Won

PROJECT TITLE: DESIGN OF ROLLING MACHINHOSTING COMPANY:
AMARA WATER WORKS AND CONSTRUCTION ENTERPRISE
Name ID
2 Belete AdmasETR/145/06
Advisor: Mr.Chalachew Zegeye

Company Supervisor: Mr. Anteneh Tilahun
Sub. Date sep. 29/01/2010 e.c

Internship report 2017
DECLARATION
I declare that this internship report is our original work, that any part of this report has been submitted here or
other universities in previous internship report, which is presented for completion of my internship program at
AWWCE from Feb 16, 2017 to June 16 under supervision of my mentor Anteneh Telahun.
Approval of the mentor

According to mentor called Mr. Anteneh Tilahun contributes ways of training the work by
programming, advising and telling the working position of our work and our advisor Mr. Chalachew
Zegeye approved us and communicates with our mentor.
Advisor and Mentor Name Signature
Mr. Ayanew tsegaye
Mr. Chllachew zegeye
ASOSSA, ETHIOPIA
JUNE 08/2017G.C
COMPANY-AWWCE | PROJECT DESIGN SHEET METAL ROLLING MACHINE

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ACKNOWLEDGEMENT
First of all, we would like to thank to the almighty God for blessing in our lives and for giving us strength
to succeed and complete this report.
We would like to express our heartfelt thanksto our advisor Mr. Chalachew Zegeye for his support during
internship program and his guidance to complete this internship report.
I would also like to thank ASU for preparing this program to develop our theoretical knowledge in
accordance with practice in AWWCE Company. I am very grateful of AWWCE for accepting us and give
us a great opportunity to work with them and we also like to extend our deepest thanks for every member
of AWWCE for sharing their knowledge without any hesitation sociability to help us settle quickly
especially our company Mr. Reday, Mr. Sindu, and Mr. Endebeshaw are our guidance throughout the
internship program.The last but not the least, for our families and friends are given grateful thanks for
helping with their idea and business.

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EXECUTIVE SUMMARY
This paper is a report of an internship program at AWWCE. It is prepared as one of the compulsory
inputs for the proper execution of the internship program and it contains four different parts. The first
part contains the brief history, main products or services, the end users of its products or Services, its
organizational structure and work flow of our hosting company AWWCE.
The second part of the report fully describes the overall internship experience, that include the Section
of company we have been working, our work tasks, the challenges we face and the Measure we toke to
overcome those problem, the benefit we gained from the internship program and our recommendation
and conclusion on our internship program. The third part of the report contains the required data of the
project work we done during the internship program. Finally, we have put our general conclusion and
recommendation, every reference we use
TABEL CONTENTS PAGE

DECLARATION ...........................................................................................................................................

iii
ACKNOWLEDGEMENT ............................................................................................................................ ii
EXECUTIVE SUMMARY ......................................................................................................................... iii
CHAPTER ONE........................................................................................................................................... 1
1. COMPANY BACKGROUND .............................................................................................................. 1
1.1. HISTORY OF AWWCE ............................................................................................................................1
1.2. MISSION AND VISION OF THE COMPANY ........................................... Error! Bookmark not defined.
1.3. SERVICE OF THE COMPANY .....................................................................................................................5
1.4. INVESTMENT PROJECT OF A COMPANY ...............................................................................................6
1.5. COMPANY CUSTOMERS.............................................................................................................................6
1.6. OVERALL ORGANIZATION AND WORK FLOW ....................................................................................7
CHAPTER TWO .......................................................................................................................................... 9
2. OVERALL INTERNSHIP EXPERIENCE........................................................................................... 9
2.1. WORKING SECTIONS ..................................................................................................................................9
2.2. TASKS WE HAVE BEEN EXECUTING ......................................................................................................9
2.3. AUTOMOTIVE SERVICE STEPS ...............................................................................................................10
2.4. AUTOMOTIVE TOOLS WE HAVE BEEN USED .....................................................................................11
2.5 TECHNIQUES APPLIED IN OUR WORK TASKS.....................................................................................14
2.6 CHALLENGES ..............................................................................................................................................15
2.7. PROBLEMS FACED DURING OUR INTERNSHIP PERIOD ...................................................................16
2.7.1. IN WORK SHOEP ...................................................................................................................................16
2.7.2. IN MAINTENANCE SHOP:- ...................................................................................................................16
2.8 MEASURES BEEN TAKEN FOR THE CHALLENGE &PROBLEMS HAVE..........................................16
2.9. OVERALL BENEFIT GAINED FROM THE INTERNSHIP ......................................................................17
2.9.1 In terms of our practical skill ...................................................................................................................17
2.9.2 In terms of theoretical knowledge ............................................................................................................18
2.9.3 In terms of improving interpersonal communication skill .......................................................................18
2.9.4 In terms of improving team playing skills ................................................................................................19
2.9.5 In terms of improving leader ship skills ...................................................................................................19
2.9.6 Work ethics skills......................................................................................................................................20
2.9.7 In terms of entrepreneurship skills ...........................................................................................................21
2.10. CONCLUSION AND RECOMMENDATION ...........................................................................................21
CHAPTER THREE .................................................................................................................................... 24
3. PROJECT WORK ............................................................................................................................... 24

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TITLE: DESIGN OF SHEET METAL ROLLING MACHINE ................................................................ 24

3.2 WORKING PRINCIPLE ................................................................................................................................25
3.3.2. SPECIFIC OBJECTIVE .......................................................................................................................27
3.4 METHODOLOGY .........................................................................................................................................28
3.5 COMPONENT DESIGN OF SHEET METAL ROLLING MACHINE ........................................................28
3.5.1. DESIGN OF GEAR .................................................................................................................................29
3.5.3. BEARING SELECTION ..........................................................................................................................42
3.5.4. DESIGN OF KEYS ..................................................................................................................................43
3.5.6. DESIGN OF SCREW ..............................................................................................................................45
3.5.7. DESIGNOF MANUALLY OPERATED HANDLE ..................................................................................49
3.5.8. DESIGN OF SUPPORT END .................................................................................................................50
3.6. DRAWINGS ..................................................................................................................................................52
3.6.1 MAIN PART DRAWING...........................................................................................................................52
3.6.1 MULTI VIEW AND 3D ISOMETRIC .......................................................................................................52
3.6.2 EXPLODED DRAWING ..........................................................................................................................53
3.7. RESULT AND DISCUSSION ......................................................................................................................54
3.8 CONCLUSTION ............................................................................................................................................54
CHAPTER FOUR ...................................................................................................................................... 55
4. GENERAL CONCLUSION AND RECOMMENDATION ............................................................................55
4.1 GENERAL CONCLUSION ...........................................................................................................................55
4.2 GENERAL RECOMMENDATION ..............................................................................................................55
REFERENCE ............................................................................................................................................. 56
APPENDIX ...........................................................................................................................................................56

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LIST OF FIGUR
FIGURE 1.1ACTIVITIES PERFORMED IN THIS BRANCH ................................................................................... 5
FIGURE 1.2 OVERALL ORGANIZATION AND WORK FLOW .............................................................................. 8
FIGURE 2.1 AUTOMAINTENACE .................................................................................................................. 10
FIGURE 2.2AUTOMOTIVE TOOLS WE HAVE BEEN USED ............................................................................... 14
FIGURE3.1 SIMPLE SHEET METAL ROLLING MACHINE................................................................................. 26
FIGURE 3.2 TOOTH GEOMETRY .................................................................................................................. 33
FIGURE 3.3GEAR ARM DESIGN ................................................................................................................... 36
FIGURE 3.4LOAD ACTING ON GEAR ............................................................................................................ 38
FIGURE 3.5 STANDARD DESIGNATIONS OF BALL BEARINGS ........................................................................ 42
LIST OF TABLES
TABLE 1-1 NUMBER OF HUMAN RESOURCES IN AWWCE............................................................................ 2
TABLE 1-2NUMBER OF MACHINERIES IN AWWCE AT BAHIR DAR OFFICE AT KEBLE 14. ........................... 3
TABLE 3-1COMPARE AND CONTRAST OF DIFFERENT TYPE OF ROLLING MACHINE. ..................................... 25
TABLE 3-2 MATERIALS OF SCREW .............................................................................................................. 45
TABLE 3-3SIZE OF TOOL ........................................................................................................................ 46

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CHAPTER ONE
1. COMPANY BACKGROUND
1.1. HISTORY OF AWWCE
Amhara water works and construction enterprise (AWWCE) established in 1988 to fulfill the needs of a
society around the region and to solve the problem of the country. This company was established by
Amhara region government to work building constructions, irrigations and road constructions especially,
in the region. But it is also works in different region in the field of construction. Special concentration is
given, to solve the problem and limitations or development gap of infrastructure of a country. The
development level of our country has direct relationship with AWWCE rather than other organizations.
In addition, AWWCE give job opportunity and qualify lots of employee in the region and in some extent
in other regions in the past years up to now. And also, AWWCE established football federation to build
football club since 1998 E.C to record great contribution for the development of sport field in the region
up to now and job opportunity for youths.
In the year of(1988- 1994), the company did not do that much work in the region because of, skilled man
or women in technologies in different field of study were not found in the region and able to apply their
knowledge on required projects ,instead it try to use other skilled man and women from other country
like China and Japan as a guidance by paying un fair money, but after those years the company board-
office try to re- organized again and use regional professionals in a required technologies with
appropriate projects in the region.
In 2006e.c, this huge company is selected in international qualification product evaluation, work order
and team works and took certificate and money award at Span. Regard to this, the board-office of a
company search, examine the current development level of the country and create modern organization
and improve its office in 2006 e .c such as, Bahir Dar main office old mans helping building at G+3,
south Wollo at Commbolcha city in east Amhara construction office, G+5 building in west Amhara
construction and machinery management and garage office at Bahir Dar Keble 14 which is built by itself.
The companys Information, communication and documents center told us, the first transformation and
development plan of the region since (2003 -2006e.c) partially fulfill by the quality works of AWWCE.
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For example, in 2006e.c, around 100 projects have been worked and in 2007e.cbudget year, 76 clean
water projects, 20 building construction projects and 31 irrigation projects with Tanabelles, totally 127
projects are in the working process. This number indicates that the growth of projects and society job
skill and professions in year to year.
Here, are some projects working in Amhara construction office of AWWCE that we are try to select as a
sample project from listed projects (2007-2009 E.C ) like;
In west Amhara construction office (Denbecha clean water work project, Tetum, Koga and Tanabells
irrigation project etc.)
In east Amhara construction office (kobo and Sekota irrigation project, Desietishu cultural project,
Ayserawm and Gemera soil dam project)
The Information and communication center of AWWCE told us, one of the resource of AWWCE are
humans, for example, the human source growth as they recorded since 1993e.c. up 2007e.c from total
number of four office of company are tabulated below.
Table 1-1 Number of human resources in AWWCE
Year (E.C) Permanent Temporary Total

worker Worker
1993 176 6 182
1994 166 13 179
1995 170 16 186
1996 186 10 196
1997 280 44 324
1998 276 45 321
1999 301 48 349
2000 395 14 409
2001 438 82 520
2002 543 183 726

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2003 761 237 998

2004 824 645 1469
2005 971 519 1500
2006 988 637 1625
2007 1058 721 1779
2008 1102 798 1900
2009 1254 843 2097
In addition to human resources, machinery resource growth of AWWCE is increased in year to year to
improve its working methods. For example, in 2006E.c number of different type of construction
equipment were584 and number of machineries were 384 with a total number of 968 and in 2007E.c with
additional 10 different type of machinery with total number of 1000 are involved in working projects.
Even though, this company has dead machinery in different construction site. For example, number of
dead machinery is above 34 which are found at Bahir Dar Keble 14 office of the company.
The enterprise has three main maintenance shop sites such as, Bahir Dar maintenance site, Combolcha
maintenance site and Tan abeles maintenance site. We apply on Bahir Dar maintenance site.
This site have different maintenance shop such as, engine assembly and disassembly shop, body
maintenance and painting shop, welding shop and electrical system diagnosis shop. It also has machinery
spare part shop, light vehicle spare part shop and salvage store. When construction machinery is signs
malfunction or stop to work some different type of construction machineries found at Bahir Dar work
office of AWWCE are tabulated in below.
Table 1-2Number of machineries in AWWCE at Bahir Dar office at Keble 14.
Type of machinery Number of machinery

No
1 Bus 4
2 Light vehicle 101
3 Dump truck 99

3
4 Crane 15
5 Trailer 10
6 Grove crane 1
7 Lobed 5
8 High bed 3
9 Truck mounted 5
excavator
10 Water bootee 12
11 Fuel bootee 7
12 Dozer 24
13 Grader 10
14 Excavator 24
15 Wheel type excavator 3
16 Loader 22
17 Back hoe loader 2
18 Front dumper 4
19 Smooth foot 12
compactor
20 Sheep foot compactor 12
21 Fork lift 1
22 Wagon drill 5
23 Tractor 12
24 Crusher 6
25 Mixer 3
Total 401
26. Roller compactor 1 Dead
27. Sheep foot 2 Dead
4
compactor
28. Dump truck 4 Dead
29. Excavator 2 Dead
1.3. SERVICE OF THE COMPANY

Those activities are also be classified in different categories shown below:
1. Hydraulic structure such as water supply systems, dams and irrigation works
Projects currently under taken;
Addiskdam water supply project
Durbete water supply project
Debretabor water supply project
Tanabeles sugar irrigation project
Rib dam for irrigation etc.
2. Building such as schools, institutes, hospitals, industrial buildings.
3. Automotive maintenance
Figure 1.1Activities performed in this branch
Provide body maintenance (painting and welding), part welding, assembling and disassembling for
construction machinery and vehicles
Car body builder

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Simple general mechanical system checkup of the automotive

Electrical system of the cars
Changing of different components
4. Manufacturing area
Gate ways components
Dam and irrigation components
5. Machinery training center Actions to be performed;
Give training in heavy construction operators
Give training for mechanics
Other profession related training is heeled for the staff
1.4. INVESTMENT PROJECT OF A COMPANY

Establish Amhara plastic factory with external investors
It is a members of ;Abay bank association and Abay insurance S.C
Tana paper and pulp factory ( in process)
Built G+5 building and hauls can contains above 600 people for its own company
Build automobile assembling , disassembling and diagnosis garage in the region ( in process
)and
Establish construction machinery operators and garage technicians school.
1.5. COMPANY CUSTOMERS

The main visible end product of the company is expressed in terms of irrigation, water supply,
construction etc. But there are also other complimentary activities which are not considered as
main product. Even though it works for the final benefit of surrounding population, each
activity is feed to each other for the successful continuous work flow. Like maintenance and
manufacturing they are primarily used for the proper function of other field of activities. In
maintenance section all vehicles are serviced for the proper function in different project sites
carried out by the company.
In order to maintain its market leadership & deliver the best customer service, the management
of AWWCE has developed a simple & compelling vision; to become full fill basic needs and

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machinery distribution & Retail Company in the country. Their beloved customers, who
include:
Government agencies,
Individuals,
Private companies,
1.6. OVERALL ORGANIZATION AND WORK FLOW
(Board of Directors)
General Manager
Internal Audit Service

Legal Service
Construction control and Plain administration,

contractor administration work improvement and law supporter
flow work flow
Human Purchasing,
power work finance and
leader resource
supporter administration
work flow supporter work
flow
West Amhara
construction East Amhara
Machinery
main work flow construction main
administration and
work flow
maintenance office
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Figure 1.2 overall organization and work flow

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CHAPTER TWO
2. OVERALL INTERNSHIP EXPERIENCE
2.1. WORKING SECTIONS

During our internship period we have been working in the Automotive maintenance &work shop part of
the company. Because, it consist of all activities related to our theoretical knowledge that we have learnt
for three years as courses.
2.2. TASKS WE HAVE BEEN EXECUTING

In the manufacturing section;
We are mainly involved in machining since the components of the Tanabeles irrigation were
produced.
Different joining mechanism is manufactured in different ways. Example for the internal thread
system it can be carried out in two ways, those are by using working tools in the lathe machine
and the other new thing we are interested to perform by using a dais mechanism (mostly it is
suitable, accurate and appropriate for small diameter ) rather than in case of large diameter
internal threads. Simultaneously other tasks also carried out like cutting work piece by using
electronic (automatic machines), punching, pressing, facing, turning, etc. are performed before
further activities being precedes.
While in the maintenance section, we had been performing the following activities;
Disassembled, assembled and serviced different types of brake systems like;
Air and hydraulic for different types of car servicing the following activities were
performed such as; Brake Shoe, wheel cylinder, seal, bearings, bolts and nuts
welding or replacement if necessary and changing of greases.

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Figure 2.1Automaintenace
Check defective alternators and test charging voltage. This diagnosis is performed using a multi
meter. In this process, the parts of alternators that should be checked are regulator, slip rings,
carbons, diodes, windings and bearings.
Weld body and broken parts of automobiles and paint car bodies (body maintenance). Body of a
car maintained using gas welding and arc or stick welding and painted by required colors.
Change engine, transmission and differential oils based on the manual of the manufacturer.
Replace oil, fuel and air filters based on the manual of the manufacturer or as their defectiveness.
Replace broken synchronizers and bearings during transmission servicing.
Comment technicians when they face a problem
2.3. AUTOMOTIVE SERVICE STEPS

Measuring
Disassembling
Machining
installing new or serviced parts
Reassembling
Adjusting
1) Measuring: Before we start working on a vehicle, we must find out whats wrong with it we often
began by measuring. We take measurements in millimeters and in centimeters as well as meters
As when we listen to a running engine we measure engine knock.
When we check the oil in an engine, we measure its level in the crank case by dipstick.
When we check engine vacuum or compression, we measure engine performance.

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We use test instruments to measure battery condition. The result of this measurement tells to us
what sort of job we have to do.
2) Disassembling: Sometimes the measurement shows that there is trouble. If so we have to disassemble
the components and get all the trouble by removing parts from the engine like brake system transmission,
gear box, clutch etc.
3)Machining: removing metal from parts. Example: Valve and valve seats.
4) Install new or service parts: We might find that some parts are so warn that they must be thrown
away then new parts must be installed in their place. Example: engine bearing.
5) Reassembling or putting parts together. -after a repair ,you might have to put some parts back to
gather .we put the parts back together to make a complete assembly. Example
Water pump
Crank shaft
Camshaft etc.
6) Adjusting:-As vehicle operated, parts normally wear; this requires adjustment from time to time. Also
adjustment may be required after a service job. After grinding the valves we put everything back
together. Then we measure the valve action. If it is not right, adjustments must be made. This require
after service job.
2.4. AUTOMOTIVE TOOLS WE HAVE BEEN USED

Hammers
Screw drives
open end wrench
extension lever
adjustable wrench
safety stand
socket wrench
compressor
digital multi meter

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Different type of hammer

Box wrench
Different type of screw driver
Combination wrench
Socket wrench adjustable wrench
L-
Internal snap ring remover
Mechanical pillar
External snap ring remover

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Hydraulic Floor Jack (Crocodile Jack)
Hydraulic Jack (Bottle Jack)
Digital Type multi tester
Hex wrench (Allen wrench)
Kind of Chisel
Hydraulic Lifter (Baby Crane) Floor stand

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Jumper cable
Figure 2.2Automotive tools we have been used
2.5 TECHNIQUES APPLIED IN OUR WORK TASKS

To tighten and loose bolts and nuts extension levers are used to multiply force.
To make brake adjustment count the number of threads (should be equal on each side of
front or rear wheel of the vehicle).
Fitch fuel from the tank through tube by creating vacuum in it by using mouth.
If tool is not available perform the activities by hand.
Lubrication is made if bolt or nut is highly tightened to lose it.
Use plastic hammer to not damage the parts.
The essential stages in the repair of the vehicle are carried out by:
Inspecting the damage and checking its alignment to locate the exact position and extent of
the damage.
Correction is carried out by using alignment and repair equipment like Hydraulic pulling
and hydraulic pushing equipment but if the customer have agreed economic and he permit to
repair can be cut out and replaced with new sections by using a combination of power tools
and welding equipment.
The next stage of the repair is the realigning and reshaping of the body shell structure and is
normally known as roughing out the damage.
After alignment checks have been made, hydraulic equipment is used to push and pull the
body shell back to its correct shape. It is advisable to tough out all damaged sections even
though some of these may eventually need replacing with new panels. The reason for this is
that the successful fitting of a replacement Section will depend on the correct alignment of

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the surrounding areas ,which can best be achieved by restoring them to as near the true
shape as possible before the removal or cutting away of the sections began repair.
Carry out the foundation tasks common to all procedures e.g. removing and replacing bolt, screws and
clips, replacing seals, extracting damaged fasteners, cutting, drilling, filling, using fabrication skills etc.
Contribute to the maintenance of a safe and efficient workshop and adhere to the
dealership/garages business processes (e.g. environmental awareness, servicing a vehicle, record
keeping, customer contact) and standard workshop operations.
Access specific information e.g. vehicle repair information, wiring diagrams, maintenance tables,
technical production information and apply appropriately.
Use diagnostic, mechanical and electrical measuring equipment.
Inspect and prepare a vehicle to the required quality standard for handover to the customer e.g.
following a service, complex repair, pre-delivery inspection etc.
Service and maintain a vehicle without supervision.
Remove repair/replace components in line with manufacturers standards.
Investigate symptoms of vehicle fault(s) and identify the likely underlying causes.
Apply advanced diagnostic principles and logical problem-solving techniques, supported by
diagnostic tools and testing regimes, to establish electrical, mechanical and electronic faults.
Use current flow diagrams and electrical test equipment to carry out standard diagnostic
2.6 CHALLENGES
Behind every success, there is /are obstacles or challenges. Among the challenges we have been faced,
some of them are;
Adapting the workers and the compound
lack of team work
lack of safety materials
Absence of measuring devices
Shortage of tools and equipments
The working place is so rough and dusty, which exposes us for loss of interest at the time of
work

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2.7. PROBLEMS FACED DURING OUR INTERNSHIP PERIOD
2.7.1. IN WORK SHOEP

Sheet metal rolling machine needs more labor force; which needs high labor cost.
Poor in Kaizen management.
2.7.2. IN MAINTENANCE SHOP:-
When air cleaners are dirty, they are cleaned directly to the environment.
Old (wear) brake shoes are removed from their lining by hammering.
Bolts are loosened or tighten by using wrenches acted by man force.
Heavy tires (tires of loaders, Sino trucks, Nissans, etc.) are assembled with the contribution of three or
more technicians.
Poor in Kaizen management.
2.8 MEASURESBEENTAKEN FOR THE CHALLENGE &PROBLEMS HAVE

Through time it is obvious that relations are made between workers and internship
students, because they discuss and helping each other for problem solving issues.
We try to make our own team.
We suggest every worker should come up with safety materials.
We use some measuring devices which are available for the required task
As much as possible, we try to use different materials in the place of necessary
equipments and by manufacturing our project which is engine and differential stand we
try to minimize one of these absences
Cleaning air cleaners directly to the environment pollutes materials around their and also
damage human beings due to dust and other tiny particles in it. To overcome this problem,
it is better to clean using in a closed container. The container should have water reservoir
to suck dusts, and air clear holder inside it.
Removing wear brake shoes using a hammer is enervating, consumes more time and
causes asbestosis. So, we recommend that using hydraulically or mechanically operated
pressing tool to remove the rivets connecting the lining and shoes is better.

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Loosening and tightening of bolts by man power is time consuming, enervating and also
may not tighten to the required torque. So, we recommend that using electrically assisted
tool is selected.
2.9. OVERALL BENEFIT GAINED FROM THE INTERNSHIP

As we have mentioned above the company widely works in manufacturing and maintenance sector, it
helps us to improve our theoretical skill related to those and other courses like internal combustion
engine, workshop, mechanism of machinery and other gained in compass life. Those benefits can be
described below in terms of different perspectives:-
2.9.1 In terms of our practical skill

The internship program helps us for improving our theoretical knowledge to implement practically. It is
so interesting to face the real world; by this internship program we have try to relate the theoretical
knowledge with the practical part, technical, subject-specific knowledge and understanding. We know
that it is better to show some thing rather than teaching for some one. Psychologically we are good and
we gain confidence how to practice something and how to change ideas practically. Generally, in this
internship we get the following practical skills.
1. We can take off and install the engine from the vehicle
2. We can differentiate the problem of the vehicle and maintain if it is necessary to do so

with the help of our coworkers.
3. We can inspect problems around gearbox, transfer and differential, and come up with a
solution easily
4. We can disassemble and assemble the wheel of the vehicle
5. We know how to test fuel nozzle and adjust it
6. We notice how to manipulate different kinds of car jacks and cranes
7. Easily we can notice a problem around filters ( air, oil and water) and adjust them in a
proper manner

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2.9.2 In terms of theoretical knowledge

There is a slight difference between what we have learned in class and the practical work around
industries. However, having a deep knowledge about the practical work makes us more intensive
for the theoretical knowledge. Moreover we are upgraded what we have been learned in the class.
Among these:
breaking system, axle shaft, and bearing
Damping system: like shock absorber, coil spring, leaf spring, and different types of
bushes.
fastening: like bolting, pin and welding ( metal inert gas and Oxygen)
Thread, screw, gear, and differential
Combustion process, crank shaft, connecting rod and cylinder
lubrication system: like different type of oil and greases
cooling of engine: like oil, coolant water and air (for radiator)
Stator and rotor in the alternator etc...
2.9.3 In terms of improving interpersonal communication skill

When we are working, communication was the important way of gaining knowledge or skills. As
we know, working in a shop is a team work that performed not only by one person rather than
cooperation with other. The success of the work is depending on the worker relation and this also
related with their communication. This success couldnt be achieved without developing good
communication skill. During our internship period we have improved our communication skill
by communicating with different workers on shop from high level employee up to daily labor.
To know more technical knowledge, we listen and respect skilled and unskilled labors. Without
communication we all did not gain and received any information. Generally, we have developed
communication skills through:
Adaptation of those different workers

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Most of the workers have practical knowledge rather than the theoretical one that
makes a barrier between us. But through time we can solve our problem by sharing
ideas.
Through working our project, we were having a deep connection with the company`s
advisor, our mentors and coworkers.
2.9.4 In terms of improving team playing skills

Team playing skills are one of the basic requirements for the proper working of a good company,
regardless of its size and its service. A company with properly functioning dedicated working
team will always have a graph going up wards with different workers, working as different team.
However, they work to contribute same goal for the progress of the company.
For the proper functioning of a team, each member must be aware of its mission, vision,
behavior, working style, and goal. They must personally and organizationally dedicate to the
team. Team members must believe in one another and must be ready to work hand to hand in
both adverse and favorable situation.
General skills such as; good communication, concentration, fast decision making, self-
confidence and a wellbeing feeling are important for all team members to engage profitable
work. For instance, during our project work we notice that team playing skill is very crucial.
Because in our company any type work or problem are accomplished with the co-operation of
each other. This situation helps us to develop a team playing skill, since we were one of the members
of the company.
2.9.5 In terms of improving leader ship skills

A leader ship is leading, managing, controlling and administering manpower and resources in
their profession. Problems in a given work can arise from different directions in different period
of time in order to solve this problem a good leader must be needed. A good and effective
leadership must have confidence, effective communication skill and devotion is very important.
Leader ship is critical management and skill is being the ability to motive a group of people
towards a common goal. As a manager he must master to be successful and shows his
management skills to build a way towards success.

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The leader should have to control his fear and forward his knowledge or an idea about what he
going to do with a confidence. A leader must have a communication skill that helps him to
persuade his followers.
Leadership skills that we gained from this internship program were;
to lead, motive, inspire and encourage workers, develop work ethics and values;
like accountability, which is answerable to the decision and acts we took and
transparency, which is our openness of activities that we done to the customers and
works of the company.
The ability to transfer work orders: - it helps to control the work flow and make
works to be done at the desired period of time
How the workers accept their work orders
How to face the risk and manage it.
The ability to inspire and motivate other workers-this increase the worker to do
their activity effectively and quickly.
Respect and listen others opinions and needs: - accepting others peoples opinion
will help in gaining knowledge and improve their experience
How to decide around a management carrier and intended to do large projects.
2.9.6 Work ethics skills

Having a good work ethics is making good attitude and finishing their work on time people like
to be around someone who is positive and in turn helping them have a better working
environment. During this program we improve the following work ethics.
Punctuality Responsibility
Reliability Tolerance
Accountability Respecting each other.
Honesty
Some of the methods to develop strong work ethics are:-
Arrive to work on time

20
Respect yourself and others, without regarding their religion, race, language and
customs.
Be confident and self- motivated in your ability to handle job responsibility
The quality and quantity of work is a direct reflection of personal characters and
integrity.
Respect what others contribute to the work environment. Concentrate on your job and
commitment to proactive attitude.
Work ethical employees are a key to productive. All of the employees have to be
disciplined and ethical in their working environment
2.9.7 In terms of entrepreneurship skills

It is defined by their habit of innovation and redefines markets. It can be realized that when
someone engages or creates profitable job, which is/are significant for the society. From
entrepreneur principle we notice the following points
If you have enough money, even if you have neither talent nor profession, you can make a
business by employee those educated or talented persons. To do so, you have to analyze the most
needed demand in the community.
If you are not educated/have no profession and money, you may have talent. Therefore, you can
start a business regard to your talent.
If you have not money and talent, but you are an educated/you have profession, you can also
make a business specially this is related to us. As we know, our country is one of the developing
countries in our entire planet earth. Therefore, we have a chance to create a lot of things by using
our resources. For instance, after finishing our internship project successfully we understand that
we can also make another problem solving and profitable mechanisms for different
organizations.
2.10. CONCLUSION AND RECOMMENDATION

CONCLUSION

21
From the overall internship experience, we can conclude that the internship program gives us
tangible advantage for improving practical skill as well as theoretical knowledge. We develop
our knowledge about how theoretical studies are related to practical applications and we are
initiated to perform a better effort for the future.
Regarding this, we can say that we had a successful and interesting time during our internship
experience.
RECOMMENDATION
In AWWCE Company, there are some problems which can be categorized as major and minor.
Which are presented as follows:-
Major problems
Organizational arrangement
Time appropriateness
Resource supply and utilization
Safety guarded materials
Measuring devices
Minor problems
Time taking respond for requested spare parts
Shortage of tools and equipments
Lack of time correspondent courses
Shortage of sanitation for workers
Un appropriate selection of working place
Regarding to the above problems the company should take some improvements in
The company should have suitable organizational arrangement for the sake of
productivity and customer satisfaction.
Every employee of the company should be punctual and accountable for his/her
action.
The company should fulfill basic tools and equipments in order to maintain
quality and productive service for the customers.

22
In order to initiate and improve the knowledge of workers there should be time
corresponding courses.
Safety guard materials are very crucial for any company to protect their workers
from injury and sudden accidents.
At last but not least, there should be scientific measuring devices and should give quick respond
for requested spare parts.
RECOMMENDATION TO THE UNIVERSITY
Internship program offers a list of advantages to the students, as mentioned above, for instance it
helps us to upgrade not only practical experience and knowledge related to our academic lesson
and career goals, but also our social skills because it is known that we will meet different kinds
of people in our profession that help us for the future. Therefore, Bahir Dar University plays
tremendous role on creating practice oriented graduates on the field of their possessions by
working with different infrastructures and by creating good linkage with the outside industry.
Therefore we recommended that this program should be continued for every summer of the year
beside at 4th year student in order to improve the students ability.

23
CHAPTER THREE
3. PROJECT WORK
TITLE: DESIGN OF SHEET METAL ROLLING MACHINE
3.1 SUMMARY OF THE PROJECT
Sheet metal rolling machine is a process of turning the flat sheet metal of appropriate length into
a desired curvature as the manufacturer wants or into a complete hollow cylinder. Rolling
machine has an application in manufacturing of heat exchanger, pressure vessel, octagonal
blender etc. The metal sheet is feed continuously between upper and two lower rollers. The
lower roller revolves freely in the circular hole at the both support end. The upper roller is
adjustable roller which slide upward and downward direction normal to the roller.
Three roller sheet metal rolling machine is a process of converting metal sheet of varying
thickness into curve sheet at required circumference or into complete hollow cylinder at required
radius. The factors on which the sheet metal rolling machine is designed includes maximum
thickness of sheet to be used,minimum and maximum diameter of hollow sheet cylinder which
the company want from rolling machine,
The sheet metal rolling machine include component:-
1. Gear: - transmits power &multiply torque.

2. Roller:-The metal rolling machine has two lower rollers and one upper roller between
which the sheet metal is feed.
3. Manually operated handle: - which give power to the pinion shaft.
4. Power screw; to adjust and carry the third roller.
5. Support end:-The rolling has two support ends on both side of the roller. One support
has a single complete assembly and the other end can be split into two. The upper half
support end can be removed completely so that the after the end of metal rolling process
the hollow cylindrical sheet can be removed.
24
3.2 WORKING PRINCIPLE

1. The Sheet Metal, which is to be formed in cylindrical shape, is present at the edge by
hammering. To start the operation easily and to avoid flats at the beginning and at the ends
of the rolled form. In rolling cylindrical shapes a gradual curve is to be put in the metal
rather than sharp bends. Now the sheet metal is introduced between the top and the bottom
rolls, the gap between the top and bottom rolls are adjusted as per the required diameter by
regulating the screw rods. When the hand wheel is rotated, then the pinion gear will rotated
that meshed to super gear, which is keyed to the driving roller, and then driving roller rotates.
In the second mesh pinion (super gear) which is fixed to the driving roller also rotates so that
the spur gear which is keyed to the bottom roll. The third roller rotates due friction force
from the two rollers. Both driven rollers rotate in the same direction.
The difference between motor used, gear used, and none of two (presented) are expressed by
compare and contrast method.
Compare and contrast of different type of rolling machine.
Table 3-1Compare and contrast of different type of rolling machine.
Criteria simple machine Gear mechanism used motor used
1, Availability highly Moderate low
2, Cost of machine Very low low very high
3, Human power highly used Moderate low
4, Complexity very simple simple Complex
5, Machinability simple simple complex

25
`
Figure3.1 Simple sheet metal rolling machine
According to this criteria for the company gear mechanism are preferable and profitable,
so we are selected gear mechanism.
3.3 PROBLEM STATEMENT AND JUSTIFICATION
One of the problem we identified during our internship program in AWWCE were thereis a
sheet rolling machine which needs high power, not save time ,less production per time and very
tedious to the worker. The company workers are working in tediously, so the companies are not
beneficial in business and quality production. When we asked the company leader and worker
they are very interested to be solved this problem with low cost and high production rate per
time. So we are interested and aimed to solve this problem. To overcome this problem we
modify this machine by adding gear drive mechanism to it; since the machine presented on
AWWCE have not any of gear mechanism and motor used, simply by applied higher force by
two /three person. Because gears;can change speed or torque of rotating members as we required.
We are select super gear type hence; the spur gear, are designed to operate on parallel shaft and
having teeth parallel to the shaft axis, less expensive than helical gear& low speed (N<3500rpm).

26
3.3 OBJECTIVE
3.3. 1 MAIN OBJECTIVE
The main objective of the project is to design(modify) and manufacture sheet metal rolling
machine.
3.3.2 SPECIFIC OBJECTIVE

The Specific objective of the project is to design;
Gear
Roller
Key
Power Screw
Manually operated handle
Support end
Bearing

27
3.4 METHODOLOGY
1. Gathering information:-the fundamental step in any design is gathering &
collecting information about a particular project ,in these case a design of
sheet metal rolling machine .So we should collect all & detailed information
about sheet metal rolling machine and its component through:-
Observation
Interview
Reading
2. Analysis of the components:-it is the next step after collecting of information
about sheet metal rolling machine .In this section analytical design of
components take place.
3. Modeling:The importance of modeling and simulation in manufacturing
technology is increasing due to the need for continuous reduction of
development times. We model our design using solid work software.
4. Fabrication:-after design of sheet metal rolling machine on a paper (word) it

should fabricated based on the design dimensions that is calculated during the
design of the components. Therefore the component of sheet metal rolling
machine will be fabricated or manufactured & assembled in design procedure.
5. Testing of the product:-it is the last but very important stage of the fabricated
product, if it meets the company needed it will forward to the customers unless
redesign is recommended.
3.5 COMPONENT DESIGN OF SHEET METAL ROLLING MACHINE

Given data:-
Power (p) =150w

Input speed (N1) =60rpm
Input velocity ratio (i1) =3.5
Length (L) of roller=2600mm

28
3.5.1. DESIGN OF GEAR

We select super gear because of the following reason:-
Less expensive than helical gear

Low speed (N<3500rpm)
It include given gearing ratio
because,Gearing ratio for super gear 1:1
to 6:1&pith line velocity (v)=25 m/s
Material selection
We select materials based on the following properties:-
1) Casting
2) Strength
3) Machining4) cost
4) Wear etc.
By considering the above properties of the materials, we select heat treated carbon steel which
have: -Allowable static stress (o) MPa or N/mm2carbon steel-heat treated 210 to 245MPa static
we take that allowable strength (o) =210Mpa

29
o= u/ 3.
General assumptions:-
Pressure angle or angle of obliquity () ranges from14.50 to 200&we take 200ecnis the
increase of the pressure angle from 14 /2 to 20 results in a stronger tooth, because the tooth
acting as a beam is wider at the base. The 20 full depth involutes system has a strong tooth to
take heavy loads.
Factor of safety =2
The number of teeth for the first pinion gear be T1=18;for 200
pressure angle to avoid interference
Now we can determine the number of teeth for other three gears as follow:-
For the first gear;
From gear train ratio i1=N1/N2=T2/T1=3.5 (eq1)
T1=18&N1/N2=3.5
So; T2 becomes 3.518=63
Ans. T2=63
For the second mesh the pinion gear ; since driving roller(shaft)&driven shaft should have the
same rotation; so gear train ratio becomes i2=N3/N4=T4/T3=1
From eq1 -we obtain N2=N1/3.5=60rpm/3.5=17.14rpm=N3;since gear 2&3 lie on the same
shaft.
So we can take by assuming it is equal to the first pinion T3=18 and T4=19
NB we take T4=19, to avoid interference.
COMPANY-AWWCE | PROJECT DESIGN SHEET METAL RLLING MACHINE

30
MODULE CALCULATION (m)
Module calculation is important to determine the other geometry of gear like addendum,
duodenum, tooth thickness etc.
From Lewis equation;
Wt=Qwbpcy=Q0CVb my .1
Where;
Wt=tangential tooth load

Q0=Allowable static stress
Cv=velocity factor
b=face width
m=module
y=tooth fact
Now; y= 0.154 -0.912/ T, for 20 full depth involute system.
But T=18
So, y=0.103
According to the Barth formula, the permissible working stress,
w= oCV
Where: -o= Allowable static stress, and
CV= Velocity factor.
The values of the velocity factor (CV) are given as follows:
CV=3/ (3 + v) for ordinary cut gears operating at velocities up to 12.5 m / s.
v = Pitch line velocity in m / s,
v= DN/60

31
D = Pitch circle diameter in meters
We know that circular pitch,
Pc= D / T = m . (m = D / T)D = m*T
Thus, the pitch line velocity may also be obtained by using the following relation,
i.e. . . . .v =DN/60= m T N /60where m = Module in meters, and
Pc= m1860/60T = Number of teeth.
=18m..2
We know that the design tangential tooth load,
WT=p/vCVby substituting each value it becomes
=8333/m...3
In actual practice, the face width (b) is taken as9.5 m to 12.5 m, we assume that b=10m
So , b=10m...4
Now by substituting equation 2, 3&4 into equation 1 it becomes
20385.8m3-470812m-24999=0
Solving this equation by hit and trial method, we find thatit is b/n 4.8 & 5
But: The recommended series of modules in Indian Standard are 1, 1.25, 1.5, 2, 2.5, 3, 4, 5, 6,
8, 10, 12, 16, 20, 25, 32, 40 and 50.
So, m=5 ans.

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Figure 3.2 Tooth geometry

By using this module values we can calculate the tooth geometry as follow;
1. ADuodenum =1.25 m =6.25mm
2. duodenum =1m =5mm
3. Minimum total depth =2.25m=11.25mm
4. WMinimum clearance =0.25 m= 1.25mm
5. Tooth thickness =1.5708m=7.854mm
6. Fillet radius at root =0.4 m =2mm
7. working depth =2 m=10mm
Pitch circle for each gear:-
I. Pitch circle diameter for each gears are as follow:-
II. for first pinion gear Dp1=mT=518=90mm=0.09m
III. for first gears Dg1=mT=563=315mm=0.315m
IV. for second pinion gear Dp2=518=90mm=0.09m
V. for second gear Dg2=519=95mm
FORCE ANALAYSIS:-by calculating the dynamic, static and maximum wear load we
can check whether design of super gear mesh is safe or not.
I.e. for safety,
The static tooth load (WS) should be greater than the dynamic load
The maximum limiting wear load (Ww) must be greater than the static load
Assume both the gears are made of the same material, therefore pinion is the weaker. Thus the
design will be based upon the pinion.

33
1. FOR THE FIRST MESH

Given data; for pinion Tp1=18 for gear Tg1=63
Dp1=90mm &V.R=3.5
DYNAMIC TOOTH LOAD (WD):-
WD = WT + WI
Where, WD = Total dynamic load,
WT = Steady load due to transmitted torque,
WI = Increment load due to dynamic action.
WT=p/vCV= (150/0.283) (3/3+0.283)=484.34N.ans.
WI=21v (bC+ WT)/ (21v+ (bC+ WT))
Where,b = Face width of gears in mm=50mm, and
C = A deformation or dynamic factor in N/mm.The value of C in N/mm may be determined

by;
C=Ke/ ( + )
K = A factor depending upon the form of the teeth. K= 0.111, for 20 full depth involute
system
EP&EG = Young's modulus for the material of the pinion& gear in N/mm2.
(1)
e = Tooth error action in mm. =0.0925
Since both the gears are made of the same material (forged carbon
steel),Ep=Eg=170Gpa=170103Mpa
By substituting each value it become WI=79.9N..ans.
So dynamic load, WD=484.34N N+79.9N=564.24N..ans.

34
STATIC TOOTH LOAD: -
The static tooth load (also called beam strength or endurance strength of the tooth) is obtained
by Lewis formula by substituting flexural endurance limit or elastic limit stress (e) in place
of permissible working stress (w). Static tooth load or beam strength of the tooth,
WS = ebpcy= ebmy where: - e=252Mpa
But, b=50mm, Pc=15.7mm, & Y=0.103
WS =20,385.79Nans.
WEAR TOOTH LOAD

The maximum load that gear teeth can carry, without premature wear, depends upon the
radii of
From Buckingham equation,
Ww= DPbQK
Where:-Ww= Maximum or limiting load for wear in Newton,
DP = Pitch circle diameter of the pinion in mm,
b = Face width of the pinion in mm,
Q = Ratio factor
Ww = 2V.R/ (1+V.R) =2TG/ (TG+TP), since V.R=T.G/T.P
K = Load-stress factor (also known as material combination factor) in N/mm2

According to Buckingham, the load stress factor is given by the following relation:
K= (es) 2sin ()/1.4(1/Ep+1/EG) =0.352
Where,es = Surface endurance limit in MPa or N/mm2, es = (2.8 B.H.N. 70)

N/mm2=910MPa. Where B.H.N. =350MPa
= Pressure angle,
EP = Young's modulus for the material of the pinion in N/mm2, andEG = Young's
modulus for the material of the gear in N/mm2.

35
Ww= DPbQK=90502.562.38=27417.6Nans.
The design issafe, since it satisfies both conditions:-i.e.
WS >WD, 20385.7N>546.24N.ans.
Ww>Ws, 27417.6N>20385.7N.ans.
WS and Ww are greater than WD, therefore the design is safe.
2. For the second mesh

In all load condition it is similar to the first mesh except it defer only on wear load .since the
velocity ratio is deferent .i.e. V.R=1 .so we should calculate the wear load only and take the
other load from the first mesh.
Q =2, since V.R=T.G/T.P=1
Ww = DPbQK=906022.38=25,704N
The design is safe, since it satisfies.
WS >WD, 20385.7N >546.24N..ans.
Ww>WD, 25,704N >20385.7N .ans.
WS and Wware greater than WD, therefore the design issafe.
GEAR ARM DESIGN
Large gears (Dp>250)are provided with arms to join the hub and the rim. So the second gear
(DP=315mm) needs arm &the number of arms may beSelected from table. For Pitch circle
diameter up to 0.5 m 4 or 5. We take 4.

36
Figure 3.3Gear arm design
Now the thickness of rim (tR)calculated by using the following relation, i.e.
tR =m (T/n) =5 (63/4) =20mm
Let us assume that the cross-section of the arms is elliptical with major axis (a1) equal to
twicea1
The minor axis (b1). These dimensions refer to hub end.

Section modulus (Z) of arms, = = ...... (Since; b1 = a1/2)
WS = = =2385.9N (:.Ws=stalling load)
Maximum bending moment on each arm,
M= =
Bending stress (b) =42=M/Za1=30mm

b1=15mm
Since the arms are tapered towards the rim and the tapers 1 / 16 per unit length of the arm
a2=a1-taper=30-1/16=29.9mm
b2=14.9mm
3.5.2. DESIGN ROLLER/SHAFT
General datas -input power (Pin) =150w
-rotational speed N =60 rpm
-length of shaft=2400mm
-WT =484.34N
The material we select a carbon steel 4SC8 have:-

Yield strength y=390MPa
Ultimate strength ul=700MPa
We select this material because of the following reason,
i. have good wear resistance
ii. have good toughness
iii. have greater strength

37
A. FOR FIRST PINON SHAFT
Figure3.4load acting on gear
1. First of all, find the normal load (WN), acting between the tooth surfaces. It is given by
WN = WT / cos ...where,WT = Tangential load, and

= Pressure angle load (WN), acting between the tooth surfaces.
WN=515.42/ (cos200) =515.42N..ans.
2. The weight of the gear is given by
WG = 0.001 18 TG.b.m2 (in N)
=0.00118185052 =26.55Nans.
Where, TG = No. of teeth on the gear=18

b = Face width in mm=50
m = Module in mm=5
3. Now the resultant load acting on the gear,
WR = ((WN) 2 WG) 2 WN WGcos
= ((515.42N) 2+ (26.55N) 2+2515.42N26.55Ncos20)
=540.44..ans.
4. since t, then bending moment on the shaft due to the resultant l he gear is overhung on the
shaftoad,
M = WR x
Where, x = Overhang =2m
Assume thatthe weight of the hand wheel negligible.
M=540.442=1080.88N.mans.

38
5. Since the shaft is under the combined effect of torsion and bending, therefore we shall
determine the equivalent torque. We know that equivalent torque,
Te= ((M) 2 T) 2)
Where T = Twisting moment = WT DP / 2=484.340.09/2=21.8N.m
Te= (1080.882+21.82) =1081.09N.m
6. Now the diameter of the gear shaft (d) is determined by using the following relation, i.e.
Te=/16 d3where, = Shear stress for the material of the gear shaft=0.5y=195MPa
Te=1081090N.m=/16 195d 3
d=40.45mm.
We take d=45mm, to make standard.ans.
Check whether the design is safe or not:-
Using Maximum Shear Stress Theory (Guests or Trescas Theory)
max. =1/2 ((t2) + (2)) =97.5Mpa where t=WT/
Since these maximum shear stress is less than allowable shear stress, so that the design is safe
.i.e. max<all. =97.5MPa<195MPa
B. FOR DRIVING ROLLER
1) WN=515.42N
2)WG = 0.001 18 TG.b.m2 (in N), TG=63
=92.925Nans.
3. WR = ((WN) 2 WG) 2 W WG cos

=539.Nans.
4 Mmax=WRmaxx wheres x the distance between the center of the gear to the base
support. I.e. x=2.2m
Mmax=539.N2.2

39
=1185.8N........................ans.
Since the moment is maximum at large weight of gear.
5. Te = ((Mmax) 2+ (Tmax) 2)) Where Tmax= Twisting moment = WT
2=127.341.008/2=64.164Nm
=7995.062^2+64.164^2
=7995.294Nm................................................................................................ans.
Te= /16 d3= 7995294Nmm
d=59.337mm=60mm
..ans.
Check whether the design is safe or not:-
Using Maximum Shear Stress Theory (Guests or Teresas Theory)
max. =1/2 ((t2) + (2))but;t= WT/ =484.34N/3600mm2=134.5KPa
=134.5KPa
.i.e. max<all. =134.5KPa<195MPa
C. FOR FIRST DRIVEN ROLLER
The shaft/roller is stepped with maximum diameter in the middle portion and minimum
diameter at two ends.
From the above:-
1. WN=135.512N
2 WG = 0.001 18 TG.b.m2 (in N), but TG=19
=918.323Nans.
3. WR = ((WN) 2 WG) 2 W WG cos

= ((135.512N) 2+ (918.32N) 2+2135.512N918.32Ncos20)

40
=1046.68N..ans.
4. M = WR x
Where, x =2.52m
M=2637.6336Nm.ans.
5. Te= ((M) 2 T) 2)
Where T =Twisting moment=WT DP / 2=127.340.288/2=18.34N.m
Te= (2637.63372+18.342) =2638N.m
Te=/16 d 3
Te=2638000N.mm=/16 195d 3
d=41.002mm=42mm.
We take d=45mm, to make standard
But the diameter of driving roller is greater than these one so we should take the larger
diameter to maintain the safeness and uniform roller rotation.
So, d=60mm.ans.
Using Maximum Shear Stress Theory (Guests Theory)
max. = ((t2) + (2)) but;t= = =91.91KPa
=97.5MPa
.i.e. max<all. =97.5MPa<195MPa
D. FOR SECOND DRIVEN ROLLER

41
There is not Overhang gear on it so that the weight of gear and moment has less effect on it.
By considering the rotation of the other roller and it should have the same diameter to other,
so that the diameter so d=60mm..ans.
Now in order to make maximum diameter(D) in the middle portion which enables contact
with the sheet metal we assume, based on second pinion gear Dp2=90mm=0.09m&for second
gear Dg2=95mm
Take the second gear Dg2=95mm,for safe clearance.
D=Dg2-dendum-sheet metal thickness +minimum clearance=95mm-6.25mm-2.5-

1.25mm=85mm
Says D=85mm
3.5.3. BEARING SELECTION

A bearing is a machine element which supports another moving machine element. Bearings
are designated by a number. In general, the number consists of at least three digits .We select
rolling bearing due to contact between the surfaces in rolling.
Figure 3.5 Standard designations of ball bearings
BEARING SELECTION FOR PINON SHAFT
We select ball bearing because it has high load carrying capacity, by using shaft diameter
(d=45mm) we select bearing number 309. (i.e. 095=45mm, shaft/bore diameter). And we
read from table Do=100mm& w=25mm.
K 6
Dynamic load rating (L) = ( revolution C=W
Where, L = Rating life,

42
C = Basic dynamic load rating,

W = Equivalent dynamic load, and
k = 3, for ball bearings,
Assume we select row deep groove bearing working for an average life of 4 years to 8 hours
per day, uniform, steady load condition & 300 work days
So, life of bearing, LH=5 300 8=12,000hours
L=60 N LH=60 60 12,000=43.2 106revolution.
The dynamic equivalent radial load (W) for radial and angular contact bearings,
W = X. V. WR + Y. WA where: V= A rotation factor=1,
WR=WG=26.55N&
WA=WT=484.34N
To find X &Y by using standard Table 27.4 Values of X and Y for dynamically loaded
bearings (source: from A Textbook of Machine Design) Co=30KN &C=41.5KN
= =0.02=e Y=0 & X=1
So, =1 1 26.55=26.55N
C=26.55 =93.16N
Since the calculated dynamic load capacity is less than the table dynamic load capacity, so the
selection of bearing and rating life is appropriate.
93.16N<41.5KN is appropriate selection of bearing.
3.5.4. DESIGN OF KEYS

We select rectangular sunk keys type, are provided half in the keyway of the shaft and half in
the keyway of the hub or boss of the gear. The material we select is steel which have yield
stre yt=340Mpa
I. Keys for pinion gear shift
Given data -diameter of shaft=42mm
- yield strength of shaft yt =390MPa
Assume that factor safety=2

43
Let l = Length of key.

Width of key, w = d / 4=10.5mm, but from standard = 14 mm; and
Thickness of key, t = 2w / 3 = d / 6=7mm, or from standard t=9mm
Where d = Diameter of the shaft or diameter of the hole in the hub.
According to maximum shear stress theory, the maximum shear stress for the
Shaft
max=yt/ (2F.S) =390MPa/ (22) =97.5MP
And maximum shear stress for the key,
k= 340/22=85MPa
We know that the maximum torque transmitted by the shaft and key,
T=/16 d3=/16 97.5423=1.410^6Nmm
First of all, let us consider the failure of key due to shearing. We know that the maximum
torque
Transmitted(T),
T= l w k d/2=1.410^6Nmm= l148542/2
l=56.02mm
Now considering the failure of key due to crushing, we know that the maximum torque
Transmitted by the shaft and key (T),
T= lt/2ckd/2=1.4106=l9/2340/242/2 where ;ck=yt/ (F.S)
l=87.16mm
For safeness, taking the larger of the two values, we have
l = 87.16 say 88 mm..Ans.
II. KEYS FOR THE OTHER ROLLER &GEAR
Given data -diameter of shaft=60mm
- yield strength of shaft yt=390MPa
Assume that factor safety=2
From table w=20mm
t=12mm
The maximum shear stress for the Shaft
max=yt/ (2F.S) =390MPa/ (22) =97.5MP

44
And maximum shear stress for the key,

k=340/22=85MPa
The maximum torque transmitted by the shaft and key,
T=/16 maxd3=/1697.5603=4.13510^6Nmm
First consider the failure of key due to shearing. We know that the maximum torque
Transmitted (T),
T= l w k d/2=4.13510^6Nmm= l208560/2
l=81.08mm
Now considering the failure of key due to crushing. We know that the maximum torque
Transmitted by the shaft and key (T),
T= lt/2ckd/2=4.135106=l12/2340/260/2
l=135.13mm
For safeness
Taking the larger of the two values, we have
l = 135.13 say 136 mm..Ans.
3.5.6. DESIGN OF SCREW

The power screws are used to convert rotary motion into translator motion.
We select square threads types of screw threads because ofit is adapted for the transmission of
power in either direction, employedinhoisting &results in maximum efficiency and minimum
radial or bursting pressure on the nut.
Table 3-2 materials of screw
Application Material of Material of nut Pressure(MPa) Rubbing speed

screw (m/min)
Hand press Steel bronze 17.5-24.5 low
Screw jack Steel CI 12.6-17.5 <2.4
Lead screw Steel bronze 4.2-7.0 6-12
Hoisting Steel Cast iron 1.05-1.7 >15

45
Select the screw material steel y=520Mpa & Ultimate stress= 860Mpa and nut material is
cast iron for press screw, because of its strength is high, material cost & Suitability for the
working conditions in services.
NB: we use each supporter as nut.
We assume that; Factor of safety= 2
all. = /F.s=520/2=260Mpa
W= allAc,but W=load of driving roller

W=yAc=260Mpa1/4 Dc2=551070N
Ac=W/ all= /4=551070N/260
Dc=51.94mm=52mm, to make standard.
Table 3-3SIZE OF TOOL
Nominal Major Major Minor Pitch(p) Depth Depth Area of

Diameter(d1) diameter diameter diameter(dc) of of core(Ac)
bolt(d) nut(D) thread thread
bolt(h) nut(H)
55 55 55.5 52 3 1.5 1.75 2124
Torque required torise by the square threaded screw
Let p = Pitch of the screw,
d = Mean diameter of the screw,
= Helix angle,tan=L/ d=dc+p/2=52+3/2=53.5mm
tan=p/
=3.094

46
Find the torque (T1)required to rotate the screw and find the shear stress () due to this
torque
Since the load is being lifted, therefore the force of friction (F = .RN) will act downwards.
All forces acting on the body.
P=Wtan ( +)
Our material of the screw is steel and nut material is cast iron for hoisting screw and low
velocity then the coefficient of friction from table will be 0.09 =tan()=0.09
P=W (tan +tan ())
P = Effort applied at the circumference of the screw to lift the load,
W = Load to be lifted, and
= Coefficient of friction, between the screw and nut
= tan , where is the friction angle. =load angle
P=551.07KN (0.09+0.0535) =73.56KN
lower
the load
T=P =73.56KN mm=1967.73Nm &Shear stress due to torque T
=16 16 =139.9N/mm=139.9MPa
Also find direct compressive stress (c) due to axial load.
c= = =259.62MPa
Find the height of nut (h) considering the bearing pressure on the nut (supporter). We
know that the bearing pressure on the nut
Pb=4

47
Bearing pressure fromabove table Pb=1.7N/mm=4
n = 27.32=28, to make integer ; n=number of threads in contact with screwed spindle.
h=np=283=84mm
Check the stresses in the screws and nut as follows
(screw) = =80.35N/mm where t=p/2=1.5mm
Find inner diameter (D1) outer diameter (D2) and thickness (t1) of the nut collar
The inner diameter (D1) is found by considering the tearing strength of the nut, we know that
W= [D1-do] t/4
551070N = [D1-55]
The inner diameter of the collar is equal to the outer diameter of the screw
D1=do=42.25mm
The outer diameter (D2) find by considering crushing strength of the nut collar
W=/4[D2-D1]c=/4[D2-42.25]259.62=551070N
D2=67.00mm
Design handle of screw
Assuming that the material of the handle is same as that of screw &the person a force of 400N
intermittently the length of handle required
L=T/400=196773Nmm/400=491.9mmsays 492mm
The diameter of handle(D) may be obtained by considering bending effects

M=/32bD (b=t or c)
M=/32259.62D , M=FL/2=400492/2=98400Nmm
D=15.68mmsay16mm

48
Now check whether the design of screw is safe or not:-
1. Checking the screw for buckling load.(Wr)
Effective length or unsupported length of the screw
L=left of screw +1/2 height of nut=150+84/2=192mm
Buckling or critical load.Wcr=Acy [1-( ) ( ) ]
Where y=yield stress
E=Young's modulus for steel = 210 kN/mm2.
C= end fixity coefficient the screw is considered to be a strut with lower end fixed and
load end free,
For one end fixed and the other end free C=0.25
K=radius of gyration=0.25dc=0.25*52=13
Wcr=2124520[1-( ) 1104480N
Buckling (crippling)load wcr is greater than the design load so it is safe regarding to the
buckling load.
i.e1104480N>551070Nsafe
3. Maximum shear stress theory (also known as Guests or Trescas theory).
(max) =1/2[ ] =1/2[ ] =129.82N/mm
It is safe, since (max)<129.82<139.9
3.5.7. DESIGNOF MANUALLY OPERATED HANDLE

It used to rotate the pinion gear which attaches it to the pinion shaft. We select the material the
same as roller because to make weld in ease manner.
i.e.carbon steel 4SC8 has:- L1

49
Yield strength y=390MP
Ultimate strength ul=700MPa L2
Shear stress =y/2=195MPaL3
Force F=400N
Assume that it is Z in shape L1=120mm=L3, L2=200m

Now the torque T
T=FL2=400200=80,000Nmm
The diameter of handle become
T=/16 d3
80000Nmm=/16195d3
18.78mm says d=20mm.ans.
3.5.8. DESIGN OF SUPPORT END

The base support is designed based on the total load of machine&a human force. We select
the material carbon steel which haveYoungs modulus for the material of the section as200
kN/mm2.We obtained its diminution and shape based on roller size, length of handle, and size
of power screw,
WidthB=400mm
Height of supporter D=800mm
Thickness t (length) =outside diameter of nut collar=67mm
Now by calculating all weight acting on it we should check buckling effect. Assumethat
weight of bearing negligible.
W = Wg + Wr + Wh + Fh these is our design load.
=26.55N+92.925N+3551070 N+400N=1653.73KN
Assumethat its shape approximatelyis an I-section, 800mm 400mm 200mm and 67mm
long is used as a strut with one ends fixed.

50
The moment of inertia of the I-section about X-X,
IXX= - = - =13466106mm4
And moment of inertia of the I-section about Y-Y,
IYY =2( + =2( + =729.705 106mm4
Since IYY is less than IXX, therefore the section will tend to buckle about Y-Y axis.Thus we
shall take I as IYY=729.705 106mm4
Since the column is fixed at its both ends, therefore equivalent length,
L = = = 47.4 mm
We know that the crippling load,Wcr= =201507.136KN
Buckling (crippling) load wcr is greater than the design load so it is safe regarding to the
buckling load.i.e201507.136KN>1653.73KNsafe

51
3.6. DRAWINGS
3.6.1 MAINPART DRAWING
3.6.1 MULTI VIEW AND 3D ISOMETRIC

52
3.6.2 EXPLODED DRAWING

53
3.7. RESULT AND DISCUSSION

As we have seen from our project; a gear drive sheet metal rolling machine can reduced the
human labor and time .And it can produce cylindrical or conical shape.
3.8 CONCLUSTION
We get this gear drive rolling machine is so applicable and interesting for the company as well
for the society. It increases the working frame of the company which means while this project
is in application; it can work in the best way. This type of investment is so profitable to the
company and cost wise to the society after once installed.
Generally this simple gear drive sheet metal rolling machine can use to a plain sheet metal
into cylindrical or conical shape by a power screw.

54
CHAPTER FOUR
4. GENERAL CONCLUSION AND RECOMMENDATION
4.1 GENERAL CONCLUSION
From the overall internship experience, we can conclude that the internship program gives us
tangible advantage for improving practical skill as well as theoretical knowledge. We develop
our knowledge about how theoretical studies are related to practical applications and we are
initiated to perform a better effort for the future.
4.2 GENERAL RECOMMENDATION
First we would like to recommend the industrial linkage group of the institute when they
contacts with the company for the placement of the students, it is better that they complete all
related tasks even announcing the departments of the students to be join in to them. But this
problem may not be in all companies, since initially they identify what they accept. Otherwise
students may lose their beginning time by forming a suitable atmosphere in the company.
Internship program offers a list of advantages to the students, as mentioned above, for
instance it helps us to upgrade not only practical experience and knowledge related to our
academic lesson and career goals, but also our social skills because it is known that we will
meet different kinds of people in our profession that help us for the future. Therefore, Bahir
Dar University plays tremendous role on creating practice oriented graduates on the field of
their possessions by working with different infrastructures and by creating good linkage with
the outside industry. Therefore we recommended that this program should be continued for
every summer of the year beside at 4th year student in order to improve the students ability.

55
REFERENCE
[1] AWWCE magazine from 1993-2007
[2]Khurmi, R.S. and Gupta J.K., Text book on Machine Design, Eurasia Publishing
House,14th Edition 2005.
[3] J.E Shigley and C.R Mischiefs, Mechanical Engineering Design, McGraw Hill
th
Publication, 5 Edition. 1989.
[4]www.ask.com
APPENDIX
AWWCE:AmharaWater Works Construction Enterprise

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PROJECT TITLE: DESIGN OF ROLLING MACHINHOSTING COMPANY:

AMARA WATER WORKS AND CONSTRUCTION ENTERPRISE

Advisor: Mr.Chalachew Zegeye

Sub. Date sep. 29/01/2010 e.c

Approval of the mentor

Advisor and Mentor Name Signature

Mr. Ayanew tsegaye

Mr. Chllachew zegeye

COMPANY-AWWCE | PROJECT DESIGN SHEET METAL ROLLING MACHINE

COMPANY-AWWCE | PROJECT DESIGN SHEET METAL ROLLING MACHINE

TABEL CONTENTS PAGE

COMPANY-AWWCE | PROJECT DESIGN SHEET METAL ROLLING MACHINE

COMPANY-AWWCE | PROJECT DESIGN SHEET METAL ROLLING MACHINE

TITLE: DESIGN OF SHEET METAL ROLLING MACHINE ................................................................ 24

COMPANY-AWWCE | PROJECT DESIGN SHEET METAL ROLLING MACHINE

COMPANY-AWWCE | PROJECT DESIGN SHEET METAL ROLLING MACHINE

Table 1-1 Number of human resources in AWWCE

Year (E.C) Permanent Temporary Total

COMPANY-AWWCE | PROJECT DESIGN SHEET METAL ROLLING MACHINE

2003 761 237 998

Table 1-2Number of machineries in AWWCE at Bahir Dar office at Keble 14.

Type of machinery Number of machinery

COMPANY-AWWCE | PROJECT DESIGN SHEET METAL ROLLING MACHINE

1.3. SERVICE OF THE COMPANY

Figure 1.1Activities performed in this branch

COMPANY-AWWCE | PROJECT DESIGN SHEET METAL ROLLING MACHINE

Simple general mechanical system checkup of the automotive

1.4. INVESTMENT PROJECT OF A COMPANY

1.5. COMPANY CUSTOMERS

COMPANY-AWWCE | PROJECT DESIGN SHEET METAL ROLLING MACHINE

1.6. OVERALL ORGANIZATION AND WORK FLOW

Internal Audit Service

Construction control and Plain administration,

Figure 1.2 overall organization and work flow

COMPANY-AWWCE | PROJECT DESIGN SHEET METAL ROLLING MACHINE

2. OVERALL INTERNSHIP EXPERIENCE

2.1. WORKING SECTIONS

2.2. TASKS WE HAVE BEEN EXECUTING

Disassembled, assembled and serviced different types of brake systems like;

COMPANY-AWWCE | PROJECT DESIGN SHEET METAL ROLLING MACHINE

2.3. AUTOMOTIVE SERVICE STEPS

As when we listen to a running engine we measure engine knock.

COMPANY-AWWCE | PROJECT DESIGN SHEET METAL ROLLING MACHINE

2.4. AUTOMOTIVE TOOLS WE HAVE BEEN USED

COMPANY-AWWCE | PROJECT DESIGN SHEET METAL ROLLING MACHINE

Different type of hammer

Different type of screw driver

Socket wrench adjustable wrench

Internal snap ring remover

External snap ring remover

Hydraulic Floor Jack (Crocodile Jack)

Hydraulic Jack (Bottle Jack)

Digital Type multi tester

Hex wrench (Allen wrench)

Hydraulic Lifter (Baby Crane) Floor stand

COMPANY-AWWCE | PROJECT DESIGN SHEET METAL ROLLING MACHINE

Figure 2.2Automotive tools we have been used

2.5 TECHNIQUES APPLIED IN OUR WORK TASKS

COMPANY-AWWCE | PROJECT DESIGN SHEET METAL ROLLING MACHINE

COMPANY-AWWCE | PROJECT DESIGN SHEET METAL ROLLING MACHINE

2.7. PROBLEMS FACED DURING OUR INTERNSHIP PERIOD

2.7.1. IN WORK SHOEP

2.7.2. IN MAINTENANCE SHOP:-

Poor in Kaizen management.