South Road Authority New 123
South Road Authority New 123
2.Mebrat Markos………………………………………………….RU3771/11
3.Abriham Mathewos…………………………………………….RU3975/11
4.Teshale Abraham…………………………………………….….RU3776/11
Students Name ID
2.Mebratu Markos…………………………………………………RU3771/11
3.Abriham Mathewos……………………………………………...RU3975/11
4.Teshale Abraham………………………………………………..RU3776/11
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ABSTRACT
This paper contains the final Internship Report which aims to explain the general internship
experience we had during the three months stay at the South Road Authority. This place is more
concerned with maintenance of light and heavy-duty vehicles. Since we were in the same group
at the work place, we got the same workshops at the same time so uniformly shared similar
ideas. This report contains five chapters excluding the conclusion and recommendation each
chapter discussing about different aspects of the overall internship experience. During the time
we were trying to contribute for the hosting company by identifying some problems and
providing solutions for these problems. The internship program also helped us to develop
different skills both academically and professionally. This report discusses about the background
of hosting company, the overall experience that we get, the overall benefits of the program, the
design of our project, Result and discussion, cost analysis, conclusions and recommendation
about the whole internship experience then appendix for additional points. In the course of the
design, we have tried to mention essential points like problem identification, impacts of the
problem, proposed solution, literature review, working principle, specification, Objectives,
Scope, Significance, design process, methodology, concept generation, concept evaluation, parts
to be designed, material selection, and then finally the calculation which consist the design of
each parts and miscellaneous parts. Then the results during the course of the design will be
mentioned and their safety in according to the property of the material will be discussed. After
that the costs of materials will be estimated in birr by considering the mass of selected materials.
The conclusion and the recommendation for both the University and the company will be the last
part of the content then additional points in table and figures will be under the appendix. So we
think that we have done what is expected from us in both theoretically and practice because we
have followed the format that was given to guide us.
Key words: Company, Mission, Vision, values, Goals, Challenge, Procedure, Method,
Machine, Shop, Section, Objective, Scope, Design, Result, Cost, Appendix
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2.4.1 Engine shop.................................................................................................................. 11
2.4.2 Engine system .............................................................................................................. 11
2.4.3 Parts of engine.............................................................................................................. 11
2.4.4 Defects of engine ......................................................................................................... 12
2.4.7 Cooling system............................................................................................................. 12
2.4.8 Parts of cooling system ................................................................................................ 13
2.4.9 Lubrication system ....................................................................................................... 13
2.4.10 Parts of lubrication system ......................................................................................... 13
2.4.11 Function of lubrication system................................................................................... 13
2.4.12 Intake and Exhaust system ......................................................................................... 14
2.4.13 Intake system ............................................................................................................. 14
2.4.14 Parts of air intake system ........................................................................................... 14
2.4.16 Exhaust system parts .................................................................................................. 15
2.4.17 Fuel system ................................................................................................................ 15
2.4.18 Washing and greasing area ........................................................................................ 15
2.4.19 Mechanical shop ........................................................................................................ 15
2.4.22 Power train system ..................................................................................................... 18
2.4.23 Requirements of Transmission System ................................................................... 18
2.4.24 Machine shop ............................................................................................................. 19
a) Drilling machine ................................................................................................................ 20
2.4.25 Electrical shop ............................................................................................................ 22
2.4.27 Battery ........................................................................................................................ 22
2.4.28 Charging system......................................................................................................... 22
2.4.29 Welding shop ............................................................................................................. 24
2.4.30 Caterpillar machine .................................................................................................... 25
2.5 Procedures we have been following during work tasks ...................................................... 26
2.5.1 General methods and procedures of technical task are ................................................ 26
2.6 How good we have been in performing task ...................................................................... 27
2.7 Challenges we have been facing during work tasks ........................................................... 27
Proposed solution to overcome the challenges ......................................................................... 28
CHAPTER THREE ...........................................................................................................................................................28
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4.13 Evaluation methods ........................................................................................................... 46
4.14 Collection of data .............................................................................................................. 47
4.15 Function and Task Analysis .............................................................................................. 48
DESIGN PROCESS .........................................................................................................................................................48
4.16 Recognition of need .......................................................................................................... 48
4.17 Definition of problem ....................................................................................................... 50
4.18 Design calculation ............................................................................................................. 50
4.18.1 Design Procedure for Gear & Pinion ......................................................................... 50
4.18.2 Design of shafts.......................................................................................................... 54
CHAPTER FIVE ..............................................................................................................................................................71
CONCEPT DEVELOPMENT ............................................................................................................................................71
5.1. Introduction ........................................................................................................................ 71
5.2. Idea generation ................................................................................................................... 71
5.3 Using Reverse brainstorming .............................................................................................. 72
5.4. Evaluation of ideas ............................................................................................................. 72
5.5 Concepts .............................................................................................................................. 74
Alternative one .......................................................................................................................... 74
Alternative two.......................................................................................................................... 75
Alternative three........................................................................................................................ 75
5.6. Concept selection ............................................................................................................... 76
CHAPTER SIX ................................................................................................................................................................78
RESULTS AND DISCUSSIONS ........................................................................................................................................78
6.1. Results ................................................................................................................................ 78
6.1.1. Results of the Design Procedure ................................................................................. 78
6.1.2 Procedure to be followed during testing and designing ............................................... 79
6.1.2 Usage............................................................................................................................ 79
6.1.3 Technical principle....................................................................................................... 79
6.1.4. Materials and manufacturing ...................................................................................... 80
6.1.5. Safety .......................................................................................................................... 83
6.2. Discussions ........................................................................................................................ 83
6.2.1. Project outcome .......................................................................................................... 84
6.2.2. Process ........................................................................................................................ 84
6.2.3. Use of methods ........................................................................................................... 84
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LIST OF TABLES
Table 1 Human Resources .............................................................................................................. 5
Table 2 Road construction and maintenance machineries .............................................................. 6
Table 3 Concept selection criteria................................................................................................. 76
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CHAPTER ONE
INTRODUCTION
Ethiopian road authority has different branches one of its branch was our three month Internship
Company called south roads authority (SRA). Historic chronicles of the 17th and 18th centuries
show that there were a number of small roads trails and foot paths, in addition to the traditional
shoulder porter age, animals like mules, donkeys and horses and camels were used as a means of
transportation in Ethiopia. During the Italian occupation roads were built by them and they were
established to meet the requirements of the Military control rather than to promote the overall
development of the country’s economy. In addition, the roads lacked most of the modern
location, design and construction features desirable for present day high speed traffic. The roads
and trails built and improved during the 5 years Italian occupation were about 6000km.
approximately 2500 km of them were given a single asphalt surface treatment, drainage
structures were usually of stone masonry and at least three tunnels were built. However, when
Ethiopia regained its independence, the Italians in their fleeing attempt almost undid what they
created by blasting bridges and dynamiting roads.
Following the eviction of the Italian occupiers, the Imperial Ethiopian Government was
convinced that Road Agency solely responsible for restoring and expanding the road network
throughout the country had to be established. Accordingly, the Imperial Highway Authority
(IHA) was established under proclamation No. 115/1951 as a semi-autonomous agency with
specific duties to plan, design, construct, and maintain roads. Responsibilities for construction
and maintenance of roads remained under a single autonomous authority (IHA) for 26 years
(1951-1977). In 1980, the Military Government that took power in 1974 reformed the agency
into the Ethiopian Transport Construction Authority (ETCA) by proclamation No. 189/1980 and
became answerable to the newly formed Ministry of Construction. Following the shift from a
command-based economy to a market oriented one in 1991, ERA was reestablished by
proclamation No.63/1993 with a view to providing a strong administration under the leadership
of a Board. As part of its reform, the government assigned administration of rural roads to the
The south Roads Authority (SRA), since it was established in 1989 E.C by declaration has been
working on design study, Road construction and Maintenance with a great deal of sectorial
responsibility in the region's different zones, special woredas. In the activity of roads
maintenance, for the last 13 years, more than 9500 kms have been made get routine and periodic
maintenance. They all are made comfortable for traffic and well secured. In the activity of Road
design study until now, more than 2000kms Roads have been studied and designed for standard
road construction. Road network study that shows the status of the region's road network has
been studied and implement. To implement the road's development policy, the regional
government is increasing the amount of the yearly budget, is strengthening the works of
construction and maintenance of roads and bridges including design study in order to fulfill the
road of the region's people. In relation with this, the regional government is purchasing different
road construction and maintenance machineries to develop the authority’s capacity. On the other
hand authority to tackle different problems and to satisfy the need of customer, has implemented
BPR study.
➢ Construct road which connect lots of urban and rural area in the region
➢ Upgrade the standard of roads to the current best road technology and to appropriate
design for specific environment
➢ Human resources
These are the man power for the company who conduct the service of the company
2. Grader 15 10
3. Loader 20 10
4. Roller 17 8
5. Bacon loader 3 3
6. Tractor 10 5
7. Excavator 1 1
8. Low bed 3 2
9. Fuel holder 4 4
TOTAL 198 63
Work flow
1. Mechanical shop
Under this shop different vehicle part maintenance is done.
a) Power train: it including clutch, gearbox, propeller shaft, differential and other parts of
the power train maintenance or service.
b) Steering system: it including steering wheel, steering gear box, steering shaft and idler.
c) Suspension system it including spring, shock absorber and axles and their bearings.
d) Braking system: it including braking pad, braking drum, break piston, braking caliper,
changing braking fluid and service parking braking
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for maintenance. According to the identified problem the vehicle may be placed in electric,
mechanical, manufacturing, welding, greasing or engine shop. Under these shops there are a
number of trained and experienced workers so workers mentioned by the maintenance case team
will be the one who will perform the task. In addition to these another workers also collaborate
and support each other for better accomplishment. Then after finishing the maintenance the
technician will check the vehicle about three times and if it is ok the customer check it.
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➢ Flywheel& cooling fins
➢ Fuel injector, fuel pump, Oil pan& oil pump
➢ Glow plug, spark plug, valves, Piston& piston rings
➢ Head & head gasket
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2.4.8 Parts of cooling system
a) Radiator Rejects the coolant heat to the surrounding air.
b) Radiator cap to cover the radiator from any dust
c) Wax Thermostat if temprature is beyond reliable it opens for the water to flow from
radiator
d) Breazer used to return the water in to the reservoir
e) Cooling Fan Maintain an adequate air flow across the radiator matrix.
f) Water pump used to pressurize the water to retun back after finishing its cycle
g) Hoses takes and returns the water
h) Reservoir used to accumulate the water that returns in the form of vapour.
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Figure 2.3 Parts of lubrication system (mobile capture)
Defects
➢ Wearing
➢ Breaking and deformation of parts
➢ Overheating and frictional loss
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Here are some essential points about exhaust system like its parts and principle of recirculation
Classification of Fuels
1. Primary fuels which occur in nature as such, e.g. coal, petroleum and natural gas.
2. Secondary fuels which are derived from the primary fuels, e.g. coke, gasoline, coal gas,
etc.
Types of fuel injection system
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Figure 2.5 Mechanical shops (mobile capture)
There may be different steps and methods to replace the shock absorber
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➢ Stop the vehicle on leveled area and insert support under the tires
➢Separate the brake hose and brake pipe then the shock absorber from the knuckle arm
➢ Remove the strut mounting nut and compress the coil spring
➢ Remove the bearing dust cover and remove the nut from the top of the shock absorber
➢ Inspect and collect the disassembled part then assemble the parts with correct places.
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When the brake piston is dried and can’t play freely then vehicle can’t stop as we need so
we must service it by cleaning and greasing.
Firs cheek all brake system components are work because the hose of the fluid are leaks then the
fluid may finished before its recommended time. After filling the fluid the in order to avoid the
air in the middle of the fluid, we push the fluid up to the tip of the hoses through all hoses by
pressing the pedal before driving the vehicle. When the air removes out and the pedal is ok we
can finish and cheek the vehicle.
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2.4.24 Machine shop
This place is where we get the opportunity to meet machinists who willingly give us the essential
tangible knowledge by allowing us to do what they are doing, following, guiding us.
a) Lathe machines
In this shop there are two lathe machines. They are used to different applications like fabrication
of shaft with different features, bolts and nuts
Used to press different parts if it is ruptured inside host parts like piston line. There are two types
of press machine electrical and manually operated.
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Figure 2.10 Lathe machine
a) Drilling machine
For producing holes in jobs on lathe, the job is held in a chuck or on a face plate. The drill is held
in the position of tailstock and which is brought nearer the job by moving the tailstock along the
guide ways
b) Burner
It’s a simple device which generate an air with a motor to burn the inserted fuel (charcoal) in the
burner house. Used for heat treatment application after they fabricate some components like bolts
and nuts.
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d) surface grinder machines
There are two grinders to work surface finish of fabricated and to reduce the size of component
Bench vise
Its well-known device which used to hold the work piece and apply some mechanical works
like hammering, bending and so on
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2.4.25 Electrical shop
2.4.27 Battery
Designed to only power motors for a short time (starter)
Functions
➢ Recharges battery after cranking
Components:
1. Alternator 2. Voltage Regulator 3. Wiring 4. Indicator 5. Drive Belt
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Figure 2.12 components of charging system (mobile capture)
Starting system
Starting system uses battery power and an electric DC motor to turn engine crankshaft for engine
starting. It changes electrical energy to mechanical. Provides gear reduction/torque multiplication
(16:1 to 20:1) When the ignition key is turned on the current flows through the solenoid coil.
This closes the contacts, connecting battery to the starter motor.
Starter circuit
1. The control circuit: Connects battery power at the ignition switch to the magnetic switch
which controls the high current to the starter motor.
2. The starter circuit: Carriers the heavy current from the battery to the starter motor through a
magnetic switch in a solenoid.
Ignition system
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➢ Battery supplies power to entire system
➢ Ignition Switch turns engine on or off
➢ Ignition Coil transforms volts
➢ Switching device triggers ignition coil
➢ Spark Plug and wires distribute spark
Lighting system
How many light bulbs are on a modern vehicle?
2.4.29.1 Welding
Weld is made when separate pieces of material to be joined and combine to form one piece when
heated at temperature higher enough to cause melting. It is dependable, efficient, economic and
permanent way.
Arc welding
A method which employees an electric power supply to create an arc which melts the base metal
to form a molten pool. The filler metal is then added either automatically or manually.
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Oxyacetylene welding
The oxyacetylene welding process uses a combination of oxygen and acetylene gas to provide a
high temperature flame. A manual process in which the welder must personally control the torch
movement and filler rod application. oxy fuel gas welding refers to all the equipment needed to
weld. Cylinders contain oxygen and acetylene gas at extremely high pressure.
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Figure 2.16 Heavy duty vehicles (mobile capture)
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hammer and chisel
➢ At the first week we can’t to communicate with workers because we weren’t recognizing
the name of tools which they use by italic name.
Example, menzo, Stela, bind a…..
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➢ Safety materials were not fully provided to us specifically when we were in washing and
greasing area
➢ We can’t too loose large nut and bolt because we have not enough power to fix it
➢ Lack of electric power that happened throughout the country affected our practices
➢ There was also lack of clean water to drink
➢ The shelter of mechanical shop is not fully protected or covered if there is much no. of
vehicles it’s not enough to work inside so when we work at the afternoon it’s hard to
resist the weather.
➢ At the final weeks of the internship the company faces lack of budget this hinder us from
practicing more since the spare parts for services can’t be purchased.
➢ We have tried to be familiar with the name of the tools in the way the mechanics calling.
➢ We take care when we perform tasks those are without any safety materials.
➢ We captured the wisdom of mechanics instead of using unnecessary force and effort.
➢ We clearly communicate with our supervisor.
➢ We were discussing with workers if there is no work instead of getting back to home.
CHAPTER THREE
OVERALL BENEFITS OF THE INTERNSHIP
Here is strong evidence to suggest that internship placements and work experience re extremely
valuable in terms of both academic performance and personal skill. Internship holds considerable
value for personal and professional development and should be encouraged and provided to all
where possible. The internship program helped me to develop different skills and qualities
related to my study and also my overall personality. I have categorized the overall benefits I have
gained from the internship as follows.
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During the four months stay at the company we have tried to link our theoretical knowledge with
the practical atmosphere. As a result, we have practiced different skills which will help in the
future. We were following the workers step by step by capturing what they are trying to do and
also practicing what they already have shown us. Generally, we have gained practical skills on:
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3.6 Practical skill under electrical shop
➢ Design and the working principles of the electrical system on vehicles
➢ How to install the system based on the given design of vehicles
➢ The operation and principles of the vehicles starter motor
➢ About the charging, lighting and accessory points
➢ Charging of different batteries repairing automotive accessories
Also, we have learned about the working principle of internal combustion engines, mechanisms
of a transfer case on four-wheel drive vehicles, mechanisms and use of differential, and
mechanical and electrical systems that control the different functions of vehicle parts.
Since engineering is not a one-man assignment, it need for a person to team up with one another
in order to do a given task quickly and more efficiently. In our internship period, we teamed up
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with five other students which helped us to gain different communication and team working
skills which were important to perform our tasks effectively. These team working skills we
acquired during my stay are listed as follows.
➢ Communication – Being able to clearly communicate ideas with the group, being able to
convey information via phone and in person.
➢ Conflict management – Being able to mediate problems between team members, being able to
negotiate with teammates to settle disputes and make sure everyone is happy with the team choice
➢ Listening – Being able to listen ideas and concerns of peers in order to be an effective member
➢ Asking – Being able to ask questions for clarification and using verbal cues.
➢ Reliability – Being a reliable team member by sticking to deadlines and complete any assigned
tasks on time to gain colleagues’ trust.
➢ Respectfulness -Conveying respect to coworkers and their ideas, making eye contact and
actively listening when a person speaks to make the person feel appreciated. The other
interpersonal skill I gained is the ability to accept criticism. Coworkers give different constructive
criticisms which will help improve working skills with a reduced probability of errors and
increased efficiency. It will also enable a person to understand quickly and better.
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Figure 3.2 Team working skill (mobile capture)
➢ Commitment – Willing to put in the extra hours to complete tasks and assignments.
➢ Motivation – inspiring coworkers for better achievements of the team.
➢ Communication – explaining clearly the specific tasks for the team.
➢ Delegating–Identifying the skills of each coworkers and assign duties based on their
skills.
➢ Responsibility – Being responsible for both successes and failures of the team
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3.12 Work Ethics and Discipline
Since the company we have applied for internship is essential for transportation, work ethics and
discipline are basic requirements. Work ethic and discipline are one of the major factors for the
step to professionalism. They are important for being successful in any career. Forming good
habits such as focusing, staying motivated and finishing tasks immediately helps to create good
work ethic. The skills those we have developed to have good work ethics and discipline includes:
➢ Punctuality
➢ Responsibility
➢ Respecting others and their ideas
➢ Polite communication
➢ Being open minded
➢ Being professional
➢ Developing good behavior
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CHAPTER FOUR
DESIGN OF MULTI NUT REMOVER
4.1 INTRODUCTION
➢ Vehicle is an important machine in human daily life. Nowadays, each family has at least
one car to make the transportation easier and faster. For a car, the tool set-up for each
vehicle is a T-nut wrench and car jacker which is hard to use for a women or teen to open
their car’s nut. One of the problems of a vehicle is tire problem. If the vehicle tires have
some problem then the user must remove the tires and fix the problem. And for a car user,
it’s difficult to remove tire’s nut especially for women users. The disadvantages are waste
of time and force needed. In India and other countries automotive market there is no tool
that is easy to use to remove the nuts. The time to open a car’s tire nut is too long and the
car user’s time is wasted with utilization of high force and especially this is big hurdle for
women users. To overcome the waste of time and high force needed, a tool have been
designed to remove five nuts of a tire in single time with decremented applied force. CAR
is not a symbol of luxury anymore. It is a need for every family. People need car due to
several reasons. Some of them are, to go to a destination, to travel conveniently, to do daily
job and to move things to a greater distance. The problem occurs the most during car
operation is the problem with tire puncture. The punctured tire needed to be replaced with
spare tire. Therefore, drivers need to know basic knowledge of tire replacement procedure
if such problem occurs. In order to change the tire, one requires minimal skills. Virtually
every car has a tire replacement tools such as the L-shaped nut remover and jack supplied
by the manufacture.
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4.2 Problem statement
During changing tires of a vehicle, it is hard to unscrew lug nuts of the tire using the tire lug
wrench in a short period of time. It is time consuming and requires high energy. It takes a long
time to unscrew all the lug nuts; Any one can’t unscrew all the nuts simultaneously this take
time. Time is a very important aspect of life, and as engineers we always seek to come up with
easy and efficient solutions for problems. To unscrew lug nuts, it has its own rules; the nuts
should be unscrewed by the same torque and speed. And it should be unscrewed step by step.
But it is hard to follow these all rules, it takes additional more time. Due to these all difficulties
that mechanics face in changing tires, we came up with the idea of this project which is to make
the procedure of changing tires much easier and time saving.
4.3. Objective
The specific object of this project is to design and analysis parts of tire changer wrench and then
assembling the whole parts to give a well-designed and usable machine. Parts to be designed
are:-
This project is to atomize the labor work in tightening or loading the nuts one by one. This
project focuses on the minimization of human effort and time consumed for fixing five nuts with
a single stroke of lever by using multiple operated spanners. This is achieved by developing a
planetary gear mechanism as such occurs which reduced the time and effort for the above
mentioned task that is losing or tighten the nut of the car wheel. To avoid time wasting and a lot
of energy used to change the tire, a special tool is designed and fabricated to allow driver or
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machine to remove Five nuts of wheel at once with less energy consumption. In this project, the nut
removal steps, type of tools needed, basic gear theory, spur gear terminology, standard gear
calculation, standard spur gear tooth, the project calculation, and material specification will be
analyzed and shown.
This paper presents a method to design & construct a multi nut remover by using a lathe, grinding
wheel, drilling machine, taps. The use of material will be reliable for the better result. In order to
make it more simple and to easy to machining the parts. Construction and mechanism is simple
therefore mounting with wheel is easy. Application domain of Multi nut remover is in auto-bus
industries. According to our preplanned project we describe the following places where it can be
used successfully:
➢ It can be used as standard equipment provided with a new vehicle for the purpose of
opening and refit a punctured wheel in the midway.
➢ It can be used in workshops to open a wheel in place of using pneumatic guns which are
restricted to the availability of light and compressed air; it can be easily operated with
hands.
➢ It can be used in assembly line of auto-bus where more time is consumed in tightening all
the five nuts one by one. As it takes less time to fit a new tire, it will lead to increase
productivity.
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LITERATURE REVIEW
4.6. Introduction
Known torque-responsive power screw drivers which are driven by electric motors or
pneumatically have a relatively high speed of rotation in order to obtain a short screwing in time.
Since the maximum moment of tension for the screw to be screwed requires a determined torque,
the driving power of the screw driver must likewise be made high in accordance with the
relatively high speed of rotation, although a high torque is required for only a short time during
the tightening of the screw, unless some shock action is utilized for the purpose of producing this
peak degree. The limitation of the degree of tightening of the screw is usually effected by means
of ratchet couplings or striking mechanism. When screwing in expansion screws, this degree of
tightening must be kept constant within very narrow, since these screws, are stressed almost to
their yield point during screwing in. Torque-responsive screwing drivers having a shock effects
are useless for this purpose. The degree of tightening achieved is greatly dependent on the
number of blows applied, which however cannot be kept constant because of the rapid
succession of blows, while in addition the power of the individual blow is variable within wide
limits because of the indeterminable reaction of work piece, screw and screwing tool on the
striking operation. In addition, the shock effect causes rapid wear on the striking surface, which
results in a considerable variation of the face of the blows and a relatively short life of the
Torque-responsive screwdrivers having striking mechanisms are impractical where accurate
tensioning of a screw is necessary. It has moreover been found that, at the high speeds used,
ratchet couplings also apply a powerful shock action and are therefore likewise unsuitable for
tightening expansion screws. The main purpose of using gears is to transfer power from a source
to an application. Moreover, the modern technology of gears in its current form ages backs to
only 100 years ago. Nevertheless, the oldest form of gears can be traced back to fourth century
B.C. Greece. In addition, there are a lot of application that involves gearing systems in them such
as, robotics, automotive and power transmissions. Moreover, there are different types of gears
that can be used such us, bevel gears, helical gears and spur
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gears. In this project, the gear train that is being used is consisting of spur gears that are meshed
in a way to achieve the aim of this project that is to design and manufacture an automotive tire
multi nut remover.
In the paper of Vaibhav Chowki Adjustable Multi nut wheel opener is a special purpose tool
made to open/close all the five nuts of a wheel in one time with less effort. Although various
methods are used for opening nuts, they require a lot of effort to open a single nut. The main
objective of work is to develop a single tool with multiple mechanisms, which can be made use
during assembling and dismantling of wheels in automobiles. It can be successfully used as a
standard tool. Also it can be used in assembly line of automobiles, garages, workshops and
service stations.
In the paper of B. Sivakumar a gear or "gear wheel" is a rotating machine part having cut teeth,
or cogs, which mesh with another toothed part in order to transmit power. Two or more gears
working in tandem are called a transmission and produce mechanical advantages through a gear
ratio and thus may be considered asimple machine. Gears are mostly used in the mechanical field
for power transmission, this project report on stress analysis of spur gears. Spur gear made of
cast iron which is use for high strength.
In the paper of A. S. Udgave Multiple-spindle drilling machines are used for mass production, a
great time saver where many pieces of jobs having many holes are to be drilled. Multi- spindle
head machines are used in mechanical industry in order to increase the productivity of machining
systems. The multiple spindle drilling machines is a production type of machine. It is used to
drill two holes in a work piece simultaneously, in one setting. The holes are drilled on number of
work pieces with the same accuracy. So we adopt the basic design for over project
Gears transmit mechanical power and can be classified to parallel axis gears and nonparallel
gears. One of the types of parallel axis gears is spur gears (Figure 1.1), which is considered to be
the most suitable for machine transmission. Spur gears have
straight teeth, and are mounted on parallel shafts and usually have 20 degree of pressure angle.
This book includes details about spur gears design, specifications, and selection of gears. This
project is based on a gear system where the materials provided in the book are considered to be a
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reference for gear systems. It helps to provide the formulas needed to calculate torque, forces
acting on gears, and module. Moreover, it explains how different types of gears work such as
epicycle. So, it is a basic need to design this project.
The concepts and terminology of gears is a requirement to design any gear system. Gear terms
and concepts are necessary to design, build and improve gear drive systems. To design and build
a gear drive system, it is necessary to understand all concepts of gears and their mechanism.
Moreover, ratio of gears depends on teeth of gears and tells the designer how much the driver
gear rotates to complete one turn for the driven gear. For example, if the ratio for two gears is
1:3, this means that the driver gear must turn three times to get the driven gear to make one
complete turn as shown in the figure below.
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Figure 5Figure 4.2 Driven to driver gear
Another concept discussed in the article is the calculation of center to center. However, this
source clarifies more about spur gears and how they are being used to design a gear system.
It is good to understand from these studies removing multi nuts at a time is very economical
whereas removing one by one is time consuming and it requires another additional force.
Removing multi nuts is done by gear system. Gears are used to transmit powers. And also it
multiplies by some ratio. The objectives of the project are to design a 5-nut removal mechanism
and minimize the cost of it. This project uses one of most common types of gears, which is spur
gears, pinion gears and worm gears, to reduce the torque and force. Worm gears can multiply the
input power by higher ratios. It is up to 100 ratios. So, using worm gear is very economical
rather than using electrical and pneumatic motors. Therefore in this case worm gear is used to
multiply the input manual torque or power.
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chaos and disorder. But actually, sometimes there is a method to this madness. And sometimes
there’s a methodology. There will be a lot of information about the process and journey
throughout the making of this project. There will be flow chart showing the process of us making
the whole project. This flow chart will explain the processes we took. Next, is the Gantt Chart,
which will show the actual and planning throughout all the weeks of our final year project
journey.
Brainstorming collection of information about the basic design aspects. In addition, using
brainstorming method can specify the features of our design. In this phase, we define the major
aspects needed for building the prototype such as, gears, shafts, bearings and spanners. Also, in
this phase we conduct the Gantt chart, where we divide the tasks and their time durations for the
project. Second phase includes gathering information about the conceptual design of our project
from, books, journals, and old projects.
In this project there were interviewed two mechanics who have many year experiences with their
work of maintaining the bus. The first person said that about the problem they faced when
maintaining brake, tyre wheel hub, or services around the tire. They actually found it as very
interesting question because they have faced a lot of challenges when they are trying to service
the tire part. The second person is mechanic Betsegaw who is the person responsible in
preventive maintenance. He is very emotional when he told us about problems, he said that "he
always feared losing his health and pains after removing nuts from tyres using steel and bare
hand without controlled and unknown torque". He suggested that if there is easy way removing
the nuts with less effort and in short time. His first question was will this cause any damage to
the alloys?
You shouldn’t have to ask this really but it’s good for your own peace of mind. The safe removal
of wheel nuts has to be without question
➢ His second question was how long will the wheel nut removal take?
41 | P a g e JIT 2022
This product answered
It’s always handy to know just how long it will take to remove a locking nut. This can depend on
how tight the existing nut is.
4.10.2. Observation
Over tightened stud an analysis from the Accidents and Defect databases of the south road
Inspectorate shows that a total of 323 cases of wheel loss had been identified since we are there.
Not all cases resulted in the preparation of a defect report but those which were prepared showed
that some 72% of the failures were related to maintenance or abuse. Common problems were
failure to tighten wheel nuts to the specified torque, over tightening of wheel nuts causing
damage and failure to regularly check tightness of wheel nuts. Since not all wheel losses are
reported. Some consider the cause of the problem to be due to a relaxation of the tension in the
studs due to settling between the numbers of interfaces involved in the wheel assembly. Use of
locking devices will not prevent relaxation and since the wheel integrity is dependent upon the
friction grip provided by the stud tension, the relative looseness of the wheels will damage the
studs and result in eventual wheel loss due to failure of the fixing. The recommended procedure
is that following wheel replacement the wheel studs should be tensioned to the torque prescribed
by the vehicle manufacturer and retensioned after a period of 30minutes or 40km to 80km road
running.
All engineering activities necessarily begin with some ideas with high or low innovative content,
translated into definite plans for their realization in the form of products. This is the essence of
design engineering. The ultimate success depends on a thorough consideration of how the
product will be made and used as well as on the attention to detail paid by the design
engineering. This is applicable equally for a minor redesign of a existing product or for a most
innovative one. The project model is designed in SOLID WORKS. It is CAD/ CAM based
software. Manufacturing the prototype depends on analysis and calculation of design. Analysis
and calculation of design has a lot of calculations that include dimensions such as gears centers,
pitch diameter, thickness of gears, size of shafts, number of teeth, and ratio of gears. Moreover,
the calculations include the torque required to unscrew one nut, power transmitted from the
42 | P a g e JIT 2022
motor and factor of safety (FOS). Additionally, the design of our prototype is made using Solid
Works. Solid Works includes all dimensions of the parts, 2D drawing, and assembly of the parts.
Fourth phase is buying parts and manufacturing in market. Also, estimating the cost and the
availability of parts in market whether there are gears, shafts, spanner and joints, because some
parts need to be made in workshops. The design of the vehicle multi-nuts remover tool is
performed by commercial computer aided design (CAD) software. Several static load analyses
are also performed in order to find the safety factor of the design. Theoretical calculation
analysis is carried out with the purpose of validation. The force required for removing five
numbers of nuts is,
F = 5τ / (l RG)
Where, F is the applied force, τ is the torque required to remove one nut, l is the length of
level and
RG is the gear ratio of central gear and driven gears of the tool.
In the fabrication of Multi nut remover tool, two processes are performed; milling and fitting.
Since the gears are not available in the market, custom designed gears need precision milling and
fitting processes. Once the tool is ready, an experiment is performed with the intention to find the
time required to remove the nuts. This result is then compared with the time required using
ordinary L-shaped wrench. Experiment using impact wrench is also performed.
43 | P a g e JIT 2022
4.11.1 Material selection
The amount of raw materials, their composition, quality, any special heat-treatment that is
required, etc. influence the unit cost of materials. The unit cost generally depends also on the
quantity of raw material that is purchased in a single lot. Special steel materials, for example,
cost much more in the market when purchased in small quantities from a retailer than in bulk
directly from the steel mill/stockyard.
B. Availability
The material should be readily available in adequate quantities. Material availability is closely
linked with the variety and level of technology obtained in a given geographic location.
Procuring materials from far and wide can be expensive, due to the additional cost for transport,
for transporter taxes and duties etc.
C. Manufacturing Process
Facilities for shaping and treating the selected material into the finished product or component
must be available for economic production. Otherwise, the production cost goes up. For
example, the selection of forged alloy steel for a connecting rod design necessarily assumes that
suitable forging facility is available along with the necessary dies and other accessories. If the
alloy is of a rare quality, then facilities for its heat treatment might not be available.
The desired function and performance of any product depends to a great extent on the use of
materials with the right physical and chemical properties. In general mechanical engineering
44 | P a g e JIT 2022
these properties can be classified into different categories depending on how a particular
property affects the function and life of a component. The main property groupware:-
No matter what you do for a living, the success of your business probably depends on how good
and creative you are. The ability to come up with fresh and exciting ideas is what separates top-
performers from their less successful peers, so we definitely need to think of how to improve this
skill. Idea generation is defined as the process of creating, developing and communicating
abstract, concrete, or visual concepts. To put it simply, it’s the process that requires finding new
solutions for practical problems in all fields of life and work. In our aspect the product we have
done is overcome different stages during the idea generation.
A. Social Listening
Idea generation doesn’t mean you have to come up with a great suggestion single-handedly. On
the contrary, sometimes it’s enough to do a little bit of social listening and see what the target
audience has to say about a certain topic. Besides that, you can always organize an opinion poll
to directly ask people what they want. For example, this project come back with the solution
after suggestions rewarded from the public bus service workers
B. Brainstorming
Brainstorming is a well-known method that people all over the world use for decades already.
There is no right or wrong. We just need to say the first thing that comes to our mind and that’s
it. After a quick brainstorming session, we just need to filter through all suggestions and find the
ones that have the biggest potential to succeed. As we know this product eases up the work.
C. Role Playing
We were responsible for removing wheels and be in the mechanics shoes to understand the real
problem and Walking in someone else shoes is everything bueasy, but sometimes it’s the only
way to break the barrier and think of a brilliant idea. The process is simple: you just need to
switch places with your colleagues and try to embrace their point of view. It doesn’t guarantee
immediate results, but it often leads to interesting conclusions and brand new ideas.
D. Collaboration
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As the term indicates, collaboration is about two or more people joining hands in working for a
common goal. Designers frequently work in groups and engage in collaborative creation in the
course of the whole creative process. This project is result of collaboration
1. Clarity
We can select the idea that makes the fewest assumptions. By choosing an idea that has the
fewest unknowns a leader can safeguard against surprises and disasters.
2. Usability
Does the idea fulfill a practical need? That is, does it answer some particular problem or meet
some particular market demand. Yeah it does If it does, is it likely that the idea can find a market
niche? The practicality, usability, and marketability of an idea are crucial.
3. Stability
Is this idea answering a one-time unique need or customer demand? Does the idea have some
market stability over time, or is it a fad? Ideas that become antiquated before they even reach
market are ideas that should be selected with extreme caution.
4. Scalability
Is the prototype capable of being scaled? Can it be duplicated with consistency, meet continuous
standards, and be replicated in such a way that it can be produced and produced again without
constantly being reinvented or adjusted?
5. Stickiness
Can this idea become a habit or a trend? Often "stickiness" is used from the utilitarian standpoint
(that is, its usability) but stickiness can also define its emotional appeal. Is the idea or prototype
capable of bringing to market a product that will be driven over time by the customers' sense that
it is a necessity?
6. Integration
46 | P a g e JIT 2022
Is this idea fully integrated with the organizational strategy? Often ideas and prototypes are
wonderful in their own right, but outliers in the organizational strategy may not receive the
organizational support necessary to sustain the viability of the effort. They will peter out. Great
ideas, useable prototypes must be integrated, or capable of being integrated with the overall
strategy of the organization.
7. Profitability
The outcome of the quantitative research methods is an answer to the questions below and is
used to measure anything tangible.
Qualitative data collected through the one to one interviews and focus groups
The existing wheel nuts remover which is a normal L wrench and nut spanners are really
inconvenient and difficult to use. It can remove only a single nut at a time and it requires man
power for removing and tightening of the nuts. Thus for old and weak peoples, the replacement
of the tire by this normal method is really inconvenient and difficult process. Not only for old
47 | P a g e JIT 2022
people there are many examples like medical emergencies, job, and everyone in this world is
really busy and in rush all the time.
During tyre removing Operation the person was supposed to remove individual nuts to remove
the tire which has very high fatigue level. So Our Intention was to remove all nuts at a time, to
reduce human fatigue level. Multi-nut opener is a device designed at developed for loosening or
tightening of wheel hub nuts.
➢ Bus workshops
➢ Bus manufacturing units
➢ Garage
➢ Junkyards
Advantages of using this product
➢ It act as a convenient and simple method for tire replacement process thus It is more
suitable in using this setup for tire removal in every vehicles for reducing the time
consumed and for reducing the man power wasted for the tire replacement and to
overcome the emergency situations. Thus the vehicle multi wheel nuts remover and
tightener can be used in all buses shops and can be carried in each vehicle for instant tyre
replacement which saves lot of time and energy for every person.
DESIGN PROCESS
4.16 Recognition of need
Design process generally starts with the identification of need, a problem or with the recognition
of a potential market for a product, device or process. Recognition of the need requires a lot of
imagination and creativity, because the need is generally not clear and evident and can be vague.
Recognition of a need is the first and the most important step of the machine design or system
design cycle, without this first step no further steps of the machine design can be taken. It is the
48 | P a g e JIT 2022
need that gives birth to various other steps of the design. If there is no need there won’t be any
reasons to start the detailed, time consuming and highly complex problem of designing.
In this case we need to design and fabricate a hand operated tool by using worm gear mechanism
to multiply the input torque (supplying small torque then getting large amount of torque ) and
used for screwing and unscrewing of car tire nuts which is known as Multi Nut Remover. It acts
as a convenient and simple method for tyre replacement process thus It is more suitable in using
this setup for tire removal in every vehicles for reducing the time consumed and for reducing the
man power wasted for the tyre replacement and to overcome the emergency situations. This tool
can be operated by anyone of different ages from young people to old people as it is easy to use
and light in weight. The vehicles multi wheel nuts remover reduces the time in the normal
process and also the man power used.
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4.17 Definition of problem
The multi nut remover used to open the wheel nuts is designed for ergonomic, easy to handle and
requires small space for storage. However, it is difficult for women and the elderly drivers due to
high required torque to remove the nuts of the tire. If the nuts are successfully removed, the
problem to tighten the nuts will arise. If the required torque is not applied in tightening the nuts,
they will get loose, and this will endanger the driver’s safety. This tool can also function as tire
nuts tightener. Impawrench which is commonly used for removing of tire nuts is also a time-
consuming tool. For these reasons, to avoid wasting of time and energy, a special tool is
designed and fabricated to allow driver or mechanic to remove five nuts of tire simultaneously
with little energy consumption. The design is based on standard pitch circle diameter for most of
the cars available
Spur gears are the least expensive of all types for parallel shaft applications. Their straight teeth
allow running engagement or disengagement using sliding shaft and clutch mechanisms. Typical
applications of spur gears include automatic motor vehicle gearboxes, machine tool drives,
conveyor systems, electric motor gearboxes. The majority of power gears are manufactured from
hardened and case-hardened steel. Other materials used include iron, brass, bronze, and polymers
such as poly amide (e.g. nylon). The center distance by measuring the distance from center of the
wheel to all the nuts of a bus:-
C = 170mm, then we take pitch diameter of pinions and pitch diameter of sun gears as,
DP = 100mm
DS = 240mm
Now, as we know
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= п × 4mm
=12.57mm
=100mm/4mm
= 25 teeth
= 240mm/4mm
= 60 teeth
R = 60teeth / 25teeth
R = 2.4
= 108mm
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= 240mm + 2 × 4mm
= 248mm
From the user manual of Yutong bus torque required to unscrew and to tighten one nut is in the
interval of 400Nm - 480Nm. Therefore based on this due to safety to design this multi nut
remover, we choose the maximum torque required for one nut. That is 480Nm. So, based on this
we can do analysis of torque transmission through the gears. The total torque required to unscrew
and tighten 5 nuts is Ttot = 5×480Nm. Then we can calculate and estimate the torque and
horsepower needed to unscrew the five nuts based on ratio of gears: Since the maximum torque
required for one nut is equal to 480Nm, torque on each shafts of spur gear is equal to 480Nm.
Therefore maximum torque of each spur gear is 480Nm.
𝑇𝒐𝒓𝒒𝒖𝒆 𝒐𝒇 𝒅𝒓𝒊𝒗𝒆𝒏
R=
𝑻𝒐𝒓𝒒𝒖𝒆 𝒐𝒇 𝒅𝒓𝒊𝒗𝒆𝒓
Tspur 480𝑁𝑚
Torque on the pinion, Tpinion = =
𝑅 2.4
Tpinion = 200Nm
Therefore, the torque on the pinions by each spur gears is equal to 200Nm. We can calculate the
total torque on the pinions.
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Ttotal(pinion) = 1000Nm
From these conclude that to unscrew and tighten the five nuts simultaneously we need torque
input, Tinput = Ttotal(pinion)
Tinput = 1000Nm
Torque, T = Pt r and r = Dp /2
2 × Torque on spur
Tangential force on the spur gear, Pt = DP
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480Nm
Pt = 0.24m
Pt = 2000N
The resultant normal force between the tooth surfaces of pinion and spur gear,
Pt 2000𝑁
PN = cos θ = cos 20
PN = 2128.34N
Pr = 727.94 N
There are two ways of designing the Spur Gear: (a) Bending Strength, (b) Wear Strength. If the
wearing constraint of the gear is of supreme importance then the Spur Gear should be designed
using the pitting resistance, but in this study the Spur Gear is Designed using the Bending Stress
Fatigue criteria because it is the primary requirement in the industry. According to the bending
Strength theory, the fatigue Strength (S) of the Spur Gear should be greater than or equal to the
Bending Stress on the Spur Gear teeth. σ ≤ S
According to the Lewis Theory, Spur Gear must be able to withstand the Tangential Load (Pt).
The Lewis Bending stress equation is used as it is fairly simple to calculate the Material Index of
the Spur Gear using it[4]. The Tangential force according to the Lewis theory is shown below:
Pt 2000𝑁
PN = cos θ = cos 20
PN = 2128.34N
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Weight of the pinion, WP = 0.00118 NP.b.m2
WP = 0.00118 (25)(36)(4)2
WP = 16.992N
WR =√4598087.92N
WR =2144.32N
Assuming that the pinion is overhung on the shaft and taking overhang as 100 mm, therefore
Bending moment on the shaft due to the resultant load,
M b= 214 432Nmm
Te = √( Mb )2 + ( Ttotal(pinion) )2
Te = 1,022,732.13 Nmm
Te = 1022.732Nm
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π
Te = × Ⴀ (d)3 ,
Ⴀ - shear stress of the pinion shaft
16
Ultimate stress
Ⴀ = factor of safety
Have selected carbon steel material for pinion shaft, where its ultimate stress is equal to 465
N/mm2 and we chose factor of safety, Fos = 4
465 N/mm2
Ⴀ=
4
Ⴀ = 116.25N/mm2
Therefore,
π
Te = × Ⴀ(d)3
16
π
1,022,732.13 Nmm = × (116.25N/mm2)(dp)3
16
(dp)3 = 44 806.3mm3
dp = 35.52mm
= 1.8 dP = 1.8 × 35.52mm = 63.94mm and length of the hub = 1.25 dP = 1.25 × 35.52mm = 44.4
mm
Since the length of the hub should not be less than that of the face width i.e. 36 mm, therefore let
us take length of the hub as 36 mm.
Pt 2000𝑁
PN = =
cos θ cos 20
PN = 2128.34N
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Weight of the spur gear, Ws = 0.00118 Ns.b.m2
Ws = 0.00118 (60)(36)(4)2
Ws = 40.7808N
WR =√4694617.52N
WR =2166.71N
Assuming that the pinion is overhung on the shaft and taking overhang as 100 mm, therefore
Bending moment on the shaft due to the resultant load,
M b= 216 671Nmm
Te = √( Mb )2 + ( Tspur )2
Te = 526.637 Nm
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Know, that equivalent twisting moment (Te ),
π
Te = × Ⴀ(d)3 ,
Ⴀ - shear stress of the pinion shaft
16
Ultimate stress
Ⴀ = factor of safety
Have selected carbon steel material for pinion shaft, where its ultimate stress is equal to 465
N/mm2 and we chose factor of safety, Fos = 4
465 N/mm2
Ⴀ=
4
Ⴀ = 116.25N/mm2
Therefore,
π
Te = × Ⴀ(ds)3
16
π
526 636.782 Nmm = × (116.25N/mm2)(ds)3
16
(ds)3 = 23 072.1644mm3
ds = 28.47mm
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4.18.2.3 Design of worm gear
Velocity ratio of 40 have chosen, therefore the worm gear can multiply the input torque
efficiently.
1. Design of worm
Let, x = the distance between the center of worm and worm gear
Given, x = 250mm
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lN = Normal lead, and
λ = Lead angle.
cotλ = V.R. = 40
cotλ = 3.42
λ = 16.3°
X 1 1 𝑉.𝑅.
Know, that, = [ + cos λ ]
lN 2π sin λ
250mm 1 1 40
= [ + cos 16.3° ]
lN 2π sin 16.3°
250mm 1
= 2π [3.563 + 41.68] = 7.2
lN
250mm
lN = 7.2
lN = 34.72mm
l = 36.18 mm
From appendix, for a velocity ratio of 40, the number of starts or threads on the worm,
n = TW = 1
pa = l / 1 =36.18 mm / 1
pa = 36.18 mm
∴ m = pa / π = 36.18 mm / π
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m = 11.52 mm
pa = π m = π × 12 mm
= 37.7 mm
l = pa. n = 37.7 mm × 1
= 36.2 mm
X 1 1 𝑉.𝑅.
= [ + cos λ ]
lN 2π sin λ
lN 1 𝑉.𝑅.
x = [ + cos λ ]
2π sin λ
36.2 mm 1 40.
x = [sin 16.3° + cos 16.3° ]
2π
x =5.76[3.563 + 41.68]
x = 260.7mm
𝑙
We know that, tan λ = 𝜋𝐷𝑊
𝑙 37.7 mm
DW = 𝜋 tan λ = 𝜋 tan 16.3°
DW = 41.04mm
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Since the velocity ratio is 40 and the worm has single thread,
TG = 40× 1 = 40
From above, the face length of the worm or the length of threaded portion is
LW = 170.404mm
This length should be increased by 25 to 30 mm for the feed marks produced by the vibrating
grinding wheel as it leaves the thread root. Therefore let us take,
LW = 195 mm
h = 23.5 mm
From above,
a = 12mm
DOW = 65.04 mm
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DG = m. TG = 12× 40 = 480 mm
DG = 0.48 m
DOG = 518.21 mm
Throat diameter,
DT = 503.98 mm
b = 96.23 mm
Let us now check the designed worm gearing from the standpoint of tangential load, dynamic
load, static load or endurance strength, wear load and heat dissipation.
2×𝑇 2 × 1000Nm
WT = =
𝐷𝐺 0.48 m
WT = 4,166.67N
∴ Velocity factor,
Let us assume velocity factor, Cv = 0.75 and tooth form factor for 14½° involute teeth,
0.684
y = 0.124 - 𝑇𝐺
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0.684
y = 0.124 - 40
y = 0.1069
Since the worm gear is generally made of phosphor bronze, therefore taking the allowable static
stress for phosphor bronze,
σo = 84 MPa or N/mm2
WT = (σo . Cv) b. π m . y
WT = 24,432.05 N
Since this is more than the tangential load acting on the gear ,
(i. e. 4,166.67N), therefore the design is safe from the standpoint of tangential load.
(b) Check for dynamic load
WD = WT / Cv = 24,432.05 N / 0.75
WD = 32 576.07 N
Since this is more than WT = 4,166.67N, therefore the design is safe from the standpoint of
dynamic load.
WS = σe . b. π m . y
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WS= 168 MPa× 96.23 mm × π × 12 × 0.1069
WS = 65 152.13 N
Since this is much more than WT = 4,166.67N, therefore the design is safe from the standpoint of
static load or endurance strength.
Assuming the material for worm as hardened steel, therefore from Table above, we find that for
hardened steel worm and phosphor bronze worm gear, the value of load stress factor,
K = 0.55 N/mm2
WW = DG . b . K
WW = 25 404.72 N
Since this is more than WT = 4,166.67N, therefore the design is safe from the standpoint of wear.
𝑇 𝑔𝑒𝑎𝑟 1 250Nm
Tworm = =
𝑉.𝑅. 40
Tworm = 31.25Nm
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WT = Axial force on the worm gear
WT = 1522.904N
2 × 𝑇𝑔𝑒𝑎𝑟 2 × 1 250Nm
WA = =
𝐷𝐺 0.48m
WA = 5,208.33N
WR = 1,346.97 N
take the distance between the bearings of the worm shaft (x1) equal to the diameter of the worm
gear (DG), i.e.
x1 = DG = 480mm
∴ Bending moment due to the radial force (WR ) in the vertical plane
𝑊𝑅 × 𝑥1 1,346.97 N × 480mm
= =
4 4
=161,636.4Nmm and bending moment due to axial force (WA) in the vertical plane
𝑊𝐴 × DW 5,208.33N × 41.04mm
= =
4 4
= 53,437.47Nmm
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M1 = 161,636.4Nmm + 53,437.47Nmm
= 215,073.87 N-mm
Know, that bending moment due to tangential force (WT) in the horizontal plane,
𝑊𝑇 × DG 1522.904N × 480mm
M2 = =
4 4
M2 = 182,748.48Nmm
Mworm = √( M1 )2 + ( M2 )2
Mworm = 282,230.01Nmm
Tew = 283,954.82Nmm
π
Te = × Ⴀ(dw)3 ,
Ⴀ - shear stress of the worm shaft
16
Ultimate stress
Ⴀ=
factor of safety
Carbon steel material have been selected for worm shaft, where its ultimate stress is equal to 465
N/mm2 and we chose factor of safety, Fos = 4
465 N/mm2
Ⴀ= 4
Ⴀ = 116.25N/mm2
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Therefore,
π
Te = × Ⴀ(dw)3
16
π
283,954.82Nmm = × (116.25N/mm2)(dw)3
16
(dw)3 = 12,440.17mm3
16𝑇𝑒 16 × 283,954.82Nmm
Ⴀ= =
πd3w π(24mm)3
Ⴀ = 104.6N/mm2 and direct compressive stress on the shaft due to the axial force,
𝑊𝐴 5,208.33N
σc = π = π
𝑑2 (24mm)2
4 𝑤 4
σc = 11.513N/mm2
1
τmax = 2 √( σ𝑐)2 + 4 ( Ⴀ)2
1
τmax = 2 √( 11.513N/mm2)2 + 4 (104.6N/mm2)2
Since the maximum shear stress induced is less than Ⴀ = 116.25N/mm2 , therefore the design
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We have calculated above that the axial force on the worm gear
= 1522.904N
= 1,346.97 N
Know, that bending moment due to the axial force on the worm gear,
= 182,748.48Nmm
The bending moment due to the axial force will be in the vertical plane.
Let us take the distance between the bearings of the worm gear shaft (x2) as 250 mm.
= 84,185.625Nmm
The bending moment due to the radial force will also be in the vertical plane.
Know, that the bending moment due to the tangential force in the horizontal plane ,
M4 = 325,520.625 N-mm
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Mgear = √( M3 )2 + ( M4 )2
Mgear = 420,972.08Nmm
Already calculated that the torque acting on the worm gear shaft,
T gear =1,250Nm
Teg = 1,318,983.508Nmm
π
Teg = 16 ×Ⴀ(dG)3 ,
Ultimate stress
Ⴀ = factor of safety
Carbon steel material selected for worm shaft, where its ultimate stress is equal to 465 N/mm2
and we chose factor of safety, Fos = 4
465 N/mm2
Ⴀ=
4
Ⴀ = 116.25N/mm2
Therefore,
π
Teg = × Ⴀ(dG)3
16
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π
1,318,983.508Nmm = × (116.25N/mm2)(dG)3
16
(dw)3 = 57,785.19mm3
CHAPTER FIVE
CONCEPT DEVELOPMENT
5.1. Introduction
The working of the vehicles wheel nuts remover and tighter is simple and can be performed by
anyone. It does not require any skills or anything, just basic knowledge about the setup is
required for operation. We developed the concepts that work under the principle of removing the
wheel nuts at the less time by automatic process with the help of a electric motor. It consists of
an electric motor, a shaft, box socket. First the machine setup is placed with correct fitting of the
box socket to the nut of the vehicle wheel. Then the motor regulator is turned on. The motor
drives the shafts which then lead the box socket at the end of the shaft. As the shaft rotates the
socket also turns and the nut in the wheels are thus removed or tightened by the rotation of the
socket. The tightening and removing process can be changed by changing the rotation of the
motor. Thus the wheel nut can be tightened and removed by this process. It is found to be a
simple process and very much convenient for every one for the tyre removal and tightening
process. Thus with this simple process we succeeded in making a convenient process in the tyre
replacement technique. By this setup the tire could be easily removed and tightened more
efficiently with less wastage of time and energy used.
There are different methods to overcome to the solution but before that identify the depth of the
problem. After knowing the problem with direct observation and one to one interview with the
mechanics, they are asked if there was product which they were used. And founded that a big
machine which can remove and reinstall wheel but it didn't work that product was done by
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students who have got apparent chance in South road authority public service. So digging the
problem of that machine before implementing new idea is essential. We found that existing
machine couldn't work because of its hugeness, existing of unnecessary parts and many other
problems related to power and torque.
Evaluation is a tool for making decisions, not a decision-making system so as much as possible
this project makes the evaluation through some criteria’s.
1. Clarity
Does the idea fulfill a practical need? That is, does it answer some particular problem or meet
some particular market demand. Yeah it does if it does, is it likely that the idea can find a market
niche? The practicality, usability, and marketability of an idea are crucial.
Is this idea answering a one-time unique need or customer demand? Does the idea have some
market stability over time, or is it a fad? Ideas that become antiquated before they even reach
market are ideas that should be selected with extreme caution.
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➢ Yes it answers customer demand till there is bus customer and fabrication of bus.
4. Scalability
Is the prototype capable of being scaled? Can it be duplicated with consistency, meet continuous
standards, and be replicated in such a way that it can be produced and produced again without
constantly being reinvented or adjusted?
5. Stickiness
Can this idea become a habit or a trend? Often "stickiness" is used from the utilitarian standpoint
(that is, its usability) but stickiness can also define its emotional appeal. Is the idea or prototype
capable of bringing to market a product that will be driven over time by the customers' sense that
it is a necessity?
➢ The idea is making working environment comfortable. So it's actually necessity in today's
life
6. Integration
Is this idea fully integrated with the organizational strategy? Often ideas and prototypes are
wonderful in their own right, but outliers in the organizational strategy may not receive the
organizational support necessary to sustain the viability of the effort. They will peter out. Great
ideas, usable prototypes must be integrated, or capable of being integrated with the overall
strategy of the organization.
This is usually what everyone focuses on. Competing ideas are always ranked by their perceived
earning potential.
➢ It is potentially profitable
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5.5 Concepts
Alternative one
This device operates on the principle of gear arrangement system. It consists of five gears in
which the centre gear called pinion (driver) gear is used to drive three other gears (driver gear)
that meshed with it. This work may have solved the problem of five nut removal and force usage
utilization to some extent without the application of an electric motor or any hydraulic and
pneumatic devices. Quite several multi nut tighter or remover devices have been developed in
the present decade having similar construction features such as sun gear, planetary gear, shaft
carrying the box spanner etc. Some of these devices include those that are manually, electrically
and pneumatically controlled which are in commercial production around the globe. designed
and fabricated a five-wheel opening spanner. In the work, each of the five nuts is losing/tighten
individually by simultaneously applying the spanner/lever. Either with the help of mechanism
developed that one can loosen or tighten all five nuts at a time and at the single stroke of the
hand operated or motor operated lever. This is done by adjusting the five gears between two side
plates operated only by lever or input pinion shaft.
➢ Less weight relative to other alternatives but at a time last number of nuts will loosen.
➢ High mobility because of simplicity.
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Figure 5.1 Multiunit remover
Alternative two
This device operates on the principle of gear arrangement system. It consists of 10 gears in
which the centre gear called pinion (driver) gear is used to drive six other gears (driver gear) that
meshed with it. This work may have solved the problem of 10 nut removal and force usage
utilization to some extent with the application of an electric motor or any hydraulic and
pneumatic devices.
➢ This type of multi nut remover will need high electric energy
➢ If it is hydraulic it needs pumps and
➢ If it is pneumatic it needs compressor
➢ It is very huge it is not possible for manual use
➢ It is difficult for mobility
Alternative three
This device operates on the principle of gear arrangement system. It consists of six gears in
which the centre gear called pinion (driver) gear is used to drive five other gears (driver gear)
that meshed with it. This work may have solved the problem of five nut removal and force usage
utilization to some extent without the application of an electric motor or any hydraulic and
pneumatic devices.
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In the work, each of the five is losing/tighten individually by simultaneously applying the
spanner/lever. Either with the help of mechanism developed that one can loosen or tighten all
five nuts at a time and at the single stroke of the hand operated or motor operated lever. This is
done by adjusting the five gears between two side plates operated only by lever or input pinion
shaft.
The following design consideration is taken into consideration with their respective priority to
select the best attentive.
➢ Cost..........................30%
➢ Functionality.............10%
➢ Manufacture ability....15%
➢ Control.......................10%
➢ Maintenance...............10%
➢ Wear...........................5%
Weight.....................5%
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Cost ✓ ✓
Function ability ✓ ✓
Safety ✓ ✓ ✓
Maintenance ✓ ✓
Control ✓ ✓
Manufacturability ✓ ✓
Wear
Weight ✓
➢ Simple in estimate
➢ Less weight
➢ Low control utilization
➢ Can be worked effortlessly
➢ No use of electric resource
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CHAPTER SIX
Every car manufacturer provides tools such as L wrench and jack but easy and fast removal of
nuts using these tools requires a skilled person. But vehicle all wheels nut remover and tightener
allows driver to remove all nuts at once with less energy consumption and save time. In case of
emergency puncture in the tires of the ambulance, it will be a time consuming process for
removal of nuts. In those cases, it will be more useful in vehicle multi wheel nuts remover. The
vehicle multi wheel nut remover and tightened remove all the nuts by torque. The wheel will be
replaced by low consumption of time. The fabrication of all wheel nut removers tool was
completed by milling, welding and fitting process. So this design helps to avoid time wasting and
a lot of energy used to change the tire, it allows driver or mechanic to remove five wheel nuts at
once with little energy consumption.
It works on the principle wheel is a very frequent job performed by the operator. Normally each
of the 5 nuts is losing/tighten individually by simultaneously applying Rotary motion with gear
arrangement either with the help of mechanism developed that one can loosen or tight all five
nuts at a time with motor operated multi nut spanner. This is done by adjusting the five gears
between two side plates operated only motor or input pinion shaft. Device for screwing or
unscrewing tightly the fixing bolts of a wheel of a vehicle. Which is directly coupled to the
wheel, comprising housing in the form of a parallel piped, a socket wrench and a sleeve fixed at
the end of an adjustable arm. Here, the socket wrench engages a fixing bolt of the wheel to be
screwed, the sleeve guaranteeing the stability of the housing of the device during the loosening
or tightening of the above-mentioned bolt, by engaging another fixing bolt of the wheel. The
housing contains a reduction gear assembly letting to loosen tighten the bolt, by rotating a crank
with minimal effort. Multi nut remover consists of three small input gear and five bigger output
gears
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6.1.2 Procedure to be followed during testing and designing
1. Firstly, the torque required for each nut using lug wrench will be tabulate using the torque
measuring equipment. Now, the time taken for removal of all nuts using each of equipment will
not down.
2. Then, the nuts are again re-tightening using all the tools mentioned tools and time required for
the same was noted.
3. Finally, all the results were analyzed and conclusion was drawn. The results of test proved that
the all-wheel nut remover could efficiently remove all the nuts simultaneously. Also, the tool is
efficient and with some required modifications could be efficiently used in future.
6.1.2 Usage
➢ There must be human effort for rotating the handle, also for suspend the machine.
➢ Then we have to insert the sockets to the nut perpendicularly by jumping one nuts in
between two sockets.
➢ Then check whether all sockets are plug in their place
➢ Following to that smoothly rotate the handle during this, the sun gear rotates and drive
the 5 gears in opposite direction then the gears drive the sockets and the nuts will be
loosen.
➢ After loosening the nuts remove the nuts from the tire by our bare hand for accelerating
our work
➢ Then after maintenance we have to tighten the nuts to their original position using this
device with the same fashion but in different direction
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6.1.4. Materials and manufacturing
A. Gears
The commonly used generating processes used for the generation of gear teeth are:-
In this process a pinion shaped cutter is used which carries clearance on the tooth face and sides.
It carries a hole in the center for mounting on the stub arbor or spindle of the machine. The cutter
is mounted with the axis vertical and is reciprocated up and down by sliding the spindle head
along the vertical ways on the machine. In addition to the reciprocating motion, the cutter and the
gear blank both are rotated slowly their own axis. The relative speed of rotation of the two is the
same as the gear to be cut will have with a pinion of the same number of teeth as the cutter. It is
accomplished by providing a gear train between the cutter spindle and the work spindle. The
cutter in its rotation generates the tooth profile on the gear blank. All gears cut by the same cutter
will mesh correctly. This is specific advantage of this process over the forming process using
rotary cutters. Also it is a much faster process than rotary cutting.
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2. Gear Planning
In this process rack type cutters for generating of spur. In volutes rack has straight edges and
sharp corners and hence can be manufactured easily and accurately. The cutters generate as they
are cut and as the name implies, the machine cuts the teeth by reciprocating planning action of
the Cutter. This is a true generating process since it utilizes the principle that an in volute curve
can be formed by a straight generator when a gear blank is made to roll without slip relative to
the generator.
3. Gear Milling
Milling is one of the metal removal process best known for making gear. Here a firm cutter is
passed through the gear blank to affect the tooth gap, helical gear, worm & worm wheel and
bevel gear can be manufactured by milling. Gear milling is less costly and less accurate process
and it is employed for the following:-
➢ Coarse pitch
➢ Gear Racks of all pitches Worms
➢ Toothed parts as sprockets and
➢ Ratchets.
The production capacity in this method is low since each space is machined separately and the
time is lost in re tuning the job to its initial position and in indexing for each tooth. In actual
practice a series of cutters are selected for a number of teeth to be milled.
3. Gear Hobbing
In this process, the gear blank is rolled with a rotating cutter majority of the involute gears are
produced by this method. A gear hob looks like a worm, but carries a number of straight flutes
(gashes), cut all around, parallel to its axis. This results in the production of separate cutting teeth
and cutting edges. In operation, the hob is rotated at as suitable speed and fed into the gear blank.
The blank also rotates simultaneously. The speeds of the two are so synchronizes that the blank
rotates through one pitch distance for each complete revolution of the hob. There is no
intermittent motion of the two and the generating continues steadily. The hob teeth are just like
screw threads, i.e. having a definite helix angle. The hob is, therefore tilted to its own helix angle
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while cutting the gear so that its teeth are square with the blank and produces a true involute
shape. Out of all above processes we select the Gear Hobbing for the manufacturing of all the
gears. The various reasons for selection of this process are as following:-
1. Turning
It may be defined as the machining the operation for generating external surfaces of the
revolution by the action of the cutting tool on a rotating work piece. When the same action is
applied to internal surfaces of the revolution, the process is termed as boring.
2. Facing
Operation machines the ends of the work piece. It provides a surface which is square with the
axis of the work piece from which to start the job. Facing is done by feeding the cross slide or
compound in or out. In facing the cutting tool moves from the center of the job towards its
periphery and vice-versa. Facing is primarily used to smooth off a saw- cut end of a piece of bar
stock or to smooth the face of rough casting.
3. Cover or Base Plate
In the manufacturing of the Cover or Base Plate following operations are used
4. Drilling
This is the process of making holes in a work piece. Either the work piece rotate or drill is
stationary or vice-versa. When drilling on the lathe is being done, generally the work piece
rotates in the chuck and the drill held in the tail stock is fed into the work piece by means of the
hand wheel on the outer end of the tail-stock assembly. It is possible to do drill by holding and
rotating the drill in the lathe spindle while keeping the work stationary, supported by a special
pad mounted in tail-stock quill. Since drill feed is by hand, care must be taken, particularly in
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drilling small holes. Coolant should be withdrawn occasionally to clear chips from the hole and
to aid in getting coolant to cutting edges of the drill.
6.1.5. Safety
Ensure no change in nuts during loosening of nuts
6.2. Discussions
We discuss on the existing wheel nuts remover which is a normal L wrench and nut spanners are
really inconvenient and difficult to use. It can remove only a single nut at a time and it requires
man power for removing and tightening of the nuts. Thus for old and weak peoples, the
replacement of the tyre by this normal method is really inconvenient and difficult process. Not
only for old people there are many examples like medical emergencies, job and everyone in this
world is really busy and in rush all the time. So in these cases where time is valuable this normal
method becomes really inconvenient. Therefore, to overcome these problems we designed
vehicles multi wheel nuts remover and lightener. This tool can be operated by anyone easily and
it removes all the five nuts in a single process. Thus our projects saves time and man power and
help everyone in their emergencies.
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6.2.1. Project outcome
The Internship experience and this project are designed to help students maximize their
understanding of Mechanical engineering through the integration of previous theoretical
classroom knowledge with practical experience. It also provides students working towards
professional mechanical engineers with an opportunity to develop insight in to the practical
application of academic knowledge.
6.2.2. Process
Generally, spur gears are used for transmitting power between non-parallel intersecting shafts.
So spur gear arrangement is used for actuating the five socket spanners at a time. The cam and
follower mechanism is used for making the project adjustable. For this purpose, radial cam is
used because the follower moves in the direction perpendicular to the cam axis. And spherical
face follower is used because the side thrust and wear is considerably low.
The multi nut remover used to open the wheel nuts is designed for ergonomic, easy to handle and
requires small space for storage. However, it is difficult for women and the elderly drivers due to
high required torque to remove the nuts of the tire. If the nuts are successfully removed, the
problem to retighten the nuts will arise. If the required torque is not applied in tightening the
nuts, they will get loose, and this will endanger the driver’s safety. This tool can also function as
tire nuts lightener. Impact wrench which is commonly used for removing of tire nuts is also a
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time-consuming tool. For these reasons, to avoid wasting of time and energy, a special tool is
designed and fabricated to allow driver or mechanic to remove five nuts of tire at simultaneously
with little energy consumption. The design is based on standard pitch circle diameter for most of
the cars available. For designing of multi nut remover the basic fundamental of law of gearing
have to be followed in designing of gears. The fundamental law of gears state that, for a pair of
gear to transmit constant angular velocity ratio. The tooth profiles of these mating gears must be
designed in such a way that the common normal line or the line of action passes through a fixed
point, or also known as the pitch point, on the lines of the centres. The tire nut removal has been
designed In order to fabricate the various parts of Multi Nut Remover correctly we need to
design the model in Modelling Software. So, we have used SOLIDWORKS 2017 as suitable
CAD software for designing the tool.First, we have modeled all parts like Frame, Driver Gear,
Driven Gear, Sprockets, Handle, Shafts, Bolts, Nuts, Spanners according to dimensions using
various sketch entities and features in part drawing and then all these parts were assembled using
constraints.
i. The multi nut remover is fixed to certain model of the car so in further work we will change
the tool into adjustable type which can be suited for any model of the car.
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ii. We will try to reduce the cost of the model infurther work.
iii. The weight of the model is heavy so in future we will try to reduce the weight by fabricating
the model with different lightweight materials.
iv. Now operating energy of the model is mechanical energy so in further step we will try to
arrange motor to rotate the tool.
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CHAPTER SEVEN
Thus the design and fabrication of vehicle all wheels nut remover and lightener is successfully
done. This project is practically implemented in south road authority and it found that the results
are positive. The project is economical, and it sustains all the required feasibilities. Vehicles all
wheels nut remover and lightener is a perfect tool for assembling and dismantling a wheel in a
four wheeler.
7.2. Recommendation
Before finalizing the final project we recommend to search for the available parts and materials
in the market, and find alternatives if the needed materials or parts are not available. In addition,
sometimes you can't find the needed parts in the local market, so we have seen many alternatives
and we come with the idea to exploit our resources. Despite the fact that the tire removing
machine works effectively, the following recommendations are made;
1. The tire multi nut removing machine should be redesigned in order to accommodate the bigger
tires such as the Lorries‟ tires which are very big and heavy for this design.
2. The machine should always be kept clean, lubricated and in a dry environment in order to
prevent corrosion and distortion of the support
It act as a convenient and simple method for trye replacement process thus It is more suitable in
using this setup for tire removal in every vehicles for reducing the time consumed and for
reducing the man power wasted for the tyre replacement and to overcome the emergency
situations. Thus the vehicle multi wheel nuts remover and tightener can be used in bus garages
and can be carried in each vehicle for instant tyre replacement which saves lot of time and
energy for every persons.
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APPENDICES
1. Cover
2. Crank
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3. Flat head screw
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5. Nut socket
6. Shaft gear
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7. Shaft key
8. Shaft pinion
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9. Spure gear
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Appendices
APPENDEX1
APPENDEX 2
APPENDEX 3
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APPENDEX 4
APPENDEX 5
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REFERENCE
[1] Childs, P. R. N. (2014). Mechanical Design Engineering Handbook Chapter 8(1st Ed.).
Oxford, United Kingdom: Butterworth-Heinemann.
[2] Design of Machine Elements, Third Edition. By V B Bhandari. The McGraw Hill Company.
[3] Improvement And Optimization Of Tire Nut Removal With 114 PCD (2006).
[4] Jones, H. L. Horton and H. H. Ryffel (2008) “Machinery’s Handbook 28th Edition”.
[5] M. F. Abd Rahim “Design, Development and Fabrication of Tyre Lug Wrench”.University
Teknikal Malaysia Melaka (UTeM), Thesis Degree, 2007
[6] R. Abd Aziz “Improvement and Optimization of Tyre Nut Removal with 114 PCD”.
University Malaysia Pahang, Thesis Degree, 2008
[7] R. Abdul Rahman, C. A. Che Ismail and M. Y. Abdullah “Mechanik Mesin”. University
Teknologi Malaysia Publisher, 2003
[9] Spur Gear Terms and Concepts (2017). GEARS Educational Systems 105
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ASSEMBLY DRAWING
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