Desta Final PDF

HAWASSA UNIVERSITY
INSTITUTE OF TECHNOLOGY
School of Mechanical and Industrial Engineering
INTERNSHIP REPORT
HOSTING COMPANY፦ MESFEN INDUSTRIAL ENGINERRING
BY DESTA SOLOMON
ID/NO 1728/07
DURATION -
1 PREPAIRED BY DESTA SOLOMON

EXCUTIVE SUMMARY
This internship paper report is an outcome of the exercise. I conduct during an internship period in
Mesfin industrial engineering. It presents the four month experience in five chapter.
In the first chapter it tells about the company profile in the background it tells about the foundation of the
company and its work on the foundation year how did the company get it names and at last of the
background it indicate that the company is awarded ISO 9001:2008 QUALITY MANAGEMENT
SYSTEM CERTIFICAT. Next to background it indicates about the gelan plant why it is established and
its mission, vision, valuse, Main products and service at last it indicate about Customers or end users of
the company and it finish the chapter one.
The second chapter of the report contains about the overall internship experience gained from the four
shop. It indicates the task performed in each shop. Starting from the first shop which is the material
preparation about task performed on the shop work flow of the shop and about machine present in this
shop. Next it explain about the fabrication shop the three section found in this shop task performed in
each shop and machine used on the shop. The third shop is the finishing and painting shop it explain work
description on the shop and step followed in painting the body. On the last of the chapter two about the
Maintenance shop the two type of maintenance given, the eight step followed to carry out the two type of
maintenance, the broad maintenance policy on last it contains task I don with the maintenance work.
The third chapter explain Over all benefit gained from internship In terms of improving practical skill,
upgrading theoretical skill, improving inter personal communication, improving team playing skill,
improving leadership skill, understanding about work ethics and related issues, entrepreneurship skill.
The fourth chapter deals with project designing manually operated feeding mechanism for the shearing
machine it explain problem statement, objective, scope, Methodology, Literature review, Design analysis
and Cost analysis about the project.
The last chapter contains conclusion about the internship program, recommendation for the company,
reference and at last appendix.

List of table
Table 2.3. Number of teeth on the smaller sprocket.
List of figure
Fig.1 bending machine
Fig.2 accessory shop draw bar, tool box and wheel carrier fabrication
Fig.3 false chassis and frame jig for cargo body
Fig.4 board fitting for cargo
Fig.5 LB tack and final welding.
Fig.7 finishing and painting shop
Fig.6 trailer frame tacking and final welding
Fig.9 A. gearbox with broken part of shaft in B. shaft
Fig.10 electro card
Fig.11 showing that a lot of labor is required in shearing machine to cut large materials

Table of content
Declaration
Acknowledgements
Executive summary
List of table and figure
CHAPTER ONE
1. INTRODUCTION ……………………………………………………………………………………………………………………. 6
1.1 Back ground of MIE ……………………………………………………………………………………………………………… 6
1.2 Gelan manufacturing plant ……………………………………………………………………………………………………. 7
1.3 Mission ....................................................................................................................................... 7
1.4 Vision …………………………………………………………………………………………… 7
1.4 Values …………………………………………………………………………………………………………………………………….. 7
1.6 Main products and service ………………………………………………………………………. 7
1.7 Customers or end users of the company …………………………………………………………. 9
1.8 Organizational structure ………………………………………………………………………………………………………….. 10
CHAPTER TWO
2 Overall internship experience …………………………………………………………………………………………………….. 11
2.1 Material preparation shop report ……………………………………………………………………………………………. 11
2.2 Fabrication department ………………………………………………………………………………………………………….. 15
2.3 Finishing and painting shop …………………………………………………………………………………………………….. 22
2.4 Maintenance shop ………………………………………………………………………………………………………………….. 24
2.5 Challenge that I have faced ……………………………………………………………………………………………………… 27
CHAPTER THREE
3 Over all benefit gained from internship ………………………………………………………………………………………. 28
3.1 In terms of improving practical skill ………………………………………………………………………………. 28

3.2 In terms of upgrading theoretical skill ……………………………………………………………………………………. 28
3.3 In terms improving inter personal communication ………………………………………………………………… 28
3.4 In terms of improving team playing skill …………………………………………………………………………………. 29
3.5 In terms improving leadership skill …………………………………………………………………………………………. 29
3.6 In terms understanding about work ethics and related issues ……………………………………………….. 29
3.7 In terms of gained entrepreneurship skill …………………………………………………………………………………. 29
CHAPTER FOUR
4. PROJECT ……………………………………………………………………………………………………………………………………. 32
4.1 Problem statement ……………………………………………………………………………………………………………………. 32
4.2 Objective …………………………………………………………………………………………………………………………………… 33
4.2.1 General objective ……………………………………………………………………………………………………………………. 33
4.2.2 Specific objective ……………………………………………………………………………………………………………………. 33
4.3 Scope ………………………………………………………………………………………………………………………………………… 33
4.4 Methodology ……………………………………………………………………………………………………………………………… 33
4.5 Literature review ……………………………………………………………………………………………………………………….. 35
4.6 Design analysis …………………………………………………………………………………………………………………………… 35
4.6.1 Design of columns …………………………………………………………………………………………………………………. 35
4.6.2 Design of beams……………………………………………………………………………………………………………………... 38
4.6.3 Chain and sprocket specification ……………………………………………………………………………………………. 39
4.6.4 Design of handle ……………………………………………………………………………………………………………………… 41
4.6.5 SELECTION OF BEARING …………………………………………………………………………………………………. 42
4.6.6 BEARING HOUS…………………………………………………………………………………………………………………….. 43
4.7 Cost analysis……………………………………………………………………………………………………………………………….. 43
CHAPTER FIVE
5.1 conclusion ………………………………………………………………………………….. 49
5.2 Recommendation …………………………………………………………………………… 49
5.3 Reference ……………………………………………………………………………………………. 49

CHAPTER ONE
1. INTRODUCTION
1.1 Back ground of MIE
MIE’s history began in 1982 E.C. its foundation was laid during the armed struggle-wagged by
the TPLF against the dictator derg regime of Ethiopia. The TPLF had established a work shop,
which could support its movement in the bushes the work shop was established with few
professionals in electricity, electronics, metal works, chemistry, etc who were educated and trained
in colleges and universities in the Diaspora and inside the country. Few high school students who
were interested in working in the workshop were also trained by those professionals to work in the
workshop.
The workshop was helping the armed struggle by maintaining electronics apparatus like wireless
communication radios which were important to the army; broken down generators and engines
were also being maintained in the workshop. All the machines used at the workshop were either
captured from the Derg regime or (bought) from outside.
In 1991 E.C the derg regime was toppled down. EPDRF, a national front in which the TPLF was
significant arm, came to Ethiopia. During this time situations had been changed and TPLF had to
change its activities to fit to the situations. The war time had ended and everybody had to think of
democracy and development in the country. The TPLF had a significant capital in cash and in kind
collected during the 17 years of army struggle. It had two choices, at that time of what to do with
the money and other resources.
One choice was to divide the resources to all the members. This choice was not acceptable at that
time, because it meant completely wasting all the resources collected in 17 years for nothing,
distributing it in hundreds of birr in to the pockets of individual members. The second choice was
to donate it to an endowment fund so that it could be invested in different business entities and
contribute to the development endeavor of the country at large and the Tigray region in particular.
This second choice was acceptable. Therefore, based on the accepted choice MIE was founded in
1993e.c as one the effort owned company with a total initial capital of 7 million Ethiopian birr.
And its name Mesfin was derived from a former fighter technician who graduated from poly
technique college Ethiopia and was the manager of the workshop in the bushes during the armed
struggle and who died in duty. MIE is the leading engineering company in Ethiopia has got-ISO
9001:2008 quality management system certificate NO, FM512406 F from BSI from for the
following scope:

1.2 Gelan manufacturing plant
This plant was established with the aim of availing a facility near where the majority of customers
are Present. With its 5000 meter square covered area and machinery for material preparation,
fabrication and finishing jobs, Gelan plant is cable of handling most Of MIE’s main fabricated
products like cargo bodies, trailers, semi-trailers and so on. Its proximity to customers has given
MIE additional advantage in improving capacity utilization, faster delivery time and
competitiveness.
1.3 Mission
To provide competitive engineering products, electro- mechanical and industrial construction services
create maximum to wealth to effort, provide development opportunities to employs, bring a positive impact
on society and play a leading role in the utilization of Ethiopia.
1.4 Vision
Became the leading company in east Africa in power plant, cement, sugar and automotive industries
withUSD200 million annual turnover over and 4 an USD 30Mmm millions annual profits by 200
1.5 Values
 Integrity and transparency,
 Maximize owner’s value,
 Customers first,
 Continues learning and improvement,
 Professionalism source of competitive advantage,
 Highly skilled committed work force,
 Excellent reputation,
 Latest technology
1.6 Main products and service

Mesfin industrial engineering is one of the huge companies in Ethiopia and leading company for
the development and transformation in our country by giving different services and products. Now
a day MIE has above 1000 workers. As we have mentioned before the company produce different
products such as for construction, machineries, automotive, industrial and construction
equipment’s.
Construction
 Painted and galvanized polygonal advertisement and lighting masts,
 Galvanized poles and steel towers for overhead transmission and distribution lines,
 Pre engineering steel buildings,
 Silos, cyclones, dust collectors,
 Environmental equipment,
 Warehouse equipment,
 Under ground and above ground tankers(for fuel, water),
 Pipe lines fabrication and installation,
 Erection service
Machineries
 Draw bar trailer,
 Low-bed and high-bed semi-trailers,
 Agricultural trailers,
 Chemical tank with semi-trailers,
 Fuel tank with semi-trailers,
 Fuel tank with trailers,
 Cargo bodies,
 Dump trucks,
 And other different custom based truck mounted bodies, trailers,
Industrial and construction equipment

 Overhead cranes,
 Lifters,
 Different production plant accessories like dryers, kilns, pre-heaters, economizers, boilers, burners,
bag-houses, conveyors, etc
 Electro mechanical boards
Some examples from machine in MIE;
Pantograph፦ this machine is used for shearing and drilling of sheet metal and metal plate. It works
through computerized program. To operate this machine we can use three different setting
mechanisms to get the desired dimension. These mechanisms are;
o It has the standard dimension (memory) from the manufacturer
o Give a drawing using AutoCAD
It can be set manually, after selecting one of the above mechanisms the machine can shear or
cut the work piece by itself because it has sensor.
Overhead crane; - this is very important and interesting tool to the company. This machine is used
to carry heavy parts from one place to the other. It has a capacity to carry load up to 5 ton.
Other machines are:
o Different lathe machines,

o Rolling machines,
o Sheet metal bending machine,
o Welding machines,
Some of the raw materials that are used as input to the company are the following:

Different size of metal plate (above 4mm thickness),
Sheet metal (below 4mm thickness),
Axle,
Angle iron,
Round pipe,
Solid bars etc.
1.7 Customers or end users of the company

The capacity of production for this company is increase from time to time. In has different customers. Some
of them are:
Trailer customers
 Tikure abay,
 Transe Ethiopia,
 Bekeicha,
 United alpha,
 Comment housing,
 Shebelle,
 Shimsala etc…
Customers relatedto manufacturingandelectromechanical
 Messebo cement factory,
 Dashen beer factory,
 Rail way,
 Sheba tannery,
 Awash construction,
 Machew particle board,
 Mugger cement factory, etc
 Suppliers of the company: most of the materials are brought from china and turkey. The following
institutions are suppliers of the company.
 Metal market company (MMC),
 Metal trader company (MTC). These two companies are suppliers of MIE from turkey.

1.8 Organizational structure
General Manager
Organizational Structure
of MIE –
Proposed Planning & Internal
Monitoring Dept. Audit service
Legal
AA Office Coordinator service
DGM Design & DGM DGM Support

Marketing DGM Plants Projects
Power Services
plants Sales &
Design Prom. Dept Mekelle Gelan EMW Dept
Water ICT Dept.
team Manufg. Manufg.
supply plant
Business Plant Industrial
system Devt. Dept. Construction HRD
Design Tower & Automotive
Automotive Dept
team Galvanizatio Assembly Equipment
& n Plant Plant General
locomotive Adm. Service
Design Industrial & Mainte.
Sugar
team Electrical QC & Safety
maintenance service
plants Design team Dept. Dept Finance
Project A Dept.
Design After sale
team service Outsourcing
Cement Supply
centers (AA Dept. Dept.
plant &Mekelle) Project B
Design
Team

CHAPTER TWO
2 Overall internship experience

Within the four month of internship time I work in different workshop such as material preparation,
fabrication, maintenance and finishing & painting shops. Starting from material preparation shop
to finishing and painting shop it has its own work flow. The Gelan plant is composed of facilities
and activities described below.
2.1 Material preparation shop report

This is the plant where all the raw materials for the fabrication process are prepared. In this process
all the pre-welding and assembly activities are carried out. The quality of production in this plant
determines the precision and functionality of final products. Therefore, MIE has acquired and has
been using state of the art machinery for material preparation i.e. shearing, bending, plasma,
drilling, band saw, pneumatic press, rolling machines. During the first month, I was perfectly
identified machines present in MIE the company especially in material preparation shop when I
was in maintenance shop since in maintenance shop all machines present in the company are
maintained. So I got a chance to see and identify the machines.
These machines are: - Shearing machine, Bending machine, Drilling machine and press
machine, flame (Oxy-acetylene) are actively performs the day to day activities. But, there are other
machines which is present in the shop like Plasma arc cutting (pantograph) machine which is not
actively perform. In material preparation shop there are daily and weekly Job orders to be
performed. These planned activities are performed efficiently and effectively as I see. In this shop
the materials are prepared in the desired dimension and size before going to the fabrication shop
to be assembled.
As I see, first the job ordered material present to the material preparation shop and the material
cuts by using shearing machine based on the required dimensions. Then some material can be flow
directly to the fabrication shop, some are flow to the bending machine and some are going to the
press machine. And also from bending machine some materials can be flow into drilling machine
and cutting by flames (Oxyacetylene) machine. After finishing all the necessary processes in
material preparation shop, the material can be flow into fabrication shop based on the companies
transfer slip. As we have seen, the material preparation shop acts as a supplier for the fabrication
shop. The fabrication shop receives by signing in the document (transfer slip) and the material
preparation shop gives all the materials to the fabrication shop. Job orders and reports in material
preparation shop are performed based on the following format.
There are steps to present the materials from store to the material preparation shop. Starting from
planning manager department up to the Forman to prepare the pick slip, store issue and then taking
the material from store and put in the temporary store in material preparation shop.
After the job order is distributed to the workers by Forman, the workers start their work based on
the job order. As I see in material preparation shop, the workers start on shearing machine at the
first step to cut plates and sheet metals based on the required dimensions, size and shapes. These
the above listed components of Cargo and Trailer in the table are first the material is shearing ,
then Bend, Press, Drill, cut by flame and cut by band saw as required and store these materials in
temporary storage area. There is a quality management system (QMS) which is the company
follows. The QMS succeeds when the cost of the system is less than the cost of defects and poor
services which would otherwise result. The aim of a QMS is to assure that an organization
consistently meets customer needs by controlling the core processes that affect them such as sales
orders, design, production, inspection, delivery, etc. The requirements also go beyond these “core”
process to address support processes like purchasing, training calibration, maintenance and
performance metrics. These activities proceed based on the job order came from the shop for man.
There is weekly job orders, this job orders are distributed to all the workers and the workers done
their job efficiently and effectively. On these days based on the job order the workers perform the
above activities by guiding Shear machine, Bending machine, Drilling machine, Press machine,
Flame cutting ,Band saw and Grinder whenever it is necessary. In this day based on the job order
the workers first sheared the stiffness, Rear beam, Front beam, Types of cross members, Trolley
support beam, Grill support, un siding support and Hinges based on their dimensions. And then
bend the cross members and others which required to be bend to get the desired size and the
required shape of the component. After completing all the, the worker put these prepared materials
in temporary store area by using forklift or crane in material preparation shop. This storage area
used to store semi-finished products i.e. parts ready to transfer o the fabrication shop. In general
the workers perform these type of works based on the job orders that received from foreman and
they are finished their duty on the required way accordingly and placed temporarily store until
transferring to the fabrication shop. There are different components that are cut and then bend and
then after bending these components will be transferred to another machine or to the temporary
seat place. For example Front beam, Rear beam and External cross members are cut by shear
machine and bend these components. Since, Shearing and bending machines are basically
performed all the day rather than other machines. For example, pantograph is not active to do any
work. Due to this preseason Web plate, upper and lower plates come from Mekele after cutting
and bending. The workers perform the work based on the Job-order that they are received from
Forman. According to the Kaizen, the workers evaluate/assess their accomplishment and compare
the actual and targets products and give marks based on their evaluation. Since, QMS is applicable
in this company. In conclusion, the daily Job-orders are completely done and the semi-finished
products are placed in temporary storage area.

Work flow of the shop
The following diagram shows the process starting from material entrance or arrival to the material
preparation shop to producing a semi-finished product.
Department Production Drawing and work

Planning-Job order manager receive manager receive order for
and drawing release drawing and work order and drawing supervisor
order
Prepare check list
Put material on Take Store Issue Prepare pick

temporary Prepared plan by
material voucher slip
store Supervisor/Form
from store an
Shear Temporary Pantograph Band saw Flame

machine store
Press
Bending machine
Drilling Flame Bending
Drilling Press
machin
e
Flame
Material
Transfer
area
Material Transfer to
fabrication shop
Generally almost all parts of the trailer and cargo are prepared in this shop. In each machine different or
same parts will be prepared. Let’s see what parts are manufactured in each machine.

Shearing machine; Shearing machine is useful for manufacturing a lot of parts. It is the most useful
machine in the company. Shearing machine is designed constructed for cutting flat metal material up to
3070mm length and of maximum thickness 16mm thickness in case of 42kg/cm square mild steel plate.
The HNC shearing machine is designed and constructed for cutting flat metal material up to 3070mm in
length and of maximum 16mm thickness. The vertical movement of the cutting beam, which is actuated by
hydraulic cylinders, result in shearing action with a heavy blade sliding vertically in groove. A set of bottom
and top blades, which are made of special hardened alloy steel material, perform shearing process. The
HNC supplied with the electronic control system which is automatically set the shear rake and blade gap
with the help of its menu- based software. In addition, programmable shearing and back gauge position as
well as cutting length adjustment is possible through the control.
Fig.1 bending machine
Bending machine; like shearing machine bending machine is one of the most necessary or basic machine
for the production of cargo and trailer. Many parts bend with the required and appropriate dimensions. The
working procedure that has to be followed is similar to that of the shearing machine. This machine bends
the material that was sheared and transferred to bending machine. Hence they follow the same procedure.
The difference between them is their output. The CNC bending machine designed and constructed for press
bending of flat metal materials up to 6100mm length through use of hydraulic pressure power of maximum
400 tons which adjustable. At maximum tonnage, the material thickness that can be formed is 12mm if it
is as long as the machine’s length. But if the material is short, the machine can bends up to 40mm thick
metal. The bending force is applied by down acting beam, which is actuated by two hydraulic cylinders.
The lower beam is stationary (die). A set of top and bottom tools must be used for bending.
Band saw machine; Band saw machine (manual and automatic) is used to cut non-flat metals which can’t
be cut under shearing machine. This machine capacity is depend on the size of the metal to be cut.
ARC welding machine
Arc welding is a process that is used to join metal to metal by using electricity to create enough heat to melt
metals, and the melted metals when cool result in binding of the metals. It is a type of welding that uses a
welding power supply to create an electric arc between an electrode and the base material to melt to melt
the metals at the weld point. They can use either direct (DC) or alternating (AC) current, and consumable
or non-consumable electrodes. The welding region is usually protected by some type of shielding gas, vapor
or slag. Arc welding process may be manual, semi-automatic or fully automated. First developed in the late
part of the 19th century, arc welding became commercially important in ship building during the Second
World War. Today it remains an important process for the fabrication of steel structures and vehicles.
MIG machine
Originally developed for welding aluminum and other non-ferrous materials in the 1940’s. GMAW was
soon applied to steels because it provides faster welding time compared other welding processes. The cost
of inert gas limited its use in steels until several years later, when the use of semi-inert gases such as carbon
dioxide became common. Further developments during the 1960’s gave the process more versatility and as
a result, it became highly used industrial process. Today, GMAW is the most common industrial welding
process, preferred for its versatility, speed and the relative ease of adapting the process to robotic
automation. Unlike welding processes that do not employ a shielding gas, such s shield metal arc welding
process, it is rarely used outdoors or in other areas of air volatility. A related process, flux cored arc
welding, often doesn’t use a shielding gas, but instead employs am electrode wire that is hollow
Radial drilling machine
It is a type of machine which is used to drill metal plate for the purpose of bolt and nut or for other
accessories.
Automatic pantograph machine (plasma cutting machine)
Ts Plasma cutting is a process that cuts through electrically conductive materials by means of an accelerated
jet of hot plasma. Typical materials cut with plasma torch include steel, stainless steel, aluminum, brass and
copper, although other conductive materials may be cut as well. Plasma cutting is often used in fabrication
shops, automotive repair and restoration, industrial construction, and salvage and scrapping operations. Due
to the high speed and precision cuts with low cost, plasma cutting sees widespread use from large scale
industrial CNC applications down to small hobbyist shops. The basic plasma cutting process involves
creating an electrical channel of supper heated, electrical ionized gas i.e. plasma from the plasma cuter
itself, through the work piece to be cut, thus forming a completed electric circuit back to the plasma cutter
via a grounding clamp. This is accomplished by a compressed (oxygen, air, inert and others depending on
the material being cut) which is blown through a focused nozzle at high speed toward the work piece. An
electrical arc is then formed within the gas, between an electrode near or integrated in to the gas nozzle and
the work piece itself. The electrical arc ionizes some of the gas, thereby creating electrically conductive
channels of plasma. As electricity from the cutter torch travels down this plasma it delivers sufficient heat
to melt through the work piece. At the same time, much of the high velocity plasma and compressed gas
blow the hot molten metal away, thereby separating i.e. cutting through the work piece. Plasma cutting is
an effective means of cutting thin and thick materials alike. Hand held torches can usually cut up to 38mm
(1.5 inch) thick steel plate, and stronger computer- controlled torches can cut steel up to 150mm (6inch)
thick. Since plasma cutters produce a very hot and much localized “cone” to cut with, they are extremely
useful for cutting sheet metal in curved or angled shapes.
Currently the machine is not working due to system failure.

2.2 FABRICATION DEPARTMENT
This department has three section or shop. The task which is performed in the first and third
section is the same. But the second shop task or activities are different, It has its own name called
accessory shop. Accessory shop is the shop where all accessory parts are fabricated.
After receiving the work shop drawing and material utilization from concerned office the following
task are done in this shop:
1. sub assembling of longitudinal beam tacking and welding

2. sub assembling of frame
3. sub assembling of axle &assembling (for 3 axle draw bar trailer)
4. sub assembling of board
5. sub assembling of draw bar (for 3 axle draw bar trailer)
6. general assembly
The fabrication shop deals with fabricating and manufacturing of many parts.The proses of sub
assembling and general assembling is used to convert the received semi-finished in to finished product.
THE FINISHED PRODUCT ARE
1. TRAILER fabrication with it is all part and component.

2. CARGO here the cargo base part are imported which is not made here the cargo base
part include.
A. cargo body B. motor
C. axel D. wheel and rim
E. chassis F. fuel tanker
The following part are manufactured in the fabrication shop and assembled with the cargo
base with the help of bolt not by welding in order to prevent the damage of the chassis of
the cargo base part. Some of the cargo part fabricated assembled here include false chassis,
plate form, board, stand, grill, twist lock, big hook and small hook, winch, latch catch, tool
box etc…
The main machine used in this shop are:
1. MIG machine(inert gas welding)

2. arc welding machine
3. grinder
4. rolling machine and other accessory tools
1. ACCESSORY SHOP (fabrication shop 2)
Task performed in accessory shop:

 fabrication of draw bar

 fabrication of board
 fabrication of stand
 fabrication of hinge
 fabrication of fuel tank
 fabrication of grill
 fabrication of board protector
 fabrication of wheel carrier
Fabrication of front board for trailer and truck

 place front board metal which is prepared in material preparation shop on board jig
(2-pieces)
 tacking seal on the board
 tack angle iron on both rough end
Fabrication of side board for truck and trailer

 placing side board material on board jig (244mm length for trailer and 210mm
for truck)
 tacking seals
 tacking flat plate on both rough end
 final welding side board
In the first and third shop there is assembly and semi finishing of accessory parts of
dry cargo and trailer
Fig.2 accessory shop draw bar, tool box and wheel carrier fabrication

2. FABRICATION IN 1st & 3rd SHOP
COMPLETE PRODUCTION PROCESS OF CARGO BODY
Station 1
 frame tacking on frame jig
tack and welding side beam
tack and weld front beam
tack and weld rear beam
take diagonal measurement to check dimension
tack and weld side support
tack and weld big omega inserting
tack and weld small omega
False chassis
 place chassis material in chassis jig

 cutting chassis material from inside to increase the width of rear end
 tack extension chassis to obtain full length
 insert central cross member and tack
 check diagonal dimension
 finalize the required welding
Station 2
 False chassis with frame
 place the frame on the earth
 measure center to center to gate accurate position of false chassis on the
frame
 properly place false chassis on the frame and tack
 tack and weld triangular reinforcement
 welding winch lock
 welding big and small hook
 painting anticorrosion die

Fig.3 false chassis and frame jig for cargo body
Station 3
 return to other face ( the bottom is chassis and top is frame )
 welding false chassis with frame from in side
 mounting twist lock
 cover the frame floor with chequared plate
 board assembly with its accessory :-
 fixed and movable hing
 latch catch
 pocket
 stand
 board protector
Fig.4 board fitting for cargo

Cargo body mounting
 properly mount cargo body on car
 bolting with bolt guide
 welding fixed bracket on cargo body
 tightening false chassis with main chassis
 fitting fender on cargo body
 fitting ladder
 tool box on cargo body
 reflector
Complete production process of trailer
Station 1
 longitudinal beam tacking (using arc welding)
 loading lower plate using bridge crane
 loading web plate on the jig upper the lower plate with the help of bridge
crane and tacking it at 90
 loading the upper plate on the upper side of the web plate and tack it at 90
 unloading the tacked beam and transfer to final welding station
Station 2
 longitudinal beam final welding
 loading tacked LB from its station to final welding jig
 tighten it on the jig properly both side
 final weld the tacked longitudinal beam parallel both side using mig
welding machine
 unload the welded longitudinal beam transfer to frame tacking station
Fig.5 LB tack and final welding.

Station 3
 frame tacking and final welding
 loading the two longitudinal beam on the frame jig
 check the height and other dimension of two LB
 check the central distance of the two LB
 assemble and tack internal cross member and level for turning table and
tacking vertical reinforcement
 assemble side beam tacking and welding
 assemble external cross member and tack it with side frame and
longitudinal beam
 tack winch, winch reinforcement side and hook
 assemble front beam with side beam ,weld two corner reinforcement
and welding if I-beam for turning table
 check and weld all tacked parts of frame
 transfer to axel assembly station
Fig.6 trailer frame tacking and final welding.
Station 4
 platform for trailer(1)
 drill trolley table
 fasten turning table with trolley table
 transfer to axel assemble
Station 5
 axel assemble and mounting
 loading the axel on the jig
 loading leaf suspension on the axel and fasten with it by u- bolt
 loading suspension block and fasten with axel
 check the distance between two successive block
 loading I-beam and weld with suspension block
 weld gust plate with suspension block
 loading welded frame with assembled axel
 fasten turning table with I-beam and welding turning table guide
 weld frame with suspension block
Station 6
 plate from trailer (2)
 tool box welding
 twist lock tack and weld
 longitudinal omega welding
 rear beam tacking and welding chequared plate tacking and welding
Station 7
 board fitting and surface finishing
 front board loading and weld
 stand insert (pocket) welding and stand loading
 side and rear board fitting
 board hinge and board protector tack and welding
 stand cover plate latch catch tacking and welding
 grill support welding
 surface finish and transfer to final station
Station 8
Final assembling
 tire bed, fuel tanker carrier tack and welding

 air cylinder support , valve support, rear light
 support tacking and welding
 rear fender, mechanical hand brake and roller tacking and welding
 mud protector
 draw bar fasten
 tire assembly
 check surface finishing and transfer to finishing and painting shop
2.3 Finishing and painting shop

After the assembled process is over in fabrication shop it transferred in to painting and finishing
shop. In painting and finishing shop work description includes (steps followed in painting the
body);
1. Cleaning,
2. Anti-rest, painting,
3. Rectification,
4. Stucco per metal,
5. Cleaning,
6. Primary painting,
7. Normal stucco,
8. Cleaning and
9. Final painting.
Fig.7 finishing and painting shop
In addition to this the following task is done in this shop if the product is 3-axle draw bar
trailer. For other, those parts are already installed where they were assembled.
Brake system
The break system of 3-axle draw bar trailer performs breaking by instruction comes from
cargo order by driver and installed as;
 Installing break chamber,

 Distributor valve,
 Emergency valve,
 Filter,
 Coupling,
 Connecting filter with emergency valve,
 Connecting each chamber with corresponding pipe,
 Assemble air tanker,
 Connecting air tanker with distributor valve and emergency valve and
 Assemble fuel tanker.
Company logo and chain assembly
 Fasten company logo,

 Fixing reflector pate,
 Mud protector assembling,
 Number plate and
 Check and transfer to store by transfer slip.
2.4 Maintenance shop
This is the plant where all the machines are maintained. In this shop all the machines which are
available in all working areas will be maintained. The main focus of machinery and equipment
maintenance policy is to reduce the cost operation and down time thereby insuring optimum
utilization of equipment reducing maintenance cost and down time.
Two types of maintenance have been used

1. Breakdown maintenance.
2. Preventive maintenance.
They give the preventive and breakdown maintenance in material preparation shop, fabrication shop,
trading center and finishing shop
To Carrey out the breakdown and preventive maintenance the following steps are applied
1. Maintenance order request፦ Break down maintenance request will be initiated by Machine operator and get the
approval of Supervisor
2. Diagnosis፦ Team leader will diagnose the fault and propose solutions and troubleshooting procedures
3. Pending፦ Jobs which are not completed within 5 days shall be listed on the pending list and the job will be rectify
after the requirement resources
4. Resource assigning፦ once faults are diagnosed all the necessary spare, tools, manuals and workmen will be
assigned
5. Request፦ if parts are required, store requisition voucher shall be initiated
6. Execute፦: Maintenance team will repair the fault
7. Test፦: Test will be done by Technician, or Forman if the machine operational
8. Operation resume, & record፦ Operation resumes and machine operator shall sign on the Maintenance report &
and all major activities shall be recorded in the history jacket file

In my duration in maintenance I have seen many part there working principle there function if they stop
giving service how could they maintain some of them are listed below.
Breakdown of shaft
A shaft is a rotating machine element. Which is used to transmit power from one place to another. Here in
the overhead crane it transmit power from gear box which is connected to motor in to the wheel of the crane
when the power is reached to the crane wheel it is able to move forward and backward to give its useful
function.
A. B.
Fig.9 A. gearbox with broken part of shaft in B. shaft
When we are trying to fix the problem first we take out the broken part of shaft from the gear box and wheel
of crane by putting on the bending machine and applying axil force on them by putting metallic material
on the medium after that we clean the gear box and wheel of crane then we replace the new shaft instead of
the broken one.
ABSENCE OF PHASE LINE

The MIG machine metal inert gas welding get the power supply in three wire A. phase Neutral Ground
most of the time the absence of phase which make impossible to carry out the welding proses we fix it by
TIGHTEN the phase line which is missed.
Sensor
Sensor indicates give light when the blade reach its lower limit and when it reach its upper limit give
information to PLC(programmable logical control) then the PLC Give order to rely the rely close or open
the valve and change the supply of oil then it changes the movement of the blade direction. When the
sensor was miss positioned the sensor function was stopped then we clean up the sensor and we return to
its original and accurate position.
ELECTRO CARD line cut

Fig.10 electro card
Electro card is an integrated circuit which consist resistor, inductor, capacitor, rectifier, diode, it serve as a
control unit for MIG machine.
In this control unit some excitation electrical line was found which stops the work of electro card and it is
solved by welding it by led.
SHORT CIRCUIT OF CONTACTOR
Contactor is an electrically controlled switch used for switching an electrical power circuit. A contactor is
typically controlled by a circuit which has a much lower power level than the switched circuit, such as a
24-volt motor switch. Without contactor protection the occurrence of electric current arcing causes
significant degradation of the contacts which suffer significant damage
Here the problem occurred in the contactor was the presence of short circuit in the coil spring when the
phase and neutral are come in contact which is detected by check meter because of this the contactor stop
giving its service.
Measure they take to solve the problem was changing the contactor which is not working with new
contactor.
Incorrect stab of wire in Motor
In MIG welding machine the motor which contain gear motor control the feeding of wire bar electrode in
to the welding area
The problem occurred here where the wire was drawn in the opposite direction the problem was incorrect
stab of wire in the electro card we fix the problem easily by inserting the wire in the correct position after
this the wire bare electrode will draw into the weld area in the correct position.
Oil leakage
Seal is a circular hose which shutting down a hole and closes the movement of oil when the seal stops
giving its service oil leakage was occurred which corrected by fitting the seal accurately.
2.5 Challenge that I have faced
 There was no mentor assigned by the company for us and it was difficult to us to decide from
where to start the work on which path to follow the work since we didn’t now the work flow

 Due to currency problem on the country and the company the part which are imported to the
company on the four month stay I didn’t seen how this part are mounted and assembled with
other part.
 In the company most of the time welding activity are carried this affect the shop
environment and it cause health effect especially in respiratory system and sight.
Measure taken to overcome the challenge
 For the mentor problem we tell the problem for the administration office and they assighn
to us mentor
 To fill the missing to which I didn’t have seen due to currency problem I try to ask my
mentor and to read note book present in the company.
 For healthy problem I use safety equipment during the work.

CHAPTER THREE
3 Over all benefit gained from internship
3.1 In terms of improving practical skill
Mesfin industrial engineering carry out material preparation, fabrication, assembly, maintenances,
painting and finishing. Those task are done in under different shops and managed by office. Hence
by participating in those tasks i have developed my practical skills.
In material preparation shop, I have learned how to read design from paper and interpreted to solid
work how to operate different machines like shearing, bending, band saw, flame cutter, plasma
cutter and press machine.
In fabrication shop, in this section welding, many sub assembling and general assembling is done.
In each station I have learned how smaller materials comes together and gives needed object. In
3-axel draw bar assembling station igained practical skill, how each part assembled together and
inspected, in addition to this I learned welding using metal inert gas machine.
In painting shop and finishing shop, I see how welded metals can be smooth and filled by stucco,
how different types of paints mixed together to form homogenous mixture and painting process
takes place.
In maintaining different equipment and machine parts I gained knowledge how to maintain some
electrical, hydraulic parts and vehicle body since the company gives after sale maintenance, after
sale maintenance is only dedicated to body maintenance for other heavy vehicles and all system
for 3-axel draw bar trailer.
3.2 IN TERMS OF UPGRADING THEORETICAL SKILL
Mesfin industry engineering is a company that applies some of the theoretical skill that we acquired
at university, like machine elements and machine design, hydraulic and pneumatic maintenance,
mechanisms of machinery, machine drawing and manufacturing. Due to this fact on my stay at the
company has helped me to upgrade my theoretical skills on these fields.
3.3 IN TERMS OF IMPROVING INTER PERSONAL COMMINICATION
In company where many employers are working interpersonal communication skill is crucial. MIE
employs nearly 350 of workers and those workers are appointed at a task according to their
personal skill, a task might be appointed to one or more persons, IN THIS CASE INTERPERSON
communication skills are essential, dividing the task and assigning it to different person is more
suitable than everyone trying to do one thing. So when I was working with many worker it help
me to improve inter personal communication skill.
3.4 IN TERMS OF TEAM PLAYING SKILL

In terms of team playing. I have learned the ability to work cooperatively and task sharing, by
working together on wider task by handling responsibility, working diligently, and finishing the
task on one time. MIE has applying kaizen philosophy and this help the company to build
productive team worker. Above all I have learned the significance of the contribution of an
individual makes to the success of the team.
3.5 IN TERMS OF IMPROVING LEADERSHIP SKILL
Leadership skill is critical for any company to be productive accomplish its task, in the company
I was practicing starting from manger to Forman they pass through the tasks they are one leading.
They have knowledge what has to be done and ways to be done and this tasks are simple and
smooth which improve our leadership skill.
3.6 IN TERMS OF UNDERSTANDING ABOUT WORK ETHICS AND RELATED

ISSUES
What impress me during my stay in this company is work ethics and discipline of the worker they
understood that work ethics is the major factors for the step to professionalism. They know issues
that are related to work ethics like punctuality, honesty, loyalty, and performance are what make
a company a success or failure products on time. Worker should understand the value of time and
use it effectively.
The other factor that is related to work ethics is maintain a peaceful environment at work place
there are some workers that quarrel with everybody in reach. This kind of behavior interrupts the
work progress and affected the whole company. Workers should also treat the company property
as their own and try to handle. So we now the above thing in the internship program
3.7 INTREPRENEUSHIP SKILL WE CAN GAINS
MIE is one of the most technologically company in our country which has been participating in
many mechanical and electrical sector and has been playing vital role in the development of the
country, public limited company, As i understood from the company participating in many tasks
such as, sugar factory, cement factory, hydropower, automotive and other this increase its
productivity.
This shows how entrepreneurship is very crucial for one country, in developing technology,
consolidating creativity, reducing employability and helps the government in responsibility of
creating job for citizen one of the other benefits of entrepreneurship is the ability of producing
people with certain personal attributes such as: creativity, dedication, determination, flexibility,
leadership passion, self-confidence
In my job-trading at this industry I have been able to prevent to perceive the new opportunities
that are being made and the technical community can participate in the new transformation, hence
developing my entrepreneurial skills. I have also have developed the skills on how to manage a
company, motivate the workers, and break into the market and so on.
CHAPTER FOUR
4. PROJECT
4.1 Problem statement

One of the big machine which is found in Mesfin industrial engineering is HNC shearing
machine. And this machine is the basis of the company it has cutting capacity up to 10mm
thickness sheet metal plate and it works around 7hours per day. Large material work pieces are
feed to the shearing machine by using electric overhead crane, which results in unstable feeding,
electric cost, and labor cost etc. additionally to perform feeding and shearing at least a minimum
of five men’s are required, where two of them at the back to push the work peace and two of them
at the front to stabilize and measure the required dimension to be cut and the fifth one to control
the crane. Not only number of peoples or workers is a lot but it is also not a safe way for the
workers and to the machine and a lot loss of electricity and labor cost.
Fig.11 showing that a lot of labor is required in shearing machine to cut large materials

4.2 Objective
4.2.1 General objective
The general objective of this project is to design manually operated feeding mechanism for feeding large
materials to the shearing machine. To reduce the number of labor needed and to increase work safety and
to have good dimensional accuracy.
4.2.2 Specific objective
The specific objective of this project is;
To design each components (columns, beams, chain, ratchet wheel, handle etc…) of the manually operated
feeding machine.
 reduce excessive man power used

 reduce the number of worker for better profit
 minimize the time required to cut sheet metal plate
 increase workers safety
 increasing the profit and productivity of the company
4.3 Scope
This sheet metal plate feeder is used to convey metal weight up to 9kN. It is applied in material
preparation shop in front of the shear machine.
4.4 Methodology
The following deals with the design of manually operated feeding mechanism. This includes step
by step guide to design of each components of feeding mechanism these include column design,
shaft design, bearing selection, beam design, chain selection, ratchet wheel and as well as other
important parameters are used. Before starting the design first selecting a proper material that have
a good strength for both column and beam can be considered.
Column
 Select a standard material size and cross section. And then specify the length of columns.
 Calculate the slenderness ratio, and check with the desired value to check whether the
column is Euler or not.
 Perform the force analysis.
 Calculate the critical stress induced and check the safety using the yield strength.
Beams
 Select a standard material size and cross section. And then specify the length of beam.
 Perform the force analysis.
 Calculate the bending moment.
 Calculate the moment of inertia of the cross section.
 Calculate the bending stress induced and check the safety using the yield strength.

Bearings
 There are four bearings but the two bearings at intermediates are the same.
 Using bearing loads from shaft analyzing, determine static and dynamic load constants (c
and c0).
 Calculate dynamic equivalent radial load for different load applied equation.
 Check the life of bearing based up on the applied load.
Chain
The chain drive is designed as discussed below:
 First of all, determine the velocity ratio of the chain drive.

 Select the minimum number of teeth on the smaller sprocket or pinion from Table 21.5.
 Find the number of teeth on the larger sprocket.
 Determine the design power by using the service factor, such that
Design power = Rated power × Service factor
 Choose the type of chain, number of strands for the design power and r.p.m. of the
smaller
sprocket from Table 21.4.
 Note down the parameters of the chain, such as pitch, roller diameter, minimum width of
roller etc. from Table 21.1.
 Find pitch circle diameters and pitch line velocity of the smaller sprocket.
 Determine the load (W) on the chain by using the following relation, i.e.
 Calculate the factor of safety by dividing the breaking load (WB) to the load on the chain
(W). This value of factor of safety should be greater than the value given in Table 21.2.
 Fix the center distance between the sprockets.
 Determine the length of the chain
The other dimensions may be fixed as given in Art. 21.17
Handle
 Calculate and check it have sufficient strength to support the applied load to
transmit the force involved in the task

4.5 Literature review
4.6 Design analysis

4.6.1 Design of columns
Design parameters
Total load maximum = 693.1N
Load per column, p = 693.1N/6 = 115.51N
Take factor of safety as 2,
L1 = 870mm
L2 = 895mm
L3 = 1080mm
Where L1 is length of front column,
L2 is length of central column and
L3 is length of rear column
Material selection
For columns st37 steel is selected with yield strength of 500Mpa.
Cross section area= A = 100mm*50mm-90mm*40mm = 1400𝑚𝑚2
100mm
5mm
50mm
 For two front columns

Let’s check first the slenderness ratios that weather it is below 80 or not in order to say the column
is short or long.
L/K= 870mm/25mm=34.8
To be sure that this is an Euler column

2𝜋 2 𝐶𝐸 1⁄ 2𝜋 2 𝑥1.2𝑥210𝐺𝑝𝑎 1⁄
(𝑙⁄𝑘)1 = ( ) 2 =( ) 2 = 99.74
𝑆𝑦 500𝑀𝑝𝑎
This indicates that it is ended column.
Then the creeping stress would be

𝑝𝑐𝑟 𝐶𝜋 2 𝐸
𝜎𝑐𝑟 = = , where I is the moment of inertia of the section. And it should be the minimum
𝐴 (𝑙⁄𝑘)2
of the two.
ℎ𝑥𝑏 3 −((ℎ−2𝑡)(𝑏−1𝑡)3 ) 50𝑥1003 −((50−2𝑥5)(100−2𝑥5)3 )
𝐼𝑦𝑦 = = = 1736666.667𝑚𝑚4
12 12
𝑏𝑥ℎ3 −((𝑏−2𝑡)(ℎ−2𝑡)3 ) 100𝑥503 −((100−2𝑥5)(50−2𝑥5)3 )

𝐼𝑥𝑥 = = = 561666.6667𝑚𝑚4
12 12
Y b
X X
t h
Therefore for design purpose the minimum moment of inertia will be taken, i.e. 𝐼𝑥𝑥 . Hence design
calculation will be base on 𝐼𝑥𝑥 .
𝑝𝑐𝑟 𝐶𝜋 2 𝐸 1.2𝑥𝜋 2 𝑥210𝐺𝑝𝑎𝑚𝑚4
𝜎𝑐𝑟 = = , = = 205.37Mpa
𝐴 (𝑙⁄𝑘)2 34.82
𝑆𝑦⁄
𝜎𝑐𝑟 ≤ 𝑛,
500𝑀𝑝𝑎⁄
𝜎𝑐𝑟 ≤ 2 = 250Mpa
Since the critical stress is less than the safe stress the design is comfortable.
 For two central columns
is short or long.
L/K= 895mm/25mm=35.8

2𝜋 2 𝐶𝐸 1⁄ 2𝜋 2 𝑥1.2𝑥210𝐺𝑝𝑎 1⁄
(𝑙⁄𝑘)1 = ( ) 2 =( ) 2 = 99.74

𝑝𝑐𝑟 𝐶𝜋 2 𝐸𝐼𝑥𝑥 1.2𝑥𝜋 2 𝑥210𝐺𝑝𝑎
𝜎𝑐𝑟 = = 2 , = , = 194.06Mpa
𝐴 (𝑙⁄𝑘)1 35.82
𝑆𝑦⁄
500𝑀𝑝𝑎⁄
𝜎𝑐𝑟 ≤ 2 = 250Mpa
Since the critical stress is less than the safe stress the design is comfortable
 For two rear columns
is short or long.
L/K= 1080mm/25mm=43.2

2𝜋 2 𝐶𝐸 1⁄ 2𝜋 2 𝑥1.2𝑥210𝐺𝑝𝑎 1⁄
(𝑙⁄𝑘)1 = ( ) 2 =( ) 2 = 99.74

𝑝𝑐𝑟 𝐶𝜋 2 𝐸𝐼𝑥𝑥 1.2𝑥𝜋 2 𝑥210𝐺𝑝𝑎
𝜎𝑐𝑟 = = 2 , = , = 131.43Mpa
𝐴 (𝑙⁄𝑘)1 43.22
𝑆𝑦⁄
500𝑀𝑝𝑎⁄
𝜎𝑐𝑟 ≤ 2 = 250Mpa
Since the critical stress is less than the safe stress the design is comfortable
4.6.2 Design of beams

Material selection
For beams st37 steel is selected with yield strength of 500Mpa.

𝑝𝑙
M= , since p is uniformly distributed load.
4
The load for each beam will be;
P = N/5= 138.64N
The beam is supported at the center so the maximum bending moment will occur at L =1500mm.
hence the length for the bending moment calculation is 3000mm. and also the load will be splitted
in to half as 138.64N.
l = 3000mm
138.64𝑁𝑥3000𝑚𝑚
M= = 103980Nmm
4
b =40mm
y = 𝑏⁄2 = 40/2 = 20mm
b Y
X b X
b = 40mm
t = 2mm
Therefore,
𝑏 4 −(𝑏−2𝑡)4 404 −(40−2𝑥2)4
I = 𝐼𝑥𝑥 = 𝐼𝑦𝑦 = = = 880384𝑚𝑚4
12 12
𝑀𝑦 103980𝑁𝑚𝑚𝑥20𝑚𝑚
𝜎= = = 2.362𝑁⁄𝑚𝑚2 = 2.362 Mpa
𝐼 880384𝑚𝑚4
To check the safety;
𝑆𝑦
𝜎≤ ,
𝑛
Where n is factor of safety, n = 2, and
𝑆𝑦 Is yield strength of the material and is equal to 500Mpa.

500𝑀𝑝𝑎
𝜎≤ = 250Mpa
2
Therefore the design is safe
4.6.3 Chain and sprocket specification

Material selection
Stain less roller chain fully meets all ANSI standards and is durable, corrosion resistant and it has
a tensile strength of 1,560Ibs and is constructed entirely out of 304-grade stainless steel. Making
a roller chain using 304-grade stainless steel creates a stainless steel roller chain that is high
strength, resistant to chemical attack and highly resistant to corrosion.
Chain specification:
For this project a chain with the following specification is selected. The chain is selected according
to IS: 2403 — 1991
ISO chain no …………… 08B
Pitch (p) in ………………..12.7mm
Roller diameter maximum……8.51mm
Width between inner plates (𝑏1 ) …….7.75mm
Transverse pitch (𝑝1) ……………13.92mm
Minimum breaking load ………….17.8 KN
Length of chain, L
The aproximate length of the chain L in pitches is
𝐿 2𝐶 𝑁1 +𝑁2 (𝑁1 −𝑁2 )2

= + +
𝑝 𝑃 2 4𝜋 2 𝐶⁄𝑝
Where C = is center distance bitween two ratchet wheels
𝑁1 = number of teth on the driving wheel
𝑁2 = number of teeth on the driven ratchet wheel

In our case the number of teeth of driving and driven ratchet wheel are equal. i.e. 31.
The center to center distance C is taken as 6150mm,
Therefore
𝐿 2𝐶 𝑁1 +𝑁2 (𝑁1 −𝑁2 )2 2𝑥6150 31+31 (31−31)2

= + + = + 𝑥1000 + 4𝜋2 𝑥6150⁄12.7 = 31.968m
𝑝 𝑃 2 4𝜋 2 𝐶⁄𝑝 12.7 2
Sprocket specification:
Table 2.3. Number of teeth on the smaller sprocket.
From the above table for a speed ratio of one and roller chain the minimum number of teeth is 31.
The rest parameters of the sprocket will be obtained based on the pitch of the chain and number of
teeth.
1. Tooth flank radius (𝑟𝑒 ) = 0.008 𝑑1 (𝑇 2 + 180) …………………………Maximum

Where 𝑑1 =roller diameter, and
T = number of teeth
2
= 0.008 𝑥8.51(31 + 180) = 73.52mm
2. Roller seating radius (𝑟𝑖 ) = 0.505 𝑑1 +0.069∛𝑑1 …………………..Maximum
= 0.505 𝑥8.51 +0.069∛8.51
= 0.605 mm
90°
3. Roller seating angle (α) = 140° - …………………………………………..Maximum
𝑇
90°
= 140° - 31
= 137°
0.8𝑝
4. Tooth height above the pitch polygon (ℎ𝑎 ) = 0.625p – 0.5 𝑑1 + …. Maximum
𝑇
0.8𝑥12.7
= 0.625x12.7– 0.5 x8.51 + 31
= 4.01 mm
𝑝 180 180
5. Pitch circle diameter (D) = = pcsc { } = 12.7xcsc { 31 } =125.54mm
sin(180⁄𝑇 ) 𝑇
6. Top diameter (Da) = D + 1.25 p – d1 ...(Maximum)
= 125.54mm + 1.25 x 12.7mm – 8.51mm
= 132.9mm
7. Root diameter (Df) = D – 2 ri = 125.54mm – 2 x 0.605mm = 124.33mm
8. Tooth width (bf1) = 0.93 b1 when p ≤12.7mm
= 0.95 b1 when p >12.7mm
= 0.93 b1 = 0.93 x 7.75mm = 7.2075mm
9. Tooth side radius (rx) = p = 12.7mm
10. Tooth side relief (ba) = 0.1 p to 0.15 p
= 0.12p = 0.12 x 12.7 = 1.524mm
11. Widths over teeth (bf 2 and bf3 ) = (Number of strands – 1) pt + bf1
Number of strand = 1, so width over teeth = bf1 = 7.2075mm
12. Power transmitted
1000𝐾𝑟 𝑁1 1.5 𝑝0.8
The nominal power transmitted, 𝐻1 = ℎ𝑝
𝑛1 1.5
Where; 𝑁1 = number of teeth, 31
𝑛1 = sprocket speed in rev/min 90rpm,
p = pitch of the chain, 0.5in
𝐾𝑟 = 2.9 for chain numbers 25, 35; 3.4 for chain 41; and 17 for chains 40-240, 29
1000𝑥2.9𝑥311.5 0.50.8
𝐻1 = ℎ𝑝 = 3.36707 hp
901.5
4.6.4 Design of handle

MATERIAL SELECTION
MATERIAL IS ST 37
Yield stress 𝝈𝒚 = 𝟐𝟓𝟎𝑴𝒑𝒂
Tensile strength 𝝈𝒖 = 𝟑𝟐𝟎𝑴𝒑𝒂
Assumptions
𝒅 = 𝟐𝟎𝒎𝒎
𝒓 = 𝟏𝟎𝒎𝒎
𝑭 = 𝟖𝟎𝒌𝒈 = 𝟖𝟎𝟎𝑵(HUMAN EFFORT )
𝒇. 𝒔 = 𝟑
ANALYSIS
𝝈𝒚 𝟐𝟓𝟎
𝝈𝒂𝒍𝒍 = = = 𝟖𝟑. 𝟑𝟑𝑴𝒑𝒂
𝒇. 𝒔 𝟑
𝝉𝒚 = 𝟎. 𝟓 ∗ 𝝈𝒚 = 𝟎. 𝟓 ∗ 𝟐𝟓𝟎𝑴𝒑𝒂
= 𝟏𝟐𝟓𝑴𝒑𝒂
𝝉𝒚 𝟏𝟐𝟓
𝝉𝒂𝒍𝒍 = =
𝒇. 𝒔 𝟑
= 𝟒𝟏𝑴𝒑𝒂
A TORQUE CREATED BY THE HUMAN EFFORT EXERTED ON THE HANDLE WITH ITS RADIUS R
WILL BE
𝑻=𝑭∗𝒓
= 𝟖𝟎𝟎𝑵 ∗ 𝟎. 𝟎𝟏𝟎𝒎
= 𝟖𝑵𝒎
NOW WE CAN CALCULATE THE WORKING SHEAR STRESS ON THE HANDLE AS
𝝅𝒅𝟑 𝝉
𝑻=
𝟏𝟔
𝟏𝟔𝑻
𝝉=
𝝅𝒅𝟑
𝟖𝑵𝒎
= 𝟏𝟔 ∗
𝝅 ∗ 𝟎. 𝟎𝟐𝟓𝟑
= 𝟐. 𝟔𝟎𝟕𝑴𝒑𝒂
SINCE THE WORKING SHEAR 2.607MPA IS LESS THAN ALLOWABLE SHEAR STRESS 41MPA,
THE DESIGN IS SAFE .
4.6.5 SELECTION OF BEARING
A bearing is a machine element which supports another moving machine element (known as
journal). It permits a relative motion between the contact surfaces of the members, while carrying
the load. A little consideration will show that due to the relative motion between the contact
surfaces, a certain amount of power is wasted in overcoming frictional resistance and if the rubbing
surfaces are in direct contact, there will be rapid wear. In order to reduce frictional resistance and
wear and in some cases to carry away the heat generated, a layer of fluid (known as lubricant) may
be provided. The lubricant used to separate the journal and bearing is usually a mineral oil refined
from petroleum, but vegetable oils, silicon oils, greases etc., may be used.
In the time gear selection things that must be consider is
 Loading capacity
 Movability or speed
 Location
 Lubrication supply
 Torque capability
So by considering all the above parameters the selected bearing for the purpose of design
project is roller bearing. Roller bearing has its own advantage than other, this advantages
makes preferable for my design, among those advantage some of them are listed below.
1, load carrying capacity is good in either axial or radial
2, easy for maintenance
3, has good rotation or lubrication simplicity
4, easily available and has low cost. Etc…
Therefore a bearing with internal diametere of 25mm is selected .
4.6.6 BEARING HOUSE
 Handle bearing housing
By itself it is so difficult to join or connect the bearing with other components due to this a bearing
house is needed. This bearing house used to fasten the bearing with the horizontal bar without any
vibration.
4.7 Cost analysis
The cost of the machine is estimated based on three categories’ material cost, fabrication cost and
labor cost. Hence cost analysis would be done as below.
Material cost
The price of one kilogram of st37 steel as standard is 16.85 birr. Therefore material cost
is estimated by considering this price. By taking the dimension of each part to calculate
their volume and then their mass and finally multiplying the mass by the unit price.
Almost all part are made from the same material st37 having a density of 7850kg/𝑚3 .
1. Column cost
I. For the two front columns
Cross section: RHS
Dimension: 870x100x50x5
Volume, V= ((100x50)-(90x40)) x870x10−9 𝑚3
=0.001218𝑚3
Mass, M =volume x density = Vx𝜌=0.001218𝑚3 x 7850kg/𝑚3
=9.5613kg
Cost= M x unit price = 9.5613kg x 16.85 birr = 161.11 birr.
For two columns
Cost =322.22 birr.
II. For the two central columns
Cross section: RHS
Volume, V= ((100x50)-(90x40)) x895x10−9 𝑚3
=0.001253𝑚3
=9.836kg
For two columns
Cost =331.47 birr.
III. For the two rear columns
Cross section: RHS
Volume, V= ((100x50)-(90x40)) x1080x10−9 𝑚3
=0.001512𝑚3
=11.8692kg
For two columns
Cost =399.996 birr.
2. Cross members cost
I. For three cross members
Cross section: RHS
Volume, V= ((40x40)-(36x36)) x1235x10−9 𝑚3
=0.00037544𝑚3
= 2.947kg
For three cross members
Cost =148.98 birr.
II. For four cross members
Cross section: RHS
Volume, V= ((40x40)-(36x36)) x1435x10−9 𝑚3
=0.0043624𝑚3
= 3.425kg
For four cross members
Cost =230.81 birr.
3. Longitudinal beams
I. For two side longitudinal beams
Cross section: RHS
Volume, V= ((80x40)-(76x36)) x5900x10−9 𝑚3
=0.0027376𝑚3
= 21.49016kg
Cost= M x unit price = 21.49016kg kg x 16.85 birr = 362.109 birr.
For two longitudinal beams

Cost =724.22 birr.
II. For three central longitudinal beams

Cross section: RHS
Volume, V= ((40x40)-(36x36)) x6000x10−9 𝑚3
=0.00182𝑚3
= 14.3184kg
For three longitudinal beams
Cost =723.27birr.
4. For two guide plates
Dimension: 6000x50x5
Volume, V= x6000x50x5x10−9 𝑚3
=0.0015𝑚3
= 11.775kg
For two guide plates, cost = 2x198.4birr = 396.8birr
5. Cost of vice
I. Lower part
=0.0012375𝑚3
= 9.714kg
II. Upper part
=0.0003𝑚3
= 2.355kg
6. U-profile
Volume, V= (0.040x0.040−0.034𝑥0.037)𝑥6𝑚3
=0.02052𝑚3
= 16.1082kg

For two u-profiles,
Cost = 2x271.42birr = 542,84birr
7. Bearing cost
Total number of bearing is eight and the standard price of one bearing having an inside
diameter of 25mm is averagely 400birr.
Therefore the total cost for bearing would be
Cost = 12x400 =4800 birr
8. Bearing housing
V = (0.112x0.01+0.072x0.036+𝜋0.0362 − 𝜋0.0262 ) x 0.02
= 0.0001132𝑚3
= 0.88862kg
Cost= M x unit price = 0.88862 kg x 16.85 birr = 14.97birr.
For four bearing housings
Cost = 4x14.97birr = 59.88birr
9. Handle shaft
V = ( 𝜋0.01252 − 𝜋0.00952 ) x 1.7
= 0.0003525𝑚3
= 0.2.767kg
Cost= M x unit price = 2.767kg x 16.85 birr = 46.626birr.
10. Upper Bearing housing
V = (0.055x0.027− 0.017𝑥0.050 ) x 0.035 - 𝜋0.01252 x0.01
= 0.0000173 𝑚3
Mass, M =volume x density = Vx𝜌=0.0000173x 7850kg/𝑚3
= 0.135805kg
Cost= M x unit price = 0.135805kgx16.85 birr = 2.288birr.
For eight upper bearing housings
Cost = 8 x 2.288birr = 18.304birr
11. Ratchet wheel
V = 𝜋0.062772 x0.007
= 0.0000866 𝑚3
Mass, M =volume x density = Vx𝜌=0.0000866x 7850kg/𝑚3
= 0.67981kg
Cost= M x unit price = 0.67981kgx16.85 birr = 11.455birr.
For two ratchet wheels
Cost = 2x11.455 = 22.91birr
12. chain
Since it is a standard material its cost will be based on standard. Assume the cost of chain for a
length of 12244mm is 3000birr.
Finally the total cost of the machine spended on material is
Total material cost = 322.22 birr + 331.47 birr + 399.996 birr + 148.98 birr + 230.81 birr + 724.22
birr +
723.27birr + 396.8birr + 163.69 birr + 39.68 birr + 4800 birr + 59.88birr +

46.626birr + 18.304birr + 22.91birr + 542.84 birr 3000birr
= 11972.026birr
Labor cost
For assembling and welding two mans is enough in one day.
So cost of labor = 2x150birr, assuming the price per day is 150birr
Therefore labor cost = 300birr
Machining cost
Here for this machine the machining cost is only for welding and grinding.
Approximate total length of weld is 3900mm, changing to many results to a birr of 1000 cost.
Total cost of the ma chine
Total cost of the machine is the sum of material cost, labor cost and machine cost
I.e. total machine cost = 11972.02birr + 300birr + 1000birr = 13272.02birr

CHAPTER FIVE
5.1 CONCLUSION
In the internship training program in the MIE Company I was able to see the overall structure,
background, the workflow, and the overall activity of the company. During the four month time I
was participating in some of the sub-assembly, assembly, maintenance, and welding activities of
the company and the above activities helps me to know the work on the plant in practices. I was
able to put my theoretical skill in to practice and improve team playing, leadership,
entrepreneurship and work ethics related skills. On my stay in in the company I see the good quality
like፦ applying kaizen philosophy, production efficiency, creating smooth working condition, good
management, giving a good service for employers and workers diligence and punctuality.
5.2 RECOMNDATION
MIE Company at gelan branch works big jobs on small work area. This creates difficulty for
storing raw material and finished products. If the company increases this work area this problrm
can reduced
The company was producing cargo body, 3 axel draw bar trailer and fuel tanker during in this
plant. If the company gives the chance for students in the feature to go to different branch of the
company the knowledge of the student taking there internship program on this company will
increase.
Specialized maintenance operator must be needed failure of working machine especially on

shearing and bending is occurred.
The sound produced around shearing machine and fabrication shop is very high which affects
the ear of the workers. So the company has to reduce this situation by building sound absorbing
hall and using sound absorbing materials.
5.3 Reference
 Machine design, R.S khurmi and J k Gupta 2005

 shigly, mechanical engineering design,8th edition
 mechanical design hand book 2nd edition
 www.amazon.com
 Some not books from the company

APPENDICES
 Upper bearing carrier
Other accessories
1 2

3 4
5 6
7 8
1, upper bearing carrier pin
2, vice base
3, hexagonal nut
4, vice pine

5, vice roller
6, vice thread
7, vice upper part
8, handle
Appendix Sample of the feeding mechanism

Appendix: Real sample of the feeding mechanism


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HAWASSA UNIVERSITY

1 PREPAIRED BY DESTA SOLOMON

2 PREPAIRED BY DESTA SOLOMON

Table 2.3. Number of teeth on the smaller sprocket.

Fig.1 bending machine

Fig.3 false chassis and frame jig for cargo body

Fig.4 board fitting for cargo

Fig.5 LB tack and final welding.

Fig.7 finishing and painting shop

Fig.6 trailer frame tacking and final welding

Fig.9 A. gearbox with broken part of shaft in B. shaft

Fig.10 electro card

3 PREPAIRED BY DESTA SOLOMON

List of table and figure

1.1 Back ground of MIE ……………………………………………………………………………………………………………… 6

1.2 Gelan manufacturing plant ……………………………………………………………………………………………………. 7

1.3 Mission ....................................................................................................................................... 7

1.4 Vision …………………………………………………………………………………………… 7

1.4 Values …………………………………………………………………………………………………………………………………….. 7

1.6 Main products and service ………………………………………………………………………. 7

1.7 Customers or end users of the company …………………………………………………………. 9

1.8 Organizational structure ………………………………………………………………………………………………………….. 10

2.1 Material preparation shop report ……………………………………………………………………………………………. 11

2.2 Fabrication department ………………………………………………………………………………………………………….. 15

2.3 Finishing and painting shop …………………………………………………………………………………………………….. 22

2.4 Maintenance shop ………………………………………………………………………………………………………………….. 24

2.5 Challenge that I have faced ……………………………………………………………………………………………………… 27

3.1 In terms of improving practical skill ………………………………………………………………………………. 28

4.1 Problem statement ……………………………………………………………………………………………………………………. 32

4.2 Objective …………………………………………………………………………………………………………………………………… 33

4.2.1 General objective ……………………………………………………………………………………………………………………. 33

4.2.2 Specific objective ……………………………………………………………………………………………………………………. 33

4.3 Scope ………………………………………………………………………………………………………………………………………… 33

4.4 Methodology ……………………………………………………………………………………………………………………………… 33

4.5 Literature review ……………………………………………………………………………………………………………………….. 35

4.6 Design analysis …………………………………………………………………………………………………………………………… 35

4.6.1 Design of columns …………………………………………………………………………………………………………………. 35

4.6.2 Design of beams……………………………………………………………………………………………………………………... 38

4.6.3 Chain and sprocket specification ……………………………………………………………………………………………. 39

4.6.4 Design of handle ……………………………………………………………………………………………………………………… 41

4.6.5 SELECTION OF BEARING …………………………………………………………………………………………………. 42

4.6.6 BEARING HOUS…………………………………………………………………………………………………………………….. 43

4.7 Cost analysis……………………………………………………………………………………………………………………………….. 43

5.1 conclusion ………………………………………………………………………………….. 49

5.2 Recommendation …………………………………………………………………………… 49

5.3 Reference ……………………………………………………………………………………………. 49

5 PREPAIRED BY DESTA SOLOMON

1.1 Back ground of MIE

6 PREPAIRED BY DESTA SOLOMON

1.6 Main products and service

Industrial and construction equipment

Other machines are:

o Different lathe machines,

8 PREPAIRED BY DESTA SOLOMON

1.7 Customers or end users of the company

9 PREPAIRED BY DESTA SOLOMON

DGM Design & DGM DGM Support

10 PREPAIRED BY DESTA SOLOMON

2 Overall internship experience