Construction of Wheelbarrow

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CONSTRUCTION OF WHEELBARROW

BY

KANU NDUBUISI .U
ACKNOWLEDGEMENT SAMPLE

First and foremost, my gratitude goes to God Almighty, who has been so merciful and
generous in my life.

I am highly indebted to my parents who have vowed to leave no stone unturned in their
quest to give me formal education. May God bless them.

Last but not the least, when a tedious job has been done, one has to refer back and think who
and who contributed towards the success of the job. As a matter of fact, I must acknowledge
my debt of gratitude to my project supervisor, Mr./Mrs. ……………………………..without
whose diligent guidance and advice this study would not have seen the light of the day.

I also wish to place on record the invaluable help and commitment rendered by my friends
and well-wishers for the moral and financial support given to me throughout the course of
my study.

My thanks and appreciations go to my senior sister Mrs. ……………………………. and


her husband for their financial contributions toward the successful completion of my
academic career.

Also I must acknowledge the contribution given to me by …………………………, my


greetings extended to him due to his moral assisting, advice, understanding, lovely, caring
and financing support through out my academic pursuit.

My sincere thanks go to all those who have assisted me in one way or the other during the
collection of materials and data necessary for the research work who in spite of their
crowded responsibilities still had time to provide me with a good number of relevant
materials for this work.

Finally, my special thanks go to my parents Mr. & Mrs. ………………………… also my


humble sisters and brothers for their understanding, love, caring and financial assistance in
the time of difficulties throughout the period of my staying in the school.

My prayer is that God will reward those that contributed immensely for me towards this
project directly or indirectly.
DEDICATION SAMPLE

This project is dedicated to Almighty God, the owner and giver of wisdom and

knowledge and to the Holy Spirit, the Great teacher, because man plans his

way but, God directs his steps. May his name be highly glorified. Amen.
LETTER OF TRANSMITAL
Department of Chemical Engineering,
I.M.T. Enugu.
P.M.B 1079
Enugu
Enugu State
July 2005

The Head of Department,


Chemical Engineering Department,
Institute of Management and Technology,
Enugu.

Dear Sir,

SUBMISSION OF WHEELBARROW PROJECT


We hereby, submit this projects in partial fulfillments of the requirements for
the Award of National Diploma (ND) in Chemical Engineering of the Institute
of Management and Technology (IMT), Enugu.
However, the aim of this fabrication projects is to convey load from one place
to another.
Moreso, this project is mainly a fabrication work which involves operations
such as sketch drawing, engineering drawing, marking one of shape, punching,
culting, folding, drillings, welding and coupling up of necessary parts.
In summary, the operation involves the fabrication and assembly of some parts
of the wheelbarrow:
a. The handle
b. The tyre
c. The platform
This construction work was carried out in the mechanical workshop of the
institute, which we now humbly submit to the chemical Engineering
Department, I.M.T, Enugu.

Yours faithfully,

KANU NDUBUISI .U. CHE/N2003/024


AGWU ONWUWA .O. CHE/N2003/121
OSUJI BENEDICT CHE/N2003/029
OHA CHINENYE .N. CHE/N2003/127
OSUJI CHINWENDU CHE/N2003/144
OGBEBBA KINGSLEY CHE/N2003/154
NWANKWO AMAUCHE CHE/N2003/267
ABSTRACT

Wheelbarrow can be defined as a machine that is used by labourers, farmes,

gardeness, and others for transporting loads to heavy by hand it from one place

to another.

However, materials used for construction purpose are bought in standard sizes

wither in long bars or standard sheet sizes. Moreover, depending on the type to

be constructed, the materials are then reduced to smaller and more convenient

sizes. The shapes and forms are changed by filing, drilling, reaming, tapping,

broading etc. Also depending on the size of the workshop, some of these

operations may be carried out using manual or mechanized processes.

In addition, procedures involved in constructing a locally made “V” shape

wheel barrow include MARKING OUT, PATTERN DEVELOPMENT,

CUTTING, DRILLING, BORING and WELDING OPERATIONS. High

quality materials were used to contruct the wheel barrow that processes the

required standard.

The medium was tested with some amount of local to know if its ability was

optimum, the machine handle moved freely and smoothly after the handle was

lifted.
TABLE OF CONTENT

Title page

Dedication

Acknowledgement

Letter of transmittal

Abstract

Table of content

CHAPTER OF ONE

1.1 INTRODUCTION

1.2 Origin and history

1.3 Indemnification offered

CHAPTER TWO: LITERATURE REVIEW

2.1 Historical review of wheelbarrow

2.2 Theory (Mechanism) of operation of wheelbarrow

2.3 Wheelbarrow and other classes of lever

2.4 Uses/importance of wheelbarrow


2.5 Material selection

CHAPTER THREE: FABRICATION/CONSTRUCTIONS OF

WHEELBARROW

3.1 Procurement of the materials of construction

3.2 Marking one 1 centre punching

3.3 Culting and rolling

3.4 Welding

3.5 Painting

CHAPTER FOUR

4.1 Costing

4.2 Discussion

4.3 Recommendation

4.4 Conclusion

CHAPTER FIVE: REFERENCES


CHAPTER ONE

1.1 INTRODUCTION

This is a hand-pushed vehicle, consisting of a dish-shapes body supported on

two shafts, arrangal in a “V” shape with handles at the spread end and a wheel

and axle at the point. The wheelbarrow at the axle, the serve applied at the

handles and coal or resistance between the two in the body. It is used by

laborers, farmers, gardeners and others for transporting loads too heavy or

bucky to be carried by hand and is similar to hand trucks used by warehouse

men and industrial workers expect that the latter has two wheels. Modern

wheel barrow are made of wood or of a light metal, such as aluminum, and

have a rubber fire on the wheel. A two-wheel vehicle for carrying garden

materials is more properly called a garden cart.

The purpose of the production of this machine is to reduce alleviate and

possibly eliminate the sufferings, time, money, wastage of man-power and

more especially the need for technological break-through and self reliance,

which has been a major concern of the federal government.


Moreover, this project at hand has delved into simplicities and the construction

of this machine that can be used to carry different types of heavy load to any

distance.

1.2 ORIGIN AND HISTORY

The wheelbarrow like any technology in the common place, was a story to tell.

The west was very slow to invent the wheelbarrow. Do the earliest known

European wheelbarrow gleams down from a stained glass windows in charless

cathedral.

But the Chinese have had wheelbarrow for millennia. They celebrate a half-

mythical inventor named K0 Yu. It is not know when he lived but since then,

the Chinese have shaped wheelbarrows in enormous variety. They’ve used

them for every kind of task.

It migue help to consider just what an industrial wheelbarrow is. It combines

the advantages of both the wheel and the leveler. The load is centered behind a

single wheel that way, you have to lift only a small part of the load. The two

handles give an intimacy of control you don’t have with a four-wheeled cart. If
you ever had to use a wheel barrow, you know its easy with the load in the

right place. It can be back breaking when the load’s too far behind the wheel.

Chinese armies made the first use of the wheelbarrows. It give them such an

advantage in moving goods that it was kept secret. Early Chinese writings talk

about wheelbarrows in code. K0 Yu, one ancient text tells us built a “wooden

goat” and rode away into the mountains on it. They called a wheelbarrow with

handles in front a “wooden ox” one with handles at the back was a “glinding

horse”

Long ago, the Chinese invented wheelbarrows with sails that were no idle

experiment said – driven wheelbarrows became a well-developed and

widespread technology. And the sails were prefect miniatures of the ones used

in junk.

And we, with all our vaunted technology, have yet to build wheelbarrows with

the grace, balance, variety and features of these in China.

It was not until the seventeenth century, when direct contact was made

between European and China, as a result of trade, each area had it own distinct

form of wheelbarrow, although by this time both were frequently modified to

serve other needs than those for which they were designed.
1.3 IDENTIFICATION OFFERED

The purpose of the production of this machine is to reduce difficulties and

probably eliminate the suffering time, money, cost of man-power and most

especially the need for technological break through and self-reliance which has

been a major concern of the human being. Carrying of load on human head has

been a tiring problem in the society from this commercial especially towards

our loco-parenthesis.

It helps eradicate those problems; this project write up has been delivered into

simplifications and the constructions of this machine that can be used in

carrying different types of this machine that can be used in carrying different

types of heavy objects to different areas.

Wheelbarrow is a machine that makes use of a bowel, made of metal used in

carrying loads or is a simple machine that helps us life, pull, increase direction

of heavy things change the direction of force and increase force.


CHAPTER TWO

LITERATURE SURVEY

At a very early stage man released that the means of moving thing about which

nature had provided him left much to be desired. He is severally limited in

loads, he carries the area he could carry them and the speed at which he could

travel. One is right to guess that the physical exertion involved was no more to

his liking them, than it is today.

Man started by mean of training suitable animals to enable heavier loads to be

carried at far distance, and at high speed than he was capable of attaining and

there was an added advantage than most of the effort was provided by animal,

while the man could at ease.

Heavy loads were dragged upon sledges until an early and unknown engineer

invented the standard barrow. This was made possible because construction

material was made of wood upon which heavier loads could be carried more

easily.

The draw back to the use of this type of standard wheelbarrow was that it could

not carry much heavy loads because of the strength of the materials in which it

was made of. The wheelbarrow can’t absorb shock, which may probably
damage some perishable/breakable good s loaded on it. Above all, it cannot

move on the road that is not smooth and hard.

As new materials and manufacturing methods were developed it became

possible to improve in standard wheel barrow that are new made up of

materials that can withstand shock, carry heavier loads, more in any type of

road and above all, have to withstand load.

Other types of wheel activities that can carry load were also developed such as

stream engines, electric card and internal combustion engines.

2.1 HISTORICAL REVIEW OF WHEELBARROW

The origin and development of the wheel holds an important place in the

history of invention because it’s clearly illustrates a phenomenon known as

independents invention. Thus, the wheelbarrow has more than a single source

of origin and was developed for different purposes.

The earliest form of wheelbarrow was developed in China shortly before

AD200, and traditionally its design is attributed to a general in the imperial

any, although these probably mere folktale. The mape of the Chinese

wheelbarrow alone is enough to suggest how it originates. The single wheel is


large, often three or four fat in diameter and usually has a dozen or more

spokes. It is set between the shafts at a considerable distance from the front

end of the barrow, while a boxing or wooden frame is built up from the shaft to

encase the upper half of the wheel. Platforms projected from the shaft on both

sides. The goods to be carried are loaded on these platforms and on the upper

surface of the boxing. If the burden are correctly placed not only would its

weight balance on both sides of the wheelbarrow but it would also before and

after the axle of the wheel. The weight of the load is barrow could use his

energy solely for moving it and maintaining its balance.

This kind of barrow appears to have been developed from a two-wheeled

handcarts on which, with modification, the pair of wheel. In many parts of

China, especially in the wet, rice growing area, field boundaries are often no

more than narrow embarkment, the tops of which must also serve as paths.

This wheelbarrow, therefore seems to be an adoption of the hand cart designed

to allow it to move along narrow paths. Indeed, early illustration of Chinese

wheelbarrows and forward placing apart from pusting and balancing has to lift

a large part of the burden. It was totally unsuitable for shifting goods over long

distances.
This until the seventeenth century, when direct contact were made between

Europe and China, as a result of trade, each area had its own distinct form of

wheelbarrow, although by this time both were frequently modified to serve

other needs than those for which they were designed.

2.2 THEORY & MECHANISM OF OPERATION OF

WHEELBARROW

Wheelbarrows are artificial tools in the fields of construction, landscaping,

home improvement, and gardening. Most wheelbarrows are designed around

the idea of toppling the wheelbarrow over or strenuously lifting the handless to

unload it and are typically equipped with a single wheel in front. While this is

a simple concept, it can lead to out of control loads and accidental spills.

Aspect Engineering designed a new wheelbarrow with the goals of providing

the stability, loading capacity, and ease of use that typical wheelbarrows fall to

provide. The “Rolling Barrel” has half of a 55 gallon derum mainted on a

frame to hold the transportable contents, which can then be related about its

center of mass to unload it.


The typical wheelbarrow design has accomplished the ability to transport a

large amount of cargo safely and efficiently with some success, but with

enough creative engineering and consideration, this concept can be improved.

The capabilities of this basic wheelbarrow can be largely surpassed when the

bar is raised to new capacities and functionality.

But problems may arise when the wheelbarrow is loaded heavily. The user

must lift the handle to rotate the load about an axis far from the load’s center of

mass. At times, this means the wheelbarrow cannot be unloaded with a single

a single wheel for support while transporting contents. The wheelbarrow can

easily tip over, especially when the wheelbarrow is heavily evaded to one side,

or being rolled across a slope. This can usually be attributed to a high centre of

gravity, inadequate lateral supports, and the inability of the wheelbarrow to

adjust for such conditions.

DESIGN PARTITION

A junction tree was designed to break up all possible concepts into the required

subsystems. This was done to ensure that all aspects of the wheelbarrow are

taken into consideration and to ease the design process. The tree show the
wheelbarrow subsystems: a tub to contain the materials to be moved, afram and

handles to support and maneuver the tub, an unloading mechanism for

removing the materials from the tub, and the wheels and axle to move the

materials.

WHEELBARROW

AXLE & FRAME & TUB UNLOADING

WHEELS HANDLES MECHANISM

CONCEPTUAL IDEAS

The first two ideas are simple additions to the basic wheelbarrow design. The

“pump and dump” design is based on the basic wheelbarrow, but instead of

lifting the load by the handles, the operator steps on a lever that flips the load

over the front wheel.

The “Adjustable Handle” design is also based on the basic wheelbarrow, but

the handle used to move and lift the load can slide up and down for increased

leverage while unloading and allows the operator to life using leg muscles

rather than back muscles.


The “Splitting Barrel” design has a drum that separates along the bottom to

allow the load to fall through to the ground, thereby using the stored potential

emery to unload the contents. The operator simply unlatches the barrel

quarters from each other at the bottom.

The “Rolling Barrel” design has a drum that is rotated about its center of mass

by way of a handle or crank. The barrel is unloaded by applying a small force

to rotate it upside – down, thereby allowing the stored potential energy to

unload the contents.

The final concept is much like a box on wheels. “Old N0.5 has a door on the

front that opens, and a mechanism to push/pull the contents through the door.

ENGINEERING ANALYSIS

There are two main objectives in these engineering analyses. First, the device

must not fail unclear heavy loading therefore, the maximum stress and

deflection produced in the cross beam of the wheelbarrow from the load of the

drum was investigated. Second, the forces required to unload the wheelbarrow

were investigated. The analysis of the crossbeam is presented first.


First a maximum load was defined to be sand that would fill up the barrow and

also be heaped above. The volume of sand would approximately be 55 gallons.

The density of sand is 2,300kg/m 3. So the total weight of the sand is 1060

pounds. With two cross beams this weight is divided between the two making

the force on one crossbeam 530 pounds.

Next, the maximum value of the moment in the crossbeam was found. The

force and moments acting on the crossbeam were defined as a downward force

at the center of the beam, and an upward force as well as moment acting on

both ends of the beam.

From beam analysis the maximum moment was determined to be:

M = 3PL

8 ------------------ (1)

Where P is the downward force acting on the center, and L is the length of

crossbeam.

The maximum stress occurring in the beam was found from the moment and is:

Ơ = 3PLh

16I ------------------ (2)


In the equation h is the height of the beam and I is the moment of inertia of the

beam.

The maximum deflection of the beam occurs at the center. It is related to the

downward force by equation 3.

Ơmax = 5PL

192EI ------------------ (3)

Young’s modules are represented by the variable E. For a solid beam the

moment of inertia is given by:

I = bh3

12 ------------------ (4)

For a hollow beam the moment of inertia is:

I = bh3-(b-2t) (h-2t)3

12 ------------------ (5)

In both moment of inertia equations, b is the width of the crossbeam and t is

the inner thickness for the hollow beam.

For a 2”x2”x28” steel beam the maximum stress is 4ksi. This stress is well

below the yield strength of steel of 36ksi with a safety factor of 9. Also the

downward deflection of the beam at the centre is 0.0078”. In a hollow steel


beam of the same dimensions with an inner thickness of 0.125” the maximum

stress is 10ksi. The safety factor for the hollow beam is 3.6. The deflection at

the center is 0.019”.

Next, the analysis of the force required to turn the barrel is presented. This

analysis is performed for two different designs the first is a simple handle

design the second is a gear design.

The handle design consists of a barrel with a simple handle to related the

barrel. The distance from the axis of mation to the handle is the same as the

radius of the barrel, or half of the with, W.

The force required to pivot the barrel is called Fn the gear design consists of

the barrel with one large gear mounted on the axis of rotation and a smaller

gear with a handle.

The force required to rotate the barrel is called fg. The ration of the larger gear

diameter to the smaller gear is called r. the handle length is Ln.

By summing the moments about the axis of rotation, the following relationship

between the over all torque, T, required to rotate the barrel and the force, Fn for

the handle design is derived.


T = Fn W

2 ------------------ (6)

For the Gear Design, the overall torque, T is a function of the gear ratio, handle

length and force, Fg.

T = Ln Fg ------------------ (7)

By combining equations 6 and 7, a ration of the forces for the two designs

indicates the mechanical advantage of the Gear Design over the Handle

Design.

Fg = W

Fn 2rLn ------------------ (8)

The distance from the center of mass to the axis of rotation is called d.

d = 2W

3n ------------------ (9)

Again, W is the width of the barrel so, by summing the moments about the axis

of rotation, the static torque, Ts, is a function of G & d.

Ts = Gd ------------------ (10)

Where G is the gravitational force acting on the center of mass of the barrel

(including the load).


Substituting for G with product of the density of the medium inside the barrel,

p, the volume of the barrel, v, and the acceleration due to gravity, g, equation

10 becomes:

Ts = pVgd

Substituting for the volume= with the length, L, and width of the barrel, W,

equation 5 becomes

Ts = W3Lpg

12

Next, the dynamic torque required to rotate the barrel was investigated.

Neglecting all friction, the dynamic torque to rotate the barrel, Td, is a function

of the angular acceleration, , and the mass moment of inertia of the load in

the barrel, J.

Td = J ------------------ (11)

The mass moment of inertia, J, as a function of the density of the medium in

the barrel, P, and the dimensions of the barrel, L and W.

J = PLW4

64 ------------------ (12)
2.3 WHEELBARROW AND OTHER CLASSES OF LEVER

The Lever

The simplest machine, and perhaps the one with which we are most familiar, is

the lever. A seesaw is a familiar example of a lever in which one weight

balances on the other. You will find that all levers have three basic parts: the

fulcrum, F, a force or effort, E, and a resistance, R

First Class Levers: In the first class lever, the fulcrum is located between

the effort and resistance. As mentioned earlier, the seesaw is a good example

of a first class lever. The amount of weight and the distance from the fulcrum

can be varied to suit the need. An oar is another goal example. The ocerlock is

the fulcrum, and the water is the resistance. In this case, the force is applied

one one side of the fulcrum and the resistance to be overcame is applied to the

opposite side; this is a first class lever. Crowbars shears, and pliers are

common examples of this class of leavers.

Second Class Levers: The second-class lever has the fulcrum at one end,

the effect applied at the other end and the resistance somewhere between these
points. A wheelbarrow is a good example of a second-class lever. If you apply

50 pounds of effort to the handles of a wheelbarrow 4 feet from the fulcrum

(wheel), you can lift 200 ponds of weighed 1 foot from the fulcrum. If the load

were placed further away from the wheel, would it be easier or harder of lift?

Levers of the first and second class are commonly used to help in overcoming

big resistances with a relatively small effort.

Third class levers: Sometimes you will want to speed up the movement

of the resistance even though you have to use a large amount of effort levers

that help you accomplish there are in the third class of levers.

2.4 USES/IMPORTANCE OF WHEELBARROW

The uses and importance of a wheel barrows are numerous and can not be over

emphasized. It is used in various aspects of work and they are as follows:

a. It is used in the farm to transport farm implements from one place to

another, transporting weeds or residues that are to be disposed of their

incarnation points; and for short distance, for moving the farm produce

to the point they are needed.


b. It is also used in the workshop for moving materials for any purpose

from one points to another.

c. It helps reduce the work of man i.e. it helps man to move things around

easily.

2.5 MATERIAL SELECTION/MATERIAL OF CONSTRUCTION

This is mostly affected by the non-accountability of suitable materials that

would have been best suited for some specific parts, so the material of

construction was given serious consideration of the standard wheelbarrow.

The materials to be considered for any of the component manufacturer, must

have the relative property usefulness and appropriate for the function of that

component parts.

Handle cover: It is made of elastic rubber, in order to avoid friction and

bruise of the palm.

Stands: Mild steel bar is used in the construction of bowel support

bar. The material is chosen because of its relative

cheapness, availability. Some other materials like

aluminum, cost iron and stainless steel but because of their


high cost of production and processing, mild steel is chosen,

not minding the other materials; though stainless steel is

better because of its ability to withstand corrosion and good

finish.

Handle or frame: Steel pipe is normally used because of its corrosion

resistance and its light weight.

Wheel: This material is used because of its relative cheapness, it is

easily sheared or cut and above all its resistance to

corrosion )carbon steel sheet and mild steel).

Bowel: Cudvconised caamon steel is used because it is easy to cut

and relatively cheap and resistant to corrosion.

Spindle or shaft: Mild steel is used to construct the spindle as a result of its

relative cheapness and easy machinable property.

Ball bearing: There are two in number and are made of sintered metal

because it can easily be rolled into balls due to its ductility.


CHAPTER THREE

FABRICATION/CONSTRUCTION OF WHEELBARROW

3.1 PROCUREMENT OF THE MATERIAL FOR CONSTRUCTION

This talks about the factors that must be considered before the material for the

construction is selected. Some of the more important economic factors and

physical and mechanical properties that are involved in material and process

selection are discussed briefly in the proceeding paragraphs.

“Availability and cost of materials” vary continually and as the change is

towards favourable or unfavourable conditions designs will necessarily

undergo corresponding alterations for economic reasons. At times certain

materials may become unavailable for general industrial use, and the necessity

may arise for substitute designs based on procurable materials. A forceful

example of this expediency occurs during national emergencies when

alternative designs are required to avoid the use of strategic materials as well as

processes that are affected by the unavailability of equipment.

“Strength” is necessary to prevent failure of the member by rupture. However,

some steels have the descriable property of high ultimate strength coupled with

low ductility, which may be undesirable in members subject to stress


concentration. The use of high-ultimate strength steels. Such as those caused

by concentration of mass, surface decarbonization, and quenching cracks.

“Rigidity” is of importance in members whose deflections are limited by

service requirement. For instance, the transverse deflection of a shaft of a

speed reducer may be limited by the following requirements.

1. Clearance in film – lubricated bearing which support the shaft for

satisfactory bearing life as relatal so wear.

2. Alignment for instance, of gears mounted on the shaft, as related to

gear- teeth wear, and vibration characteristics of the shaft, which

depend mostly on the deflection of the shaft rigidity depends upon the

modules of elasticity.

“Resistance to fatigue” should be the basis for the design if members that are

subjected to cycle loading. This property is measured by the endurance limit.

Notch sensitivity and clamping capacity is designed as the energy dissipated as

heat by unit volume of the material during a completely reversed cycle of

stress.
“Resilience” should be considered when the material is subjected to shock

loading. A material with a suitable yield point should be selected and the

member should be designed so as to secure a desirable resilience of the part.

“Weight” may be important often it is desirable, as in the case of foundations

and flywheels; but it is undesirable in other cases, such as aircraft parts, where

light metals, such as aluminum, magnesium alloys or titanium may be used.

“Resistance to wear or corrosion” may be determining properties; the former is

unlubricated or poorly lubricated friction surfaces. Generally, like materials in

contact are not satisfactory for friction surfaces, although there are exceptions.

Corrosion resistance is important in members subjected to a corrosive

environment. The effect of corrosion is especially serious in the presence of

stress concentration in cyclic loading.

“Law friction” is of importance in bearing materials. The friction conditions

are affected by the materials in contact and the surface finish. Certain

combinations of materials that are in contact in bearing surfaces produce

satisfactory results.
3.2 MARKING OUT/CENTRE PUNCHING

This involves the drawing of lines on the metal surface with use of scribers,

metal rule dividers etc indicate the profile or outline of the finished compound

and making the necessary holes in the material. The tool used for centre

punching is a drill but.

IMPORTANCE OF MARKING OUT

1. It helps to define the shape or the outline of the article

2. To keep the wastage of material to a minimum

3. When metal has to be removed from several faces marking out

ensures that correct amount is removal from each face.

4. To mark the lines, which will help the machinist set up the work

correctly on the machine and to serve as a guide that the correct size

has been attained.

5. To indicate precisely the position of holes and similar features.

3.3 CUTTING AND ROLLING


Common sheet metal cutting operations include shearing, blanking, piercing

and nothing shearing into long strips are usually done with the ciullctine or

manual shearen, while blanking, piercing and not clung are usually done with

punches and die that are mounted in a standard type the set. There should be a

set of die for each different job.

Rolling occupies the most important position of all back defermation

processes. Over 95 percent of all materials that is ever defermed is subjected

to rolling.

Flat rolling refers to the process of reducing the thickness of a slab to yield a

thinner and longer but only slightly wider product. It is the most important

primary dyarmation process, because it allows a high degree of automation and

very high speeds, and thus provides starting material for various secondary

sheet metal working processes at a low cost.

Shape rolling has a long history, beginning with the rolling of channels of lead

for stained glass windows. The largest industrial application is nao in the hot

rolling of structural shapes, which is a specialized primary defermation

process, practiced in special purpose mills.


Seamless rings, which are examples of ring rolling, are important constructural

elements, ranging from the steel gives of railways car wheels to rotating rings

of jet engines and races of ball bearings. After making a hole by any suitable

technique, the thick-walled ring is rolled out by reducing its thickness and

increasing its diameter.

Transverse rolling can be explained or experiences, when a work piece is

placed between two counter rotating rolls with its axis parallel to the roll axes,

it suffers plastic deformation during its rotation between the rolls. The

consequences of this deformation depends on the shape and angular alignment

of the rolls and, as in all compression on the h/l ration.

The projected length of contact between roll and work piece is regarded as L of

the jerging tool, and the average height is taken as h. when h/l > I, the in

homogeneity of deformation predominates and the pressure – multiplying

factor is Qi. The roll force is estimated from:

Pr = LWQiƠjm

When h/l < I, friction effects are over-riding and the pressure – intensification

factor is Ơp. The roll force is estimated from:

Pr = LW Qp Ơfm
Where W is the width of strip and Ơfm is the mean flow stress, used because

the strip hardens while it is deformed in the roll gap. In hot working, the flow

stress must be taken at the typical average strain rate.

Em = V in ho

L hi

The torque required to rotate the rolls can be obtained by assuming that the

rolling force acts in the middle of they are of contact. Since there are two rolls

to be driven the total torque will be

MT = 2PrL =

and the horse power requirement is readily calculate from

hp = 2PrLN

33,000

where N is rpm, L is in units of feet, and P is in units of pounds. In the SI

system the power requirements are calculated in kilowatts units.

KW = 2PrLN

60,000

where P is the roll force in newtons, L is in meters, and N is rpm.


3.4 WELDING

In mechanical engineering, welding is extensively employed to manufacture

structures from plate rolled stock (reservoirs, tanks, hoppers, coverings,

lininers, etc) until from pipes and shaped rolled stock (frame structures, trusses,

columns, pillars, etc). Nowadays housings and base members are also made by

welding, including the most massive and stressed parts (for example, the beds

of presses and hammers).

In individual and small lot production welded structures are used instead of

one-piece forgings when the manufacture of dies is not justified by the scale of

production and also as a means to make the manufacture of complicated part

less expensive. Low-carbon steel (< 0.25 percent c), low alloy steel with a

small content of c and nickel steel weld very well. High-carbon, medium and

high-alloy steels are more difficult to weld.

The strength of welds is inferior to that of solid material because of the cost

structure of the welded joints with its deneritic and acicular crystallites typical

of cast metal.
The strength of welds is inferior to that of solid material because of the cost

structure of the welded joints with its deneritic and acicular crystallites typical

of cast metal.

The strength and resilience of the material is a weld are impaired by

penetration of slay, formation of pores and gas bubbles and also because of

chemical and structural changes in the weld (alloying elements burn-out,

formation of carbides, oxides and nitrides). If the material of a weld is

saturated with air nitrogen even in small quantities the weld will lose much of

its plasticity and will become much more brittle.

The mechanical properties of welded joints depend on the welding process and

in manual work on the skill of cause defects impairing the life of the weld and

its strength. Lots of welded products are tested selectively by cutting up of

specimens, by tensioning, bending and flattening them and by investigating

their microstructure and chemical composition of the metal in the weld.

3.5 PAINTING

This is one of the processes used for the protection of metal surfaces form

corrosion. It is used to coat vast amount of mild steel, not only to protect
corrosion, but also to provide an attractive finish. Optimum results are

obtained by first “phosphate” the surface of the steel. This involves treating it

with a phosphoric avid preparation, which not only dissolves rust, but also

coats the surface of the steel with a dense and slightly rough surface of iron

phosphate. This affords some protection against corrosion, but also acts as an

excellent “key” for the priming paint and the under coat of subsequent paint.
CHAPTER FOUR

4.1 COSTING

The cost of standard wheelbarrow is grouped into three sections:

a. Labour cost analysis

b. Material cost analysis

c. Miscellaneous expenses

Labour Cost Analysis

Number of hour worked per day =

Number of day s worked

Each labourer is entitled to N60 per hour

Total number of hour worked = 13x3

= 39 hours

Total cost of labour per labour = N60x39

= 2,340:00

total labour cost = number of labour x total cost of labour

= 2x2,340:00

= N4,680:00
Material Cost Analysis

S/N0 Material Description Quantity Used Source Total Cost

1 One metre square of All Market 1,500

galvanized carbon steel sheet

2 3,250 steel pipe long All Market 1,3

3 16mm thick mild steel All Market 600

4 Ball bearing 32 crunchier All Market 300

50.8mm

5 Belt, nut and washer 14 Market 250

6 Draying machine 1 Market 300

7 Paint All Market 200

8 Electrode 10 pieces Market 100

9 Two plastic handle cover All Market 140

10 Fleet bare 40mm 380mm 4 Marker 800

supporter gross bar


MISCELLANEOUS EXPENSES

Other expenses = N500:00

Total cost of project = Labour cost + Material cost + Miscellaneous

expenses.

= N4,680 + N5490 + N500

= N10, 670:00

4.2 DISCUSSION

Every machine that is contructed today is for a purpose. Hence, the objective

of this “Y” shape wheelbarrow is a fulfillment of the Ordinary National

Diploma (OND) and its function is to convey objects or goods.

However, lines were drawn on the galvanized metal surface with the use of

scriber, divider, etc to indicate outline of the finished component, to indicate

the position of holes, to mark out lines that will help the machinist set up the

work correctly, to remove the excess left over of the metal on its sides to

reduce wastage of material. The already marked one galvanized metal was

then folded, inorder to correct some abnormalities during the operation. After

which the galvanized metal sheet was sheared or cut into long strips with

guidline or manual shears. The metal sheet usage also blanked, pierced,
notched with the use of punches and dies that are mounted in a standard type

die set. Then smooth files were also used to polish and to produce smooth

surfaces on the metal. Moreover, drilling hits were used to make holes in the

metal and the holes were also enlarged, inorder for it to be able to house the

required nuts, bolts, etc, and a lot of sacrificial metals were subjected to high

heat which melt it and on looking fuses together the two parent metals to be

joined. This welding process was done continuously, until the required

structure of the wheelbarrow was formed.

In addition, using manual smooth files to polish the metal was not easy,

because of lets of bruises made on the palms of the labourers owing to the fact

that they were not wearing hand gloves us a result of lack of automatic filing

machine. Hence, hand glaves, automatic filing machines should be provided.

Also pumping tyre was used instead of a tubeless tyre because it is easier to

maintain, it hast longer but tubeless tryes once had it can not be repaired. Tiny

bolt & nuts were used instead of galvanized ones because they are more

economical but have shorter life span. In addition, the bowel of the “v” shaped

wheelbarrow was bent and folded instead of press forging for time and energy

sewings and also increase in quality, but due to its non-accountability and high
cost, it was not used. Ball becoming was used instead of sealed bearing which

are self lubricating.

Finally, the standard wheelbarrow which cannot be compared to the

constructed wheelbarrow, because most of the materials used are of lower

standards.

4.3 RECOMMENDATION

The following recommendations are made on completion of this projects:

1. Power supply must be frequently available for works to progress all

the time.

2. The workshop should be supplied with new and modern

technological machines because the ones available at our disposal

were worn out and absolute.

3. Necessary working tools should be made available for the effective

work to be done by students.

4. Materials should be provided at the disposal of the students for the

project.
We advise that the school management should look into these

recommendations to supplement the students effect and the avoid repetition in

the near future, and to increase efficiency and safety of students in the

workshop.

4.4 CONMCLUSION

Government should encourage technical education and should also try to

patronize our locally made mechanical madunes because we look forward to a

better tomorrow when our country Nigeria will completely favour the rest of

the welding technological advancement.


CHAPTER FIVE

REFERENCES

Raymond A. Higgins and Edward Arnold (1988):

“Material for the Engineering Technician” Avolden

and Stoughton press.

B.R Schlenken (1974): “Introduction to Material Science” John Wiley &

Sons Australasian Press Ltd.

John .A. Schey (1977): “Introduction to Manufacturing Processes” McGraw-

Hill Book Company.

P. Orlor (1986): “Fundamentals of Machine Design” Translated From

Russia by A. Trotsky Mir Publishers.

Paul h. Black and Eugene O. Adams (Jnr) (1968):

“Engineering Materials” McGraw-Hill Book

Company.

Syvia Bermin J. (1992): “Cost Metals Technology” Addison-Wesley

Publishing Company.

Mc Gannin H.F (1971): 0“The Making, Shaping and Treating Steel” United

State Steel Corporation.


Harfors, William David, and Cadded Reberty M. (1998):

“Metal Forming – Mechanical Metatherogy” Prentice

– Hall Eagle Wood Clidds, N.J.

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