Bahir Dar Institute of Technology

Faculty of Mechanical and Industrial Engineering

Automotive Engineering Department
Internship Report

Project Title: Design of Gearbox stand

Hosting Company: Organization for Rehabilitation and Development in Amhara

(ORDA)

By: Name----------------------------------------ID

1. Dawit Asmare _______________0600510

2. Desie Yalew ________________ 0600563
3. Fentaye Abebaw______________0600730

Mentor: M.r Kebede Zegeye

Company Supervisor: M.r Getachew Tegegn

February, 2017

I
 DECLARATION

We are a 4th year Automotive Engineering students in Bahir Dar institute of technology and we
declare that this report is our own original and new work based on the past consecutive four
month internship program from oct.23/2009 to January 23/2009 at ORDA. And all the sources or
materials used for this internship project have been duly acknowledged.

Name Signature
1. Dawit Asmare __________________
2. Desie Yalew ___________________
3. Fentaye Abebaw ___________________
Approval
According to mentor and company supervisor called Mr. Kebede and Mr. Getachew they
contributed a lot of things in our training program by advising and telling the working position of
our work and the way how to work internship project.

Signature of supervisor Signature of mentor

----------------------------- ------------------------------

It is approved that this report has been written in compliance with the formatting rules laid down
by the school of Mechanical and Industrial Engineering.

II
 ACKNOWLEDGEMENT

First and foremost we would like to thank GOD which gives us strength and wisdom in every
step of our life even in this internship and to our family for supporting and encouraging us.

Secondly, we have to extend our greatest gratitude to BIT (Bahr Dar Institute of Technology) for
providing such kind of an opportunity for students to stretch their understanding on how a given
work is carried out on their respective filed of studies, which in our case was Automotive
Engineering. We would also like to thank our mentor, M.r Kebede he contributed a lot of things
in our training program by advising and telling the working position of our work and the way
how to work internship project.

Finally we also like to thank the service advisor of ORDA Mr. Getachew for his hospitality and
openness to give us the data we need. Many technicians’ in this company also supports us in
many ways among them: Yibeltal, Amlaku, Dawit, Tadele, Sintayehu, Mulat and other whom
works in ORDA vehicle repair and maintenance room. And also our friend Fekade Abebaw he
support design part of our project.

III
 EXECUTIVE SUMMARY

This internship report document is based on the four month long internship program that we had
successfully completed in ORDA. It includes brief history of the company, main services,
organizational structure, work flow, mission, vision, objectives of the company. From the report
we have also included the section of the company we have been working with, work flow and
work tasks and also the types of tools, methods and techniques are stated briefly. The report
includes major problem while performing the work task and their proposed solution and then
result & discussion with recommendation for the identified problem. Finally, the report talks
about the overall benefits we have gained from the internship and then the report concludes with
recommendation.

Another chapter of this report includes the project on design of gear box lift stand. It starts by
short summary of the project and then followed by identified problem and their justification.
Then describes the objective & methodology and then finalizes by giving a conclusion with
supported recommendation. The result & conclusion is done by taking the analysis of each
component and assembly from the software CATIA v5. The use of this software, CATIA v5,
makes the project simpler and smarter.

IV
 Table Contents
CHAPTER ONE..............................................................................................................................1
1. BACK GROUND OF ORGANIZATION for REHABILITATION and DEVELOPMENT in
AMHARA (ORDA).........................................................................................................................1
1.1 BRIEF HISTORY OF ORDA...............................................................................................1
1.1.1 ORDA Governance and Structure..................................................................................1
1.1.2Major Areas of Program..................................................................................................2
1.2 Main services of ORDA........................................................................................................3
1.3 MAIN CUSTOMERS/END USERS.....................................................................................4
1.4 ORGANIZATIONAL STRUCTURE...................................................................................4
1.5 WORK FLOW.......................................................................................................................5
CHAPTER TWO.............................................................................................................................6
INTERNSHIP EXPERIENCE.........................................................................................................6
2.1 THE REASON WHY WE SELECT THE COMPANY.......................................................6
2.2 SECTIONS OF WORK.........................................................................................................6
2.2.1 Mechanical shop.............................................................................................................6
2.2.1.1 Work Flow of Mechanical Shop..............................................................................7
2.2.2 Works in Mechanical Shop.............................................................................................7
2.3 MECHANICAL ENGINEERING METHODS, TOOLS AND TECHNIQUES AT THIS
SECTION....................................................................................................................................9
2.2.3.1 Tools used..............................................................................................................10
2.4 MAJOR CHALLENGES FACED AND THERE PROPOSED SOLUTION&
RECOMMENDATION.............................................................................................................12
2.5 OVERALL BENEFITS WE GAINED FROM INTERNSHIP...............................................13
2.5.1 Improving practical skills.............................................................................................13
2.5.2 Upgrading theoretical knowledge.................................................................................14
2.5.3 Improving Team playing skills.....................................................................................14
2.5.4 Improving Leadership skills.........................................................................................15
2.5.5 Understanding about related work ethics & Industrial Psychology.............................15
2.5.6 Entrepreneurship skills.................................................................................................15
2.5.7 Improving Interpersonal communication skills............................................................16
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 2.6 Conclusion and Recommendation.......................................................................................16
CHAPTER THREE.......................................................................................................................18
DESIGN OF GEARBOX STAND................................................................................................18
3.1 SHORT SUMMARY OF THE PROJECT..........................................................................18
3.2 PROBLEM STATEMENT & JUSTIFICATION...............................................................19
3.3 OBJECTIVE........................................................................................................................21
3.3.1 MAIN OBJECTIVE.....................................................................................................21
3.3.2 SPECIFIC OBJECTIVES.............................................................................................21
3.4 METHODOLOGY..............................................................................................................22
3.5 LITRETURE REVIEW.......................................................................................................23
3.6 Material Selection................................................................................................................34
3.7 COMPONENT DESIGN.....................................................................................................35
3.8 RESULT AND DISCCUSION............................................................................................48
3.9. COST ANALYSIS.............................................................................................................48
3.10 CONCLUSION AND RECOMMENDATION................................................................49
CHAPTER FOUR.........................................................................................................................50
GENERAL CONCLUSIONS AND RECOMMENDATIONS....................................................50
4.1 CONCLUSIONS.................................................................................................................50
4.2 RECOMMENDATIONS.....................................................................................................50
References......................................................................................................................................51

VI
Lists of figures
Figure 1 organization structure........................................................................................................4
Figure 2 work flow..........................................................................................................................5
Figure 3 tools.................................................................................................................................10
Figure 4 Compressor......................................................................................................................11
Figure 5 bench vice and jack.........................................................................................................11
Figure 6 gearbox stand...................................................................................................................18
Figure 7 gearbox stand...................................................................................................................19
Figure 8 screw nut.........................................................................................................................29
Figure 9 holding and lower plate...................................................................................................35
Figure 10 stress analysis of plate...................................................................................................37
Figure 11 translational displacement magnitude of plate..............................................................37
Figure 12 screw..............................................................................................................................38
Figure 13 stress analysis of screw.................................................................................................41
Figure 14 translation displacement analysis of screw...................................................................41
Figure 15 sliding arm.....................................................................................................................42
Figure 16 beam..............................................................................................................................43
Figure 17 beam stress analysis......................................................................................................46
Figure 18Beam Translational Displacement Analysis..................................................................46
Figure 19 leg..................................................................................................................................47

VII
 CHAPTER ONE

1. BACK GROUND OF ORGANIZATION for

REHABILITATION and DEVELOPMENT in AMHARA (ORDA)
1.1 BRIEF HISTORY OF ORDA
Organization for Rehabilitation and Development in Amhara (ORDA), which is a registered
charity organization according to the Ethiopia charities and societies proclamation number
621/2009, article 68 (with a Registration number 0607), is an indigenous, non- for-profit, non-
government development organization.

ORDA, the former Ethiopia Relief Organization (ERO), was established by voluntary and
committed individuals in 1984 and involved in the response to the famine caused by drought and
civil war in the northern part of the century till1991.From the period 1991to 1996, the
organization mainly focused on extending its previous relief and rehabilitation interventions
integrating with soil and water conservation, supply of crops seeds, plough oxen and other farm
tools activities.

The organization has designed and implementation three strategic plans so far: the first strategic
plans (from 1997to 2003) the second strategic plan (2004to 2008)

And the third strategic plan (from 2009 to 2013), ORDA has mainly engaged in three pillar
program: Natural Resource Development, water resource development, food Security and
Agricultural development.

1.1.1 ORDA Governance and Structure

ORDA is constituency based organization from which its General Assembly Is formulated. Its
second highest governing body, elected by the General Assembly (GA) for four years term is the
board of directors, which in turn it assigns the executive and deputy directors. The board of
directors oversees the implementation of organization strategies and plans and provides overall
quittance to the management of the organization.

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 1.1.2Major Areas of Program

 Natural Resource Development Program,

 Food security and Agricultural Development program and
 Water Resource Development Program,
 Food security and Agricultural Development program and
 Youth and Gender program
 Vehicles repair and maintenance
I. Annual Budget

The annual budget increased from 21.77 million in 1997 to 54 million in 2003. In 2013, ORDA
mobilized resource amounting to over 600 million birr including food commodities

II. Intervention Districts

In 2004, its operational areas were limited in eight districts

In 2011, this number reached at 80 that benefit more than 3.5 million people.

In 2012, ORDA project, which would benefit 1.6million people, have intervened in 64 districts.

In 2013, ORDA extended its projects over 63 woredas including Bahir dar city and reaching
1.3million people.

III. Partnership Development

 In 2004, the number of funding organizations which support ORDA was only seven;
 In 2011, the number of active funding organization was 26.
 In 2012, the number of active funding organization has reached at 30.
 From 1992to 2012, a total of funding partners collaborating with ORDA is about 44.
IV. Project coordination offices

ORDA has about seven Zonal coordination offices and in 2013, orda implemented 78
development projects (31 water and 47 various other projects) funded by 32 funding partners at
grassroots or district level.

V. Human resource

Currently, ORDA’s total number of employees is 958 (237 female), out of which 237 (49female)
are working at head office (Bahir dar), 685(188female) at project and zonal coordination office,
and 12 at resource mobilization and liaison office (Addis Ababa)

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  Technical staff 319(79 are females) and
 Supportive and administrative staff are 436(136 are females).

3
VI. International and National Awards

International: Agro Action.

National: First Class National Green Award in 2007, for its excellence performance of Natural
Resource Development.

 The mission of ORDA

Empowering poor communities and their organizations to achieves livelihoods and

environmental security in Amhara region

 The vision of ORDA

ORDA envisions prosperous society in Amhara region of Ethiopia.

 Organization of ORDA

Contributing for the over efforts of ensuring food, livelihood and environment and social
transformation in the Amhara region of Ethiopia.

 Motto

Transformation through collaboration

 Core Value
 Respect and redaction to the people
 Integrity
 Endurance
 Transparency and accountability
 Inclusiveness

1.2 Main services of ORDA

ORDA garage:
Periodic maintenance: This includes changing oil, changing grease, changing oil filter,
changing timing belt, etc.

General service repair: The general repair service comprises of units overhauling (like
engine, automotive & manual transmissions/transaxles, fuel injection, pumps, differentials,
steering gearboxes, vane pumps, starters, alternators, etc.) and diagnosis and repair of any
malfunctions on the vehicle using the state of art equipment and tools available in the service
centers.

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 1.3 MAIN CUSTOMERS/END USERS
ORDA's primary target groups for changes are both rural and urban poor communities with due
attention to:

 Women

 Landless

 Unemployed youth and

 Persons with disability

1.4 ORGANIZATIONAL STRUCTURE

5
Figure 1 organization structure

6
 1.5 WORK FLOW

Garage Inspector

Transport Division

Mini Garage Work Shop Head

Mechanic Group Leader

Technician/Mechanic

Figure 2 work flow

Address
 Head office
 P.O. box 132
 Bahir dar, Ethiopia
 Tel: +251(58)2264376
 Fax: +251(58)2200987
 E-mail: orda-1atethionet.et

7
 CHAPTER TWO

INTERNSHIP EXPERIENCE
2.1 THE REASON WHY WE SELECT THE COMPANY
The reason for the selection of this company includes many criteria’s. We have tried to see some
companies but finally we have selected ORDA as our internship hosting company. Because we got
the following advantage:

 There are qualified and experienced technicians (mechanics) who can give me a detailed
Knowledge about general vehicles.
 ORDA have many project in different place and use many vehicles for these purpose and
the vehicles maintain and repairs in the garage. And this is another criterion why we
select the company.

2.2 SECTIONS OF WORK

There are three sections of work in this company, the following are among this

1. Mechanical shop
2. Body shop
3. Electrical shop
We have been working in almost all sections, but mostly we spent our time in Mechanical shop,
because works in this section are more related to our many courses we have taken such as Power
train, Engine over hauling, Suspension and ride control, Fundamentals of Automotive
Engineering, CATIA, IC engine, machine element & many others.

2.2.1 Mechanical shop

This is the shop that the engine, gear box and transfer case, and differential of the vehicle is
being serviced and repaired. There are 3 mechanics working here. We can discuss the services
taken by the vehicle at this shop by classifying into three types of works.

Namely;

 Power train (Gear box, transfer gearbox & Differential services )

 Brake, Steering & fuel systems

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 2.2.1.1 Work Flow of Mechanical Shop
The work flow of this shop consist all the general steps followed by the company. Such steps are:

 Remove from the body disassemble

 Disassemble
 Cleaning
 Inspection (visual and measurement)
 Reassembly

2.2.2 Works in Mechanical Shop

Gear box and transfer case service: gear box and transfer case is the main part for
changing the speed, torque and acceleration of the vehicle by changing the meshing gears. The
gear box let then vehicle and the driver to choose the active gear meshes from 1st to 5th level and
also the reverse. The transfer case will transfer the rotation to the propeller shaft. For 4WD (4
wheel drive) the propeller shafts are for front and rear wheel. Works like then following can be
executed in this section:

In the period of internship one land cruiser hard top entered in our work shop because of hard
shifting and transmission jumps out of gear (3 & 4 gears) the work shop took remedy by removal
of the gear box from the vehicle.

We used the following steps to Removal of transmission

1 Disconnect battery cable from negative terminal

2 Loosen fan shroud of the cooling fan to avoid damage to fan

3 remove shift lever

4 Disconnect propeller shaft

6 Remove stiffener plate

7 Remove clutch release cylinder

8 Remove starter

9 Remove vacuum hose

10 Remove 4WD and back up light switch connector

11 Remove speedometer cable

12 Remove exhaust pipe

9
13 Remove cross member

Figure 4 assembled gear box

Figure 5 Disassemble of gear box

Differential service: differential is a gear set arranged in planetary gear arrangement with almost
6 bevel gears used. The main purpose of a differential is to transfer the rotation it gets from the
propeller shaft to the axle of the wheel. The other use of the differential is to stabilize the rotation
of the two sides paired right and left wheel during turning.

The Function of Differential (final drive)

 Transmit torque from drive shaft to drive axles and rear wheels
 Transmit torque at a 90 degree angle

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  Provides a gear reduction between the drive pinion and drive axles.
 Split driving torque between the two wheels
 Allows drive wheels to turn at different speeds when turning corners.
 Supports the Chassis, drive axles, and differentials
 Provides the means to attach the suspension system brake assemblies, and drive wheels

Service of this part of the vehicle is taken at any time of damage.

Some of the works done in section includes:

 Replacing bolts
 Cleaning the gears and housing
 Replacing bearings
 Keeping the initial torque using torque wrench and
 Filling the differential with differential oil

Figure 6 differential

2.3 MECHANICAL ENGINEERING METHODS, TOOLS AND

TECHNIQUES AT THIS SECTION
In this section, all the above work tasks are performed according the standard instruction
manuals formulated by Toyota Company. And these guidelines contain many mechanical
engineering methods and techniques. Among these methods we try to list some of them below:

Some of the mechanical engineering techniques and methods are:

Safety: - All mechanics and cleaners in this section wear a standard safety shoe which can
hold 50kg load that might cause damage to foot fingers. The company also provides a standard
work wearing and putting a rule that all mechanics should wear at work with gloves. Also each
mechanics have their own table and box for putting their own work tools.
11
Cleaning: - For a good service and maintenance a good cleaning is needed from engineering
point of view. For this matter there are 2 cleaners which work equal time as mechanics cleaning
the ground and the space around.

Reuse of replaced materials: - The other methods we have seen are how they use the
wasted materials and oils. For instance the replaced engine oils are collected and sold to the
outside customers.

2.2.3.1 Tools used

Hand Tools

Figure 3 tools

 Socket  Socket Adapter

 Universal Joint (Socket Wrench  Extension Bar (Socket Wrench Set)
Set)
 Spinner Handle  Sliding Handle
 Ratchet Handle  Boxed Wrench (Boxed wrench)
 Opened Wrench (Spanner)  Adjustable Wrench
 Screwdriver  Needle-Nose Pliers
 Slip-Joint Pliers  Cutting Pliers (Nipper)
 Hammer  Gasket Scraper
 Center Punch  Pin Punch

12
Figure 4 Compressor

Auto lift

 Car jack
 Bench vice

13
Figure 5 bench vice and jack

2.4 MAJOR CHALLENGES FACED AND THERE PROPOSED

SOLUTION& RECOMMENDATION
Behind every success, there is /are obstacles or challenges. Among the challenges we have been
faced, some of them are;

Adapting the workers and the compound

lack of team work

lack of safety materials

Absence of measuring devices

Shortage of tools and equipment’s

The working place is so rough and dusty, which exposes us for loss of interest at the time of
work

Time taking respond of officials to maintain vehicles

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2.4.1 Measures Taken To Overcome the Challenges

Through time it is obvious that relations are made between workers and internship students,
because they discuss and helping each other for problem solving issues.

We try to make our own team.

We suggest every worker should come up with safety materials.

We use some measuring devices which are available for the required task

As much as possible, we try to use different materials in the place of necessary equipment’s
and by manufacturing our project which is gearbox and differential stand we try to minimize one
of these absences

We adapt the working place by taking measurements like spraying water over the dust,
selecting cloth and shoes which are relates to the weather condition

We solve the problem by asking the officials of the company repeatedly

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 2.5 OVERALL BENEFITS WE GAINED FROM INTERNSHIP
In this 4 months internship experience, we have got much skills, knowledge and higher
confidence about many things. Generally we have got such benefits in terms of:

 Improving Practical skills

 Upgrading theoretical knowledge
 Improving team playing skills
 Improving leadership skills
 Understanding about work ethics related issues
 Understanding how to be entrepreneurship skills
 Improving interpersonal communication skills
 Understanding industrial psychology
 Industrial problem solving capability

2.5.1 Improving practical skills

Working with experienced mechanics gives us much skills about automotive maintenance ,
repair and use of other machines.
From this internship program, we have got a good chance to improve our practical skill highly.
We can develop our skill by participating ourselves into different parts as we had learned
theoretically in our department course. Among them
Designing new project- by taking problem of the company under consideration we have
designed to solve the main problem of the company.
 To do Periodic maintenance of mechanical machines
 To know How a vehicle works
 To know Tools and their proper using
 To know repair practical Vehicle systems like:
Suspension system
Power steering system
Final drive system
Transmission system
Engine system and electric system etc…
 Assembling and disassembling of different parts of a vehicle
 To explore modern technologies about automotive
Generally, we know many things practically which works mostly in the company, such as:
 Power train service
 Oil filter replacing
 Fuel filter replacing
 Replacing AC and alternator belts
 Disassembling and assembling of gear box
 Spider kit replacement
 Detecting leakages on parts
 Maintaining brake system

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 2.5.2 Upgrading theoretical knowledge
In addition to the practical skill this program helps to us strengthen our theoretical knowledge.
The practice depends first on theory, it is easy to work for the one having good theoretical base.

Theoretical knowledge is dependable on principles, logic and calculations.

The following are some points that we improved our theoretical knowledge:

 Upgrading theoretical knowledge of courses like Power Train, IC engine, Engine

overhauling, Fundamentals of Automotive Engineering, Suspension and Ride control,
CATIA, Pneumatic & Hydraulic systems, instrument and measurements, heat transfer
and other supplementary courses
 Know about different vehicle systems
 Know How safety is taken while working
 Know about application of pneumatic & hydraulic systems
 Know about how to assemble & disassemble vehicle parts
 Know how to maintain, repair and service vehicles

2.5.3 Improving Team playing skills

Since most of the works in any industry done by a group of workers, there should be good
relationship between each member. In our section also more than 3 mechanics are worked
together peacefully and by helping each other. So we have improved our team playing skills by
gaining the following benefits:

 Appreciating & encouraging each other

 Communicates constructively
 Listening each other
 Helping one another
 Shares openly and willingly
 Compromise others mistakes
 Flexible & Simple to one another
 Shows commitment to the team
 Works as a problem- solver
 Treats others in a respectful and supportive manner

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 2.5.4 Improving Leadership skills
Leadership is a skill to guide, control and monitor peoples. There are one foreman and three
leads with general manager and service manager. This shows that we take a lot of experiences
from their leading. They control each employee in their day to day activities. That means we got
the chance to saw the strength and weakness of each leader. We have gained the following
benefits which improved our leadership skills:

 Committed to the work

 Understanding others idea
 Peaceful with others
 Upgrading with knowledge etc

2.5.5 Understanding about related work ethics & Industrial Psychology

By working in this company we also gain understanding about industrial psychology which is a
very important tool for the success of the company.

 Punctuality
 Office disciplines
 Reliability
 Honesty
 Cooperative
 Good leadership
 Self confidence

2.5.6 Entrepreneurship skills

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 this internship include the following:

 Self-confident multi-skilled
 Results-orientated
 A risk-taker
 Total commitment
 Finally, to cope with this changing nature of work, students must be enterprising and
flexible, and may need to become entrepreneurial.

Generally, the internship has the following benefits and goals.

 Run more about a chosen field and Apply classroom theory to real work situations.
 Become more knowledgeable about general work functions in particular fields.
 Investigate organizational cultures and Learn career-related skills.
 Identify transferable skills and Strengthen written and oral skills.

18
  Find out what it's like to work in a business environment.
 Make contacts to gain future employment and Bridge between college and work.
 Gain an increased awareness of skills, attributes, personal qualities and values.
 Gain meaningful engineering experience to complement academic studies.
 Develop a professional attitude that is reflected in the performance of responsibilities and
tasks, and learn about the importance of professionalism in the real world.
 Obtain more interesting and satisfying jobs because of the internship experience.
 Earn money while gaining valuable experience
 Use the activities carried out during an internship term as the basis of a fifth- year thesis.

2.5.7 Improving Interpersonal communication skills

Since services and mechanic work is a team work by its nature you will face different individuals
with different professions and personalities come up together and communicate with each other
to solve different problems and run the whole work. We can say that we have got good lesson
regarding communication skill while our stay in the company for the internship program.

2.6 Conclusion and Recommendation

Recommendation

We would like to recommend some things regarding to our internship for the company as well as
the reader of this document. We have recommended the following things;

Fulfill working tools and equipment

Fulfill safety materials and vehicle manuals
Improve working area and increase number of employs lack of training for new vehicles to
all workers to understand the manual and operation.
There is lack of special tools; therefore the organization should buy different equipment for
increasing productivity and to decrease breakdown.
Old vehicles should be remove to decrease material and labor costs
It is better for the organization to give annually training courses for the drivers because it
increases car handling and decrease vehicle failures
We would like to recommend students who join the internship program for the future to use their
time effectively and change their theoretical knowledge to practical.

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Conclusion

During our intern ship in ORDA we have gain a lot of knowledge regarding integrating theory
with practice, introducing us to industrial world, working with industry practitioners and also this
practice enhance me with different skills such as inter personal communication, team playing and
leader ship skill in addition we have also improve our technical writing skill.

During our stay in ORDA entrepreneurship we have learned a lot of skills and develop
knowledge in different ways. This internship program has also brought a spectacular experience
for us concerning the field that we study.

We have also gained a lot of new knowledge on different topics of our field of study which we
haven’t taken and the topics which we couldn’t get from campus. Problems in the working
environment were not confusing as in the one’s we solve in class rooms. This is due to the fact
that the problems are real sense with all the challenges and excitements. Apart from the
professional skill, we have built up good cooperative attitude with other partners.

As time goes our working ability was growing tremendously. But there had been some
challenges while performing my tasks which we had to take different measures to overcome.
Generally we was doing well except the fact that we couldn’t complete my task as a professional.

20
 CHAPTER THREE

DESIGN OF GEARBOX STAND

Figure 6 gearbox stand

21
 Abstract
This report includes the project on design of gear box lift stand. It starts by short summary of the
project and then followed by identified problem and their justification. Then describes the
objective & methodology and then finalizes by giving a conclusion with supported
recommendation. The result & conclusion is done by taking the analysis of each component and
assembly from the software CATIA v5. The use of this software, CATIA v5, makes the project
simpler and smarter.

22
 3.1 SHORT SUMMARY OF THE PROJECT
This project deals with the design of gearbox stand. The project contains a problem of statement
which states the problem, objective of the project, methodology, literature review ,the design of
each component ,results and discussions and final states a conclusion and recommendations.
Gearbox stand is a tool commonly used to repair large heavy gearboxes. Gearbox stand provides
a convenient means of turning the gearbox over for disassembly and reassembly. The gearbox
stand is made to accept various size gearboxes and allow the gearbox to be worked on in a safe
and feasible way. The gearbox stand should allow the user or the mechanic to be able to move
the gearbox while it is on the stand. The stand should also allow the user to work on the gearbox
in various positions.

23
Figure 7 gearbox stand

24
 3.2 PROBLEM STATEMENT & JUSTIFICATION
There are many problems in ORDA automotive garage. Such as; lack of lifting tools, working
area also full of gravel and dust, different materials also store in the garage area by this reason
the vehicles store disorderly.

But these problems could not solve due to different cases like; lack of awareness and knowledge,
management problem… From these problems, our major focus on lifting tools, so that during the
maintenance of vehicles, holding the gear box in order to assemble and disassemble to and from
the vehicle is not an easy task. This operation also needs plenty of time and labor so as to
perform safely.

There is also physical damage during the process. i.e, the mechanic may be injured. The problem
is serious when maintaining heavy duty vehicles. Since their gearbox is very huge and difficult to
carry on it.

In order to solve all the above problems we have come up with a good idea which will reduce all
the above difficulties. We proposed to design a GEARBOX STAND. This machine makes easy
the maintenance of gearbox by minimizing labor force, increases safety and ease up maintenance
time needed to carry on it to assemble and disassemble to and from the vehicle.

25
 3.3 MAIN OBJECTIVE
The main objective of the project is to design a GEARBOX STAND which can carry up to
150kg at proper manner and can travel it to the required place at a comfortable situation and
short period of time with minimized labor force.

3.3.1 Specific Objectives

The specific objective of this project includes:

To design each part of a gearbox stand

 Design of sliding arms

 Design of holding and lower plate
 Design of beam
 Design of screw
 Selection of wheels and bearings

3.4 Significance of The Project

To save working time

To save labor force

To maintain better Safety of mechanics who maintain the gearbox

26
 3.5 LITRETURE REVIEW
Several gearbox stands were developed up to this time. The stand models first developed were
flat tables. Such a stands are not suitable for the workers, needs more labor and waste more time.
In addition to this, these stands are not manufactured in our county. The price of the tool is too
expensive when it is imported from abroad. The stand developed in this project has a sliding and
roiling for transporting purpose and have a very cheap cost.

The gearbox stand will be developed by using several models for the component. The models
used are directed at a specific aspect of the stand’s response to loading. We are attempted to
identify several basic loading and resultant responses. The stand consists of different
components. Mainly it consists of about 6 components.

1. Holding and lower plate: these is a rectangular plates used to support the applied load,
and transmit the load to the screw. Since the plates are subjected to bending stress and
shear stress, we have to check the above two types of stress.

Bending stress

Where M = Bending moment acting at the given section,

 = Bending stress,

I = Moment of inertia of the cross-section about the neutral axis,

y = Distance from the neutral axis to the extreme fiber,

Shear stress

Where P= applied load

A= shear area

27
 2. Screw
The power screws (also known as translation screws) are used to convert rotary motion into
translator motion. For example, in the case of the lead screw of lathe, the rotary motion is
available but the tool has to be advanced in the direction of the cut against the cutting resistance
of the material. In case of screw jack, a small force applied in the horizontal plane is used to raise
or lower a large load. Power screws are also used in vices, testing machines, presses, etc.

In most of the power screws, the nut has axial motion against the resisting axial force while the
screw rotates in its bearings. In some screws, the screw rotates and moves axially against the
resisting force while the nut is stationary and in others the nut rotates while the screw moves
axially with no rotation.

28
29
Torque Required to Lower Load by

Square Threaded Screws

A little consideration will show that when the load is being lowered, the force of friction (F =
RN) will act upwards. All the forces acting on the body are shown in Fig. 17.4.

30
Maximum Efficiency of a Square Threaded Screw

Stresses in Power Screws

A power screw must have adequate strength to withstand axial load and the applied torque.

Following types of stresses are induced in the screw.

1. Direct tensile or compressive stress due to an axial load. The direct stress due to the axial
Load may be determined by dividing the axial load (W) by the minimum cross-sectional area of
the Screw (Ac) i.e. area corresponding to minor or core diameter (dc).
31
Direct stress (tensile or compressive)

W/Ac

This is only applicable when the axial load is compressive and the unsupported length of the
Screw between the load and the nut is short. But when the screw is axially loaded in compression
and the unsupported length of the screw between the load and the nut is too great, and then the
design must be based on column theory assuming suitable end conditions in such cases, the
cross-sectional area corresponding to core diameter may be obtained by using Rankin-Gordon
formula or J.B. Johnson’s

Formula According to this,

Note : In actual practice, the core diameter is first obtained by considering the screw under
simple compression and then checked for critical load or buckling load for stability of the screw.

2. Tensional shear stress. Since the screw is subjected to a twisting moment, therefore tensional

Shear stress is induced. This is obtained by considering the minimum cross-section of the screw.
We know that torque transmitted by the screw,

Or shear stress induced,

32
When the screw is subjected to direct stress and tensional shear stress, then the design must be
based on maximum shear stress theory, according to which maximum shear stress on the minor
diameter section,

It may be noted that when the unsupported length of the screw is short, then failure will take
place when the maximum shear stress is equal to the shear yield strength of the material. In this
case,

Shear yield strength,

3. Shear stress due to axial load. The threads of the screw at the core or root diameter and the
threads of the nut at the major diameter may shear due to the axial load. Assuming that the load
is uniformly distributed over the threads in contact, we have Shear stress for screw,

Figure 8 screw nut

4. Bearing pressure. In order to reduce wear of the screw and nut, the bearing pressure on the
thread surfaces must be within limits. In the design of power screws, the bearing pressure
depends upon the materials of the screw and nut, relative velocity between the nut and screw and
the nature of lubrication. Assuming that the load is uniformly distributed over the threads in
contact, the bearing pressure on the threads is given by

33
Therefore, from the above expression, the height of nut or the length of thread engagement of the
screw and nut may be obtained.

34
The following table shows some limiting values of bearing pressures.

3. Sliding arms; these components are adjustable in order to fit for different gearbox
models. Four sliding arms are used. Each sliding arms balance or guides the gearbox
motion when it moves. Its dimensions designed based on the dimension of holes in the
gearbox and slots in the lower plate. Due to this reason we select the sliding arms.

P = Force or load acting on a body, and

A = Cross-sectional area of the body.

d 2=outer diameter

d 1=inner diameter

Buckling: when the length of column increase it undergoing the vertical deformation known as buckling .

Where; E= young’s modulus

I = polar moment of inertia

35
 L = length of column

Pcr = critical load

4. Beam:
In engineering practice, the machine parts of structural members may be subjected to static or
dynamic loads which cause bending stress in the sections besides other types of stresses such as
tensile, compressive and shearing stresses. Consider a straight beam subjected to a bending
moment M as shown in Fig. 5.4. The following assumptions are usually made while deriving the
bending formula.

1. The material of the beam is perfectly homogeneous (i.e. of the same material throughout) and
isotropic (i.e. of equal elastic properties in all directions).

2. The material of the beam obeys Hooke’s law.

3. The transverse sections (i.e. BC or GH) which were plane before bending remain plane after
bending also.

4. Each layer of the beam is free to expand or contract, independently, of the layer, above or
below it.

5. The Young’s modulus (E) is the same in tension and compression.

6. The loads are applied in the plane of bending.

Where

M = Bending moment acting at the given section,

= Bending stress,

36
I = Moment of inertia of the cross-section about the neutral axis,

y = Distance from the neutral axis to the extreme fiber,

E = Young’s modulus of the material of the beam, and

R = Radius of curvature of the beam.

5. Leg; is a vertical member that support the overall weight of the system, consequently
buckling and compressive stress are develop through the member, but the member is too
short so, it does not subjected to buckling.

6. Bearings
In rolling contact bearings, the contact between the bearing surfaces is rolling instead of sliding
as in sliding contact bearings. We have already discussed that the ordinary sliding bearing starts
from rest with practically metal-to-metal contact and has a high coefficient of friction. It is an
outstanding advantage of a rolling contact bearing over a sliding bearing that it has a low starting
friction. Due to this low friction offered by rolling contact bearings these are called antifriction
bearings.

Advantages and Disadvantages of Rolling Contact Bearings Over Sliding

Contact Bearings
37
The following are some advantages and disadvantages of rolling contact bearings over sliding
contact bearings.

Advantages

1. Low starting and running friction except at very high speeds.

2. Ability to withstand momentary shock loads.

3. Accuracy of shaft alignment.

4. Low cost of maintenance, as no lubrication is required while in service.

5. Small overall dimensions.

6. Reliability of service.

7. Easy to mount and erect.

8. Cleanliness.

Disadvantages

1. More noisy at very high speeds.

2. Low resistance to shock loading.

3. More initial cost.

4. Design of bearing housing complicated.

38
 7. Selection of wheel
Wheels are other key components of the stand, which provides the technician to move the stand
in any required place even including the gearbox. There are four wheels in number. The wheels
are directly selected according to the maximum load the gear stand can subjected. The wheels are
directly purchased from the market.

These wheels must carry a maximum amount of weight which is the sum of the maximum
applied gearbox weight and the weights of the gearbox stand parts.

39
 3.6 Material Selection

We have selected the suitable material for our project depending on the following criteria’s. Those
are:

 Availability of the material

 Suitability of the material for the working condition
 The cost of the material
 Property of the material
 Recommendation from the company or availability of the material in the company

Generally the material selected and its property is shown in the table below;

40
 3.4 METHODOLOGY
The design procedures for this design project are as follows;

 Identify the problem

 Good literature review, State forces and stress at each components of the stand and state
what type of model is developed for each components of the gearbox stand.
 Design each components of the gearbox stand;
 Design of bolts and nuts; during the design of bolts and nuts the following tasks must
be performed;
 Geometric, force and stress analysis
 Catia V5 analysis
 Design of sliding arms; during the design of sliding arms the following tasks must be
performed;
 Geometric and force analysis buckling
 Catia V5 analysis
 Design of holding plate; during the design of holding plate the following tasks must be
performed;
 Geometric and force analysis
 Check the holding plate due bending and shear stress
 Catia V5 analysis
 Design of horizontal shaft; during the design of horizontal shaft the following tasks must
be performed;
 Geometric analysis
 Check due to bending stress
 Catia V5 analysis
 Design of lower plate; during the design of lower plate the following tasks must be
performed;
 Geometric and force analysis
 Check the lower plate due bending and shear stress
 Catia V5 analysis
 Design of square thread bolt; during the design of square thread bolt the following tasks
must be performed;
 Geometric, force and stress analysis
 Check due to bending stress
 Catia V5 analysis
 Selection of wheels and bearings

41
 3.7 COMPONENT DESIGN

1) Design of holding and lower plate

Figure 9 holding and lower plate

M=P*L

=1500N*0.280m

=420Nm

420 173.3
bt 3 = t
12 2

12∗420000 12∗420000
t2 = = = 27.4
b∗2∗173.3 0.53∗2∗173.3

t = 5.2m = 6m

V = l*w*h = 0.53*0.56*0.006 = 1.7808*10-3m3

W = ῥ*v*g = 7.920*1.7808*10-3*9.81 = 140N

42
43
│ ─────────560mm───────│

580mm

6mm

WT=1500+140=1640N=1.64kN

Checking for shear stress

P P P 1500 N
τ= = = = = 0.47Mpa
As t∗0.53 6 m∗530 m 6∗530

There for it is less than 50Mpa, so our design is safe

Catia analysis of lower plate

Material

Material Steel

Young's modulus 2e+011N_m2

Poisson's ratio 0.266

Density 7860kg_m3

Coefficient of thermal expansion 1.17e-005_Kdeg

44
 Yield strength 2.5e+008N_m2

Relative
Applied
Components Reactions Residual Magnitude
Forces
Error

Fx (N) -5.0449e-010 1.4121e-009 9.0766e-010 9.1980e-013

-1.7244e-
Fy (N) 2.0382e-007 -2.0555e-007 1.7475e-012
009

Fz (N) 1.5000e+003 -1.5000e+003 8.7721e-010 8.8894e-013

Figure 10 stress analysis of plate

45
Figure 11 translational displacement magnitude of plate

46
2 Design of screw

Figure 12 screw
d
T1=wtan(ϕ- α)
2

P=wtan(α - ϕ)

μ =tna(ϕ)

0.21=tan(ϕ)

tan-1(0.21)=11.860 = ϕ

2α=90 - ϕ

α =390

d
T1=wtan(ϕ- α) =1640tan(11.86-39)200 = 703159.36Nm
2

π
T= * τ (dc)3
16

16T= π* τ (dc)3

16 T 16∗703159.36
(dc)3 = = =41.5mm
π∗τ π∗50

dc = 43mm,

47
48
From the standard table we get

d1=46mm P=3mm Ac=1452mm

d=46mm h=1.5mm
D=46.5mm H=1.75mm
W
σ = Ac

1640
173.3= π d c 2
4

4∗1640
dc 2 =
173.3∗π

520 800 2
=1452*520[1- ( )]
4∗0.25∗π 2∗190 10.75

= 404.492kN

16T 16∗703159.36
τ = π (dc)3 = π∗(43)3 = 45Mpa

W
σ= = 1640/1452=1.13Mpa
Ac

1
τmax= (1.13)2 +4∗(45)2 = 45.012Mpa
2√

it is less than 50Mpa so, our design is safe

W
σscr = π∗n∗dc∗t

1640
= n=15
π∗15∗43∗1.5

=0.54Mpa t=1.5

It is < 50Mpa, safe

49
 W
σnut = π∗n∗do∗t

1640
= = 0.5Mpa < 50Mpa safe
π∗15∗46.5∗1.5

Major diameter Depth of

thread
bolt nut bolt nut
d D h H
46 46.5 1.5 1.75

Bearing pressure

W
W 4∗1640
Pb ¿ = π =
πdtn
4
[ ( do ) 2−( dc ) 2 ] n [ ( 46.5 )2− ( 43 )2 ]15

= 0.444Mpa < 17.5Mpa so, our design is safe

Catia analysis of screw

Materials
Static Case

Material Steel

Young's modulus 2e+011N_m2

Poisson's ratio 0.266

Density 7860kg_m3

Coefficient of thermal expansion 1.17e-005_Kdeg

50
 Yield strength 2.5e+008N_m2

Relative
Applied
Components Reactions Residual Magnitude
Forces
Error

Fx (N) 0.0000e+000 2.7711e-013 2.7711e-013 9.6728e-016

-2.5935e-
Fy (N) 0.0000e+000 -2.5935e-013 9.0527e-016
013

-1.5916e-
Fz (N) -1.5100e+003 1.5100e+003 5.5557e-015
012

Mx (Nxm) 0.0000e+000 1.1857e-013 1.1857e-013 1.0347e-015

My (Nxm) 0.0000e+000 1.0969e-013 1.0969e-013 9.5720e-016

51
Figure 13 stress analysis of screw

Figure 14 translation displacement analysis of screw

52
 2) Design of sliding arm

Figure 15 sliding arm

W 1640
P= = = 410N
4 4

From the standard of stainless steel pipes, we got, D o = 33.4mm

W 4∗W
W
σc = A = π 2 2 =
[ ( Do ) −( Di ) ] π [ ( Do )2−( Di )2 ]
4

4∗410
173.3=
π [ ( 33.4 )2−( Di )2 ]

From this we got Di=32.055mm

There for the pipe is strong enough to carry the applied load

4∗W 4∗410
σc = π ( Do )2−( Di )2 = π ( 33.4 )2−( 32.055 )2
[ ] [ ]
=6.06Mpa < 173.3Mpa, so our design is safe

The sliding arms also subjected to buckling, due to that we have to check for buckling

IE ( π )2
Pcr = 2
( L)
2
π ( Co 4−Ci 4 )∗E∗π 2 ( Di )
= 2
4 (L)

π 3∗190∗10 9∗( 16.7 4−16.0425 4 )

=
4∗(8002 )

= 265667*1010N

Since Pcr of the material greater than the critical applied load, the design is safe.

53
54
 3) Design of beam

Figure 16 beam
First of all we have to calculate the overall weight applied on the beam

WT=Wplate+Wscr+Wsliarm+Wapplied

Wplate=2*Wapp = 2*140 = 280N

Wscr = v∗ρ∗g ; v=π r 2 l = π∗0.0232∗0.82 = 1.33*10-3m3

=1.33*10-3*7920*9.81

=103N

Wsarm, since the mass of stainless steel pipe is 1.3kg/m

Then the total mass of sliding arm is given by

Wsarm = 4*0.8*1.3 = 4.16kg

= 40N

Wapplied = 1640N

WT=Wplate+Wscr+Wsliarm+Wapplied

=280N+103N+40N+1640N

=2.063kN

Now find moment of beam

P=WT/2=2.063kN/2=1031.5N

55
 ↓ P=1031.5N

R1↑ R2 ↑

M=P*l=1031.5N*425 => R1+R2=1031.5N ; R1=R2

=438387.5Nmm 2*R1=1031.5N

R1=515.75N

From the standard table we select square tube of 50.8mm width and 1.2mm thickness

│1.2│mm

h=48.4mm

│------- 50.8mm-------│

b4 −h 4 50.84−48.4 4
Ixx= = = 97676.3mm4
12 12

My 438387.5∗25.4
δ= =
I 97676.3

=114Mpa < 173.3Mpa so, our design is safe

Checking shear

P 1031.5
τ= =
As ( 50.8 )2−( 48.4 )2

=4.33Mpa < 50Mpa, so our design is safe

56
Catia analysis of beam

Materials.1
Static Case

Material Steel

Young's modulus 2e+011N_m2

Poisson's ratio 0.266

Density 7860kg_m3

Applied Relative
Components Reactions Residual
Forces Magnitude Error

Fx (N) -7.5000e+002 7.5000e+002 -1.1423e-009 3.1289e-012

Fy (N) -7.8063e-015 7.8657e-011 7.8649e-011 2.1542e-013

Fz (N) -1.2490e-013 1.2761e-010 1.2749e-010 3.4920e-013

Mx (Nxm) -2.9240e-014 -2.8669e-011 -2.8698e-011 1.9409e-013

57
 My (Nxm) -1.4438e+002 1.4438e+002 -2.4366e-010 1.6479e-012

Mz (Nxm) 6.4508e-009 -6.4350e-009 1.5756e-011 1.0656e-013

Figure 17 beam stress analysis

58
Figure 18Beam Translational Displacement Analysis

59
 4) Design of leg

Figure 19 leg
Similar to beam we select from the standard table, it is square tube of 50.8mm width and 1.2mm
thickness

│1.2│mm

│------- 50.8mm-------│

Length of leg = 100mm

Hence that the length of the leg is too short, buckling does not considering in the design, rather it
subjected to compressive stress.

P P
σc = A =
Ao −Ai 2
2

W 2063
=>P = = = 515.75N
4 4
515.75
σc = = 2.166Mpa
50.52−48.4 2
It is less than 173.3Mpa, so our design is safe
6) Selection of bearing
Radial contact groove ball bearing,
Single row bearing
WOR=XOWR+YOWA
But the axial load is approximately zero
=> WOR=WR

60
Life of bearing is 4000-8000

L 1/k
C=W( )
106
L=60NLHrev
Select from the table LH approximately 8000
L=60*200*8000
=96*106rev

96∗106 1/3
C=515.75*( )
106
=2.36kN
Bearing number from the table have the following values
C=4kN and CO=2.24kN

Working principle of project

• Manual force is applied on the wheel.

• The rotational motion of the wheel is transmitted to the screw via upper table.

• When the wheel rotates in clockwise direction, then the gear box stand lift up.

• When the wheel rotates in anticlockwise direction, the rotation transfer by the screw then
the gearbox stand moves down.

The screw
rotates The gearbox
Force applied
clockwise and stand lift up
on wheel
anticlockwise or down
direction

61
 3.8 RESULT AND DISCCUSION
All the components are checked its strength according to by loading gearbox. So the designed
gearbox stand is capable of withstanding the applied load. The material selected for each part is
available in the market in their standard. And also it support by catia V5, to make the analysis.
Generally our gearbox stand is perfectly loaded the selected gearbox therefore our design is safe!

62
 3.9. COST ANALYSIS

All this components are directly purchased from the market.

 Cost of rectangular holding steel plate ;

6mm thickness, 580x560 mm =800ETB

 Cost of rectangular base steel plate;

6mm thickness, 580x560 mm =800ETB

 Cost of wheels;

Four sets of small caster wheels = 250*4=1000ETB

 Cost of bearings
Two set of bearing = 2*100=200ETB
 Cost of Screw = 300ETB
 Cost of circular steel tube = 4*100 = 400ETB
 Cost of rectangular steel tube = 100ETB
 Manufacturing and labor cost = 1300 ETB
 Total cost = 4900ETB

63
 3.10 CONCLUSION AND RECOMMENDATION
All the analyses in this project are done by considering all the parts as different structural model
for a better design purpose such as beam, column and other models. The work performed in this
project is designed to help the workers by creating a comfortable working condition, highly
decrease the labor force and time. This project meets the proposed objectives and gives a
solution to all identified problems in the selected work section. The strength of the stand is
checked by using catia v5 software, so there is no fear of failure and nothing keeps them from
using the stand. So we conclude that the designed gearbox stand can hang a gearbox up to a
weight of 150kg and can be manufactured with low cost.

All the works performed in this tool is very safe, because in addition to manual calculations catia
v5 also used to make the tool is surly designed. So, this stand can be manufactured according to
the design parameters/dimensions and perform all works using this tool without any frustrations.
The users can also use this stand for transporting some equipment from place to place. We were
in a problem of finding the exact weight of the gearbox, so we recommend the future designer to
gather all the required data’s from anywhere.

64
 CHAPTER FOUR

GENERAL CONCLUSIONS AND RECOMMENDATIONS

4.1 CONCLUSIONS
Generally, both the internship and the project were completed with great success. In the last four
months we had worked in ORDA, we have gained many skills. It gave us the highlight of our
future as an Automotive Engineer. It also gave us the chance to revise what we have learned for
the past three years directly or indirectly. It was a big step in improving our communication,
team playing and leadership skills, improving practical skills, upgrading of theoretical
knowledge, understanding of work ethics and entrepreneurship skills, industrial problem solving
capabilities. It was the best way to see our theoretical knowledge and experience it in the real
life. In our stay in this company we obeyed the rules and regulation of the company, for example,
coming early in the morning and obeying companies work disciplines. This helps us to be a good
and disciplined worker for future work experience in any environment. Generally, our stay in this
company meets the main objective of the internship program which helps a student who is well
armed in theoretical and practical knowledge.

4.2 RECOMMENDATIONS
The gearbox stand should be manufactured for and it should be put into practice for the desired
work task.

 Fulfill working tools

 Safety stands should be used in repair shop
 A clean and proper table should be made for putting disassembled parts
 The garage area is full of gravel and dust, so it should be clean
 The vehicles should be park orderly
 The company should have a car pulling machine in its compound rather than wasting the
time & energy of the workers.

We would like to recommend students who join the internship program for the future to use their
time effectively and change their theoretical knowledge to practical.

65
 References
1. R.S.Kuhrmi, J.K.Gupta, “A text book of machine design”, fourteenth edition: Eurasia
publisher, 2005.
2. Beer, Ferdinand, P., “Mechanics of Materials”, Second Edition, McGraw-Hill, Inc.: Santa
Fe, NM 1992.
3. ORDA’s Personnel
4. Company’s history profile
5. Company’s service and repair manual
6. Catia V5 software
7. Internship report guideline manual

66