Student’s declaration:

We had been the internship program in ‘Amhara metal industry and Machine Technology
Development Enterprise’ for the consecutive four months from November 2018 to Jun 2018 with
a good participation. We declared that the prepared final internship report is given below. We
declare that, this paper is our own internship paper. We approved by our signature and by our
academic mentor supervisor certify this.

Name; signature

1. LUEL GETYE -------------------------

2 MIKIYAS …………………….

3 GETANH ………………………

Bahir Dar Institute of Technology

Approved by; signature

Company supervisor: ---------------------------------

Academic mentor

Mr. Netshanet Signature------------------------------

 Acknowledgment

First of all we would like to thank Almighty God for giving us health, strength, and stamina to
prepare this report. Next to this, we would like express our sincere gratitude to our advisor Mr.
Netshanet and Mr Yibeltal for there invaluable guidance and support in checking, commenting
and giving constructive advices all along our report work.
We would also like to thank to Bahir Dar University, especially mechanical Engineering
department and our mentor, for giving this fantastic chance to improve our practical skill and to
consolidate our theoretical knowledge. Finally, we would like to acknowledge the workers of
AMIMTEDE for supporting, guiding and advising us during the internship period
 Executive summary

Amhara metal industry and machine technology development enterprise (AMIMTDE)

established in 1985 by the name of Bahir Dar Rural Technology Promotion Center with the aim
of multiplying of and popularizing agricultural implements, rural industry development and rural
energy development team. But after 1996, after the center has been re-organized with the
objective of supporting the sustainability of the agricultural development in the region through
design, testing and promoting agricultural implements. During this time it was rearranged in
prototype design and studies and production and maintenance team. Finally in 1999 the name of
the center changed to Bahir Dar Agriculture mechanization and Food Science research center
and started to conduct research on generating/selecting, developing, adopting and it promotes
appropriate agricultural, and mechanization technologies at the regional level. In our internship
program, we are able to learn the techniques relevant to our profession as well as practical work.

This program helps us to aware or makes the students: how to convert the theoretical
knowledge in to practical one, how much the theoretical parts converted in work practically in
the company, how the working condition is in the company concerning with the information
flow, how to communicate with each other, and we have gained to assert the leadership as well
as entrepreneurial skill. In this document design of major components of the automatic multi
spindle drilling machine with cost analysis and detail drawings made by using solid work.

The report has been finalized by clearly giving final conclusion, recommendation, reference and
appendices of the document.
CHAPTER TWO

1. BACKGROUND OF THE COMPANY

Amhara Metal Industry and Machine Technology development Enterprise(AMIMTDE)

undertakes problem oriented agro-ecological based research on pre harvest and irrigation
technologies, post harvesting and processing technologies, animal husbandry technologies and
alternative energy technologies for developments, testing and popularization of need based farm
implement and machinery to increase productivity of the land labor through time line of
operations efficient use of resources, improvement quality of products and comfort of farmers
and reduce drudgery

Figure 1:1 logo of the company

1.1 Brief History of the Company

ANRS Metal Industry and Machine Technology Development enterprise had established by
Regulation no 127/2014 in order to Carrie out the task of manufacturing and Commercializing
metal and Machine technology product and Which is capable &bringing about technological
transformation to the Region. By the way resolving those impediments having to do with the
technological need for, Provisional, Vitalization & teleology within the manufacturing industry
and Agricultural Sector of the country.

The company established in 1985 by the name of Bahir Dar Rural Technology Promotion
Center with the aim of multiplying of and popularizing agricultural implements, rural industry
development and rural energy development team. But after 1996, after the center has been re-
organized with the objective of supporting the sustainability of the agricultural development in
the region through design, testing and promoting agricultural implements. During this time it was
rearranged in prototype, design studies, production and maintenance team. Finally in 1999 the
name of the center changed to Bahir Dar Agriculture mechanization and Food Science research
center and started to conduct research on generating/selecting, developing, adopting and it
promotes appropriate agricultural, and mechanization technologies at the regional level.

Bahir Dar Agricultural Mechanization & Food Research Center, (BAM&FSRC) undertakes
problem oriented, agro-ecology and based research on pre-harvest and irrigation technologies,
post-harvest handling and processing technologies and alternative energy technologies for
developments , testing and popularization of need based farm implement and machinery to
increase productivity of land labor through timelines of operations efficient use of inputs ,
improvements in quality of product, safety and comfort of farmers as well as reduce drudgery.

1.2 Location

The center is located in Bahir Dar city, Keble 07 beside the Papyrus Hotel along the high way to
Addis via Ties Abbey or locally around Amado gebeya. It is situated approximately 11.60’
latitude and 37.38’ longitude. Altitude (m): 1770.

1.3 Mission, Vision and Values of the company

Developing globally competitive technologies and manufacturing industries that are capable of
solving bottle necks in agricultural and industrial sector and insuring sustainable growth by
developing, producing and machine technologies.

Vision

To become one of the top ten technology capabilities in Africa up to 2025 and seeing the developed
region in near feature with great motto “Building Competitiveness.”

Values

 They are passionate about their customers

 Their employees are the heart of their business
 They are committed to deliver exceptional values
  They care about the environment

1.4 Objectives

To realize the economic structural transformation of the region by supporting the manufacturing
industry sector with a technology and for agri cultural technology.

1.5 Activities of the company

The major activities include;

Adaptation of agricultural technologies to the mandated areas

Agricultural technology generation

Promotion of Agricultural technologies in collaboration with other research departments and

others take holders in the region and outside the region.

Recently, in 2008, the Bahir Dar Agricultural mechanization & Food Science Research Center is
organized into Metal Industry and Machine Technology Development Enterprise. It contains
different structures and parts. These are:-

 Varies parts
 Buildings and offices
 Official offices
 Assemble and disassemble part
 Design part
 End product showing part
 Training Hall
 Discussion class
 Store room
 Lounge
 Toilet room
 Library
 Machine shops
 Metal fabrication
 Forging and heat treatment
 Material laboratory
 Woodwork and foundry shop
1.6 Maine product or service of the company

The following are the main product or service of the company:-

I. Agricultural equipment manufacturing

Most products of the company are agricultural products, which are valuable for
our country. Because our countries economy is majorly depend on agriculture.
This company simplifies the production method of agriculture. Such thresher,
Sheller, Milking equipment and harvesting technology

Figure1. 1 : agricultural equipment’

II. General equipment manufacturing

The company has functional and general machines that can manufacture various products for
general purpose. Some examples of general equipment manufacturing machines are

Manufacturing and selling machine spare part

Advising and training service

Shed construction for large store/reservoir etc.

III. Food processing equipment manufacturing

Since, food is one of the basic needs for human being the company plays a great role for a
society by importing different food oven machines. Nowadays, eating three times in a day is
becoming very difficult. So, the organization can solve this burning problem.
Figure1.3: food manufacturing equipment

Environmental protection equipment manufacturing and supplier

Envairomental problem is also a burning issue just like that of food problem, espsifically; the
problem which occurred in Addiss Ababa, Koshy. To solve this type of problem the company
plays a great role by manufacturing machines which can recycle the waste plastic materials.

IV. Transportation equipment manufacturing

In developing countries especially, in Ethiopia transportation is a headache for the people.
Because most societies are unable to use their own transportation. So, the company assists the
people by manufacturing local and cheap transportation equipment’s.

Figure1.4: transportation equipment

1.7 Main consumers or end user of the product to the organization

 The main product user organization are;

 Enterprises
 Awscod
 Different industries
 Some NGOs
 Universities for research
 Rural developments of Agriculture
 Universities
 Graduate and post graduate students
 Different factories
 Researchers
 Ministry of health
 Agricultural research institutes
 Different governmental and nongovernmental organization
1.8 Organizational structure of the company
Figure2.5: organizational structural of the company

1.10 Work flow

Figure1.10: work flow of the company

1.10workshops of the Company

1 machine shop- is one of the workshop in which machining operations are performed
like turning, drilling, facing e.t.c. some of the machines found in machine shop are

1.1 .Lath machine

Lathe is one of the most versatile and widely used machine tools all over the world. It is
commonly known as the mother of all other machine tools. The main function of a lathe is to
give the materials required shape and size.
 Figure1.11: lathe machine

1.12. Milling machine

Milling is a machine that the metal or work piece is cut by means of a rotating cutter having
multiple cutting edges. For cutting operation, the work piece is fed against the rotary cutter. As
the work piece moves against the cutting edges of milling cutter, metal is removed in the form of
chips. There are different types of milling cutters.

Figure1.13 end mill mahine

2 Welding shop- is one of workshop in which joining of two part(metal) takes place by
using different joining processes. Some of the welding machine found in welding shop
are

2.1 NC gas cutting machine

NC cutting machine is operated with acetylene gas which used to cut different shapes such as,
curve circle and ellipse.

Figure1. 14: NC gas cutting machine

3 sheet metal workshop- is one of the workshop in which shearing, bending

operations performed. Some of the machines found in this shop are

3.1 Shearing machine and fish polarizer

Shearing machine is used to cut sheet metals by shearing action whereas; fish pelletized is used
to mix food of fishes.
Fig 1.15- Hydraulic shearing machine

Figure1. 16: pneumatic shearing machine

4 Wood and foundry shop- in this shop different wood patterns and funitures are
manufactured and also sand moulds are made. Some of the machines found in the shop
are
Fig 1.17- mortizer machine fig 1.18 - wood plainer

Fig 1.21 circular saw fig1.20 vertical belt Sandler

Fig 1.22-Wood lathe machine
CHAPTER THREE

2. OVERALL INTERNSHIP EXEPERIENCE

2.1 introductions

Primarily; like any other students, after BDU gives us the application paper for the companies we
were searching; the companies which can accept and which company is change our theoretical
knowledge in to practical. Finally, we decided to be here we applied to Amhara Metal Industry
and Machine Technology Development Enterprise after then, their response was positive. Before
proceeding to any of our activities we got our contacting person Mr. Woldie who is manager of

the company. We were talking with him clearly and he told as we start to attend the practice on,
November, 11. 2017.

In the first week, we have visited the workshops and various machines as well as wrenches
which are existed in the company based on rough orientation of metal shop director Mr.,
Alemayehu he is next manager to Woldie for the company In week two we have seen machine
installation and erection of machines such as, lathes, drilling machines, power hack saw
machine, milling machines, hydraulic press machine, gas welding machine, gas cutting machine
and hydraulic bending machines

2.2 Benefits that we have gained from the internship

Internship is one method of making college students potentially valuable and explore career
avenue as well as specific companies .It is also very important to relate the application of what
we learned theoretical knowledge to practical one, improve interpersonal communication skills
and understanding about work ethics as well as entrepreneur skill.

Internship helps to applying our theoretical knowledge to practical experience and working with
others. The internship program helps us to know by touching and looking practically that we
have learnt theoretically before. We have gained the following benefits

Creativity and an innovative approach to solve problems

Upgrading our knowledge to solve problems such as; Agricultural and industrial problems.
  The ability to manufacture materials
 The ability to design, and manufacture
 Understanding about machine operations practically
 Effective assessment and management of risks, resource and time
 The ability to analyze and approach difficult works
In addition to relating the practical knowledge with theoretical one; it also helps us to consolidate
and upgrading of our previous theoretical knowledge by visiting and working on different
machines. We have also acquired more knowledge about design and manufacturing.

Improving team work, Team work has a dramatic effect on one’s organizational performance.
An effective team can help the organization to achieve goals. We have understood that team
work is an essential thing to solve problem and nothing is impossible when we work together.
Team work also helps us to strength our communication skill and to generate different ideas
which can solve various challenging problems. Generally, our team playing skill helps us to
improve the following qualities.

 To communicate constructively
 To be active participant
 Cooperate and help others
 To tolerate differences
 Showing commitment to the tea
Generally During the internship period with respect to leadership skills we have learned and
convicted to have the following attributes to be successfully

Ethical work enables us to posses’ appropriate behaviors in the work and so we developed proper
relationship with coworkers and it enables us to create good working environment. We have
improved such the following ethics.

 Concern for the wellbeing of others  Punctuality

 Honesty  Be inevolence (doing good)
 Fairness  Be hard worker
The following are the common professional ethical principle what we are gaining during the
internship period.

i. Punctuality- means keeping the companies work beginning and ending time and
to complete a given task within a given period
ii. Office discipline-in work place you should not disturb the working environment
for example opening loud voice, loud music, songs and things which disturb other
worker’s working mood
iii. Reliability-the workers should be qualified for part he is supposed to be
performing
iv. Honesty-regarding this value each worker regardless of its status should abstain
from bad behavior such as; cheating, bias and corruption
We are also improving our interpersonal communication skill. The purpose of communication is
to get our message across to others clearly and without ambiguity. Inability to communicate with
office mates makes it nearly impossible to compute effectively in the work place and sharing
constructive ideas and to generate new and difference ideas which are very important for creative
nesses and entrepreneurship of the students.

Generally, without smooth communication with coworkers there is no satisfactory success on our
job. We have got the following basic experiences from our internship period.

How to communicate with people operating on machines and shops

How to express ideas freely accordingly

How to communicate with people working in different companies

Improve communication during team work which is very important

2.2 Metal Fabrication

Metal fabrication is the main shop to the company because it is doing parts that to manufacture
every types of proto type and it is the back bone of the industry. Therefore more manufacturing
is taking place from these shops. Some of these are bending of pipes mechanically cutting and
grinding and welding of frames and colons, shearing of sheet metals and other supervision
activities. When we were doing these activities and have been using various types of work piece.
Such as; pipes, Mild steel, HSS sheet metal, and RHS. And the tools that we were using to
accomplish these tasks are squadron for adjusting of the equipment during assembly and grinder
for cutting of pipes and RHS.

2.3 The engineering Methods Tools and Techniques

In Amhara metal industry and machine technology development enterprise(AMIMTDE) Use

Rivers engineering and it manufactures different types modified machine parts such that gear,
shaft and other types machines.
 2.4 Major challenges and problem

1. All machines are old, used and huge for no reason. And also some machines are some times
blocked

2. There is shortage of organized data; reference books and no permission to students copy any
material from the company.

3. The company has no pocket money & other benefits for the students; like work clothes and
soap for cleaning.

4. Shortage of man power on mechanical engineering so it becomes difficult for me asking &
getting real information

5 The company has high wastage of material means in producing time high scraps their

2.5 propose as a solution /recommendation to the company

The recommendation to the company at the time to produce or manufacture the product has high
wastage or scraps and with in this cause the company will not be profitable and not achieve the
aim of the goal. But to prevent this wastage we would have to search solution for that how to
prevent wastage or scraps.

The solution for the problem is to design and manufacture Furnace for molding the scraps.

If the design is success and manufacture then it will reduce the wastage for the company.

2.6 Gained in terms of improving practical skill and upgrade theoretical

knowledge

From the company totally given practical application therefore it is so interesting, joy full and
good skill full than theoretical part and the cause that interesting and joy full through practical
application we were upgrading the theoretical approaches and the formation that good theoretical
one freely doing practical application.

2.7 The gained in terms of improving team playing skill.

Improving team work, team work has a dramatic effect on one’s organizational performance. An
effective team can help the organization to achieve goals. We have understood that team work is
an essential thing to solve problem and nothing is impossible when we work together. Team
work also helps us to strength our communication skill and to generate different ideas which can
solve various challenging problems. Generally, our team playing skill helps us to improve the
following qualities.
  To communicate constructively
 To be active participant
 Cooperate and help others
 To tolerate differences
 To create good approach
 To share experience
 To Showing commitment to the team
In general team playing skill is very important for the organization to be productive and
achieving the aim of the goal and if it archives that goals and the organizations will success.

2.8 The gained in terms of improving leadership skills

Leadership skills can play a large role in career development. Often, your technical skills can
only take you so far. To help someone move forward in his career, you need soft skills such as
the ability to be a good leader. Therefore, leadership skills are considered to be important traits
which can help you get to the top of your career field. And I understood which area can be
controlled in order of more productive and reliable for easiness of the work flow in the factory.
Moreover I made contacts to the manager for to understand the leading condition of one’s
company. And I have learned mostly during the regulation takes place in the industry. Generally,
it made me more confident whenever making a leadership to the future in any organization or an
industry.

2.9 The gained in terms of understanding about work ethics issue, industrial
physiology and related issues

Work Ethics and discipline is one of the major factors for the step to professionalism. Our
supervisor was always advising us that we should be ethical and responsible professionals for the
future. He has been showing how to develop this good behavior during our stay in the company.
By our stay in the company, we were very punctual, daily attendant of the work and responsible
to our professionals. We have been guided and obeyed by the rules and regulations of the
company. Some of the work ethics are as follows:

 Punctuality
  The office discipline
 Reliability
 Honesty
 Cooperation

2.10 The gained in terms of entrepreneurship skill

Enterns, to cope up with this of work, students must be enterprising and flexible, and may need
to become entrepreneurial. Entrepreneurship can be defined as the process of involving the
creation of new enterprises and that the entrepreneur is the founder. The major characteristics of
entrepreneurs that we have been observed in the company such that.

 Self-confident multi-skilled
 Innovative skills
 Results-orientated
 A risk-taker
 Total commitment
2.11 Interpersonal communication skills.

One of the major reasons for reliable work is the work force. Many workers are appointed a task
according to their personal skills. In the duration of the internship, we have been able to ask
different kinds of people from all standards of living. Therefore, we have gained confidence on
how

 To ask different questions

 To make discussions
 To answer questions when asked
 To respond to superior and the like
Generally, from the internship Experience we had been able to upgrade our communication skills
during our internship
2.12 Conclusion and Recommendation

Since, we have gained so many incredible benefits during internship period. Such as; practical
knowledge, team work skill, interpersonal communication skill, entrepreneurship skill and leader
ship skill we can conclude that internship is absolutely important for college students. To create
competitive generation with other developed countries. Every college has to give enough
internship periods beside theoretical knowledge.

In this four month internship practice we have learnt so much practical knowledge, by using
engineering methods, tools and techniques attending at different section of the company. Not
only this but also we have learnt how we can face problems, upgrading theories to practice,
improving team work skill and leadership skill, understanding work ethics, improving
entrepreneurship skill and interpersonal communication. Finally, we would like to give valuable
recommendation for the company. They would be willing to give information about the company
except secret things, to fulfill enough instruments and measurements, old agricultural machines
are simply failed as wastes. The organization will be better keeping those machines safely and
try to repair as much as possible.
CHAPTER FOUR

DESIGN OF AUTOMATIC MULTI SPINDEL DRILLING

MACHINE

Summary of the project

The advancement and growth of any country depends on its manufacturing industries, and in day today
manufacturing workers uses a number of different kinds of tools and machines, and from thus different
kind of machine a drilling machine is one of the most popularly used machine.

Drilling machine is one of the most widely used machines used in the manufacturing industries and they
can be stationary or portable and they are used to drill and form a hole on the desired point and dimension
on the work peace.

In AMIMTDE foundry and wood shop one of the manufactured products are patterns of different kind,
and this pattern work involves the use of a radial arm drilling machine. Since they don’t have this
machine we decide to design a radial arm drilling machine, and in this project we design the components
of drill machine, we perform force analysis, compare the stationary radial arm drill machine with portable
drill machine, and suggest the fabrication process of this machine.

Problem statement

We perform our intern in AMIMTDE wood and foundry shop ,and we notice that they use a portable
drilling machine to drill a hole ,and this portable drill machine is used only for small capacity operations,
requires extra clamping and also it is not accurate, so to solve all the above problems we decide to design
a stationary radial arm drilling machine.

Objective of the project

Main objective

The main objective of this project is to design a stationary radial arm drilling machine that used for
medium and heavy duty activities.

Specific objective
The specific objective of this project is to increase the accuracy of work, to minimize errors and create a
stable working environment, to perform multi drilling operations at once.

Methodology

This study was employed the following methods and procedures regarding study method

 Data collection
 Material selection
 Analysis or calculation
 Design of components
 modeling of design by using solid work
Data collection
In this study the data collection are primary data collection i.e. questionnaire, and
secondary data collection i.e. collecting data basically from documents records and
reports of others.

MATERIAL SELECTION

As per the market study for material selection on the basis of Strength, Hardness, Weld
ability, Availability,
Mach inability and cost it was found out that the Steels of different type are suitable
material for fabrication .

Analysis
After collecting the required data and analyzing and selecting the appropriate material for the
design we start analysis and design of components of drilling machine. The major components of
drilling machine are
1 Motor 6 Table
2 Pulley 7 Column
3 Belt 8 Bed
4 Shafts 9 Lead screw and Nut[2]
5 Gears
Selection of motor
Force and power calculation
Cutting parameter- From CMTI page no 656 table 277 the cutting speed ranges from 20 m/min to
23 m/min. As we are not using cooling fluid therefore the cutting speed is decreased , and also
for multi spindle drilling it is less, so we assume a cutting speed of 18 m/min.
Calculation of RPM of spindle
V=π*d*n/1000
n=1000*v/π*d……………………….Assuming the maximum drilling diameter is 16 mm.
n= 1000*18/π*16
n= 358 rpm = 360 rpm
Feed for drilling
From CMIT page number 656 table numbrer 278 for hole diameter of 16 mm the feed will be
0.15 mm/ rev.

Material factor (K) = 1.5 for 198 HB

= 2.03 for 22 HB
Power at spindle is given by (P) = (1.25 d2Kn ( 0.056 + 1.55))/ 105
= ( 1.25*162*1.5*360*( 0.056+1.55))/ 105
= 0.485 KW= 485 W
The power at one spindel is 485 W, so for 4 spindels the total power will be
Total power( Pt) = P* 4
= 485 W * 4
Total power (Pt) = 1942.4 W
Efficiency of transmission is (nm) considered as 90 %
Power at the motor is given by (Pn) = Pt/ nm
= 1942.4 W/ 0.9
= 2158.2 W
1HP= 746 W so the power at the motor interms of horse power is given by
Pm= (2158.2 / 774) HP
= 3 HP
To ensure continuous running of machine we will use next standard motor, and we select 5 HP
motor.
Torque at spindel
Torque for one spindel is given by (Ts) =975 *( Pt/ n)
= 975 * ( 1942.4/ 360)
 = 5.26 Kgf.m………………( as 1 Kgf.m = 9.81 Nm)
Ts= 5. 26 Kgf.m * 9.81 Nm
= 51.6 Nm
Torque for four spindel is calculated as(T) = Ts* 4= 51.6*4= 206.4 Nm.

Thrust on spindel

Thrust on one spindel is given by ( Thr) =1.16 K*d*( 100* S)0.84

= 1.16*1.5*16*( 100* 0.15)0.84
= 270.8 Kgf
Thr= 270.8 Kgf *9.81 N= 2656.55N
Thrust on four spindel will be = Thr* 4
= 2565.55* 4=10,626 N

Time for drilling ( Td)= L/ (S*n)

= (160 * 10)/( 0.15* 360)
= 3.15 min = 188 sec

SELECTION OF TIMMING BELT PULLEY

Drive ratio ( DR) = speed of faster shaft/speed of lower shaft
= 1000/ 430
= 1.34
Calculation of design power
This is obtainedby multiplying the motor power ( P) by application f1,f2,f3,f4. Design power is
given by
Pd= P( f1+f3-f4)*f2
Where f1- Application factor/ service factor related to the type of driver & driven equipment for
the daily usage.
F2- Application factor/ service factor related to the speed increasing driver.
F3- Application factor if ideler is used then add 0.2.
F4- Application factor if machine only used intermittently or seosonaly deduct 0.2 from
service factor.
In our case
 Pd= P* f1
= 3 HP *1.7
=5.1 KW
Selection of belt pulley
Applying the calculated design power and speed of the smallest pulley to the belt selection graph
for metric series belt and then suitable pitch is selcted. The selected pitch is 14mm ( 14M-
designation).
HTD belt are selected because they provide a more compact, quiter drive and preffered for new
application.
Pulley selection
For economic and availability reasons it is preferable to use pulleys of maximum 80 teeth and to
minimum belt fatigue a minimum of 20 teeth is preferable. Generally 28 teeth, 14M pitch is
standared one andthis is used for dmall pulley.
Using standared drive ratio we select the number of teethh on large pulley. For drive ratio of 2.34
teeth on large pulley is 64,

Thus
Small pulley has 28 teeth and 14M pitch.
Large pulley has 64 teeth and 14M pitch.

Determination of belt length and center distance

Determination of belt leangth
Nc= (2*Ao)/p+ (z1+z2)/2+( 2.533*p*(z2-z1)2)/ (100* Ao)
Where Ao= Approxiately center distance( mm)
P= belt pitch
Nc= (2*50)/14+ (28+64)/2+( 2.533*14*(64-28)2)/ (100* 50)
Nc = 62.33
From standared bellt length table for 63 teeth in belt for 14M pitch belt length will be 966 mm.
Determination of actuall shaft center
A= P/4{ NA-( z1+ z2)/2+{(NA- ( z1+ z2)/2)2-(2.027( z2-z1))10}0.5}
Where NA- number of teeth on belt
A= 14/4{ 63-( 28+ 64)/2+{(63- ( 28+ 64)/2)2-(2.027( 64-28))10}0.5}
A= 77.45 mm
Now calculation of selection power for belt width is
 PS= Pd*FS………………….. Where PS- Selection power
PD- design power
FS- factor of dafety
PS= 5kw * 1
= 5 kw
Also knowingthe size of small pulley and relative shaft speed now belt width factor is calculated
as
WF= PS/ PR…...................where WF- belt width factor
PR- Rated power
WF= 5.1/ 13.51
WF = 0.4
From table using the belt width factor we find rhe belt widt and the belt width is 40mm.
Compound Gear Design

The drill machine will have four spindels so we will use a compound gear . The material selected
for the gear is En36A having SUt= 1200 N/mm2..
En36A is 3.6% nickel-chromium high hardenability, case hardend ( carburizing) steel and reason
we select this material is
 Has high core streanght because it is hardened and tempered and carburized.
 Excellent toughnes and fatigue resistance.
 High surface wear resistance.
As per standared design data we selected gear profile is 20° full depth involute profile.For 20°
pressure angle minimum number of teeth Zmin=17 but due to required speed of spindel and space
consideration the diameter of gear should be less than 100mm.

Number of teeth on gear A ( input gear)= ZA= 32

Calculation of module

For gear A and B

Power (Kw)= 5.1, NM=1000 rpm, NA=NP= 430 Rpm

Factor of saftey= 1.5

Service factor= 1
Number of teeth on A are 32 i.e ZA= 32, b=12m, y= 0.364

Pitch line velocity= 3 m/s……………..assumed

Velocity factor (CV) = 3/(3+V)

= 0.5 m/s

Module is given by

M= [(60*10^6)/π*((Kw*Cs*Fs)/ZP*π*np*Cv*(b/m)*SUt/3*y)}1/3

=[(60*10^6)/π*((5*1*1)/32*π*430*0.5*12*1200/3*0.364)}1/3

= 3 mm

Now pitch circle diameter of gear ( dp)= Zp* m

= 32* 3

= 96 mm

Pitch line velocity (V)= π* dp*np/ ( 60* 1000)

=π* 45 * 430/ (6*10^4)

= 1.01 m/s

Velocity factor ( CV) =3/ (3+ 1.01)

= 0.75

Face width= 12*m

= 12 * 1.4= 17mm

Addendum ( ha)= module (m)= 1.4mm

Dedendum (hF)= 1.25*m = 1.25 * 1.4 = 1.75 mm

Clearance (c) = 0.25*m= 0.25 * 1.4= 0.35mm

Tooth thickness (s ) = 1.571 *m = 1.571 * 1.4 = 2.2 mm

Pitch circle diameter ( p.c.d ) for gear B= ZB/ m

= 150 / 3

= 50 mm

Rpm of gear B= Nb= ( ZA/ZB)*NA= (32/50) *430 = 275 Rpm

For gear c ( Sun gear)- gear B and C are compound gears

NB= NC= 275 RPM

Pitch circle diameter of gear c is 92 mm and number of teeth is ZC= P.C.D/m= 96/3 = 32

For side gear the module is 3mm and the number of teeth is 22. Then the pitch circl diameter will be

P.C.d= ZD * m= 22 * 3 = 66 mm and ND = 400RPM

N:B All four side gears are same dimension. The number of side gears are four so the arrrangement of the
side gear around the sun gear will be

360°/ 4= 90° from each other.

Gear load analysis

Static load on gear

Torque transmission (Mt) = (60 * 10^6* Kw) /2 *π* NP

=(60 * 10 ^6* 3 )/ 2 *π* 430

= 66.6 * 10 ^3 Nm

Tangential load (Pt) = ( 2 * Mt)/ dA

= ( 2 * 66.6 * 10^3)/ 96

= 1387.9 N

Effective tooth load

Pitch line velocity ( V)= (π* dA* nA) / 6 * 10 ^4

= (π* 96* 430) / 6 * 10 ^4

 = 2.16 m/s

Velocity factor (CV) = ( 3+V)/3= 1.72 m/s

Effective tooth load ( PEff)= ( CS * Pt)/ Cv

= (1.5 * 1387.9N )/ 1.72 m/s

=12104.4 N

Beam streangth ( SB) = m* b *(SUT/3)* Y

= 3* 36 *( 1200/3) * 0.364

= 15724.8 N

To avoid tooth failure due to bending, SB> PEff

SB= PEff * f.s

f.s= SB/ PEff

f.s= 15724.8/12104.4

f.s= 1.3 …………. The design is safe

Dynamic Load on Gear

Pd= [21*v (c*e*b + Pt)]/ [21+v (c*e*b + Pt)1/2]…… ………… M.F spotty equation
Gears are having grade 6
Error in tooth profile ( e ) = 8 + 0.63 (m + 0.25( D )1/2)
eA= 8 + 0.63 (3 + 0.25( 96 )1/2) = 11.43 micro meter.
eB = 8 + 0.63 (3 + 0.25( 150 )1/2) = 11.82 micro meter
Total error in tooth profile (e) = eA + eB= 11.43 + 11.82 = 23.25 micrometer
Value of deformation factor ( C) = 1140n/mm2
Pd= [21*v (c*e*b + Pt)]/ [21+v (c*e*b + Pt)1/2]
= [21*2.16 (1140*23.25*36 + 1387.9)]/ [21+2.16 (1140*23.25*36 + 1387.9)1/2]
= 1137.34 N
PEff =G * Pt * Pd
 = 1.1 * 1387.9 * 1137.34
= 2664.03 N
F.s= SB/PEff
= 15724.8/ 2664,03 = 6 …………… the design is safe
Wear streangth
SW = dA * b *Q *K
Ratio factor ( Q) = ( 2* ZB)/ (ZB -ZA)
= ( 2* 50)/( 50- 32)
= 5.55
K= 0.16 *( BHN/100)2
To avoid gear failure due to spitting , SW > PEff . Let F.S = 2
SW= 2* PEff
= 2 * 2644.03 N
= 5328.06 N
SW = dA * b *Q *K
= dA * b *Q *0.16 *( BHN/100)2
BHN= [ (SW * 10 ^4 )/ (dA * b *Q *0.16) ]1/2
=[ (5328.06 * 10 ^4 )/ (96 * 36 *5.5 *0.16) ]1/2
= 132.35….. rounding it to standard value = 140… required hardeness
 Input pulley

Gear B Gear A

Gear d Gear C Gear d

Fig 1.23- meshing gear arrangement

Design of shaft

Design of spindel shaft

Selection of material for shaft

The material selected for the shaft is SAE8620, and the reason for selection of SAe8620 is because

 It has sufficient streangth to resist failure due to breakage.

 It provide rigidity and more stability.
Composition of SAE8620 is 0.2% C, 2% Ni, 1% Cr, 0.15% Mo.

Mechanical property of SAE8620 is - SUT = 800 N/mm2

-Syt = 530 N/mm2

Calculation of permissible shear stress = 0.30 *Syt = o.3 * 530 N/mm2= 159 N/mm2

= 0.18 * SUT = 0.18 * 800 N/mm2 = 144 N/mm2

Select the lowwer value of the two which is 144 N/mm2. Since key ways are present the permissible
shear stress will be

max = 0.75 * permissible stress

= 0.75 * 144 N/mm2

= 108 N/mm2

According to ASME code and maximum shear stress (MSS) theory of failure

max = ( 16/π* d3)* [ ( Kb * Mb)2 + (Kt * Mt )2]1/2

Where Kb – Combined shock and fatigue factor applied to bending moment = 1.5.

Kt – Combined shock and fatigue factor applied to tensional moment = 1.

So using the maximum shear stress theory formula shown above we can calculate the diameter of the
shaft

max) * [( Kb * Mb)2 + (Kt * Mt )2]1/2

Where Mb = (3 * mb)/ (π* d3) = 516882 N/mm2

Mt max *π * d3) /16 =356188 N/mm2

2
) * [( 1.5 * 516882 N/mm2) 2+ (1 * 356188)2]1/2

D = 34.26 mm but the next standard shaft diameter is 35 mm

Design of intermediate shaft

Selection of material for shaft

The material selected for the shaft is SAE8620, and the reason for selection of SAe8620 is because

 It has sufficient streangth to resist failure due to breakage.

 It provide rigidity and more stability.
Composition of SAE8620 is 0.2% C, 2% Ni, 1% Cr, 0.15% Mo.
Mechanical property of SAE8620 is - SUT = 800 N/mm2

-Syt = 530 N/mm2

Calculation of permissible shear stress = 0.30 *Syt = o.3 * 530 N/mm2= 159 N/mm2

= 0.18 * SUT = 0.18 * 800 N/mm2 = 144 N/mm2

Select the lowwer value of the two which is 144 N/mm2. Since key ways are present the permissible
shear stress will be

max = 0.75 * permissible stress

= 0.75 * 144 N/mm2

= 108 N/mm2

According to ASME code and maximum shear stress (MSS) theory of failure

max = ( 16/π* d3)* [ ( Kb * Mb) + (Kt * Mt )]1/2

Where Kb – Combined shock and fatigue factor applied to bending moment = 1.5.

Kt – Combined shock and fatigue factor applied to tensional moment = 1.

So using the maximum shear stress theory formula shown above we can calculate the diameter of the
shaft

D= ( 1 max) * [( Kb * Mb)2 + (Kt * Mt )2]1/2

Where Mb = (3 * mb)/ (π* d3) = 804040 N/mm2

Mt max *π * d3) /16 =517716 N/mm2

2
+ (1 * 517716 )2]1/2

D = 39.55 mm but the next standard diameter of shaft is 45 mm

Design of input shaft

Selection of material for shaft

The material selected for the shaft is SAE8620, and the reason for selection of SAe8620 is because
  It has sufficient streangth to resist failure due to breakage.
 It provide rigidity and more stability.
Composition of SAE8620 is 0.2% C, 2% Ni, 1% Cr, 0.15% Mo.

Mechanical property of SAE8620 is - SUT = 800 N/mm2

-Syt = 530 N/mm2

Calculation of permissible shear stress = 0.30 *Syt = o.3 * 530 N/mm2= 159 N/mm2

= 0.18 * SUT = 0.18 * 800 N/mm2 = 144 N/mm2

Select the lowwer value of the two which is 144 N/mm2. Since key ways are present the permissible
shear stress will be

max = 0.75 * permissible stress

= 0.75 * 144 N/mm2

= 108 N/mm2

Twisting moment ( Mt ) = 60 * 106 * P / ( 2*π * N )

= 60 * 106 * 3 kw / ( 2*π * 430 rpm )

= 66.62 KN/mm2

Bending momentum ( Mb ) = ( T1 – T2 ) = 150 ……… where T1 and T2 are the belt tension in tight and
slack sides.

T1 – T2 = ( Mb / 150)

T1 – T2 = 444.15N………………..Assuming T1 = 3T2

3T2 – T2 = 444.15 N

T2 = 222 N and T1 = 666 N

Now T1 + T2 = 888 , and the tangential and radial stress component is given by

Pt = Mt / 48

= 66622 / 48 = 1388 N
 Pr = Pt * tan 20°

= 1388 N * tan 20° =505.17 N

The diameter of the input shaft is calculated as

max = ( 16/π* d3)* [ ( Kb * Mb)2 + (Kt * Mt )2]1/2

1.5 *662676)2 + (1 * 66622 )2]1/2

D = 36mm but the next standard diameter of shaft is 40 mm.

The speed of the all four shaft is same as the speed of their respective gear so the speed of each shaft is
given below

 Speed of the input shaft is 430 rpm.

 Speed of intermediate shaft is 275 rpm
 Speed of spindle shaft is 360 rpm
 Speed of motor is 1000 rpm

The speed chart for speed of the all four shaft is given as
 speed chart of shafts

1200

1000

800

shafts
600
RPM of shafts

400

200

0
0 1 2 3 4 5 6 7

Fig 1.24 speed chart

Design of Screw and Nut

Force analysis on bolt

The shearing load carried by screw is given by

PS = (π /4) *d2 *σ*n………….. where PS= Shearing load = 49050 N

D = major diameter

σ= allowable stress

n = number of screw = 1

factor of safety = 3
allowable stress is given by = σy/ F.s

= 410 N/ mm2 / 3

= 136.67 N/mm2

PS = (π /4) *d2 *σ*n

d = [4 * PS / π *σ *n ] ½

= [4 * 49050 / π * 136.67*1 ] 1/2

= 37.88 mm

Determing the root diameter of the screw by using the nominal diameter of the screw as follow by using
the standared table dimension of screw thread for screw. Screw and nut of course and fine series, so from
table

Major diameter of screw = 39 mm = M39

Pitch of screw = 4 mm

Minor diameter of screw = 34 mm

Stress area = 976 mm2

Depth = 2.454 mm

Calculation of root diameter (DR) = DN – 2 * depth )

= 39 – 2 *2.454

= 34.092 mm

Using the above parameters we can calculate the crushing stress on the bolt to check weather the design
is safe or not

σc = P/ (π * ( DN2 – DR2 )

= 49050 / ( π * ( 392 – 342 )

= 43.09 N /mm2

Since the crushing stress value is less than the allowable stress we can conclude that the design is safe.
Design of Nut

The upper circular length from peak to peak is given by

DO = 1.5d + 3 mm

= 1.5 * (39 mm ) + 3 mm

= 61.5 mm

The shear stress induced in the nut will be

- the load needed to be exerted

A- Area of nut
Area of nut- A= ( π* ( DO2 – Di2 )) / 4

= ( π* ( 61.52 – 392 )) / 4

= 1776 mm2

N / 1776 mm2 = 27.62 N/ mm2

The allowable stress of nut is 205 N / mm2 , so the shear stress is less than the allowable stress so the
design is sfe.