Bahi

rDarUni
ver
sit
y
Bahi
rDarI
nst
it
uteofTechnol
ogy
Facul
tyofMechani
calandI
ndust
ri
alEngi
neer
ing
Mechani
calEngi
neer
ingDepar
tment
I
nter
nshi
pRepor
t

Hoi
sti
ngCompany-Amhar aMetalI
ndust
ryandMachine
Technol
ogyDev
elopmentEnter
pri
se(AMIMTDE)
Pr
ojectTi
tl
e:Desi
gnofPor
tabl
eManualFor
kli
ft

By
: I
DNUMBER
1.Abr
ham Mi
nal
e………….
BDU1207429

2.Sur
afel
Alene…………….
BDU1203015

3.Yaschi
l
alAbu……………BDU1203297
Ment
or:
Eli
asT.,
Mel
akM.
andBer
hanu
A.
CompanySuper
visor
:Mr
.Kef
ial
ew
Dat
e:25/
05/
2016E.
C
Bahi
rDar
,Et
hiopi
a
 Decl
arat
ion
The name l
i
sted bel
ow ar
e Mechani
calEngi
neer
ing st
udent
,hav
e undert
aken our
i
nter
nshi
pexper
iencei
nAmhar
aMet
alI
ndust
ryandMachi
neTechnol
ogyDev
elopment
Ent
erpr
ise(
AMI
MTDE)f
rom aper
iodofMay26,2023t
oSept
ember26,
2023undert
he
gui
danceofAcademi
cAdv
isor
.

Wecer
ti
fyt
hat
,ourwor
kisor
igi
nalandcompl
ainedaccor
dingt
othei
nter
nshi
prepor
t
wr
it
inggui
del
i
negi
venbyt
hei
ndust
ryl
i
nkageof
fi
ceoft
hei
nst
it
ute.Wehonest
lydecl
are
t
hatt
hiswr
it
tendocumenti
sourownwor
k.

Abr
ham Mi
nal
e

St
udentname Si
gnat
ure

Sur
afel
Alene

St
udentname Si
gnat
ure

Yaschi
lalAbu

St
udentname Si
gnat
ure

Ihonest
lydecl
aret
hatt
hiswr
it
tendocumenti
sthei
rownwor
k.

Academi
cadv
isorname Si
gnat
ure

i
 ACKNOWLEDGMENT

Fi
rst
,wewoul
dli
ket
oext
endourgr
ati
tudet
oGodf
orhi
sendl
essmer
cy,st
rengt
hand
wi
sdom t
oaccompl
i
sht
hei
nter
nshi
pandt
odot
hepr
oject
.Secondl
y,wewoul
dli
ket
o
ext
end ourgr
eat
estgr
ati
tudet
o Bahi
rDarI
nst
it
uteofTechnol
ogyf
orpr
ovi
ding t
his
i
nter
nshi
poppor
tuni
tyf
orus.t
oappl
yourunder
standi
ngonhow agi
venwor
kiscar
ri
ed
outonourr
espect
ivef
iel
dofst
udy
,whi
chi
nourcaseAmhar
amet
ali
ndust
ryandmachi
ne
t
echnol
ogydev
elopmentent
erpr
ise.

Fi
nal
l
y,wewoul
dli
ket
oexpr
essourpr
ofoundsenset
odeepestt
oAMI
MTDE,whi
chi
s
wi
l
li
ngt
oacceptouri
nter
nshi
ppr
ogr
am,f
orv
aluabl
egui
dance,sy
mpat
hycooper
ati
onf
or
pr
ovi
ding necessar
yfaci
l
iti
esand sour
cedur
ing t
hisi
nter
nshi
p pr
ogr
am Wewi
sh t
o
r
egi
steroursi
ncer
egr
ati
tudet
oal
lAMI
MTDEempl
oyees,especi
all
yMr
.Mekuanentand
Mr
.Kef
ial
ew f
ort
hei
rendl
essef
for
ttot
rai
nsol
i
dwor
k.

i
i
 EXECUTI
VESUMMARY

Thi
sint
ernshi
prepor
tdocumenti
sbasedont
hef
our
-mont
hlongi
nter
nshi
ppr
ogr
am t
hat
wehadsuccessf
ull
ycompl
etedi
nAMI
MTDE.I
tincl
udesbackgr
oundoft
hecompany
,mai
n
ser
vices,or
gani
zat
ionalst
ruct
ure,wor
kfl
ow,mi
ssi
on,v
isi
on,obj
ect
ivesoft
hecompany
.
Fr
om t
her
epor
twehav
eal
soi
ncl
udedt
hesect
ionoft
hecompanywehav
ebeenwor
king
wi
th,wor
kfl
ow andwor
ktasksandal
sot
het
ypesoft
ool
s,met
hodsandt
echni
quesar
e
st
atedbr
ief
ly.Ther
epor
tincl
udesmaj
orpr
obl
em whi
l
eper
for
mingt
hewor
ktaskandt
hei
r
pr
oposedsol
uti
onandt
henr
esul
t&di
scussi
onwi
thr
ecommendat
ionf
ort
hei
dent
if
ied
pr
obl
em.Fi
nal
l
y,t
her
epor
ttal
ksaboutt
heov
eral
lbenef
it
swehav
egai
nedf
rom t
he
i
nter
nshi
pandt
hent
her
epor
tconcl
udeswi
thr
ecommendat
ion. Anot
herchapt
eroft
his
r
epor
tincl
udest
hepr
ojectondesi
gnoff
orkl
i
ft.I
tst
art
sbyshor
tsummar
yoft
hepr
oject
and t
hen f
oll
owed by i
dent
if
ied pr
obl
em and t
hei
rjust
if
icat
ion.Then descr
ibes t
he
obj
ect
ive & met
hodol
ogy and t
hen f
inal
i
zes by gi
vi
ng a concl
usi
on wi
th suppor
ted
r
ecommendat
ion.The r
esul
t& concl
usi
on i
s done by t
aki
ng t
he anal
ysi
s ofeach
componentandassembl
ybyusi
ngsol
i
dwor
ksof
twar
e.

i
i
i
Tabl
eofCont
ent
s
Decl
arat
ion i
ACKNOWLEDGMENT i
i
EXECUTI
VESUMMARY i
i
i
Li
stofFi
gur
es v
ii
i
Li
stofTabl
es x
CHAPTERONE 2
1.I
NTRODUCTI
ON 2
1.
1.Backgr
oundoft
heCompany 2

1.
2.Or
gani
zat
ional
Str
uct
ure 3

1.
3.Wor
kFl
owoft
heCompany 3

1.
4.Obj
ect
ivesoft
heEnt
erpr
ise 4

1.
5.Vi
sion,
Missi
onandVal
uesoft
heCompany 4

1.
5.1.Vi
si
onoft
heCompany 4

1.
5.2.Mi
ssi
onoft
heCompany 5

1.
5.3.Val
uesoft
heCompany 5

1.
6.Ent
erpr
iseEngagement 5

1.
7.Machi
nesi
ntheWor
kshop 6

1.
7.1.Lat
heMachi
ne 6

1.
7.2.Mi
l
li
ngMachi
ne 6

1.
7.3.Dr
il
li
ngMachi
ne 7

1.
7.4.Hy
draul
i
cShear
ingMachi
neandBendi
ngMachi
ne 7

1.
8.Shopsoft
heCompany 8

1.
9.Pr
oductoft
heCompany 9

CHAPTERTWO 12
2.WORK,
RESPONSI
BLI
TIESandASSI
GNMENTS 12

i
v
 2.
1.Wor
kingSect
ionoft
heCompany 12

2.
2.Wor
kTasks 13

2.
2.1.TaskOne 13

2.
2.2.TaskTwo 14

2.
2.3.TaskThr
ee 14

2.
3.TheTaskWeHav
eAssi
gnedt
oWor
kinTheAssembl
ySect
ion 15

2.
4.Wor
kandResponsi
bil
i
tiesofAMI
MTDE 15

CHAPTERTHREE 16
3.I
NTERNSHI
PEXPERI
ENCEANDBENEFI
T 16
3.
1.Engi
neer
ingMet
hods,
Tool
sandTechni
ques 16

3.
2.Chal
l
engesandPr
obl
ems 16

3.
3.Measur
etoOv
ercomeThi
sChal
l
engeAndPr
obl
ems 17

3.
4.Ov
eral
lBenef
it
sofI
nter
nshi
p 17

3.
5.Tool
sUsed 18

3.
6.I
mpr
ovi
ngPr
act
ical
Ski
l
ls 18

3.
7.Upgr
adi
ngOurTheor
eti
cal
Knowl
edge 19

3.
8Impr
ovi
ngTeam Pl
ayi
ngSki
l
l 19

3.
9.LeaderShi
pSki
l
l 19

3.
10Acqui
ri
ngEnt
repr
eneur
shi
pSki
l
ls 20

3.
11.Wor
kingEt
hics 20

3.
12.I
mpr
ovi
ngI
nter
per
sonal
Communi
cat
ion 21

CHAPTERFOUR 22
4.DSI
GNEOFPORTABLEHANDDRI
VENFORKLI
FT 22
4.
1.I
ntr
oduct
ion 22

4.
.2.
1.Backgr
oundofThePr
oject 22
v
 4.
3.Pr
obl
em St
atement 23

4.
4.Obj
ect
iveofThePr
oject 23

4.
4.1.Gener
alObj
ect
ive 23

4.
4.2.Speci
fi
cObj
ect
ive 23

4.
5.Li
ter
atur
eRev
iew 23

4.
6.Met
hodol
ogy 24

4.
7.Desi
gnofComponent
s 25

a. Desi
gnoft
hescr
ew 25

4.
7.1.Ty
pesofScr
ewThr
eadsusedf
orPowerScr
ews 26

b.Desi
gnoft
hef
ork 31

C.Desi
gnoft
hegui
de 35

d.Desi
gnf
ort
hecupoft
hegui
de 38

E.Desi
gnofgear
-meshf
ort
het
wost
rai
ghtbev
elgear
s 40

F.Desi
gnofpi
nionshaf
t 44

G.Keydesi
gnf
orpi
nionshaf
t(handl
e) 48

H.Desi
gnoft
hegearhouse 48

Sel
ect
ionofbal
lbear
ings 50

I
.Desi
gnoff
oot
-st
epbear
ing 51

J.Desi
gnoft
hebase 54

K.Desi
gnofLeg 55

L.Sel
ect
ionofwheel 55

M.Wel
ddesi
gn 56

CHAPTERFI
VE 61
5.CONCLUSI
ONANDRECOMMENDATI
ON 61

v
i
 5.
1Concl
usi
on 61

5.
2Recommendat
ions 61

5.
2.1Recommendat
ionToAMI
MTDE 61

5.
2.2Recommendat
iont
oBDU 61

REFERENCES 63

PARTDRAWI
NGS 64

v
ii
 Li
stofFi
gur
es

Fi
gur
e1:
Organi
zat
ional
str
uct
ure 3

Fi
gur
e2:
Wor
kfl
owoft
hecompany 4

Fi
gur
e3:
lat
hemachi
ne 6

Fi
gur
e4:
Mil
l
ingmachi
ne 7

Fi
gur
e5:
Hydr
aul
i
cbendi
ngandshear
ingmachi
ne 8

Fi
gur
e6:
Shopsi
nthecompany 9

Fi
gur
e7:
wor
ktasksi
nthedesi
gnsect
ionoft
hecompany 14

Fi
gur
e8:
Met
hodol
ogy 25

Fi
gur
e9;
typesofpowerscr
ews 26

Fi
gur
e10:
Desi
gnofscr
ew 30

Fi
gur
e11:
for
kpar
tdesi
gn 34

Fi
gur
e12:
crosssect
ionoft
hegui
de 35

Fi
gur
e13:
desi
gnoft
hegui
de 37

Fi
gur
e14:
Desi
gnoft
hecupwi
tht
ap-
bol
ts 38

Fi
gur
e15:
desi
gnoft
hegearmesh 44

Fi
gur
e16:
desi
gnofshaf
tfort
hepi
nion 47

Fi
gur
e17:
desi
gnoft
hegearhouse 50

Fi
gur
e18:
sect
ionoff
ootst
epbear
ing 52

Fi
gur
e19:
desi
gnf
ootst
epbear
ing 54

Fi
gur
e20:
desi
gnoft
hebase 55

Fi
gur
e21:
desi
gnoft
hel
eg 55

v
ii
i
Fi
gur
e22:
handl
ewel
d 57

Fi
gur
e23:
for
kwel
d 58

Fi
gur
e24:
Assembl
ypar
t 64

i
x
 Li
stofTabl
es

Tabl
e1:Basi
cdi
mensi
onsf
orsquar
ethr
eadsi
nmm (
Nor
malser
ies)accor
ding t
oIS:4694
–1968(
Reaf
fi
rmed1996) 28

Tabl
e2:
Greyi
roncast
ings,
asperI
S:210–1993 31

x
 CHAPTERONE

1.I
NTRODUCTI
ON

1.
1.Backgr
oundoft
heCompany

TheAmhar
aMet
alI
ndust
ryandMachi
neTechnol
ogyDev
elopmentEnt
erpr
ise(
AMI
MTDE)
i
san aut
onomousgov
ernmentdev
elopmentent
erpr
iseest
abl
i
shed byt
heCounci
lof
Regi
onalGov
ernmenton Nov
ember28,2004 wi
tht
he r
egul
ati
on Number127/
2014
i
ntendi
ngt
ocr
eat
eandbui
l
duponest
rongmet
alengi
neer
ingcent
ersi
nther
egi
onwhi
ch
car
ri
esoutt
het
asksofmanuf
act
uri
ngandcommer
cial
i
zingmet
alandmachi
net
echnol
ogy
pr
oduct
ssoast
oal
l
evi
atei
mpedi
ment
sint
echnol
ogysuppl
yandut
il
izat
ionwi
thi
nthe
manuf
act
uri
ngi
ndust
ryandagr
icul
tur
alsect
or.

Tor
eal
i
zet
het
echnol
ogi
caldev
elopmenti
ntheRegi
on,AMI
MTDEhaspr
emedi
tat
edt
o
wor
k wi
thr
esear
cher
s and i
ndust
ri
alpar
tner
s.I
twor
ks i
n col
l
abor
ati
on wi
tht
he
r
esear
chcent
ers,col
l
egesanduni
ver
sit
iesi
nor
dert
oadv
ancet
heknowl
edgei
na
par
ti
cul
arf
iel
dort
oimpr
ovet
hegi
vent
echnol
ogyonest
epahead.I
tal
sopr
ovi
desan
i
ntegr
atedi
ndust
ri
aldev
elopmentsuppor
t,t
rai
ningandcounsel
i
ngser
vicef
ort
hose
pr
ivat
e i
nvest
ors, cooper
ati
ves, mi
cro and smal
l
-scal
e ent
erpr
ises and ot
her
st
akehol
der
sengagedi
nthet
echnol
ogydev
elopmentsect
ors.

AMI
MTDE wor
ks f
ocusi
ng on coppi
ng and adapt
ing appr
opr
iat
etechnol
ogi
es.
Ev
aluat
ingeacht
echnol
ogyf
ort
echni
calmer
it
,commer
cialoppor
tuni
tyandst
ateof
appr
opr
iat
eness,i
timpl
ement
sthedesi
gndev
elopment
,pr
oduct
ionofpr
otot
ypesand
t
henhar
vest
ingi
t,consecut
ivel
y,f
ort
hosef
easi
bleandsel
ect
edt
echnol
ogi
es.

Themasspr
oduct
ionoper
ati
onf
orv
eri
fi
edt
echnol
ogi
eswi
l
lbecar
ri
edoutt
hrough
out
sour
cingandowncapaci
ty. Thel
argeamountofpr
oduct
ioni
sint
endedt
obe
manuf
act
uredt
hroughout
sour
cingwi
thcr
it
icalf
oll
ow upandqual
i
tycont
rolpr
ocess,
how eachpar
toft
het
echnol
ogyi
sper
for
medperpr
oposedf
unct
ional
i
tyr
egar
ding
capabl
eofbei
ngmadeeconomi
calandt
obeat
tract
ivef
ort
het
arget
edconsumer
s.
Par
ti
cipat
eonheav
yandadv
ancedt
echnol
ogi
es.Hence,ont
hecur
rentsi
tuat
ion,i
ts

xi
oper
ati
oni
sli
mit
edt
othel
i
ghtandmedi
um scal
emet
alandmachi
net
echnol
ogi
es
undermet
alengi
neer
ingdi
vi
sion.Env
ironment
alpr
otect
ionequi
pmentmanuf
act
uri
ng
subpr
ogr
am.

I
n addi
ti
on t
othese t
echnol
ogy pr
ogr
ams,t
he Ent
erpr
ise par
ti
cipat
ein shade
const
ruct
ionofst
eelst
ruct
ure,pl
anti
nst
all
ati
onandmai
ntenanceser
vices,consul
ti
ng
andt
rai
ning,commi
ssi
oni
ngandpr
epar
ingmachi
nespeci
fi
cat
ionsbasedoncust
omer
r
equest
s.Al
so,t
hecompanyhav
ethev
isi
ont
obeoneofAf
ri
ca'
stop10t
echnol
ogi
cal
capabi
l
iti
esby2017.

Amhar
aNat
ionalRegi
onalSt
ateMet
alI
ndust
ryandMachi
neTechnol
ogyDev
elopment
Ent
erpr
isewasest
abl
i
shedaccor
dingt
opr
ocl
amat
ionnumber127/
2007E.
Ctomeet
t
hegapoft
echnol
ogyr
equi
rementamongManuf
act
uri
ngI
ndust
ry,Agr
icul
tur
eSect
or,
Mi
croandSmal
lent
erpr
isei
nter
msofpr
oductandser
vice.Cur
rent
lyt
heEnt
erpr
isei
s
st
art
ingt
omanuf
act
uredi
ff
erentt
ypesoft
echnol
ogi
calpr
oduct
sbyt
het
woexi
sted
wel
l
-or
gani
zed wor
kshopsf
ound atBahi
rDarand KombuchaCi
ty(
Amhar
aregi
on)
.
Regi
onalgov
ernmentent
erpr
isehav
ingi
tsownl
egalper
sonal
i
tyandhasi
tscapaci
tyt
o
br
ingt
echnol
ogi
calt
ransf
eraswel
lasi
ncr
easi
ngt
hepr
oduct
ionandpr
oduct
ivi
tyi
nthe
r
egi
oni
npar
ti
cul
arandNat
ionalcar
ryoutpr
oduct
ionandcommer
cial
i
zat
ionofmet
al
and machi
ne t
echnol
ogi
es t
hrough sol
vi
ng t
he demand suppl
y and ut
il
iz
ati
on
obst
ruct
ionseeni
nthemanuf
act
uri
ngi
ndust
ryandagr
icul
tur
alsect
orsi
nther
egi
on.

2
1.
2.Or
gani
zat
ionalSt
ruct
ure

Fi
gur
e1:
Organi
zat
ional
str
uct
ure

1.
3.Wor
kFl
owoft
heCompany

Fi
rst
ly,
theconcer
nedbodyoft
hecompanyi
dent
if
iespr
obl
em andt
henv
aluei
s
expl
ainedi
ncl
ear
lyi
nor
dert
osel
ectt
heappr
opr
iat
etechnol
ogy
.Thi
sleadst
othe
machi
net
obesel
ect
edi
sdesi
gnedbyt
hedesi
gnercaset
eam.Themanuf
act
uri
ng

3
t
eamsmanuf
act
uret
hepr
otot
ypeoft
hemachi
neandexami
net
hemachi
newhet
heri
t
i
sfunct
ional
ornot
.

Fi
gur
e2:
Wor
kfl
owoft
hecompany

1.
4.Obj
ect
ivesoft
heEnt
erpr
ise

TheGener
alobj
ect
iveoft
heent
erpr
isei
stof
ulf
il
lthegapsoft
echnol
ogyr
equi
rement
amongManuf
act
uri
ngI
ndust
ry,Agr
icul
tur
eSect
or,Mi
croandSmal
lent
erpr
isei
nter
ms
ofpr
oductandser
vice.

4
1.
5.Vi
sion,
Missi
onandVal
uesoft
heCompany

1.
5.1.Vi
sionoft
heCompany

Tobecameoneoft
het
op-
10t
echnol
ogycapabi
l
iti
esi
nAf
ri
caby2025.

1.
5.2.Mi
ssi
onoft
heCompany

Dev
elopi
nggl
obal
l
ycompet
it
ivet
echnol
ogi
esandmanuf
act
uri
ngi
ndust
ri
est
hatar
e
capabl
eofsol
vi
ngt
hebot
tl
enecksi
nagr
icul
tur
ali
ndust
ri
alandensur
ingsust
ainabl
e
gr
owt
hbydev
elopi
ngpr
oduci
ngandcommer
cial
i
zingmet
alandmachi
net
echnol
ogi
es.

1.
5.3.Val
uesoft
heCompany

 Wear
epassi
onat
eaboutourcust
omer
s.

 Ourempl
oyeesar
ethehear
tofourbusi
ness.

 Wear
ecommi
tt
eddel
i
verexcept
ional
val
ues.

 Pr
ofi
tabi
l
ityi
sthecor
eofourbusi
ness.

 Webui
l
dthr
ustandactwi
thhonest
y.

 Webel
i
evei
nwor
kingt
oget
her
.

 Wenev
erst
opl
ear
ningandgr
owi
ng.

 Wecar
eaboutt
heenv
ironment

1.
6.Ent
erpr
iseEngagement

Theent
erpr
isei
sengagedi
nthesev
enengi
neer
ingandmet
alsubsect
orsmanuf
act
uredi
n
demanddr
ivenbased,
namel
y

 Agr
icul
tur
alt
echnol
ogypr
oduct
ionandsuppl
y

 Foodpr
ocessi
ngmachi
nepr
oduct
ionandsuppl
y

 Gener
almachi
nepr
oduct
ionandsuppl
y

5
  Tr
anspor
tmachi
nepr
oduct
ionandsuppl
y

 Env
ironment
alpr
otect
ionmachi
nespr
oduct
ionandsuppl
y

 Const
ruct
ionmachi
nes,pr
oduct
ionandsuppl
yDi
ff
erentmachi
ner
yspar
epar
ts
pr
oduct
ionandsuppl
y

1.
7.Machi
nesi
ntheWor
kshop

1.
7.1.Lat
heMachi
ne

Lat
hei
soneoft
hemostv
ersat
il
eandwi
del
yusedmachi
net
ool
sal
lov
ert
hewor
ld.I
t
hadcommonl
yknownast
hemot
herofal
lot
hermachi
net
ool
s.Themai
nfunct
ionofa
l
athei
stogi
vet
hemat
eri
alsr
equi
redshapeandsi
ze.

I
tisamachi
net
oolusedpr
inci
pal
l
yforshapi
ngar
ti
clesofmet
al,wood,orot
hermat
eri
al.
I
nlat
hemachi
nescoul
dper
for
m di
ff
erentoper
ati
ons:f
aci
ng,t
urni
ng,t
aper
ing,bor
ing,
t
hreadet
c.

Fi
gur
e3:
lat
hemachi
ne

1.
7.2.Mi
ll
ingMachi
ne

Mi
l
li
ngi
samachi
net
hatt
hemet
alorwor
kpi
ececut
ti
ngbymeansofar
otat
ingcut
ter
hav
ingmul
ti
plecut
ti
ngedges.Forcut
ti
ngoper
ati
on,
thewor
kpi
ecehadf
edagai
nstt
he
r
otar
ycut
ter
.Ast
hewor
kpi
ecemov
esagai
nstt
hecut
ti
ngedgesofmi
l
li
ngcut
ter
,met
al

6
r
emov
edi
nthef
orm ofchi
ps.

I
tisamachi
net
oolusedt
orot
atesi
ngl
eormul
ti
plecut
ti
ngedgesandr
emov
esmet
al
whenwor
kisf
eedagai
nstar
otat
ingcut
ter
.Mi
l
li
ngmachi
nesar
eoneoft
heessent
ial
machi
nesi
nanymoder
nmachi
neshopTheyar
ecapabl
eofmachi
ningf
latorcont
our
ed
sur
faces,
slot
s,gr
oov
es,
recessest
hreads,
gear
s,spi
ral
sandot
herconf
igur
ati
ons

Fi
gur
e4:
Mil
l
ingmachi
ne

1.
7.3.Dr
il
li
ngMachi
ne

I
tisadev
iceusedt
omakehol
esi
nahar
dsur
face.Themostcommonmachi
ning
oper
ati
onsper
for
medonadr
il
lpr
essar
edr
il
li
ng,r
eami
ng,t
appi
ng,count
erbor
ing,
count
ersi
nki
ng,
andspotf
aci
ng.

A.Radi
alDr
il
li
ngMachi
ne

Dr
il
li
ngmachi
nei
stomakeci
rcul
arhol
esont
hecomponent
swi
tht
hehel
pofdr
il
lbi
tes.
But
,thepur
poseoft
her
adi
aldr
il
li
ngmachi
nei
susedt
odr
il
lthehol
esi
nthegi
venr
adi
al
di
stanceandt
hiswi
l
lbeused,
whent
hecomponentsi
zei
slar
gei
nter
msofhei
ght
.

Whent
hecompot
esar
elar
ge,i
tcannotf
iti
tsst
ruct
urei
nthemachi
nev
ice.Ther
efor
e,
t
hecomponenthast
obepl
easedont
hegr
oundandt
her
adi
alar
m oft
hedr
il
li
ng
machi
nehast
ober
otat
edw.
r.
tthecomponentt
odot
heoper
ati
on.

1.
7.4.Hy
draul
icShear
ingMachi
neandBendi
ngMachi
ne

Shear
ingmachi
nei
susi
ngt
ocutsheetmet
alsbyshear
ingact
ion,wher
eashy
draul
i
c

7
bendi
ngmachi
nei
susi
ngt
obendsheetmet
alsaswel
laspl
ate.

.
Fi
gur
e5:
Hydr
aul
i
cbendi
ngandshear
ingmachi
ne

1.
8.Shopsoft
heCompany

Amhar
aMet
alI
ndust
ryandMachi
neTechnol
ogyDev
elopmentEnt
erpr
isehast
hef
oll
owi
ng
wor
kshopmai
nly
.Thosear
e

A:
wel
dingwor
kshop

B:
met
alwor
kshop

8
 C:WoodandFoundr
yWor
kshop

D:
Assembl
i
ngandFi
nishi
ngWor
kshop

Fi
gur
e6:
Shopsi
nthecompany

1.
9.Pr
oductoft
heCompany

Amhar
aNat
ionalRegi
onalSt
ateMet
alI
ndust
ryandMachi
neTechnol
ogyDev
elopment
Ent
erpr
ise est
abl
i
shed t
o meet t
he gap of t
echnol
ogy r
equi
rement among
Manuf
act
uri
ngI
ndust
ry,Agr
icul
tur
eSect
or,Mi
cro andSmal
lent
erpr
isei
nter
msof
pr
oductandser
vice.Cur
rent
lyt
hecompanypr
oducedi
ff
erentpr
oductbasedonr
ever
se
engi
neer
ing t
echni
ques.such t
echni
ques ar
eimpor
tantf
ordev
elopi
ng count
ryt
o

9
pr
oducedi
ff
erentspar
epar
tandmachi
necomponent
s.

Someoft
hecompany
’smai
npr
oduct
sar
e:

 I
ndust
ri
alPar
kandcarpar
kingshades

 Fi
shf
eedpel
l
eti
zermachi
ne

 Manual
barcut
er

 Seedcl
eaner

 Scr
ewt
ypel
i
ftt
abl
etr
uckwi
thouthy
draul
i
cpump

Someoft
hecompany
’smai
nser
vicesar
e:

 Counsel
l
ingandt
rai
ningser
vices

 I
nst
all
ati
on,
commi
ssi
oni
ngandmai
ntenanceser
vices

 Machi
nespeci
fi
cat
ionpr
epar
ati
on

 Spar
epar
tspr
oduct
ionandsel
l
ing

 Met
alandmachi
net
echnol
ogymanuf
act
uri
ngandsel
l
ing

 Di
ff
erentequi
pment
’sf
orbui
l
dingani
ndust
rypar
k

Rev
erseengi
neer
ing:

Asy
stemat
icmet
hodol
ogyf
oranal
yzi
ngt
hedesi
gnofanexi
sti
ngdev
iceorsy
stem,
ei
therasanappr
oacht
ost
udyt
hedesi
gnorasapr
erequi
sit
eforr
e-desi
gns.The
pr
ocess of dev
elopi
ng t
echni
cal i
nfor
mat
ion suf
fi
cient t
o dupl
i
cat
e an i
tem
accompl
i
shedbyphy
sical
l
yexami
ning,measur
ingort
est
ingexi
sti
ngi
tems;r
evi
ewi
ng
t
echni
cal
dat
a;orper
for
mingengi
neer
inganal
ysi
s.

Rev
erseEngi
neer
inghel
pst
o:

 Dev
elopasy
stemat
icappr
oacht
othi
nki
ngaboutt
heengi
neer
ingdesi
gnofdev
ices
andsy
stems

 Acqui
reament
aldat
abankofmechani
cal
desi
gnsol
uti
ons

10
  Si
mpl
i
fiest
heengi
neer
ingpr
obl
ems,

 Bepr
ofi
tabl
eandhel
pst
orunwi
thwor
ldt
echnol
ogy

Li
mit
ati
onofr
ever
seengi
neer
ing

I
tli
mit
sfur
therst
udyofengi
neer
sandmi
nimi
zenewi
nvent
ions

 Uni
for
m pr
oduct
sar
epr
oducedmostoft
het
ime

 Therearesomeeffi
ciencyl
ossesdur
ingdi
sassembl
i
ngandassembl
i
ng

Themai
ncur
rentpr
oduct
soft
hecompanyar
e-

• St
ruct
ural
beam

• Channel
gat
e

• Carparki
ngandshade

• Fi
shf
eedpel
l
eti
zesmachi
ne

• Pi
pebender

• Manualbarcut
ter

• Threshermachi
necomponentl
i
kebol
t,nut
,gear
,shaf
t,keyet
c.…

11
 CHAPTERTWO

2.WORK,
RESPONSI
BLI
TIESandASSI
GNMENTS

2.
1.Wor
kingSect
ionoft
heCompany

Wehav
ebeenwor
king i
nrev
ersedesi
gnsect
ionoft
hecompany
,becauseaf
ter
submi
tt
edt
her
equestpapert
othecompany(
AMI
MTDE)
,thecompanysupperv
isor
assi
gnedussoast
owor
kont
hedesi
gnsect
ion.

The Amhar
a Met
alI
ndust
ry and Machi
ne Technol
ogy Dev
elopment
alEnt
erpr
ise
(
AMI
MTDE)i
nBahi
rDarconsi
stsofv
ari
oussect
ionst
hatcont
ri
but
etoi
tsov
eral
l
oper
ati
onsandgoal
s.

I
naddi
ti
ont
othi
s,t
her
eisadi
ff
erentwor
kingt
eam i
ntheent
erpr
ise,
suchas

 desi
gnt
eam,

 manuf
act
uri
ngt
eam and

 Qual
i
tyi
nspect
iont
eam.so,t
hecompanymanagermadesi
xgr
oup,eachgr
oup
hav
efi
ve member
s Ev
en i
fther
e was t
his cat
egor
ize,al
lgr
oup member
s
par
ti
cipat
edi
nal
lwor
kingsect
ionsoft
hecompany
.

I
tfocuses on agr
icul
tur
almechani
zat
ion and f
ood pr
ocessi
ng,among ot
herar
eas
Ther
efor
e,i
tisl
i
kel
ythatt
heent
erpr
isehassect
ionsdedi
cat
edt
o:

Mechani
calEngi
neer
ing:Thi
s sect
ion woul
dinv
olv
ethe desi
gn,dev
elopment
,and
mai
ntenanceofv
ari
ousmechani
cal
syst
emsandequi
pment
.

Manuf
act
uri
ng:Gi
vent
heent
erpr
ise'
sai
mtocov
ert
hemar
ketgapi
nthemanuf
act
uri
ng
i
ndust
rysect
ors,i
tisr
easonabl
eto assumet
hatt
her
eisa sect
ion dedi
cat
ed t
o
manuf
act
uri
ngdi
ff
erentpr
oduct
s,suchasmachi
ner
y,t
ool
s,andequi
pment
.

Agr
icul
tur
alTechnol
ogy Dev
elopment
:The ent
erpr
ise i
sinv
olv
ed i
n agr
icul
tur
al
mechani
zat
ionandf
oodpr
ocessi
ng,i
ndi
cat
ingt
hepr
esenceofasect
ionf
ocusedon
dev
elopi
ngandi
mpr
ovi
ngagr
icul
tur
alt
echnol
ogi
esandmachi
ner
y.

Resear
chandPr
oductDev
elopment
:Theent
erpr
isemayhav
easect
iondedi
cat
edt
o
12
r
esear
ch and pr
oduct dev
elopment
,wher
e engi
neer
s and t
echni
cians wor
k on
i
nnov
ati
vesol
uti
onsandi
mpr
ovement
sforexi
sti
ngpr
oduct
s.

Qual
it
yAssur
anceandCont
rol
:Toensur
ethepr
oduct
ionofhi
gh-
qual
i
typr
oduct
s,t
he
ent
erpr
isemayhav
easect
ionr
esponsi
blef
orqual
i
tyassur
anceandcont
rol
,conduct
ing
i
nspect
ionsandt
est
stomai
ntai
nst
andar
ds.

2.
2.Wor
kTasks

Wegr
oupedundersol
i
dwor
ksof
twar
etr
aini
ng;duet
othi
sreasonwet
rai
nedv
erywel
l
.
Thi
shel
psust
owor
kourpr
ojecteasi
l
yandcl
ear
ly.Aswepar
ti
cipat
edi
ndesi
gnsect
ion,
wehav
ebeenr
ever
singt
hebenchv
icemachi
nebyt
aki
ngonet
oonedi
mensi
oni
nor
der
t
omodelanddr
afteachpar
tandassembl
ebysol
i
dwor
ksof
twar
etomanuf
act
urei
t.
Her
eweknewt
heconceptofr
ever
seengi
neer
ing,sol
i
dwor
kandwor
kingmechani
sm
ofbenchv
ice.Fi
nal
l
y,wepr
esentourwor
kforcompanymanager
sandempl
oyer
sand
t
hent
heyr
evi
ew ourwor
kanddeci
det
omanuf
act
urei
t.So,wear
esubmi
tt
edf
ull
document
ati
onbyhar
dcopyandsof
tcopyt
hatcont
aindet
ailmodel
i
ng,assembl
i
ng
dr
aft
ingandsi
mpl
edescr
ipt
ionaboutt
hebenchv
ice.

2.
2.1.TaskOne

Sol
idWor
ksgener
alconcept
s-Sol
i
dWor
ksi
samechani
caldesi
gnaut
omat
ion
sof
twar
epackageusedt
obui
l
dpar
ts,
assembl
i
esanddr
awi
ngst
hatt
akesadv
ant
ageof
t
hef
ami
l
iarMi
crosof
tWi
ndowsgr
aphi
caluseri
nter
face.I
tisaneasyt
olear
ndesi
gn
and anal
ysi
stool
,(Sol
i
d Wor
ksSi
mul
ati
on,Sol
i
d Wor
ksMot
ion,Sol
i
d Wor
ksFl
ow
Si
mul
ati
on,Sust
ainabi
l
ity
,et
c.)i
tpossi
blef
ordesi
gner
stoqui
ckl
ysket
ch2Dand3D
concept
s,

Af
terbui
l
dupt
heconcept
sof Sol
i
dWor
ks2019sof
twar
etol
ear
ndesi
gnand

anal
ysi
sPar
tsofdi
ff
erentmachi
nes.l
i
keshownasf
oll
ows;

13
 Fi
gur
e7:
wor
ktasksi
nthedesi
gnsect
ionoft
hecompany
2.
2.2.TaskTwo

Sol
id wor
k pr
act
ice-wi
thi
n 2019 sol
i
d wor
k sof
twar
e we hav
e sket
ched f
orkl
i
ft
machi
newhi
chmakescr
eat
e3Dpar
tsandassembl
i
esanddet
ail
2Ddr
awi
ngs.

2.
2.3.TaskThr
ee

wehav
eseendi
ff
erentmachi
neshowt
owor
kmachi
nepat
ter
nsi
nfoundr
y
l
ab l
i
ke Lat
he machi
nes,dr
il
li
ng machi
ne,mi
l
lmachi
ne CNC machi
ne
t
radi
ti
onalandnon-
tr
adi
ti
onalLazmachi
nesort
heabov
emachi
nepar
tsby
mi
l
l,dr
il
li
ng,andCNCmachi
net
owor
kmachi
nepar
tpat
ter
ns.Wehav
enot
gai
nedoppor
tuni
tyt
obui
l
dourknowl
edgeduet
ocount
ryi
ssueaswel
las
i
nter
netconnect
ions.

14
Thewor
kfl
owi
ntheassembl
ysect
iongener
all
ylooksl
i
ke:
-

 Team wor
kinagr
oup

 Cl
eani
ngandcl
ear
ingt
hewor
kingar
eaorshop

 Mai
ntai
ning t
he componentl
i
ke cl
eani
ng each componentbyusi
ng netcl
oth,
l
ubr
icat
ingbyoi
l
ingandgr
ease.

 Cl
earunder
standi
ngoft
hewor
kingpr
inci
pleoft
hemachi
ne

 Of
fer
ingal
lthenecessar
ytool
swhi
chi
susedf
orassembl
ypur
pose

 Subassembl
yandassembl
yofeachcomponentt
hemachi
ne

 Fi
nal
l
ycheckt
hemov
ementoft
hemachi
neandl
ubr
icat
eifnecessar
y.

2.
3.TheTaskWeHav
eAssi
gnedt
oWor
kinTheAssembl
ySect
ion

I
nthi
sassembl
ysect
ionofAMI
MTEDE,wear
ewor
kingasat
eam memberi
ndi
ff
erent
wor
ksoft
hesect
ion.Att
hebegi
nni
ngofouri
nter
nshi
ppr
ogr
am,
wedr
aftaschedul
eto
seeeachandev
eryr
oom oft
hecompany
,thenouri
nter
nshi
padv
iserataccompanyMr
.
Mequanentshowusaf
tergi
vesasanassi
gnmenteachoft
hewor
kingpr
inci
pleandt
he
met
hodhow t
oassembl
e,t
hedi
ff
erentt
ypesoft
ool
susedanddi
ff
erentt
ypesof
machi
neswhi
chi
sfoundi
nthewor
kshop.heal
soshowsusf
ort
heassembl
ybench
v
icemachi
neandwehav
eseenhow hemai
ntai
nit
. Thenwebegi
nwor
kingand
st
udy
ingaboutev
ery
thi
ngi
ndet
ail
andwewer
eal
sost
udy
ingourownassi
gnment
s.

2.
4.Wor
kandResponsi
bil
it
iesofAMI
MTDE

Pr
oduct
ionandManuf
act
uri
ng:AMI
MTDEi
sinv
olv
edi
npr
oduct
ionandmanuf
act
uri
ng
act
ivi
ti
es.I
tmayber
esponsi
blef
orpr
oduci
ngmet
alpr
oduct
sandmachi
net
echnol
ogy
component
s.

Cont
inuous I
mpr
ovement
: AMI
MTDE emphasi
zes cont
inuous i
mpr
ovement i
n i
ts
oper
ati
ons.Thi
ssuggest
saf
ocusonenhanci
ngef
fi
ciency
,qual
i
ty,
andpr
oduct
ivi
ty.

Communi
cat
ion:Ef
fect
ivecommuni
cat
ioni
sconsi
der
edi
mpor
tantwi
thi
nAMI
MTDE.

15
Thi
sli
kel
yinv
olv
es cl
earand ef
fi
cientcommuni
cat
ion channel
s bet
ween di
ff
erent
t
eamsanddepar
tment
s.

Rel
evantWor
kExper
ience:Jobpost
ingsr
elat
edt
oAMI
MTDEment
iont
her
equi
rement
ofsev
eraly
ear
s ofr
elev
antwor
k exper
ience.Thi
s suggest
sthatempl
oyees ar
e
expect
edt
ohav
eexper
iencei
nthef
iel
dofmet
ali
ndust
ryandmachi
net
echnol
ogy
dev
elopment

16
 CHAPTERTHREE

3.I
NTERNSHI
PEXPERI
ENCEANDBENEFI
T

3.
1.Engi
neer
ingMet
hods,
Tool
sandTechni
ques

Met
hod:-i
swayofdoi
ngsomet
hingi
nasy
stemat
icway
.Her
e“sy
stemat
ic”i
mpl
i
esan
or
der
lyl
ogi
cal
sequenceofst
epsort
ask.

Techni
quei
saspeci
fi
cappr
oacht
obeef
fi
cient
lyaccompl
i
shi
ngat
aski
namannert
hat
maynotbei
mmedi
atel
yobv
ious.

I
nthi
ssect
ion,
all
wor
ktasksar
eper
for
medaccor
dingt
hest
andar
dinst
ruct
ionmanual
s
f
ormul
ated by Company
.In addi
ti
on,t
hese gui
del
i
nes cont
ain many mechani
cal
engi
neer
ingmet
hodsandt
echni
ques.Amongt
hesemet
hods,wet
ryt
oli
stsomeof
t
hem bel
ow:

Someoft
hemechani
cal
engi
neer
ingt
echni
quesandmet
hodsar
e:

Saf
ety
:-Al
lmechani
csandcl
eaner
sint
hissect
ionwearast
andar
dsaf
etyshoewhi
ch
canhol
dhi
ghl
oadt
hatmi
ghtcausedamaget
ofootf
inger
s.Thecompanyal
sopr
ovi
des
ast
andar
dwor
kwear
ingandput
ti
ngar
ulet
hatal
lmechani
csshoul
dwearatwor
kwi
th
gl
oves.Al
so,eachmechani
cshav
ethei
rownt
abl
eandboxf
orput
ti
ngt
hei
rownwor
k
t
ool
s.

Cl
eani
ng:-f
ora good ser
vice and mai
ntenance,a good cl
eani
ng i
s needed f
rom
engi
neer
ingpoi
ntofv
iew.

3.
2.Chal
lengesandPr
obl
ems

Ther
ear
edi
ff
erentpr
obl
emst
hathav
ebeenf
acedi
ncompanyt
hosear
e:

 I
thasnoenought
echnol
ogi
calmachi
neorl
i
ftst
omov
eequi
pmentandmachi
nes
t
oar
rangei
nit
sposi
ti
ons.

 I
nthest
oret
her
aw mat
eri
als,t
ool
sorequi
pment
’sar
enotar
rangedor
der
lyi
.e.
,
kai
zeni
snotappl
i
ed.

17
  I
nthewoodshopst
her
eisnoawayofr
emov
ingt
hechi
psoft
hewoodst
hismayt
he
causeofmanyheal
thpr
obl
emsf
orwor
ker
s.

 Ther
ear
esomemachi
nes,
whi
char
epl
acedout
sidet
hewor
kshopt
hatar
eexposed
t
othesunandr
ain,
whi
chcausecor
rosi
onandot
herdef
ect
s.

 I
naddi
ti
on,manuf
act
uredpr
oduct
sar
est
ayi
ngout
sidet
heshopar
eexposedf
or
weat
hercondi
ti
onanddustunt
ilt
hecust
omerbuy
sthem.

3.
3.Measur
etoOv
ercomeThi
sChal
lengeAndPr
obl
ems

 Wedesi
gnedt
hepor
tabl
emanualf
orkl
i
ftt
omov
eequi
pmentandmachi
nest
o
ar
rangei
nit
sposi
ti
ons.

 wehav
edi
scussedt
othemanagert
oappl
ykai
zenf
ordi
sor
der
edmat
eri
alsand
gi
vet
rai
ningaboutkai
zenf
orcompanyempl
oyees.

 Wehav
egi
venanadv
icet
ousebl
owermachi
net
oremov
est
hechi
psort
ouse
ot
hermechani
sms

 Wet
ryt
ocommuni
cat
etot
heempl
oyer
,team l
eaderandmoni
tori
nor
dert
o
wor
kingt
oget
her
.

 Fort
he machi
nes,whi
ch ar
e pl
aced out
side t
he wor
kshop,we t
ellt
othe
managert
opr
epar
etempor
arysheds.

3.
4.Over
allBenef
it
sofI
nter
nshi
p

Thi
sint
ernshi
ptr
aini
ngi
sver
yimpor
tantf
orusbecausei
tgener
ateski
l
lful
lgener
ati
on
t
ocr
eat
ethenewt
echnol
ogyont
hef
utur
e.Thi
sint
ernshi
pisal
sousedt
osol
vet
he
pr
obl
emsandt
oimpr
oveourpr
act
ical
knowl
edge.Gener
all
y,i
nthi
sfour
-mont
h
i
nter
nshi
pexper
ience,
wehav
emuchski
l
ls,
knowl
edgeandhi
gherconf
idenceabout
manyt
hings.

Thosear
e:-

 I
mpr
ovi
ngt
othewayofpr
obl
em sol
vi
ng

18
  I
mpr
ovi
ngPr
act
ical
ski
l
ls

 Upgr
adi
ngt
heor
eti
cal
knowl
edge

 I
mpr
ovi
ngt
eam pl
ayi
ngski
l
ls

 I
mpr
ovi
ngl
eader
shi
pski
l
ls

 Under
standi
ngaboutwor
ket
hicsr
elat
edi
ssues

 Under
standi
nghowt
obeent
repr
eneur
shi
pski
l
ls

 I
mpr
ovi
ngi
nter
per
sonal
communi
cat
ionski
l
ls

3.
5.Tool
sUsed

Tool
susedi
nAMI
MTDEdur
ingouri
nter
npr
ogr
am ar
e:

 Adj
ust
abl
ewr
ench

 Openwr
ench

 Cal
i
per

 Met
er

 Al
l
enkey

 Handt
ool
s

3.
6.I
mpr
ovi
ngPr
act
icalSki
ll
s

Thi
sint
ernshi
ptr
aini
ngi
susedt
oimpr
ovi
ngourpr
act
icalski
l
ls,how t
oimpr
ovedour
knowl
edgei
nwhi
chsi
tuat
ion,howt
osol
vet
hepr
obl
emsandhowt
ocommuni
cat
ethe
wor
ker
s.Butbef
orei
nthi
sint
ernshi
ptr
aini
ng,wehav
en’
tenoughpr
act
icalski
l
land
l
abor
ator
yexper
ience,sowedon’
tknow how t
ochanget
het
heor
yoft
hel
ear
ning
pr
ocessi
ntopr
act
ical
process.

Buti
nthi
sint
ernshi
ptr
aini
ngwehav
egai
nedt
heknowl
edgehowt
omai
ntai
n,r
ever
sing
oft
hemachi
nes,
oper
ati
onofsomemachi
nes.Forexampl
e,i
nwor
kshop(
lat
hmachi
ne,

19
mi
l
li
ngmachi
ne,shapermachi
ne,hy
draul
i
cpr
ess,bendi
ngmachi
ne,r
oll
ermachi
neand
soon)andt
hepr
ocessofel
ementpr
oducedl
i
kegear
,pul
l
ey,st
eppedshaf
tdi
scpl
ate
et
c.I
ngener
al,i
twasanef
fect
iveexper
iencei
nimpr
ovi
ngourpr
act
icalski
l
lsi
nvar
ies
aspect
sdur
ingt
hei
nter
nshi
ppr
ogr
am.

3.
7.Upgr
adi
ngOurTheor
eti
calKnowl
edge

Oneoft
heai
msoft
hisi
nter
nshi
ppr
ogr
am i
stodev
elopt
het
heor
eti
calknowl
edgei
nto
pr
act
icaloneal
soencour
agest
het
heor
ythatwehav
elear
nt.Ther
efor
e,i
nourst
ayi
n
t
hecompanywehav
edev
elopedt
heknowl
edget
hati
sknowni
ntheor
ywi
tht
he
par
ti
cipat
ingi
noper
ati
onalsy
stem oft
hecompanyaswel
lasi
nthef
act
ory
’swor
king
condi
ti
onoft
hepr
oduct
ioni
npl
anni
ng,i
ndesi
gnanddev
elopment
,inqual
i
tycont
rol
,
st
oresy
stem,andal
soi
nmai
ntenanceact
ivi
tyBesi
dest
hiswehav
egat
her
edt
he
r
elev
anti
nfor
mat
ion whi
ch i
simpor
tantt
o under
stand t
he t
heor
yforpr
act
ical
appl
i
cat
ion.

Gener
all
y,wehav
egot
tenf
ulli
nfor
mat
iondur
ingt
hei
nter
nshi
ptoi
ncr
easet
heor
eti
cal
knowl
edgeandhowt
ochanget
het
heor
eti
cal
ski
l
lint
opr
act
ical
.

3.
8Impr
ovi
ngTeam Pl
ayi
ngSki
ll

Thi
sint
ernshi
ptr
aini
ngi
susedt
oimpr
ovi
ngt
eam pl
ayi
ngski
l
ls.Wor
kwi
thourf
ri
ends,
wit
h
wor
kerofcompany
,wi
tht
hest
udent
sofot
heruni
ver
sit
ytoshar
eideaandexper
ience.

Wehav
ewor
kedwi
thski
l
ledf
ullengi
neer
sinsol
i
dwor
ktr
aini
ng,mai
ntenanceof
machi
neandot
heroper
ati
ons.I
nthi
scase,
ourr
olei
sfol
l
owi
ngt
hewayofmai
ntenance.
Gener
all
y,wear
ewor
kingt
oget
herandshar
eidea.

3.
9.LeaderShi
pSki
ll

Thi
sint
ernshi
pisusedt
oimpr
ovi
ngourl
eader
shi
pski
l
l.Wehav
esomeknowl
edge
aboutl
eader
shi
p;how t
oleadat
eam andhow t
ocont
rolt
hewor
kerorempl
oyer
.we
hav
eknownt
hemani
fest
ati
onofgoodl
eadershi
pchar
act
eri
sti
csf
rom t
hecompany
l
eader
s.Gener
all
y,wewer
eful
l
yhel
pedandor
ient
edbyt
hesuper
visorwhat
everwe
askedhi
m,bot
htheor
eti
cal
l
yandpr
act
ical
l
y.Whenwej
oint
hecompanybef
orewe
st
art
edourwor
kthesuper
visori
ntr
oducesuswi
thal
lthemachi
nesi
ntheshopandal
l

20
t
hesaf
etypr
ecaut
ions.

Benef
it
sfr
om ourst
ayi
nAMI
MTDEwer
einanumberofr
espect
sbycl
osel
ywor
king
t
oget
herwi
tht
heempl
oyerofAMI
MTDE.Webecomemuchmor
eawar
eofourown
posi
ti
onwi
thr
espectt
othef
unct
ionoft
heor
yandmet
hodf
ort
heengi
neer
ingsci
ence.

3.
10Acqui
ri
ngEnt
repr
eneur
shi
pSki
ll
s

Ent
repr
eneur
shi
p can bedef
ined ast
hepr
ocessofi
nvol
vi
ng t
hecr
eat
ion ofnew
ent
erpr
isesandt
hatt
heent
repr
eneuri
sthef
ounder
.Knowi
ngcondi
ti
onsoff
act
oryand
t
ypesoft
echnol
ogi
esusedi
nfact
ori
eshel
pst
oident
if
yrequi
redpr
oducti
nthemar
ket
.
Al
so,
dur
ingt
hei
nter
nshi
pway
sofpr
ocessi
ngandmechani
smsusedi
nthef
act
oryar
e
obser
ved.

 Sol
vi
ngengi
neer
ingpr
obl
emsf
ort
hesoci
ety

 Jobcr
eat
iveness

 Per
for
mingourt
askwi
thpl
an

 Est
abl
i
shmentofbusi
nesscent
ersbyownway

3.
11.Wor
kingEt
hics

Thi
sint
ernshi
ptr
aini
ngi
susedt
ounder
standi
ngt
hewor
kinget
hics.I
nAmhar
amet
al
i
ndust
ryandmachi
net
echnol
ogydev
elopmentent
erpr
ise,wehav
ewor
kedt
oget
her
wi
thcompanyempl
oyer
s.Basedont
hist
rai
ningwehav
egai
nedaccount
abi
l
ityoft
he
wor
kingoft
hepr
oduct
.Ev
eryempl
oyerorwor
keroft
hecompanywor
ksont
asks.We
know t
hatWor
ket
hicsi
ncl
udenotonl
yhow onef
eel
saboutt
hei
rjob,car
eer
,butal
so
how onedoeshi
s/herj
oborr
esponsi
bil
i
ties.Thi
sinv
olv
esat
ti
tude,behav
ior
,respect
,
communi
cat
ion,
andi
nter
act
ion;
howoneget
sal
ongwi
thot
her
s.

Wor
ket
hicsi
nvol
vesuchchar
act
eri
sti
csas:

 Honest
yandaccount
abi
l
ity

 punct
ual
i
ty

21
  Hav
eaposi
ti
vewor
kat
ti
tude

 Wor
kindependent
ly

 Taker
esponsi
bil
i
ty

 Communi
cat
eef
fect
ivel
y

 Managet
imeef
fect
ivel
y

Gener
all
y,t
hisi
nter
nshi
pusedt
ounder
standgoodwor
ket
hics.

3.
12.I
mpr
ovi
ngI
nter
per
sonalCommuni
cat
ion

When we wer
eint
he i
nter
nshi
p sessi
on,we di
dtoo manyf
ormaland i
nfor
mal
communi
cat
ionswi
tht
hecompanymanagerandt
heper
sonnel
’
sandt
hewor
ker
soft
he
company
,pr
oduct
ionmanager
sandqual
i
tyheadsaswel
last
hef
act
oryt
eam l
eader
s
t
hatcoul
dhel
pust
odev
elopourcommuni
cat
ionski
l
lsv
erywel
l
.

Anydut
iesandr
esponsi
bil
i
tiesassi
gnedt
oper
for
mer
sint
her
esear
chanddev
elopment
i
ntheconv
ent
ionalmanuf
act
uri
ngf
act
orycor
epr
ocessar
eusual
l
yaccompl
i
shedi
na
cr
ewori
ndi
vi
dualconsi
sti
ngofl
ow-
lev
elwor
ker
stohi
ghl
yexper
iencedt
echni
cian.The
t
asksst
rongl
ydemandt
opr
ocessappr
eci
abl
ecommuni
cat
ionabi
l
ityandcooper
ati
on
neededi
nor
dert
omeetgoal
sandsat
isf
act
oryr
esul
ts.Dur
ingt
hewor
kor
derf
low,we
saw f
rom i
nit
iat
ion t
o appr
ovaland execut
ion,t
he pr
ocessi
ncur
sinv
olv
ementof
exper
ti
se f
rom mul
ti
ple sect
ors.Besi
des t
his,we i
mpr
oved our i
nter
per
sonal
communi
cat
ionski
l
landknowl
edgei
nourst
ayi
nthecompany
.Ithast
hef
oll
owi
ng
usage:

 Toexchangenewi
deasandknowl
edgewi
tht
heot
her

 I
mpr
ovet
obui
l
dupsel
fconf
idence

 I
timpr
ovesourspeaki
ngandl
i
steni
ngski
l
ls

 I
mpr
over
elat
ionshi
pswi
tht
heot
her
.

22
 CHAPTERFOUR

4.DSI
GNEOFPORTABLEHANDDRI
VENFORKLI
FT

4.
1.I
ntr
oduct
ion

4.
.2.
1.Backgr
oundofThePr
oject

Li
ft
ingmachi
nesar
eal
way
sthebackboneofwor
kshopswher
eloadi
ng,t
ranspor
ti
ng
anddr
aggi
ngofwor
kpi
eces,v
ices,gear
boxesandcasi
ngst
akespl
ace.I
nthi
spr
oject
t
hef
orkwhi
chcar
ri
est
hel
oadsl
i
desov
ert
hesquar
ethr
eadsoft
hescr
ewt
hrought
he
t
orqueappl
i
edmanual
l
ybyt
hehandl
e.

Obv
iousl
y,i
t’
snotanewi
deawecr
eat
edbutwet
ri
edt
odot
hisbecausewehav
eseen
suchpr
obl
emsi
nourhostcompany
.sot
hati
tcanbeusedf
orl
i
fti
ngl
oadswi
thout
wor
ryi
ngaboutmuchspacet
akenbyt
hemachi
ne.Somemi
l
li
ngandshapermachi
nes
uset
hesquar
ethr
eadscr
ew i
nor
dert
omov
eupanddownt
hebed.Thesemachi
nes
ar
eli
mit
edt
osmal
lhei
ght
sbecauseast
hescr
ew gr
aduat
est
hehandl
emov
esal
ong
wi
tht
hebedwhi
chmakesi
tdi
ff
icul
tfort
heoper
atort
owor
kathi
gherhei
ght
s.These
andot
hert
echni
cal
i
tiesar
eanal
yzedandr
edesi
gnedt
osui
tourf
orkl
i
ft.

23
4.
3.Pr
obl
em St
atement

I
nwor
kshopssomet
imeswemayhav
etodealwi
thheav
ywor
kpi
ecesl
i
keshaf
tsand
pl
ateshav
ingawei
ghtwecan’
thandl
einhumanl
abor(
ourbar
ehands)al
sot
henor
mal
v
ehi
cl
efor
kli
ft
sar
esobi
gtof
itbet
weenmachi
ner
ies,ev
eni
fwedohandl
eiti
nhuman
l
abort
ofi
nisht
hewor
kther
eisal
otoft
imewast
ageandmanuf
act
uri
ngdel
ayscaused
byl
oadi
ngandunl
oadi
ngofcomponent
s.Toolpost
s,gearboxesandcasi
ngsar
e
t
ranspor
tedt
oandf
rom t
hedepar
tmentwi
thagr
eatdealofl
aborev
enwi
tht
heex
ist
ing
i
nconv
eni
entl
oadi
ngmachi
ner
ieswhi
char
ebi
ganddi
ff
icul
ttooper
atewi
thasi
ngl
e
oper
ator
.So,
thi
spr
ojectai
mst
otackl
etheabov
e-ment
ionedpr
obl
emst
echni
cal
l
y.

4.
4.Obj
ect
iveofThePr
oject

4.
4.1.Gener
alObj
ect
ive

 Todesi
gnapor
tabl
eandmanual
l
yfor
kli
ftt
opr
ovi
deef
fect
ivewayofmount
ingand
t
ranspor
ti
ngmachi
necomponent
s.

4.
4.2.Speci
fi
cObj
ect
ive

 Handl
ethewei
ghtofsl
i
ght
lyheav
yobj
ect
swel
i
ftandt
ranspor
t.

 Todesi
gnoft
hecomponent
sthatcanbeeasi
l
ymai
ntai
nedbyt
heuseri
fit
’sneeded

24
 andwi
thasf
ewpar
tsaspossi
ble.

 Model
l
ingoft
hecomponent
susi
ngsol
i
dwor
kssof
twar
e2019Edi
ti
on.

4.
5.Li
ter
atur
eRev
iew

Mat
thew Spar
ker
s[4]Forcompani
est
ryi
ng t
o besust
ainabl
eand car
bon neut
ral
,
war
ehousi
nganddi
str
ibut
ioncanbedi
ff
icul
t.I
t’
sfi
net
omakegr
eenpr
oduct
s,buti
tis
mor
edi
ff
icul
ttof
indagr
eenwayt
ogett
hem i
ntost
ore.

Hi
ghRi
skWor
kaGui
det
ofor
kli
ftsaf
etybyGov
ernmentofSout
hAust
ral
i
a[5]count
er
bal
ancef
orkl
i
fti
susual
l
ysuppor
tedatt
hreepoi
ntscal
l
ed‘
tr
iangl
eofst
abi
l
ity
’.Thef
ront
l
eftwheelt
hef
rontr
ightwheelandmi
ddl
eofr
earaxl
eatt
hepi
votpi
nconnect
edt
othe
st
eeraxl
emakeani
magi
nar
ytr
iangl
e.Thi
sisi
mpor
tantbecauset
hecent
erofgr
avi
ty
mustr
emai
nwi
thi
nthi
str
iangl
eofst
abi
l
ity
.

Desi
gnandst
ruct
ureanal
ysi
sofMechani
calFor
kli
ftUsi
ngANSYSSof
twar
ebyPr
of.
kshi
rsagarPr
ashant
.R[
6]west
udyt
hest
ruct
ureanal
ysi
soft
hef
orkl
i
ftusi
ngANSYS
sof
twar
e.Theor
eti
calcal
cul
ati
oni
scompar
edwi
thANSYSsof
twar
eanal
ysi
sisdonet
o
v
eri
fyduet
othi
ssel
ectt
hef
orkl
i
ftmat
eri
alasmi
l
dst
eelduet
ohi
ghspeci
fi
cst
if
fness
andst
rengt
h.Li
ftbyt
hef
orki
ttr
iedt
odef
orm andbendi
napar
ti
cul
ardi
rect
ionsoi
n
or
dert
opr
epar
edesi
gnoff
orkl
i
ft.

Mat
eri
alHandl
i
ng Equi
pmentSel
ect
ion Usi
ng Wei
ght
ed Ut
il
it
yAddi
ti
ve Theor
yby
Pr
asadKar
ande,
ShankarChakr
abor
ty[
7]usi
ngwei
ght
edut
il
it
yaddi
ti
vemet
hodt
osol
ve
mat
eri
alhandl
i
ngequi
pmentsol
uti
on.Thi
smet
hodi
scompar
edwi
thdr
ivebyt
hepast
r
esear
chwi
thpr
ovi
det
hei
tspot
ent
ial
i
ty,appl
i
cabi
l
ityandaccur
acyt
osol
vemachi
ning
pr
obl
em.

4.
6.Met
hodol
ogy

Themet
hodol
ogyt
odot
hepr
ojecti
sst
art
ingf
rom scr
eeni
ngoutt
he
pr
obl
em and t
hen,cont
aint
he dat
athr
ough pr
imar
y and secondar
y
sour
cesar
ethef
oll
owi
ng.Thepr
imar
ydat
awi
l
lbecol
l
ect
edbyusi
ng
obser
vat
ion.Secondar
ydat
awi
l
lbecol
l
ect
edf
rom wr
it
tendocument
s.

25
  Usi
ngpr
eli
minar
ydat
acol
l
ect
ionf
orr
ecogni
zet
heneedand,✓ i
dent
if
icat
ionof

pr
obl
em.

 Sel
ect
ingmat
eri
alsf
oreachcomponent
.

 Anal
ysesofdet
ail
desi
gn(
mat
hemat
ical
cal
cul
ati
on)
.

Thef
oll
owi
ngchar
tshowst
hedet
ail
met
hodol
ogyasshownbel
ow:

Recogni
ti
onoft
heneed

Def
ini
ngt
hepr
obl
em.

Dat
agat
her
ing

Sel
ect
ingmat
eri
alsf
or
eachcomponent
.

Anal
ysesof det
ail
desi
gn
(
mat
hemat
ical
cal
cul
ati
on

Model
i
ngcomponentsusi
ng
sol
i
dworkssof
twar
e

Fi
gur
e8:
Met
hodol
ogy

4.
7.Desi
gnofComponent
s

a.Desi
gnoft
hescr
ew

Thepowerscr
ews(
alsoknownast
ransl
ati
onscr
ews)ar
eusedt
oconv
ertr
otar
ymot
ion
i
ntot
ransl
ator
ymot
ion.Forexampl
e,i
nthecaseoft
hel
eadscr
ew ofl
athe,t
her
otar
y

26
mot
ioni
sav
ail
abl
ebutt
het
oolhast
obeadv
ancedi
nthedi
rect
ionoft
hecutagai
nstt
he
cut
ti
ngr
esi
stanceoft
hemat
eri
al.I
ncaseofscr
ew j
ack,asmal
lfor
ceappl
i
edi
nthe
hor
izont
alpl
anei
susedt
orai
seorl
oweral
argel
oad.Powerscr
ewsar
eal
sousedi
nvi
ces,
t
est
ingmachi
nes,
presses,
etc.

4.
7.1.Ty
pesofScr
ewThr
eadsusedf
orPowerScr
ews

Fol
l
owi
ngar
ethet
hreet
ypesofscr
ewt
hreadsmost
lyusedf
orpowerscr
ews:

Squar
ethr
ead:Asquar
ethr
ead,
asshowni
nFi
gur
e10(
a),
isadapt
edf
ort
het
ransmi
ssi
on
ofpoweri
nei
therdi
rect
ion.Thi
sthr
eadr
esul
tsi
nmaxi
mum ef
fi
ciencyandmi
nimum r
adi
al
orbur
sti
ngpr
essur
eont
henut
.

Acmeort
rapezoi
dal
thr
ead:Anacmeort
rapezoi
dal
thr
ead,
asshowni
nFi
gur
e10(
b),
isa
modi
fi
cat
ionofsquar
ethr
ead.Thesl
i
ghtsl
opegi
vent
oit
ssi
desl
ower
stheef
fi
ciency
sl
i
ght
lyt
hansquar
ethr
eadandi
tal
soi
ntr
oducesomebur
sti
ngpr
essur
eont
henut
,but
i
ncr
easesi
tsar
eai
nshear
.Iti
susedwher
easpl
i
tnuti
srequi
redandwher
epr
ovi
sioni
s
madet
otakeupwearasi
nthel
eadscr
ewofal
athe.

But
tresst
hread:Abut
tresst
hread,
asshowni
nFi
gur
e10(
c),
isusedwhenl
argef
orcesact
al
ongt
hescr
ewaxi
sinonedi
rect
iononl
y.Thi
sthr
eadcombi
nest
hehi
gheref
fi
ciencyof
squar
ethr
eadandt
heeaseofcut
ti
ngandt
headapt
abi
l
ityt
oaspl
i
tnutofacmet
hread.I
tis
st
rongert
hanot
hert
hreadsbecauseofgr
eat
ert
hicknessatt
hebaseoft
het
hread.The
but
tr
esst
hreadhasl
i
mit
edusef
orpowert
ransmi
ssi
on.I
tisempl
oyedast
het
hreadf
or
l
i
ghtj
ackscr
ewsandv
ices.

27
 Fi
gur
e9;
typesofpowerscr
ews

Duet
otheabov
ereasonsquar
escr
ewt
radei
spr
efer
abl
eforourdesi
gn.

Mat
eri
alsel
ect
ion:

Al
ocal
l
yav
ail
abl
emat
eri
al,
C-30st
eeli
schosenbecauseofi
tsr
elat
ivel
yhi
ghst
rengt
hand
l
ow cost
.Ithasat
ensi
l
e/compr
essi
vel
oadcapaci
t mm2 andy
yof500N/ iel
dst
rengt
hof
mm2.
300N/

Anal
ysi
s

Nowassumi
ngaf
act
orofsaf
ety3,
wewi
l
lfi
ndt
heper
missi
blest
resses

τy =0.
5×300 =150N/
mm2
σc 500N/mm2
σall = = =166.67N/
mm2
f.
s 3
τy 150N/mm2
τall = = =50N/mm2
Fs 3

Unl
i
kescr
ew j
acks,t
hisscr
ew i
sloadedi
ndi
rect
lywi
thaf
orceof
fsetatsomedi
stance
whi
chcr
eat
esamomentoni
tasshownbel
ow.
Tof
indt
hedi
rectf
orcet
hatactont
hescr
ew,wedi
vi
det
hemomentbyt
hecor
edi
amet
er
whi
chi
snotobt
ainedy
et.

M =F×R =4905×300mm =2943000Nmm

M 294300Nmm
F= =
dc dc

Weknowt
hat
,

28
Nowsubst
it
uti
ngt
hef
orcei
neq.1i
ntot
heabov
eequat
ionandsol
vi
ngf
ordcweget
:

2943000Nmm ×4
dc3 =
π ×166.
67N/
mm2
dc=28.
22mm,
say30mm

Butt
heabov
edi
amet
ercannotbeusedasi
tfai
l
stof
ulf
il
lthemaxi
mum
shearst
resst
heor
yinl
atercal
cul
ati
ons,soaf
teranumberofi
ter
ati
ons
40mm cor
edi
amet
eri
spr
ovent
obesaf
easf
oll
ows:

Accor
dingt
oISnor
malser
ies(
4694-
1968)r
eaf
fi
rmed1996,
wehav
ethef
oll
owi
ng
squar
ethr
eadpar
amet
ers,

dc =40mm

do =48mm,
P =8mm

Tabl
e1:
Basi
cdi
mensi
onsf
orsquar
ethr
eadsi
nmm (
Nor
mal
ser
ies)accor
dingt
oIS:
4694
–1968(
Reaf
fi
rmed1996)

Squar
ethr
eadpowerscr
ewi
schosenbecauseofi
tshi
ghl
oadcar
ryi
ngcapaci
ty.

dc+do 40 +48
dm = = =44mm
2 2
p 8
t
an a= = =0.
058
πdm π ×44

29
Assumi
ng,av
eragequal
i
tyofmat
eri
alsandwor
kmanshi
pandav
eragewor
kingcondi
ti
ons
wet
akecoef
fi
cientoff
ri
cti
on0.
18.

μ =t
an ∅ =0.18
-1
∅ =t
an 0.18 =10.
204
-
1
∅ =tan 0.
058 =3.31

Weal
sonowknowt
hatt
hef
orcewhi
chactont
hescr
ew,

M 2943000Nmm
F= = =73575N
dc 40mm

Now,
tor
quer
equi
redt
orai
set
hel
oadbyov
ercomi
ngf
ri
cti
onbecomes,

d w ×tan (α +φ)×dm
T =P × =
2 2
d 73575×tan (3.
31 +10.
204)×44
T =P × =
2 2
T =389021.
81Nmm

Asi
tcanbeobser
vedφ >t
an a,
whi
chmeanst
hatt
het
orquer
equi
redt
olowert
hel
oadi
s
posi
ti
ve,consequent
lyourscr
ewsel
f-
locki
ng.t
hel
oadi
sposi
ti
ve,consequent
lyourscr
ew
i
ssel
f-l
ocki
ng.

Checki
ngMaxi
mum st
ressesi
nducedi
nthescr
ew

16T 16×389021.82Nmm
τ = 3= =30.
96N/mm2
πdc πdc3

F 73575N ×4
σ = = =58.
96N/ mm2
A π ×402

Nowchecki
ngt
hemaxi
mum pr
inci
pal
str
ess(
compr
essi
ve)wehav
e,

30
 σ + σ2 +4τ2
σmax=
2

σmax=71.
88N/
mm2,
whi
chi
slesst
han166.
67N/
mm t
husi
tissaf
e!
Fi
nal
l
y,checki
ngt
hemaxi
mum shearst
ressi
nducedi
nthescr
ewhav
e,

552 +4τ2
58.
τmax=
2
[58.
552 +4* 962]
30.
τmax =
2
2
58.
55 +4×30.962
τmax=
2
τmax =42.
26N/mm2

whi
chi
slesst
han50N/
mm2(
all
),t
husi
tissaf
e!

Ef
fi
ciencyoft
hescr
ew

T0
η = , wher
eto =t
orquerequi
redt
olif
tthel
oadwithoutfr
ict
ion.
T
Ft
an αdm 73757* t
an 3.31*44
η = = =0.
24 =24%,
whi chl
esst han
2T 2* 389021.
82

50%,
resul
ti
ngsel
f-
locki
ngscr
ew.
Buckl
i
ngoft
hescr
ew
Thescr
ew canbeconsi
der
edasast
rutbot
hendsf
ixed,weknow t
hatcr
ushi
ngl
oador
cr
ippl
i
ngl
oadi
s,
CEπ3dc4
Wcr = ,wehav
e
64L
2(
C =1. bot
hendsf
ixed)
L=1500mm (
lengt
hoft
hescr
ew)
E =y
oung'
smodul
us =200000N/
mm2
I=massmomentofi
ner
ti
a

31
 CEπ3dc4 1.
2*200000* 404
π3 *
Wcr = = =198.
44MN
64L 64*1500

whi
chi
smuchgr
eat
ert
hant
hel
oad, 575KN,
73. thusi
tissaf
e!

Fi
gur
e10:
Desi
gnofscr
ew

b.Desi
gnoft
hef
ork

Mat
eri
alsel
ect
ion:

Themat
eri
alf
ort
hisnuti
sgr
eycasti
ront
ypewi
tht
hef
oll
owi
ngmechani
cal
pr
oper
ty.

Yi
eldst
rengt mm2
h=310N/

32
 Tensi
l
est
rengt mm2
h=139N/

Compr
essi
vest
rengt mm2
h=604N/

Shearst
rengt mm2
h=192N/

Br
inel
lhar
dness=198

Al
l
owabl
ebear
ingpr
essur
e=17. mm2
5N/

Tabl
e2:
Greyi
roncast
ings,
asperI
S:210–1993

Anal
ysi
s:
Assumi
ngaf
act
orofsaf
ety3,
Theper
missi
bleshearst
ressbecomes,

33
 σy 310N/mm2
σall = = =103.33N/
mm2
F.S 3
τy 192N/mm2
τall = = =64N/mm2
F.S 3

Let
,n =numberoft
hreadsi
ncont
actwi
tht
hescr
ew
H =hei
ghtoft
henut
t=t
hicknessoft
hescr
ew
Pb =bear
ingpr
essur
e
Assumi
ngt
hatt
hel
oadi
sdi
str
ibut
eduni
for
mlyov
ert
hecr
oss-
sect
ional
areaoft
henut
,

F
Pb = ,t
henrearrangi
ng
π/4[d2
o-d2
c]n
F
n =
π/4[ 2 2
dc]
do- Pb
73575* 4
n = =7.6say ,8teet
h
17.
5* π* [482-402]

Thenmi
nimum hei
ghtoft
henutbecomes,
H =n*
p,wher
epi
spi
tch
H =8*
8 =16mm,
butf
ort
hesakeofuni
for
mit
ywi
tht
hef
orkhei
ghtl
et'
stake100mm.

Maxi
mum shearst
ressesi
nducedi
nthenutandscr
ewt
hreads
F
τmax(screw) = , et=p/
wher 2 =8/
2 =4mm
πndct
73575 τall)
τmax(screw) = =18.
3N/
mm2,
whi
chi
smuchl
esst
han50N/
mm2( ,thussaf
e!
π*
8* 40*4

34
35
Nowf
ort
henut
,

F
τmax(nut) =
πndot
73575
τmax(nut) = =15.
09N/
mm2,
whi
chi
slesst
han64N/
mm2
π*
8* 48*4

(
đ11)
,thussaf
e!

Nowassumi
ngt
hatwhent
hef
orki
ssubj
ect
edt
othel
oadi
tisonl
ycar
ri
edbyt
hegui
denot
t
hescr
ew,
wehav
ebendi
ngandshearst
ressesi
nducedi
nit
.

Forbendi
ngwehav
e,

̅
My
σb = ,
I
M =4905N *
500mm =2452500Nmm

Nowf
ort
hemomentofi
ner
ti
awet
aket
her
ect
angul
arsect
ionoft
hef
orkatwhi
chi
tst
art
s
t
odecr
easei
tst
hicknessaswegetcl
osert
othel
oadasshowni
nthef
igur
eabov
e.

bh3 150*603
I = = =2700000mm2
12 12
̅
y =30mm
2452500Nmm *30mm
σb = =27.
25N/
mm2
2700000mm4

Fort
heshearst
ressatt
hej
unct
ionwehav
e,

F 4905N
τ= = =0.
545N/
mm2
A 150mm *60mm

Usi
ngmaxi
mum shearst
resst
heor
y,

36
 [σ2 +4τ2]
τmax =
2
2 2
27.
25 +4*
0.545
= =13.
63N/
mm2,
whi
chi
slesst
hant
he
2

al
l e(
owabl mm2)
64N/ ,thussaf
e!

Fi
gur
e11:
for
kpar
tdesi
gn

C.Desi
gnoft
hegui
de

Mat
eri
alsel
ect
ion:

Thegui
det
hati
schosenf
ort
hispar
ti
cul
arappl
i
cat
ioni
smost
lyusedi
n
t
hef
act
orymachi
ner
iesi
ngui
dingt
hebedofmi
l
ler
s(t
hev
ert
icalones)
andshaper
smai
nlyupanddownwi
that
rapezoi
dalcr
osssect
ion.I
tis
madef
rom gr
eycasti
ront
ypeAast
henutwi
thmechani
calpr
oper
ty
descr
ibedbel
ow:

 Yi
eldst
rengt mm2
h=310N/

 Tensi
l
est
rengt mm2
h=139N/

37
  Compr
essi
vest
rengt mm2
h=604N/

 Shearst
rengt mm2
h=192N/

 Br
inel
lhar
dness=198

Anal
ysi
s

Assumi
ngaf
act
orofsaf
etyF.
s3,wecal
cul
atef
ort
he
per
missi
blest
ress

=103. mm2
33N/

Thi
sgui
dehast
ocar
ryal
lthebendi
ngmomenti
mposedoni
tbyt
hef
ork
i
nor
dert
oenabl
ethemachi
newor
kpr
oper
lywi
thoutf
ail
ure.Thegui
de
hast
rapezoi
dalcr
osssect
ion.Thef
reebodydi
agr
am i
sshowni
nthe
f
igur
ebel
ow:

Sot
hegui
dei
ssubj
ect
edt
obot
hdi
rectaxi
alcompr
essi
vel
oadandabendi
ng
moment
.

Fi
gur
e12:
crosssect
ionoft
hegui
de

So,
weknowt
hat
,

̅
My
σb =
I

Wer
e,

38
 M =moment
‾
y=t
hev
ert
ical
dist
anceoft
hecent
roi
d
I=momentofi
ner
ti
aofcr
osssect
ion
M =4905N *
500mm =2452500Nmm

Nowf
rom t
hecr
osssect
ion,

̅ ∑
ay
y=
∑a
∑ay=[(1/2*50*50)*50/3*2 +(300*50)*25]=416666.67mm
3

∑a=[2(1/2*50*50)+(300*50)]=17500mm ]Clal2

̅ 416666.
67
y= =23.
81mm
17500

Nowsubt
ract
ingmomentofi
ner
ti
aoft
wot
ri
angl
esf
rom t
hewhol
erect
angl
ewegetIf
or
t
het
rapezi
um.

bh32bh3
I = -
12 36
400* 503 2*50* 503
I = -
12 36
I =3819444.45mm4
2452500Nmm * 23.
81mm
σb = =15.
29N/
mm2
45mm4
3819444.

Nowcal
cul
ati
ngf
ort
heaxi
all
oad,

F
σa = =17500mm2
Atrap,
WhereAAr
ap
4905N
σa = =0.
28N/
mm2
17500mm2

Now,
thet
otal
maxi
mum st
ressbecomes

39
 σmax =σa +σb =0.28 +15.
29 =15.
57N/
mm2

Whi
chi
smuchl
esst
hant
heal
l e(
owabl 103. mm2)t
33N/ hussaf
e!

Fi
gur
e13:
desi
gnoft
hegui
de

d.Desi
gnf
ort
hecupoft
hegui
de

Mat
eri
alsel
ect
ion:

Themat
eri
alf
ort
hiscupi
scasti
ronast
hegui f
de(rom pr
oper
tyt
abl
e2)
.
I
tisat
tachedt
othet
opoft
hegui
debyt
wot
apbol
ts.I
tisal
sot
heone
t
hatt
hef
oot
stepbear
ingi
sat
tachedt
obyt
ap-
bol
t.Thecasti
ronhast
he
sameal
l
owabl
ebendi
ngandshearst
rengt
hast
hegui
de.

Anal
ysi
s

Assumi
ngaf
act
orofsaf
etyF.
s3,
wecal
cul
atef
ort
heper
missi
blest
ress

40
 σy
σall =
F⋅
S
310N/mm2
σall = =103.33N/
mm2
3
τy 192
τall = = =64N/mm2
3 3

Thecupmayshearduet
otheappl
i
eddi
rectupwar
dfor
cet
hus,

F
τind =
A

73575N
τind = =9.
2N/
mm2whi
chi
slesst
hant
heal
l
owabl
ethusi
tissaf
e!
60* 400

Fi
gur
e14:
Desi
gnoft
hecupwi
tht
ap-
bol
ts

Mat
eri
alsel
ect
ion:

Themat
eri
alchosenf
ort
hesebol
tsi
sav
eryst
rongst
eel
C-45.
Yi
eldst
rengt
h =360N/
mm2
Tensi
l
est
rengt
h =710N/
mm2

Assumi
ngaf
act
orofsaf
ety1.
5

41
 σt
σall =
F.S
710
σall = =473. 33N/
mm2
1.5

Letw bet
hel
oadi
nabol
tperuni
tdi
stanceduet
othet
urni
ngef
fectoft
hegui etW1
deandl
bel
oadoneachoft
hebol
tsatdi
stanceL1f
rom t
hebase.

Weknowt
hatdi
rectt
ensi
l
eloadcar
ri
edbyeachbol
tis,

W 73575N
Wte = = =36787.
5Nand,
n 2

w(
loadonbol
tperuni
tlengt
h)haspr
edet
ermi
nedf
ormul
a

W* L
W = 2
2[
(L1)]
73575*145
= 2
=8534.
7N/
mm
2[
(25)]

Weknowt
hatt
heheav
il
yloadedbol
tisatadi
stanceofL1mm f
rom t
hebase,
thenl
oadon
heav
il
yloadedbol
t,

Wt1 =w ×L1 =8534.

7*25 =213367.
5N

Then,
max
imum t
ensi
l
eloadonheav
il
yloadedbol
t:

Wt =Wte +Wt1 =213367.

5 +36787.
5 =250155N

Nowl
etdcbet
hecor
edi
amet
eroft
hebol
t,

π 2
Wt = * σall
dc *
4
π 2
250155 = *dc *473.33
4

8say24mm,
dc =23. andf
rom I
S4218r
eaf
fi
rmed1996wechose
M30.

42
E.Desi
gnofgear
-meshf
ort
het
wost
rai
ghtbev
elgear
s

Mat
eri
alsel
ect
ion:

The mat
eri
alsel
ect
ed f
ort
he gear
sis st
eel
-ANSI
/AGMA2003-
B97 wi
tht
he
f
oll
owi
ngmechani
cal
proper
ty.

Al
l
owabl
ebendi
ngst
ress=13500psi
( mm2)
95N/

Al
l
owabl
esur
faceendur
ancel
i
mit=190000psi
( mm2)
1310N/

Sur
facehar
dness=50HRC

Young’
smodul mm2
us=200000N/

Heatt
reat
ment……………….
.fl
ame/
induct
ionhar
dened

Anal
ysi
s

Assumpt
ions:

Basi
cappr
oxi
mat
ebasal
met
abol
i
crat
eofanadul
thumanbei
ngi
s100W

 Anav
eragef
orcet
hatcanbeexer
tedbyhumanbei
ngi
s250-
300N

 Ar
mlengt
hfort
hehandl
eis250mm

 Gearr
ati
otaken3

 Thegear
sar
enor
mal
pressur
eangl
eof14

 Theshaf
tcent
erl
i
nesi
nter
sectper
pendi
cul
arl
ytodel
i
vert
hepower
.

 Pi
niondi
amet
er40mm andgeardi
amet
er120mm

Fi
rstl
et’
sdet
ermi
net
hespeedoft
hegear
s,

43
Ar
mlengt
hoft
hehandl
e250mm

Av
eragehumanf
orce250N

Av
eragehumanpower100W,now wecanest
imat
ethespeedoft
hehandl
e
r
otat
ion(
pini
ongear
)

Ph =T*
ω =F*
r*ω
P 100
ωp = = =1.
6rad/
sec=15.
28r
pm say15r
pm and,
wit
h
Fr 250*0.
25

t
hegearr
ati
o

ωp 15
ωg = = =5rpm =0.
53r
ad/
sec
3 3

Tor
quer
equi
redr
aisi
ngt
hel
oad,

T =389021.
82Nmm =389.
021Nm

Powert
ransmi
tt
edt
othegear
,

ωg =389.021 *
P =T* 0.53 =206.
2W =0.
28hp

Nowf
ir
stbasedont
heal
l
owabl
ebendi
ngst
resswef
indt
hemodul
e(m)whi
chhel
pust
o
f
indt
hedi
mensi
onsoft
hegear
s.

Letm =modul
einmm
Knowi
ngt
hatt
het
woshaf
tsar
eatr
ightangl
e,pi
tchangl
eoft
hepi
nionbecomes,

Dp
an-1
θp1 =t (D)=tan (14200)=18.4
g
-
1 0

θp2 =90-
θp1 =90-
18. 60
4 =71.

Tep =Tpsec θp1Nowf

ormat
ivenumberoft
eet
hforpi
nion,
Wer
e,

44
 Dp
Tp(pini
onteeth)= Then
m
m 42.2
TEp = sec 18.
4= andformati
venumberofteet
hfort
hegear
,
m m
120 380.2
TEg =Tgsec θp2 = sec 71. 6=
m m

Si
ncebot
hthegear
sar
emadef
rom t
hesamemat
eri
al,
thepi
nioni
sweakert
hust
hedesi
gn
shoul
dbebasedupont
hepi
nion.

10
I
tisknownt
hatt
oot
hfor
mfact
orf
ort
hepi
nionwi
th142 composi
tet
eet
h,i
s

0.684
Yp =0.
124-
TEp
0.684*m
=0.
124- =0.
124_
0.02m
42.
2

Thent
hepi
tchl
i
nev
eloci
tybecomes,

=0.
03m/
s

Taki
ngv
eloci
tyf
act
or,

Si
ncesl
anthei
ghtoft
hepi
tchcone,

=63.
25mm say64mm
Assumi
ngaf
acewi
dth,

b=1/
3*L=1/
3*64=21.
33say22mm Nowt
orqueont
hepi
nion,

=131.
3Nm =131300Nmm

Thus,
tangent
ial
ont
hepi
nionbecomes,

45
 =656.
5N

I
tisal
soknownt
hatt
angent
ial
loadont
hepi
nioni
s

Sol
vi
ngt
heabov
eequat
ion,
weget
,

m =6.
15say7mm

Nownumberoft
eet
honeachgear
,

1say6

=17.
14say18
Checki
ngt
hegear
sforwear

Si
ncel
oadst
ressf
act
ori
s,

K=3.
069andf
ort
her
ati
ofact
or,

Thenmaxi
mum al
l
owabl
eloadf
orweari
s

=5123.
22N,
sincet
hisv
aluei
s

46
muchl
owert
hant
het
angent
ial
load,
iti
ssaf
e!

Pr
opor
ti
onsoft
hegear
smaybef
oundasf
oll
ows

Addendum =1m =7mm

Dedendum =1.
2m =1.
2*7=8.
4mm

Cl
ear
ance=0.
2m =0.
2*7=1.
4mm

Wor
kingdept
h=2m =2*
7=14mm

Thi
cknessoft
het
oot
h=1.
5708m =1.
5708*
7=11mm

Fi
gur
e15:
desi
gnoft
hegearmesh

F.Desi
gnofpi
nionshaf
t

Mat
eri
alsel
ect
edf
ort
hishandl
eist
hest
eel45whi
chi
schosenf
ort
het
ap
bol
tswi
thy
iel
dst
rengt mm2.
hof360N/

Anal
ysi
s

=0.
5* mm2=180N/
360N/ mm2

Assumi
ngaf
act
orofsaf
ety1.
5,t
heal
l
owabl
eshearst
ressbecomes,

mm2
120N/

Letdp=pi
nionoft
heshaf
t

47
Weknowt
hatt
orqueont
hepi
nion,

T=131300Nmm andl
engt
hofpi
tchconeel
ement
,

L =64mm

Meanr
adi
usoft
hepi
nioni
sknownas

16.
6mm

Weal
soknowt
hatt
angent
ial
for
ceact
ingont
hemeanr
adi
usi
s

=7927.
55N

Axi
alf
orceact
ingont
hepi
nionshaf
t

Andr
adi
alf
orceact
ingont
hepi
nionshaf
t

Thenbendi
ngmomentduet
oWRH,
WRVandt
heappl
i
edf
orcebyt
heuser
,

Andbendi
ngmomentduet
oWT

Thenr
esul
tantbendi
ngmomentont
heshaf
tbecomes,
48
 M =M12 +M22
=1615272 +396377.
52 =428025.
8Nmm

Si
ncet
heshaf
tissubj
ect
edt
obot
htwi
sti
ngandbendi
ngmoment
,equi
val
entt
wist
ing
momentbecomes,

Teq =M2 +T2

82 +1313002 =447711.
=428025. 71Nmm

Thent
ofi
ndt
hedi
amet
er,

π
Teq = * τ *d3
p
16 all
π
447711.71 = * 120*d3
p
16
dp =26.6say27mm

Remar
k

Weknowt
hatt
orqueont
hepi
nioni
s131300Nmm andar
mradi
usoft
he
handl
eis250mm,di
vi
dingt
hef
ir
stv
aluebyt
hesecondwegett
hef
orce
t
hathav
etobeexer
tedbyhand,525Nwhi
chi
slar
gert
hant
heav
erage
v
aluest
atedpr
evi
ousl
y.Sof
ormaxi
mum l
oadi
ngwhi
chi
srar
eatt
he
wor
kshopst
woper
sonswi
l
lbeneededf
ort
heoper
ati
oneachexer
ti
ng
263N.

49
 Fi
gur
e16:
desi
gnofshaf
tfort
hepi
nion

F.Desi
gnoft
hekey

Mat
eri
alsel
ect
ion:

Themat
eri
alsel
ect
edf
orbot
hoft
hekey
s(gearandpi
nion)i
sC-
45st
eelwi
th
y
iel
dst
rengt mm2andt
hof360N/ ensi
l
est
rengt mm2.
hof710N/

Anal
ysi
s

Nowassumi
ngaf
act
orofsaf
ety1.
5,wewi
l
lfi
ndt
heper
missi
blest
resses.

τy =0.
5*σy=0.5 *
360N/
mm2 =180N/
mm2
σy 360N/mm2
σall = = =240N/
mm2
F.S 1.
5
yFτ 180N/mm
τall = = =20N/
mm2
F.
S 1.
5

Keydesi
gnf
ort
hegear
Asquar
ekeyi
schosenwi
tht
hef
oll
owi
ngdi
mensi
onsaccor
dingt
oIS:2292and2293-
1974
(
Reaf
fi
rmed1992)f
orshaf
tdi
amet
erof48mm.
Wi
dthofkey =16mm
Thi
cknessofkey =16mm

Thel
engt
hoft
hekey(
1)i
stakenequal
tot
hel
engt
hoft
hehub.

L=1 =1.
5d =1.
5*48 =72mm

Checki
ngt
hei
nducedshearandcr
ushi
ngst
resses
Weknowt
hatmaxi
mum t
orquet
ransmi
tt
edi
s

50
 ,whi
chi
smuchl
esst
hant
heal
l
owabl
eshearst
ress,t
husi
tis
saf
e!

Consi
der
ingt
hekeyi
ncr
ushi
ng,

,whi
chi
sal
sol
esst
hant
heal
l
owabl
ethus
t
hekeyi
ssaf
e!

G.Keydesi
gnf
orpi
nionshaf
t(handl
e)

Accor
dingt
othesamest
andar
dusedf
ort
hegear
,ISf
orshaf
tdi
amet
er27mm
asquar
ekeywi
l
lhav
ewi
dthandt
hicknessof10mm.

Lengt
hoft
hekey=L=1.
5*d=1.
5*27=40.
5mm

Checki
ngt
hei
nducedshearandcr
ushi
ngst
resses,weknowt
hatmaxi
mum t
orque
t
ransmi
tt
edi
s

,
whi
chi
ssaf
e!

Consi
der
ingt
hekeyi
ncr
ushi
ng,

,whi
chi
sal
soi
ntheal
l
owabl
eli
mit
,thus
saf
e!

H.Desi
gnoft
hegearhouse

Thegearhousesuppor
tst
hescr
ew,
gear
,pi
nion,
handl
eandt
wobear
ings.I
tis
bol
tedt
othebasebyt
apbol
ts.
51
Mat
eri
alsel
ect
ion:

Mat
eri
alsel
ect
edf
ort
hiscomponenti
sthesamecasti
ront
hatwehav
e
usedear
li
erf
ort
henutwi
thy
iel
dst
rengt mm2
hof310N/

Assumi
ngaf
act
orofsaf
ety2al
l
owabl
ecr
ushi
ngst
ressbecomes,

mm2
=155N/

Desi
gnofbol
tsf
ort
hehouse

Themat
eri
alchosenf
ort
hesebol
tsi
sC-
45st
eel
ast
hecapbol
ts.

Yi
eldst
rengt mm2
h=360N/

Tensi
l
est
rengt mm2
h=710N/

Assumi
ngaf
act
orofsaf
ety1.
5,

473. mm2
33N/

Letwbet
hel
oadi
nabol
tperuni
tdi
stanceduet
othet
urni
ngef
fectoft
he
gui
deandl
etW1bel
oadoneachoft
hebol
tsatdi
stanceL1f
rom t
hebase.

Weknowt
hatdi
rectt
ensi
l
eloadcar
ri
edbyeachbol
tis,

=18393.
75N

Unl
i
ket
hecapbol
ts,t
hesef
ourbol
tsshar
eequalamountofl
oadsi
ncet
heyar
e
equi
dist
antt
othel
oadwhi
chi
satt
hecent
er.

Nowl
etdcbet
hecor
edi
amet
eroft
hebol
t,

dc=7.
03say8mm,
andf
rom I
S4218r
eaf
fi
rmed1996IchoseM-
10

52
 Fi
gur
e17:
desi
gnoft
hegearhouse

Sel
ect
ionofbal
lbear
ings

Thebear
ingschosenf
orscr
ewshaf
tandhandl
eoft
hepi
nionar
esi
ngl
e
r
ow deepgr
oov
ebal
lbear
ing.Formachi
nesusedi
nter
mit
tent
lywhose
br
eakdownwoul
dnothav
eser
iousconsequences,
thel
i
feoft
hebear
ing
i
staken4000hour
s(LH)
.

Nowwehav
etocal
cul
atedy
nami
cloadf
act
orf
ir
sti
nor
dert
ochooset
hebear
ing,

Wr(
radi
all
oad)=1945.
39N,

Wa(
axi
all
oad)=647.
14N,
andN=15r
pm

Li
feofbear
ingi
nrev
olut
ions(
L)=60N*
LH =60*
15*
4000=3600000r
ev.

,t
aki
ng, =0.
5fr
om t
abl
es

X=0.
56andY=1.
2

53
Nowdy
nami
cequi
val
entl
oadf
act
or,

,
taki
ngvas1

Ser
vicef
act
orKs f
orbal
lbear
ingsi
s1,sobear
ingshoul
dbesel
ect
edf
or
1865.
99N

Nowweknowt
hatbasi
cdy
nami
cloadr
ati
ngi
s

=2.
9KN

Taki
ngt
heabov
eval
uef
rom st
andar
dIndi
ancat
alogIhav
echosenbear
ing
number200.

I
.Desi
gnoff
oot
-st
epbear
ing

Thebear
ingsel
ect
edf
ort
heupperendoft
hescr
ewspi
ndl
eisf
oot
-st
ep
orpi
vott
ypet
hrustbear
ingbecausei
tal
l
owst
heshaf
ttor
otat
einsi
dei
t
wi
thoutenabl
i
ngi
ttoadv
ancev
ert
ical
l
yandi
t’
sal
sosui
tabl
eforsl
ow
r
unni
ngandl
i
ght
lyl
oadedshaf
t.Si
ncet
heweari
spr
opor
ti
onalt
othe
v
eloci
tyofr
ubbi
ngspeed,
rubbi
ngv
eloci
tyi
ncr
easeswi
thi
ncr
easi
ngr
adi
i
f
rom t
heaxi
soft
heshaf
t.Ther
efor
e,wearmaxi
mum att
heout
err
adi
us
andzer
oatt
hecent
er.Tocompensat
ethi
sscr
ew-

54
shaf
tissuppor
tedonapi
l
eofdi
scsasshownbel
ow.

Fi
gur
e18:
sect
ionoff
ootst
epbear
ing

Thebear
ingi
smadeupoft
hesamecasti
ront
hatwehav
ebeenusi
ngwi
thal
l
owabl
e
bendi
ngst
r mm2
essof103N/

Let
,

W =Loadsuppor
tedatt
hecent
er,

α=Di
stancebet
weencent
ersofhol
dingdown
bol
ts, l
=Lengt
hoft
hebear
ing,
andt=Thi
cknessoft
hecap.

Weknowt
hatmaxi
mum bendi
ngmomentatt
hecent
er,

55
 W*a
M = ,
andt
hesect
ionmodul
usoft
hecap,
4
0.
5* t*
l
Z=
6

Bendi
ngst
ress,

M 2W ⋅
a
σb = = 2
Z 2lt
3Wa 3* 73575*80
t = = =37.
7say38mm
2σbl 2*103*60

Checki
ngf
ordef
lect
ionoft
hecap,

W*a3
δ = 3
4tEI
803
73575*
= =0.
12mm,
(accept
abl
e)
4*
200000* 383
60*

Nowdesi
gnf
orhol
dingdownbol
ts

Themat
eri
alchosenf
ort
hesebol
tsi
sC-
30st
eell
i
ket
hescr
ewbecauseofi
tsst
rengt
hand
av
ail
abi
l
ityi
ntheAMI
MTDE.
Yi
eldst
rengt
h =300N/
mm2
Tensi
l
est
rengt
h =500N/
mm2

Si
ncef
ail
ureoft
heset
apbol
tsi
scat
ast
rophi
ctohumanl
i
fe,
weassumeaf
act
orofsaf
ety
4.

σt 500N/mm2
σall = = =125N/
mm2
F.S 4

4W
Thel
oadoneacht
apbol
tist
aken33%hi
ghert
hant
henor
mal
load,
whi
chi
s .
3n
dc =cor
edi
amet
er,

56
 4W π
= * σ* d2
c
3n 4 t
16W
dc =
3nπσt
16*
73575
= =22.
4say23mm accor
dingt
oIS4218r
eaf
fi
rmed
3*2*π*125

1996M27t
apbol
twaschosen.

Fi
gur
e19:
desi
gnf
ootst
epbear
ing

J.Desi
gnoft
hebase

Thebasewhi
chsuppor
tst
hewhol
est
ruct
urehasadi
mensi
on500 ×1500×100whi
chi
s
madef
rom casti
ron,
ismanuf
act
uredei
therbywel
dingsev
eralmachi
nebasest
oget
heror
bycast
ingpr
ocess.Thi
scasti
roni
sthesamemat
eri
alt
hati
susedt
odesi
gnt
hegui
de.The
Lshapehandl
ebar
sar
ewel
dedt
othegui
det
opr
ovi
dest
abi
l
ityandeasyhandl
i
ngt
othe
machi
neasshownbel
ow.

57
 Fi
gur
e20:
desi
gnoft
hebase

Noanal
ysi
sisdonef
ort
hebasesi
nceheav
iestmachi
nesl
argert
hant
hisscr
ewdr
iven
f
orkl
i
ftuset
hist
hicknessorl
ess100mm.

K.Desi
gnofLeg

Thel
egi
soneoft
hepar
tswhi
chconnectt
hebaset
othewheel
.Thel
egi
smanuf
act
ured
f
rom t
hesamemat
eri
all
i
ket
hebase,casti
ront
ypeA.I
tismadef
rom wel
dedmet
albar
s
f
ormi
ngaf
ramet
oget
heri
nsuchawayt
otr
ansmi
tthel
oadst
othewheel
s

Fi
gur
e21:
desi
gnoft
hel
eg

58
L.Sel
ect
ionofwheel

Thewheel
schosenf
ort
hismachi
near
enott
heor
dinar
yty
pest
hatar
e
madeupofr
ubberf
il
ledwi
thai
r.Rat
herar
oll
ermet
alcov
eredwi
th3600
r
evol
vi
ngmechani
smsl
i
kebear
ingi
susedbecauset
hesewheel
scar
rya
l
arge amountofl
oad.Fourwheel
s ar
e at
tached t
othe l
eg.Thei
r
mi
nimi
zedcont
actar
eahel
pst
heoper
atort
opusht
hem wi
thal
i
ttl
e
ef
for
t.Thewheel
sar
eav
ail
abl
einAMI
MTDE.

M.Wel
ddesi
gn

Wel
ddesi
gnf
ort
hegui
de:
Nowt
hegui
dei
sat
tachedt
otheL-
shapewhi
chi
ntur
nisat
tachedt
othebase.Thegui
dei
s
wel
dedt
othepl
atebyt
oident
ical
fil
l
etwel
ds.

Let
,T=t
orqueact
ingont de1 =l
hegui engt
hoft
hewel
d
s=si
zeoft
hewel
d
t=t
hroatt
hickness,
and
J =pol
armomentofi
ner
ti
aoft
hewel
dsect
ion
3 3
x|
| x|
|
J =2× = Ther
otat
ionduet
othet
orquei
sresi
stedbyshear
ingst
ressdev
eloped
12 6
bet
weent
ofi
l
letwel
dsandt
hehor
izont
alpl
ate.
shearst
ressatt
het
hroati
sgi
venby
:

T*
0.5l*6 3T
τ= 3
= 2
t*l t*
l

hatτall (
Weknow t all
owabl
emaxi
mum shearst
ress)i
nthewel
dusi
ngbar
eel
ect
rodei
s
55N/
mm2

T =2943000Nmm
L=200mm
t=0.
707s,
then

59
 3T 3T 4.
242T
τall = 2= 2
= 2
t×l 0.707s×l s×l
4.
242*2943000
55 =
s×2002
s =5.
67say6mm
t =0.
707s=0.
707*
6 =4.
24mm

Nowt
hewel
ddesi
gnf
ort
hehandl
eoft
hebase:

Fi
gur
e22:
handl
ewel
d

Theonl
ydi
ff
erencewi
tht
hepr
evi
ouswel
disonl
ythel
engt
h.L=50mm

s=90.
7say91mm
t=0.
707s=0.
707*
91=64.
33mm

Wel
ddesi
gnoft
hef
ork
60
Thef
orki
scomposedoff
ourcomponent
swel
dedt
oget
herasshown
bel
ow.t
wot
ypesofwel
dsar
eusedf
ort
hispur
pose,
fil
l
etandbutwel
ds.

Let s=si
zeofwel
dinmm,t=t
hroatt
hicknessi
nmm l=l
engt
hoft
he
wel
d

Thewel
dissubj
ect
edt
odi
rectshearst
ressandbendi
ngst
ressduet
othemoment
.

Fi
gur
e23:
for
kwel
d

Ther
ect
angul
arboxwi
thwhol
eatt
hemi
ddl
eisf
il
letwel
dedt
othet
wo
i
dent
ical
lef
tandr
ightf
orkswi
thi
tsei
ghtsi
des.Wedesi
gnf
oronesi
dewel
d
atmaxi
mum l
oadi
ngwi
thi
tsmi
nimum wel
dlengt
h.

Nowf
ir
stf
ort
hef
il
letwel
dwehav
eknownpar
amet
ers,

P=4905N,

Eccent
ri
cdi
stance=e=610mm

l
=100mm

Al
l
owabl
eshearst
ressoft
hewel mm2
d=55N/

Nowar
eaatt
het
hroat
,

=141.
4s

61
 ,
and

= =2992050Nmm

Sect
ionmodul
usoft
het
hroatbecomes

4smm3
=2357.

mm2
N/

Weal
soknowt
hatmaxi
mum shearst
ress, maxbecomes:

s= =11.
6say12mm

Desi
gnofwel
dtot
hegui
dehol
der

Theonl
ydi
ff
erencewi
tht
heabov
eonei
sthatt
heeccent
ri
cit
yoft
hel
oadand
l
engt
hoft
hewel
dgotl
arger
.

e=800mm

l
=500mm

=707s

,
and

62
 =3924000Nmm

Sect
ionmodul
usoft
het
hroat
,

46smm3
=58934.

mm2
N/

Weal
soknowt
hatmaxi
mum shearst
ress, maxbecomes;

s=0.
6say2mm

63
 CHAPTERFI
VE

5.CONCLUSI
ONANDRECOMMENDATI
ON

5.
1Concl
usi
on

Tosummont
hepr
ojectf
ocusesonconcept
ualdesi
gnbyconsi
der
ingsomeusef
ul
par
amet
ersl
i
ke manuf
act
ure abi
l
ity by consi
der
ing t
he capabi
l
ity of AMI
MTDE
wor
kshop,
easymai
ntenancewi
thi
nit
sowncompanywor
kshop,
easi
eri
noper
ati
onand
bysel
ect
ingmat
eri
alsav
ail
abl
ewi
thi
nthemar
ketandi
nthewor
kshop.Thedet
ail
desi
gnoft
hepr
ojecti
smai
nlyf
ocusedont
hebasi
cdi
mensi
onandst
ressanal
ysi
s
t
hroughmachi
nedesi
gnconcept
s.Thedet
aildr
awi
ngofcomponent
sandassembl
y
wasdoneusi
ngsol
i
dwor
ks.

5.
2Recommendat
ions
5.
2.1Recommendat
ionToAMI
MTDE

Webel
i
evet
hedesi
gni
simpor
tanti
nsav
ingunnecessar
yhumanl
aborandef
fect
ive
wayofmount
ingandt
ranspor
ti
ngmachi
necomponent
sincr
owdedwor
kshops.Thus,
wehi
ghl
yrecommendAMI
MTDEt
ohav
eaddi
ti
onalt
estandf
abr
icat
ethepr
otot
ypef
or
t
echnol
ogydi
ssemi
nat
ioni
nsi
mil
arar
easoft
hest
udy
.

 Fur
therpr
ojectwor
kshoul
dbedonebymodi
fyi
ngt
hedesi
gnandt
est
ingi
nthe
f
utur
etost
rengt
hent
hepr
ojectout
put
.

 Thecompanyshoul
dber
eadyf
ori
nter
nshi
pst
udent
sbypr
epar
ingpr
ojectt
asks
andmot
ivat
ionst
oachi
evet
hisi
nter
nshi
ppr
ogr
am.

 Ther
eisnor
esear
chanddev
elopmentdepar
tment
,thi
scausest
hewor
ker
stohav
e
l
esssenset
oupgr
adet
hei
rknowl
edgeandi
mpr
ovet
hiscompany

 Thecompanywor
keri
sconsi
der
edt
hati
nter
nshi
pst
udent
sar
enotper
for
m any
t
askand

 Thecompanymustbemanagedandar
ranget
het
imet
ododi
ff
erentt
aski
n
r
otat
ion,
rat
hert
hanper
for
m si
ngl
etaskdur
ingi
nter
nshi
pper
iod

64
5.
2.2Recommendat
iont
oBDU

Thi
sint
ernshi
ppr
ogr
am of
fer
sal
otofadv
ant
agest
othest
udent
s,asment
ioned
abov
e,f
ori
nst
ance,i
thel
pedmet
odev
elopnotonl
ypr
act
icalexper
iencebutal
so
t
heor
eti
calknowl
edger
elat
edt
omyacademi
c,mysoci
alski
l
lsandcar
eergoal
s.
Becauseoft
hisandal
lthel
i
stedadv
ant
agesabov
ewewoul
dli
ket
orecommendour
uni
ver
sit
ytokeepgi
vi
ngt
hisgr
eatchancef
ort
hest
udent
s.

TheUni
ver
sit
ycanal
soshar
eusef
uli
deaandexper
iencesf
rom ot
herUni
ver
sit
ies,
SomeUni
ver
sit
ysendi
tsst
udent
stoEur
opeandot
hercount
ri
esout
sideEt
hiopi
ato
bui
l
dbr
idgebet
weent
hedev
elopedcount
ri
es.

The Uni
ver
sit
yIndust
ri
alLi
nkage of
fi
ce shoul
d send r
equestorannounce t
othe
compani
es ear
li
ert
othei
nter
nshi
pper
iodsot
hatt
hecompanywi
l
lhav
ereser
ve
pl
acet
othei
nter
ntohosthi
m/her
.Inaddi
ti
ont
othi
stheUni
ver
sit
yIndust
ri
alLi
nkage
shoul
d cr
eat
e awar
eness f
orpr
ivat
e and gov
ernment
alor
gani
zat
ions how t
his
i
nter
nshi
ppr
ogr
am i
sver
yusef
ult
oourcount
ryandot
herconcer
nedpeopl
eusi
ng
possi
ble means ofcommuni
cat
ions i
ncl
udi
ng adv
ert
isi
ng i
n medi
a.Gener
all
y,t
he
benef
itoft
hisi
nter
nshi
ppr
ogr
am f
orpr
oduci
ngef
fi
cientengi
neer
sisunquest
ionabl
eif
pr
oper
lyhel
d.

5.
5.2.
3Recommendat
iont
oourdepar
tment

Thef
acul
tyofmechani
calmakeoppor
tuni
tyandcommuni
cat
ionswi
thanycompanyt
o
ar
ranget
hest
udentt
owel
lknowcompany
.Thef
acul
tymustar
rangebef
orei
nter
nshi
p
per
iod,t
ovi
si
tsomecompanyt
oreduceanyconf
usi
ondur
ingl
ear
ningt
ime.Especi
all
y
f
ormechani
caldepar
tmentst
udentbef
oret
aki
ngdesi
gncour
set
heymustbev
isi
t
somecompanyt
hatar
eimpor
tantt
oper
for
mthei
rdesi
gnv
erywel
l
.

65
REFERENCES

1.Er
ikOber
g,Fr
ankl
i
nD.Jones,Hol
brookL.Hor
ton,andHener
yH.Ry
fel
.(2004)
.
Machi
ner
y'
sHandbook.NewYor
k:I
ndust
ri
alPr
essI
nc.

2.Fer
dinandP.Beer
,E.
Russel
lJohnst
on,JohnT.Dewol
f,Dav
idF.Mazur
ek.(
2012)
.
Mechani
csofMat
eri
als.NewYor
k:McGr
awHi
l
l.

3.Hi
bbel
er,R.(
2004)
.Engi
neer
ingMechani
c,St
ati
cs.New Jer
sey
:Pear
sonPr
ent
ice
Hal
l
.

4.Hi
bbel
er,
R.C.(
2011)
.Mechani
csofMat
eri
als.Bost
on:
Pear
sonPr
ent
iceHal
l
.

5.Mai
tr
a,G.M.(
2001)
.HandbookofGearDesi
gn.NewDel
hi:
McGr
awHi
l
lPubl
i
shi
ng.

6.Mi
schke,S.(
2006)
.St
andar
dHandbookofMachi
neDesi
gn.New Yor
k:McGr
aw
Hi
l
lsPubl
i
sher
.

7.R.
S.Khur
miandJ.
K.Gupt
a.(
2005)
.A t
extbookofmachi
nedesi
gn.New Del
hi:
Eur
asi
aPubl
i
shi
ngHouse.

8.Ti
moshenko,S.(
1998)
.St
rengt
hofMat
eri
als.Tor
ont
o:D.VanNost
randCompany
,
I
nc.

9.www.
algood-
cast
ers.
com.(
n.d.
).

10.
www.
ercc.
gov
.et
.(n.
d.)
.

11.
www.
schi
oppa.
com.
br.(
n.d.
).

12.
www.
wiki
pedi
a.com.(
n.d.
)

66
 PART
DRAWI
NGS

67
68
 4 3 2 1

F F

E E

D D

C C

B B
UNLESS OTHERWIS
FE
I
NIS
: DEBURA
RND
DIMENSIONSAREI
NMILLIMETERS BREAKHARP DONOTSCALEDRAWI
NG REVI
SION
SURFACE EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SI
GNATU
ER DAT TI
TL
DRAW
CHK'
D
APPV'
D

A
MFG
Q.
A MATERI
AL DWGNO.
A
A
WEI
CASTI
GHT:
RON
SCALE:
1:20
BAE SHEET 1 OF

4 3 2 1 69
 4 3 2 1

F F

E E

D D

C C

B B
UNLESSOTHERWISESPECIFI
EDF
:I
NIS: DEBURR
AND
DIMENSIONSAREI
NMI LLI
METERS BREAKS
HARP DONOTSCALEDRAWI
NG REVI
SION
SURFACEFINI
SH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SI
GNATU
ER DATE TI
TL
DRAWN
CHK'
D
APPV'
D

A
MFG
Q.
A MATERI
AL: DWGNO.
A
A4
WEI
GREYCASTI
GHT:
RON
SCALE:
1:20
GUI
DE SHEET1OF1
70
4 3 2 1
71
72
73
74
75
 4 3 2 1

F F

E E

D D

C C

B B
UNLESS OTHERWI
SE
FI
NI: DEBUR
AND
DIMENSI
ONS ARE I
N BREAK
HAR DO NOT SCALE REVI
SIO
SURFACE EDGE
TOLERANCE

NAM SI
GNAT
E DAT TI
T
DRAW
CHK'
APPV'

A
MF
Q. MATERI
A DWG A
A
WEI
GREYCARN
GH
ST
SCALE:
1:
GU
D SHEET 1

4 3 2 1

76
77
Fi
gur
e24:
Assembl
ypar
t

78
79