DD

DIRE DAWA
UNIVERSITY

AKAKI BASIC METAL INDUSTRY

INTERNSHIP REPORT

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DD

DURATION: - FROM OCT.24/2011 UP TO FEB.10/2012.

PREPARED BY: - YARED SEIFU WOLDEYOHANNIS

ID NO./R/944/01 MENTOR NAME: - BELAWGIZEW NIGUS

CAMPANY ADVISOR:-ALEMAYEHU FIKERE

SUBMISSION DATE:
-FEB.27/2012.

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 Acknowledgements
First of all, I would like to tank for our university to get this internship training.
Next I would like to tanks to Akaki Basic Metal Industry; which gives the chance to do work with
working man (laborer). I would like to tanks to instructor and mentor Belawgizew, Nigus
Capitan (shamble) Jamal (Manager of personnel Administration and Training), MetoAleqa
Behylu (The second manager of foundry) which gives the computer, Ato Alemayehu Fikere he is
My supervisor, Ato Million Assefa (Manager of pattern division), Ato Woubeshet (Manager of
non-ferrous) which is gives the information about My project that is Tambling machine, and Ato
Abebe (Manager of mechanical maintenance). Finally I would like to thank all the management
and staff of the company help me work and useful information.

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 Executive Summary
Akaki Basic Metal Industry is the largest engineering company in the country;
which has different section there are, manufacturing (PPC (Production Process Control) section,
Design and method, Pattern shop, Core section, Hand mould, Ferrous foundry, Non-ferrous
foundry, Cast-finishing, Mechanical work shop, Forging shop, and Heat treatment), Quality,
Sales, Finance (Cost and Budget). All each sections are net work to each other by work process.
This training used to develop personal skill made me awareness to make a product increased
practical skills spatially pattern making in foundry shop, how to change the material object in to
pattern. Generally this internship training very important and helps used to how to change
theoretically part into practical parts.

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 Table of contents
Contents
I. Acknowledgements --------------------------------------------------------------i
II. Executive summery ---------------------------------------------------------------ii
III. List of figures and Tables---------------------------------------------------------vi
1, Chapter one
1.1, History of Akaki Basic Metal Industry-----------------------------------1
1.2, Main customers-------------------------------------------------------------1
1.3, Main products--------------------------------------------------------------2
1.3.1, Production capability---------------------------------------------------4
1.4, over all organizational structure and flow chart-----------------------6
2, Chapter two
2.1, over all internship experience---------------------------------------------9
2.2, working flow of Akaki Basic Metal Industrial -------------------------10
2.3, Foundry shop --------------------------------------------------------------10
2.3.1, Pattern and pattern making -----------------------------------------11
2.3.1.1, Pattern allowance ------------------------------------------------11
2.3.1.2, Advantages and disadvantages ---------------------------------12
2.3.1.3, Pattern storage and their machines----------------------------13
2.3.1.4, Process of Main carrier head shaft pattern ------------------14
2.3.1.5, Work piece on pattern shop ------------------------------------15
2.3.2, Mechanized molding-----------------------------------------------16
2.3.2.1, Mechanized molding Process ----------------------------------16
2.3.3, Hand molding ------------------------------------------------------17
2.3.3.1, Hand molding Process -----------------------------------------17
2.3.4, Core shop -------------------------------------------------------------19
2.3.4.1, Core shop Process ----------------------------------------------19
2.3.5, Sand mold features --------------------------------------------------20
2.3.6, Mold paint and preparation ---------------------------------------20
2.3.7, Foundry sand, binders, sand laboratory and sand system-----------21
2.3.7.1, Sand --------------------------------------------------------------------21
2.3.7.2, Sand laboratory-------------------------------------------------------21
2.3.7.3, Sand system -----------------------------------------------------------25
2.3.8, Cleaning of cast products ------------------------------------------------26
2.3.9, Melting practice -----------------------------------------------------------29
2.3.9.1, In ferrous foundry -----------------------------------------------------29
2.3.9.2, In non-ferrous foundry -----------------------------------------------30
2.3.9.3, Process of furnace charge -------------------------------------------31
2.3.10, Shot blast (Pang born) machine ------------------------------------34
2.3.10.1, Process of shot blast ---------------------------------------------34
2.4, Mechanical work shop ------------------------------------------------------36
2.4.1, Electro plating section ---------------------------------------------- ---37

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Prepared By:-Yared Seifu
 2.4.2, Hand tools and cutlery section ---------------------------------------- 38
2.4.2.1, Thread roller machine ----------------------------------------------38
2.4.3, Milling section ------------------------------------------------------------38
2.4.4, Lathe section --------------------------------------------------------------38
2.4.5, Gear hobbling section ---------------------------------------------------38
2.4.5.1, Bevel gear machine --------------------------------------------------39
2.4.5.2,-Hobbling machine ---------------------------------------------------39
2.4.5.3, Slotting machine -----------------------------------------------------39
2.4.6, Heavy duty section -------------------------------------------------------39
2.4.6.1, Plano milling machine ----------------------------------------------40
2.4.6.2, Horizontal lathe machine -------------------------------------------40
2.4.6.3, Vertical lathe machine ----------------------------------------------40
2.4.6.4, Copy machine --------------------------------------------------------40
2.4.7, Surface grinding section -------------------------------------------------41
2.5, Forging shop --------------------------------------------------------------------41

3, Chapter Three
3, over all benefits of internship-----------------------------------------------46
3.1, improving our practical skills---------------------------------------------46
3.2, upgrading our theoretical knowledge------------------------------------46
3.3, improving team playing skills-------------------------------------------- 47
3.4, Leader ship skills----------------------------------------------------------- 47
3.5, working ethics----------------------------------------------------------------47
4, Chapter four
4, Conclusion and recommendation-------------------------------------------48
4.1, Conclusion-------------------------------------------------------------------48
4.2, Problems and recommendation-------------------------------------------48
5, Chapter five
5.1 Project on Tumbling machine--------------------------------------------50
5.2 Objective --------------------------------------------------------------------50
5.3 Design procedure-----------------------------------------------------------50
5.4 Challenges in our project--------------------------------------------------54
5.5 Project 0n sand washing machine----------------------------------------54
VI. References ------------------------------------------------------------------56

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 List of figures
Figures
Fig-1---Main products----------------------------------------------------------------3
Fig-2---Over all organization structure---------------------------------------------6
Fig-2(a)Quality section structure-------------------------------------------------6
Fig-2(b)--Marketing and supplies department structure--------------------------6
Fig -2(c) ---Manufacturing department structure----------------------------------7
Fig-2(d) ---Administration and HRD department structure----------------------8
Fig-2(e) ---Finance department structure-------------------------------------------8
Fig-3---Main carrier head shaft pattern -------------------------------------------15
Fig-4---Hand molding (roller) ------------------------------------------------------19
Fig-5---Non-ferrous sand system ---------------------------------------------------26
Fig-6Sand system for ferrous foundry -------------------------------------------28
Fig-7pouring of molten metal -----------------------------------------------------32
Fig-8Shot blast (Pang born) machine -------------------------------------------36
Fig-9Prodaction of thread roller machine --------------------------------------38
Fig-10Sloting machine -------------------------------------------------------------39
Fig-11large horizontal lathe machine --------------------------------------------40
Fig-12 copy Machine ----------------------------------------------------------------41
Fig-13Forging product --------------------------------------------------------------45
Fig-14 Tumbling machine------------------------------------------------------------53
Fig-15 sand washing machine------------------------------------------------------55

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Prepared By:-Yared Seifu
 List of tables
Tables
Table-1---Characteristics of silica sand -------------------------------------------20
Table-2New sand ------------------------------------------------------------------25
Table-3---Reclaimed sand -----------------------------------------------------------25
Table-4---Acid refractorys material------------------------------------------------30
Table-5---Neutral refractorys material --------------------------------------------31
Table-6---Composition of pig iron--------------------------------------------------33
Table-7---composition of alloy ------------------------------------------------------33

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 1. Chapter one
1.1 History of Akaki Basic Metal
Industry
Akaki Basic Metal Industry is a state owned business organization mainly engaged in
manufacturing and sale of spare parts, hand tools, cutlery and so on. It is the largest
engineering company in the country; which has got for different production workshops with
multipurpose machineries. It can be said that the company is achieve industry as it has the
capacity to produce different industrial spare parts and machinery. The company is situated in
the south of Addis Ababa about 25k.m on the Addis Ababa/Nazareth main road and about 3k.m
of east of village of Akaki. It was initially established as a public enter pries in 1989 in the name
of Akaki Spare parts and Hand Tools Factory. In October, 1999; the company has been re-
established as a share company in according with the proclamation No. 146/98 with a capital of
birr 142298000 (One Hundred Forty tow Million Tow Hundred Ninety eight Thousand)
subscribed by the government and change the name of Akaki Spare parts and Hand Tools
Factory in to Akaki Basic Metal Industry by using E.F.D.R state and minister of council No.
183/2002.

1.2 Main Customers

The main customers of Akaki Basic Metal Industry are:-
*, Fincha Sugar Factory
*, Wonji Sugar Factory
*, Metahara Sugar Factory
*, Akaki Textile
*, Kombolcha Textile Factory
*, Asmara Textile
*, Dire Dawa Textile
*, Mugher Cement Factory
*, Massimo Cement Factory
*, Addis Ababa Cement Factory

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 *, Dire Dawa Cement Factory
*, Ethiopian Telecommunication Corporation (E.T.C)
*, Ethiopian Electric Power Corporation (E.E.P.CO)
*, Ethiopia Iron and Steel
*, Ethiopian Fiber
*, Elfora Agro Industry
*, Adei Ababa
*, Wonji Show S.F
*, Kolfe House Hold
*, Nardelli Paolo
*, Midroc Construction
*, Walya transport, etc

1.3 Main Products

The main products or services of Akaki Basic Metal Industry are:-
Roller; for Sugar Factories (Fincha, Wonji, Metahara)
Billet for cane knife; for sugar Factories
Missile Shell Metec Research and Development; for Defense
Sprocket for chain link drive; for Beshoftu Automotive
Gear Box Housing; for E.E.P.CO
Inter Mediate Carrier Sprocket; Fincha
Dust Collector; for Mugher Cement
Fire Grete; for East Africa
Balance Weight; for Dejen Aviation
Gears (Spur, Bevel, Helical and Worm)
Shafts
Keys
Steel Balls
Bearing Housing
Sheet and Plate Parts

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 Forged Parts
Hand Tools and Cutlery.

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Fig-1 Main Products

1.3.1 Production Capability

The following briefly describes the production capabilities of the different shops.

1. Foundry
Area: - 5476m2
The foundry has ferrous and non-ferrous department with an annual capacity of 4450
tons in two shifts. The capacity of the furnaces in the two departments is as follows:-
1.1 Ferrous department
Three (3) furnaces for grey iron/steel --------3.3 tons each.
Furnace for steel ----------250k.g
1.2 Non- ferrous departments
Furnace for Aluminum-----------500 kg.
Furnace for Bronze/Brass --------- 500 kg.
Furnace for Aluminum alloys -------500k.g.
2. Machine shop
Area: - 11664m2
2.1 Cutting section
Power hack saws
#, Cut bars up to max diameter of 350 mm.
#, Hydraulic shear for plates up to 16*2500 mm.
#, Rolling machine for plates up to 20*2500 mm.

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 2.2 Turning Section
Center lathes having max center height of 800 mm.
Max distance between centers 6000 mm.
Vertical lathe to machines up to 1400 mm.
Turret lathes to accommodate bars up to 67 mm.

2.3 Drilling Section

Horizontal boring and drilling machines are up to 60mm.
Pillar drilling machine is up to 40mm.
Radial drilling machines max drilling capacity up to 50mm.
2.4 Gear cutting Section
Spur gears, helical gears, sprockets, worm gears are up to diameter of 1250mm and module
14mm.
Straight bevel gears are up to 610mm and module 8.5mm.
2.5 Milling Section
Vertical Milling is up to a dimension of 800*280*420mm.
Universal Milling has up to 1000*340*500mm.
Plano Miller machines up to 1000*6000*900mm.
2.6 Grinding Section
Internal grinding is from 60mm - 100mm.
External grinding is up to 200*1000mm.
Surface grinding is up to 2000*500mm.
Center less grinding is 10mm - 150mm.
3. Forging
Area: - 288m2
Equipped with ; 2 electric motor driven power hammers of 27k.g, one for open
and die forging up to 450k.g and 40k.g respectively and the other one for forging steel balls for
cement factories.

4. Laboratories and Quality Control

Metallurgical and mechanical testing

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 Laboratories equipped with spectrometer and other lab equipments.

1.4 Over all organization and work flow

Board of Management
Internal Audit service
General Manager

Legal Manager Organization and Information method service

Quality Assurance service

Planning and Information technology service

Administration and HRD department

Marketing and Supplies department
Finance Manufacturing department
department
Fig-2 Over all organization structure

Quality

Inspection section Laboratory section

Fig-2(a) Quality section structure

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 Marketing and supplies Department

Sales and sales promotionProcurement

division Market research
divisionMaterial management division and product development divi

Fig-2(b) Marketing and supplies department structure

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 Manufacturing department

esign, production planning andFoundry

controlMechanical
division
division work
Heatshop
anddivision Maintenance
surface treatment division division

Milling
Foundry method and pattern making section
section Electrical maintenance unit
Heat treatment unit
PPC section
Hand Tool and Cutlery section

Design and method Surface treatment unit

Mechanical maintenance sectio
Sand preparation, mould and core unit
Lathe section

Heavy duty section

Ferrous foundry unit Machinery and equipment maintenance un

Surface grinding section

Non-ferrous foundry unit

Gear hobbling section
Vehicle maintenance unit
Cast finishing section
Fabrication section

Plant service unit

Forging shop
Fig-2(c) Manufacturing department structure

institute Page 7
 General Manager

Administration and HRD department

Clinic

Personnel Administration and Training division

General services division

Fig-2(d) Administration and HRD department structure

General Manager

Finance department

General accounts division Cost and Budget division

Fig-2(e) Finance department structure

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 2. Chapter two
2.1 Over all internship experience
I get the internship training in the Akaki Basic Metal Industry by the help of
University-Industry-Linkage (UIL) coordinator. This company is very large and different
working section. In the first day we are separated in to five groups.
*, PPC Engineering
*, Design and Development
* Machine shop
* Non-ferrous section
*, Cast iron casting
So, my group is design and development and connected with supervisor of company. He
helps to visit the whole cast iron casting and non-ferrous for one week. Cast iron casting
sections are there different parts.
*, Pattern making shop
*, Core shop
*, Hand molding section
*, Mechanized molding section
*, Ferrous foundry
*, Cast finishing
*, Shot blast (Pang born).
We work in Akaki Basic Metal Industry some section such as foundry shop (pattern
making, Hand molding, Mechanized molding, Core shop, Ferrous and cast finishing), Non-
ferrous and some visited about machine shop, forging shop, heat treatment and maintenance
division.

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 2.2 Working flow of Akaki Basic Metal Industry
The working flows of Akaki Basic Metal Industry are the following
1, First come the customer in to the company with free hand sketch when the products are new.
2, Then, they are connecting with sales. The sales are seen the sample then connect with PPC
(Production Process Control) section.
3, The PPC (Production process control) are looks the storage to identify, what the raw material
and other equipments are available. After checking the storage and all raw materials are
available to produce the product.
4, Next the sales are estimating the cost of product.
5, Transferred in to PPC. Then plan the work, in what method can be done? In which section can
be done?
6, The PPC are transfer in to design room, the designer are design the product.
7, After design the product the methods are making the runner, getting system, sprue base, riser.
Then transfer in to the pattern room.
8, Next, make the pattern (split or simple) by using wood material.
9, When the product is large; transfer into hand molding section and make the mould.
10, When the product is small, transfer in to mechanized molding section and make the mold.
11, Next, pouring the molten metal in to mould either ferrous or non-ferrous according to need of
customer.
12, Solidify, and transfer in to cast finishing.
13, Next, transfer in to machine shop and machined the product.
14, Finally customer are be receptive the product.

2.3 Foundry shop

This division has the responsibility of coordinating and controlling the activities of the
foundry methods and pattern making section, sand preparation, mould and core unit, the ferrous
foundry unit, the non-ferrous foundry unit and the cast finishing unit.
Most of the spare parts produced the major customers of the company are the out puts of this
division.

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 2.3.1 Pattern and pattern making
Pattern is the method to produce the mould cavity or replica of the final object in
pattern shop. Pattern is made from: - wood, plastic, metal and so on, but in this company made
from wood. Because of it is low cost, easy for product, easy for worked. There are many types of
pattern:

Solid (single) pattern

Split pattern
Cope and drag pattern, and so .
2.3.1.1 Pattern design consideration
1) Shrinkage allowance
2) Machining allowance
3) Draft angel
4) Parting line
Pattern allowance: - A number of allowances must be made on the pattern to ensure that the
finished casting is dimensionally correct.
1, Shrinkage allowance:-
It is the ability of molten metal to be contract during solidification at solid state.
It measured length with mm/m linear (shrinkage).
Shrinkage allowance is important only during designing of patterns.
Shrinkage allowance depends on:-
To shape and size of the casting.
On the method of moldings.
To the temperature of pouring.
2, machining allowance:-
It is the extra amount of metal which is providing on the surface to be machined.
It is included in the pattern design.

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 1. Machining allowance is needed to:-
To get the precise dimension and good surface finish.
To remove rough surface or imperfections.
2. Machine finish allowance depends on:-
Type of metal used in casting (ferrous or non-ferrous).
On the method of casting (sand, die casting).
The Size and shape casting.
1.5mm allowance is considered for non-ferrous and 3mm for ferrous.

3, Draft angel
It is required to avoid damage at the sharp edge of the mold during pattern removal.
Patterns are tapered at some angel along its vertical surface.
Drafts are designed in degree or mm/m.
Amount of draft of draft depend on:-
On the shape and size of casting (depth of casting).
For most casting draft of 10-20mm is used 10-50.
4, parting line
It must be straight line to make the casting is economical and accurate.
2.3.1.2 Advantages of woods.
Woods are very easily available
Due to its softness, it is easy for machining, sanding
Light in weight and hence is possible to use for bigger sizes of casting
Can be easily cut, give curved
Disadvantages
Are easily affected by environmental factor (humidity)
Due to the strength they can easily be broken
Proper storage is required

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 2.3.1.3 Pattern storage
Pattern should be stored in a controlled room
It should free from humidity
It should be stored in proper way
It should not exposed to sun light
It must be stored in their identification number
In the pattern shop many machines are there:-
Lath machine (small & large) Band saw (small& large)
Jointer (small & large) Grinder (two)
Drilling machine Thickneser
Milling machine Combination
Sating and grinding machine Butt welding
Vertical sander Boring machine
Disc sander for two faces Crane, capacity (250 kg)
In this shop I worked different patterns. For example, Main carrier head shaft. The
Main carrier head shaft pattern making processes are:-
First, coming the main carrier head shaft drawing includes the all runner system,
riser, and sprue from method room in to pattern shop.
The main carrier head shaft design consideration:-
*, Shrinkage .. 2%
*, All draft angles .. 2o
*, All machining 8mm
*, Main Dimensions . 711x165
*, Chamfer 45o
*, J.O (Job order) .. 032/04
*, P.C (pattern code) 40-2588-01
*, Material 46 Mn si4
P.C:- means pattern code, 40; is material type that is 46 Mn si4 (steel), 2528; means
number of order pattern, and 01; means number of core that is one core.

2.3.1.4 Process of main carrier head shaft pattern

*, First ready the wood that is kwanza.
*, Adjustment and first face the angle, by using jointer machine.
*, Second face and uniform the thickness of carrier head by using thickneser machine.

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 *, Cutting the wood by 711 by using band saw machine.
*, 5th turn or face the pattern by using lathe machine.
*, Smooth the pattern by using disc sander.
*, When the pattern between space, we can fill the space of pattern by using stucco.
Now stucco is prepare from hardener and stucco. Hardener is red color, used for dry and
stucco is white color and used for bind. The hardener is 1/10 of the stucco.
*, After we use stucco gap from five up to seven minutes, then we are use sand paper.
*, make hexagonal type (14 places) by using milling machine.
*, Make the dowel (3 or 4 places). Because of the pattern is split. So, the dowel is used
for perfectly aligned the two (cope and drag) that means not misalign.
*, Make one core. B y using core box and core print we can make the core.
*, Then add the sand mold in to core box. After some minute remove the core from the
core box.
*, make lather connection (raccordo), for 5mm radius.
*, Make gating system that is conduit network through which liquid metal enters a mold
and flows to fill the mold cavity that is:-
Runner
Top riser
Sprue base
*, Finally; paint the pattern yellow color and paint core print black color.
In the carrier head shaft half parts in the cope and another half parts in the drag. But in the
cope add the sprue, riser.

Fig-3 main carrier head shaft pattern

2.3.1.5 Work piece on pattern shop
Clamp or morsa Hammer Pencil Ruler (meter)
Grinder Hand drill Hare punter pinca Pinca
Geksow Height gauge Chisel Cutter(H.S.S)

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 Compass Bar compass Varner caliper (small and large

2.3.2 Mechanized molding

2.3.2.1Mechanized molding process
st
1 come the small patterns from pattern room.
Prepare the plate or flask used supports the mold for pattern.
Connect the pattern and the car by bolt and nut (4-6) places.
Transfer the car with pattern plate by using roller conveyor by using controlled cars
button (switch).
Add the sand (sand + resin + catalyst) from mixer machine.
Put the sprue in the sprue base in pattern plate.
Rammed the mold by using vibrater, and make the vent.
Transfer the car in to rollover machine, by using car roller (left, right, forward and back
ward) switch.
After some minutes (3-5) disjoin the mold from rollover machine by using put the button
(switch)
Then, when the product finished, the pattern go to in the store. But the product not
finished the pattern is recycles a gain.
Next the mold go to in the mold finished, then make the air and mold paint in the cavity.
Prepare for melting metal. So assemble the cope and drag by using manipulator.

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 Finally, make two bares and bind or tie the cope and drag, then make the new sand
between the cope and drag.

2.3.3 Hand molding

2.3.3.1 Hand molding process
st
1 come the large patterns from pattern shop. But not making the gating system like;
sprue base, runner, riser etc
For example Roller for sugar factories diameter 1100mm and length 2150mm.
Make eleven flasks, seven flasks are make the mold by using 1100mm pattern, for each
flask. The flask size is 1500x1500x321mm
One flask is roller print. And another one is at the bottom setting of the all flakes.
Another two flasks are at the top of roller that is preparing the pouring basin, riser and
sprue.
The gating system is step type. This means the malt is gain in bottom direction.
Bind the eight (8) flasks by using bolt and nut. For each flash (12-15) bolts.
Make the core 530mm and small core 40mm.This small core used for remove the air,
hot crake and full the sand in to the core box, and ram.
After some minutes (15-20) remove the core box.
Get in nine flasks by using crane (20 ton) into hole. The hole size is; 3000mm*3000mm.
Then, add the new sand in between flasks, outside and inside of flasks.
Add the core into the mold cavity
Coat the calla (vinabel glue) in to the upper of pattern and bind the two flasks that is
pouring basin in to the nine flasks. And tie by bolt and nut.
Finally, add the melting in to the mold.
Solidify (3-5) days.
Then disjoin the flask and collages the mold and remove the product (rover)

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 Transfer into cast finishing
Lastly going to in machine shop. Then machined and make drill for bolts.
N.B height of pattern is 7x321mm= 2247mm
Total height is 10x321+ (150) = 3360mm.

Fig roller for sugar factory Fig Horezontal lathe machine

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 Fig-4 hand molding (Roller)
2.3.4 Core shop
Core means: - Made of sand aggregates
Used to make hallow regions
2.3.4.1 Core shop process
st
1 coming the core box from pattern shop in to the core shop.
Add the new sand (catalyst + resin + new sand) from mixer machine in to core box.
Then rammed the sand.
After some minutes (15-20) remove the core from the core box.
Work piece in core shop, mechanized molding and hand mold
Rammer Different size sprue Vent
Manipulator Crane of 500kg capacity, 10 tone, and 20 tone

2.3.5 Sand mold features

Flask.. Supports the mold.
Pouring basin in which molten metal is poured in to sprue.
Sprue through which molten metal flows down ward.

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 Runner system ..Channels that carry molten metal from the sprue.
Risers .... Supply additional molten metal, to the casting during shrinkage.
Vents used to carry off gases that are produced and exhaust air from the mold
cavity as metal flows on to the mold.
Cope . Upper or top most section of a flask, mold or pattern.
Drag .. Lower or bottom section of a flask, mold or pattern.
Parting line . A line on a pattern or casting corresponding to the separation between
the parts of a mold.
2.3.6 Mold paint
Before some years Akaki basic metal industry is used the mold paint known as Isomer.
Isomer is come from Italy, German and other countries. In this condition when the isomer is
finished the product is late by mold paint. So, after nine (9) months research creates the mold
paint by Asamenew Debela and his friends.
Preparation of mold paint
Equipments
Water
Sodium silicate
Green sand
Refractory (Tyker)
Tyker: - High refractory material, white color and comes from furnaces.
1st come the refractory material (Tyker) from furnaces.
Crushed the Tyker by using crusher machine.
Blown the Tyker by using different size of sieve (0.18mm, 0.14mm, 0.105mm) sieves.
Mixed the water, sodium silicate, green sand and Tyker by using mixer machine
Finally, paint the mold cavity.
N.B. Green sand is come from Negale Borena ( ).

2.3.7 Foundry sand, binders, sand laboratory and sand system

2.3.7.1 Sand
Akaki Basic Metal Industry is uses silica (sio 2) sand for the application of molding and
core system. This sand came from Merahabite north shewa in Ethiopia. Silica sand (sio2) is:-
Can be used repeatedly for making molds.
Are in expensive.
The sands maintain their shape and other characteristics even at very high temperatures
while they are in contact with molten metals.
After ramming; the mold remains sufficiently porous or permeable to give vent to the
gases.
Generally, these silica sands are the most widely used sands.
Akaki Basic Metal Industry is used resin and catalyst for the binders of molding system.
Resin is acted as bonding material and catalyst is used to fast the reaction of resin and sand.

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Chemical name of catalyst and resin are:-
For catalyst .. Selphonic acid
For resin .. Furfural alcohol
2.3.7.2 Sand laboratory
Sand laboratory when selection and testing of proper foundry sand is done for quality
and casting. The following tests are conducted in the sand lab.
i. Clay content test
Clay is a very fine particle with the size less than 0.005mm diameter, naturally found in
the form of mixture with sand grains. The elimination of clay particles from molding sand is very
crucial due to the following basic reasons.
Presence of clay is the cause for poor permeability.
It causes poor surface finish and increases re-work costs.

Testing procedures
Weight 50g of washed sand
Add to the beaker
Measure 10ml of 5% sodium pyrophosphate and add to the mixture
Put the mixture under the agitator m/c and agitate for 5min.
Add the mixture to the washing apparatus using the funnel
Open the controlling top so that the clay particles could easily float on the top and
removed away through exhaust tube
When the mixture becomes pure remove the mixture from apparatus to the beaker.
Filter the mixture using 20 micro filter paper
Dry the sand and at the temperature of 110oc for 2 hrs.
Weight the sand using the digital weighing scale.
Calculate the weight deference of sand before and after washing.
Put the value sand in terms of %.
For example weight of sand before experiment =50g
- The value achieved after experiment = 49.7g
Clay content = original weight new weight x 100
Original weight
= 50-49.7 = 0.60%
50
The value obtained is acceptable, the amount of clay in new washed sand should always be
<1%.
Characteristics of silica sand

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 Table -1 characteristics of silica sand
Characteristics Silica
Color White-light brown
Specific gravity 22-26
Fusion point (1427-1760)oc
AFA/S fineness 40-47
Chemical reaction Acid-Neutral

ii. Moisture content determination: - This is to completely determine the amount of

moisture found in the sand. After drying the sand, the amount of moisture will be 0.1
min .
iii. Permeability test: - This is to determine the ability of each sand grain to pass the
gasses of molten metal ferrous during pouring operation. If the permeability of the
sand is low, casting defects such as porosity, cavities and others might appear on the
surface of the cast.
Component reference
Air drum Water container
Switch valve Double orifice
Rubber stopper Precision pressure gauge
iv. Loss on ignition test (LOI)
This is to determine the weight lost during process due to burning of organic matter and
very fine particles that are found in the sand. If the weight of the burnt particles excess from this
value the mould will lose its strength and molten metal will automatically penetrate the mould.
Procedures
Weight 50g sand and put in a muffle furnace.
Burn the sample to 100 oc for, 1 - 2hrs.
Cool the sample sand and weight
Calculate the weight deference and change to percent age.
For example - Weight of s and before test = 50g.
- Weight of s and after test = 48.82g.
LOI = original weight new weight x 100
Original weight
= 50 - 48.82
50
LOI of old s and = 2% max
Regenerated sand = 0.064%
New sand = 0.23%
LOI = 2.36 (not acceptable)

v. Grain fines number (GFN) test

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 GFN test is mainly used to know the fineness or coarseness of sand at the same
time, to know whether the sand grain falls within the international standard.
N.B The international standard for GEN of foundry sand is 40 60.
If the number is less than 40, the sand is coarse, hence, not preferable because of the
coarse grain cannot be easily compacted during mould making. It causes poor surface finish on
the cast. If the GFN is greater than 60 again the sand is not recommended because the sand and
grain is fine.
Thus, the sand consumes too much binder for compaction and:-
Causes poor permeability which in turn, is the main causes for porosity and other
casting defects.
Low sintering temperature
Re work cost will be high
GFN test is usually called sieve analysis. Sieve analysis is accomplished by using
sieves of different diameter holes. Normally, the size of the sieve hole diameter ranges from
1.68mm (coarse) to 0.05 (pan and it is very fine).
Procedures to accomplish sieve analysis
-
Weight 100g of dry sand (it can be new or old sand).
Add to the sieve machine.
Sieve the sand for 15min.
Remove each sieve carefully and weight the amount you obtained on each sieve separately
and turn by turn according to their sequences. (use digital weighting scale and special brush)
Record each values carefully on the format provided for this purpose which contains sieve
number and diameter
Mark the distribution graph on the format following each value
Select the three maximum distribution graph and calculate the mean value of the three
graphs.
Compare the value against the standard.

Component reference
1. Traverse glide 3. Lid 5. Different size sieves 7. Timer
2. Clamp 4. Guide bar 6. Vibration intensity regulator

Table -2 New Sand

No Type of Test Standard

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 1, Clay content before wash 16-200%
2, Clay content after wash 1% Max
3, Moisture content after wash 0.5%
4, Grain fineness No (GFN) 40-60
5, Loss on ignition (LOI) 1%

Table -3 Reclaimed Sand

No Type of Test Standard
1 Grain fineness No 40 60
2 Loss ignition 2%

2.3.7.3 The sand system in foundry

The sand system in Akaki Basic metal Industry is comprises of new sand, mechanically
reclaimed sand (Reclaimed sand) and thermally reclaimed sand and (Regenerated sand).
New sand
Sand brought from Merahabite for Akaki Basic Metal Industry and currently washed
manually and deposited on concrete silos (7) on the ground floor via a hopper vibrator (1)
bucket elevator (5) and belt conveyor (6). The sand from the concrete silos on the ground floor
(7) is excavated using a shove hoper and feed to the drier (10) via a hopper (2), the dried sand is
finally transported to the two steel silos (12) of 50m3 capacity by pneumatic propulsion. The
new sand stored in silos (12) can either be transported to the hand molding (HM), mechanizes
molding (MM), core shop (CS) or to the regenerated sand silos via the cover of the hot rec.

Reclaimeds and (mechanical reclamation)

After pouring molten metal in to the mould, the mould is allowed to cool for a
reasonable time following which it is transported in to the 4 in 1 system where the operations
of separating be casting and the mould, shot blasting, sand reclamation and separation of shots
and for re-circulation is carried out. The reclaimed sand is then propelled. Transferred into the
hand molding (24), mechanized molding (23) or reclaimed sand silos (14). As shown in fig-6.

Non-ferrous and system

This is made possible only by transporting sand by a shovel hopper and dumping it to the
shakeout grid of the non ferrous foundry following which it is automatically transported to the
4
molding line hopper (17m3) as shown in fig 5. 1
Capacity of silos
Big silos = 75 ton (50m3)
Medium silos= 45 ton
Small silos = 15 ton

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Hopper of non-ferrous = 25 ton (17m3) 2
Hopper of hand molding = 30m3
Hopper of mechanized molding = 2 5m3
Hopper of core-shop = 17m3
1. Shake out grid
2. Reclamation unit
3. Propellsor
4. Hopper/silo Fig-5 Non-ferrous sand system

2.3.8 Cleaning of the cast products

When the metal has cooled sufficiently for the casting to hold its shape, it is
separated from the mould by mechanical or manual methods. Where sand moulds are used, the
process is often referred to as shake out, and large amounts of dust may be generated.
After casting, some pieces of metal are removed and often collected for re-melting. In ferrous
castings and larger non ferrous castings, they may be removed by sawing or cutting using band
saw, pendulum grinder, and grinder
Finishing
A range of finishing processes is usually undertaken these include:-
Cleaning to remove residual s and
Removal of excess metal or surface blemishes
Rectification of defects by welding, etc

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1. Sand washed 10.Drier 19. Hopper (3) 28.Molds
2. Sand Transportation 11.Sender 20.Hopper (4) 29. Pusher
3. Hopper (1) 12. New Sand 21.Mixer
4. Vibrator 13.Regenerated Sand 22. Core Station
5. Elevator 14. Reclaimed Sand 23.Mechanized Station
6. Distribution Belt 15. Sender (2) 24.Hand Molding Station
7. Concrete Soils 16.Hot-rec 25. Silo
8. Jop dog (Power Shovel) 17.Screw Conveys 26. Sender (3)
9. Hopper (2) 18.Screen 27. Shot Blast

2.3.9 Melting practice

Melting furnaces
In Akaki Basic Metal Industry molten metal furnace are different materials are there
cast iron and its alloy, steel and its allay, copper allay and aluminum.
2.3.9.1 Ferrous foundry
Cast iron
Nodular cast iron
Gray cast iron and
White cast iron
Steel
There are four furnaces in this section.
The three (3) furnaces melting capacity are: - 3300 kg for each furnace and another one (1)
furnace melting capacity is 250k.g
Total melting capacity is:- 10150 k.g
Induction furnace

2.3.9.2 Non-ferrous foundry

There are three (3) furnaces in this section
Furnace for aluminum and aluminum alloy are two (2), the melting capacity are 500 k.g
for each furnace
Furnace for copper alloy (Bronze and Brass) is one (1), the melting capacity is 500 k.g
The total melting capacity is 1500 k.g

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 Akaki Basic Metal Industry melting furnace electric power used from E.E.P.Co, 15000v.
From this power convert AC (Alternative current) in to DC (Direct Current). Then heat develops
by using refractory. Refractory are classified in to three. There are:-
a. Acid refractoriness
b. Basic refractoriness
c. Neutral refractoriness

a) Acid refractoriness:- E.g. Cast

Table 4- Acid refractoriness material
Type Temperature
Silica 1700oc
Aluminum silica 1780oc
Alumina (Al2O3) 2050oc

In this case we can melt the cast that is (gray cast iron, Nodular cast iron, white cast
iron). But cannot use for the steel.
b) Basic refractoriness:- e.g. steel
Magnesia 2800oc
Dolomite
In this case we can melt the steel. But cannot use for the cast.

c) Neutral refractoriness
Table 5-neutral refractoriness material
Type Temperature
Chromate 2180oc
Graphite 5000oc
In this case we can melt both (cost and steel).

2.3.9.3 Process of furnace charged

Assume, the melting is Nodular cast iron or ductile cost iron. So our refractory materials
are acid refractory.
First put the Amentayte sheet 1.5mm thickness in to furnace. It is used to safety
for coil. Mixed the refractory and boric acid, the ratio is for 100 Kg of refractory (4) used 2
(two) k.g of Boric acid. The total refractory is 1400 kg or 56 per and used 28 kg of Boric acid.
Then add the mix of refractory and Boric acid in to the furnace up to 500 kg of refractory and

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ram by using vibrator. Then put the former that is circular sheet metal 5mm thickness in to the
furnace, and add the mix of refractory and Boric acid up to corner of furnace and ram by using
vibrated. Make the thin ceramic fiber in around of furnace.
Finally add the charge used pig iron and open the power let us we are started
three (3) oclock. Then from (3-4) = 100oc, (4-10) 200oc, (10-11) = 300oc, and for one oclock
add 100oc. Finally from (4-5) = 900 oc. Then starting the melted and add silicone (75), carbon,
silicone (45), and measured by thermocouple. After20 oclock, pouring the melted from furnace
in to ladle. Then heat the Mg (magnesium) and add in to ladle, mg is very high evaporated.
Then after add the Mg make chip, Asbestos and packed the ladle. Next, pouring the molten metal
in to the mould.

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 Fig-7 pouring of molten metal
Akaki Basic Metal Industry is used pig iron having different composition for varying
application.

Table -6 composition of pig iron

Type Composition (%)
Carbon Silicon Manganese Phosphorous Sulfur
Pig iron for gray iron 3.5 min 2-2.5 0.85 0.1 Max 0.04 max
Pig iron for ductile 3.5 1.0 Max 0.4 max 0.1 Max 0.04 max
iron (nodular iron)
Pig iron for white 4.3 0.008 0.008 0.027 0.006
iron

Akaki Basic Metal Industry used alloying elements commonly used chemical
composition is shown in bellow table-7.

Table-7 Composition of alloy

Alloying elements Chemical Composition (%)
Ferro-silicon 45 Si= (40-47), P=0.05% max, C=0.2%
Ferro-silicon 75 Si= (72-80)%, Al=1%, P=0.02% max, c=0.15%
Ferro-magnesium Mg= (5-6)%, Si=(43-48)%,ca(0.1-1.3)%, Al=

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 0.12%
Ferro-silicon-magnesium Mg= (5-10)%, Si= (43-48)%, ca= (1-1.7)%
Ferro-chromium 70 Cr= (65-70%, c= (0.25-0.5, s=0.03%
Ferro-mollbedium Mo= (55-75)%, Si=1% max, s=0.05% max
Carburizer (milled graphite electrode) C=99.9%, H=0.15%
Copper CU= 99.9% pure
Ferro-silicon manganese SCO2O Mn= (75-85)%, p=0.05%, Si=0.03%

Non-ferrous section
Non-ferrous metal: - All other metals and their alloys are referred to as non-ferrous metals.
For example: - copper, zinc, Aluminum, Tin, Nickel, Bronze, Brass etc
In this section different machine are there; piston die machine, center fugal machine, mixer,
holding furnace machine, etc. and three furnaces. The two Ammonium furnaces are resistance
furnace. But the other one is (copper alloys either Bronze or Brass) is induction furnace. In this
section stored aluminum materials, Aluminum chips, Aluminum scrap, Bronze (chips, material,
return casting), Brass (scrap, chip, material).
Amount of cranes
i. Moving large crane
In ferrous foundry
1. 20 Ton .. on ferrous furnace and hand mold
2. 10 Ton .. on ferrous material
3. 10 Ton on cast finishing
4. 2 Ton .. on mould
ii. Fixed small crane
1. 250 kg . On core shop
2. 250 kg . On mechanized molding
3. 500 kg . On pang born (Blast shooting)
4. 500 kg . On cast finishing (pendulum grinder)
5. 500 kg . On furnace (ladle reheat)
6. 250 kg . On cast finishing
7. 250 kg . On patter n shop (large lathe machine)
In non-ferrous foundry
i. Moving large crane
1. 2 Ton . On mold assembling (manipulator)
2. 2 Ton .. on pouring molten metal
ii. Fixed small crane
1. 250 kg . On mixer machine
2. 250 kg . On shake out machine

2.3.10 Shot blast (pang born) machine

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 Shot blast (pang born) machine type ES mineral rot-oblast machine complete with
sand reclamation and reconditioning system with the following components and specifications.
Scope of work
Accommodate no-bake molds up to 1200 mm x 1000 mm x 800 mm
Maximum weight of mold is 2 tons.
Production of eight molds per hour
Blast knock-out and cleaning cabinet
It is 3110mm wide x 2790mm long x 3500 mm high, fabricated of thick low carbon steel
plate, rigidly mounted on structural framing.
2.3.10.1 Process
First open the air valve, then switch on the main button, and (Rotary valve and
exhauster) then Elevate (1) control conditioner, (screw cover and magnets separator), Rot-oblast
sand reclaiming, hook rotation pre selection, and (Elevated (2), separator screw conveyer was
vibrating screen). Setting the mold, in the molding handler by using roller car and transfer the
mold from mold handler in to self powered carrier by hydraulic system. Moved the car by base
bar, when the care touch lime switch sense the door, then open, and get in the care then closed
the door. Then blast the mold by Abrasive. After (5-8) minute open the exit door and out
the car with product. Then get in the abrasive, residual ferrous and mold remains in the hopper
(vibrating conveyor). This vibrating conveyor 3300mmlength800mm width, 2000mm long with
4mm diameter opening. Then transfer in to Elevator No.1 (11700mm height). And get in from
Elevator No.1 in to hopper by using belt-bucket. Separate the large size by using sieve and the
abrasive (shot) storage bin from sand and residual ferrous. Get in sand and residual ferrous and
small size of abrasive in to primary sand storage bin by using sand spiral conveyer and separate
the dust. Then remove residual ferrous particle in the sand by using magnetic separator, unit is
composed of 315mm diameter x 965mm long drum with permanent magnet. Then the sand gets
in to Elevator No.2 (6990mm height). The sand has transfer from Elevator No.2 in to silos, by
belt bucket. Then the sand gets in to regenerated sand storage bin by using gravity. W hen the
storage full closed the electro valve.

Finally we can transfer the sand in to three directions.

1. Hand molding section
2. Mechanized section
3. External (Hot-race)
By using pneumatic conveyor, When sand transfer in one direction, then closed the two lines by
using closed the diaphragm.

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 Fig-8 Shot blast (pang born) machine

2.4 Mechanical work shop

Mechanical work shop is one of manufacturing department in Akaki Basic Metal
Industry. This division is fabricating different spare parts and machine tools. It has different
sections. These are:-
Heavy duty
Fabrication
Electro plating
Hand tool and cutlery
Lathe section
Milling section
Grind surface area
2.4.1 Electro plating section
Electro plating section known as surface treatment plate it has four different sections.
1. Nickel 3.Chrom
2. Galvanize 4. Phosphors
In this section nickel and chrome are not used. Because of the cost is high. But the cost
of galvanize and Phosphors are not high, it is low cost.
Process of electro plating (galvanize)
First, the material is come by using crane. Then, plate in to storage of hydrochloric acid.
Hydrochloric acid is small cost, high clear, from other materials. After (2-5) minutes get in to
water storage, the material setting in to base bare, and again dipping or soaking in to water
storage. Then, dip into Sodium hydroxide (caustic soda), with electric system that is heat the
chemical (3-5) minutes. Then moving in to water storage by crane and dipping the material by

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base bare and wash. Then again dipping into another storage water and wash then moving in to
storage of neutralization by crane and dipping the material, in this stapes not use electric that
means the chemical is cool. Then moving in to storage of water and washing the material. Next,
dip the materials in to storage of Zinc (Zn) plate with electric system. (10-15) minutes in this
steep there are two chemicals. Ammonium chloride and zinc chloride. Ammonium chloride is
closed by bag. It is made from clothe. Zinc chloride is 99.9% is pure zinc.
Then moving in to storage of water and wash the material and dipping the material in to
chrome plate storage without electric system. Finally wash the material three (3) storages of
water.
N.B. Hydro choleric acid is used for removed the rust.
- Sodium hydro oxide is used for remove the oil and grease.
- Chromic acid is use for hard and smooth material.
- Length of storage 1.80m 70-80c.m width and 120cm of height
- On other large galvanize electro plate storage in 300cm length, 100cm width and 100cm
of height.
N.B- Charges are flow from negative to positive due to this the positive part of electric is
connected to the material to be surface treated and negative part is connected to the Zink
solution. This shows the process is from Zink to metal.

2.4.2 Hand tool and cutlery section

In this section different machine using; like thread forming machine (six), piercing, etc
2.4.2.1Thread roller machine
Thread rover machine is used to make thread by using different dies. This machine has a
roller which is different shaper and different size of pitches (minimum pitches 1.75 mm and 2m,
2.5mm, 5mm, 6mm, and maximum are 7mm). Shape of roller die is (sharp, ring, and ring and
some radius). Product by thread roller machine:- N-80 pin ( 16), N-95 pin ( 19), 15kv pin
( 20), 33kv pin ( 25), N-80 hook ( 16) N95 hook ( 19) 15kv hook ( 20), 33kv hook (
25), big collar, small collar, deadened hook, suspension hook, etc. it is using C-10 material

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 Fig-9 production of thread rover machine
2.4.3 Milling section
Milling machine is used to make gear hexagonal and hexagonal nut, square nut etc
2.4.4 Lathe section
Lath machine is used to produce different machine element such as shaft, fly wheel,
flange, bolt etc by using H.S.S and carbide cutters. This machine is make turning, facing boring,
threading (internal and external).
2.4.5 Gear hobbling section
In this section used different machine are there such as: - Gear shaper machine, hobbling
machine (vertical and horizontal), bevel gear machine, slotting machine.

2.4.5.1 Bevel gear machine

It is used to make only bevel gear not use for other gears.

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 2.4.5.2 Hobbling machine
This machine is used to make spare, helical, worm chain sprocket.
2.4.5.3 Slotting machine
Slotting machine is used to make a key way grove.

Fig-10 Slotting machine

2.4.6 Heavy duty section

Heavy duty section is huge and used to produced large elements such as mill roller,
shaft, etc. it operated by using touch display. In this section different machine are there such as:-
Plano miller machine, vertical lath machine, horizontal lath machine, radial drill press, boring
machine etc.
2.4.6.1 Plano milling machine
It is the same as to milling machine. It is used to make facing, boring, drilling etc

2.4.6.2 Horizontal lathe machine

It is the same as to lathe machine. But in this machine to make large or huge elements such
as: - large shaft, hammer. Show in fig-11.

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 Fig-11 large horizontal lathe machine
2.4.6.3 Vertical lathe machine
It is same as to horizontal lathe machine, but in this machine the work piece is lower
and the cutter is in the above (upper) to the work piece. It is used to make hug elements.

2.4.6.4 Copy machine

Copy machine is used to make knife, spoon, etc to copy one to one scales.

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 Fig-12 copy machine
2.4.7 Surface grinding section
In this section used to make different types of elements such as cutting tools. Plates, gears,
flanges, etc
In this section different ma chine are there. Such as:-
- Surface grinding machine: - it is used to face cutting tool.
- Cylindrical grinding machine: - it is used to make rotary surface.
- Center less grinding machines: - it is operated by magnetic motor. It is used to make
chins.
2.5 Forging shop

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 Forging section is one of manufacturing department. Today the forging industry covers
wide range of services and technology available to the market.
Forging product the material could be from steel, aluminum, copper alloy and soon. Those
difficult to fabricate alloys typically will demand slow or controlled deformation rate by forging
technical. In order to deform materials like carbon steel is requires extremely high deforming
dynamic load. In this case we need huge and bulky forging hammers. This type of hammer does
not exist for various reasons, instead we heat the work material to its re-crystallization
temperature so that it loses its resistance to deformation, this operation is called hot drop
forging. The main advantages of forging operation are to get the best material quality and for
mass production.
Typical examples of forging products are hand tools. Like hunting knives, pliers, knives of
different size, steel balls ranging from 25mm to100mm, different types of hammers, axes, and
so on.
Some examples of servicing operation are:-
- Forge
- Piercing
- Shearing
- Up-setting
- Bend
- Roll
- Trim, and so on
In this section different machine are there, such as:-
i. Self compress hammer machine
- The machine capacity is 2.8 ton dynamic load
- It is forge by hammer
- It is forging process
When the material is large or huge cannot used by human power. Because of it is difficult. So by
using mano-palter machine we can forge the material.
ii. Hot shearing machine
- It is use the round bar e.g. 6m, 5m
- It is she ring process
For example, we need 10cm round bar, from 6m so, the round bar straight to the
electrical system furnace adjust the length, and we can cut the round bar by using stopper.
iii. Drop forging machine
- It is pneumatic system
- The blow is not constant
- Mechanical hammer

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 iv. Rolling machine
- It is using lower and upper dies
- It is used to make round bar in to flat and add the length of bar
- It is rolling process
v. Up-setting machine
- It is using criper die and punch
- It is used increase the diameter and decrease the length of bar
- It is upsetting process
vi. Forging induction heater machine
- It is opposite of rolling machine
- It is used to make the flat bar in to round bar.
vii. Piercing ma chine
- It is using puncher and lower die
- Its capacity is 60 ton
- It is piercing process.
viii. Eccentric machine
- It is used to make bend
- It is bending process e.g. bicolor
ix. Bending machine
- It is used to make bend
- It is bending process
x. Trimming machine
- It is used to make trim
- It is trimming process e.g. hammer
Die materials
H-13.. Hot material
D-2 Cool work in

Forging procedures
In this section there are two ground holes. Then full the keros in gas up to 13000
litters. Transfer the gas in to accumulator by tube line. Move in to heater by thin tube line, the
heater and muffle furnace are connected by two tubes. Then crate the fire and connect with small
cloth and getting near to the furnace then start the muffle furnace by using fan. Then heat the
material according to material temperature when the material is hard; temperature is high. But
the material is soft temperature is less. After heating we can make the material any size and
shape by using different types of dies.

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 Fig-13 Forging products

Chapter Three
3. over all benefits of internship
This internship training is very important for Ethiopia because of used to generate skill full
generation to crate the new technology on the future. This internship is used to solve the
problems and to make the project. To know how to change theoretical parts in to practically
increased the theoretical knowledge that means to see the new things. From this internship
improve the following things.
3.1 Improving our practical skills
This internship training used to improving our practical skills, how to improved their knowledge
in which situation, how to solve the problems and how to communicate the workers. But in our
university is not enough machineries and laboratory, so before this internship we dont know
how to change the theory of the learning process in to practical process. But in this internship
training l am gained the operation of some machines, for example in pattern room (Jointer
machine, Thickneser machine, Band saw, Lath machine, milling, Disc sander and so on) and the
process of element to be produced (the process of pattern making, example: - Mean carrier head

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shaft, Gear box housing, Hand molding process, example: - Roller, Mechanized molding process,
core making process, and the process of pouring molten metal for example:-Nodular cast iron).
Generally, understand the work flow and self confidence by improving practical skill.
3.2 Upgrading our theoretical knowledge
This internship training is used to upgrading our theoretical knowledge. Most of the time
universities are not enough laboratory and machineries; this means the learning process are not
detail and not change in to practical skill. But in this internship solve this problem and increased
the theoretical knowledge with practices; for example: - how to make the pattern, how to malt
the molten metal (nodular cast iron, steel), how to make the roller in hand molding and process
of the elements to be produced. Generally, I get full information, increased the theoretical
knowledge, and how to change the theoretical skill in to practical.

3.3 Improving team playing skill

This internship training is used to improving team playing skills. Work with our friends, with
worker of company, with the students of Bahir Dare University to shear idea and to make the
thing. For example: - I have worked with Teshome in pattern shop about split pattern (Main
carrier head shaft). In this case my role is supporter. Another example: - I have worked with
Abebe he is the Manager of Mechanical maintenance about motor of Pang Born (Shout Blast)
machine. So, in this my role is supporter. Generally, we are working together and to shear idea.
3.4 Leader ship skill
This internship is used to improving leadership skill. Know I have some knowledge about
leadership; how to lead a team how to control the worker or employer, for example: - in my
section design and control room our leader is wizero Eyerusa. She is the best leader in the
company. I have learn from she how to lead the worker, how to communicate between leader and
employer and how to manage the company. But before this internship I have no information how
to lead the company.
3.5 Working ethics
This internship training is used to understanding the working ethics. In Akaki Basic Metal
Industry we are worked together. Based on this training I gained accountabilities of the working
of the product. Every employer or worker of the company works on tasks. When the worker is
mistake fail or rejects the product, decrease the demand of customer, decrease the profit of the
company, and decrease the development of country. Generally, this internship used to
understanding the working ethics.

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 CHAPTER FOUR
4, Conclusion and recommendation
4.1 Conclusion
This internship training is used to make the students are skill full in practical, theoretical
knowledge and how to change the theoretical parts into practice. Akaki Basic Metal
Industry is a big complex, comprising of foundry, forging, machining, heat treatment and
quality control shops. The plant has been designed to produce different items varying in
shape, size, material, design, and production technology and so on, according to their
engineering application. The factory is planned to serve primary the textile, sugar, metal
work, cement and other construction material industries. Amongst the product of the
plant the main ones are gears, shafts, sprockets, rollers, keys, steel balls, bearing housing
sheet and plate parts, various castings and so on.
4.2, Problems and recommendation
Akaki Basic Metal Industry is huge Company. As huge company many
problems are there. The problems are:-
1, Shortage of machine is one of the most problems in this company. Many
machines are brake and stop in different section; like pattern room (small band saw,
vertical sander, grinder and combination machine), core shop (crane housing), cast
finishing (pneumatic grinder) and non-ferrous (shakeout machine).
2, Luck of re-cord maintenance is another problem. In this company does not use
re-cord of machine maintenance, this means not re-cord maintenance day, failure, cause,
and how to solve the problem.
3, Shortage of worker is one of the most problems in this company. Because, not
agreement between employer and manager by case of low salary

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 4, Shortage of fire accident protection is one of the most problems in this
company. For example one day in cast finishing foundry shop crate the fire accident by
one employer. The case of fire accident is by tinnier gas. In that time does not protection
of fire accident.
5, Lack of chemical (catalyst and rasin)
6, Lack of lubrication
7, Lack of service transport
Based on the above problems i recommended the following
#, For storage of machine we are gating the proposal for captain Jemal. And
maintain by worker some machine; for example small band saw.
#, Crate a worker motivation by increases their month salary and other additional
benefit.
#, Before brake dawn the machine cheek for every month; this means preventive
maintenance.
#, For the fire accident put the powder protection 4-5 item for every section.
#, Increase amount of the service.
#, For shortage of chemical (catalyst and rasin); before finished the chemical
make ready another chemical

Chapter five
5.1 Project on: - Tumbling machine

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 In Akaki Basic Metal Industry there are many problems. For example shortage of
Tumbling machine, Sand Washed machine, Lake of chemical (catalyst and resin) and so
on. One day the non-ferrous manager Woubeshet seen different machines are there
problems. Like shortage of Tumbling machine, Pendulum grinder, and Shock out
machine, then we are visit that machines. Finally we are selecting the larger problem that
is Tumbling machine.
In Akaki Basic Metal Industry four Tumbling machines are there. Tumbling machine
is used to wash materials comes from Hand Toll (Hammers, Players and Wrenches),
E.P.CO products of the company (different size of Hooks) and cement bolls.
But numbers of machines are not enough or there is shortage of this machine in non-
ferrous section. To solve this problem, we have taken the solution by doing design
analyses of Tumbling machine.
5.2 Objective
To solve shortage of Tumbling machine.
To reduced the cost of company.
To increased the product of company.
To decreased the rust of materia

5.3 Design Procedure

When we have done the design analyses of Tumbling machine. We have taken the
following procedures:-
1, Gear design 7, Selection of Bolt and Nuts
2, Shaft design 8, Design of Housing cover
3, Coupling design 9, Design of Drum
4, Design of chain drive 10, Design of Vertical support
5, Bering selection 11, Design of Horizontal bar
6, Selection of Key 12, Cost of material
We are started the design from the given data
Given: - Power=4.4kw
Input speed=N1=1500 r.p.m
Assumption: - Gear ratio=i=12

Gear design
From above data we are find:-
1. Geometric analysis

Number of teeth, speed, deameter, module, addendum, dedendum, clerance, working depth,
face width, diametral piche, circular pich, angular velocity and so on.

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 2. Force analysis

Tangential force (Ft) and radial force

3. Stress analysis

By using AGMA equation:- Bending sress and contact sress.

Shaft design
Depanding on:-Maximume banding moment and Torsion.

We have three shaftes and we are find:-

The mass, volume, weight, maximume bending moment, Checke the deflaction, and
diameter of shaft.

Design of Coupling
Depending on:- --Speed of input shaft.

--Diameter of the input shaft.

--Torque in the input shaft.

We are Design:- Flunge, hub, key and bolts

Design of chain drive

Depanding on:---Speed of output shaft

--Speed of Input chain drive

--Speed of otput chain drive

We are find:- The rated power, velocity ratio, number of teeth, diameter, velocity, and length of
chain.

Bearing sellection
Depanding on:- --Shaft diameter

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 --Radial force

We are find:-out side diametre and width of bearing.

Key sellection
Depanding on:- --Torque in the shaft

--Shaft diameter

We are find:- width and thickness of the key.

Frame (Vertical and Horizontal supports)

Depanding on:- --Applide force and wight.

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 Fig-14 Tumbling machine

During washing process, the components used to wash the materials are:-

Water.
Abrasive.
Coustic soda (Na OH).
5.4 Challanges in our project
When we have done this Tumbling machine design analysis, we have face some problems

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 Lack of Laibrary:- by maintanance case.
Lack of Internate accesse.
Shortage of paper writing
Collapce of the work time and project work.
The manager has busy, for our project presentation; by conference case.

From abuve Problems we are using some methods;-like

By using soft copy,for example:- CD, DVD.

By using hard copy , for example:-our hand out of gear, chain, coupling and so on.
By using pucket mony.
By using our extra time , for example:- to night, to Saturday and to Sunday.
By using another library, for example:-
---public library in akaki.
--Addis Ababa Engineering and Technology (5- killo ) university .

5.5. Design of sand washing machine

Problem identification

The sand washing process done by human power

The worker couldn't address washed sand to the company

the washing method is consume very high amount of time,mony and human power

Objective
To increase the quality and quantity of washed sand

Save time,humanpower and increasing the productivity of the company by addressing

washed sand on time

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 Fig-15-sand washing machine

Conclusion
Increase the amount of washed sand 400kg to2ton per day
Decrease the clay content of the sand upto1%
fig-sand washing machine

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 References
, Training of Quality control inspectors on Foundry sand technology and process control;
Abera Deginet; March 2008.
, Report on the promotion seminar on Akaki Basic Metal Industry; Addis Ababa, Ethiopia; 1-3
August 1995.
, Sand laboratory; Assamenew Debela.
, Gear design text book.
, Reference to foundry engineering text book.

, Engineer Baruna by giving different sources.

, Shingly, text book of machine design.

, Foundry technology text book.

, Material science text book.

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