INTERNSHIP EXPERIENCE AT

INFRASTRUCTURE MACHINERY
ENGINEERING INDUSTRY
AN INTERNSHIP PROJECT REPORT BY:

YEABSRA MEKDIM ID: ETS1080/07

Submitted in partial fulfillment of the

Requirements for the award of
Degree of Bachelor of Science in Mechanical Engineering

SUBMITTED TO:

Department of Mechanical Engineering

ADDIS ABABA SCINCE AND TECHNOLOGY UNIVERSITY
ADDIS ABABA

i
 DECLARATION
I hereby declare that this internship project report is an authentic record of my own works
as requirements of Industrial Training during the period from March 5, 2018 to June 13,
2018 for the award of degree of B.Sc. in Mechanical Engineering, Addis Ababa Science
and Technology University, Addis Ababa, under the guidance of Mr. Dawit G.

Yeabsra Mekdim
ETS 1080/07

Date: June 18, 2018

i
 ACKNOWLEDGEMENT
I would like to express my deepest appreciation to all those who helped me and provided
the possibility to complete my internship period in a great performance. Special thanks to
my company supervisor Mr. Asmamaw who gave me the golden opportunity to do this
internship under his guidance, stimulating suggestions and encouragement throughout the
internship period. I would also like to acknowledge with much appreciation to my
academic advisor Mr. Dawit G. who advised me throughout the internship period and
guided me on how to prepare the internship and project reports.

ii
 EXECUTIVE SUMMARY

The primary purpose of this project is to develop an engine stand for a construction vehicle
engine that is capable of holding the engine at a comfortable height to work and give access
to all the various areas of the engine including its rotation giving full access to the
underside, topside and the various ends. This engine stand will be designed and
manufactured for the Infrastructure Machinery Engineering Industry, Debre Birhan in
order to provide safe and easy working conditions for engine assembly. The engine stand
is going to be designed using low cost and locally available materials. The mechanism
involves using gears that mesh at the same axis of rotation. One gear is rotated using a lever
arm which will drive the other gear attached to a shaft which is welded to a plate which
supports the engine. This project will solve the problem with the current uncomfortable
and potentially dangerous working condition in the workshops and add value to the
productivity of the industry.

iii
 CONTENTS

Topic Page number

DECLARATION .............................................................................................................................i
ACKNOWLEDGEMENT ............................................................................................................. ii
EXECUTIVE SUMMARY ........................................................................................................... iii
CONTENTS ................................................................................................................................... iv
List of Figures ................................................................................................................................ vi
List of Tables.................................................................................................................................. vi
CHAPTER ONE: INTRODUCTION.......................................................................................... 1
1.1 Background and Justification ...................................................................................... 1
1.2 Problem Statement ........................................................................................................ 1
1.3 Objective......................................................................................................................... 2
1.3.1 General Objective .................................................................................................. 2
1.3.2 Specific Objectives ................................................................................................. 2
1.4 Scope of the Project ....................................................................................................... 2
1.5 Significance of the Project ............................................................................................ 2
CHAPTER TWO: LITERATURE REVIEW ............................................................................ 3
2.1 Introduction ................................................................................................................... 3
2.1.1 Types of engine stands........................................................................................... 3
2.2 Literature survey ........................................................................................................... 5
CHAPTER THREE: PROJECT METHODOLOGY................................................................ 6
3.1 Project Management ..................................................................................................... 6
3.2 Data Collection .............................................................................................................. 6
3.3 Data analysis method .................................................................................................... 6
CHAPTER FOUR: DESIGN PROCESS .................................................................................... 7
4.1 Function Structure ........................................................................................................ 7
4.2 Design concept generation ............................................................................................ 8
4.3 Design concept evaluation ............................................................................................. 9
4.4 Product Definition ......................................................................................................... 9
4.4.1 Worm and worm gear ........................................................................................... 9

iv
 4.4.2 Caster .................................................................................................................... 10
4.4.3 Mounting plate and arms .................................................................................... 10
4.4.4 Solid Shaft ............................................................................................................ 10
4.4.5 Hollow shaft ......................................................................................................... 11
4.4.6 Bearing ................................................................................................................. 11
4.4.7 Key ........................................................................................................................ 11
4.4.8 Main Frame.......................................................................................................... 11
4.4.9 Lever arm ............................................................................................................. 12
4.4.10 Bolts ...................................................................................................................... 12
4.5 Design Calculation ....................................................................................................... 12
4.5.1 Design of Worm ................................................................................................... 12
4.5.2 Design of worm gear ............................................................................................ 15
4.5.3 Design of worm shaft ........................................................................................... 17
4.5.4 Checking for self-locking of the worm ............................................................... 18
4.5.5 Design of worm gear shaft .................................................................................. 19
4.5.6 Bearing selection of the worm ............................................................................ 20
4.5.7 Bearing selection of the worm gear .................................................................... 22
4.5.8 Design of key for worm gear ............................................................................... 24
4.5.9 Design of bolts ...................................................................................................... 26
4.5.10 Design of column.................................................................................................. 27
4.5.11 Design of lever arm .............................................................................................. 28
CHAPTER FIVE: CONCLUSION AND RECOMMENDATION ........................................ 30
5.1 Conclusion .................................................................................................................... 30
5.2 Recommendation ......................................................................................................... 30
References .................................................................................................................................... 31
Appendix ...................................................................................................................................... 32

v
List of Figures

Figure 1 Engines put on vehicle tire ................................................................................................ 2

Figure 2 Heavy duty engine stand ................................................................................................... 4
Figure 3 Medium duty engine stand ................................................................................................ 4
Figure 4 Flat engine stand ............................................................................................................... 4
Figure 5 Function structure ............................................................................................................. 7
Figure 6 Engine stand without gear box .......................................................................................... 8
Figure 7 Engine stand with gear box ............................................................................................... 8
Figure 8 Engine stand with electric motor drive ............................................................................. 8
Figure 9 Worm and worm gear ....................................................................................................... 9
Figure 10 Caster ............................................................................................................................ 10
Figure 11 Mounting plate and arms............................................................................................... 10
Figure 12 Solid shaft ..................................................................................................................... 10
Figure 13 Hollow shaft .................................................................................................................. 11
Figure 14 Rolling contact bearing ................................................................................................. 11
Figure 15 Rectangular hollow steel ............................................................................................... 11
Figure 16 Lever arm ...................................................................................................................... 12
Figure 17 Bolt................................................................................................................................ 12

List of Tables

Table 1 Design concept evaluation.................................................................................................. 9

Table 2 Number of starts to be used on the worm for different velocity ratios ............................. 13
Table 3 Values of X and Y for dynamically loaded deep groove ball bearing ............................. 21
Table 4 Values of service factor (𝐾𝑠)............................................................................................ 21
Table 5 Basic static and dynamic capacities of various types of ball bearings ............................. 22
Table 6 Proportions of standard parallel, tapered and gib head keys ............................................ 24

vi
 CHAPTER ONE: INTRODUCTION

1.1 Background and Justification

Engine stands are the most essential devices for a company like the Infrastructure
Machinery Engineering Industry because this company deals with the manufacturing and
maintenance of earth-moving vehicles. Surprisingly, there are no proper engine stands in
the maintenance workshops of the industry which directly led to the need for design and
manufacturing of heavy duty engine stand.
The purpose of this project is to design and manufacture engine stand which is believed to
greatly improve the current working condition of the engine maintenance workshop. The
current engine stands in the workshops are not safe for both the engine and the workers.
Also, it does not allow for effortless and quick maintenance. If this project is carried out it
will have significant contribution for the improvement of engine maintenance as well as
productivity of the industry. The project will eliminate the probability of engine damage
during maintenance, increase workers motivation and productivity, and it will reduce the
number of workers involved in maintaining a single engine which will allow more engines
to be maintained simultaneously. These advantages will increase the overall productivity
of the workshops while decreasing production time.
Regarding the cost of the project, it is going to be carried out using low cost and available
materials. The projects will cost less than the cost of damages to engines during the current
maintenance condition of the company’s workshops. Therefore, if the project is approved
it is guaranteed to increase the productivity of the company.

1.2 Problem Statement

In the Infrastructure Machinery Engineering Industry there is no suitable engine stand for
the purpose of assembling and disassembling while maintaining an engine. The workers
place an engine on a simple support beam or vehicle tire. This is not comfortable since the
engine cannot be rotated and workers do not have access to the underside and various areas
of the engine. Also, it will take more time to assemble and disassemble an engine which
will slow down the overall vehicle maintenance process.

1
 Figure 1 Engines put on vehicle tire

1.3 Objective

1.3.1 General Objective

The main objective of this project is the design, Analysis, and Simulation of heavy duty
engine stand to eliminate the lack of proper engine stand in the workshops.

1.3.2 Specific Objectives

• To design an engine stand which will allow 360-degree rotation of the engine.
• To design an engine stand with gear box to minimize operator’s effort.
• To design an engine stand with low cost of production.
• To minimize the total time of engine maintenance.

1.4 Scope of the Project

This project includes the design of engine stand using the total design approach, analysis
including detail and assembly drawings, software modelling using CATIA V5R16.

1.5 Significance of the Project

This project is very significant since it focuses on solving the problem with the current
working situation for engine assembly. It aims in designing and manufacturing of engine
stand which could have several importance including, holding the engine at a comfortable
height to work on and give access to all the various areas of the engine, allowing the engine
to rotate giving access to the underside, and move the engine around the workspace for
better space management.

2
 CHAPTER TWO: LITERATURE REVIEW

2.1 Introduction
An engine stand is a very important tool that every mechanic should have which is
commonly used to repair large and heavy gasoline or diesel engines. It uses heavy
cantilevered support structure to hold the engine in midair so that the mechanic has access
to any exposed surface of the engine. While small single-piston engine can commonly be
laid on a table for repair, a large engine is normally meant to be supported from its engine
mounts or from the flywheel transmission case mounts, and fragile components such as oil
pans and valve covers would be crushed if the large engine were placed on a flat surface.
Engine stands are typically mounted on large casters so that an engine can be moved around
the shop to different test and repair stations, and the engine can often be rotated in midair
to provide easier access to underside surface of the engine. The engine stand is commonly
used in combination with engine crane to remove or install an engine in a vehicle, break in
that engine, and perform repairs.
Engine stand is also used to turn the position of an engine in a full circle using torque
turning with appropriate pin for lock to prevent sliding of the shaft that is rigidly tighten
with an engine in bolt. Engine stand is mainly constructed from simple rectangular bar
metal by simple welding process of its different components of the stand.
On the other hand, an engine stand is illustrated having a universal mounting apparatus for
securing loads such as different sizes of automotive engines and the like to a rotatable face
plate which has a wheeled stand.

2.1.1 Types of engine stands

There are different types of engine stands based on the arrangement and shape of the engine
cylinders. Some of them are:
• Heavy duty engine stands
• Medium duty engine stands
• Flat engine stands
Heavy stand is a stand for inline cylinder engines or v-type cylinder engines which is used
to hold and rotate the engine with the required degree while maintenance. It helps to avoid
the complexity of assembling and disassembling of engines since the engines are heavy.
This type of engine stand uses two columns or posts to support the engine from two ends.

3
 Figure 2 Heavy duty engine stand
Medium duty engine stands are also used for inline cylinder engines or v-type cylinder
engines. It is used to hold and rotate medium weight engine with the required degree while
maintenance. This type of engine stand has only on column and supports the engine from
on end.

Figure 3 Medium duty engine stand

Flat engine stands are used for putting an engine after it is removed from a vehicle before
going through maintenance process. It is also used to put an engine after maintenance
process is finished. This engine stand does not allow engine to be rotated in any degree. It
is only used to place an engine outside of its vehicle.

Figure 4 Flat engine stand

4
 2.2 Literature survey
The GM Ecotec 2.2L engine on a swivel stand is designed for student instruction and
practice covering engine mechanical inspection, disassembly, measurement and
reassembly. The engine is securely mounted to a heavy duty rotating device equipped with
an automatic lock to allow full 360-degree rotation. A steel mounting plate is used for
engine mounting that allows full access for rear main seal and flywheel service. Each
engine comes equipped with a manual transmission flywheel. The engine starting station
contains all components and systems necessary for the starting and running of the GM 2.2L
ECOTEC engine. All necessary engine systems connections are provided to allow live
operation of each swivel engine stand.
ARI-HETRA’s Model AH-06187 Diesel Engine Stand features a solid base structure for
working on heavy-duty diesel engines. This stand eliminates the need to struggle with
rebuilding engines on a bench or on the ground. The sturdy AH-06187 helps reduce the
possibility of damaging expensive diesel engines.
Torin T25671 engine stand has a square type sturdy design which is one of three most
common designs for engine stands. Construction consists of one base plate and two legs.
The legs cannot be folded. It means that the engine stand will take its space whole time and
you can’t place it in any other smaller size space. Engine stand is made out of high quality
steel and construction is very strong and durable. It is not recommended to place engines
heavier than the maximum capacity because it may cause bending of mounting arms or
even construction.
The Rolls-Royce engine stand is ground based engine-built stand which has been designed
on the basis of two manipulators. It has its unique features such as 45-degree positioning
wheel with ball lock pin which secures engine giving eight angles of maintenance access,
sturdy welded steel construction, easy maneuvering with two swivel and two rigid heavy-
duty casters, center foot operated grips firmly to stabilize stand during maintenance
operation, and handy oil recovery pan.
Black Bull ES4W engine stand is made from heavy duty tubular steel that is painted in
neutral black color. Because of this material it is able to withstand weight that is up to ½
ton or 1000 pounds letting you hold most V8 type engine blocks on it while you are
repairing the engine itself or the car. The design of this engine also prevents even the heavy
engines from tipping forward
Mountain MTN5138 engine stand is a perfect stand for small-type engines with weight up
to half a ton. It has a very strong and stable steel construction despite the small size. The
size is a benefit because this engine stand will mostly fit between legs of engine hoists.
This Mountain engine stand has a very good and durable steel construction that is perfectly
suited for holding engines up to 0.5 tons (1000 lb.). It has the square type shape and
construction can be very stable if even heavier engines are placed on it. Two support plates
and other construction parts help to hold the heavy engines and doesn’t face any kind of
problems.

5
 CHAPTER THREE: PROJECT METHODOLOGY

3.1 Project Management

Project management refers to planning and overseeing the tasks necessary to achieve a
goal. It is important because it ensures proper expectation are set around what can be
delivered. It also helps to have better control of the variables which contribute to the well-
being of the project process. For these reasons we tried to follow some procedures which
will enable the whole project to be efficient and effective. Since the engines at the
Infrastructure Machinery Engineering Industry are very huge and heavy, the engine stand
should heavy duty engine stand. The design project is done following certain procedures
in order to complete it properly. These procedures are:
• Identifying the problem with the current engine stand
• Find possible solutions for the problems
• Prepare project proposal
• Select the required material for the project design and analysis
• Design each components of the engine stand
• After designing draw part and assembly drawing of the engine stand
• Determine the manufacturing process of each component

3.2 Data Collection

There are different data collection methods we have used from the beginning to the end of
this project. The major data collection method was observation which enabled us to identify
the problems with the current engine assembly difficulties without proper engine stand. We
also tried to collect data through interviews. We interviewed some of the workers in the
engine maintenance workshop and we were able to gather information on what should the
engine stand we are going to design include in order to solve the identified problems.

3.3 Data analysis method

After collection of data it was important to analyze in order to choose which ones are
relevant and which are not for the design project. To do this we used qualitative data
analysis method that seeks to reduce and make sense of vast amounts of information from
different source. After analyzing the data collected we were able to identify what should
the design project include to meet the requirements and objectives. After completing this
step we began the design process by formulating a function structure, generating design
concepts, and evaluating these concepts. These steps are discussed in the next chapter.

6
 CHAPTER FOUR: DESIGN PROCESS

4.1 Function Structure

The function structure shows the sequential order in which different processes of this
project are done. Boxes represent processes and arrows represent the flow or direction of
sequence. Boxes which are drawn in series shows that the processes cannot be completed
simultaneously and parallel boxes show processes which can be done simultaneously.

Literature Review Design Concept Design Concept

Generation Evaluation

Design of Worm Design calculation Product Definition

Design of Worm Design of Worm Design of Worm

Gear Shaft Gear Shaft

Bearing Selection of
Worm

Bearing Selection of
Design of Handle Worm Gear

Design of Key

Design of Bolt

Detail Drawing Software Modelling

Figure 5 Function structure

7
 4.2Design concept generation
Design concepts were generating by referring to previously used engine assembly
techniques and mechanisms. There are different design concepts according to the need and
specifications. For this project three design concepts of the engine stand were generated.
The difference between these concepts is the driving and gear box mechanisms. These are
listed as follows:
Design concept one
An engine stand with two columns which is going to be operated manually without having
gear box. This concept will surely be inexpensive but require more effort from operators.

Figure 6 Engine stand without gear box

Design concept two
This engine stand will also have two columns which is going to be operated manually with
a gear box mechanism. This concept will surely be more expensive than the first but will
decrease the amount of effort needed by the operator.

Figure 7 Engine stand with gear box

Design concept two
This engine stand is the same as the one on concept two, but instead of manually operating
the gear box it will be operated by an electric motor. It is believed to be expensive but it
will be effort less and guarantee smooth operation.

Figure 8 Engine stand with electric motor drive

8
 4.3 Design concept evaluation
The three design concepts are compared and contrasted by using weighted mean method
using different criteria as follows. (Scores are given out of 10, total value is the sum of the
product of score and weight)

Concept One Concept Two Concept Three

Criteria Weight
Score Weight Score Weight Score Weight
Ease to
0.1 10 1 9 0.9 7 0.7
manufacture
Availability of
0.2 9 1.8 9 1.8 8 1.6
materials
Reliability 0.2 7 1.4 9 1.8 10 2
Cost 0.4 9 3.6 8 3.2 6 2.4
Ease to use 0.1 6 0.6 8 0.8 10 1
Total 1 8.4 8.5 7.7
Rank 2 1 3
Table 1 Design concept evaluation
Therefore, according to the above table Design concept two is selected.

4.4 Product Definition

The engine stand which is going to be designed in this project has different members.
These members are discussed as follows.
4.4.1 Worm and worm gear
Worm and worm gear drive is used to drive the shaft which is connected to the engine
mounting plate. The worm gear arrangement will provide 90-degree power transmission
and helps reduce the operator effort.

Figure 9 Worm and worm gear

9
 4.4.2 Caster
A caster is wheeled device which can be mounted at the bottom of the engine stand to
enable relatively easy rolling movement of the engine stand. It is important for the engine
stand to move around the workshop easily and casters will provide that ability.

Figure 10 Caster
4.4.3 Mounting plate and arms
These are the parts of the engine stand where the engine is going to be bolted and held. The
arrangement can be rotated 360-degree with the help of a handle which makes every part
of the engine easy to reach.

Figure 11 Mounting plate and arms

4.4.4 Solid Shaft
Shaft is a rotating member which is used to transmit rotating power or torque. It will
transmit the rotation from the worm-gear arrangement to the plate where the engine is held.

Figure 12 Solid shaft

10
 4.4.5 Hollow shaft
This is the member in which the solid shaft passes through. It will act as hub for the solid
shaft and guide its motion.

Figure 13 Hollow shaft

4.4.6 Bearing
It is a machine element which supports another moving machine element and guide its
motion. It will support the worm and worm wheel. The two main types of bearing are
sliding contact bearing and rolling contact bearing. The type of bearing used for this project
is rolling contact bearing because of availability.

Figure 14 Rolling contact bearing

4.4.7 Key
It is a machine element which is used to connect rotating machine element to a shaft. It
prevents relative motion between two parts and enable torque transmission. In this case a
key is used to connect shaft to the worm gear.
4.4.8 Main Frame
Rectangular hollow steel is used for the horizontal and square hollow steel for vertical
members. The horizontal and vertical members are the main building blocks of the engine
stand. Two vertical members will hold the engine from the two ends axially. The horizontal
members will connect the vertical members and act as the base of the engine stand. Also,
casters will be fixed on the horizontal members.

Figure 15 Rectangular hollow steel

11
 4.4.9 Lever arm
It is an arm keyed at right angle to the end of the worm shaft, by which motion is imparted
to the worm gear. It mainly suffers from torsional stresses so medium carbon steel is used
as it combines merits of malleability and sufficient torsional strength.

Figure 16 Lever arm

4.4.10 Bolts
A bolt is s form of threaded fastener with an external male thread. Bolts are used to hold
the engine through the mounting arm. They are fitted on the engine through the fly wheel
mounting internal threads.

Figure 17 Bolt

4.5 Design Calculation

Materials selected for the design calculation:
Worm = hardened steel
Worm gear = Alloy cast iron,
Endurance limit, 𝜎𝑒 = 210 𝑀𝑃𝑎
Ultimate strength, 𝜎𝑢 = 420 𝑀𝑃𝑎
Allowable static stress, 𝜎𝑜 = 140 𝑀𝑃𝑎
4.5.1 Design of Worm
Initial assumptions taken for the design calculation process:
• Distance between the shafts, 𝑥 = 180 mm
• Velocity ratio = 5

12
Let, 𝑙 N = Normal lead, and
𝜆 = Lead angle.
The value of 𝑥 / 𝑙 N will be minimum corresponding to
3
cot 3 𝜆 = 𝑉. 𝑅 or cot 𝜆 = √𝑉. 𝑅
3
cot 𝜆 = √5
cot 𝜆 = 1.7099
𝜆 = cot −1 1.7099
𝜆 = 30.319 0
𝑥 1 1 𝑉.𝑅
We know that = ( + )
𝑙𝑁 2𝜋 sin 𝜆 cos 𝜆
180 1 1 5
= ( + )
𝑙𝑁 2𝜋 sin 30.319 0 cos 30.319 0
180 1
= (1.9809 + 5.7922)
𝑙𝑁 2𝜋

180
∴ 𝑙𝑁 = 1.237 = 145.49 mm
𝑙𝑁 145.49
and axial lead, 𝑙 = = cos 30.3190 = 168.55 𝑚𝑚
cos 𝜆

From Table 2, we find that for a velocity ratio of 5, the number of starts or threads on the
worm,
𝑛 = 𝑇𝑊 = 6

Table 2 Number of starts to be used on the worm for different velocity ratios
∴ Axial pitch of the threads on the worm, 𝑝𝑎
𝑙 168.55
𝑝𝑎 = 𝑛 = 6

𝑝𝑎 = 28.09 𝑚𝑚

13
 𝑝𝑎 28.09
∴ Module, 𝑚= =
𝜋 𝜋

𝑚 = 8.942 𝑠𝑎𝑦 9 𝑚𝑚 (standard value of module)

∴ Axial pitch of the threads on the worm, 𝑝𝑎
𝑝𝑎 = 𝜋𝑚 = 𝜋 𝑥 9 = 28.27 𝑚𝑚 Ans.

Axial lead of the threads on the worm,

𝑙 = 𝑝𝑎 . 𝑛 = 28.27 𝑥 6 = 169.65 𝑚𝑚 Ans.
and normal lead of the threads on the worm,
𝑙𝑁 = 𝑙 cos 𝜆 = 169.65 𝑥 cos 30.3190 = 146.44 𝑚𝑚 Ans.
We know that the center distance,
𝑙𝑁 1 𝑉.𝑅
𝑥= ( + )
2𝜋 sin 𝜆 cos 𝜆
146.44 1 5
𝑥= ( + )
2𝜋 sin 30.319 0 cos 30.319 0
𝑥 = 23.307(1.9809 + 5.7922) = 181.168 say 182 𝑚𝑚 Ans.

Let 𝐷𝑊 = Pitch circle diameter of the worm.

𝑙
We know that tan 𝜆 = 𝜋𝐷
𝑊

𝑙 169.65
𝐷𝑊 = 𝜋 tan 𝜆 = 𝜋 tan 30.3190 = 92.34 𝑚𝑚 Ans.

Since the velocity ration is 5 and the worm has sextuplet threads (i.e. 𝑛 = 𝑇𝑊 = 6),
therefore number of teeth on the worm gear,
𝑇𝐺 = 𝑉. 𝑅 𝑥 𝑛 = 5 𝑥 6 = 30
Length of the worm or length of threaded portion is,
𝐿𝑊 = 𝑝𝑐 (4.5 + 0.02𝑇𝑊 ) = 28.27(4.5 + 0.02𝑥6) = 130.6074 𝑚𝑚
∵ 𝑝𝑐 = 𝑝𝑎
This length should be increased by 25 or 30 mm for safety. Say 𝐿𝑊 = 155 𝑚𝑚 Ans.
We know that depth of tooth,
ℎ = 0.623 𝑝𝑐 = 0.623 𝑥 28.27 = 17.6122 𝑚𝑚 Ans.

14
and addendum,
𝑎 = 0.286 𝑝𝑐 = 0.286 𝑥 28.27 = 8.085 𝑚𝑚 Ans.
∴ Outside diameter of worm,
𝐷𝑂𝑊 = 𝐷𝑊 + 2𝑎 = 92.34 + (2 𝑥 8.085) = 108.5 𝑚𝑚 Ans.

4.5.2 Design of worm gear

Pitch circle diameter of worm gear,
𝐷𝐺 = 𝑚. 𝑇𝐺 = 9 𝑥 30 = 270 𝑚𝑚 Ans.
Therefore, outside diameter of worm gear,
𝐷𝑂𝐺 = 𝐷𝐺 + 0.8903 𝑝𝑐 = 270 + 0.8903(28.27) = 295.2 𝑚𝑚 Ans.
Throat diameter,
𝐷𝑇 = 𝐷𝐺 + 0.572 𝑝𝑐 = 270 + 0.572(28.27) = 286.2 𝑚𝑚 Ans.
Face width of worm gear,
𝑏 = 2.15 𝑝𝑐 + 5𝑚𝑚 = 2.15(28.27) + 5 = 66 𝑚𝑚 Ans.
Let us now check the designed worm gearing from the standpoint of tangential load,
dynamic load, static load and wear load.
• Check for the tangential load
Let 𝑁𝐺 be speed of worm gear in rpm
𝑁𝑊
Velocity ratio of drive, 𝑉. 𝑅 = 𝑁𝐺

𝑁𝑊 10
𝑁𝐺 = = = 2 𝑟𝑝𝑚
𝑉. 𝑅 5
∴ Torque transmitted,
𝑃 𝑥 60 15.7 𝑥 60
𝑇= = = 74.96 𝑁. 𝑚
2𝜋𝑁𝐺 2𝜋 𝑥 2
Tangential load acting on the gear,
2 𝑥 𝑇𝑜𝑟𝑞𝑢𝑒 2 𝑥 74.96
𝑊𝑇 = = = 555.27 𝑁
𝐷𝐺 0.27

15
Pitch line or peripheral velocity of the worm gear,
𝜋. 𝐷𝐺 . 𝑁𝐺 𝜋 𝑥 0.27 𝑥 2
𝑣= = = 0.028 𝑚/𝑠
60 60
∴ Velocity factor,
6 6
𝐶𝑣 = = = 0.995
6 + 𝑣 6 + 0.028
Tooth form factor,
0.912 0.912
𝑦 = 0.154 − = 0.154 − = 0.1236
𝑇𝐺 30
Since the material selected for the worm gear is alloy cast iron, allowable static stress is
𝜎𝑜 = 140 𝑀𝑃𝑎
Designed tangential load,
𝑊𝑇 = (𝜎𝑜 . 𝐶𝑣 ). 𝑏. 𝜋𝑚. 𝑦 = (140 𝑥 0.995)66 𝑥 𝜋 𝑥 9 𝑥0.1236 = 32129.6 𝑁
since the value is more than the tangential load acting on the gear, 𝑊𝑇 = 555.27 𝑁,
therefore the design is safe from the stand point of tangential load.
• Check for dynamic load
Dynamic load,
𝑊𝑇 32129.6
𝑊𝐷 = = = 32291.1 𝑁
𝐶𝑣 0.995
Since this is greater than 𝑊𝑇 = 555.27 𝑁, therefore the design is safe from the standpoint
of dynamic load.
• Check for static load or endurance strength
Flexural endurance limit for cast steel is
𝜎𝑒 = 210 𝑀𝑃𝑎
∴ Static load or endurance strength,
𝑊𝑆 = 𝜎𝑒 . 𝑏. 𝜋. 𝑚. 𝑦 = 210 𝑥 66 𝑥 𝜋 𝑥 9 𝑥 0.1236 = 48620.15 𝑁
Since this is greater than 𝑊𝑇 = 555.27 𝑁, therefore the design is safe from the standpoint
of static load or endurance strength.
• Check for wear
Assume material for worm as hardened steel. Load stress factor for hardened steel and
alloy cast iron 𝐾 = 0.345

16
∴ Limiting or maximum load for wear,
𝑊𝑊 = 𝐷𝐺 . 𝑏. 𝐾 = 270 𝑥 66 𝑥 0.345 = 6147.9 𝑁
Since this is greater than 𝑊𝑇 = 555.27 𝑁, therefore the design is safe from the standpoint
of wear.

4.5.3 Design of worm shaft

Let 𝑑𝑊 be diameter of worm shaft
Torque acting on worm gear shaft, (taking 25% overload)
1.25 𝑃 𝑥 60 1.25 𝑥 15.7 𝑥 60
𝑇𝑔𝑒𝑎𝑟 = = = 93.7 𝑁. 𝑚 = 93.7 𝑥 103 𝑁. 𝑚𝑚
2𝜋𝑁𝐺 2𝜋 𝑥 2
∴ Torque acting on worm shaft, (taking 89% efficiency)
𝑇𝑔𝑒𝑎𝑟 93.7
𝑇𝑤𝑜𝑟𝑚 = = = 21.056 𝑁. 𝑚 = 21.056 𝑥 103 𝑁. 𝑚𝑚
𝑉. 𝑅 𝑥 𝜂 5𝑥 0.89

Tangential force on the worm, (equal to axial force on the worm gear)
2 𝑥 𝑇𝑤𝑜𝑟𝑚 2 𝑥 21.056 𝑥 103
𝑊𝑇 = = = 456.057 𝑁
𝐷𝑊 92.34
Axial force on the worm, (equal to tangential force on the worm gear)
2 𝑥 𝑇𝑔𝑒𝑎𝑟 2 𝑥 93.7 𝑥 103
𝑊𝐴 = = = 694.07 𝑁
𝐷𝐺 270
Radial or separating force on the worm and worm gear,
𝑊𝑅 = 𝑊𝐴 . tan 𝜙 = 694.07 𝑥 tan 250 = 323.65 𝑁
Assume distance between bearing of worm shaft equal to the diameter of the worm gear,
i.e.
𝑥1 = 𝐷𝐺 = 270 𝑚𝑚
∴ Bending moment due to radial force in the vertical plane,
𝑊𝑅 𝑥 𝑋1 323.65 𝑥 270
= = = 21846.38 𝑁. 𝑚𝑚
4 4
Bending moment due to axial force in vertical plane,
𝑊𝐴 𝑥 𝐷𝑊 694.07 𝑥 92.34
= = = 16022.6 𝑁. 𝑚𝑚
4 4

17
∴ Total bending moment in vertical plane,
𝑀1 = 21846.38 + 16022.6 = 37868.98 𝑁. 𝑚𝑚
Bending moment due to tangential force in horizontal plane,
𝑊𝑇 𝑥 𝐷𝐺 456.057 𝑥 270
𝑀2 = = = 30783.84 𝑁. 𝑚𝑚
4 4
∴ Resultant bending moment on the worm shaft,

𝑀𝑤𝑜𝑟𝑚 = √𝑀1 2 + 𝑀2 2 = √37868.982 + 30783.842 = 48802.71 𝑁. 𝑚𝑚

Equivalent twisting moment on the worm shaft,

𝑇𝑒𝑤 = √𝑇𝑤𝑜𝑟𝑚 2 + 𝑀𝑤𝑜𝑟𝑚 2 = √(21.056 𝑥 103 )2 + 48802.712 = 53151.29 𝑁. 𝑚𝑚

Also, equivalent twisting moment is, (assume 𝜏 = 50𝑀𝑃𝑎 )

𝜋 𝜋
𝑇𝑒𝑤 = 𝑥 𝜏(𝑑𝑊 )3 , 53151.29 = 𝑥 50 (𝑑𝑊 )3 , 53151.29 = 9.8174(𝑑𝑊 )3 ,
16 16
(𝑑𝑊 )3 = 5413.945 𝑜𝑟 𝑑𝑊 = 17.6 𝑚𝑚 𝑠𝑎𝑦 20 𝑚𝑚 Ans.
Let us now check for the maximum shear stress induced.
Actual shear stress,
16𝑇𝑒𝑤 16 𝑥 53151.29
𝜏= 3
= = 33.837 𝑀𝑃𝑎
𝜋(𝑑𝑊 ) 𝜋(20)3
Direct compressive stress on the shaft due to the axial force,
𝑊𝐴 694.07
𝜎𝑐 = 𝜋 =𝜋 = 2.209𝑀𝑃𝑎
(𝑑 ) 2 (20) 2
4 𝑊 4
∴ Maximum shear stress,
1 1
𝜏𝑚𝑎𝑥 = √𝜎𝑐 2 + 4𝜏 2 = √2.20922 + 4𝑥33.8372 = 33.853 𝑀𝑃𝑎
2 2
Since the maximum shear stress induced is less than 50 MPa (assumed), therefore the
design of worm shaft is safe.
4.5.4 Checking for self-locking of the worm
1 tan2 𝜙 1 tan2 25
𝜂= − = − = 0.3913 = 39.13%
2 2 2 2
Since the efficiency is less than 50% the worm is self-locking.

18
 4.5.5 Design of worm gear shaft
Let 𝑑𝐺 be diameter of worm gear shaft
We have calculated above that,
Axial force on the worm gear = 456.057 N
Tangential force on the worm gear = 694.07 N
Radial or separating force on the worm gear = 323.65 N
Bending moment due to axial force on the worm gear in vertical plane,
𝐴𝑥𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 𝑥 𝐷𝐺 456.057 𝑥 270
= = = 30783.85 𝑁. 𝑚𝑚
4 4

Let us take the distance between bearing of worm gear shaft is X2 = 200 mm
∴ Bending moment due to radial force of the worm gear in vertical plane,
𝑅𝑎𝑑𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 𝑥 X2 323.65 𝑥 200
= = = 16182.5 𝑁. 𝑚𝑚
4 4
∴ Total bending moment in vertical plane,
𝑀3 = 30783.85 + 16182.5 = 46966.35 𝑁. 𝑚𝑚
Bending moment due to tangential force in the horizontal plane,
𝑇𝑎𝑛𝑔𝑒𝑛𝑡𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 𝑥 X2 694.07 𝑥 200
𝑀4 = = = 34703.5 𝑁. 𝑚𝑚
4 4
∴ Resultant bending moment on the worm gear shaft,

𝑀𝑔𝑒𝑎𝑟 = √𝑀3 2 + 𝑀4 2 = √46966.352 + 34703.52 = 58396.67 𝑁. 𝑚

We have already calculated torque acting on worm gear shaft, 𝑇𝑔𝑒𝑎𝑟 = 93.7 𝑥 103 𝑁. 𝑚𝑚

∴ Equivalent twisting moment on the worm gear shaft,

𝑇𝑒𝑔 = √𝑇𝑔𝑒𝑎𝑟 2 + 𝑀𝑔𝑒𝑎𝑟 2 = √(93.7 𝑥 103 )2 + 58396.672 = 110407.7 𝑁. 𝑚𝑚

19
Also, equivalent twisting moment is, (assume 𝜏 = 50𝑀𝑃𝑎 )
𝜋 𝜋
𝑇𝑒𝑔 = 𝑥 𝜏(𝑑𝐺 )3 , 110407.7 = 𝑥 50 (𝑑𝐺 )3 , 110407.7 = 9.8174(𝑑𝐺 )3 ,
16 16
(𝑑𝐺 )3 = 11246.12 𝑜𝑟 𝑑𝐺 = 22.4 𝑠𝑎𝑦 30 𝑚𝑚 Ans. (because of engine load)
Let us now check the maximum shear stress induced.
Actual shear stress,
16𝑇𝑒𝑔 16 𝑥 110407.7
𝜏= 3
= = 20.215 𝑀𝑃𝑎
𝜋(𝑑𝐺 ) 𝜋(30)3
Direct compressive stress on the shaft due to the axial force,
𝐴𝑥𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 456.057
𝜎𝑐 = 𝜋 = 𝜋 = 0.6452𝑀𝑃𝑎
(𝑑 ) 2 (30) 2
4 𝐺 4
∴ Maximum shear stress,
1 1
𝜏𝑚𝑎𝑥 = √𝜎𝑐 2 + 4𝜏 2 = √0.64522 + 4𝑥20.2152 = 20.217 𝑀𝑃𝑎
2 2
Since the maximum shear stress induced is less than 50 MPa (assumed), therefore the
design of worm gear shaft is safe.

4.5.6 Bearing selection of the worm

From the above calculation we have,
𝑊𝑅 = 323.65 𝑁
𝑊𝐴 = 694.07 𝑁
𝑁𝑊 = 10 𝑟𝑝𝑚
Since the average life of the bearing is 5 years at 300 days a year 10 hour per day,
therefore life of the bearing in hours,
𝐿𝐻 = 5 𝑥 300 𝑥 10 = 15000 Hours
Life of bearing in revolutions,
𝐿 = 60𝑁 𝑥 𝐿𝐻 = 60 𝑥 10 𝑥 15000 = 9 𝑥 106 rev
Basic dynamic equivalent radial load,
𝑊 = 𝑋. 𝑉. 𝑊𝑅 + 𝑌. 𝑊𝐴

20
 𝑊𝐴
In order to determine the radial load factor, 𝑋, and axial load factor, 𝑌, we require 𝑊𝑅
𝑊𝐴
and . Since the value of basic static load capacity 𝐶0 is not known, therefore let us
𝐶0
𝑊𝐴
assume = 0.5. Now from Table 3, we find that the values of 𝑋 and 𝑌 corresponding
𝐶0
𝑊𝐴 𝑊 694.07
to = 0.5 and 𝑊𝐴 = = 2.1445 (which is greater than e = 0.44) are,
𝐶0 𝑅 323.65

𝑋 = 0.56 and 𝑌 = 1

Table 3 Values of X and Y for dynamically loaded deep groove ball bearing
Dynamic equivalent radial load (V= 1 for most bearings),
𝑊 = (0.56 𝑥 1 𝑥 323.65) + (1 𝑥 694.07) = 875.314 𝑁
From Table 4, we find that for uniform and steady load, the service factor (𝐾𝑠 ) for ball
bearings is 1. Therefore, bearing should be selected for 𝑊 = 875.314 𝑁.

Table 4 Values of service factor (𝑲𝒔 )

Basic dynamic load rating, (k = 3 for ball bearings)
𝐿 1 9 𝑥 106 1
𝐶 = 𝑊( ) 𝐾 = 875.314( )3 = 1820.726 𝑁
106 106

From Table 5, let us select bearing No. 200 with the following basic capacities,
𝐶𝑜 = 2.24 𝐾𝑁 and 𝐶 = 4 𝐾𝑁 , then

21
 𝑊𝐴 694.07
= = 0.309
𝐶𝑜 2240

Table 5 Basic static and dynamic capacities of various types of ball bearings
From Table 3, the values of 𝑋 and 𝑌 are, 𝑋 = 0.56 and 𝑌 = 1.2
Substituting these values, we have dynamic equivalent load is,
𝑊 = (0.56 𝑥 1 𝑥 323.65) + (1.2 𝑥 694.07) = 1014.128 𝑁
∴ Basic dynamic load rating,
𝐿 1 9 𝑥 106 1
𝐶 = 𝑊( 6 ) = 1014.128(
𝐾 )3 = 2109.47 𝑁 = 2.1 𝐾𝑁
10 106
From Table 5, for shaft fitting the bearing number 204 having 𝐶 = 10 𝐾𝑁, may be
selected. Therefore, Bore diameter = 20 mm
Outside diameter = 47 mm
Width = 14 mm Ans.

4.5.7 Bearing selection of the worm gear

From the above calculation we have,
𝑅𝑎𝑑𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 = 323.65 𝑁
𝐴𝑥𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 = 456.057 𝑁
𝑁𝐺 = 10 𝑟𝑝𝑚

22
Since the average life of the bearing is 5 years at 300 days a year 10 hour per day,
therefore life of the bearing in hours,
𝐿𝐻 = 5 𝑥 300 𝑥 10 = 15000 Hours
Life of bearing in revolutions,
𝐿 = 60𝑁 𝑥 𝐿𝐻 = 60 𝑥 10 𝑥 15000 = 9 𝑥 106 rev
Basic dynamic equivalent radial load,
𝑊 = 𝑋. 𝑉. 𝑊𝑅 + 𝑌. 𝑊𝐴
𝑊𝐴
In order to determine the radial load factor, 𝑋, and axial load factor, 𝑌, we require 𝑊𝑅
𝑊𝐴
and . Since the value of basic static load capacity 𝐶0 is not known, therefore let us
𝐶0
𝑊𝐴
assume = 0.5. Now from Table 3, we find that the values of 𝑋 and 𝑌 corresponding
𝐶0
𝑊𝐴 𝑊 456.057
to = 0.5 and 𝑊𝐴 = = 1.409 (which is greater than e = 0.44) are,
𝐶0 𝑅 323.65

𝑋 = 0.56 and 𝑌 = 1
Dynamic equivalent radial load (V= 1 for most bearings),
𝑊 = (0.56 𝑥 1 𝑥 323.65) + (1 𝑥 456.057) = 637.301 𝑁
From Table 4, we find that for uniform and steady load, the service factor (𝐾𝑠 ) for ball
bearings is 1. Therefore, bearing should be selected for 𝑊 = 637.301 𝑁.
Basic dynamic load rating, (k = 3 for ball bearings)
𝐿 1 9 𝑥 106 1
𝐶 = 𝑊( 6 ) = 637.301(
𝐾 )3 = 775.238 𝑁
10 106
From Table 5, let us select bearing No. 200 with the following basic capacities,
𝐶𝑜 = 2.24 𝐾𝑁 and 𝐶 = 4 𝐾𝑁 , then
𝑊𝐴 456.057
= = 0.203
𝐶𝑜 2240
From Table 3, the values of 𝑋 and 𝑌 are, 𝑋 = 0.56 and 𝑌 = 1.4
Substituting these values, we have dynamic equivalent load is,
𝑊 = (0.56 𝑥 1 𝑥 323.65) + (1.4𝑥 456.057) = 819.7238 𝑁
∴ Basic dynamic load rating,
𝐿 1 9 𝑥 106 1
𝐶 = 𝑊( 6 ) = 819.7238(
𝐾 )3 = 997.145 𝑁 = 0.997 𝐾𝑁
10 106

23
From Table 5, because this bearing supports the load of the engine, the bearing number
206 having 𝐶 = 15.3 𝐾𝑁, may be selected.
Therefore, Bore diameter = 30 mm
Outside diameter = 62 mm
Width = 16 mm Ans.

4.5.8 Design of key for worm gear

Material selected for key is low carbon steel with,
𝜎𝑦 = 370 𝑀𝑃𝑎

𝜎𝑢 = 440 𝑀𝑃𝑎
Assumption, Factor of safety = 4
From Table 6, we find that for a shaft diameter of 30 mm,
Width of key, 𝑤 = 10 𝑚𝑚
Thickness of key, 𝑡 = 8 𝑚𝑚

Table 6 Proportions of standard parallel, tapered and gib head keys

24
Let length of key be 𝑙 and is obtained by considering the key in shearing and crushing.
Considering shearing of the key, shearing strength is,
𝑑
𝑇 = 𝑙 𝑥 𝑤 𝑥 𝜏𝑘 𝑥 ,
2
𝜎𝑦 370
𝑎𝑛𝑑 𝜏𝑘 = = = 46.25 𝑀𝑃𝑎
2𝐹. 𝑆 2𝑥4
30
∴ 𝑇 = 𝑙 𝑥 10 𝑥 46.25 𝑥 = 6937.5 𝑙 𝑁. 𝑚𝑚 𝑖
2

Torsional shearing strength of the shaft,

𝜋 𝜋
𝑇= 𝑥 𝜏𝑠 𝑥 𝑑 3 = 𝑥 50 𝑥 303 = 265071.9 𝑁. 𝑚𝑚, 𝑖𝑖
16 16
𝜎𝑦𝑠
∵ 𝜏𝑠 =
2𝐹. 𝑆
From equations i and ii,
265071.9
265071.9 = 6937.5 𝑙 , 𝑙= = 38.21 𝑚𝑚
6937.5
Considering crushing of the key, crushing strength is,
𝑡 𝑑
𝑇=𝑙𝑥 𝑥 𝜎𝑐 𝑥
2 2
𝜎𝑦 370
𝑎𝑛𝑑 𝜎𝑐 = = = 92.5 𝑀𝑃𝑎
𝐹. 𝑆 4
8 30
𝑇=𝑙𝑥 𝑥 92.5 𝑥 = 5550 𝑙 𝑁. 𝑚𝑚 𝑖𝑖𝑖
2 2
From equations ii and iii,
265071.9
265071.9 = 5550 𝑙 , 𝑙= = 47.76 𝑚𝑚
5550
Taking the larger value,
𝑙 = 47.76 𝑚𝑚 say 50 mm Ans.

25
 4.5.9 Design of bolts
Material selected for the bolt is 304 stainless steel with yield strength:
𝜎𝑦 = 215 𝑀𝑃𝑎

Safety factor assumed is F.S = 2

Number of bolts, 𝑛 = 8
Engine weight 𝑃 = 2000𝑙𝑏 = 8900𝑁
The internal thread found on the engine for fitting the bolt is 12mm. Therefore, diameter
of bolt d = 12mm.
Considering shearing of the bolt, shearing strength is,
𝜋𝑑2 𝜏𝑏𝑜𝑙𝑡
𝑃𝑙𝑜𝑎𝑑 =
4
Load on each bolt
𝑃 8900
𝑃𝑙𝑜𝑎𝑑 = = = 1112.5 𝑁
𝑛 8
Therefor shearing strength will be,
𝜋122 𝜏𝑏𝑜𝑙𝑡
1112.5 =
4
4 𝑥 1112.5
𝜏𝑏𝑜𝑙𝑡 = = 9.84 𝑀𝑃𝑎
𝜋122
But allowable shear stress is,
𝜎𝑦 215
𝜏𝑎𝑙𝑙 = = = 53.75 𝑀𝑃𝑎
2𝐹. 𝑆 2𝑥2
Since 𝜏𝑏𝑜𝑙𝑡 = 9.84 𝑀𝑃𝑎 is less than 𝜏𝑎𝑙𝑙 = 53.75 𝑀𝑃𝑎 , the design is satisfactory.
Considering crushing of the bolt, crushing strength is,
Torque transmitted
𝑇 = 𝑘 𝑥 𝑑 𝑥 𝑃𝑒𝑎𝑐ℎ = 0.2 𝑥 12 𝑥 1112.5 𝑁 = 2670 𝑁. 𝑚𝑚
k = 0.2 for non-lubricated bolts
∴ crushing strength is,
2𝑇 2 𝑥 2670
𝜎𝑐 𝑏𝑜𝑙𝑡 = 𝜋 = 𝜋 = 3.934 𝑀𝑃𝑎
𝑑 3 123
4 4

26
But allowable crushing stress is,
𝜎𝑦 215
𝜎𝑐 𝑎𝑙𝑙 = = = 107.5 𝑀𝑃𝑎
𝐹. 𝑆 2
Since 𝜎𝑐 𝑏𝑜𝑙𝑡 = 3.934 𝑀𝑃𝑎 is less than 𝜎𝑐 𝑎𝑙𝑙 = 107.5 𝑀𝑃𝑎 , the design is satisfactory.

4.5.10 Design of column

The column is the vertical supporting member for the engine stand which supports the
engine load.
The material selected for the column is mild steel with crushing stress 𝜎𝑐 = 320 𝑀𝑃𝑎
The ideal working height for most humans on engine repair is 130 mm. Therefore, the
length of the column is assumed to be L = 100 mm.
The steel is square section b = h and thickness of column is assumed to be 4 mm.
Now let us check whether the column is safe or not by using Rankine’s formula.
𝑓𝑐 𝐴
𝑃=
𝑙𝑒
1 + 𝑎( )2
𝑘
Where, P = critical load
fc = Crushing stress
A = Cross-sectional area of column
le = Equivalent length of column
a = Rankine’s constant
k = Least radius of gyration

h t

b
Since the column is fixed at on end the effective length, Le = 2L = 2000 mm
Load coming at the column is, P = Pengine / 2 = 4450 N
1
Rankine’s constant for mild steel, 𝑎 = 7500

27
Area of cross-section, A = (bh)-[(b-2t) x (h-2t)] = 4bt + 4t2 =1664 mm2, since b = h
𝑏ℎ3 (𝑏−2𝑡)(ℎ−2𝑡)3
Moment of inertia, 𝐼 = −[ ] = 2363392 mm4
12 12

𝐼 2363392
Radius of gyration, 𝐾 = √𝐴 = √ = 37.686 𝑚𝑚
1664

∴ Crushing load
𝑓𝑐 𝐴 320 𝑥 1664
𝑃= = = 387.1 𝐾𝑁
𝑙𝑒 2 1 2000 2
1 + 𝑎( ) 1+ ( )
𝑘 7500 37.686

Since the load coming at the column is much less than the crushing load, the design is
safe.

4.5.11 Design of lever arm

The lever arm has L-shape and the length of this lever is selected as, l = 180 mm.
Let d = Diameter of handle in mm.
The load applied by the operator is assumed to be 50N. And 𝜎𝑏 = 100 𝑁/𝑚𝑚2
The force applied acts at a distance of one-third of the length of the handle from its free
end. Therefore, maximum bending moment is
1 1
𝑀 = (1 − ) 𝑥 𝑃 𝑥 𝑙 = (1 − ) 𝑥 50 𝑥 180 = 6000 𝑁. 𝑚𝑚
3 3
Section modulus,
𝜋 3
𝑍= 𝑑 = 0.0982𝑑 3
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Therefore, twisting moment is
𝑀 = 𝜎𝑏 𝑥 𝑍 = 100 𝑥 0.0982𝑑 3
𝑑 = 8.485 𝑚𝑚 𝑠𝑎𝑦 10 𝑚𝑚 Ans.
Cross-section of the lever arm
Let t = thickness of lever arm in mm
b = width of lever arm in mm
Assume width is twice the thickness.
The lever arm is to be designed for 25% more bending moment.

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Therefore, maximum bending moment is
𝑀 = 1.25 𝑥 𝑃 𝑥 𝑙 = 1.25𝑥 50 𝑥 180 = 11250 𝑁. 𝑚𝑚
Section modulus,
1 1
𝑍 = 𝑥 𝑡 𝑥 𝑏 2 = 𝑥 𝑡 𝑥 (2𝑡)2 = 0.667𝑡 3
6 6
𝑀 11250
σ𝑏 = 100 =
𝑍 0.667 t 3
𝑡 = 5.53 𝑚𝑚 𝑠𝑎𝑦 6 𝑚𝑚 Ans.
𝑏 = 2𝑡 = 12 𝑚𝑚 Ans.
Let us now check the lever arm for induced bending. Bending moment on the lever arm
near the boss (assuming that the length of the arm extends up to the center of shaft) is given
by,
𝑀 = 𝑃 𝑥 𝑙 = 50 𝑥 180 = 9000 𝑁. 𝑚𝑚
Section modulus,
1 1
𝑍 = 𝑥 𝑡 𝑥 𝑏 2 = 𝑥 6 𝑥 (12)2 = 144 𝑚𝑚3
6 6
𝑀 9000
σ𝑏 = = = 62.5 𝑁/𝑚𝑚2
𝑍 144
Therefore, the induced bending stress is within safe limits.

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 CHAPTER FIVE: CONCLUSION AND
RECOMMENDATION

5.1 Conclusion
This design project aims in designing and analysis of heavy duty, manually operated engine
with gear box drive. The main objective of the design project is to eliminate the lack of
engine stand in the maintenance workshops of the industry. It aims to design an engine
stand with low cost of production which will improve the current working condition and
provide ease in engine maintenance. Design concepts are generated by referring to previous
designs and literatures. The best design concept is selected considering cost, availability,
efficiency, and other criteria. After selecting the best alternative design calculations for
each component is carried out. Detail drawings and assembly drawing is done using
AutoCAD and CATIA V5R16 software. Generally, I can say that most of the design
objectives are met throughout the project.

5.2 Recommendation
Due to the limited time I had at the Infrastructure Machinery Engineering Industry, I was
not able to manufacture the engine stand which is designed in the project. So, I recommend
the industry and other mechanical and manufacturing engineering students who are going
to take internship in this industry in the future to develop the prototype and check the
general functionality of the project.

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 References
1. A Textbook of Machine Design by R.S KHURMI AND J.K GUPTA[NAQASH]
2. The Theory and Practice of Worm Gear Drives by Iles Dudas
3. Shigley’s Mechanical Engineering Design

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 Appendix

Detail drawings and assembly drawing of the engine stand

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