two post car lift is designed as the all components will have material selection plays a key
role in designing a machine and also influence on several factors such as: durability, strength,
resistance which finally leads to increase the life of machine.
 Availability (easy available).
 Resistivity for corrosion (high).
 Durability.
Strength and In other words, what is a typical speed and torque operating point for your system?
Choose a motor that is capable of providing this much mechanical power. (Most motors are
classified according to their power.) Usually you will choose the smallest, lightest, most
inexpensive motor that meets your specifications.

CHAPTER SIX

6. Conclusion and Recommendation in about project

6.1 Conclusion
Generally in this three month we gain more knowledge especially when we see in terms of
improving our personal skills, we can easily see the difference between theory and practical
work. When you do practical work, you can easily see each and individual thing so this make
better to improve our personal skills. And when we see in terms of upgrading our theoretical
knowledge, the knowledge that we know in theory only is not enough but when you see the
theory in practical, it is unforgettable so this makes to upgrade your theoretical knowledge and
when you look in terms of work ethics you learn to be punctual and to work your work properly.
The activities done on each factory helps to see and to know different things because a lot of
activities are done in each day on each series of that factory and we develop my software

51
knowledge by knowing a software called solid, this helps to do part, assembly, sand draft and so
it is helpful to know this software.
This mini project helped us to know more things and to read different books so, sure, this will
help us in the future to go further of this project and take new large projects.

6.2. Recommendation
Based on project we have seen and gain during our intern ship program we have drawn the
following recommendations.
The design progress was decent, but the minimum length of the base .then the future the give
time must be enough to complete the project and our design project we used mechanical power
system the main point of view then we can be reason progress two post car lift we used hydraulic
or pneumatic system.

REFERNCE
1.Ivan sun it Rout, Dipti Ranjan Patra, Sidhartha Sankar Pdhi, Jitendra Narayan Biswal, Tushar Kanti
Panda, ―Design and Fabrication of Motorized automated object lifting jack‖, IOSR Journal of
engineering, ISSN(e): 2250-3021, ISSN(p): 2278-8719, Volume 4, Issue 05, may 2014.

2. Shripad Virkar, S.S. Pawar, A.H. Ingle, ―A Review paper on battery operated screw jack‖,
International Journal of Research in Science & Engineering, Volume 3, Issue: 2, March-April 2017, e-
ISSN: 23948299, p-ISSN: 2394-8280.

3. Bhandari, V. B., 2010 Design of Machine Elements, 3rd, Edition. New Delhi: Tata
McGrawHill Education.
4. Prof. F.M. Oduori, E. D. O., 2016, material Selection for a Manual Winch Rope Drum.
Volume1.
5. Choudhary. S, Ravi Kumar D, Pasbola D & Dabral S, ―Development of Motorized Car Jack‖, Journal
of Applied Mechanical Engineering, ISSN 2168-9873, Volume 5, Issue 4.

52
PART DRAWING

53
Figure 13 2D and 3D power screw

54
Figure 14 2D and 3D fork

55
Figure 15 2D and 3D fork holder

56
Figure 16 2D and 3D Base

57
Figure 17 2D and 3D Worm gear

58
Figure 18 2D and 3D Gear

59
Figure 19 3D Assembly
Key
1. Base
2. Frame
3. Pulley
4. Fork
5. Power screw
6. Shaft
7. Gear
8. Bolt with nut

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61
.

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