ARBA MINCH UNIVERSITY

ARBA MINCH INSTITUTE OF TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

A REPORT ON INTERNSHIP WORK AT

ANBESSA CTIY BUS SERVICE ENTERPRIS

NAME ID

YIFRU SEYIFE 1967/11

ARBAMINCH, ETHIOPIAN

SEPTEMBER, 2015
 INTERNSHIP REPORT ON ANBESSA CITY BUS SERVICIS INTERPRISE

ACKNOWLEDGMENT

First of all, I would like to thank God for everything. Then I would like to thank my advisors
for they come to my internship work place and for advising me in such a good manner. I am
greatly indebted to all lecturers of Mechanical Engineering department. I have special thanks
to all staff members of Mechanical Engineering department for their valuable commitment to
make me interested in Mechanical Engineering. My acknowledgement also extends to
Anbessa City Bus Enterprise because the company for allowing me to practice my internship
program

Moreover, we would like to acknowledge our supervisor Mr. TEHAYE the manager of
mekanissa depot and for his support, advise and provision of motivation throughout the
internship period, and I would like to acknowledge Mr. ZERIHUN the manager of machine
shop in yeka depot for his relentless help in our internship journey. To all workers of ACBSE,
thank you for your positive attitude towards us in helping and accepting with smile face
whenever we need help and support. It is your close friendship that makes the program
unforgettable.

Finally, we would like to thank our advisers Mr, KBROM for his relentless support, advise
and provision of motivation throughout the starting up to the completion of the internship
time.

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EXECUTIVE SUMMARY
This report is an outcome of the Internship, which was conducted during my stay at Anbessa
City Bus Enterprise. This was an opportunity for me to put in practice the theoretical
knowledge I had acquired during my study. The Internship also gave a real opportunity to gain
valuable experience to fill the gap between study and the beginning of working lives.
Moreover, the practical exposure offered an experiential learning component that can
strengthen previous theoretical knowledge and also motivated me in perusing with Mechanical
Engineering. Additionally, my experimental learning has proven to be helpful to develop mine
detail skills about Engine, Transmission (gear box and clutch), Body, break down and Tire
repairing. In this internship report, it is outlined the practical experience obtained while
working with a team of professionals which revealed the strength and weakness one had and
helped to eradicate the weakness. In this project I design the pneumatic operating sheet metal
cutting machine in Anbessa city bus service enterprise Easy maintenance and repair also it
saves time. In this project concerning about time consumption and energy saving for workers
by simple pneumatic operating machine system.

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TABLE OF CONTENTS
ACKNOWLEDGMENT ............................................................................................................ ii

EXECUTIVE SUMMARY ....................................................................................................... iii

TABLE OF CONTENTS .......................................................................................................... iv

LIST OF FINGURE ................................................................................................................ viii

LIST OF TABLES ..................................................................................................................... x

LIST OF ACRONYMS ............................................................................................................. xi

CHAPTER ONE ......................................................................................................................... 1

1. INTRODUCTION .................................................................................................................. 1
1.1 Company Background and Overviews ............................................................................. 1

1.2. Vision and Mission of Anbessa City Bus Service Enterprise (ACBSE) ......................... 2

1.2.1. Vision of the Enterprise ............................................................................................ 2

1.2.2. Mission of the Enterprise .......................................................................................... 2

1.3. Vehicle Ownership and Management............................................................................. 3

1.4. Organizational Structure .................................................................................................. 3

1.5. The Main Services of The Company ............................................................................... 5

1.6. Main Purpose for Establishment Of ACBSE .................................................................. 6

1.7. Major Sectors of the Enterprises ..................................................................................... 7

1.7.1. Operation and transport service ................................................................................ 7

1.7.2 Technical service ....................................................................................................... 7

CHAPTER TWO ...................................................................................................................... 11

2. WORK, RESPONSIBILITIES AND ASSIGNMENTS ...................................................... 11

2.1. Task One: (understand Automotive Workplace Safety Fundamentals) ........................ 11

2.2. Task Two:(Understand the Tools, we have been using in the workshops) ................... 12

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2.3. Task Two: (Preventive maintenance shop) ................................................................... 15

2.4.1. Changing Oil .......................................................................................................... 16

2.4.2. Changing oil filter................................................................................................... 17

2.4.3. Checking fluid levels ............................................................................................. 17

2.4.4. Checking Condition of the Tire ............................................................................. 18

2.4.5. Repair and replace worn parts such as brake pads and wheel bearing .................. 19

2.4.6. Changing fuel filter................................................................................................. 20

2.4.7. Cleaning and Changing air cleaner ........................................................................ 20

2.4. Task Three: (Breakdown maintenance shop) ............................................................... 21

2.5. Task four (Observe Disassembling Engine part in Engine shop).................................. 22

2.6. Task Five (On Machine shop) ....................................................................................... 26

2.7. Summary of Duties ........................................................................................................ 29

CHAPTER THREE .................................................................................................................. 30

3. TECHNICAL ASPECT OF THE INTERNSHIP ................................................................ 30

3.1. Objectives of the Internship ....................................................................................... 30

3.1.1 General Objective .................................................................................................... 30

3.1.2 Specific Objective.................................................................................................... 30

3.2. Methods and Procedures While Working ..................................................................... 31

3.2.1. Methods used for Working in Anbessa city bus enterprise .................................... 31

3.2.2. Procedures That We Followed While Performing a Task ...................................... 31

3.3. Technical tasks in terms of Practical Skills. .............................................................. 31

3.4. Knowledge and Acquaintances Acquired .................................................................. 32

3.4.1. Improving Practical Skills ...................................................................................... 32

3.4.2. Improving theoretical knowledge ........................................................................... 33

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3.4.3. Improving interpersonal communication................................................................ 33

3.4.4. Improving team skills ............................................................................................. 33

3.4.5. Improving leadership skill ...................................................................................... 34

3.4.6. In terms of understanding work Ethics and Related Issues .................................... 34

3.4.7. In Terms of Entrepreneurship Skill ........................................................................ 35

3.5. Problems Encountered During the Internship Period ................................................ 35

3.6. Contributions ................................................................................................................. 35

CHAPTER FOUR .................................................................................................................... 38

4. PROJECT TITLE: DESIGN OF PNEUMATIC OPERATED SHEARING MACHINE ... 38

4.1. INTRODUCTION ......................................................................................................... 38

4.2. Problem Statement......................................................................................................... 39

4.3. Objective of the Project ............................................................................................. 40

4.3.1. General object ..................................................................................................... 40

4.3.2. Specific object .................................................................................................... 40

4.4. Scope of the project ................................................................................................... 40

4.5. Significance of the project ......................................................................................... 40

4.6. Limitation of the project ................................................................................................ 40

4.7. Literature Review .......................................................................................................... 40

4.8. Types of shearing machine ............................................................................................ 42

4.8.1. Hydraulically operated: .......................................................................................... 42

4.8.2. Spring operated: ...................................................................................................... 42

4.8.3. Rack and pinion operated: ...................................................................................... 42

4.8.4. Pneumatically operated: ......................................................................................... 42

4.9. Methodology.................................................................................................................. 43

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4.10. Working principle ........................................................................................................ 43

4.11. Material Selection ........................................................................................................ 47

4.12 Design of Components ................................................................................................. 48

4.12.1. Specification ......................................................................................................... 48

4.12.2. Design of Cylinder ............................................................................................... 48

4.12.3. Design of piston .................................................................................................... 50

4.12.4. Design of Pins....................................................................................................... 52

4.12.5. Design of Shearing Blade Cutters ........................................................................ 53

4.12.5. Selection of Directional Control Valve ................................................................ 55

4.12.6. Design of Bolt....................................................................................................... 57

4.12.7. Design of nut ........................................................................................................ 57

4.12.8. Design of base plate .............................................................................................. 58

4.12.9. Flexible Hose: ...................................................................................................... 59

4.12.10. Pneumatic Compressor ...................................................................................... 60

4.13 Cost Analysis ................................................................................................................ 61

CHAPTER FIVE ...................................................................................................................... 62

CONCLUSION AND RECOMMENDATION ....................................................................... 62

5.1 Conclusion ...................................................................................................................... 62

5.2. Recommendation ........................................................................................................... 63

REFERENCES ......................................................................................................................... 63

APPINDEX ................................................................................................................................. I

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LIST OF FINGURE

Figure 1. 1 Historical Background of ACBSE Buses Image Flow ............................................ 2

Figure 1. 2 organizational structure of the company ................................................................. 4

Figure 1. 3 depot structure the company .................................................................................... 5

Figure 1. 4 Pictures During Work [captured in ACBSE] ........................................................... 6

Figure 1. 5 Garage workshop [captured in ACBSE] .................................................................. 8

Figure 2. 1 Working Tools ....................................................................................................... 13

Figure 2. 2 Different Types of Wrenches [captured in ACBSE].............................................. 13

Figure 2. 3 Piston Ring Expander [captured in ACBSE] ......................................................... 14

Figure 2. 4 Socket and Extension [captured in ACBSE].......................................................... 14

Figure 2. 5 Changing engine [captured in ACBSE] ................................................................. 17

Figure 2. 6 Oil filter [captured in ACBSE] .............................................................................. 17

Figure 2. 7 Wheel bearing [captured in ACBSE] ..................................................................... 20

Figure 2. 8 Fuel filter [captured in ACBSE] ............................................................................ 20

Figure 2. 9 Cleaning Air Filter and New air Filter [captured in ACBSE] ................................ 21

Figure 2. 10 Breakdown Maintenance Shop ............................................................................ 21

Figure 2. 11 Engine block [captured in ACBSE] ..................................................................... 23

Figure 2. 12 Cylinder head [captured in ACBSE] .................................................................... 23

Figure 2. 13 Connecting rod [captured in ACBSE].................................................................. 24

Figure 2. 14 Crank shaft [captured in ACBSE] ........................................................................ 24

Figure 2. 15 Clutch and pressure plate of the vehicles [captured in ACBSE] ......................... 25

Figure 2. 16 Flywheel of the cars [captured in ACBSE] .......................................................... 26

Figure 2. 17 Lathe Machine [captured in ACBSE] .................................................................. 27

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Figure 2. 18 Radial Drilling Machine [captured in ACBSE] ................................................... 28

Figure 2. 19 Pressing Machine [captured in ACBSE ............................................................... 28

Figure 3. 1 The Flow of the pneumatic compressor. ............................................................... 36

Figure 4. 1 General layout ........................................................................................................ 44

Figure 4. 2 Position ‘A’ non-Actuated Circuit Diagrams ......................................................... 45

Figure 4. 3 DCV Valve in Left Hand Position. ........................................................................ 45

Figure 4. 4 DCV Valve in Right Hand Position. ...................................................................... 46

Figure 4. 5 Position ‘C’ non-Actuated Circuit Diagrams ......................................................... 46

Figure 4. 6 DCV Valve back to Position ‘A’. ......................................................................... 47

Figure 4. 7 General Layout of Pneumatic Shearing Machine. ................................................. 47

Figure 4. 8 Pneumatic Cylinder ................................................................................................ 48

Figure 4. 9 cylinder under hoop stress ...................................................................................... 50

Figure 4. 10 Piston .................................................................................................................... 51

Figure 4. 11 Cutter Blade ......................................................................................................... 53

Figure 4. 12 Movable and Fixed Cutter Blade. ........................................................................ 54

Figure 4. 13 DCV ..................................................................................................................... 57

Figure 4. 14 Nut ........................................................................................................................ 58

Figure 4. 15 Base Plate ............................................................................................................. 59

Figure 4. 16 Hose ..................................................................................................................... 60

Figure 4. 17 Pneumatic Compressor......................................................................................... 60

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LIST OF TABLES
Table 1. 1 Route and Buses Distribution by Sub City ................................................................ 9

Table 1.2 Capacity by Depots................................................................................................... 10

Table 4. 1 Standard Valve Size ............................................................................................... 56

Table 4. 2 Cost Estimation Table ............................................................................................ 61

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LIST OF ACRONYMS
ACBSE Anbessa City Bus Service Enterprise

DAF
Dutch Automotive Factory

PTC
Public transport corporation

PM
Preventive maintenance

BM
Breakdown Maintenance

PMS
Preventive maintenance shop

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CHAPTER ONE
1. INTRODUCTION
1.1 Company Background and Overviews
The first public transport service arrive in Addis Ababa is the Anbessa city bus service
enterprise (ABCSE) which is established in 1945G.C with five military vehicles running only
five routes. Now it celebrating 77 years of anniversary since it began. The company has
launched its operation by giving service to Addis Ababa and provinces on 1951 G.C. as a
share company and named as „‟ Ethiopian Vehicles Services SC‟‟. From 1952 to 1974 it was
operated by shareholders, which included the government, the royal families, the Ethiopian
Orthodox Church and prominent merchants.

The transport service was launched by Ten Buses using four main routes with a tariff payment
of birr 0.15. It has strengthened its service from time and increased the number of buses to one
hundred sixty-three until 1966 and it had constructed an office building and a garage currently
known to be Lideta area.

On august 1974 G.C., the Enterprise was transferred to ownership under the supervision of the
Government. By the year 1976 G.C, it was transferred to the national road transport
corporation’s public transport service, as main organizational unit. In the year 1981 G.C, in
order to strengthen the service of the enterprise, one hundred cross-country and fifty city buses
were purchased. The public transport service was dissolved and a newly organized, entity with
the name of public transport corporation started to administer of the company the present head
office of the enterprise known by the name “Anbessa Garage” which includes Yeka Depot
was launched in the year 1987 G.C.

During the Dergue Regime, when private companies were nationalized, Anbessa fell under the
Ministry of Communication & Transport. This time, the number of buses grew to 205 and the
routes were expanded to 42. Today Anbesa city bus enterprise has around 960 busses,
including the 500 Bishoftu buses, which are assembled locally by Metals and engineering
corporation and also in 2019 puts a new modern automatic bus. A newly established military
industrial complex of the Ethiopia government it has included in its fleet more than 500 of
these locally assembled buses known as Bishoftu Buses, which began the town’s name where
the assembly plant is located seventh of these buses are in Jimma.

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Figure 1. 1 Historical Background of ACBSE Buses Image Flow

Today ACBSE provides a relatively affordable transportation service in and around Addis
Ababa the service of the enterprise has proven a remarkable surge during the past few decades
this time a fleet of nine hundred sixty buses are operating in a full day base covering four
hundred fifty routes within and fifty more routes around the city and in nearby town in
Oromia.

1.2. Vision and Mission of Anbessa City Bus Service Enterprise (ACBSE)
1.2.1. Vision of the Enterprise

❖ In order to make competitive and commendable African urban transport service

❖ To see that the daily activities of the community are done in a sustainable and satisfactory
level.

1.2.2. Mission of the Enterprise

Providing modern, suitable, sustainable, and speedy urban transport service with an affordable
price to the enterprise beneficiary community

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1.3. Vehicle Ownership and Management

The Anbessa city bus service enterprise is led by board committee of the company. However,
the board is appointed by the Federal public enterprises, supervisor authority and the chairman
of the enterprise is the Addis Ababa city manager as such Anbessa is subject to a strong level
of political direction particularly with regard to affordability of its services.
1.4. Organizational Structure
The current structure of the Enterprise are seven divisions and two services each of them
containing its sub sections and own aim.
A. Division of organization
❖ Operation Division
❖ Technical Division

❖ Service Researching, Designing and supervision Division

❖ Access request division

❖ Property purchasing and provision division.

❖ Finance and Human resource division

❖ Audit and inspection service

B. Service
❖ Plan and data processing service
❖ Legal service

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ORGANIZATIONAL STRUCTURE

Figure 1. 2 organizational structure of the company

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Figure 1. 3 depot structure the company

Shigella & Kality Depots are under construction via 1.30 billion Birr budget by Addis Ababa
City Administration. Institutional Reform Program i.e., New Organization Structure has been
Studied and is in the process of Placement of competent Man Power. Purchase of 700 new &
Modern City Bus is in Process of Negotiation with potential Suppliers.

1.5. The Main Services of The Company

Anbessa City Bus Service Enterprise is the biggest transportation company in Ethiopia
especially, in Addis Ababa. The company gives almost all services for the buses except spare
part equipment’s.

The main services given by the Anbessa City Bus Service Enterprise are as follows; Overall
bus Mechanical part maintenance, Engine problem maintenance, Gear box (manual
transmission) maintenance, Breakdown body maintenance and rebuilding, grinding old paint
and change by a new one, Different lathe machine operation like grinding, facing, turning,

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boring, cutting etc., Crankshaft grinding to the standard level by using lath machine,
Replacement of spare parts, gaskets, seals, piston rings, Welding of different body parts and
different broken spare parts by using electric ARC Welding, Tire repairing service, Bus body
washing for the company, Conducting Research and development activities, Conducting
automotive capacity building training, Gives training and workshop for the new drivers.

Figure 1. 4 Pictures During Work [captured in ACBSE]

1.6. Main Purpose for Establishment Of ACBSE

❖ To solve the problem of transportation in and around Addis Ababa sub city

❖ Giving service for the customers with fair price.

❖ To engage within maintenance and over hauling of the buses.

❖ To manufacture spare parts of the buses.

❖ To engage in any other activities necessary for attainment of its purpose.

Customers: The customers ACBSE could be governmental or nongovernmental

organizations which include: - People of Addis Ababa and around Addis Ababa and also
Jimma by transportation, Ethiopian Electric Power Corporation using service for their
employers, many insurance companies while an accident is occurred on their customers cars,
Ethiopian Airlines for their service and World Vision’s and other nongovernmental
organizations for car maintenance.

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1.7. Major Sectors of the Enterprises

1.7.1. Operation and transport service
The enterprise is rendering the city transport service in four bigger depots, four terminals
sixteen posts, and more than one thousand four hundred prepared buses stations. The depots
are;

❖ Yeka ❖ Kalty
❖ Mekanissa ❖ Shegole
The above depots are organized as branch station and bus allocation and maintenance works,
petrol, provision store services etc. are undertaken. The branch office of Jimma is rendering
transport service to Jimma city and the surrounding by having eight buses, forty-two workers
and minor maintenance.

1.7.2 Technical service

In spite of the fact that, the total numbers of buses exit in the enterprise are 522, more than
60% of them have finished 8 years of service. Currently the daily average number of Buses
getting service is on an average rate of 270 up to 290 for immediate maintenance and support.

Currently a most of the buses transports an average of 80 travelers per day and it renders nine
double tripe services per day. As per the new directive business process the number of
travelers reach about an average of 90 and future arrangement is to increase it to thirteen.

The Garage workshop is organized in a modern manner at the head office compound (Yeka
depot) have capacity to properly maintain and preparing the enterprise’s buses. In addition, the
sector usually referred as central workshop has quality and efficiency to undergo external
(individual as well as companies) vehicle maintenance and this branch is accompanied by the
modern equipment and skilled work force on the field.

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Figure 1. 5 Garage workshop [captured in ACBSE]

The following are the sequence of depot structure in the enterprise.

I. Under General Manager

❖ Mass transport operation core process

❖ Technical service core process

❖ Purchase and supply support process

❖ Financial support process

❖ Human resource support process

❖ And also has depot manager under the control of general manager.

II. Depot Manager

❖ Transport sub process

❖ Maintenance version

❖ Supplies case team

❖ Financial case team

❖ Human resource case team

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1.7.3 Anbessa City Bus Service Enterprise

Depots Main Function

❖ Reducing time weighting

❖ Calculating mileage

❖ Clear and neat working atmosphere

❖ Considering area of parking

The formal bus operation in Addis Ababa city bus service enterprise maintains detailed record
of its passenger carrying on each of the all routes.

Table 1. 1 Route and Buses Distribution by Sub City

Sub city Total routs Total bus

Kirkos 37 95
Arada 22 75

Addis ketema 29 92

Nifas silk 18 63

Ledeta 10 48

Yeka 13 50

Kolfe 19 65

Gerges 19 65

Bole 11 49

Akakikality 13 50

The routes and buses distribution of the enterprise gives a service for many people around the
city by nearest to the depots. The informal sector makes no attempt to collect passenger
number only being interested in the revenue that they generate.

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Several study to improve urban transport carried out detailed loading survey at a limited
number of sites, from which it concluded that carryings on minibus and modified Taxis were
roughly at three quarter of the level of those on the larger buses. However, the average trip
length on the smaller vehicle is considered to be significantly less than for the buses and might
therefore result in passenger number being up to 50% more than on Anbesa.

The urban transport study attempted to estimate passenger number carried by the minibus and
modified taxis and came up with widely varying estimates for the number carried by each
vehicle ranging from [Link] situation in Addis Ababa is complicated by the authorized
fare’s structure. The number of minibuses and modified taxis actually operation in Addis
Ababa has been the subject of considerable conjecture, and there is no consistency in the
source documents however the transport authority has now introduced a new computerize
registration system form which it is possible to deduce that their combined number. The
Anbessa city bus enterprises there are four depots with different capacity those are used as a
bus station. Depots situated in the corner of four directions in city.

Table 1.2 Capacity by Depots

Depot DAF Rigid Articulate New Double Total

rigid decker

Yeka 60 72 68 58 20 278

Shegole 40 50 43 37 5 175

Mekanisa 17 32 8 32 10 89
Kalty 20 25 10 20 5 80
Total 137 179 129 147 40 632

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CHAPTER TWO
2. WORK, RESPONSIBILITIES AND ASSIGNMENTS

Among different companies visited during the selection of internship hosting company, there
were several criteria’s that had been put in place. Such as; Knowing about the company and
find out if it interests us to stay there for the internship period, if there is internship vacancy,
and convenience of the company’s location. Based on the above criteria, ACBSE Yeka district
Automotive Garage has been selected because it encompasses workshops which provides the
following opportunities: - Machine shop, Accessory shop, Electric system shop, Engine shop,
Radiator shop, Body and frame shop, Transmission (Gearbox and clutch shop,
Maintenance(breakdown) shop, Tire retreading shop, Instrument or damaged working tool
remade and store shop, Differential shop. As a well-equipped and staffs of long year work
experience, practical work is done in full equipped workshop which provides a realistic
working garage environment.

On our first day at ACBSE we took an internship orientation in the company about the
company background what we are expected to do and not with some useful advices. Then
after that MR. ZERIHUN the ACBSE lead foreman gave us some information about the
working sections and introduce us to the technicians. Placing us to our working area was also
Mr. ZERIHUN duty. So, he assigned us to work in Preventive maintenance shop to work with
the senior technicians as an assistant technician. So, we were working with the senior
technicians to repair and give service for ACBSE cars. The tasks we have been participating
are described below

2.1. Task One: (understand Automotive Workplace Safety Fundamentals)

Safety: - means protecting our selves and others from injury or any other accidents. These
accidents in the workplace are prevented by the following;

❖ Working safely and avoiding horse play.

❖ Follow the right work procedure.

The ways to learn and understand safety are;

❖ Accidental experiences and

❖ Safety education.
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Accidental Experiences: - are experiences which were caused by accidents. But we can’t
afford to learn safety through experiences. However, being safe can mean the difference
between life and death.

Safety Education: - means knowing by learning safety before performing any task. This is a
method which makes us aware of dangerous situations to avoid accidents or injuries. In
general, there are three safety guide lines and called general workshop safety procedures.
These are: -

❖ Personal safety,

❖ Tools and equipment safety and

❖ Work area safety

2.2. Task Two:(Understand the Tools, we have been using in the workshops)

As we were fresh to the working environment, we were supposed to know the tools and
methods used to execute different types of tasks. If someone has no idea about how to use
different tools and methods, he/she will be wasting time and also may damage parts. Same
hand Tools used anbessa city bus enterprise are:
❖ pen wrenches ❖ Sockets
❖ Ratchets ❖ Screw driver

❖ Hammers (plastic and metal) ❖ Hacksaws

❖ Glass paper / sand paper ❖ Closed wrenches

❖ Torque ❖ T- handle

❖ Piston inserter ❖ Liner extractor and etc

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Figure 2. 1 Working Tools

Wrenches: - Wrenches are used to fasten a joint comprising a nut and bolt. Wrenches are also
known as spanners in some parts of the world. They are made from a chromium-vanadium
alloy. Chromium plating helps in preventing the wrench from rusting.

Figure 2. 2 Different Types of Wrenches [captured in ACBSE]

Piston ring expander: It is generally use to expand and remove the piston rings from their

grooves without breaking.

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Figure 2. 3 Piston Ring Expander [captured in ACBSE]

Socket spanners: These types of spanners are useful in restricted spaces where common types
of spanners cannot be used. They consist of sockets of different sizes which can be used with
various types of handles. The handles have projection at one end around which the sockets fit.

Special Sockets: Screwdriver (including Torx® driver) and Allen wrench attachments are
also available for use with a socket wrench. Set of specialty socket drivers. These socket
wrench attachments are very handy when a fastener cannot be loosened with a regular
screwdriver. The leverage given by the ratchet handle is often just what it takes to break a
stubborn screw loose.

Extensions: An extension is commonly used to separate the socket from the ratchet or handle.
The extension moves the handle away from the bolt and makes the use of a ratchet more
feasible.

Figure 2. 4 Socket and Extension [captured in ACBSE]

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2.3. Task Two: (Preventive maintenance shop)

Preventive maintenance shop is a vital shop in ACBSE in which the buses are checked and
fixed periodically in each half of month. It is a set of activities performed on machinery, and
systems before the occurrence of a failure in order to protect them and to prevent or eliminate
any degradation in their operating conditions. But the vehicles are also maintained on such
shop. when they faced problem while they travel. The main aim of preventive maintenance is
to reduce failure probabilities by maintaining such buses before failure or significant
degradation has occurred. When the mechanics observe problems are sustained on the vehicles
during preventive checkup, they fix it. According to PMS rule there are four types of service.
They are classified into P, A, B and C service.

Service “A”: - Change engine oil and change oil filter change the bus move 11,500 km for
low floor (for double decker 10,000km both the filter and oil together) based on their manual.

Service “B”: - Change fuel filter or deferential oil (40,000 fuel filter, 65,000_70,000
differential and also change transmission fluid (180,000km).

Service “C’: - work on wheel service and air drier (every three months or by referring to the
owners’ manual) will be changed.

Service “P”: - visual inspection air cleaner cleaning (every 15 days) and every time the
vehicle is called for a checkup.

The preventive maintenance is work according to the following sequence:

I. Maintenance schedule is prepared by the maintenance team and communicate.

II. Preparation of all the required facilities and spare part for the maintenance work.
III. Inspector calls the bus for maintenance according to the schedule and gives it to the
mechanic.
IV. The mechanic maintains the bus based on the check list.
V. After completion of maintenance work the mechanic will check and give it back to the
inspector for final inspection.
VI. Inspector inspect the bus:
❖ If it passes the test, inspector will send the bus to cleaning and then operation.
❖ If it not passes the test, inspector will send it back to the mechanic for rework.

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VII. The mechanic will record all his maintenance work and file to the history jacket of the bus.

Maintenance tasks we carried out during a vehicle service includes:

❖ Replacing the oil filter

❖ Changing oil

❖ Replace the air filter

❖ Replace fuel filter

❖ Check brake pads/liners, brake discs/drums, and replace if worn out

❖ Check and refill power steering fluid

❖ Check and refill automatic/manual transmission fluid

❖ Grease and lubricate components

❖ Check conditions of the tire

❖ Check Suspension

2.4.1. Changing Oil

Motor oil is mainly used for lubrication in the internal combustion engine. Proper lubrication
decreases fuel consumption, wasted power and increases engine efficiency, reduce friction,
help to collect and remove debris within the engine and protect engine parts from corrosion
and wear. Oil should be changed every 12000 KM driven for cars. We can check oil level,
whether it is clear or dirty and its viscosity using oil dipstick. To check the oil property, we
should pull out the dipstick and wipe it off with a clean cloth after doing this we put the dip
stick back in. After 3-5 sec we will pull it out to check the oil level on the dipstick gauge
whether it is low or full. If it’s too low or too dirty to read, then we should change the oil.

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Figure 2. 5 Changing engine [captured in ACBSE]

2.4.2. Changing oil filter
The oil filter helps to remove contaminants from the car engine’s oil that can accumulate over
time as the oil keeps your engine clean. Clear motor oil is important because if the oil were
left unfiltered for a period of time, the debris could become tiny sediment later on the
sediment become hard particles that can wear surfaces in the engine and also close passage
lines within the engine. Therefore, the Oil filter should be changed every 12000 km.

Figure 2. 6 Oil filter [captured in ACBSE]

2.4.3. Checking fluid levels
One of the most critical elements for an automobile to function is fluid system. A car has
different fluid system for the various sub systems within it, when the fluids become dirty or
below the optimal level it can create serious side effects that will end up getting to replace

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expensive parts. So, it is important to be aware of different type of fluids and their functions.
Here are some most common car fluids and their typical uses:

❖ Brake fluid: The brake fluid is solely encapsulated within the brake system of a car and
should not leak or become low. Therefore, if we notice leaking brake fluid, we should go to
the nearest automotive shop for repair leaking brake fluid. If it is not fixed it is dangerous and
can lead to brake failure. Brake fluid can be checked during an oil change and should be done
so frequently as a preventive measure and safety precaution. Brake fluid absorbs moisture,
which reduces its performance. For that reason, its best practice to change brake fluid every
two years.

❖ Coolant or radiator fluid: coolant, radiator fluid or antifreeze, is what helps keep the
engine from overheating or freezing under extreme temperature or stress. When coolant
becomes low, the radiator is susceptible to damage as well as to other components of the
engine. Engine overheating is relatively easy to avoid, just keep the fluid full.

❖ Transmission fluid: Transmission fluid is a dark reddish and brownish liquid that is
responsible for gear shifting, and making the transmission smooth. If the transmission fluid
becomes full of debris (small particles), it can cause serious issues in the transmission. Most
manufacturers recommend replacing transmission fluid every 30,000 to 60,000 miles. The
automatic transmission fluid (ATF) should be Changed sooner if it gets dirty and if its level
drops.

❖ Power steering fluid: Allows a car to take turns smoothly and accurately. When the
power steering fluid becomes low or contaminated, it can be a major cause for suspension
failure. Along with brake fluid, power steering fluid should be checked during oil changes.

2.4.4. Checking Condition of the Tire

A tire is a ring-shaped component that surrounds a wheel's rim to transfer a vehicle's load
from the axle through the wheel to the ground and to provide traction on the surface over
which the wheel travels. Most tires, such as those for automobile and bicycle are
pneumatically inflated structures, which also provide a flexible cushion that absorbs shock as
the tire rolls over rough features on the surfaces were checking the tire by using pressure
gauges based on manual around ten bar mainly uses.

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2.4.5. Repair and replace worn parts such as brake pads and wheel bearing
Brake pads: are key part of a vehicle’s brake system which are placed between the brake shoe
that clamps down the wheel disk (decreasing the rotation of the wheel). Without servicing the
brake pads other related elements of the vehicle like discs, rotors, and caliper will begin to
wear away. The brake pad will wear down over time. This is done to protect the disc brake
from damage. Signs when the brake pad should be replaced:

I. Squealing or screeching noises: the first indication any driver will notice is a squealing,
screeching, or whining noise when the brakes are engaged. This sound is caused by a
small metallic shim indicator that's embedded in the brake pad for just this purpose.

II. Less than a quarter inch of brake pad: look through the tire spokes and see the brake
pad, if the pad is less than 1/4inch thick (about 3mm) then it should be replaced with the
new one.

III. Indicator light: some modern vehicles have an indicator light on the dash board that will
signal when it’s time to replace the brake pads.

Wheel bearing: is a set of steel balls held together by a metal ring called race. It helps wheels
spin fast with a little friction as possible. On cars, a wheel bearing rides on a metal axle shafts
and fits tightly inside the hub, which is a hollow chunk of metal at the center of the wheel.
Eventually, all wheel bearing wears out and will need to be replaced, assuming normal service
under typical driving condition. The newer, "hub-assembly" style bearing found on most
modern vehicles should last around 100,000 miles when maintained properly and we will
cheek the bearing and change the grease.

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Figure 2. 7 Wheel bearing [captured in ACBSE]

2.4.6. Changing fuel filter
The fuel filter screens dust and rust particles from the fuel, keeping them away from entering
the engine. Typically, the fuel filter is either located inside the fuel tank (in the opening of the
fuel line, which feeds gas to the cars). Fuel filter should be replaced after72,000km travel
distance.

Figure 2. 8 Fuel filter [captured in ACBSE]

2.4.7. Cleaning and Changing air cleaner
The purpose of the engine air filter is to prevent dust, dirt and other environment contaminants
from getting in to the engine. Over time, the air filter becomes dirty and clogged, and so we

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might need to replace it. But if it’s not too dusty we can always clean it by using air pressure
and reuse it.

Figure 2. 9 Cleaning Air Filter and New air Filter [captured in ACBSE]
2.4. Task Three: (Breakdown maintenance shop)
Breakdown maintenance apply when the vehicle part is failed or the part is broken-down,
which is to be provided when the vehicle becomes immobilized due to faults created during
running. The problems occur on this maintenance are damaged: gearbox, air regulator, door
valves, any bolt, differential change air bag (suspension system) etc., if one of them is fail it
will be changed in the breakdown maintenance.

Figure 2. 10 Breakdown Maintenance Shop

The workflow breakdown maintenance is according to the following sequence:

I. Driver reports to the operation center when breakdown is occurred on the bus.

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II. Inspector checks and gives to the mechanic by identifying the defected parts.

III. Mechanic resaves the bus and prepares the required spear parts if required and
facilities for the maintenance work.

IV. Mechanic performs the repair work.

V. After completion of the repair work the mechanic will check and give it back to the
inspector for final inspection.

VI. Inspector inspects the bus.

❖ If it passes the test inspector will send the bus to cleaning and then to operation.

❖ If it not passes the test inspector will send it back to the mechanic for rework.

VII. The mechanic will record all his maintenance work and file to the history jacket of the bus.

There are several activities to perform breakdown maintenance that includes:

❖ Fail-repair: The failed item is restored to its operational state.

❖ Adjustment: Re-adjust vehicle parts for the purpose of achieving the optimum system
performance.
❖ Alignment: Re-align vehicle parts for the purpose of achieving the optimum system
performance.
❖ Servicing: Cleaning, lubricating, charging, flushing etc., of failed vehicle parts or their
components for the purpose of achieving the optimum system performance.

2.5. Task four (Observe Disassembling Engine part in Engine shop)

The engine shop has different working areas. E.g., engine maintenance, engine assembling
and disassembling, gear box disassembling and assembling and differential disassembling and
assembling.

Engine block: is a large casting of metal that is drilled with holes to allow for the passage of
Lubricants and coolant through the block and provide spaces the movement of mechanical
parts.

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Figure 2. 11 Engine block [captured in ACBSE]

Cylinder head: it fits on the engine block to close off and seal the top of the cylinders. The
Combustion chamber is an area in to which the air-fuel mixture is compressed and burned.

Figure 2. 12 Cylinder head [captured in ACBSE]

Connecting rod: the reciprocating of the pistons must be converted to rotary motion before it
can drive wheels of a vehicle. As the piston is pushed down on the power stroke, the
connecting Rod pushes on the crank shaft it to rotate.

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Figure 2. 13 Connecting rod [captured in ACBSE]

Lubrication: the moving parts of engine need constant lubrication; lubrication limits the
Amount of wear and reduces the amount of friction in the engine. Friction heat generated
when Two objects rub against each other. Engine oil is the fluid used to lubricate and cool the
engine.

Crank shaft: is the main driven part of an engine, and its function is to reciprocate the piston
inside the cylinder by means of connected rod. But the crank shaft has high rotational speed. It
has oil holes used for lubrication.

Figure 2. 14 Crank shaft [captured in ACBSE]

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Camshaft: its main function is opening and closing the valves, by adjusting time depending
on the rotation. The valve opening and closing time of interval are designed on the engine
timing chart. The operating time is determined by the position of the cam lobe

Cylinder head Gaskets: are thin sheet materials used to assemble two metallic components
together. The main advantage of gasket is to protect the fluid or gas from losing or spilling out
of the circulation system. It also seals of the engine block

Gear box: It uses gears of various sizes to give the engine a mechanical advantage over the
driving wheels. Power from the engine is transferred through the engaged clutch disc to the
input shaft of the transmission. Gears change the torque and speed of this power input before
passing it on to other components in the drive train. Now a days there are three type of gear
box assembly: -

Differential Gear Box: It is a member of automotive part it accepts the power from the
engine transmits to the last pinion gear and it drives the wheel of the car by ring gear, in this
case the gears rotate on its axis and the car travel a straight direction. The main function of the
differential gear is to rotate the wheel in A curved path easily. The assembly includes: - pinion
gear, ring gear, planetary gears and sun gears.

A. Clutch: is a device to connect driving and driven shafts of a machine, where the driven
shaft can be disconnected almost instantaneously from the driving shaft as desired by the
operator or driver. It is used to engage and disengage the power transmitted from the engine to
the transmission.

Figure 2. 15 Clutch and pressure plate of the vehicles [captured in ACBSE]

B. Flywheel: is a fairly large wheel that is connected to the crankshaft. (Stores
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K.E during engine power stroke and release during idle strokes)

Figure 2. 16 Flywheel of the cars [captured in ACBSE]

2.6. Task Five (On Machine shop)
It is an important shop in ACBSE which helps to maintain several parts in order to make them
reused by the vehicle instead of converting these parts by new product. A number of machine-
like lathe machine, shaper machine, drilling machine, pressing machine comprises the
machine shop

I. Lath machine

It is one of the most widely used machine with main function of removing metal from job to
give it the required shape and size the job is secure1y and rigid1y held in the chuck or in
between centers on the lathe machine and then turn it against a single point cutting tool which
wi1l remove meta1 from the job in the form of chips. Besides the simple turning operation as
described above, lathe can be used to carry out other also as taper turning, knurling cutting etc.
it is work s by rotating the workpieces around a stationary cutting tool the main use of lathe
machine is to remove unwonted part of the material.

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Figure 2. 17 Lathe Machine [captured in ACBSE]

In ACBSE some problems related to differential housing, king pin, flywheel, dis brake bolt
and nut etc. are maintained using lathe machine. It maintains different parts using facing
when problem occurred on flywheel and king pin and by producing treaded rod in differential
housing problems.

II. Shaper machine

Shaper is a reciprocating type of machine tool in which the ram moves the cutting tool
backwards and forwards in a straight line. It is intended primarily to produce flat surfaces.
These surfaces may be horizontal, vertical, or inclined. In general, the shaper can produce any
surface composed of straight-line elements. Head of hexagonal bolt, square cross-sectional
parts, thrust washer are some of the parts produced on shaper machine in ACBSE.

III. Radial Drilling Machine

A drilling machine is a machine tool designed for drilling holes in metals by removing a
volume of metal from the job by cutting tool called drill. It is one of the most important and
versatile machine tools in a workshop. A drill is a rotary end-cutting tool with one or more
cutting lips and usually one or more flutes for the passage of chips and the admission of
cutting fluid. Most of the problems in ACBSE are not maintained in one machine. A number
of problems related with gear box, fly wheel, gear box housing is maintained on such machine
in addition to other machine-like lathe.

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Figure 2. 18 Radial Drilling Machine [captured in ACBSE]

IV. Pressing Machine

It is a machine used to press the metal to fit it with another metal as desired by the operator.
To fit metals which is not achieved by human effort is done using such machine. Hydraulic
power operates such machines. We observe two pressing machines in ACBSE with different
pressing abilities and different tasks. The smaller one is used to disassemble the old clutch
plate and brake liner from the disc metal and then to assemble it with new part. The disc metal
able to provide additional functioning time by fitting it with new plate and liner.

Figure 2. 19 Pressing Machine [captured in ACBSE

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2.7. Summary of Duties

This summary describes briefly about time, duration and types of duty we carried out during
our internship in the company. On our first day at ACBSE we took an internship orientation in
the company about its background, what we are expected to do and what we are not with some
useful advices were given to us.

Then after that MR. ZERIHU the ACBSE work shop lead foreman gave us some information
about the working sections and introduced us to the employees, placing us to our working area
that was also Mr. ZERIHUN duty. So, he placed us to work in preventive maintenance shop.
Since were strange to things that were going on, we spent our first week observing and
knowing parts and tools they used in workshop. But the chief mechanic Mr. Tebebe by
looking our good intention to work, he gave us some tasks and asked us to help him with some
works. In this section we have been working on different types of vehicles services (P, A, B
and C) maintenance and repair.

The tasks carried out in ACBSEPM were more like the same. Therefore, the tasks we have
been executing was not challenging us. Some of the tasks we have been executing were
servicing, checking and repairing clutch, tires, engine oil, transmission oil, differential oil,
power steering oil, fuel injector, air cleaner, fuel pump and so on.

we also spent time in the engine overhaul shop. In this workshop engines, gear box,
differential parts are observed disassembled. In this work area most of the time we checked
the parts that makes the mechanism not to function properly (totally). Then we were told that
the damaged parts and the machine will undergo sometimes simple sometimes complicated
repair mechanism in the machine shop.

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CHAPTER THREE
3. TECHNICAL ASPECT OF THE INTERNSHIP

Internship training delivers have various important outcomes. In addition to improve our
abilities of converting various theoretical knowledge into their real application in practical
world, it also delivers a number of additional benefits like Improving practical skills,
improving theoretical knowledge, improving team playing skills, improving interpersonal
communication skills, improving leadership skills and Understanding work ethics.

3.1. Objectives of the Internship

Internship program is a method of letting the students to assume themselves as potentially
responsible workman for a particular work by assigning them to actively participate in
production control as well as maintenance in industrial company. Such trends help us to have
valuable work experience. Internship programs are also potentially valuable to the company.
In this internship, we could observe what the outside industrial world looks like more than we
knew when we were at university. we learned or took many theoretically lessons even difficult
to understand theoretically. So, in this internship, we will get good opportunity to solve these
difficulties. Because those things which were theoretically difficult to understand, were not
hard to understand when we learned practically.

3.1.1 General Objective

The objective of the internship program is to facilitate reflection on experiences obtained in
the internship and to enhance understanding of academic materials by application in the
internship setting. The Internship will provide students the opportunity to test their interest in
a particular career before permanent commitments are decided.

3.1.2 Specific Objective

❖ Internship students will develop skills and techniques directly applicable to their careers.

❖ Internships will provide students the opportunity to develop attitudes conductive to

effective interpersonal relationships

❖ Internships will provide students with an in-depth knowledge of the formal functional
activities of a participating organization.

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❖ Internship programs will enhance advancement possibilities of graduates.

In general, an internship program is thought of as a program which "bridges the gap" between
the academic environment and a future work environment. Many employers prefer students
who have previous work experience and the Internship provides the experience. Students that
participate in an internship program are generally more confident and more qualified when
seeking future employment

3.2. Methods and Procedures While Working

3.2.1. Methods used for Working in Anbessa city bus enterprise
The methods that we have been using to cope with the tasks performed in different section
includes;
❖ Visual inspection during the task

❖ knowing & using different measuring instruments

❖ Proper material handling

❖ participating in each work tasks attentively

3.2.2. Procedures That We Followed While Performing a Task

To complete the tasks that we were given we have used many procedures according to each
task. These procedures are:
❖ As safety comes first, we put on safety shoes and working suit
❖ Asking the senior technicians what we are going to do
❖ Read the job card and identify the problem
❖ Prepare the required equipment
❖ Work with the technicians to fix the problem which is written on the job card
[Link] tasks in terms of Practical Skills.
When I am first started working in the company, I hadn’t any skill in bus as well as any car
maintenance. even didn’t know how to use hand tools. And also, hardly know how to use
different machines such as lath machine, grinding machine, welding machine drilling machine
shaper machine, press machine and other machines. From these responsibilities we have taken
during the internship period include: -To work with work shop mechanics at every process, to
work on engine and tire recap rooms, to identify any kind of problem and propose solution
with mechanics, identify any work-related problem with workers, keep organization materials

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and secret properly, the organization gives such responsibilities based on their willingness &
no one can force them to do so. Accordingly, they can pick up from your responsibilities if not
properly performed your work.

But, during my internship, I am acquired a lot of practical skills such as air suspension system
completely removing the wheel, hub inner bearings and clean them, overhauling of
differential, inspection and repairing of starter and other spare parts, replacement of parts such
as radiator, using lath machine and its maintenance, door maintenance and many other skills.

I am interlinked our knowledge that we have learned in theory with practical ones. And we
have checked our performance level regarding on how to solve a problem that exists in
practical work. This program helped us to develop our knowledge both theoretically and
practically. Generally, we believe that we have been doing our best at ACBSE because we had
a good communication with our senior mechanics and also other staff working there, we tried
to work effectively on the tasks that we were assigned. We also tried to fulfill the company’s
rules and regulations while we were working there

3.4. Knowledge and Acquaintances Acquired

Internship training delivers have various important outcomes. In addition to improve our
abilities of converting various theoretical knowledge into their real application in practical
world, it also delivers a number of additional benefits like Improving practical skills,
improving theoretical knowledge, improving team playing skills, improving interpersonal
communication skills, improving leadership skills and Understanding work ethics.

3.4.1. Improving Practical Skills

It is the main benefit of internship. Many knowledges we know in theory are there in ACBSE
practically. Therefore, we improve our practical skills by performing different operations as
operations of different machines. We have got a lot of practical experience while we were
trying to troubleshoot and in maintaining during systems come across problem. Also, we have
got an opportunity to work on equipment’s which we have only know theoretically on
material handling as different hoists, hand chains and several transporting equipment’s. We
improved our performances by followings: -

❖ Understanding the instrument & their functions.

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❖ Full confidence understanding of the job

❖ good human relation

❖ decision maker Increased problem-solving and soon.

3.4.2. Improving theoretical knowledge

Some of the theoretical knowledge we gained are; -

❖ Easy to name the different parts of machine tools and equipment.

❖ We become confidential on our theoretical concept what we have learn before.

3.4.3. Improving interpersonal communication

For any individual, communication is an important way of learning, which can be defined
formally as the act, process, or experience of gaining knowledge or skills. Therefore, when we
stay on ACBSE, we improve our communication skill by:

Speaking: asking questions we haven’t understood clearly when they maintain and asking the
challenges they faced in the real practical world as these improve mine ability to overcome
challenges for the future.

Listening: We improve mine interpersonal communication by speaking and listening at a

required time i.e., by speaking when questions are created in our and listening when they
speak. We learned that one full system should work efficiently with union of so many
professionals by cooperating with each other in order to make good and fantastic work.

3.4.4. Improving team skills

Most of the maintenance on ACBSE are accomplished by two mechanics and we were
working with them. Firstly, the mechanics initiate we for team work as they maintain the
vehicle by sharing their knowledge. Thus, we improve our team working skill by several
methods. For a problem held on the vehicle, we try to identify problem and its solution. In
addition, after we have discussed, we will raise questions for the mechanics to elaborate these.
So, team work gave us the opportunity to share what we know with each other and also gave
us opportunity to gain a lot of theoretical and practical knowledge from staffs on the factory
and also from students from another university.

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3.4.5. Improving leadership skill

Leadership is a process of leading the careers of the company. Problems in the company come
in all size, shape and color in different time. Thus, a person who is in the position of
leadership seeks optimal solution to the problems and should be smart enough to manage
those individuals whom he/she is leading. What we gain from the internship regarding
improving leadership is that to inspire workers in to higher levels of team work. There are,
certain things must be known to do that these are:

❖ Know myself and seek self-improvement

❖ Be technical proficient

❖ Seek responsibility and take responsibility for actions

❖ Make sound and timely decisions

❖ Keep workers informally

❖ Develop sense of responsibility in workers

❖ Ensure that takes are understood, supervised

3.4.6. In terms of understanding work Ethics and Related Issues

As worker made to specialize in different fields special codes of conduct were expected from
each worker while we were in the company most of the workers and company’s leader told us
what allowing a good ethics in working areas are: -

❖ Punctuality: - arriving at working place in time.

❖ Honesty: - spending working hours and resource totally on working rather than spending
too much time talking with friends over tea and coffees

❖ Willingness to learn: - Understanding the way things are done at work place and trying to
do it better any person however experienced will learn new things as time passed.

❖ Initiative: - being prepared to see what needs to be done and to do work without always
being asked/told to do it.

❖ Loyalty: - Supporting the employer and do what best for the growth of the organizations.

❖ Maximizing productivity: - The ability to do high quality work, faster and efficiently

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3.4.7. In Terms of Entrepreneurship Skill

Entrepreneurship is a person who sees a good opportunity for a new business and work hard to
make it grow and making it happen. It is very important for the growth of economic
development in one country. The best thing that we got in the factory is how we analyze thing
in our own performing way and improving our attitude. The major characteristics of the
entrepreneurship that we have seen and gained in during internship are: - Self-confident multi-
skilled, Innovative skill, must have a vision, Willingness to take risk and results oriented.

3.5. Problems Encountered During the Internship Period

In our internship we have faced different technical, personal, organizational problems. Those
are Lack of practical skill, Lack of sufficient knowledge, no books and also manuals that used
to develop our knowledge, Lack of sufficient material, Lack of technical skill, Adapting the
technical workers during the first two weeks, sometimes we want to take a photo and video at
the workshop, but the company didn't allow cell phone during work in the workshop, the
technicians used the Italian names for the car components and tools so we did not understand
each other for a little and also The distance between the work place and the home.

We solve this problem by:

❖ Working on break and tea time because no machine is working on break time so we can
use freely those machines

❖ By finding material from waste and un useful materials

❖ By searching and also reading books

❖ Gathering, Importing, accepting information’s from shop technicians

❖ By Repeating the previous work

3.6. Contributions
During internship period have been done the above activity properly and also can be done a
project which is pneumatic compressor during the internship period the anbessa city bus
service enterprise in the primitive maintenances shop the pneumatic compressor doesn’t work,
this compressor in this shop have been use so many purposes this are; for clean the depurators
(air cleaner), for inflating the wheel, for clean the engine dust. Soon to solve this problem we

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are maintenances this pneumatic compressor with in group with use material collect from old
bus that can’t works, work shop and older pneumatics compressor and can be done on work
shop in different machine for example drilling machine, shaper machine, lathe machine,
grinding and also welding.

Figure 3. 1 The Flow of the pneumatic compressor.

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Then the head the technical manager see the compressor, we are present the work the
technical director giving advice to the work finally the director given acknowledgement letter.

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CHAPTER FOUR

4. PROJECT TITLE: DESIGN OF PNEUMATIC OPERATED

SHEARING MACHINE
4.1. INTRODUCTION
Pneumatics, from the Greek (pneumatikos, coming from the wind) is the use of pressurized
gases to do work in science and technology. Pneumatic was first documented by Hero of
Alexandria in 60 A.D., but the concept had existed before then. Pneumatic product represents
a multi-billion-dollar industry today.

Pneumatic shear machine is used to cut sheet metal at a required profile by using compressed
air, and to increase the production rate. In this type of machine high pressure air is used as a
working fluid for the transfer of power and motion. This machine can be easily designed using
standard cylinders & other components like release/port/direction control valves, flow
regulator, piston and air compressor. Controlling of this machine is easy. Because of
compressible air, the equipment is less likely to be damaged by shock. There are numerous
types of cutting machines are available in engineering field, but we are interested to introduce
pneumatic system in sheet metal cutting machine. The operation of the unit is simplified to a
few simple operations involving a cylinder block and piston arrangement. The main function
of Pneumatic shearing machine is to cut thin metals by pneumatic power.

In the pneumatic shearing machine variable forces can be obtained by adjusting the pressure
of the compressed air. This equipment can also be used to cut larger thickness sheets with
some additional accessories are required. Pneumatic fluids are considered gases and are
compressible. Pneumatic systems are not complete circuits. Air is used to do work and is then
dumped into the atmosphere. Since the mechanism is so simple and versatile it can be handled
by any operator, constriction of the unit is very simple. Handling the machine is easy and
smooth operation is achieved. Pneumatic is one of the technologies now a days widely using
in automobile industries (particularly in Flexible manufacturing systems) to assemble the parts
of the automobiles.

In shearing operation as the punch descending up on the metal the pressure exerted by the
punch first cause the plastic deformation of the metal. Since the clearance between the punch

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and the die is very small, the plastic deformation takes place in a localizing area and the metal
adjacent to the cutting edges (Lamse, 2017).

Sheet Metal
Sheet metal is simply a metal formed into thin and flat pieces. It is one of the fundamental
forms used in metal working and can be cut and bent into a variety of different shapes.
Countless everyday objects are constructed of the material. Thicknesses can vary significantly,
although extremely thin thicknesses are considered foil or leaf, and pieces thicker than 6 mm
(0.25 in) are considered plate. Sheet metal is available in flat pieces or as a coiled strip. The
coils are formed by running a continuous sheet of metal through a roll slitter. The thickness of
the sheet metal is called its gauge. Commonly used steel sheet metal ranges from 30 gauge to
about 8 gauge. The larger the gauge number, the thinner the metal. Gauge is measured in
ferrous (iron based) metals while nonferrous metals such as aluminum or copper are
designated differently; i.e., Copper is measured in thickness by Ounce (Muhammed Ali Ablt,
Ala Qattawi, 2017).

There are many different metals that can be made into sheet metal, such as aluminum, brass,
copper, steel, tin, nickel and titanium. For decorative uses, important sheet metals include
silver, gold and platinum (platinum sheet metal is also utilized as a catalyst.)

Sheet metal also has applications in car bodies, airplane wings, medical tables, roofs for
buildings (Architectural) and many other things. Sheet metal of iron and other materials with
high magnetic permeability, also known as laminated steel cores, has applications in
transformers and electric machines.

4.2. Problem Statement

Many types of sheet metal shearing machines are used by different users and sheet producing
industries. During our internship in Anbessa city bus service enterprise we observed that most
shearing machines are powered by manually (by hand lever arm) which have a capability to
produce relatively small quantity of sheets within an hour and by persons. It results is too
tedious and requires high number of human power and waste much more time to produce a
specific number of sheets and hence reduce the rate of production and safety problem. Hence
to overcome the above-mentioned problems we proposed to design and make a design of
shearing machines as a modification of the manual shearing machine.
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4.3. Objective of the Project

4.3.1. General object
The general object of this project is to Design of pneumatic operated shearing machine for
cutting sheet metal
4.3.2. Specific object
The specific objective of this project: -
❖ To Design of pneumatic cylinder
❖ To Design of piston
❖ To Design of shearing blade cutters
❖ To Design of base plate
4.4. Scope of the project
This pneumatic shearing machine cuts a sheet metal up to 4 mm thickness and it works either
using internal combustion engine or electricity to drive the compressor. The shearing force
can be controlled by increasing or decreasing the compressed air.

4.5. Significance of the project

The Significance of the project is easy maintenance and repair. Air is available everywhere
and can be stored easily. High speed operation. Relatively low cost is produced. Continuous
operation is possible without stopping. All movements are pneumatically operated. Clean and
non-pollutant. Technology can be easily learned. No fire hazard problems due to overloading.
to reduce the man power. To fulfill need of mass production in shortest possible time. To
provides work practically in less space.

4.6. Limitation of the project

❖ Silencer must be used while compressing the air.
❖ High torque cannot be obtained.
❖ Load carrying capacity is low.
❖ The project is not supported with prototype.
4.7. Literature Review
Most of the earlier pneumatic control systems were used in the process control industries,
where the low-pressure air of the order 7-bar was easily obtainable and give sufficiently fast
response. Pneumatic systems are extensively used in the automation of production machinery

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and in the field of automatic controllers. For instance, pneumatic circuits that convert the
energy of compressed air into mechanical energy enjoy wide usage, and various types of
pneumatic controllers are found in industry. Certain performance characteristics such as fuel
consumption, dynamic response and output stiffness can be compared for general types of
pneumatic actuators, such as piston-cylinder and rotary types ([Link], [Link],
[Link] , 1998).

The final decision on the best type and design configuration for pneumatic actuator can be
made only in relation to the requirements of a particular application. The pneumatic actuator
has most often been of the piston cylinder type because of its low cost and simplicity (Hazem
I. Ali, Samsul Bahari B Mohd Noor, S.M. Bashi, Mohammad Hamiruce Marhaban, 2009).

The pneumatic power is converted to straight line reciprocating and rotary motions by
pneumatic cylinders and pneumatic motors. The pneumatic position servo systems are used in
numerous applications because of their ability to position loads with high dynamic response
and to augment the force required moving the loads. Pneumatic systems are also very reliable.
The open literature surveyed showed a wide spectrum of new applications of pneumatic
servos such as milling machines, robotics, and advanced train suspension. Therefore, the
surveyed literature reported is subdivided into three main groups. The first group is concerned
with various applications of pneumatic actuators.

The second group includes the theoretical, experimental approaches for modeling the
pneumatic actuator. The third group is related with the control strategies applied to pneumatic
actuators. In shearing or cutting operation as or blade descends upon the metal, the pressure
exerted by the blade first cause the plastic deformation of the metal. Since the clearance
between the two blades is very small, the plastic deformation takes place in a localized area
and the metal adjacent to the cutting edges of the blade edges becomes highly stressed, which
causes the fracture to start on both sides of the sheet as the deformation progresses and the
sheet is sheared (Dinesh Lamse1, Akash Navghare2, Rahul Chavhan3, Ajay Mahawadiwar4,
2017).

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4.8. Types of shearing machine

4.8.1. Hydraulically operated:
Here the lowering and raising of the header is carried over using the hydraulic piston and
cylinder arrangement. To actuate the piston and cylinder, the oil is allowed to enter the
cylinder from front or the back side of the piston. But the oil is comparatively costlier and its
leakage may cause so many problems.

4.8.2. Spring operated:

The working of spring-operated machine is similar to the rack and pinion operated machine
but differs from it in construction. Here the lowering and the raising of the heating handle are
carried out manually and it requires too much pressure for its operation and also there is
possibility of having damage to the work piece if not handled carefully.

4.8.3. Rack and pinion operated:

Here the lowering and the raising of the header are carried out manually using the rack and
pinion arrangement. In this case the required pressure is applied manually using direct hand
pressure on the rack using pinion and lever arrangement. Since the machine is robust and
requires large pressure, hence it is not suitable.

4.8.4. Pneumatically operated:

Here the advancement of the header is carried out in the upward and the downward direction
using the pneumatic double acting piston and cylinder unit arrangement along with the foot
operated direction control valve. In this type of machine high pressure air is used as the
working fluid for the transfer of power and the motion.

In literatures, efforts have been made to design and analysis of pneumatic operating machine
for cutting sheet metal, pneumatic device are used in many industrial applications generally
appropriate for application involving less force than hydraulic application, and typically less
expensive than electric application, most pneumatic device are designed to use clean dry air as
an energy source. The actuator then convert that compressed air into mechanical motion the
type of motion produced depend on the design of the actuation. Pneumatic is employed in a
variety of settings. little effort has been reported on project even though problem have not
been investigated comprehensively and exhaustively by previous studies thus, upgrading
manual cutting machine in Anbessa city bus enterprise service.
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4.9. Methodology
Methodology is the path or flow of pattern to excited this project and how we solve our
problem of statement.

Figure 4. 1 Methodology the project

4.10. Working principle
The pneumatic sheet metal cutting is supported by a table includes with support arms to hold
the sheet. The table also includes the two-way directional control valve. The two-way
directional control valve is also known as solenoid control valve. We used two-way
directional control valve that is connected with the compressor by air pipe. The compressor

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has a piston for a movable member. The piston is connected to a crankshaft, which is in turn
connected to a prime mover. At inlet and outlet ports, valves allow air to enter and exit the
chamber. When the compressor is switched ON, the compressed air is flow to inlet of the
pneumatic cylinder. The sheet is placed between the upper and the lower blade. The lower
blade remains stationary while the upper blade is forced downward. The upper blade is
slightly offset from the lower blade, approximately 5 – 10% of the sheet thickness. Also, the
upper blade is usually angled so that the cut progresses from one end to the other, thus
reducing the required force. When the pneumatic hand operated solenoid forward direction.
The upper blade which are then forced against the sheet, cutting the material. When the
pneumatic hand operated lever is moved backward, the upper blade will come to the original
position (i.e., the upper blade will move upwards). After the material is cut, adjust the
pneumatic hand operated solenoid valve to the mid position (i.e., normal position) and then
the compressor is switched off.

Figure 4. 2 General layout

Initially the Air compressor is started and allowed the receiver tank air pressure to reach up to
12 bar. The supply air is then passed to the manifold though FRL unit to condition the air and
eligible to industrial use. From the manifold a separate supply for the machine is taken out and
given to ON-Off switch so as to operate the machine at will without interrupting the running
of compressor. Then the pipe carries compressed air first to machine’s directional control
valve. At position ‘A’ shows the non-actuated circuit diagram. At this position the piston is
steady and locked. All ports are in closed condition.

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Figure 4. 3 Position ‘A’ non-Actuated Circuit Diagrams

Figure 4. 4 DCV Valve in Left Hand Position.

At position ‘B’, the Dc valve is at left hand position as shown in figure. The cap end port &
pressure port get connected to each other and the rod end port gets connected to the exhaust
port. The compressed air comes in the cap end of the cylinder and pushes the piston out wards.
The air already present in the rod end side is pushed out of the cylinder.

When the piston moves outward, the force is transmitted through the connecting link and the
upper blade moves downward. Before the actuating DC valve, the sheet is inserted in between
the upper & lower blades. As upper blade moves downward, the stress is generated in the
sheet metal and goes beyond ultimate shear stress of sheet metal. And thus, the shearing action
takes place.

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Figure 4. 5 DCV Valve in Right Hand Position.

Now the DC valve is operated to come at position ‘C’, as shown in figure. The rod end port &
pressure port get connected to each other and the cap end port get connected to the exhaust
port. The compress air comes in the rod end of the cylinder and pushes the piston inward. The
air already present in the cap end side is pushed out of the cylinder.

The sheet metal is either again inserted for further cutting in case of larger pieces the small cut
pieces are removed and the next sheet is inserted to cut.

Figure 4. 6 Position ‘C’ non-Actuated Circuit Diagrams

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Figure 4. 7 DCV Valve back to Position ‘A’.

Figure 4. 8 General Layout of Pneumatic Shearing Machine.

4.11. Material Selection
The machine is basically made up of mild steel. Reasons
1. Mild steel is readily available in market
2. It is economical to use.
3. It is available in standard sizes.
4. It has good mechanical properties i.e.; it is easily machine able.
5. It has moderate factor of safety, because factor of safety results in unnecessary wastage
6. of material and heavy selection. Low factor of safety results in unnecessary risk of
failure.
7. It has high tensile strength.
8. Low co-efficient of thermal expansion.

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Properties Of Mild Steel

M.S. has carbon content from 0.15% to 0.30%. They are easily biddable thus can be hardened
only. They are similar to wrought iron in properties. As the carbon content of the steel
increases, the ultimate tensile and compressive strength of the steel increases. They can be
easily gas welded or electric or arc welded. With increase in the carbon percentage weld
ability decreases. Mild steel serves the purpose and was hence was selected because of the
above purpose.

4.12 Design of Components

4.12.1. Specification
❖ Compressed air pressure = 20bar=20*105 pa
❖ Cylinder type – double acting
4.12.2. Design of Cylinder
Pneumatic cylinders (sometimes known as air cylinders) are mechanical devices which use the
power of compressed gas to produce a force in a reciprocating linear motion. In pneumatic
cylinder the compressed air is used as working fluid and converts it into kinetic energy as the
air expands in an attempt to reach atmospheric pressure. This air expansion forces a piston to
move in the desired direction.

Figure 4. 9 Pneumatic Cylinder

Material selected is mild steel
σy=324Mpa
E=200Gpa
A, Force produced by the compressed air in the cylinder is given by

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𝐹 = 𝑃⨉𝐴
But 𝐴 = 𝜋𝑟 2
Assume the radius of the cylinder D = 100mm = r=50mm. = 0.05m
𝐴 = 𝜋(0.052 )
𝐴 = 7.854⨉10−3 𝑚2
Then calculate the force

𝐹 = 𝑃⨉𝐴
𝐹 = 20⨉105 ⨉7.85⨉10−3
𝐹 = 15700𝑁
This force is the maximum force which must be greater than the cutting force (Fc). The
cutting force is given by:

𝐹c = 𝐿⨉𝑡⨉𝜏max

Where: τmax– is the maximum shear strength of sheet metal.

t – The thickness of the sheet metal.
L – The length of sheet metal.
𝜎𝑦
τmax = 2𝑛

Where; n is the factor of safety Take n=3

σy=324Mpa
324
τmax = 2∗3

τmax = 54 Mpa

Assume, Length=90mm Thickness = 2mm

Fc =L⨉t⨉τ max

Fc = 0.09⨉ 0.002⨉ 54 ⨉106

Fc =9720N

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𝐹 15700
i.e., Fc ⨉100 = ⨉100 = 161.5%
9720

This is the force required to cut the sheet metal which is less by 161.5% from the
initial force.
B. Determine the thickness of the cylinder.
The cylinder is subjected to hoop stress (circumferential stress) (R.S. KHURMI,J.K. GUPTA,
2005).

Figure 4. 10 cylinder under hoop stress

The thickness of the cylinder is given by:
𝑝⨉𝑑
t= 2𝜎1

where p – Pressure of the cylinder

d – Diameter of the cylinder
σ1 – The hoop stresses the hoop stress is 0.8 times the yield strength of the material
i.e., =0.8σy
σ1=0.8⨉324=259.2Mpa
Then t=20⨉105 pa⨉0.1m/ (2⨉259.2) Mpa = 0.385mm
t=0.385mm
For safety take t=2mm
4.12.3. Design of piston
The piston is fitted in the cylinder block and reciprocates inside. When the solenoid valve
supplies the air in the front end of the piston, the piston is pushed forward. This moves the
hacksaw and the cutting stroke takes place. Then the solenoid valve supplies air to the rear end

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of the piston. The pressure is same but the contact area is less due to the presence of the piston
rod and pushes the piston at a greater pressure thus resulting in a fast return stroke.

Figure 4. 11 Piston
Material selected for piston is milled steel Fe250.
The compressive strength of Fe250 is about 140 – 160Mpa.
The piston is subjected to compressive stress The length of the piston L=500mm.
Force applied on the piston is the force of the cylinder F=15700N.
Now let’s find the diameter of the piston
𝐹 𝜎𝑐
σall = 𝐴 = 𝑛

Where n - is factor of safety

σc - is compressive strength
σall – is allowable compressive stress
Take σc =140Mpa n=3

140
σall = = 46.67Mpa
3
𝐹 𝐹
σall= 𝐴 , A= 𝜎𝑎𝑙𝑙
15700
A= = 336.4𝑚𝑚2
46.67
π𝑑2
But A= 4

(4⨉336.4)⁄
𝑑 = √4𝐴⁄𝜋 = (√ 𝜋 = 20.69mm
Take d=25mm for safety issue.

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Check the piston from the buckling effect

Buckling happens when a force presses on a cylinder structure and makes it collapse. Too
great a load on the columns can cause buckling. A cylinder strut under the action of than axial
load will fail by buckling.

By using Rank line formula: Fcr= σc ×A/1+1/a(l/k)2

Where Fcr - critical force

L –Length of piston
K – Radius of gyration
a – is Rank line constant, a=7500
σc - is the compressive strength of the material
K= √𝐼 ⁄𝐴
Where I – is moment of inertia
A – is area of the piston
I= 𝜋𝑑4 ⁄64 = 𝜋(25)4 ⁄64 = 19170𝑚𝑚4
I = 19170𝑚𝑚4
A = 𝜋𝑑2 ⁄4 = 𝜋(25)2 ⁄4 = 480.87 𝑚𝑚2
K = √𝐼 ⁄𝐴 = √19170⁄480.87 = 6 𝑚𝑚
Fcr = (σc ×A)/[1+1/a(L/k)2]
= 140*480.87/1+1/7500(500/6)2
= 34956N
Therefore Fcr =34956N, the force acting on the piston is less than the critical force (Fcr), i.e.,
Fcr >F, 34956>15700N Therefore the piston will not be buckled.

4.12.4. Design of Pins

Pin is used to connect the blades with the blade holder (base) of the machine. The force acting
on the pin is tensile force.

Where Dh - Diameter of pin head

Dp - Diameter of pin F - Force acting on the pin.

Material selected for pin is low alloy steels

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Yield strength (σy) = (400 – 1100) Mpa Take σy=900Mpa

Shear stress τmax = σy⁄2n Where n- is factor of safety Take n=3

τmax = 900⁄2(3) = 150Mpa

τmax = 150Mpa
F = τmax× 𝐴
A = 𝐹 ⁄ τmax but, D = √4𝐹 ⁄𝜋τ𝑚𝑎𝑥 = √4(15700)⁄𝜋(150)
D = 11.5 mm
4.12.5. Design of Shearing Blade Cutters
A blade is used to cut the sheet metal in a desired dimension. Here we are using high speed
steel blades to cut the sheet metal.

Figure 4. 12 Cutter Blade

Material for blade, carbon steel with density 7.83×103kg/m3

The figure below shows the metal sheet shearing operation. A punch (or moving blade) is
used to push the work piece against the die (or fixed blade), which is fixed. F1 and F2 are the
shearing forces.

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Figure 4. 13 Movable and Fixed Cutter Blade.

Shearing angle α= sin−1(tmax)
Therefore, tan−1 (2⁄485.4) =0.23°, is minimum shear angle.
Where tmax - is the maximum sheet metal thickness =2mm
Ls2=85%* blade length
Ls2 - is maximum shear length,100mm Since Lb= 100mm/0.85=117.64mm.
To determine the maximum shear angle, αmax x0007
tan (αmax) =strong length/shear length =200/4845=0.413
αmax= tan−1(0.413) = 22.43°
To obtain the weight (Wb) of shearing blade apply,
Wb =Mb*g where Mb -The mass of blade
Mb = Vb*ρb and also Wb -The weight of bl
Vb = Lb*b*tb ρb -The density of blade =7.83*103 kg/m
Vb -The volume of blade
g - is the acceleration due to gravity=9.81m⁄𝑠 2
tb - The thickness of blade =7mm
Lb–The length of blade
Therefore, Vb = Lb×b×tb = 90×50×7 = 3.15× 10−3 m3
Mb = 3.15× 10−3 m3 ×7.83×103kg/m3
Mb =1.56kg Wb = Mb×g = 1.56kg×9.81m/s2
Since blades are two, T=2×1.56kg×9.81m/s2
Total mass(T)=30.4kg
Shear Blade Clearance

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The clearance between upper and lower blade determines the quality of cut edge, and can
influence shearing force. The Limit to the thickness range which can be accommodated by a
single shear are:
❖ Clearance set a range 0.05-0.07 mm for sheet metal thickness 0.04-0.08 mm.
❖ For a sheet metal thickness 1.0-2.0 mm clearance setting of 0.15mm since our sheet metal
thickness is 2mm, set clearance as 0.15mm.
Air Consumption and Volume Flow Rate
Let, D = bore diameter in cm
d = piston diameter in cm
L = stroke length in cm
P = air pressure in bar
Free air consumption in liters for forward stroke.
C = {𝜋⁄4 × D2 (p+1) ×L}/1000
C = (π (100)2× (15+1) ×20cm/1000)/4 = 2512 litter
C = 2512 Litter
Free air conception in the return stroke
C = {π⁄4 × (D2 -d 2) × (p+1) × L⁄1000
C = π (1002 -202)16× 20⁄4000 = 2411.5 litter
Hence for one complete cycle of operation for this cylinder, the free air consumption will
be C= (2512+2411.5=4923.52 litters in one cycle). The speed of a pneumatic cylinder is
dependent on the load, air pressure, and length of tubing between cylinder and control
valve, diameter of tubing and the flow rate of the control valve. The average speed of a
standard cylinder is about 0.1 - 1.5 m/sec. So, taking 0.5m/s

Free air consumption per minute (Q) =free air consumption per cycle times stroke per
minute i.e., Q= 4923.52×1/0.0333 = 164L/minute

4.12.5. Selection of Directional Control Valve

The directional valve is one of the important parts of a pneumatic system. Commonly known
as DCV, this valve is used to control the direction of air flow in the pneumatic system. The
directional valve does this by changing the position of its internal movable parts inside a
cylinder. This moving part is called spool. The spool (sliding type) consists of lands and
grooves. The lands block air flow through the valve body. The grooves allow oil or gas to

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flow around the spool and through the valve body. There are two fundamental positions of
directional control valve namely normal position where valve returns on removal of actuating
force and other is working position which is position of a valve when actuating force is
applied.

Table 4. 1 Standard Valve Size

Piston diameter Valve port size Normal width(mm) Flow rate(L/minute)

To 12 M3 1.5 80

>12-25 M5 2.5 To 200

>25-50 G 1/8 3.5 To 500

>50-100 G¼ 7 To 1140

>150-200 G½ 12 To 3000

>200-320 G 1/4, G1 18.7 To 6000

Since our piston diameter is 20mm M5 valve port is selected.

This valve was selected for speedy operation and to reduce the manual effort and also for the
modification of the machine into automatic machine by means of using a solenoid valve. A
solenoid is an electrical device that converts electrical energy into straight line motion and
force. These are also used to operate a mechanical operation which in turn operates the valve
mechanism. Solenoids may be push type or pull type. The push type solenoid is one in which
the plunger is pushed when the solenoid is energized electrically. The pull type solenoid is one
in which the plunger is pulled when the solenoid is energized. The name of the parts of the
solenoid should be learned so that they can be recognized when called upon to make repairs,
to do service work or to install them.

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Figure 4. 14 DCV
4.12.6. Design of Bolt
The material for this Bolt is plain carbon steel type which is available with the following
mechanical property.
❖ Yield strength = 310 N/mm2
❖ Tensile strength=139N/mm2
❖ Compressive strength=604N/mm2
❖ Shear strength=192N/mm2
❖ Thickness of bolt head t=0.5d
❖ Let we take factor of safety (n) = 2 We know that the allowable tensile stress
𝛿𝑎𝑙𝑙 = 𝛿𝑢𝑙𝑡⁄𝑛 = 139⁄2 = 69.5N/mm
𝞽all = τ𝑢𝑙𝑡⁄𝑛 = 192⁄2 = 96N/mm
Since the bolt is in double shear, therefore cross-sectional area of the bolt under shearing
Shear strength of the bolt.
4.12.7. Design of nut
The material for this nut is plain carbon steel type which is available with the following
mechanical property.
❖ Yield strength = 310 N/mm2
❖ Tensile strength= 139 N / mm2
❖ Compressive strength = 604 N/mm 2
❖ Shear strength = 192 N/mm2
❖ Allowable bearing pressure = 17.5N/mm2
❖ Factor of safety (n) = 2

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Figure 4. 15 Nut
We know that the allowable tensile
𝛿𝑎𝑙𝑙 = 𝛿𝑢𝑙𝑡⁄𝑛 = 139⁄2 = 69.5𝑀𝑝𝑎
𝜏𝑎𝑙𝑙 = 𝜏𝑢𝑙𝑡⁄2 = 192⁄2 = 96 𝑀𝑝𝑎
From table 8.1 the pitch for our selected diameter is 2 mm and the bolt designation is M15x2
By using the value of the pitch from (table 8.1) P = 2mm
Nominal diameter will be Dn
Dn = D-P=10mm-2mm=8mm
To calculate number of teeth
𝜋 3000
N =𝑝⁄{ 4 [ 𝑑 2 + 𝑑𝑛2 ] × 𝑝𝑏} = 𝜋[ = 6.066 say 6 teeth
102 − 82 ]×17.5}
4

Also, the height of nut will be considered the product of the pitch and number of threads.
H = P x n=2x6=12mm
The width of nut(w) is taken as:
W=1.5dn=1.5x8=12mm
to calculate maximum shear stress in the nut:
𝑝 3000 𝑝 2
𝜏𝑚𝑥𝑎 = = = 20 𝑀𝑝𝑎 where t = 𝑛 = 2 =1
𝜋𝑛𝑑𝑐𝑡 𝜋×6×8× 1

Which is much less than 155N/mm2 (so the design is safe).

4.12.8. Design of base plate
All the components of the machine are mounted on the base. It withstands the vibrations
encountered during machining. All the components of the machine are mounted on the base. It
withstands the vibrations encountered during machining.

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Figure 4. 16 Base Plate

Assume P = 9230 N, L =650 mm, B = 250 mm, H = 600 mm

p×L
Moment, M = 4

M = (9230×650)/4 =1499875N-mm

Z = (B× 𝐻 2 ) /6 = (250× 6002 ) /6 = 15000000 mm³

𝛿𝑏 = M/Z = 1499875/15000000 = 0.199N/mm²

The permissible stress for cast steel is 130 N/mm² and it is greater than =0.009464 N/mm2
bottom plate design is safe.
4.12.9. Flexible Hose:
The flexible hoses connect the solenoid valve and the cylinder block. Hoses are made of in
layer of elastomer (or) synthetic rubber and braided fabric which takes up the higher pressure.
If the hose is subjected to rubbing, it should be enclosed in a protective sleeve.

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Figure 4. 17 Hose
4.12.10. Pneumatic Compressor
An air compressor is a device that converts power (using an electric motor, diesel or gasoline
engine, etc.) into potential energy stored in pressurized air (i.e., compressed air). By one of
several methods, an air compressor forces more and more air into a storage tank, increasing
the pressure. When tank pressure reaches its upper limit the air compressor shuts off. The
compressed air, then, is held in the tank until called into use. The energy contained in the
compressed air can be used for a variety of applications, utilizing the kinetic energy of the air
as it is released and the tank depressurizes. When tank pressure reaches its lower limit, the air
compressor turns on again and re-pressurizes the tank.

Figure 4. 18 Pneumatic Compressor

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4.13 Cost Analysis

Table 4. 2 Cost Estimation Table

Components Number of components Price [in Birr]

Air compressor 1 40,000

Cylinder 1 2700

Piston 1 1000

Valve 2 2000

Hose 2 700

Bolt 28 560

Nut 28 350

Cutting blade 2 500

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Cylinder clamp 2 2000

Cylinder holder 1 2500

Blade clamp 1 1500

Total 69 51,310.00

CHAPTER FIVE
CONCLUSION AND RECOMMENDATION
5.1 Conclusion
Generally, in this four month we gain more knowledge especially when we see in terms of
improving our personal skills, we can easily see the difference between theory and practical
work. When we do practical work in Anbessa City Bus Service enterprise, we can easily see
each and individual thing so this makes better to improve our personal skills. When we see in
terms of upgrading our theoretical knowledge, the knowledge that we know in theory only is
not enough but when we see the theory in practical, it is unforgettable so this makes to
upgrade our theoretical knowledge and when you look in terms of work ethics you learn to be
punctual and to work your work properly. In ACBSE there are different workshops; machine
shop, body shop, maintenance shop. In each shop different working activity is done. Such as
repairing parts, assembling & disassembling process, change wear out parts, machining differs
parts of motor. We have designed simple pneumatic operation sheet metal shearing machine
to solve the problem, Material wasting, Shortage of sheet metal shearing process, decrease
labor force, improve safety, increase productivity, All the components are checked its strength
according to carrying capacity. So, the design of simple pneumatic operation shearing
machine is capable of withstanding the applied load. The material selected for each part is
available in the market in their standard. It also achieves its maximum and minimum cutting
thickness

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5.2. Recommendation
we strongly recommend that the range of the cutting thickness can be increase by arranging a
high-pressure compressor and installing more hardened blades. It is batter to manufacture
machine by introducing the project into the Enterprise. It is batter to fully automated it will
increase the performance of the machine and safety of operated.

REFERENCES
Dinesh Lamse1, Akash Navghare2, Rahul Chavhan3, Ajay Mahawadiwar4. (2017). Design
and Fabrication of Pneumatic Sheet Metal Cutting and Pneumatic Sheet Metal
Bending Machine. International Research Journal of Engineering and Technology
(IRJET), 04, 2337- 2342.

Hazem I. Ali, Samsul Bahari B Mohd Noor, S.M. Bashi, Mohammad Hamiruce Marhaban.
(2009). Mathematical and Intelligent Modeling of Electropneumatic Servo Actuator
Systems. Australian Journal of Basic and Applied Sciences(1991-8178), 3663-3671.

[Link], [Link], [Link] . (1998). Mechatronics '98: Proceedings of the 6th UK

Mechatronics Forum International Conference. In Mechatronics (p. 918). Sweden:
Elsevier.

Lamse, D. (2017). Design and fabrication of pnnumatic sheet metal cutting and pneumatic
sheet metal bending machine. International Research Journal of Engineering and
technology, 2337-2341.

Muhammed Ali Ablt, Ala Qattawi. (2017). Numerical simulation of sheet metal forming. The
international Journal oa Advance manufacturing technology, 1235–1250.

R.S. KHURMI,J.K. GUPTA. (2005). A TEXTBOOK OF MACHINE DESAIGN .

RAMNAGAR: EURASIA PUBLISHING HOUSE (PVT.) LTD.

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APPINDEX

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