Table of Contents

Chapter one 1
1.1History of Anbessa city bus service enterprise 1
1.2 main service of the company

How we get in to the company

Type chapter title (level 2)

Type chapter title (level 3)

5
6

ANBESSA CITY BUS SERVICE

ENTERPRISE
Chapter one

1.1 HISTORY
The Anbessa City Bus service enterprise started as Share
Company founded in 1945 and owned by Emperor Haile Selasie
and member of the royal family, before it was nationalized in
1974. It comes to public enterprise only after it was reestablished
in 1994.

Anbesa has recently begun to acquire buses assembled locally by

the metal and engineering corporation, a newly established
military industrial complex of Ethiopian government. It has
included in its fleet 180 of this local assembled buses known as
bishoftu buses, bearing the towns name where the assembled
plant is located. Eight of these buses are in jimma although

Anbessa only operates in Addis Ababa and special zones of

Oromia regional state.
Currently, there are 540 city buses under the enterprise, nearly
half of which are out of service due to technical failures. The enter
[price operates 93 routes in and around Addis Ababa. Each bus
has a capacity for 100 passengers (30 seated and 70 standings).
These buses cover a collective distance of 54,000KM daily and
provide

Currently, there are around 1000 city buses under the enterprise.
Nearly 40 percent of these are out of service due to technical

issues. The older DAF-Berkhof buses that were built in The

Netherlands are being refurbished to extend their usability. The
enterprise also operates 93 routes in and around Addis Ababa.
Each bus has a capacity for 100 passengers (30 seated and 70
standing).
These buses cover a collective distance of 54,000 km daily and
provide their services to 1.5 million people, as indicated in the
2006/07 to 2010/11 five year strategic document of the City
Administration.

figure: anbessa city bus

their service to 1.5million people as indicated in 2006/2007 to

2010/2011 five-year strategic document s of the administration.

1.2 THE MAIN SERVICE OF ANBESSA CITY BUS

SERVICE INTERPRISE.
i.

ii.

iii.
iv.

Transport service
Maintenance
Transit advertising
Annual vehicle checking

i.

Maintenance Service

The enterprises central workshop is equipped with machines,

trained and experienced staffs. The maintenance is basis:
1. Preventive maintenance: which is carried out based on
milady and time.
2. Corrective maintenance: whenever there is braking and
when correction is needed the program is in all the deport
garages and on the field.

3. Automotive part production: in the machine shop, different

accessories of the buses and small vehicles are produced
and body parts are build and rebuild as necessary.

4. External technical services: the enterprise give technical

services like vehicle maintenance, annual vehicle inspection
and other related service to external customers bused on
special contractual agreement. Maintenance including body
building, taxi sign, brake dawn maintenance and for different
organization.
5. Technical training & certification: technical training is given
to bus driver, mechanics and other technical staffs. A cc
service is also given to TEVET graduates.

1.3 How we get into the company

We have done our internship in Anbessa city bus assembly that
found in Bole Sub City after the middle of 4thyear, 1st semester
the university industry linkage (UIL) told us to find the hosting
company for the 4th year, 1st semester, we get the opportunity to
visit the 1stCompany, and then we decide to work our internship
there. Then by taking our letters from the university which
describes about internship, its benefits for the company, for the
university and for the students, we submit to the factory manager
of the company. Then we introduced ourselves and describe about
the internship for him. After that he told us, where we work and

what we work. Then we start our practical work step by step. By

executing our money and our time we try follow up with company
workers, so it helps us.
Then we are divided into different
group (4-group) and start our work indifferent shop. In our
performance work we see many good things that we are not
guessing before enter the company. Before we get the company,
we think as we learn only about the topics of our internship, but
we learn (develop) with sociability, language, communication,
how to challenge problem, and how to use the time by save.

1.4 THE SECTION OF THE COMPANY WE HAVE

WORKING
1, Power Train Shop
2, Engine Shop
3, Injection pump Shop
4, Electric Shop

Chapter two
Overall internship experience
2.1 CAR BATTERY
BASIC: what is use of battery; how it is made; what is
battery acid; does sulfuric acid add to water or water to acid?

figure: car battery

An automotive battery is rechargeable battery that supply electric
energy to an automobile for starting, lighting, and its main
purpose is to start the engine.
In a car batteries shop two basic works will done, these are
preparing and charging battery. To prepare car battery the
following are required
1.
2.
3.
4.
5.
6.
7.

Distilled water
Battery acid (Sulfuric acid)
Hydrometer
Mixer (plastic tanker)
Battery house
Charger
Acid-proof gloves and gown

Note: battery acid could refer to any acid used in a chemical cell
or battery but usually this term supplied to describe the acid used
in sulfuric acid battery.
2.1.2 Procurers
Put 65% distilled water into mixer
Slowly mix 35% sulfuric acid into distilled water, this is most
dangerous part. All pouring must be done. if you arent going
to do this right, then dont do it at all.

 Let the solution to cool (acid water) for about 24 hours

since during formation of solution the solution get hot.
Using hydrometer measure the degree of solution. The
hydrometer has three reading level, due to their mass it is
possible to detect weather a sulfuric acid or dilute water is
excess if the acid is excess more water will add, and if water
is excess acid will add.
Pour the solution in to battery house up to its level and by
referring the manual charge the battery.
When we mix concentrated sulfuric acid and water, we pour the
acid in to a larger Volume of water. Mixing the chemicals, the
other way can present a lab safety hazard. If you add water in to
concentrated sulfuric acid, it can boil and split and may get a
nasty acid burn. if you spill some acid on your skin, you have to
wash it with copious amount of running could water as soon as
possible.
2.2.3 NOTE: water is less dense than sulfuric acid, so if you pour
water on acid, the reaction occurs on the top of the liquid. If you
add the acid to the water, it sinks and reaction take place through
the water.
2.2 AUTOMOTIVE CLUTCHES
2.2.1 INTRODUCTION
An automotive clutch is used to connect/engage and
disconnect/disengage the engine and manual (hand-shifted)
transmission or transaxle, both starting up and during gear
shifting. A friction type of clutch is used in motor vehicles with
manually operated transmission or transaxle.
A manual clutch works on the principle of friction. Its function
depends upon sufficient friction being developed between the
contact surfaces of two or more members to transmit the desired
torque.

Clutch capacity (The ability of a friction clutch to transmit

torque) depends on the following factors:
1.
2.
3.
4.

Effective radius of the friction surface

Coefficient of friction acting between the friction surfaces
No of friction surface
Clamping force holding the friction surfaces

2.2.2 Clutch requirements:

It must engage the engine and transmission/transaxle
smoothly,
Once it engages, it must transmit power entirely without
slipping,
It must disengage the transmission/transaxle accurately
and quickly to
Permit gear change when a vehicle is in motion.
2.2.3 Material used for clutch
There are a number of different materials that are used to
manufacture car clutches including steel, aluminum, cotton
fabrics, polymers, vegetable fibers, fiber glass and asbestos.
Asbestos has been classified as unsafe and is generally not as
common in modern day clutched.
The following table gives a brief overview of formulation trends
for brake pads; this is relative to materials used in car clutches as
they both require materials that can withstand friction.

NEAD OF CLUTCH:
Clutch is needed because the engine spins all the time
but the cars
wheel does not.
In order for a car to stop without stopping the engine,
the wheel need disconnected from the somehow.
In order to change gear easily.

2.2.4 COMPONENT CONSTRUCTION AND OPERATION

An engine clutch consists primarily of four parts:
a) Fly wheel
b)Friction/clutch disc
c) Pressure plate assembly and
d)Release/control mechanism

a) Clutch Housing
The clutch housing is a stamped or cast metal part, which houses
the clutch and connects the transmission housing to the back of
the engine.
b) The Flywheel
The flywheel is a fairly large wheel that is connected to the
crankshaft. The clutch assembly is mounted to the flywheel,
sandwiching the clutch disk in between. It also provides a friction
surface to the clutch. A bearing, called the "pilot bearing" is
installed in a hole in the center of the flywheel. This lubricated
bearing, either a ball bearing ng or a bronze bushing, is used to
support one end of the clutch shaft, which is also the transmission
input shaft.
It is made from cast iron plate grounded to a smooth
finish.

 Fitted at the rear end of crank shaft, helps transmit

engine power through the clutch plate to the gear
box.
It falls due to wear or break of gear caused by
unproper driving
1 Flywheel removal
The easiest way to remove the flywheel attaching bolts is with an
impact wrench. If you do not have an impact wrench to remove
the flywheel, it must be kept from rotating so the attaching bolts
can be loosened. While the bolts are being removed, the flywheel
can be held in place using a flywheel turner or locked in place
with a fly-wheel holder; alternatively, a block of wood can be
placed between the flywheel and a stationary part of the engine.
Warning: Always wear eye protection when using an impact
wrench.
A flywheel is very heavy. It can cause injury or severe damage if
dropped. Do not remove the bolts completely until you have the
flywheel secured so that it cannot fall. Once the flywheel is
securely held, the bolts can be loosened and the flywheel can be
removed. Sometimes there is a flat metal spacer between the
flywheel and the crankshaft flange. The spacer should be saved
for reassembly. After removing the flywheel, check the rear main
bearing seal for leaks. If the seal is leaking, oil could reach the
new clutch disc and ruin it, just as it may have ruined the old disc.
A leaking seal must be replaced.
2. Flywheel repair
Some flywheels may be damaged beyond repair. Others may be
repaired and then reinstalled. Some of these may be fixed by
replacing the ring gear or by resurfacing. Flywheels with damaged
ring gears are usually replaced. Some ring gears can be removed
from the fly-wheel and replaced

Flywheel

Use chisel to
split and remove
ring gear
A

Torch

Heat new ring

gear to expand and
ease installation

The Figure above is most manual transmission flywheels have a

removable ring gear. AA chisel is being used to remove the ring
gear from a flywheel. Be careful not to damage the flywheel. B
You should heat the replacement ring gear with a torch or in an
oven. Be careful not to overheat the ring gear, or the metal will
lose its strength. CPlace the new ring gear over the flywheel
and ensure that it properly seated. Always wear gloves or use

tongs to prevent burning your hands when handling the hot ring
gear.
c) Friction/Clutch disc
The clutch disc friction material also called disc
lining or facing. It has an internal spanned hub through with the
clutch shaft fit. Located between flywheel and pressure plate.
The main function is to transmit power from engine to gearbox.

1. Clutch Disc Service

In most cases, the clutch disc is replaced when any kind of
clutch teardown is done, since it is relatively inexpensive. If the
disc was recently replaced or appears to be in excellent
condition, it can be reused. Before deciding to reuse the disc, it
should be carefully checked.
Warning: Asbestos dust is harmful. Avoid breathing any dust
from the clutch disc, as it can contain large amounts of cancercausing asbestos. Even new clutch discs often contain some
asbestos.
If you intend to reuse the clutch disc, do not wash it in
any kind of cleaning solvent. Solvent will ruin the clutch disc
friction facings. Inspect the clutch disc for thin or cracked friction
material. The disc thickness can be checked with a sliding
caliper, as shown in Figure 7-28. Usually, however, other
indications will be obvious and this step will be unnecessary.
Check the disc fo loose rivets, oil-soaked friction facings, or
broken cushion springs. Make sure the
hub flange splines are not worn and they slide freely on the
splines of the transmission input shaft. If the clutch disc shows
any wear or damage, it should be replaced.
If a replacement disc is to be used, it must be carefully
compared to the old one before it is installed. Many clutch

problems are caused by installing the wrong replacement disc. It

is especially important to check the hub flange size
against the old disc. A hub flange that is too large will contact the
flywheel and pressure plate, causing clutch disc damage and
gear clash. As a final check, slip the replacement disc over the
transmission input shaft to make sure it has the correct splines.
d) DIAPHRAGM SPRING
It is a disc shaped slotted steel plate. The trapped fingers
of the diaphragm act like clutch fingers by pulling the pressure
plate way from flywheel and clutch plate releasing pressure and
disconnect driving from engine.
In automotive clutch the diaphragm spring is part of the
clutch pressure plate.
Diaphragm spring service
Due to high heat (friction) the fingers that connected with the
release bearing became wear and deformed, so that the bearing
cannot push sufficiently to pull the pressure plate away the
flywheel. Hence the diagram fingers will have welded and can be
reused re new diaphragm spring should replaced.

figure: diaphragm spring fingers.

e. Release fork
The device or fork straddles the throw-out bearing and that
is used to force the throw-out bearing against the clutch release
fingers.it is found on the bell housing and throughout bearing is
located on the fingers.
Basically it helps to operate the clutch by engaging or
disengaging. it is made of high grade steel.

Figure: release fork parts

3. AUTOMOBILE BRAKE SYSTEM

A brake is a mechanical device that inhabits motion by
absorbing energy from a moving system. It used for slowing or
stopping a moving vehicle, wheel, axle, or to prevent its motion,
most often accomplished by mean of friction.
There are different types of brake systems, broadly
described as using friction, pumping or electromagnetics.
One brake may use several principles: for example, a pump may
pass fluid through an orifice.
3.1 BRAKE SYSTEM
A brake is a device by means of which artificial frictional resistance is
applied to a moving machine member,
in order to retard or stop the motion of a machine. In the process of performing this
function, the brake absorbs either kinetic energy of the moving member or
potential energy given up by objects being lowered by hoists, elevators etc. The
energy absorbed by brakes is dissipated in the form of heat. This heat is dissipated
in the surrounding air (or water which is circulated through the passages in the
brake drum) so that excessive heating of the brake lining does not take place. The
design or capacity of a brake depends upon the following factors:
1. The unit pressure between the braking surfaces,
2. The coefficient of friction between the braking
surfaces,
3. The peripheral velocity of the brake drum,
4. The projected area of the friction surfaces, and
5. The ability of the brake to dissipate heat equivalent to the
energy being absorbed
3.2 Materials for Brake Lining
The material used for the brake lining should have the following characteristics:
1. It should have high coefficient of friction with minimum fading. In other
words, the coefficient
of friction should remain constant over the entire surface with change in
temperature.
2. It should have low wear rate.
3. It should have high heat resistance.
4. It should have high heat dissipation capacity.
5. It should have low coefficient of thermal expansion.
6. It should have adequate mechanical strength.

7. It should not be affected by moisture and oil.

3.3 Types of Brakes
The brakes, according to the means used for transforming the energy by the
braking element,
are classified as:
1. Hydraulic brakes e.g. pumps or hydrodynamic brake and fluid
agitator.
2. Electric brakes e.g. generators and eddy current brakes, and
3. Mechanical brakes.
The hydraulic and electric brakes cannot bring the member to rest and are
mostly used where large amounts of energy are to be transformed while the brake
is retarding the load such as in laboratory dynamometers, high way trucks and
electric locomotives. These brakes are also used for retarding or controlling the
speed of a vehicle for down-hill travel. The mechanical brakes, according to the
direction of acting force, may be divided into the following two groups:
(a) Radial brakes. In these brakes, the force acting on the brake drum is in
radial direction. The
radial brakes may be sub-divided into external brakes and internal
brakes. According to
the shape of the friction element, these brakes may be block or shoe
brakes and band brakes.
(b) Axial brakes. In these brakes, the force acting on the brake drum is in
axial direction. The
axial brakes may be disc brakes and cone brakes. The analysis of these
brakes is similar to
clutches.
Generally, there are two types of frictional brake in bus that we
wear maintain
DISC BRAKE: disc brakes are comprised of a disc or
rotor calipers assembly, disc brake pads and wheel
bearing and hardware necessary to mount the
components on the vehicle. The caliper is connected
to master cylinder through tubes hoses and valves
that conducted brake fluid through the system.
Drum brake: comprised of a durum, and backing
plate, hub or axel assembly, brake shoes, wheel
cylinders, wheel bearing and hardware necessary to
mount the component on the vehicle. The wheel

cylinder is connected to the master cylinder through

hoses and valves that conduct brake fluid through the
system.
Drum brake have more pars than disc brake and harder to
service but they are less expensive to manufactured and they are
easily incorporated ate emergence brake mechanism.
3.4 Brake failure
One of most likely causes of no brakes is loss of fluid pressure
in your brake system. the followings are common brake related
complaints.
1. Slack(soft) brake: refers that the vehicle is not
slowing or stopping effectively when the brake is
applied.
2. Brake noise: Brake noise refers to an unwanted sound created
when the brakes are applied or while the vehicle is moving.
3. Pulling (brake steer): Pulling refers to an unintended
directional change, left or right, that occurs during brake
application
4. Smelly brake(hot)|: Smelly brakes are those that have an
unusual odor, which is typically the result of higher-than-normal
brake temperatures.
5. Poor brake mileage performance: Poor brake mileage
performance refers to the mileage between relines not achieving
established baseline goals
Typical causes of slack (soft) brakes:
Brakes out of adjustment:
Excessive push rod travel
Automatic brake adjuster malfunction or improper setup
Worn foundation components (yoke, clevis, bushing, camshaft, etc.)
Tight camshaft (poor lubrication)
Broken park brake spring (glazed lining)
Push rod and brake adjuster alignment
Brake assembly differences:
Incorrect chamber size and type
Incorrect brake adjuster length
Brake lining and drum condition:
Glazed lining
Polished drum surface
Poor choice of friction material
Contaminated lining (typically oil or grease)

 Worn brake lining, cracked or loose block

Insufficient brake lining to drum contact
Air system malfunctioning:
Air leaks and/or restrictions in application delivery system
Contaminated or worn air system components
Improper or malfunctioning applications and relay valves
Factors to consider when diagnosing brake noises
The type, pitch, volume and location of noise
Whether the brakes are warm or cold when the noise happens
At what brake application pressure the noise occurs
Whether the noise occurs at higher vehicle speeds or toward the end of the
brake application
If the noise changes throughout the braking application
Brake noise prior to or following brake burnish
Typical causes of a squealing noise when the brakes are applied
Glazed surfaces on the lining and/or the drum
Lining loose on shoe
Worn foundation:
Anchor pin, bushings
Camshaft, bushing, support bracket
Brake return springs
Foundation brake parts not meeting OEM specifications
Brake drum design and weight
Wrong lining for the application
Poor lining-to-drum contact
Improper spider alignment
Bell mouthing drum
Improper machining (arc)
Worn foundation parts

4. S- CAM SHAFT
An s- cam shaft is part of brake system used in heavy vehicles such as tracks,
bus and wheeled machinery. it consists of shaft around 4 to 25 inches longer,
turned at one end by means of air powered brake booster and leaver with an s
shaped cam at the wheel end. Turning the shaft pusher and the brake shoes against
the dram, producing friction.

5. SLACK ADJUSTER
Slack adjuster is the part of an air brake system that is used to adjust the
brake when needed.
It is located on the ax le housing near the wheel. On vehicles with drum brake, it is
between the push rod and the s-cam. On vehicle disc brake, it is between the push
rode and power screw.

6. AIR SYSTEM IN BISHOFTU BUS

6.1 Components of air system :
1. Compressor
2. Regulator
3. Air tanker
4. Four-way valve
Functional areas of air;

For read gage at the dash bored

For door opening and closing system
Clutch engage and disengage system
For brake chamber
For really valve (monitor brake chamber)
Combustion processed (for duff bus code 63)

6.2. Problems and failures in air system components:

In automobile air system problem caused by malfunction of one of the components
of the system
1. Compressor: it has five main parts
Head
Plate
Piston
Gasket
Oil compression ring
Due to failure of compression ring caused by wear the oil the used for lubrication
will pass to the compressor head then to the regulator, hence
The regulator become oily which supposed to have a clean
pressured air
The air tanker content oil which will have bad small
Solutions give to the above problems:
Change the ring
Change the regulator
Clean the pipes (air line between acupressure and regulator) by burning
the pipes)

The Compressor head failure basically due to service life which became cracked
and causes water back and due to servicing (repair of another components of
composure like to change gasket the head hits by hammer and became deformed.
Possible solution for such problem is changing the compressor head and stope
heating the head next time.
Gaskets are found between the head and the plate, and the the plate and the
compressor(piston). It function is:
To part air and water
To make a perfect fit (assembly)of the component
Basically it failure due to service life which can be identify when it became brittle
and due to heat when the driver tries to heat the engine.
Possible solution for the above problems are changing the gasket and check the
cooling water to reduce over heat.
2. Regulator
The function of regulator is to discharge air when the air tanker is full and to
separate the air produced by the compressor from moister malfunction of the
regulator is caused by the compressor when its rig wears out. Hence oil will pass
out to the regulator, and also the air dry will failure.
Possible solution for the above solution is repair the air compressor after that
change the regulator, changing the regulator only will not solve the problem since
the cause is the compressor.
3.Tanker
The function of tanker is to store pressured air produced by the compressor. There
are four tankers in bishoftu bus and others have two. cause of malfunction of the
tanker is quality of the air it may contain moisture, dusts and oil which results bad
small.
This problem can be solving by cleaning the tanker and repairing the compressor.

7.Automobile engine
As the name implies, the internal combustion engines (briefly written as I.
C. engines) are those engines in which the combustion of fuel takes place inside
the engine cylinder. The I.C. engines use either petrol or diesel as their fuel. In
petrol engines (also called spark ignition engines or S.I engines), the correct
proportion of air and petrol is mixed in the carburetor and fed to engine cylinder
where it is
ignited by means of a spark produced at the spark plug. In diesel engines (also
called compression ignition engines or C.I engines), only air is supplied to the

engine cylinder during suction stroke and it is compressed to a very high pressure,
thereby raising its temperature from 600C to 1000C. The desired quantity of fuel
(diesel) is now injected into the engine cylinder in the form of a very fine spray
and gets ignited when comes in contact with the hot air.
The operating cycle of an I.C. engine may be completed either by the two
strokes or four strokes of the piston. Thus, an engine which requires two strokes of
the piston or one complete revolution of the crankshaft to complete the cycle, is
known as two stroke engine. An engine which requires four strokes of the piston or
two complete revolutions of the crankshaft to complete the cycle, is known as four
stroke engine. The two stroke petrol engines are generally employed in very light
vehicles such as scooters, motor cycles and three wheelers. The two stroke diesel
engines are generally employed in marine propulsion.
The four stroke petrol engines are generally employed in light vehicles such
as cars, jeeps and also in aero planes. The four stroke diesel engines are generally
employed in heavy duty vehicles such as buses, trucks, tractors, diesel locomotive
and in the earth moving machinery.
7.1 Components of engine fabrication material
CONPONENT
S

cylinder

Piston

Piston ring
Piston pin

MATERIAL

cast iron or cast steel. Since the cylinder has to withstand high temperature
due to the combustion of fuel, therefore, some
arrangement must be
provided to cool the cylinder.
cast iron, cast aluminum, forged aluminum, cast steel and forged steel. The
cast iron pistons are used for moderately rated engines with piston speeds
below 6 m / s and aluminum alloy pistons are used for highly rated engines
running at higher piston speeds.
grey cast iron or alloy cast iron because of their good wearing properties
and also they retain spring characteristics even at high temperatures.
usually case hardened steel alloy containing nickel,
chromium, molybdenum or vanadium having tensile strength from 710
MPa to 910 MPa.

Connecting it should have adequate strength, stiffness and minimum weight.

varies from mild carbon steels (having 0.35 to 0.45 percent carbon) to alloy
rod
steels (chrome-nickel or chrome molybdenum steels). The carbon steel
having 0.35 percent carbon has an ultimate tensile strength of about
650MPa when properly heat treated and a carbon steel with 0.45 percent
carbon has a ultimate tensile strength of 750 MPa. These steels are used for
connecting rods of industrial engines. The alloy steels have an ultimate
tensile strength of about 1050 MPa and are used for connecting rods of aero
engines and automobile engines.
subjected to shock and fatigue loads. Thus material of the crankshaft should
Crank shaft be tough and fatigue resistant. The crankshafts are generally made of
carbon steel, special steel or special cast iron. In industrial engines, the
crankshafts are commonly made from carbon steel such as 40 C 8, 55 C 8
and 60 C 4. In transport engines, manganese steel such as 20 Mn 2, 27 Mn
2 and 37 Mn 2 are generally used for the making of crankshaft.

7.2 Engine failure

Unusual engine noses, low oil pressure, engine overheating,

loss of power, minifying, hard starting and similar drivability and
performance complaints can all be indications of problems that
need attention. The underlying cause may be something minor or
major.
There is no to know unless somebody checks it out. If a
motorist ignores such waring longer enough, it can be a very
costly mistake because eventually the engine may succumb to
whatever is causing the problem, which is a classic example of
preventive maintenance line, you can pay me now or you can
pay me later.
7.3 Causes of engine failure
The major causes of engine failures can be lumped into four basic
categories:
1. Overheating (excessive heat)
2. Lubrication (lack thereof)
3. Detonation (spark knock)
4. Misassemble (pops!)
7.4 WHAT IS AN ENGINE BLOCK?
The engine or cylinder block is the key component of an internal
combustion engine, where the power to drive the vehicle is
generated by igniting a fuel/air mixture to produce an explosion.
In any vehicle that runs on internal combustion, the engine block
is the key piece in the system, which wouldnt be able to function
without it. Usually made out of cast iron, it is also the heaviest
piece in the system, usually requiring several people to take it out
or put it in.
The engine block performs a number of functions, including
assisting with the pumping of water from the radiator to the
different parts of the engine to cool them down; housing pistons
in several cylinders that move the vehicles crankshaft; sealing in
the lubricating oil via the oil pan attached to the bottom and
generally acting as a container for various valves, gaskets and
seals that work together to keep the engine and the car as a
whole running safely.

figure engine block

7.5 ENGINE LOCK FAILURE

The engine block is one of the most essential components of a

cars internal combustion system, and it should be regularly
inspected to ensure that it has not developed any problems that
might affect its reliability and performance.
Heat is the Number 1 enemy of the engine block. If it
overheats the metal will become stressed and will eventually fail
leading to crack. Another problem is the porous engine block
which is often the result of a casting defect at the manufacturing
stage. This affects certain engines; most notoriously the old V8
used in the Range Rovers before they were fitted with BMW
engines.
Engine block crack

The main problem that might arise as far as a vehicles engine

block is concerned is the development of single or multiple cracks
in the casing. These in turn could get worse and become more
serious fractures which would, at the very least, require a
replacement engine.

A cracked engine block can cause a variety of problems, which

are listed below. Ultimately, since the circulation system that
cools the engine is comparatively fragile, a cracked engine block
will lead to coolant leaking out of the area it is needed and

leaving the engine to overheat. If left untreated, this will lead to

engine failure and may result in the vehicle having to be written
off.
In addition, some engine blocks may be porous, meaning
that liquids like antifreeze and oil can leak through the casing.
Porosity isnt something that simply develops in engine blocks
after a while the defect will have always been present in the
cast of the engine block so any problems should be noted fairly
quickly after purchase, especially if the car is brand-new.

8. COOLING SYSTEM
I.C Engines at best can transform about 25-30 % of the chemical
energy in to the fuel in to mechanical energy. About 35 % of the
heat generated is lost to the cooling medium remainder being
dissipated through exhaust and lubricating.
Considerable heat transfers to the combustion chamber
walls. Therefore, it is necessary to provide proper cooling system
especially to the combustion chamber wall due to the: Prevailing high temperature
Chemical & physical changes in the lubricating oil
This cause
Wear & sticking of the piston ring
Scoring of cylinder wall
Seizure of the piston
The Purpose of Cooling System
Prevent Overheating
Excess Heat generated in engine
Peak temperatures exceed melting point of metal
Regulate the most efficient Temperature
Regulate Temperature
Allow engine to warm up in cool weather
Maintain engine in optimum range.
Consequence of engine running too hot:

 Pre-ignition
Detonation/Knock
All result in very high pressure rise and possible damage to
engine.
Heat Fatigue of components
Burnt Pistons
Burnt Valves
Consequence of engine running too cold:
Unnecessary Wear
Poor Fuel Economy
Incomplete Combustion
Lower coolant Temperature
More energy transferred out of cylinder
Some of energy is wasted & not available for work (Power)
Promotes corrosive conditions in engine
Water of combustion reacts with sulfur oxides in exhaust
Forms acids
Allows water & sludge to accumulate in crankcase
Over time, fuel diluting the oil will accumulate
Normally lighter volatile fuel will evaporate as temperature rises.
8.1 Types of cooling System
Cooling system is used and made to circulate through the
jackets provided around the cylinder, cylinder head, valve
ports and seats where it extracts most of the heat.
The heat transferred from the cylinder wall and other parts
by convection and conduction.
8.2 There are two types of system in general
1) Liquid or indirect cooling system
2) Air or direct cooling system
1) Liquid cooling system
Mainly water
The heat from liquid in turn is transferred to air. Hence it is called
the indirect cooling system
8.3 Methods of water cooling System
Water cooling can be carried out by any one of the following five
methods
1) Direct or non-return system

2) Thermosiphon system
3) Forced circulation cooling system
4) Evaporation cooling system
5) Pressure cooling system
But in our company we see only forced circulation cooling
system; that Water or coolant is circulated with through jackets
around the parts of the engine to be cooled is kept in motion by a
centrifugal pump which is driven by the engine.
The water is passed through the radiator where it is cooled
by the forward motion of the vehicle.
A thermostat is used to control the water temperature
required for cooling.
This system consists of 4 components
Radiator, water pump, Fan, thermostat

Figure: Colling path

9. Radiator
The radiator in your vehicle is designed to remove the heat
generated by the engine to the air in order to regulate the
engine temperature and prevent overheating. The engine
block and cylinder head contain passageways filled with
coolant (usually a mixture of water and glycols). The coolant is
pumped around the car engine by the water pump and absorbs
the heat generated in the engine by the combustion process.
When it reaches the radiator the coolant flows through a series
of tubes where it is transferred to the outside air via fins. The

fins greatly increase the surface area of the radiator to make

heat transfer more efficient.
9.1 Failure of radiator
Poor maintenance is the main reason why you can be
left with a leaking car radiator, which can lead to the radiators
failing. If the coolant has not been checked or topped up
properly the inside of the cooling system will begin to rust and
become clogged. Corrosion will eventually result in small holes
developing. This will result in engine coolant loss, and a need
for car radiator repair.
9.2 How to maintain radiator
Maintaining your vehicle's radiator and cooling system is
important for keeping your car in good working condition.
A vehicle's engine produces a lot of excess heat, enough
to quickly damage or destroy the engine if it is not
properly cooled by the cooling system. There are a few
things you can do yourself to make sure your vehicle's
cooling system is in good working condition:
Always make sure that the coolant is topped up. If your
coolant level is consistently low, it can actually damage the
radiator and cooling system. Having to top up the coolant
more than a couple times per year means that you probably
have a leak and should have your radiator professionally
inspected. This is extremely important to your radiator parts
maintenance and to keep it good and running.
Keep an eye on the engine temperature. If you notice the
temperature raising more than it usually does, that probably
means that your vehicle's radiator isn't performing at top
efficiency and needs radiator parts maintenance.
Visually inspect the radiator and the cooling system. Look for
corrosion or breaks in the radiator cores, find cracked hoses
and rusted clamps, check the gasket on the radiator cap,
and watch for drip stains underneath the car.
Just like going to the dentist for a check-up, you should
regularly take your vehicles in for radiator maintenance.

This should be done at least once every two years,

especially if your vehicle is more than five years old.
When you take your vehicle in for a radiator and coolant
system check-up, they will do several tests to make sure
it is in proper working condition:
A thermostat test to make sure that it regulates the coolant
flow properly.
A pressure test on the system to make sure it does not leak
under pressure.
A fan test to make sure that the engine fan and any other
fans are working properly.
A pressure test on the radiator cap to ensure that it will
release at the proper pressure.
The service station will also likely flush and refill your cooling
system.
Basic suspension system

Shock absorber
Limit spring oscillations to smooth a vehicles ride

 One end is connected to the body or frame, the other to the

axle or control arm
When compressed or extended, oil inside the shock is forced
through small orifices, absorbing energy, damping spring
action.
Suspension system springs
Springs must jounce (compress) and rebound (extend) as a
vehicle travels over bumps and holes in the road surface
Springs must support the weight of the vehicle while still
allowing suspension travel
Types of spring
A. Coil spring
B. Leaf spring
C. Air spring
D. Torsion bar

figure:spring
types
Coil spring
Length of spring-steel rod wound into a spiral
Most common type of spring
Used on front and rear suspension
Leaf spring

 Flat strips of spring steel that are bolted together

Limited to the rear of some cars
A shackle fastens the rear leaf spring eye to the frame or
body and allows the spring to change length when bent
Rubber cylinder filled with air
Air spring
End caps are formed on the ends for mounting
Air pressure in the rubber cylinder gives the unit a spring
action
Special synthetic rubber compounds are used so the air
spring can operate properly in cold weather
Torsion bar
Made of a large spring-steel rod
One end is attached to the frame
The other end is fastened to the control arm
Jounce and rebound twists the torsion bar
Steering
Provides Precise control of the front-wheel direction.
Maintain the correct amount effort needed to turn the wheels.
Absorb most of the shock going to the steering wheel as the
tires meet bumps and holes
in the road.
Main components of steering system
1.Steering wheel
2.Steering column
3.Steering linkages
(tie rods, steering arms, etc)
4. Steering gear

Chapter three

4.1 Procedures followed while performing

the task are;
Observation and gathering general information about the
industry,
Problem identification,
Selecting suitable working area (problem),
Visualizing a mechanism for the problem,

 Analyzing the machine or the systems that are related to the

machine that has the problem,
Referring manuals from documentation room and asking
experienced technicians and technicians adviser
Identifying possible reasons,
Recommending solutions for the problem.

4.2 What Challenges you have been facing

while performing your work tasks
There are some challenges that we faced during
working. The main challenges are
The company, presently is not working with its full
capacity, so there is a problem for seeing the machines
while working, this in turn renders me from visualizing
what the mechanisms are behind the machines,
Lack of internet access to find (refer) related, existing
machines,
Lack of enough libraries.
Lack of educated man power concerning on some
machine.
Lack of man power according to the work in the company

4.3 Measure to overcome challenges

We looked the operation of some machines when there

is working
We referred some documented books.
By asking operator of machines.
By asking some persons who have more experience.
Without company using internet by money.

4.4 Overall benefits we gained from

internship

Benefit in terms of practical skill

The intern ship plays an important role to apply practically
what we have been studied theoretically in our field study. It helps

also to develop practical experience and how to handling the

theoretical knowledge when it changed to practical one.
During our field study, it seems too difficult since there is no
more practical experience and lack of sufficient workshop
availability in the campus. In addition to this, in theoretical
teaching and learning process of the course sometimes it is
difficult to interpreted and understand the subjects theoretically
in a short period of time. But practically in the internship or job
training and practical work easily interpreted and understand. As
a whole the intern ship has excellent advantages for me, because
of it deal with what we learned theoretically.
In the field which we studying that mean mechanical
engineering most of the subjects are deals practical manner. But
still these courses are over, no one shows to as or the practical
one. This renders me from the
actual performance of the courses precisely. But in our internship
we got sufficient knowledge and experience from the host
internship company. So, that the internship helps to gain different
advantage and benefits.
Similarly, Since the education policy is more of deductive, we
can say that we had very much limited by practical skill, but after
doing the internship we have improved our practical skill such as
speed of work, accuracy, independence in work and also technical
skill on machine which can be available in the company.
Benefit in terms of up grading our theoretical knowledge
The internship has many benefits in this regards, because as we
all know our knowledge is mainly based on theory, thus it was
necessary by any means to change or interpret the theoretical
knowledge to practical one. Improve theoretical knowledge is
gained by the intern ship through integrated the knowledge of our
study major course with the practical work in the intern ship
project.
The intern ship improves our theoretical knowledge through
participating practically. During the course study, if the students
have a good theoretical knowledge it is important and easy to
participate practically.
The internship was very helpful in up grading the theoretical
knowledge. For example, knowledge we have on how machines

and mechanism of work and the system behind the machines

such as hydraulic, mechanical and pneumatic system were much
clear to understand by relating to the theoretical knowledge.
Studying different kinds of process, machines and reading
manuals has also an important way for up grading my theoretical
knowledge. In addition to this, the internship has also helped as in
how we can relate my knowledge to the working environment and
I think that this is very important for my future in that we wont be
new for working environment.
Generally, up grading theoretical knowledge is important to
participate in the internship and also internship is a backbone to
apply theoretically. so, internship is the most important for our
future opportunity to job requiring and to apply the practical
experience that we gained during internship time.
Benefits in terms of improving our interpersonal
communication skill
Since the most important thing for one employee is good
and peaceful communication and for sharing of idea with other
employees, the internship has been of great help in improving our
communication skill. For example, to get different kinds of
information about the company and its function, to acquire
knowledge about the mechanical system of each machine, to
share ones knowledge with others peaceful communication was
very important.
To participate in practical activities during internship
interpersonal communication skill with the operators plays a great
role. This means in order to work and to understanding each
operation on the machines communicating with the company
workers. This lead to gain the experience how to apply this into
practical one. Additionally, to gained experience from the skilled
professional workers. Due to this reason through a time personal
communication skill improves the knowledge and ability to
approach the workers by living with other peaceful.
Personal communication skill improved depending on the
practical work and activities take place during the time.
To exchange, tools and other material during the work
time with the workers. The interpersonal communication skill
plays a great role. To asking the operators how some machines

perform its tasks and the process performing on that machine

communication is required. So, we were much benefited from
internship by improving our personal intercommunication skill.
Benefit in terms of improving our team playing skill
During the internship, we were able to work with our
department students, specifically with experienced employees to
find a solution for the problem which is mentioned earlier. During
our internship, when the workers team work with each other we
participated with them. This leads that we got some experience
from them. This implies that a group work has benefit for
improving team playing skill and for acquiring knowledge from the
team. At a time when I participating in the employees team they
appreciating my effort idea that I had been bringing as a solution
and I had fully believed that the intern ship has made me
improved my team playing skill.
Benefit in terms of improving our leadership skill
To improving leader ship skills internship is one of the basic
criteria and plays vital role in order to improving leadership skill.
Through actively observe all the works how to perform and how to
flows by the supervisors of the company or the company time
keeper. As leadership efficient is achieved and improved by
changing once attitude, the internship has made me believe that
our leadership skill has improved and I believe they were good.
The following are the benefits or advantages of internal ship
improving leader ship skill. Those are: To increase quality of work.
facilitate the manner and terminate on time.
To increase organization of the work.
To have confidence at any project activities.
To have cost effective to the company
Generally, I believed that my attitude has changed positively
and so does my leadership.
Benefit in terms of improving our leadership skill
To improve work ethics related issues, it is essential to
provide in the internship activates. Work ethics used to work with
any person or to participate in any activity which take places
during work involving in a proper manner the work ethics is
necessarily.

In the improving work ethics issues, to know a number of

ethics which is the work places is must because it is unique to
overcome any solution for the problem and to speed up a work in
short period of time. so work ethics is a basic thing ail any activity
take place in a working situation. In my internship I think that to
have good work ethics will maximize the required productivity of
any company at a given time. So in improving work ethics I got
many benefit by knowing this principle in practical at work places
during my internship. The work ethics is important in future
because we will not be new this rule and by know that respecting
and trying to implement the rule is beneficial for once and
countries development.
Generally, from my internship to improving the work ethics
issues the basic work ethics issues used in the work place that we
obligate to know them as follows these are:
Punctuality.
Honesty.
Reliability.
Responsibility.
Motivation.
Tolerance.
Good agreement with others.
Disciplinary rules and Commitment, respecting other work.
Benefit in terms of entrepreneurship skill
The internship has benefit in this respect because, at this moment
we have proof my knowledge through many activities. Not only
this but also, we proof my discussing ability with cognizant
engineers. We also proof how life is without campus was, how to
communicate with different peoples (employees) and how to
respond question with others.
I see many mechanism of machine in practical way what we
have learn in
theoretical.
I have seen what company looks like.
I have known how work flow of factory is implemented.
I have improved my technical skill.
using of time properly.

5. CONCLUSION

Anbessa City Bus Enterprise Service is huge source of various

technical and practical skills in giving car maintenance, recharge
the old materials to modern new, and solving the problem of

vehicle. In this practical work we learned so many things

(assembly, maintenance, technical system .). However, this
ACBES dont have just a disadvantages work overload and a lot of
stress recurrent.
During our internship period we were very glad, because we
got what academic caliber in all practical and technical arenas.
Before this internship we ask ourselves what we can do when we
are in the practical world because we have no experience,
knowledge and skill in the work area, but the internship was a
good chance for us to have a confidence in the practical world.
The main problem of the company is, lack of skilled person,
lack of man power, the problem satisfaction servant, nonfunctionality some machines, absences of some latest technology
machine, and lack of raw material can be need solutions that can
be implemented.

Chapter four
4. PROJECT

4.1. Title: Design Of Crank Shaft Polishers

4.2. Introduction
A crankshaft (i.e. a shaft with a crank) is used to convert
reciprocating motion of the piston into rotatory motion or vice
versa. The crankshaft consists of the shaft parts which revolve in
the main bearings, the crankpins to which the big ends of the
connecting rod are connected, the crank arms or webs (also
called cheeks) which connect the crankpins and the shaft parts.
The crankshaft, depending upon the position of crank, may be
divided into the following two types:
1) Side crankshaft or overhung crankshaft,
2) Centre crankshaft,
4.3. Material and manufacture of Crankshafts
The crankshafts are subjected to shock and fatigue loads. Thus material of
the crankshaft should be tough and fatigue resistant. The crankshafts are generally
made of carbon steel, special steel or special cast iron.
In industrial engines, the crankshafts are commonly made from carbon steel
such as 40 C 8, 55 C 8 and 60 C 4. In transport engines, manganese steel such as
20 Mn 2, 27 Mn 2 and 37 Mn 2 are generally used for the making of crankshaft. In
aero engines, nickel chromium steel such as 35 Ni 1 Cr 60 and 40 Ni 2 Cr 1 Mo 28
are extensively used for the crankshaft.
The crankshafts are made by drop forging or casting process but the former
method is more common. The surface of the crankpin is hardened by case
carburizing, nitrating or induction hardening.
4.4. Stresses in crank shaft
The following two types of stresses are induced in the crankshaft.
1. Bending stress
2. Shear stress due to torsional moment on the shaft
4.5. shaft failure
Most crankshaft failures are caused by a progressive fracture due to repeated
bending or reversed torsional stresses. Thus the crankshaft is under fatigue loading
and, therefore, its design should be based upon endurance limit. Since the failure of
a crankshaft is likely to cause a serious engine
destruction and neither all the forces nor all the stresses acting on the crankshaft
can be determined

accurately, therefore a high factor of safety from 3 to 4, based on the endurance

limit, is used.
4.6. Crank Shaft Polisher
Todays high output, close tolerance engines are more dependent than ever on
quality remanufacturing producers, durable prates and precise machining.
One of the beast way to assure long bearing life in toddys engines is to
make sure the journals n the crank shaft is properly polished.
Crank shaft journal surface should be ground and polished t a surface finish of 15
micro inches(0.000381mm) roughness average Ra or better. Journals on highly
loaded crank shaft such as diesel engines or high performance racing engines
require finish of 10 micro inches Ra or better.
The above is simple straight forward specification which can be measured with
special equipment. However, the is more t generating a ground and polished
surface than just meeting roughness speciation.
To prevent rapid, premature wear of the crank shaft bearing and to aid in the
formation of an oil film, journal surface must be ground opposite to engine rotation
and polished in the direction of the rotation.
4.7 Problem statement
In Abessa city bus, a crank shaft polishes by belt holding in the lathe
machine. The person that polish, stands in front of the lathe machine and will
polish by hand using the belt. This polishing type is traditional, requires longer
time and is
4.8 Objectives:
4.8.1 Main objectives:
The objective of this project to improve the traditional belt polishing
technique by making drive belt polisher that uses electric power rather than man.
4.8.2 Specific objective:
Identifying and selection components of the motor belt drive polisher.
which includes:
a. Electric motor
b. Polisher belt
c. Bearing
d. Beam
e. Pin
f. Spring
A. electric motor

This reversible electric motor can replace worn out or broken motors in
blowers, sanders, saws, conveyor belts and benchtop tools. Designed with a
durable rigid base, this electric motor can reach speeds up to 1800 RPM to
power your equipment like new. At 1/2 HP output, this electric motor can
give your tools the boost they need to work at peak efficiency.

Figure
Replace motors in: blowers, sanders, saws, conveyor belts and
benchtop tools
Capacitor start, 4 pole
Durable rigid base
Open drip proof enclosure
Specification
Name
SKU
Brand
Amperage (amps)
Application
Frequency (Hz)

1/2 HP General Purpose Electric Motor

67839
Smith + Jones
8.5/4.25
blowers, sanders, saws, conveyor belts and benchtop tools
60

B. Polisher belt:
Polishing Belt Materials and Design

Most quality crankshaft polishing belts are designed with an aluminum oxide
abrasive that is bonded with either glue or resin. Although the most common types
of belts have straight edges, others have scalloped edging that is designed to polish

into the radii. Though paper based belts are widely used for most crankshaft
polishing operations, abrasive cork belts are also available for super fine finishes.
Regardless of what type of belts an automotive machine shop uses, the belts lose
their effectiveness over time as the bonding agent deteriorates and as the belts
become loaded with material.
Since there is no way to dress a belt, proper belt maintenance includes blowing of
the belt with compressed air. This process helps to dislodge some of the material
that is embedded between the abrasives. Should the embedded material on the belt
become too great, it should be discarded and a new one placed into production.
Polishing belts are normally sold in quantities of ten per box. Depending on which
type of belt is purchased, the average cost can range from $2.50 to $4.00 per belt.
Ordinarily, a polishing belt that has been maintained properly can be used to polish
fifty crankshafts or more.

Resin bonded J-weight backing material

Super flexible material allows the user to push the belt up on the crankshaft
radius for smoother surface finish
1" wide
10 belts per package

 Available in 3 grits - 240, 320 and 400

C. Pulley
A pulley is a wheel on an axle or shaft that is designed to support movement
and change of direction of a taut cable or belt along its circumference.[1] Pulleys are
used in a variety of ways to lift loads, apply forces, and to transmit power. In
nautical contexts, the assembly of wheel, axle, and supporting shell is referred to as
a "block."
A pulley may also be called a sheave or drum and may have a groove or
grooves between two flanges around its circumference. The drive element of a
pulley system can be a rope, cable, belt, or chain that runs over the pulley inside
the groove or grooves.

D. Bearing
A bearing is a machine element that constrains relative
motion to only the desired motion, and reduces friction between
moving parts. The design of the bearing may, for example,
provide for free linear movement of the moving part or for free
rotation around a fixed axis; or, it may prevent a motion by
controlling the vectors of normal forces that bear on the moving
parts. Many bearings also facilitate the desired motion as much as
possible, such as by minimizing friction. Bearings are classified
broadly according to the type of operation, the motions allowed,
or to the directions of the loads (forces) applied to the parts.

figure: ball bearing

E. Ball-point pins
When sewing with stretch knit or jersey fabrics, most people
know that you should use a ball-point needle in your sewing
machine so the slightly rounded point of the needle will glide
through the knitted layers of the fabric and not break any of the
threads. But many people do not realize that when pinning stretch
knit or jersey fabrics before sewing, ball-point pins serve just as
useful.
If you have ever cut a thread on a sweater, you know
that the result is the entire unraveling of the sweater, as the
threads are knitted together in continuous loops. Stretch knit or
jersey fabrics are created much the same way, so minimizing the
breaking of threads is very important at each step of the sewing
process.
My ball-point pins are 1 1/16 in length, have nickel-plated
steel 5mm metal shafts, and have a plastic ball at the end
opposite the point. These are slightly shorter than my glass head
pins, making them easy to handle in the layers of knit. They do
not have glass head balls at the end, so if you need to press on
the fabric while pinned, be very aware of the heads in relation to
your iron. And just like with the glass head pins, the nickel-plated
steel makes them strong and rigid in the best way. Like glass head
pins, ball-point pins come in a variety of length and thicknesses,
so judge the weight of your project against the weight of the pins
used.

figure: ball head pin

4.9 Direction for crank shaft polishing

Crankshaft journal surfaces should be ground and polished to a surface
finish of 15 micros inches roughness average Ra or better. Journals on highly
loaded crankshafts such as diesel engines or high performance racing engines
require a finish of 10 micro inches Ra or better.
The above is a simple straight forward specification which can be measured with
special equipment. However, there is more to generating a ground and polished
surface than just meeting the roughness specification. To prevent rapid, premature
wear of the crankshaft bearings and to aid in the formation of an oil film, journal
surfaces must be ground opposite to engine rotation and polished in the direction of
rotation. This recommendation and examination of the following illustrations will
help make the recommendation clearer.
Metal removal tends to raise burrs. This is true of nearly all metal removal
processes. Different processes create different types of burrs. Grinding and
polishing produces burrs that are so small that we can't see or feel them but they
are there and can damage bearings if the shaft surface is not generated in the proper
way. Rather than "burrs", let's call what results from grinding and polishing
"microscopic fuzz." This better describes what is left by these processes. This
microscopic fuzz has a grain or lay to it like the hair on a dog's back. Figure 1 is an
illustration depicting the lay of this fuzz on a journal.
The direction in which a grinding wheel or polishing belt passes over the
journal surface will determine the lay of the micro fuzz.
In order to remove this fuzz from the surface, each successive operation should
pass over the journal in the opposite direction so that the fuzz will be bent over
backward and removed. Polishing in the same direction as grinding would not
effectively remove this fuzz because it would merely lay down and then spring up
again. Polishing must, therefore, be done opposite to grinding in order to improve
the surface.

In order to arrive at how a shaft should be ground and polished, we must first
determine the desired end result and then work backwards to establish how to
achieve it. Figure 2 depicts a shaft turning in a bearing viewed from the front of a
normal clockwise rotating engine. The desired condition is a journal with any fuzz
left by the polishing operation oriented so it will lay down as the shaft passes over
the bearing (Figure 2).

The analogy to the shaft passing over the bearing is like petting a dog from head to
tail. A shaft polished in the opposite direction produces abrasion to the bearing
which would be like petting a dog from tail to head. To generate a surface lay like
that shown in Figure 2, the polishing belt must pass over the shaft surface as shown
in Figure 3.

The direction of shaft rotation during polishing is not critical if a motorized belt
type polisher is used because the belt runs much faster than the shaft. If a
nutcracker-type polisher is used, then proper shaft rotation must be observed
(Figure 4). Stock removal during polishing must not exceed .0002" on the
diameter.
Having determined the desired surface lay from polishing, we must next
establish the proper direction for grinding to produce a surface lay opposite to that
resulting from polishing. Figure 5 shows the grinding wheel and shaft directions of
rotation and surface lay for grinding when viewed from the front or nose end of the
crankshaft. This orientation will be achieved by chucking the flywheel flange at the
left side of the grinder (in the headstock). Achieving the best possible surface
finish during grinding will reduce the stock removal necessary during polishing.a
The surface lay generated by grinding would cause abrasion to the bearing
surfaces if left unpolished. By polishing in the direction shown in either Figure 3 or
4, the surface lay is reversed by the polishing operation removing fuzz created by
grinding and leaving a surface lay which will not abrade the bearing surface.

Nodular cast iron shafts are particularly difficult to grind and polish because of
the structure of the iron. Nodular iron gets its name from the nodular form of the
graphite in this material. Grinding opens graphite nodules located at the surface of
the journal leaving ragged edges which will damage a bearing. Polishing in the
proper direction will remove the ragged edges from these open nodules.
All of the above is based on normal clockwise engine rotation when viewed
from the front of the engine. For crankshafts which rotate counterclockwise, such
as some marine engines, the crankshaft should be chucked at its opposite end
during grinding and polishing.