Contents

PART ONE....................................................................................................................................................1
INTERNSHIP REPORT....................................................................................................................................1
BACKGROUND OF THE INDUSTRY............................................................................................................1
1.1 INTRODUCTION.................................................................................................................................1
1.1.1 The objectives of Akaki Basic Metal Industry..................................................................................1
1.2 Inputs and raw materials of the industry...........................................................................................1
1.3 The suppliers of the industry.............................................................................................................2
1.4 Main products and customers of the industry...................................................................................2
1.5 Workshops of the industry................................................................................................................3
1.6 The organizational structure of the industry.....................................................................................5
1.7 The entire work flow in Akaki basic metals industry..........................................................................7
CHAPTER TWO.............................................................................................................................................9
GENERAL INTERNSHIP EXPERIENCE.............................................................................................................9
2.1 Work area that we worked in............................................................................................................9
2.2Tasks that we participated in..............................................................................................................9
CHAPTER THREE........................................................................................................................................11
3 OVERALL BENEFITS OF INTERNSHIP........................................................................................................11
3.1 In terms of enhancing educational knowledge................................................................................11
3.2 In terms of personal behavior..........................................................................................................11
3.3 The section that we have been interested......................................................................................11
3.3.1Foundry shop.................................................................................................................................11
3.3.1.1 Basic activities of the shop.........................................................................................................12
PART TWO.................................................................................................................................................14
CHAPTER ONE............................................................................................................................................14
PROJECT ON DESIGN OF SAND WASHING MACHINE.............................................................................14
1.1 Background and justification...........................................................................................................14
1.2 Statement of problem.....................................................................................................................14
1.3 Research objective...........................................................................................................................15
1.4 Scope and limitation........................................................................................................................15
1.5 Research methodology....................................................................................................................16
1.5.1 Data source...................................................................................................................................16
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1.5.2 Data collection..............................................................................................................................16

1.5.3 Data analysis.................................................................................................................................16
CHAPTER TWO...........................................................................................................................................17
LITERATURE REVIEW..................................................................................................................................17
2.1 Engineering design process.............................................................................................................17
2.1.1 Establishing the design requirements...........................................................................................17
2.2 What is Sand Washing Machine?.....................................................................................................17
2.3 Features of Sand Washing Machine................................................................................................18
2.4 Introduction to its Working Principle...............................................................................................18
2.5 Some notes used in this design project...........................................................................................18
2.6 Design of gears................................................................................................................................19
2.7 Shaft.................................................................................................................................................19
2.8 Bearing.............................................................................................................................................19
2.9 Keys.................................................................................................................................................19
2.10 Housing..........................................................................................................................................19
2.11 Evaluation criteria..........................................................................................................................21
CHAPTER THREE........................................................................................................................................22
RESEARCH RESULT AND DISCUSSION........................................................................................................22
3.1 Current sand washing mechanism...................................................................................................22
3.1.1 Drawbacks of the system..............................................................................................................22
3.2 Improved mechanism......................................................................................................................22
3.3Dimensional analysis of the machine...............................................................................................24
3.4Gear box design................................................................................................................................26
3.4.1 Gear box specification..................................................................................................................27
3.4.2 Gear design...................................................................................................................................27
3.4.2.1 For gear 4.................................................................................................................................29
3.4.2.2 Gear 5........................................................................................................................................32
3.4.2.3 Gear 2........................................................................................................................................33
3.4.2.4 Gear 3........................................................................................................................................34
3.4.3 Design of shaft..............................................................................................................................35
3.5 Bearing selection.............................................................................................................................41
3.6 Design of belt...................................................................................................................................43
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3.7 Design of blade................................................................................................................................47

3.8 Design of shaft.................................................................................................................................48
3.9 Design of the pulley.........................................................................................................................49
3.10 Chain-design..................................................................................................................................49
3.11 Welding design..............................................................................................................................53
3.12 COST BEFIT ANALYSIS....................................................................................................................54
3.12.1Cost of current existing system....................................................................................................54
3.12.2The cost analysis..........................................................................................................................54
3.13 Cost of the new designed system..................................................................................................55
CHAPTER FOUR..........................................................................................................................................57
CONCLUSION AND RECOMMENDATION...................................................................................................57
4.1 Conclusion.......................................................................................................................................57
4.2 Recommendation............................................................................................................................57
Reference book.....................................................................................................................................58
Part drawing..........................................................................................................................................58
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Table-1-cost of tanker & sieve...................................................................................................................61

Table- 2- total annual cost.........................................................................................................................63
Table 4-typical properties of selected materials used in engineering.......................................................83
Table 5- standard pitch lengths of v belts according to is:2494-1974.......................................................84
Table 6- dimension of standard v-grooved pulley according to is : 2494-1974.........................................84
Table 7- stress permitted by the AISC code for weld metal…………………………………………………………………...84

Table 8-bearing selection data for single-row, deep-groove, Conrad-type ball bearings..........................85

LIST OF TABLES
Table 1-Cost of tanker & sieve

Table 2-Total annual cost

Table 3- Dimension of standard v- belts according to is: 2494-1974

Table 4- Typical properties of selected materials used in engineering

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Table 5- Standard pitch lengths of v belts according to is: 2494-1974

Table 6- Dimension of standard v-grooved pulley according to is: 2494-1974

Table-7- Stresses permitted by the AISC code for weld metal

Table-8- Bearing selection data for single-row, deep-groove, Conrad-type ball

Bearings

PART ONE

INTERNSHIP REPORT

BACKGROUND OF THE INDUSTRY

1.1 INTRODUCTION
Akaki basic metals industry is found in Addis Ababa Akaki sub city. It was inaugurated on
February 4 1989 G.C with paid capital of 142,298,000 on a total area of 155,000 m 2. The
industry is expected to hire about 900 employees and currently it has around 600 employees. The
production programs were proposed by a Swedish firm known as SWECO and are proposed to
establish a plant producing 3600 items including a number of semi-finished and finished
castings.
 MU STUDENTS INTERNSHIP REPORT

The civil engineering design, product and production engineering, training, conduction of
feasibility study, supply and supervision, the erection and commission of the plant is done by the
Italian firm FATA.
At the time establishment its name is Akaki spare parts and hand tools factory. It is a huge
industry equipped with foundry shop, forging shop, machine shop, heat treatment shop, and
quality control shop.

 Its production capacity is 3600 items, approximately 4500 tons/year of melting capacity.
 Hand tools 1,600,000 pieces/year
 Cutlery 600,000 pieces/year

1.1.1 The objectives of Akaki Basic Metal Industry

 To improve the existing shortages of spare parts of the country by designing and
producing them locally thereby saving the foreign currency.
 To provide industrial development of the countries by producing necessary machine
tools.

1.2 Inputs and raw materials of the industry

The main raw materials needed for the production process are:-
 Sheet metals: - this sheet metals are of different metal type with a standard
dimensions. Some of them are imported from different suppliers around the world
while most of them are produced domestically.
 Die tools: - are tools used for attaching and dispatching the dies from the machines.
 Round bars: - are bars used for different operations for the machine shop. These
bars are of different diameter starting from small dimension to bigger one up to
300mm.
 Angle iron: - are metals used in the welding shop for making different products.
 Flat bar: - are the other input materials for the machine shop and welding shop.
 Dies: - are mostly used on different machineries in the industry. Those die are used
in different shops of the industry.
 Cast iron scrap:- are a scrap gathered from different products used for the melting
shop
 Aluminum scrap:- the other input material used for the melting shop
 Bronze scrap:- is also a scrap gathered from different materials used for the non-
ferrous metal melting shop
 Steel scrap:- are scrap used for the production of materials which requires high
quality and density.
 Brass scrap:- are also used in the melting department to be re melted
 Chemicals (resin and catalyst):- are the basic chemicals used for the mold making.
Resin is used as a binding agent while catalyst acts as a catalyst.
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1.3 The suppliers of the industry

There are a lot of foreign companies which supplies different input materials for the industry
among them Turkish supplies products like sheet metals and different types of steel bars while
Italy supplies materials like safety shoe and other safety materials. China is the other country
who supplies chemicals like resin and catalyst to the industry. India supplies the other main input
material known as refractory for the foundry shop. Germany supplies products like refinery
material and high manganese steel scrap for the melting shop.
The industry also gets different products from domestic industries like different types of scrap
metals, cast iron sheet metal, cast iron round bars, stationary products…etc.

1.4 Main products and customers of the industry

There are different products which the company produces for its main customer and others.
Products like cane knife holder, trash plate, trash roller, and other products are produced mostly
for sugar factories like Wenji, Fincha, Methehar, and to the new under establishment Sugar
Corporation. The other basic products produced are crasher ball, hooks, Joe plate, scraper plate,
and others are produced for cement factories like Messebo, Mugger and Nationa cement.
Products like man hole cover, garbage tanker, brake drum, pipes, different types of gears, water
gates and others are mostly made for different customers industries and other sectors like
beverage, steel manufacturing, agricultural, food processing, telecommunication, Ethiopiaelectric
power corporation, mining, hotel, for other metals and engineering corporation industries, and
for other different sectors.
 Anker bolt Reinforcement
garbage tanker

Cane knife holder

Hole cover Roller

Trash plate Gear

Figure 1:- Main products of ABMI

1.5 Workshops of the industry

Foundry shop
This is a shop in which castings are made. The area of this shop is 5476m 2.These shop has two
main sections namely ferrous and non-ferrous including pattern shop, melting section, sand
laboratory, melting laboratory, maintenance, mechanized mold, hand mold and core making
shop.
At the ferrous department there are 3 furnaces with a capacity of 3.3tons for each and one
furnace for steel with a capacity of 250k.g for steel.
 MU STUDENTS INTERNSHIP REPORT

At the non-ferrous department there are 3 furnaces with a capacity of 500k.g each for aluminum,
bronze and aluminum alloy pistons.
Mechanical work shop
Its area is 11,664m2.it is a section in which different operations like grinding, drilling, turning,
facing, boring, gear cutting and other operations are done. This shop had three different sections
these are:-

Section I Gear hobbling, light milling, light lathe and grinding

Section II Heavy milling, turning and drilling
Section III Welding and bar cutting
Heat treatment shop
This is a shop in which different treatment operations are made to fulfill the mechanical property
of the finished product with operations like case hardening, tempering, annealing, normalizing,
stress relieving, and induction hardening.
 Case hardening is an activity of heating to a certain temperature based on the material
type then cooling it rapidly to its normal temperature to increase the strength and
hardness of the material alloys.
 Tempering is done on hardened steel to increase ductility and reduce brittleness.
 Annealing is done in controlled atmosphere inert gas to avoid oxidation. It is used to
reduce hardness, improve roughness, and remove residual stress and others.
 Normalizing is heating above 11000c and then cooling it using air; as a result the material
will attain enhanced hardness and less ductility and avoids excessive softness in the
material.
 Induction hardening improves the wear resistance capacity of the material; while it
loss\lowers impact resistance and fatigue life of the material.
Forging shop
The area of this shop is 288m2.itis equipped with two electric motor driven powers of 27k.g, one
for open and die forging up to 450k.g and 40k.g respectively and the other one for forging steel
balls for cement factories.
Production planning and control shop (PPC)
It is a section in which planning, controlling and organizing of the production process is done. It
has two sections under it; PPC itself and design section. The design section design customer
orders and change customer drawings to ABMI drawings. Dispatching and cost analysis are also
done in this section.
Sales and marketing section
This section welcome customers, made promotion works and make market research works.
Customers have a direct contact with this section. Customers come with drawings or with a
sample and then this section will made a cost estimation and check whether the product could be
made in ABMI or not. After the checkup it accepts the order and leads it to the concerned
section. They have their own engineers to do the tasks. Most of the workers in this section are
industrial engineers
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Store
Store is a place in which raw materials, finished products and materials which are used for the
production process are stored. It is divided into five sections these are:-
1. Raw material store
2. Finished products store
3. Inventory control
4. Non-technical store
5. Technical store
1. Raw material store: this is a store that contain raw materials that can be an input for the
production process
2. Finished products store: This is a store in which finished materials are stored. The layout is
based on different known customers. For small materials there is a shelf which has 8 columns
and 58 rows. To pick the materials from the shelf crane with a capacity of 1500-5000k.g is
used.
3. Inventory control: it is a section which controls what’s in and out of the store.
4. Stationery (non-technical store): is a store which contains oil, soap, detergent, soft and extra.

1.6 The organizational structure of the industry

General Manager

Design and development section MIS

Internal audit Quality management

Safety and security Inspection

Female affairs Law service and affairs

Finance andproperty administration vice Operation

Human
vice resourceadministration and development vice
Sales and marketingvice

Precision casting factoryCast ironcasting factorySteel processingfactory

Non-ferrouscasting
Machine
factorypartscast production factory
 MU STUDENTS INTERNSHIP REPORT

Figure 2:- Organizational structure

 Design and development section: - is obligated to prepare the drawing of each products
which the customers’ orders
 Internal audit: - is the chair which is going to manage and inspect the flow of financial
aspects of the industry or checks whether the budget of the industry is being used
normally or not.
 Safety and security:-is working group which will guarantee the safe working
environment and the availability of well inspected working tools and materials.
 Female affairs: - is a working group who will corporate females together for a better
fevering of female workers and keep them safe from different attacks from other workers.
 Quality management: - is a working group who will manage the quality of working
environment and products with in pre sated standards.
 Inspection:- will inspect the quality of each produced products.
 Law service and affairs: - will guarantee that the working system of the industry is
going well with the law of the country. And also will protect the industry from any attack
from other sectors within the law.
 Finance and property: - will pay salary for the workers of the industry and will control
the financial flow of the industry and any property of the industry.
 Operation vice: - is obligated to control the working system of the machine shoe, forging
shop, foundry shop, heat treatment shop, galvanization, and other workshops of the
industry.
 Human resource and administration: - is the one who is going to control the work force
of the industry and it will also hire and fire workers as it is required.
 Sales and marketing: - will be doing different cost analysis works for the orders which
come from different customers of the industry; in addition they are obligated to promote
the industry to create a good market.
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1.7 The entire work flow in Akaki basic metals industry

Arrival of the customer

Customers are welcomed by marketing and sales section

Customers order receiving is done by marketing and sales section

The marketing section checks whether the order is done in here or not by its technicians

Yes No

Order accepted Customer order is rejected and the flow stops here.

ting section will check type of materials using spectrometer and structural micrometer.
TheFor this process
customers maythe customers
come with thepays a service charg
design

e or design is taken to the design and development section then change the sample or the drawing to Akaki basic metals drawing language

Cost factor is done by considering every process and operation that are required
 MU STUDENTS INTERNSHIP REPORT

The cost factor paper which has the part name, size, order quantity, urgency level, and delivery date is send to ppc section

PPC checked everything done by marketing and sales section

Job order is determined and Performa is prepared for the customers. The necessary improvements are done

PPC gave the Performa to the customers

 MU STUDENTS
ppc checked everything doneINTERNSHIP REPORT
by marketing and sales section

Job order is determined and Performa is prepared for the customers. The necessary improvements are done

ppc lead the work to the production shop and production started. The flow stops here.

PPC gave the Performa to the customers

ppc lead the work to the production shop and production started.
Finishing The flow stops here.

Finishing

The
The product product
is took is took
to the storeto the store

Customers come on the delivery date to the marketing section

The marketing section delivers the product to the customer

Customers come on the delivery date to the marketing section

Customers leave the system

Figure 3:- Work flow

The marketing section delivers the product to the customer

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Customers STUDENTS
leave the system INTERNSHIP REPORT

CHAPTER TWO

GENERAL INTERNSHIP EXPERIENCE

2.1 Work area that we worked in

At the first arrival day at Akaki basic metals industry, we met the general manager. He assigned
us at design pool department. This department is organized with one mechanical engineer, five
draft man & another three professionals. Design pool department is obligated to check and
approve design projects & drawings in international standards. On the days of our stay we had
participated in all jobs being done at this pool. In addition to the regular works we participated in
our supervisor also gave us a lot of mini-project works which help us a lot to enhance the
knowledge that we had with practical knowledge. Even if we were assigned at design pool
department we had also a chance to visit & look different working procedures of different
departments & working areas. From all shops we were interested in the foundry shop .This shop
is obligated to produce different casting products with different size, shapes & material property.
This production system goes under different procedures starting from sand preparation to
finishing works. As to our observation this working process was undergone with different ups &
downs on each step.

2.2Tasks that we participated in

As intern student we were egger to participate on different practical works of different working
groups. On the first instance we participated on the works of design pool department like
checking the dimension of drawing, observing how design is made. Among this job we were
mostly working on observing how design is made, this work requires knowledge of reading
drawings and understanding symbols. In this work we were obligated to prepare the steps to be
used while performing the task to the machinists. After preparing this drawing sheet we had tried
to check how machinists use this drawings & symbols, but as to the observation that we made
almost all workers handle the task in their own way, so they mostly produce parts with different
defects. On the other hand we had a chance to participate in sand preparation work for the
 MU STUDENTS INTERNSHIP REPORT

foundry shop which is so hard operation to handle with high consumption of power, time &
resource.

Patterns

Sand preparation Sand handling Sand making Molding Mold finishing Blast cleaning

Ingrate system removal

Sand laboratory Core making Core baking Mold handling

Inspection of casting qua

Metal Pouring
Charging Melting

Metal handling
Shake out

Figure 4:- Flow process chart of the foundry shop

2.2.1Challenges while performance

 The system requires more time, high labor &more consumption-- water.
 The system produces less quality of sand.
 Lack of safety shoes, clothe & gloves.
 The working area is uncomfortable which is open for rain & sun.
 The system requires more than two weeks to wash 16m3 sand.

2.2.2Measures to be taken

 Allocating the required soft material for assuring good work area.
 Building new lay out for the sand preparation system.
 MU STUDENTS INTERNSHIP REPORT

 Since the system is being held in manual system.

The whole system need to be redesigned, some& some intern students are trying to design new
sand washing machine with high capacity, less time consuming, less resource consumption.

CHAPTER THREE

3 OVERALL BENEFITS OF INTERNSHIP

3.1 In terms of enhancing educational knowledge

This internship program had helped us a lot for upgrading the knowledge that we had & getting
new knowledge. In the first hand we were able to understand own different industrial
engineering words apply to the real working system, how an mechanical engineer helps the
production system of an industry & what obligation do we have. In addition to this basic skill we
were able to enhance the knowledge of finding problem on the production system then find
industry starting the real & appropriate solutions for every problems, how the leadership goes in
the industry starting from the general manager labors (lower stage) workers, how the
organizational structure is organized, & enhancing our entrepreneur skill by looking different
real world activities & needs.

3.2 In terms of personal behavior

The industry has a lot of workers from different religion, ethnic group & culture. So from those
different peoples we had a lot of things to be inherited throughout our stay at the industry, we
had a chance to chat with different workers in related to different issues. On those days those
people had advised us a lot how we could be successful person, how we should live with
different staff members, told us a lot about the industry working environment, & gave us a
chance to participate on different social activities.
 MU STUDENTS INTERNSHIP REPORT

3.3 The section that we have been interested

3.3.1Foundry shop
A foundry is a factory that produces metal castings. Metals are casted into shapes by melting
them into a liquid, pouring the liquid metal in a mold, and removing the mold material or casting
after the metal has solidified as it cools. The most common metals processed are aluminum and
cast iron. However, other metals, such as bronze, steel, magnesium, copper, tin, and zinc, are
also used to produce castings in foundries. In this process, parts of desired shapes and sizes can
be formed.
Akaki basic metal industry had a huge foundry with an area of 5476m 2.These shop has two
sections namely ferrous and non-ferrous metal shops. It is composed of pattern shop, melting,
and sand laboratory, melting laboratory, maintenance, mechanized mold, hand mold and core
making shop. At this shop there are different activities being held like; sand preparation, pattern
making, mold preparation, core making, melting & pouring, and removing casted material after
solidification.

3.3.1.1 Basic activities of the shop

Sand preparation:- In this place the sand is firstly brought from Amhara region a place known as
Merabet. After that it will be washed in two stages.
At the first stage the sand is firstly loaded on to a sieve then it will be washed using high pressure
of water in which the sand which is smooth will sink to the tank under the sieve then again it will
be washed two times in the tank.
In the second phase it will pass the same step as in the first stage but the sieve is high denser
than the first stage and the sand used here is washed sand at the first stage. After that the clean
sand will be transported to temporary storage area using dog jog. Then will be dried using open
air which requires 2-3 days and will be taken to the cylo which is used to remove dusts which
may encountered during drying it has also hotter which has a capacity of 300-400 oc and lastly
will be stored to the tanker.
 MU STUDENTS INTERNSHIP REPORT

Pattern preparation:-This shop makes a pattern starting from small size to big and complex
structures. This shop uses different kinds of machinery, hand tools, and skilled workers. The
main raw materials used for making pattern are wanza wood, particle board from Maichew. They
first receive the design from design department and will prepare the required structure. Simple
designs can be made in a single piece or solid pattern. More complex designs are made in two
parts, called split patterns. A split pattern has a top or upper section, called a cope, and a bottom
or lower section called a drag. Both solid and split patterns can have cores inserted to complete
the final part shape. Cores are used to create hollow areas in the mold that would otherwise be
impossible to achieve. Where the cope and drag separates is called the line. When making a
pattern it is best to taper the edges so that the pattern can be removed without breaking the mold.
This is called draft.

Mold preparation:-Are obligated to make the mold using the basic raw material like pattern and
the clay sand and the three sub shops namely:- mechanized mold making, hand mold making,
and core making. In the core making process the clean clay sand is firstly transported to the
preceding tank using pneumatic system then chemicals like resin and catalyst will be added with
a proportion of 1.2 kg and 0.6 kg respectively with a 100 kg of clay sand.
The resin acts as binding agent & the catalyst as activator. The reaction takes place 10-15
minute. Then after placing the pattern on the holder (cope & drag) properly the sand is allowed
to flourish on the pattern and is rammed with the mechanized vibrator connected with it. The
next step is to prepare the original sand using either mechanized or hand mold techniques in
which both system uses recycled sand with the same proportion of chemicals. In mechanized
mold making process small to medium structures are made. In this process both sand ramming
and removal of pattern is made using mechanized machines. In case of hand mold both ramming
and removal of pattern are made manually. After the mold is done successfully in both methods
using compressed air dusts will be cleaned.
Then it will be painted a pint formerly known as isomole and iron plate, but currently they paint
it a paint which was prepared by the industry workers which has a capacity of handling above
16000c which used to control the high temperature of the molten metal and to have good surface
finish of casted material. After that using crane as handling the cope and drag will be assembled
and be ready for pouring.
 MU STUDENTS INTERNSHIP REPORT

Melting:-Melting is a process which is performed in a furnace. Virgin material, external scrap,

internal scrap, and alloying elements are used to charge the furnace. Virgin material refers to
commercially pure forms of the primary metal used to form a particular alloy. Alloying elements
are either pure forms of an alloying element, like electrolytic nickel, or alloys of limited
composition, such as ferroalloys or master alloys.

Finishing:- after the pouring is done it will be allowed to solidify for certain days based on the
size of the material. Then the mold will be destroyed using the bang porn machine after that they
will cut out the getting system from the casted material and will be taken to quality control
section.

PART TWO

CHAPTER ONE

PROJECT ON DESIGN OF SAND WASHING MACHINE

1.1 Background and justification

Sand washing machine is used for washing away the stone powder and impurity in the sand
made by the sand making machine, to increase the sand quality. Is a machine to wash sand in
coordination with the sand making machine. The current sand preparation mechanism is
manual system and high working time.

1.2 Statement of problem

Akaki basic metals industry sand washing (sand preparation process) is manual system in
which it requires more than a week to wash a single car sand (16m 3), so we can clearly see a
lot of problems like

 High working time,

 MU STUDENTS INTERNSHIP REPORT

 High amount of labor,

 High consumption of water,
 Less quality of fine sand are some of the basic draw backs.

Figure
5:- manual sand washing machines

1.3 Research objective

This project is being held to solve the different problems that are being observed currently at the
industry. Basically to change the manual sand washing system with a lot of ups and downs to
mechanized machinery with high capacity and quality which will increase the efficiency of the
industry.

 General objective
is to increase the resource utilization of the industry by correcting the manual working
culture of the industry in to mechanized system.

 Specific objective

 Design sand washing machine

 Draw part drawing
 Design of blade using software
 Reduce labor cost
 MU STUDENTS INTERNSHIP REPORT

 Reduce water consumption

 Increase production rate

1.4 Scope and limitation

This project is done at the foundry shop which is obligated to produce different casting material
basically at the sand preparation system. So in this project work we will improve the manual
sand preparation system to mechanized system by designing new machine which had low
processing time and high capacity.

1.5 Research methodology

1.5.1 Data source

Data will be assessed from different stake holders through direct interview, observation by us,
from internet, from different books, and available written documents of the industry.

1.5.2 Data collection

The whole data will be gained through the two perspectives.

Primary data:-direct observation, formal and informal interview with different workers, and
personal recording of data.

Secondary data: -Different research work by different employee of the industry, other intern
students’ paper work from different universities, and from different metal making industry
profile.

1.5.3 Data analysis (methodology)

 Using machine element analysis to design machine parts like gear box, shaft, belt …etc.
 By using catia software draw manufacture drawing and blade analysis
 It minimizes cost of the physical labor
 MU STUDENTS INTERNSHIP REPORT

 Since the machine wash high amount of sand in small operating time and consume less
water that means 60% of water consumption reduced.
 As the system will have mechanized system, it create improved efficiency
 Manual system which it requires more than a week to wash a single car sand (16m3)
But by using this machine it reduce to less than two days or only use 12 hours.
 MU STUDENTS INTERNSHIP REPORT

CHAPTER TWO

LITERATURE REVIEW

2.1 Engineering design process

The engineering design process is the formulation of a plan to help an engineer to build a product
with a specified performance goal. This process involves a number of steps, and parts of the
process may need to be repeated many times before production of a final product can begin.

It is a decision making process (often iterative) in which the basic sciences, mathematics, and
engineering sciences are applied to convert resources optimally to meet a stated objective.
Among the fundamental elements of the design process the establishment of objectives and
criteria, synthesis, analysis, construction, testing and evaluation are the basic.

The engineering design process is a multi-step process including the research, conceptualization,
feasibility assessment, establishing design requirements, preliminary design, detailed design,
production planning and tool design, and finally production.

2.1.1 Establishing the design requirements

Establishing design requirements is one of the most important elements in the design process,
and this task is normally performed at the same time as and the feasibility analysis. The design
requirements control the design of the project throughout the engineering design process. Some
design requirements include hardware and software parameters, maintainability, availability, and
testability.

2.2 What is Sand Washing Machine?

Sand washing machine is used for washing away the stone powder and impurity in the sand
made by the sand making machine, to increase the sand quality. Is a machine to wash sand in
coordination with the sand making machine. Sand washing machine is widely used for cleaning
 MU STUDENTS INTERNSHIP REPORT

materials in the industries like: quarry, minerals, building materials, transportation, chemical
industry, water conservancy, metal industry, hydropower, cement mixture station and so on.

2.3 Features of Sand Washing Machine

It has the features of high degree cleaning-up, reasonable structure, large capacity, low power
consumption, small loss of the sands during the washing process.

2.4 Introduction to its Working Principle

The electric motor runs slowly with the impellor after decelerated by the belt, decelerator and
gears wheel. The sand and stone flow into washing launder from feeding launder, roll with the
impeller, and grind each other. The impurity covering the sand is washed away. At the same
time, added more water, the strong water flow will take away low-weight waste from washing
launder. Through the above process, the washing function is finished. The clean sand and stone
are lifted up by vane. When it goes up slowly, the water begins to drop through the mesh and
falls back in the washing launder. On one hand, water is removed from the sand and stone; on the
other hand, the water can be fully used. Finally, the sand and stone go to the outer launder from
the rotary impeller to finish the washing task.

2.5 Some notes used in this design project

The basic data required for drive selection of v belts are the following
 The rated power of the driving motor or other prime mover
 The service factor based on the type of driver and driven load
 The center distance
 The power rating for one belt as a function of the size and speed of the smaller sheave
 The belt length
 The size of the driving and sheaves
 The correction factor for belt length
 The correction factor for the angle of wrap on the smaller sheave
 The number of belts
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 The initial tension on the belt

2.6 Design of gears

For the gear pair, you must specify the number of teeth in each gear, the pitch (size) of teeth, the
pitch diameter, the face width and the material and its heat treatment. These specifications
depend on considerations of strength and wear of the gear teeth and the motion requirements.
You must also recognize that the gear must be mounted on shaft in a manner that ensures proper
location of the gears, adequate torque transmitting capacity from the gears to the shafts.

2.7 Shaft

Having designed the gear pair, consider the shaft design. The shaft is loaded in bending and
torsion because of the force acting at the gear teeth. Thus, its design must consider strength and
rigidity, and it must permit the mounting of the gear and bearing. Shafts of varying diameter may
be used to provide shoulders against which to seat the gears and bearing.

2.8 Bearing

Design of the bearing is next. If rolling contact bearings are to be used, we may probably select
commercially available bearing from a manufacturer’s catalog, rather than design a unique one.
So first determine the magnitude of the load on each bearing from the shaft analysis and gear
design

2.9 Keys

Now the keys and the key seats can be designed. The diameter of the shaft at the key determines
the key’s basic size. The torque that must be transmitted is used in strength calculation to specify
key length and material. Ones the working component is designed, the housing design can begin.

2.10 Housing

The housing design process must be creative and practical. What provision should be made to
mount the bearing accurately and to transmit the bearing load safely through the case to the
structure on which the speed reducer is mounted? How will the various elements be assembled
 MU STUDENTS INTERNSHIP REPORT

into the housing? How will the gears and bearing be lubricated? What housing material should
be used? Should the housing be a casting, a weldment, or an assembly of machined parts?
 MU STUDENTS INTERNSHIP REPORT

Figure 6: -gear box

Figure 7:-different chain types

2.11 Evaluation criteria

1. Safety
2. Performance
3. Ease of service
4. Ease of service or replacement of components
5. Ease of operation
6. Law of initial cost
7. Law of operating and maintenance cost
8. Small size and maintenance cost
9. Low noise and vibration smooth operation
10. Use of readily available material and purchased components
11. Prudent use of both uniquely designed parts and commercially available components
 MU STUDENTS INTERNSHIP REPORT

12. Appearance that is attractive and appropriate to the application

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CHAPTER THREE

RESEARCH RESULT AND DISCUSSION

3.1 Current sand washing mechanism

The current sand preparation mechanism is manual system, in which it requires two tankers with
a volume of 0.7m 3, two sieve one with a diameter of 1.2mm and the other with a diameter of
0.7mm, three shovels, and four labors. The washing mechanism goes under the following steps:-

Step 1:- Attaching the sieve on to the first tanker

Step 2:- Loading the sand on to the first sieve with a diameter of 1.2mm
Step 3:- Washing it with a high pressure water injection
Step 4:- Removing the sieve from the tanker.
Step 5:- Washing the sand with high pressure water injection in the tanker three times
which is used to remove the clay
Step 6:- Repeat the above steps on the second tanker using the sieve with a diameter of
0.7mm.
Step 6:- unload the washed sand from the tanker to the temporary storage area.

3.1.1 Drawbacks of the system

 High consumption of water use about 10000 L per day

 Less sand quality
 High labor cost
 High operation time
 Less product rate…………etc.

3.2 Improved mechanism

Due to the above tangible and highly production rate affecting drawbacks this mechanized,
power driven sand washing machine design is required. This machine will have higher capacity
of production rate, less labor cost, less water consumption, and high quality of sand. This
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machine will be able to wash 0.6m3 of sand per twenty minute so it is able to wash a single car or
16m3 of sand in two working days.

Figure 8: –assembly sand washing machine drawing

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3.3Dimensional analysis of the machine

Assumption

Over all dimension of the machine 2500 ×2000 ×1000 mm

Washing capacity of the machine 0.6 m3silica sand

Total water consumption around 0.3 m3∨300 mL

kg
The density of water 1000
m3

kg
The density of silica sand 1200
m3

This assumption depend on the required washing capacity of the machine and the company data

Analysis
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Figure 9: -first washing tanker

Using the above figure we can determine the capacity of the tanker

First the area of rectangle

A=bh=2000 × 700=1400000 mm2

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1
A' = bh=0.5 ×375 × 400
2

¿ 75000 mm2

The area triangle ….2

1
A' ' = bh=0.5× 490 ×1100
2

¿ 269500 mm2

The total area of the tanker

At = A−( A' + A ' ' ) =1400000−( 75000+269500 )

¿ 1055500 mm2=1.055 m2

The volume of the tanker

V = A t ×W =1.055× 1=1.055 m 3 … …. ans

The mass of silica sand and water within the tanker

mw = ρv=1000 × 0.1=100 kg

m si =ρv=1200 × 0.6=720 kg

Total mass

m¿ =msi + mw

¿ 820 kg

The weight
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W =mg=820 × 9.81=8044.2 N

3.4Gear box design

The gear box design of a system to transmit power requires attention to the design and selection
of individual components (gears, bearings, shaft, etc…). However, as is often the case in design,
these components are not independent for example in order to design the shaft for stress and
deflection, it is necessary to know the applied force. If the force is transmitted through gears, it is
necessary to know the gear specification in order to determine the force that will be transmitted
to the shaft.
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 MU STUDENTS INTERNSHIP REPORT

Figure 10 :-gear box

3.4.1 Gear box specification

 Power to be delivered 5000w

 Input speed 1500rpm
 Output speed less than 180rev/min
 Input and output shaft extend 100mm
 Maximum gear box size 200mm×200mm in base 250mm
 Gear and bearing life of 10^8 cycle and reliability of 0.99

3.4.2 Gear design

Assumption
 20⁰ full depths involves teeth frame chosen.
 Safety factor 1.5 will be used

Characteristics of support are accurate mounting small bearings clearance minimum, precision
gear

Analysis
Over all gear box height 10 inch or 250mm
For compound reverted gyration

N2 N4
r= =8.33
N3 N5

For smallest package size both stage be the same reduction also by making the two stages
identical in line condition on the input and outputs will automatically be satisfied.
 MU STUDENTS INTERNSHIP REPORT

N2 N 4
= =√ 8.33=2.886
N3 N5
For this ratio the minimum number of teeth on the pinion interference is given by

2k
μp= × (m+√ m 2+ (1+ m ) sin 2 φ……………….[1]
(1+ 2m)sin 2 φ

2(1)
= (2.886 +√ 2.886+ ( 1+2 ×2.886 ) sin 220)
( 1+ 2× 2.88 ) sinφ

=8.43

Select the minimum number of teeth is 12….. [1]

N 2=N 4=12 teeth

N 5= N 3= 2.886×12

=34.32≈ 35

Check if w 5 is within limit

12 12
W 5 =( × )×1500 =176.32rev/min ……… acceptable
35 35

Proceeding with

N 2=N 4= 12 tooth

N 5= N 3 =35 tooth

12
W 3 =W 4 = ×1500 = 514.23 rev/min
35

Overall gear box height = 10 inch = 250mm

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N 2 N5
N 3+ + +2
M= ( 2 2 ) …………….[1]
y−clearance−wall thickness

35+6+17.5+2
= ( ) = 4.84
14−1.5

Let’s take M= 5 when clearance – wall thickness = 1.5

Let’s say m= 5

D p= mT 2= 5×12 = 60

DG = mT 3 = 5× 35 = 175

The pitch line velocity for the pinion and gear

π D 2 N 2 3.14 ×60 ×1500

V23 = = = 4.719m/s
60 60

πd 5 w 5 3.14 ×175 ×174.7

V45 = = = 1.614m/s
60 60

60 H 5000 w ×60
Wt23 = = = 1061.57N
πd 2 n 3.14 ×60 ×1500 m/s

60 H H 5000 w
Wt45 = = = = 3097 N
πd G n V 45 1.614 m/s

This calculation starts from the smallest gear because it transmits the largest load

3.4.2.1 For gear 4

Pinion tooth wear

J = 0.39
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YN =

K H ZR
√
(6c)p = [ZE W t23 K o K v K S
d wl b Z I
]

Where wt is the tangential transmitted load (N)

ZE is an elastic coefficient √ N / mm 2

K o Is the overload factor

K v Is the dynamic factor

K s Is the size factor

Pd Is the transverse diametrical pitch

b is the face width of the narrower member (mm)

KH is the load distribution factor

ZR surface condition factor

ZI is the geometry factor for pitting resistance

K o = 1 for uniform loading

K v = ( A + √ 200 v ¿ β
A

β = 0.25 (12 –Q v )2/3 when av from 3 to 7 for most commercial quality gear

Let’s take Qv = 6

β = 0.25 (12 - 6)2/3 = 0.8225

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A = 50 +56(1-β)

= 50 + 56(1- 0.8225) = 59.775

K v 23 = 59.775+ √ 200 × 4.719 = 1.514

59.775

To determine the size factor Ks from table 14.2

Y p= 0.245 for 12 tooth

1
K s= = 0.8433 (M f √ y ) 0.0535
Kb

Assume the face width of the pinion and gears 28mm

KH =1+C me (C pf C pm +C ma C e )

C me = 1 uncrowned

C e= 1 all other condition

C pm = 1 bearing immediately adjacent

18
F= =0.709inch
25.4

18
C pf = = 0.03 < 0.05
10× 60

F
Therefore we use this formula C pf = - 0.025 = 0.05
10 d

C ma = 0.247 + 0.0167(0.709) – 0.765(10-4)× (0.7092)

KH = 1+C me (C pf C pm +C ma C e )

= 1+ 1[0.05× 1 + 0.259× 1]
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= 1.309

From the fig. 14.6 (Ys) p = 0.33

Reliability factor

KR = 0.5 – 0.109 ln(1-R)

= 0.5 – 0.109ln (1-0.99)

= 1.0019635

cos 20 ° sin 20 ° 2.886

Z1 = ( ) = 01193
2 2.886+1

Pinion tooth wear

From table value (material)

ZE = 191√ Mpa …………….Strength of Grade 1 steel

1.03 ×1.309 ×1
√
(6C)P =191 1061× 1× 1.517×
60 × 20× 0.1193

= 243.64 Mpa

Contact fating strength

(SC)p= 2.22HB+200Mpa…………………….fig 14.5

= 2.22(200) + 200

=644 Mpa

Stress cycle factor

(ZN)p = 1.4488( 108 )-0.023 = 0.948

Z w = CH = 1
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Sc Z N
6 c=
SH

640∗0.948
=
243.67

= 2.48……………….. This show as pinion gear safe for wear

Pinion tooth bending

St = 0.533 HB + 88.3

=0.533×200+ 88.3

= 194.9 Mpa

t K H KB
6 p =W 23 K o k v k s
mt Y S b

1.003 1.309 ×1
= [1061×1 ×1.57 × = 73.638 Mpa
18 ×5 0.33

6 all=S t Y N

Y N = 1.3558(N) -0.0178

= 1.3558(108) - 0.0178

=0.977

6 all=¿ 194.9×0.977

= 190.4 Mpa

6 all
n=
6
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190.4
= = 2.58…………………….this show as pinion gear safe for bending
73.638

3.4.2.2 Gear 5

Bending and wear

Everything s the same as for gear 3 except YS, Y N and Z N

From the figure 14.6

J = 0.39

108 −0.0178
¿ ¿= 1.3558( ¿¿ = 0.99………………………..fig 14-14
2.99

ZN = 1

1.003 ×1.3091
GE = 1061×1 ×1.517 × = 60.2Mpa
18 ×5 ×0.39

Factor of safety for bending

SfYN 6all 194.9× 0.99

Sf (G) = = = = 3.21…….ans
6 ×YQYz 6 60.2

Gear tooth wear

1.03 ×1.309 ×1
√
(6C)g =191 1061× 1× 1.517×
60 ×20 × 0.39
= 243.64 Mpa

6call 644
n c= = = 2.65………….. this show as gear 5 safe for wear
6 243.37

3.4.2.3 Gear 2

Bending and wear

K v =¿) β = ( 59.775+ √200 × 1.614 ) 0.825 = 1.242

59.775
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From table 14.2

Y = 0.245 for 12 teeth

YQ for 35 not available in the table but we can calculate by using interpolation

34 0.371

35 Y

38 0.384

Y = 0.374

1
KS = = 0.8433 (mf√ Y ) 0.0535 = 0.8433(5×20 √ 0.374 ) 0.0535
Kβ

= 1.0508

Gear tooth wear

KHZR
√
6C = ZE WtKoKvKs
dwbZi

0.245× 1.309× 1
√
=191 3097 ×1 ×1.242×
60× 20× 0.1193
= 590.9Mpa

ScZNZR 644.05× 0.948 ×1

(SH)R = = = 1.638
6 cYQYz 590.05× 0.885 ×1

1 KBKH
6 = [W t K v K o K s × ]
b m t Ys

1.242× 0.245 ×1 ×1.309

= 3097 ×1 × = 37.5Mpa
20× 5 ×0.33

St Y N 194.9 × 0.977
(SH) = = = 5.737
6 ×YoYG 37.5× 1× 0.885
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3.4.2.4 Gear 3

For wear

1.242×1.045 ×1.309 ×1
√
6 = 191 3097 ×1 ×
60× 20× 0.1193
= 590.9Mpa

644.05× 0.948
SH = = 1.172………………….safe because factor of safety greater than one
590.9× 0.885× 1

For bending

1.242× 1.045× 1.309

6C = 3097 ×1 × = 131.6Mpa
20 × 5× 0.4

StYN 194.9× 0.977

(SH)C = = = 1.63
6 ×YQ × Yc 131.6× 1× 0.885

In summary the resulting gear specifications are

All gears modules = 5

Gear 2 grade 1 flame hardened carbonized

SC = 644Mpa St = 194.9Mpa

D2 = 175mm face width = 18 mm

Gear 3 gear 4 and gear 5

SC = 644Mpa St = 194 .9Mpa

D3 = 175mm face width = 18mm

 MU STUDENTS INTERNSHIP REPORT

D3 = 60mm and d5 = 175mm

Conclusion about gear analysis the gear have the same material and construction this will reduce
the manufacturing cost also the gear selected are spur gear type so they are simple in design and
low cost relative to their type with the same dimension.
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3.4.3 Design of shaft

Assumption

The fig below rough sketch to help a free body analysis can be performed with knowing shaft
diameter but cannot be performed without axial distance between gear and bearings. It is
extremely important to keep axial distance small

Figure 11:-sketch for shaft layout dimension in millimeter

Wt23 = 1061.57 N

Wt45 = 3097 N

Wr = Wt23 × tan 20°

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= 1061.7 × tan 20° = 386.35N

Wr= Wt45 ×tan 20°

= 3097× tan 20° = 1127.2 N

A double reduction gear box design has developed to the point that the general layout and axial
dimension of the counter shaft carrying two spur gears has been proposed as shown in fig. the
gear and bearings are located and supported by shoulders and held in place by retaining rings.
The gears transmit –through key. Gears have been specified as shown allowing the tangential
and radial force transmitted through the gear to the shaft to be determined as follows.

Where the superscripts t and r represent tangentially and radial direction respectively

Proceed with the next phase of the design in which a suitable material is selected and appropriate
diameter for each section of the shaft are estimated based on providing sufficient fatigue and
static stress capacity for infinite life of the shaft with minimum safety factor 1.5.

The general layout of the shaft, example gear, bearings and pulley must be specified early in the
design process in order to perform a free body force analysis and to obtain shear moment
diagram.
 MU STUDENTS INTERNSHIP REPORT

Figure 12:- Shaft layout and free body diagram

386N 1127.2N

X, Y plane free body

. Diagram

R AY 39mm 120 mm 39mm R BY

1061N 3097N

X, Z plane free body diagram

39mm 120 mm 39mm

R AZ R BZ

Figure 13:- Shear moment diagram in x,y plane

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Figure 14:- shear moment diagram in x,z plane

Figure 15:- octagonal plane

Octagonal
plane

22.8
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Combine orthogonal plane as vector to get total moment

J= √ 94.22 + 42.132= 103.19Nm

Start with point I where the bending moment is high, there is a stress concentration at the
shoulder and the torque is present

M a= √85.7 2+38.9 2

= 94.7Nm

t d3 175
T =W 23 = 1061* = 92.837 Nm
2 2

Material selection

Machined an cold drawn structural ASTM A-36 ………………………….[3]table 3

Sut =400 Mpa

S y =250 Mpa

This material selected b/c of expensive steel and widely available in the country

K a =a S but From table a=4.51

b = -0.265

K a = 4.5 × 400-0.265 = 0.9217

Let guess K b = 0.9

Ste =0.5 Sut = 0.5×400 = 200Mpa

Se =K a K b K c K d K e K f S tu
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Where K C =K D =K E=K F =1

Se =K a K b Ste =¿0.9217 ×0.9×200=¿165Mpa

K f =2.4∧K fs=2.1……………………………………table 4 [1]

First estimation of the smallest diameter at the shoulder at the point I use the DE Good man
criteria.

d=¿

¿¿

= 35.73
All estimates have probably been conservative so select the next standard size below 36 and
check d=36

D 36
= = 1.2
d 30

r
Assume fillet radius =0.1
d

K t =1.6…………………………………fig A- 15-19[1]

q s=0.8………………………………….fig 5

K f =1+q ( K t −1)
¿ 1+0.8(1.6−1)=1.48

K ts =1.2∧qs =0.8
 MU STUDENTS INTERNSHIP REPORT

K fs =1+ qs ( k ts −1 )=1.16

K a =0.9217

K b =¿

¿¿

Se =K a K b Stu
¿ 0.9217 × 0.86× 200

¿ 158.8 Mpa

t 32 K f M a
6 a=
πd 3
32×1.48 × 94.7
¿ =52.9
3.14 × 0.033

6tm=¿

¿¿

t t
1 6 a 6m
= +
nf Se Sut

52.9 35.15
¿ + =2.4 Mpa
158.8 400

Check yielding

Sy Sy
n y= t
=
6 +6ta
t
6 m m

250
¿ =2.84
35.15+ 52.9
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3.5 Bearing selection

Figure 16: - ball bearing

Assumption

 A design life of 1200hr

 Estimated bearing widths 18mm
 Bore size 20

Analysis
Intermediate shaft speed 514.23 rev/min
From the free body diagram

R Az = 208 R AY = 546.6 R A =584.8 N

R BZ = 2244 RBY = 966.56 R B=2443.3

 Intermediate shaft speed of 514.3 rev /min

 The design life of 1200 hr
 When searching for a deep groove bearings in manufacture catalog on the basis of
106 revolution for rating life.
 MU STUDENTS INTERNSHIP REPORT

60 min 514.23 rev

L D=12000 h × × =3.7× 108
h min

Start with bearing B since it has the higher load

The Weibull parameter are x 0= 0.02, (Q− X D ) = 4.439 and b = 1.483

C 10=a f F D ¿ RD > 0.9

LD 60 L D R 60× 12000 ×514.3

XD = = D
= = 370
LR L10 106

370
C10 =1.2×2443.3 [ ]1/3 = 34.95kN
0.02+4.439 ¿ ¿

By this load and bore diameter of the shaft select ball bearings is chosen from the SKF internet
catalog

C 10=a f F D ¿ RD > 0.9

370
FRA = 1.2×584.8[ = 8.36 KN
0.02+4.439 ¿ ¿

A specific ball bearings is chosen from the SKF internet catalog

From table-8- select ball bearing

Bearing selection data for single row, deep grove Conrad type of ball bearing

Nominal bearing dimension d=35mm, D=72mm, B=17mm,

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 MU STUDENTS INTERNSHIP REPORT

3.6 Design of belt

Belt 1

Belt 2

Belt 3

Figure 17:-belt arrangement

Selection of motor

 The given motor power 5KW and 1500rpm this motor select b/c in the company more
than five motor available in the store
 motor pulley diameter d1 = 150mm

Material selection

Select and use standard belt material and dimension

m = 0.44 kg/m
a = 400mm2

b = 2.1 Mpa
 MU STUDENTS INTERNSHIP REPORT

τ = 42 Mpa

Assumption

 Required washing blade revolution for the first tanker 60rpm

Gear box output shaft revolution μ = 0.28

 The drive pulley in all place 150mm

 Conveyor chain revolution not more than 10rpm
Analysis
First of all find the diameter of the driven pulley (d2) we know that

N1 d2
=
N2 d1

N 1d 176.3× 0.15
d2 = 1
= = 440mm for an open belt drive
N2 60

The diameter driven pulley tanker 2

N 2 d '2 60 ×150
d 3= = =360 mm
N3 25

Pulley diameter of the chain driver

N 3 d '3 25 ×150
d4= = =375 mm
N4 10

γ 1−γ 2 d 2−d 1 0.440−0.150

Sinα = = = = 0.145
x αx α

α = sin −1 ( 0.145 ) = 8°
Angle of lap on the smaller driving pulley
Q = 180 °−2 α =180 °−2 ( 8° )=164 °
 MU STUDENTS INTERNSHIP REPORT

π
164 × = 2.86 rad
180 °

Velocity of the belt

πd 1 N 1 π × 0.15× 176.3
V= = = 1.384 m/s
60 60

Centrifugal tension

TC = mV2 = 0.44×1.3842 = 0.842N

Permissible tension
Maximum tension on the belt

T = σ × a = 2.1 × 400 = 840N

Tension in the tight side of the belt

T1 = T – TC = (840 – 0.842)N = 839.5N
We know that

T1
2.3log( ) = μθ csc β
T2

= 0.28 ×2.86 csc 20 ° = 2.34

T1
Log ( ) = 1.02
T2
T1
= 10.42
T2
T1 839.15
T2 = = = 80.509N
10.42 10.42
Number of belt required
We know that the power transmitted belt
(T1– T1)V = (839.15 – 80.5) ×7.384 = 1051.975
Total power transmitted
Power transmitted per belt
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3000
= 2.85 ≅3
1051.475

3 belts required

We know that the pitch length of the belt

γ 2−γ 1 2
L = π ¿ +γ 2) + ( ¿ + 2X
x

220−75 2
= π (75 + 220) + ( ) + 2× 1000= 2947.025mm
1000

Subtracting 43mm for B type belt we find inside length of the belt

2947.025 - 43 = 2903.025mm

According to IS 2491 - 1974 the nearest standard inside length of V-belts is

3091mm……[2]

Pitch length of the belt

L1 = 3091 + 43 = 3134mm

Now let us find the new center distance (X1) between the two pulleys

We know that

L = π ¿ +γ 2) + ¿ ¿ + 2X

440−150 2
3134 = π 0.5 ¿+ 150) + 2X) + ( ¿
4X

84100
2207 = 2X + ( )
4X
 MU STUDENTS INTERNSHIP REPORT

2207 = 2X2 + 21025

Using quadratic formula

−b ± √ b2−4 ac
x=
2a

x=1093 mm … … … … … … … … … … … … … … … ans

The pitch length of the belt 2 we can determine

x 2=1276 mm … … … … … … … … … …Source assembly drawing

L = π ¿ +γ 2) + ¿ ¿ + 2X

= π (75 + 180) + ¿ ¿+ 2× 1276

¿ 3361.34 mm

Subtracting 43mm for B type belt we find inside length of the belt………………… [2]

¿3218.34mm

According to IS 2491 - 1974 the nearest standard inside length of V-belts is

3294mm…… [2]

Pitch length of the belt

L = π ¿ +γ 2) + ¿ ¿ + 2X

¿ 3294+ 43=3337 mm

Then find the new center distance (X2) between the two pulleys
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L = π ¿ +γ 2) + ¿ ¿ + 2X

3337=π ¿180+75) +¿ ¿

x=1263.8 mm … … … … … … … … … … … … … … . ans

The pitch length of the belt 3from the second tanker shaft to conveyor chain driver shaft

x 3=1155 … … … … … … … … …i . e the center distance between shaft 2 ¿ shaft 3

L = π ¿ +γ 2) + ¿ ¿ + 2X

= π (75 + 187.5) + ¿ ¿+ 2× 1155

¿ 3145.27 mm

Subtracting 43mm for B type belt we find inside length of the belt

¿ 3102.2 mm

According to IS 2491 - 1974 the nearest standard inside length of V-belts is

3294mm…… [2]

Pitch length of the belt

¿ 3294+ 43=3337 mm

Then find the new center distance (X2) between the two pulleys

L = π ¿ +γ 2) + ¿ ¿ + 2X

3337=π ¿187.5+75) +¿ ¿ ; x=1251.37 mm … … … … … … … … … .. ans

3.7 Design of blade

Material selection
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Machined an cold drawn structural ASTM A-36 ………………………….[3]table 3

Sut =400 Mpa

S y =250 Mpa
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Figure 18:- Catia analysis on blade

3.8 Design of shaft

p × 60 5000× 60
T= = = 796Nmm
2× π × N 2 2× π × 60

Since the driven pulley is over hang and distance of the center from nearest bearings is
200mm. therefore bending moment on the shaft due to pull on the belt.

M = (T1 + T2 + 2TC) 200 ×5

= (839.15 + 80.509 + 2× 0.842 ) 200 ×5

= 921693Nmm

Equivalent twisting moment

T e= √ T2+ M 2
T e= √ ( 796 ×1000 ) 2+ ( 91693 ) 2
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= 921693 Nmm

We know that equivalent twisting moment

π
Te= × τ ×D3
16

π
1217.839 ×103 = × 42× D3
16

D = 52.86mm Let us Say 55mm

3.9 Design of the pulley

The dimension for the standard V - graved pulley (ref fig 20) as shown and using table
value

W = 14 d = 15 a 4.2 c 10.8

F= 125 e = 19

We know that full width of the pulley

β = (n + 1) e + 2f

= (3 - 1)× 19 + 12.5× 2 = 63mm.

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3.10 Chain-design

Figure 19:-chain assembly

Chain type

Closed joint type chain

 Conveyor chain is usually made of marble cast iron.

 The conveyor chain at slow speeds of about 0.8 - 3m/s.
 In this project select pintail chain
 Chain constructed of a series of cast offset links coupled by steel pins or rivets suitable
for slow to moderate speed drive, conveyor and elevator service.
Material selection
Malleable cast iron
2% C 1%
ASTM A - 47
Sut = 345Mpa
Y st = 230Mpa
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Assumption
1 Load factor (K1) = 1.25 for variable load with mild shock.
2 Lubrication factor (K2) =1 for drop lubrication
3 Rating factor (K3) = 1.25 for 16 hours per day.

Pitch = 50mm

Number or teeth 10

Velocity ratio 1

Roller diameter d= 10mm

Analysis

The number of teeth on the gear

T2 N 1
= =1
T1 N 1

T2 = T1

For design power = rated power ×service factor (Ks )

KS = K1× K 2 × K 3

= 1.25×1 ×1.25

= 1.5625

Design power = 5Kw × 1.5625

= 7.81Kw

Breaking strength of the chain obtained by

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W p = 106 P2

= 106 × 50.82

= 273547.84

Dimension of the gear

180
d1 = Pcsc ( )
T

180
= 50.8csc ( )
10

= 164 .39

Pitch circle diameter

π N d1 3.14 ×10 ×0.205

V1 = = = 0.0868m/s
60 60

Load on the Chain

rated power
W= `
pitch line velocity

5 KN
= = 58.115 KN
0.867 m/s

Factor of safety

273547.84 N
= = 4.706
58115 N

The center distance between sprockets

= 30P
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= 30 × 50.8 = 1524mm

In order to accommodate initial sag in the chain, the value of center distance is reduced by 2 to
5mm.

Correct center distance

X = 1524 - 4 = 1520mm

We know that the number of chain links

T 1+T 2 2X T 2−T 1 2 P
K= + +[ ]
2 P 2π X

10+10 2× 1524
= +
2 50.8

= 10 + 60 = 70

Length of the chain

L = KP

= 70 × 50.8

= 3556mm

Number of individual chain required in the machine

2× 70 = 140 piece
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3.10.1 Sprocket gear design

Principal dimension of tooth profile

Tooth flank radius (re)

= 0.008 d1 (T2 + 180)

Where d1 roller diameter

T number of teeth

= 0.008 × 10(102 + 180)

= 22.4mm

Roller seating radius (r1)

= 0.505 d1 + 0.069√3 d 1

= 5.1986mm

Roller seating angle (α)

90 °
= 140° - = 131°
T

Pitch circle diameter

P
= = 164.4mm
sin ¿ ¿

Top diameter ( Da )

= D + 1.25 P - d1

= 164.4 + 1.25 × 50.8 - 10

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= 217.9mm

Road diameter

= D - 2r

= 164 .4 - 2×× 5.1986

= 154.202mm

Tooth height above the pitch polygon

0.8 P
= 0.625P - 0.5d1 +
T

= 30.814mm

Tooth width

0.95 b1 when P> 12.7mm

When b1 = 30.99

Where b1 width between inner plates (b1) m maximum

0.95 × 30.99 = 29.44mm

Tooth side relief

= 0.1 P to 0.15 P

Take 0.15 × 50.8

= 7.62mm
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3.11 Welding design

Welding is material joining process in which two or more parts are coalesced at their contracting
surface by a suitable application of heat and/or pressure many welding processes are
accomplished by heat alone with no pressure applied other by a combination of heat and
pressure; and still other by pressure alone, with no external hot heat supplied. In some welding
processes filler material is added to facilitate coalescence the assemblage of parts that are joined
by welding is called a weldment.

In this design project mostly used fillet weld that means is used to fill in the edges of plates
created by corner, lap, and tee joints. Filler metal is used to provide a cross section
approximately the shape of a right triangle. It requires minimum edge preparation the basic
square edges of the parts are used. Fillet welds can be single or double (i.e. welded along the
entire length of the joint or with unwelded spaces along the length

Material selection

Welding design between the sheet metal and angle iron at the point of the opening of the tanker

Sheet metal Machined an cold drawn

1018CD Sut =400 Mpa

S y =250 Mpa

For angle iron are hot rolled properties

1018 HR Sut =400 Mpa

S y =220 Mpa
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Analysis

h=5 mm

l=1000 mm

Cold rolled properties degrade to hot rolled properties in the neighborhood of the weld

τ all=min ⁡(0.3 Sut +0.4 S y )

¿ Min ( 0.3 × 400 ; 0.4 × 220 )

¿ min ( 120,88 )

¿ 88 Mpa

The weight silica sand inside the tanker

W =mg=1020 × 9.81

¿ 10006.2 N

F=0.707 hl τ all =0.707 × 5× 1000× 88 ×10−3

¿ 331 KN ………………. Safe it can carry the load i.e. the weight of the sand
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3.12 COST BEFIT ANALYSIS

3.12.1Cost of current existing system

The current existing system requires things like:-

 Four daily labor

 Two tankers with a dimension of 2200*1200*35mm
 Two sieve with dimension of 1500*1200*25mm
 Four shovels
 Monthly water consumption

3.12.2The cost analysis

 Cost of labor is calculated as:-

 Payment for a single employee per a day is 55birr

Available working day is calculated as:-

 Days in a year 365

 Working days per a week 6 days
 Working hours per a day 8 hours

So the annual available time is 365*8 = 2920 hours

But throughout the year there are days like:-

 Public holidays and Saturday afternoon= 90.5 days= 724 hours

 Annual sick and mortality leave= 25 days= 200 hors

So the total available working time per a year is calculated as:-

Total available time=annul available time-(public holiday + annul sick)

=2920-(734+200)
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=1996 hours

Then the available working day is 249.5days

So the total payment for a single employee is=249.5*55=13722.50 birr

The total payment for the four employee is= 13722.5*4=54890 birr

 Cost of the tanker and sieve is calculated as:-

N Materi Measu Qty Mater Total Direct Time Total Over Total Total
o al rement ial materi labor requir labor head over cost in
cost/ al cost cost/hr e in cost cost/hr head birr
kg in birr in birr hour in birr in birr cost(birr
1 Tanker 2200* 54k 40birr 2160 12.89 14 180.4 19.38 271.32 2611.78
122*3 g 6
5
2 Sieve 2000* 1ps 100 100 12.89 2 25.78 19.38 38.76 164.54
1000
Table-1-cost of tanker & sieve Sum 2776.28
birr

 Cost of four shovels is 360 birr

The material like tanker and sieve are used only for six month so they will incur 5552.56 birr for
a year. And the shovels are use for four month so it requires 1080 birr for a year.

So the total annual cost of the current existing system is 61522.56 birr

3.13 Cost of the new designed system

In addition to the machine cost it requires two employees one to operate the machine and one
helper. So the cost of hiring the two full time employees as to the industry salary scale it is:-

 Operator 1546birr/month
 Helper 1114birr/month
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So the annual payment for the two employees will be 20780 birr
N Materi Measu Qty Mater Total Direct Time Total Overh Total Total
o al remen ial materi labor requir labor ead overhea cost in
t cost/k al cost cost/hr e in cost cost/hr d birr
g(ps) birr in birr hour in in birr cost(birr
birr
1 Tanke 202.32 40 8093.1 12.89 18 232.0 19.38 348.84 8673.9
r kg 2 2 8
2 Shaft φ35*1 52kg 40 4160 14.01 13 182.1 35.46 499.98 4842.1
000 3 0
φ55*1 2
500
3 Stand 6000* 4ps 300 1200 12.89 5 64.45 19.38 96.9 1361.3
80*40 5
4 Gear Φ230* 40kg 40 1600 14.21 8 113.6 144.87 1158.96 2872.8
19 8 2
5 Angle 6000 2ps 250 500 12.89 2 25.78 19.38 38.76 564.54
iron
6 Bearin - 4ps 110 440 - - - - - 440
g
7 Sieve 2000* 1ps 100 100 12.89 2 25.78 19.38 38.76 164.54
1000
8 Chain - 30kg 40 1200 13.86 16 221.7 7.09 113.44 1535.1
8 Pipe ⅔ 1ps 400 400 - - - - - 400
¾ 2ps 280 560 - - - - - 560
10 Valve - 4ps 20 80 - - - - - 80
11 Motor 5kw 1ps 4000 - - - - - - 4000
Sum 25464.43 birr

Table- 2- total annual cost

The total annual cost of the current system= annual employees salary+ machine production cost

=20780+25464.43

=46244.43 birr
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CHAPTER FOUR

CONCLUSION AND RECOMMENDATION

4.1 Conclusion

This project is a power driven sand washing machine with an input power of 5kw. The machine
had a capacity of washing 0.6m3 of sand per twenty minute. If the industries manufacture the
machine it will be able to save around 20,000 birr annually & will increase the production of
sand by around 37%, it will also increase the quality of sand with less consumption of water.

4.2 Recommendation

Akaki basic metals industry has to manufacture the machine to promote the supply & quality of
sand with promising quality.
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 The machine has to be manufactured with respect to the proposed design analysis.
 While installing it; it had to be installed at low level ground with sun & rain shade
 Don’t load more than 0.6m3 of sand per one run washing activity
 While loading the motor had to be turned off.
 If it had an inlet system of belt conveyer and an outlet system of screw conveyer the
mechanism capacity will be increased.
 For reliability & safety of machine, it has to be well cleaned after work.
 For better consumption of water prepare tanker for recycling of water using simple
distillation mechanism

Reference book

Mechanical engineering design-9th-edition-Shigley

A text book of machine design-Gupta
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Machine element life & design-Boris M.

Machine element & design -4th-edition –Robert L.

Part drawing
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Table 3- dimension of standard v- belts according to is: 2494-1974

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Table 4-typical properties of selected materials used in engineering

Table 5- standard pitch lengths of v belts according to is:2494-1974

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Table 6- dimension of standard v-grooved pulley according to is : 2494-1974

Table 7-stresses permitted by the AISC code for weld metal

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Table 8-bearing selection data for single-row, deep-groove, Conrad-type ball

bearings