Aku

AKSUM UNIVERSITY
COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING
HOSTING COMPANY; Amara Metal Industry and Machine Technology

Development Enterprise
PROJECT TITLE:- Design and manufacturing of manually operated pipe bending
machine
DONE BY; EYOB SISAY
ID = 1378/07
Advisor; Mr. Kibrom M.
September 24, 2018

FINAL INTERNSHIP REPORT MED 2018
Acknowledgement
Above all I thank GOD for every opportunity I am given in life through its endless mercy, strength
and wisdom in every steps of life. Secondly I have to extend my greatest gratitude to Aksum
university for providing such kind of opportunity for students to apply their understanding on how
a given work is carried out on their respective field of studies; which in our case in Amara Metal
Industry And Machine Technology Development Enterprise .
Thirdly I would like to express my profound sense deeply to AMIMTDE(Amara metal industry
and machine technology development enterprise) ;which is willing to accept my internship
program ,for valuable guidance, sympathy cooperation for providing necessary facilities and
source during this internship program and I would like to register our sincerely gratitude to all
AMIMTDE employees.
Finally I would like to thank for my advisor Mr. Kibrom M .for giving comments and help how
BY: EYOB SISAY MECHANICAL ENGINEERING I

Exclusive Summary
This internship report document is based on the fourth month long internship program that I have
successfully completed in AMIMTDE it includes background of the company, main services,
organizational structure, work flow,mission,vision,objective of the company.
From the report we have also included the work flow of the company, major problems facing to
me while performing the work task and their proposed solutions and then the result and discussion
with recommendation for the identified problems finally the report talks about the overall benefit
I have gained from the internship and then the report concludes with recommendations.
Another chapter of this report includes the design of the project which is design of rectangular
shaped pipe bending machines.it starts by short summery of the project and then followed by
identifying problems and their justification. Then describe the objective and methodology and then
finalize by giving conclusion with supported recommendations. The result and conclusions is done
by talking the analysis of each component and assembly by using solid work software.
The recommendation we forwarded to the company are also part of the paper. During overall stay
of the company we brought various achievements theoretical knowledge and practical skill,
interpersonal, leadership and team playing
BY: EYOB SISAY MECHANICAL ENGINEERING II

Table of Content
Acknowledge ment .......................................................................................................................... I
Exclusive Summary ...................................................................................................................... II
Table of Content.............................................................................................................................III
List of Figure................................................................................................................................. VI
List of Table ................................................................................................................................ VIII
List of symbols/Nomenclature ...................................................................................................... IX
CHAPTER-ONE...................................................................................................................... 1
1 INTRODUCTION ................................................................................................................ 1
1.1 Back Ground of the Company .................................................................................................. 1
1.2 Some reports of the company and major challenges faced to me. ............................................ 2
1.2.1 Objectives of the Enterprise ............................................................................................... 2
1.2.2 Main Products or Services.................................................................................................. 2
1.2.3 Main Customer or End Users ............................................................................................. 2
1.2.4 Vision of the Company ...................................................................................................... 2
1.2.5 Mission of the company ..................................................................................................... 3
1.2.6 Values of the company ....................................................................................................... 3
1.2.7 The Section of the Agency I Have Been Working ............................................................. 3
1.2.8 Working flow of the company ........................................................................................... 4
1.2.9 Major challenges faced during stay.................................................................................... 5
1.2.10 over all benefits I gained from the internship .................................................................. 5
1.3 Location of the Company.......................................................................................................... 6
1.4 Problem Statement and Justifications ....................................................................................... 7
BY: EYOB SISAY MECHANICAL ENGINEERING III

1.5 Objective ............................................................................................................................... 8
1.5.1 General Objective............................................................................................................... 8
1.5.2 Specific Objective .................................................................................................................. 8
1.6 Significance and advantages of the project............................................................................... 8
1.6.1 Significance of the project ..................................................................................................... 8
1.6.2 Advantages of the project................................................................................................... 8
1.7 Introduction of the Machine...................................................................................................... 9
1.8 Components of Pipe Bending Machine .................................................................................. 11
1.9 Scope of the Project ................................................................................................................ 12
1.9.1 Scope ................................................................................................................................ 12
CHAPTER-TWO................................................................................................................... 13
2 Literature Review ............................................................................................................... 13
CHAPTER-THREE ............................................................................................................... 14
3 Detail Design ...................................................................................................................... 14
3.1 Methodology ........................................................................................................................... 14
3.2 Material Selection ................................................................................................................... 16
3.3 Hydraulic bottle jack selection................................................................................................ 17
3.4 Design of Shaft........................................................................................................................ 21
3.5 Bearing Selection .................................................................................................................... 31
3.6 Design of Key ......................................................................................................................... 33
3.7 Design of Housing .................................................................................................................. 36
3.8 Design of C-Channel Support ................................................................................................. 37
3.9 Design of Handle .................................................................................................................... 38
3.10 Bolt and Nut Selection .......................................................................................................... 41
BY: EYOB SISAY MECHANICAL ENGINEERING IV

3.11 selection of Washer ............................................................................................................... 44
CHAPTER FOUR ................................................................................................................. 49
4 Result And Discussion........................................................................................................ 49
CHAPTER FIVE ................................................................................................................... 50
5 Conclusion And Recommendation ..................................................................................... 50
5.1 Conclusion .............................................................................................................................. 50
5.2 Recommendation .................................................................................................................... 50
CHAPTER SIX...................................................................................................................... 55
Reference ...................................................................................................................................... 55
CHAPTER SEVEN ............................................................................................................. 56
Appendix A ........................................................................................................................... 56
Appendix B ........................................................................................................................... 74
BY: EYOB SISAY MECHANICAL ENGINEERING V

List of Figure
Fig 1 .1 Picture of our hoisting company....................................................................................... 1
Fig 1.2 Working flow of AMIMTDE Company........................................................................... 4
Fig 1.3 GPS of AMIMTDE Company ........................................................................................... 6
Fig 1.4 Workers done sheet metal bending in our hoisting company..........Error! Bookmark not
defined.
Fig 1.5 Design of PBM .................................................................................................................. 9
Fig 3.1 Methodology of the project ............................................................................................. 15
Fig 3.2 Force analysis of the shaft ............................................................................................... 22
Fig 3.3 Force analysis of the shaft in x-y plane ........................................................................... 24
Fig 3.4 Shear and bending moment at section (1, 1) in x-y plane ............................................... 24
Fig 3.5 Shear and bending moment at section (2, 2) in x-y ......................................................... 25
Fig 3.6 Force analysis of the shaft in x-z plane ........................................................................... 26
Fig 3.7 Shear and bending moment at section (1, 1) in x-z plane............................................... 26
Fig 3.8 Shear and bending moment at section (2, 2) in x-z plane................................................ 27
Fig 3.9 Shear and bending moment diagram .............................................................................. 29
Fig 3.10 Rectangular sunk key..................................................................................................... 33
Fig 3.11 Forces acting on a key ................................................................................................... 34
Fig 3.12 Handling ........................................................................................................................ 38
Fig 3.13 A washer ........................................................................................................................ 44
Fig 3.14 Positions of a washer ..................................................................................................... 46
Fig 3.15 Internal and external diameter of a washer.................................................................... 46
Fig 4.1 Simulation analysis of Bounded Parts (Shafts over Bearings) ........................................ 49
Fig 7.1 Overall Dimension of a Bending Machine ...................................................................... 56
Fig 7.2 Explode View of Table Assembly ................................................................................... 57
Fig 7.3 Over All Dimensions of Table Assembly........................................................................ 58
Fig 7.4 C-Channel Table .............................................................................................................. 59
Fig 7.5 Support Table Plate ......................................................................................................... 60
BY: EYOB SISAY MECHANICAL ENGINEERING VI

Fig 7.6 Rotating Bender Shaft ..................................................................................................... 61

Fig 7.7 C-Channel Vertical Assembly ......................................................................................... 62
Fig 7.8 Over All Dimensions of C-Channel Vertical Assembly ................................................. 63
Fig 7.9 Support C-Channel .......................................................................................................... 64
Fig 7.10 Over all dimension of support C-channel ...................................................................... 65
Fig 7.11 Explode View of Wheel ................................................................................................ 66
Fig 7.12 Over All Dimensions of Wheel ..................................................................................... 67
Fig 7.13 Wheel Base .................................................................................................................... 68
Fig 7.14 Key................................................................................................................................. 69
Fig 7.15 Wheel Arm..................................................................................................................... 70
Fig 7.16 Handle Shaft .................................................................................................................. 71
Fig 7.17 Housing.......................................................................................................................... 72
Fig 7.18 Hleix Flange Bolt........................................................................................................... 73
Fig 7.19 Exploded View Of Total Assembly............................................................................... 74
Fig 7.20 Each Components from Total Assembly ....................................................................... 75
Fig 7.21 Final assembly of bending machines ............................................................................. 76
BY: EYOB SISAY MECHANICAL ENGINEERING VII

List of Table
Table 1.1 Time period plan I used for the last four months in the company ............................... 12
Table 3.1 Different types of jacks having different parameters................................................... 18
Table 3.2 The standard dimensions of a square thread ................................................................ 19
Table 3.3 Recommended values for Cs and Km.......................................................................... 22
Table 3.4 Maximum unit pressure, temperature and clearance ratio of some alloyed metals .... 32
Table 3.5 Bearing materials and properties ................................................................................. 32
Table 3.6 Proportions of standard parallel, tapered and gibes head key...................................... 33
Table 3.7 Physical property of some engineering material.......................................................... 39
Table 3.8 Selection of a cap screw bolt with corresponding nut from standard .......................... 42
Table 3.9 METRIC- standard flat washer (Normal series, Grade A) ISO 7089 .......................... 47
VII
BY: EYOB SISAY MECHANICAL ENGINEERING
I
List of symbols/Nomenclature
A = Area
Cs = Shock factor
c/d = Clearance ratio
d1 = Nominal diameter
dc = Core diameter
E = Young’s modules
Fs = Factor of safety=n
Ft = Total force loaded
J = Polar moment of inertia
Ka = Surface condition modification factor
Kb = Size modification factor
Kc = Load modification factor
Kd = Temperature modification factor
Ke = Reliability factor
Kf = Fatigue stress concentration factor for bending
Kfs = Fatigue stress concentration factor for torsion
l = Length
Ma = Alternating bending moment
Mm = Mid-range bending moment
MR = Resultant moment
BY: EYOB SISAY MECHANICAL ENGINEERING IX
P = Pitch
Se = Endurance limit of a machine part
Sut = Minimum tensile strength of a material
t = Thickness
T = Torque required
Ta = Alternating torque
Tm = Mid-range torque
To = Output torque
V = Poisons ratio
W = Width
Wr = Radial load
Wt = Tangential load
σet = Elastic strength
η = Efficiency
µ = Coefficient of friction
τu = Ultimate shear stress
σc = Crushing stress
ϒ = Weight densit
BY: EYOB SISAY MECHANICAL ENGINEERING X

CHAPTER-ONE
1 INTRODUCTION
1.1 Back Ground of the Company
Amara National Regional State Metal Industry and Machine Technology Development Enterprise
was established according to proclamation number 127/2007 E.C to meet the gap of technology
requirement among manufacturing industry, agricultural sector, micro and small enterprise in
terms of product and service. Currently the enterprise is starting to manufacture different types of
technological products by two existed well organized workshops found at bahirdar and kombolcha
city (Amara region).the enterprise is hereby established as an autonomous regional government
enterprise having its own legal personality and has its capacity to bring technological transfer as
well as increasing production and productivity in the region in particular and national carry out
production and commercialization of metal and machine technology through solving the demand,
supply and utilization obstruction seen in the manufacturing industry and agricultural sectors in
the region.
Fig 1 .1 Picture of our hoisting company
BY: EYOB SISAY MECHANICAL ENGINEERING 1

1.2 Some reports of the company and major challenges faced to me.
1.2.1 Objectives of the Enterprise
The general objective of the enterprise is to fulfill the gaps of agricultural technologies encountered
the small folder farmers for increasing production and productivity of the agricultural products.
1.2.2 Main Products or Services

The enterprise has many products and services that are produced according to the customer needs
and order since the company is follow reverse engineering method.
Even if the enterprise starts lately there are different types of machines that are under
manufacturing and sold for the customers. Some of the products are;-
- Agricultural technology production and supply

- Food processing machine production and supply
- General machine production and supply
- Transport machine production and supply
- Environmental protection
- machine production and supply
- Construction ,machine production and supply
- Different machinery spare parts production and supply.
1.2.3 Main Customer or End Users

The above products that are produced in the company are selling to local market customers like
- Amara regional state administration office car parking and shade.

- Bahirdar university mixer and fish feed pelletizer machine
- Rural society agricultural products.
1.2.4 Vision of the Company

Metal machine technology to see the capacity built in the region.

1.2.5 Mission of the company
Metal machine technology to the promotion of the development, transfer, preparation, marketing
production and entry in to the market for performing agricultural and industrial technology to
alleviate bottlenecks in the global market and competitive technologies and extractive industry.
1.2.6 Values of the company
- We are passionate about our customers
-Our employees are the heart of our business
-we are committed to deliver exceptional values
-profitability is the core of our business.
1.2.7 The Section of the Agency I Have Been Working

There are various work sections in the agency. These are Productive section, Assembly section,
Quality control section, Design section, marketing section. Of all these we stuck with the design
section because in these section there was designing of the machine components, motion test of
machine ,the tool and method how to design the machine .
Design section is the first most section of the AMIMTEDE work flow. In this section almost all
the required products are designed and then goes into assemble section in order to produce the
desired machines.

1.2.8 Working flow of the company

The General Working Flow of the Company Is Summarized In the Below Working Flow Tree
Diagram;-
Customer Market Study
Company Management
Reverse Design Team
NO
Design Evaluation
y
e
s Material Buying and
Manufacturer
Selling Team
Manufactured Part
NO
Quality Checking
y
e
s
Assembly Room
s
e
s
Market Introduction
Fig 1.2 Working flow of AMIMTDE Company

1.2.9 Major challenges faced during stay

Behind every success there was/were obstacles or challenges among the challenges I have been
faced were;-
- Adapting the workers and the compound

- Installation of new machines takes a long time as a result there was some gap
- Lack of safety material
- Shortage of measuring devices
- Lack of computer
- Combination work habit in the company
1.2.10 over all benefits I gained from the internship

In this 4 months internship experience I have got much skills, knowledge and higher confidence
about many things. Generally I have got such benefits in terms of;-
-improving practical skills
-upgrading theoretical knowledge
-improving team playing skills
-improving leadership skills
-understanding about work ethics related issues
-improving inter personal communication skills
-understanding industrial psychologies.

1.3 Location of the Company

Amara metal industry and machine technology development enterprise main company is located
in Amara region bahirdar city which is around 561km from our capital city Addis Ababa, Ethiopia
in the northern region and its branch is located in Amara region kombolcha zone which is 681 km
in north west region from the capital city of the federal democratic republic of Ethiopia which is
Addis Ababa.
Fig 1.3 GPS of AMIMTDE Company

1.4 Problem Statement and Justifications

As I see from the company when the employers are recommended to do car parking from
along, flat, rectangular pipes what they are doing is first up to some distances they cut partly
then bend and weld same like the first the second step is continue up to the total length of the
given pipe required as shown below. This is due to the company have not a pipe bending
machine this method of bending pipes has the following draw backs;-
 It requires many more employers

 It wastes time
 It is noisy that harms the environment and
 It is less efficient that is if some load applied means it is easily brake. This all are our
main reasons to design a pipe bending machine with minimum costs.
Fig 1.4 Workers done sheet metal bending in our hoisting company

1.5 Objective
1.5.1 General Objective
The general objective of this project is to design and manufacture manually operated pipe bending
machine.
1.5.2 Specific Objective

The specific objective of this project is;-
 To design the components of manually operated pipe bending machine.

 To select a material that is suitable for our design.
 To sketch part and assembly drawings of manually operated pipe bending machine.
1.6 Significance and advantages of the project
1.6.1 Significance of the project

 It is easy to carry and use at any time and place.
 It reduces excessive time wastage
 It reduces human effort
 It reduces cost wastage
 It requires low less skills to operate the machine
 It reduces noise that disturb the employers.
1.6.2 Advantages of the project

 It is simple to operate
 It is simple in mechanism
 It is simple for maintenance
 It is high efficient and productivity.

1.7 Introduction of the Machine
Fig 1.5 Design of PBM

At present time the development of science and technology are quick, in industrial machinery
bender also have a variety of bending machine into the remedial alternative industrial processing
equipment, and bending performance of the tube with the need of the industry will continue to
improve. Of those variety of bending machine;-
 Electrical and manual form pipe bender

 CNC bending machine
 Hydraulic bending machine etc………
On the market CNC bending machines led, but different bending machines can meet the market
demand and different manufacturing process. Designed in this paper is about manual operated pipe
bending machine as shown above in FIG.
This machine is used to bend a pipe in to curve or other curvature shapes. The size of the machine
is very convenient for portable work. The machine consists of some basic components used to
operate successfully and in choosing materials for each component design it needs very attention
because it will affect the overall cost of the machine and product quality. With this consideration,
I will designed this machine with the maximum quality and low cost.
In pipe during bending operation stress concentration is occur in bend area of pipe. The bend
section may be damage during service in particular case where significant validity and thickness
version exist which are introduced during manufacturing process and operation time. Hence the
acceptance of pipe depends on the magnitude and shape of pipe. In pipe bending process the
thickness’ of the pipe is not changed. The acceptability of pipe bend is depending on the magnitude
and shape of imperfection.

1.8 Components of Pipe Bending Machine

Our designed manually operated pipe bending machine consists of the following components;-
 Hydraulic bottle jack;-is a device used for lifting the load carrying table in this case up
and down by application of much smaller force by using the hand lever and then Locke
when we reach at required position.
 Manually operated handle;-the main purpose of the handle is to apply labor in order to
bend the pipe by rotating the wheel as a result the middle shaft is rotating because both are
attached using a key and the rest two sided shafts are rotating using a stress concentration
created at a bending area.
 Rolling Shafts;-is a machine component that are used to transmit power from the hydraulic
jack system from the load applied by the handle.
 Bearing;-is a machine part whose function is to support a moving element and to guide its
motion.
 Bolts and nuts;-those bolts and nuts are used for fastening of components of manually
operated pipe bending machines.
 Key;-those key is used to attach the upper middle shaft and the handle as a result both can
rotate relatively one with the other. That is rotating the handle means the upper middle
shaft do so relatively.
 Housing;-is used to cover up and protect components of the machine for its safety
operation.
 C-channel vertical support;-there are two parallel vertically support c channel on which
the table can be moved up and down.
 Washer;-is used to prevent the bolt to remove easily from the nut.
 C- Channel horizontal support;-there are two c-channels here also the first is attached at
the bottom with the vertical support and the other is used as a table to move the pipe which
is bended up and down.

1.9 Scope of the Project

1.9.1 Scope
The scope of this project is to design manually operated pipe bending machine by selecting
appropriate materials for each components and related specifications.
Time Period Plane
 Planning the given time period in order, is very important to do our project and to finish
on time. Our working plan is used to show the time required to accomplish this project.to
complete this project, we have to follow the following schedule;-.
title First week Second week Third week Fourth week

proposal
preparation and 
process design
Design
calculations 
Material
selection and 
collection
Production of
the machine 
Table 1.1 Time period plan I used for the last four months in the company

CHAPTER-TWO
2 Literature Review
 In 2011 G.C hiroyuki goto, ichiru, hidenobu satire, yuu ishikura, and yutaka tankan
presents anew flexible bending machine and its practical applications. The proposed
machines uses a new method. When tubes are fed in to a fixed and mobile dies they are
bent by shifting the relative position of the mobile die. The bending radius is controlled by
the relative distance and orientations between the movable die and the tube.
 In 2012 G.C ”journal of material processing technology “is discovered a mechanical model
of symmetrical three roller setting round process is established and the quantities
relationship between the upper roller load. Bending curvature of each micro pipe wall
elements and the reduction are predicted. This not only lays a theoretic foundation for the
development of three roller special setting round machine and control stages. But also
provide an idea for resolving many degree of statically in determinant problems with an
elastic plastic deformation.
 In 2013 G.C prashant khandare, mayor aher,swapnil patil studied” the three roller bending
machines “such type of bending machines more important for small scale work in less cost
and more precision and accuracy of different type of bendings.the machine capacity can be
increased according to the need. Manual bending tends to minimize wrinkles and can
reduce spring buck.by its design the defects can be easily overcome. Simpler design not
only reduce the defects but also contributes to fluid pressure test during bending.it should
be noted the tendency to wrinkle and the cross section of the deformation.
 In 2014 G.C Mohan Krishna “study of hydraulic and pneumatic bending machines “he
concluded that this work has provided an excellent opportunity and experience, to use
limited knowledge.it has gained a lot of practical knowledge
regarding,planning,purchasing,assembling and machining while doing this project work.
This work is a good solution to bridge the gates between institutions and industries. The
work is completed the work with the limited time successfully.

CHAPTER-THREE
3 Detail Design
3.1 Methodology
The complete design process from start to finish is often outlined as in fig 3.1 this process begins
with an identification of need and after much iterations the process ends with the presentation of
the plans for satisfying the need. Depending on the design nature several design phases may be
repeated throughout the life of the product. When we go to summarize the planes that we processed
in the life of design as shown below;-
 Identification Of The Need;- at this phase the design process is began because before we
are going to design first we have to identify the necessity of the project that is going to be
design. And for this phase detail analysis should be done for the importance of the project.
 The Definition of Problem;-it is more specific and must include all the specifications for
the object that is to be designed. Hence our specifications is our input and output quantities
for the design of this project but on doing this project there is any irregularity regarding on
the assumptions(specifications) and should be clearly defined.
 Synthesis;-the synthesis of scheme connecting possible system element is sometimes called
the invention of the concept or concept design. Figure blow shows that the synthesis and
analysis are intimately and iteratively related.
 Analysis;-this requires that we construct or device abstract models of the system that will
admit some form of mathematical analysis. We call those models as mathematical models.
In creating them it’s our hope that we can find one that will simulate the real physical
system very well.
 Evaluation;-is a significant phase of the total design process. Evaluation is the final roof
of a successful design and usually involves the testing of prototype in the laboratory. Here
we wish to discover if the design really satisfies the need.
 Presentation;-communicating the design to others is the final, vital presentation step in the
design process. The engineer, when presenting anew solution to administrative,

management, or supervisory persons, is attempting to sell or to prove to them that this

solution is a better one.
Identification of need
Definition of problem
Synthesis
Analysis
Evaluation
Presentation
Fig 3.1 Methodology of the project

3.2 Material Selection

The material that are used for this machine can be selected due to its mechanical and physical
property and the material that found in the company. Selection of material consideration includes;-
 Availability of material.
 Optimum weight of the system.
 Cost wise.
 Ability to prevent shearing, bending and buckling stress.
 Wearing and corrosion resistance.
 Should be easily machined
 Should have wear resistance.
 Heat transmission property. Depending those considerations I selected materials for each
components of the machine.

3.3 Hydraulic bottle jack selection

Hydraulic bottle jack is a device used for lifting medium or heavy loads by the application of much
smaller forces. It’s based on the principles of Pascal’s low which states that intensity of pressure
is transmitted equally in all directions through amass of fluid at rest.
Pascal’s principle states that;-
A1V1=A2V2 where A1&A2 =area of the pipes at both ends.
V1&V2=velocities at both ends,
Choosing the Right Hydraulic Jack for Our Requirements from standards;-
 Look at some considerations we should take in to account before purchasing;-
1-the first information we will need is the weight we will require it to lift; - this means it should
be match with the weight to be lifted.
2- The ground clearance we have;-the best jack in the world is useless if we can’t place it under
the machine. Ground clearance is an important parameter to consider, we need to be able to place
the jack without damaging the machines body.
3- The maximum lifting height we should need;-to make the best choice, compare the number of
stokes and the maximum height of each hydraulic jack to do so check the number of steps the
piston has; the more there are, the larger will be the stroke, and.
4-finally we have to source a reliable distributor;-this can advise us on the capabilities of each jack
and help us to select one that will not only do the job but will last.
So considering all those the above information’s I select the one which fits to my project
from standards as shown below;-

DK40Q DK60Q DK100Q DK120Q

capacity 1-4 tons(t) 4-6 tons(t) 6-10 tons(t) 10-12 tons(t)
Minimum height 140 mm 140 mm 150 mm 150 mm
Maximum height 600 mm 600 mm 585 mm 585 mm
Frame length 800 mm 800 mm 805 mm 805 mm
Handle length 950 mm 1200 mm 950 mm 1200 mm
Frame height 240 mm 240 mm 260 mm 260 mm
width 500 mm 500 mm 530 mm 530 mm
weight 95 Kg 95 Kg 118 Kg 118 Kg
Table 3.1 Different types of jacks having different parameters
For my project the hydraulic jack is used for light duty, hence I select from 1-4 tones lifting
capacity then all the other information’s of the jack is so taken from the table above.
Calculations;-
 Depending on the information gathered above we have to do some basic analysis;-
1-Torque Required To Rotate the Nut;-
 Design of screw for spindle
Let dc=core diameter of the spindle.
Since the screw is under compression, therefore the load (W):-
𝜋𝑑𝑐 2 𝜎𝑒𝑐 𝜋𝑑𝑐 2 𝜎𝑒𝑐

W= 𝑥 = 4 x 103 = x 𝑓𝑠 w/r σet= elastic limit of jack nut maternal (phosphor-
4 𝑓𝑠 4
bronze=100Mpa) fs=factor of safety
𝜋𝑑𝑐 2 𝜎𝑒𝑐
4x103 = 𝑥 (taking factor of safety=2)
4 𝑓𝑠
𝜋𝑑𝑐 2 100𝑥 106 4𝑥4

4x103 = x =dc2 =𝜋𝑥50𝑥 103 =dc
4 2
d2 =1.01859=d=0.01m=10.09mm=10mm

For the square threads of normal series the fig dimension of the screw are selected from this
standard table as shown below
Table basic dimension for square threads in mm (Normal series) according to is: 4694-1968
(reaffirmed 1996)
Nominal Major dia. Minor Pitch(p) Depth of thread Area of

dia.(d1) dia.(dc) core(mm2 )
Bolt(h) Nut(H)
22 22 22.5 17 227
24 24 24.5 19 284
26 26 26.5 21 5 2.5 2.75 346
28 28 28.5 23 415
30 30 30.5 24 452
32 32 32.5 26 531
34 34 34.5 28 6 3 3.75 616
36 36 36.5 30 707
Table 3.2 The standard dimensions of a square thread
Hence our calculated dc=10mm is even so from table above the 1st complement even values of
dc= 24mm implies the corresponding values accordingly from the table is do=30m, P=6mm
New let us check for principal stress, we know that the mean diameter of screw is;-
𝑑𝑜+𝑑𝑐 30+24
d= 2
=d= 2
= 27mm---- (Ans.)
𝑝 6
And tan 𝛼=𝜋𝑑 = 𝜋𝑥27 =0.0707 w/r α=helix angle of screw
Assume coefficient of friction b/n screw& nut is;-
µ=tan =0.15

Then 1- torque required to rotate the screw in nut is given by;-
𝑑 𝑑
T= p × 2 =W tan (α+)2
𝑡𝑎𝑛𝛼+𝑡𝑎𝑛 𝑑
T=W⌈ ⌉
1−𝑡𝑎𝑛𝛼×𝑡𝑎𝑛 2
0.0707 +0.15 27=

=4x103 [1−0.0707×0.15 ] 12×103 Nmm
2
2. Compressive stress due to axial load
𝑊 𝑊 4×10 2
σc=𝐴𝑐 =𝜋 (𝑑𝑐2 )= 𝜋 (24)2 =8.84N/mm2
4 4
3. Shear stress due to the torque
16𝑇 16× 12 ×103

τ=𝜋(𝑑𝑐)3 = 𝜋(24) 3
=4.42 N/mm2
Therefore the maximum principal stress (tensile or compression)
1
σc (max) = [𝜎𝑐 + √(𝜎𝑐)2 + 4𝜏 2 ]
2
1
2
[8.84 + √(8.84)2 + 4 × (4.42)2 ]
1
(8.84+156.29)
2
=82.565 N/mm2
4. Efficiency of screw (η)
Toque required to rotate the screw with no friction is given by
𝑑
To = W tanα
2
27
=4x103 × 0.0707 × = To = 3817.8
2
𝑇𝑜 3817 .8
= η= = ×100%= 0.318 ×100= 31.8%
𝑇 12000

3.4 Design of Shaft

 Shaft is a machine component which is used to transmit power from the handle to the
rotating pipe w/c is going to bend.
 The material selected for design of shafts is a mild steel this is due to having high strength,
high stiffness and better rigidity. Hence the ultimate shear stress of a mild steel is τu=12
Mpa
Hence the max lifting capacity of the hydraulic jack is equal to the Normal load W=4kN then:-
Tangential load (wt.)
W=wt/cos
Wt=Wcos
=4cos200
=3.758kN≈3.8KN
Radial load (Wr)
Wr=wt tan
=3.758 tan20
=1.36KN≈1.4KN
Torque
𝑑𝑝
T=Wt x × shock Cs (i.e. dp= 40mm from solid work)
2
40 𝑥10 −3
=3.8 ×103 × × 1.5
2
T= 114Nm

Name of load Cs Km
Stationery shaft
(a) Gradually Applied 1.0 1.0

load
(b) Suddenly applied load
1.5 to 2.0 1.5 to 2.0
Rotating shaft
(a) Gradually applied or 1.5 1.0

steady load
(b) suddenly applied load
with minor shock only 1.5 to 2.0 1.5 to 2.0
(c) Suddenly Applied

load with heavy shock
2.0 to 3.0 1.5 to 3.0
Table 3.3 Recommended values for Cs and Km
Force Analysis
(Hence the Length of shaft us taken from solid work due to reverse operation.)
Wr=1.4KN Wt=3.8KN
RAZ RAY RBZ RBY
40mm 560mm
Fig 3.2 Force analysis of the shaft

FY Fz
Total vertical force in the y total tangential force in the z
+ve , ΣFy=0 +ve, ΣFZ=0
RAY+RBy-Wr=0 RAZ+RBz+Wt=0
RAY+RBY-1.4KN=0 RAZ+RBZ+3.8KN=0
RAY+RBY=1.4KN----1 RAZ+RBZ=-3.8KN----2
Taking moment at B Taking moment at B
+ve, ΣMB=0 +ve.ΣMB=0
RAYx560-1.4x600=0 (RAZx560)-(3.8x600) =0
1.4𝑥600 3.8𝑥600
RAY= RAZ=−
560 560
RAY=1.5KN and from equation RAZ=-4.07KN and from equation
(1), we have (2), we have
1.5KN+ RBy=1.4KN -4.07KN+RBZ=-3.8
RBY=-0.1KN RBz=0.27KN

X-Y plane
Wr=1.4KN 1 2
40mm 560mm
A B
RAY=1.5KN 2 RBy=-
0.1KN
Fig 3.3 Force analysis of the shaft in x-y plane
Case-1 0≤×≤40
x V1 xy, M1 xy
Wr=1.4KN 1
Fig 3.4 Shear and bending moment at s ection (1, 1) in x-y plane
+ve ΣFxy=0
V1 xy-1.4KN=0
V1 xy=1.4KN
+ve ΣM11 =0
Mxy-1.4x=0, M1xy =1.4x

But 0≤x≤=40
At x=0
MXy -1.4(0) =0
M1XY=0Nm
At x= 40
MXY-1.4(40) =0
MXY=56Nm
Case -2 40≤ 𝒙 ≤ 𝟔𝟎𝟎
M2XY
V2XY
2 |______600-x__________Rby=-0.1KN
Fig 3.5 Shear and bending moment at section (2, 2) in x-y
+ve ΣFxy=0, v2xy =0.1KN
+ve ΣM22 =0
M2xy -0.1(600-x)
M2xy =60-0.1x
At x=40
M2xy =56Nm
At x=600
M2xy =60-0.1x600
M2xy =0Nm

X-Z plane
Wt=3.8KN 1 2
A B
RAZ=-4.07KN RBz=0.27KN
1 2
Fig 3.6 Force analysis of the shaft in x-z plane
Case -1, 0≤x≤40
Wt=3.8KN 1
V1XZ, M2XZ
X 1
Fig 3.7 Shear and bending moment at section (1, 1) in x-z plane
+ve, ΣFxZ=0
V1Xz=3.8KN
+ve ΣM11 =0
M1Xz=3.8x

At x=0
M1xz=0 Nm
At x= 40
M1Xz= 3.8x40
M1xz=152 Nm
Case 2 40≤x≤ 𝟔𝟎𝟎
600-x
M2XZ v2Xz
RBZ=0.27KN
Fig 3.8 Shear and bending moment at section (2, 2) in x-z plane
+ve ΣFXZ=0
V2xz=0.27 KN
+ve ΣM22=0
M2xz=0.27(600-x)
M2Xz=162-0.27x

At x=40
M2xz= 162-0.27x40
M2xz=151.2 Nm
At x=600
M2Xz= 162-0.27 x600
M2xz= 0Nm
V1 xy=1.4KN
M1 xy=1.4x
In x-y plane V2 xy=0.1KN
M2 xy=60-0.1x
V1 xz=3.8KN
M1 xz=3.8x
In x-z plan V2 xz=0.27KN
M2 xz=162-0.27x
Resultant moment
MR=√𝑚 2𝑥𝑦 2 + 𝑀2 𝑥𝑧 2 at x =40
MR=√402 + 151.22
MR=156.40 Nm

Shear and Bending Moment Diagram
T=114Nm
Torque
1.4KN
0.1KN
56Nm
X-Y
plane
3.8KN
0.27KN
151.2Km
X-Z
plane
156.40Nm
Resultant
bending
moment
Fig 3.9 Shear and bending moment diagram

Now to calculate the shaft diameter
1
We use the formula 3
16𝑛 (2𝑘𝑓𝑀𝑅 ) [3(𝑘𝑓𝑠𝑇𝑚) 2 ]1/2

D= ( + )
𝜋 𝑆𝑒 𝑠𝑢𝑡
W/r n= factor safety = 1.5=Kfs
Kf=1=stress concentration factor for bending.
MR= resultant bending moment=156.40Nm
Se= kaxkbxkcx kd xkexsut
W/r ka=0.7017
Kb=0.9
Kc=1 are parameters for surface modification motion
kd=1.018
Ke=0.897
Kf=1.7
Sut=1120 Mpa from AISI 1050 for mild steal
Se= 0.7017 x 0.9 x 1x1.018x0.897x1120
Se=645.88
TM=mid-range torque= 114 Nm
1
3
1
16𝑥1.5 (2𝑥1.7𝑥156.49) [3(1.5𝑥114) 2 ]2
D= ( + )
𝜋 645.88 1120
D=21.25, then from standard shaft diameter we have, D=25 mm………….. (Ans.)
3.5 Bearing Selection

Bearing;-is a machine part whose function is to support a moving element and to guide its motion.
Depending up on the nature of contacts between the working surface bearings are classified in to
two those are;-
 Sliding contact bearing( also known as plain bearing)

 Rolling contact bearing.
There is no hard and fast rule or formula existing for deciding between sliding and rolling bearings.
Each type has its own advantage and dis advantages and there is no best bearing for all the
applications.
For a particular application the designer must evaluate the advantages and dis advantages of each
bearing and then reach the best compromise. For this the performance of each bearing must be
compared in relation to load, capacity, friction, space requirements, accuracy, noise, cost etc….
Hence we have Fa=4000 N
d=0.025 m
where Fa=axial force
d=diameter of the shaft
Then we can find the pressure acting on the shaft and is calculated;-
𝜋
P=Fa/d=4000 N/4 (0.025𝑚) 2 =4*4000/π (0.025)2
P=8.1487 Mpa
Hence the pressure acted on the shaft is 8.1487 Mpa now compare the standard tables below;-

Bearing metal Maximum unit c/d Max. operating

pressure in Mpa temperature,0 C
Candium base alloy 8.27-10.34 0.0008 170
Copper lead alloy 13.79-27.58 0.001 170
Silver lead indium 34.48 0.001 180
Table 3.4 Maximum unit pressure, temperature and clearance ratio of some alloyed metals
Based on the above table we select the material candium base alloy because the calculated pressure
P=8.1487 Mpa =8.2 Mpa is found in between 8.27-10.34 which belongs for candium base alloy.
Now we can use candium base alloy from standard tables below;-
Material Modules of Specific Coefficient Ultimate Hardness
elasticity gravity of tensile HB
friction(µ) strength(Mpa)
Candium
base alloy 103.46 8.4 0.15 137.88 45
Cu,Al,bronze 103.46
alloy 8.09 0.39 482.68 202
Table 3.5 Bearing materials and properties
So based on the table above I select candium base alloy for our bearing material because it has less
value of coefficient of friction.

3.6 Design of Key

Key; - is a piece of mild steel between shaft and hub of the pulley to connect those together in
order to prevent a relative motion between them.
It’s always inserted parallel to the axis of the shaft and is used for temporarily fastenings
Fig 3.10 Rectangular sunk key
Hence we select a key from the standard which is depending on the following table;-
Shaft diameter(mm)up to and Key cross section

including
Width(mm) Thickness(mm)
6 2 2
8 3 3
10 4 4
12 5 5
17 6 6
22 8 7
30 10 8
Table 3.6 Proportions of standard parallel, tapered and gibes head key

Strength of sunk key;-
Fig 3.11 Forces acting on a key
Let T=torque transmitted by a shaft
F=tangential force acting at the circumference of the shaft
d=diameter of the shaft
l=length of a key
W=width of a key and t=thickness of a key.
Force on a key; - τ & σc be shear and cruising stresses for a key material
F=area resisting to shear*shear stress
Torque transmitted by a shaft;-
T=F*d/2=l*w*τ*d/2
From the shaft design we have dshaft =25mm then the corresponding width and thickness of a key
are tabulated in the above table.
Hence for dshaft =25mm
we have w=9mm
t=8mm and take lkey =40mm

Check for shearing stress
Hence the material for a key material is a mild steel so we have τ=12 Mpa and σc=84 Mpa.
1200 Nmm=40*9*τ*25/2
Τ=2.67=3 Mpa
As a result 3 Mpa<12 Mpa so our design is safe.
Check for crushing stress of a key
δ c=2τ*F=area resisting crushing*crushing stress
δc=l*t/2*σc , where T=F*d/2
δc=l*t/2*σc*d/2=40*8/2*25/2*σc=27544.2
σc=13.7=14 Mpa
Which is 14 Mpa<84 Mpa so our design is safe.

3.7 Design of Housing

Housing;-is one of a machine component which is used to cover up and give protection to the
other components of the machine.
Most of the housings or cover plates are made either from steel or cast iron accordingly but for our
design of housing I assumed cast iron because of;-
 Cast iron is very strong in compression and weak in tension.

 It doesn’t exhibit any definite yielding point, so it’s used for machine housing and frames,
pulleys, clutch, pedal and lightly loaded gears.
 It has good vibration absorption properties.
 It’s available at relatively low cost.
 It’s easily machined.
 It has good cast ability.
 Generally cast iron are classified in to two classes;-
1-grey cast iron
 It contains most of the carbon as free carbon in the form of graphite.

 The free carbon acts as an excellent lubricants during machining.
 Offers little frictional resistance.
 Grey cast iron combined with iron (Fe) gives a white appearance called white cast iron, it’s
hard and wear resistance.
2-malleable cast iron
 Much tougher than grey cast iron.

 It’s more resistance to bending and twisting.
 It’s used for gear housing brake pedal, automotive and agricultural pedal.
 Used for heavy duties that means for large buses and transfer cases.
So the properties above I selected grey cast iron as the material for cover plates and we prepared
this grey cast iron as required through molding.

3.8 Design of C-Channel Support

We choose a mild steel for supporting purpose than steel because of;-
 It’s harder than steel.

 It can be made from a readily available natural material
 It has high wearing resistance
 For either in tension or compression loading the average normal stress is given by;-
σ=FT /hl
where FT =total force loaded
l=length of support
h=height of support
Then, FT =FN+Wshaft
Hence we have FN=4KN and WShaft =σt*area, for a mild steel (σt) =12Mpa
Wshaft=12*106 *π*dshaft 2 /4
=12*106 *π*[(25*10-3 )] 2 /4
=5890.48 N
So, Ft=4000+5890.48
Ft=9890.486 N
Hence σ=Ft/hl=9890.486/ (55*500)
σ=0.3596 N/mm2
(Note the length and height of the C-channel is taken from our solid work data)

3.9 Design of Handle

Handle is a manually operated component of a machine that are used to rotate the shaft as when
we rotate the handle because of both the shaft and handlings are attached through a key.
Fig 3.12 Handling
Material selection for a handle wheel
A large wheel will add more cost and weight to the system which are factors that have to be
considered against the smoothness of operation desired.
Dense materials such as cast iron and steel are the obvious choice for a handle wheel.aluminium
is seldom used though many metals (lead, gold, and silver, platinum) are denser than iron and steel.
On comparing cast iron and steel material for handle wheel design I assumed steel alloy as the
material for handle wheel design because of;-
 Has high strength and ability to resist the external applied force
 Has high ability to resist deformation under stress
 Has high ability to resist mechanical force and load
 Has high machinability and weld ability
 Has high weight density and strength which is suitable to absorb shock and vibration as
shown in the table below;-

Materials Poisons ratio(V) Weight Yield strength of a

density(ϒ)Ib/in3 material in N/mm2
Grey cat iron 0.28 0.26 225
Steel greed (27-54) 0.28 0.28 271
Table 3.7 Physical property of some engineering material
Then for steel material we have; -
σyield=270Mpa
τyield=150Mpa
E=200 G pa
ϒ=0.28 Ib/in3
Now from the property of steel we can then calculate;-
[1] Bending stress (σ bending);-
σbending=У*E/R
Where У=distance from the neutral axis to the external force. Assume 45 mm
E=young’s modules
R=the radius of the wheel, Now from our solid work data I have perimeter
(P) =162.84 mm2
P=2πr=162.84 mm2
Implies r=25.9 mm
Then σbending=45*200/25.9
σbending=347.49 *103 N/mm2
=347490 N/mm2

[2] Torque to rotate the wheel;-
The amount of applied torque is depends on the rim pull and the hand wheel size
Applied torque=rim pull*half the hand wheel diameter
Now, assume the rim pull or external force we exert to the wheel be F=80 Ib
We have Conversion factor
1 N=0.2732 Ib
1 Kg=2.679Ib=9.806 N and
1 In=24.4 mm
Then T=F*r
T=80*0.273 N*25.9 mm
T=565.65 Nmm

3.10 Bolt and Nut Selection

A screw element is manly composed of two elements those are bolt and nuts.the screwed joints
are widely used where the machine parts are required to be readily connected or dis connected with
out damage the machine or the fastenings
Advantages of screwed joints.
 Screwed joints are highly reliable in operation

 Screwed joints are convenient to assemble and dis assemble
 Wide range of screwed joints may be adapted to various operating conditions
 Screws are relatively cheap to produce in standardization and highly efficient
manufacturing process.
Dis advantages of screwed joints
 The main dis advantage of screwed joint is the stress concentration in the threaded portions
which are vulnerable points under variable load conditions.
Note; - the strength of the screwed joints is not comparable with that of riveted or welded joints
Locations of screwed joints;-.
The choice of type of fastenings and its location are very important. The fastenings should be
located in such away so that they will be subjected to tensile and/or shear load and bending of the
fastening should be reduced to a minimum.
The bending of fastening due to misalignment, tightening up loads or external loads are responsible
for many failures.
Common types of screwed fastenings;-
The following are the common types of screw fastening;-
1) Through bolts;-it’s a cylindrical bar with threaded for the nut at one end and head at the
other end. The cylinder part of the bolt is known as a shank. It’s passed through a drilled

holes in the two parts to be fastened together and clamped them severely to each other as
the nut is screwed on to the threaded end.
2) Tap bolts;-it’s screwed in to a tapped holes of one of the parts to be fastened without the
nut.
3) Studs;-is a rounded bar threaded at both ends, one end of the studs is screwed in to tapped
holes of the parts to be fastened while the other end receives a nut on it.
4) Cap screw;-is similar to tap bolts except that they are of small size and a variety of shapes
of heads are available in this type.
Of those all types I selected cap screw type for our project. Using the following standard tables
shown below;-
designation Pitch(mm) Major/normal dia. Effective/pitch Minor/core Depth of Stress

of bolt dia. of bolt dia.(dc)mm thread area
&nut(d=D)mm &nut(dp)mm (bolt)mm (mm2 )
bolt nut
M6 1 6.000 5.350 4.773 4.918 0.613 20.1
M7 1 7.000 6.350 5.773 5.918 0.613 28.9
M8 1.25 8.000 7.188 6.466 6.647 0.767 36.6
M10 1.5 10.000 9.026 8.160 8.876 0.920 58.3
Table 3.8 Selection of a cap screw bolt with corresponding nut from standard
So for my project I selected a bolt with designation of M8, steel metal with a tensile stress of
σt=420Mpa, shear stress of τ=150 Mpa
Then from table above for M8 bolt designation we have cross sectional area at the bottom of the
thread stress area=36.6mm2

(a) Safety tensile load;-
Safety tensile load =stress area*tensile stress
=36.6mm2*420N/mm2
=15372 N is equal to 15 KN.
(b) Stress induced in a bolt due to external forces;-
External load applied (P) =π (dc) 2 *σt/4
Hence we have dc=0.767mm and σt=420Mpa for M8 from table above so
P=π*(0.767)2 *420/4=194.05 N
(c) Shear load carried by the bolts(Ps);-
Ps=π/4*d2 *τ, hence we have d=8.000 forM8 from table above so
=π/4*82*150
=7539.8 N
=7.539 KN
(d) Maximum principal shear stress;-
τmax=1/2√(𝜎𝑡)2 + 4𝜏 2
=1/2√4202 + 4 ∗ 1502
=258.069 Mpa
(e) Maximum principal tensile stress;-
σtmax=σt/2+1/2√(𝜎𝑡)2 + 4𝜏 2
=420/2+1/2√4202 + 4 ∗ 1502
=468.06 Mpa

3.11 selection of Washer

Washers; - are a vital component of many fastened joints. Washers are critical to the operation of
virtually every device with moving parts. They perform a variety of functions beyond just securing
bolts, nuts, screw, and rivets. They can insulate, seal, lock, provide, spacing, improve appearance,
supply spring force, align parts and distribute loads.
It’s important to select the most optimal type for our specific application.faliure to specify the
correct washer can result in machine downtime and lost production.
Fig 3.13 A washer
Types of washers; -
Washers can be categorized in to three main types those are;-
 Palin washers;-are washers that are used to spread a load, and prevent damage to the
surface being fixed, or provide some sort of insulation such as electrical.
Types of plain washer incudes;-
1. Spherical washer;-consists of one radiuses surfaces which, when used with a mating nut,
allows for several degrees of misalignment between parts.
2. C-washer;-can be slid in and out of position on a bolt on shaft.
3. Countersunk washer;-when secured, this type of washer creates a flush surface.
4. Penny washer (fender washer);-a flat washer with a large outer diameter proportional to
the central hole, meaning it can distribute loads more widely.

 Spring washers;-are washers that have an axial flexibility and are used to prevent fastening
or loosening due to vibration.
Types of spring washer includes;-
1. Belleville washer;-has a slight conical shape which helps maintain tension in assemblies
where there is thermal expansion and contraction.
2. Curved disc spring;-is only curved in one direction and so is used to support relatively light
loads a with wide deflection range.
3. Wave washer;-has a wave in the axial direction which makes it suitable for use as a cushion
spring or spacer.
4. Split washer;-has a ring that is split at one point and bent into a helical shape creating more
friction and rotation resistance.
 Locking washers;-this type washer is often interchangeable with spring washer and
prevents fastening or loosening rotation.
Types locking washer includes;-
1. Toothed lock washer;-has serrations around its edge that can extend inward or outward to
bite into the surface material and provide maximum torsional resistance.
2. Helical spring;-increases the pre load on the fastener while tightening. This provides
protection against loosening.
3. Tab washer;-has side tab that can be bent into place against a nut, preventing rotation.
Material selection;-
Any type of material that can be stamped can be made in to a washer. Washers are
manufactured in abroad range of metallic and non-metallic materials. Including low and high
carbon steel, stain less steel and steel alloy, copper based material, beryllium copper etc...
Of those all materials I assumed high allowed steel or spring steel for our design because;-
 It can withstand harsh environmental conditions.

 It can goes through a cyclic loading
 It has high strength and fatigue resistance.
Purposes of washer;-
Washers is used;-
 Spacer
 Distribute load in clamped member
 Reduce head member wear
 Low coefficient of friction/losses
 Lock bolt in to the joint(lock washer)
 Increase pre load resolution(wave washer)
Fig 3.14 Positions of a washer
 Generally for our project I used flat, spring type washer because due to has flexibility
property and we can easily fastened or loosen as required.
But this kind of washer can comes in various dimensional standards, quality level, materials,
hardness grad, and finish.
Hence our selected washer have the following dimensions on our solid work data;-
- Outer diameter D0 =20 mm

- Inner diameter Di=8.8 mm depending on this values now I select flat washer with a
hardness grad A from ISO-7089 as shown below;-
Fig 3.15 Internal and external diameter of a washer

Description
This standards is for a thin, flat circular path with centrally located holes and it’s used between the
bearing surface of the fastener and the part to which is attached.
Flat washers are used to improve stress distribution and to span large clearance holes.
METRIC-standard flat washer(Normal series,greade A)
Nominal Internal diameter(ID) Outer diameter(OD) Thickness (t)

size
Max. Min. Max. Min. Max. Min.
1.6 1.84 1.7 4 3.7 0.35 0.25
2 2.34 2.2 5 4.7 0.35 0.25
2.5 2.84 2.7 6 5.7 0.55 0.45
3 3.38 3.2 7 6.64 0.55 0.45
3.5 3.88 3.7 8 7.64 0.55 0.45
4 4.48 4.3 9 8.64 0.9 0.7
5 5.48 5.3 10 9.64 1.1 0.9
6 6.62 6.4 12 11.57 1.8 1.4
8 8.62 8.4 16 15.57 1.8 1.4
10 10.77 8.89 20 19.48 2.2 1.8
12 13.27 13 24 23.48 2.7 2.3
14 15.27 15 28 27.48 2.7 2.3
Table 3.9 METRIC- standard flat washer (Normal series, Grade A) ISO 7089

Depending on the table above our selected washer have the following values;-
- Nominal size =10

- Internal diameter(ID)=8.89<ID<10.77
- Outer diameter(OD) =19.48<OD<20
- Thickness(t) =1.8<t<2.2

CHAPTER FOUR
4 Result And Discussion
According to the results that is obtained from the design of each components of the machine (that
is from the manually operated pipe bending machines) I have realize the following points;
Due to the maximum lifting capacity of the hydraulic bottled jack that is 4 KN the maximum
load carrying capacity of the machine is not exceeded more than 4000N.
Due to the maximum lifting stroke of the hydraulic jack that is from 140 mm-600 mm we can
enlarge or reduce the degrees of bending the pipes according to our wishes.
Due to the maximum resultant bending moments and maximum torque of the shaft that is
RM=156.40 Nm and T=114 Nm respectively the maximum safe perimeter of the CNC pipe which
is going to be bend is limited to 150 mm.
Safety of the parts I tried to check using solid work software that is the static nodal stress of
the material always should be less than the material yield stress. If the reverse is true means the
components I designed should be again designed.
Fig 4.1 Simulation analysis of Bounded Parts (Shafts over Bearings)

CHAPTER FIVE
5 Conclusion And Recommendation
5.1 Conclusion
Generally both the internship and the project were complicated with great success.in the last four
months we had worked in AMIMTDE, I have gained many skills it gives us the highlight of our
future as a mechanical engineer.it also gave us the chance to receive what we have learned for the
past three years directly or indirectly.it was a big step in improving our communication, team work
and leadership skill, improving practical skills, upgrading of theoretical knowledge, understanding
of work ethics and entrepreneurship skills,industial problem solving capabilities.it was the best
way to see our theoretical knowledge and experience it in the real life.in our stay in those company
we obeyed the rules and regulations of the company, for example, coming early in the morning
and obeying the companies work disciplines. Those helps us to be a good and disciplined worker
for future work experience in any environment. Generally, our stay in those companies meets the
main objective of the internship program and helps a student who was well armed in theoretical
and practical knowledge.
5.2 Recommendation
Having the internship offers a list of advantages to the students as mentioned before, it helps us to
grow not only practical experience and knowledge but also social skills since its known that we
will meet a lot of people and deal with accordingly.threfore it is interesting to have such kind of
opportunity, on the other hand there are some insignificancy that have to be improved like weak
relation between the hoisting company and the universities.it was on the other hand the company
environment lack of access in manuals and guide books etc.
We recommended the industries are not working in the direction of solving our problems with our
own and it’s better to try and solve our problems facing at our work area. As known there are many
projects designed at paper level and if they are done practically they solve many problems,
industries are not initiating engineers for problem solving by supporting financially and materially.

CHAPTER SIX
Reference
[1] GUPTA, R. K. (n.d.). text book of machine design 5th edition .
[2] J.E, S. (n.d.). Mechanical engineering design 8th edition MC Graw -Hill book.
[3] Mechanical engineering data book second edition Sdk. (n.d.).
[4] PRIYANK PATEL P, G. M. (n.d.). Productivity analysis of manually operated and

power operated sheet bending machine.
[5] Ungar, D. P. (march 1960). Mechanics of the sheet bending process Tran ASME.J
Applied mechanics .
[6] W.Johnson, M. B. (n.d.). Design of machine elements,Tata mc-Graw -hill publication.
[7] yim, T. G. (may 2001). Roll Bending ,Tran,ASME.J Mechanical design.

CHAPTER SEVEN
Appendix A
Fig 7.1 Overall Dimension of a Bending Machine

Fig 7.2 Explode View of Table Assembly

Fig 7.3 Over All Dimensions of Table Assembly

Fig 7.4 C-Channel Table

Fig 7.5 Support Table Plate

Fig 7.6 Rotating Bender Shaft

Fig 7.7 C-Channel Vertical Assembly

Fig 7.8 Over All Dimensions of C-Channel Vertical Assembly

Fig 7.9 Support C-Channel

Fig 7.10 Over all dimension of support C-channel

Fig 7.11 Explode View of Wheel

Fig 7.12 Over All Dimensions of Wheel

Fig 7.13 Wheel Base

Fig 7.14 Key

Fig 7.15 Wheel Arm

Fig 7.16 Handle Shaft

Fig 7.17 Housing

Fig 7.18 Hleix Flange Bolt

Appendix B
Fig 7.19 Exploded View Of Total Assembly

Fig 7.20 Each Components from Total Assembly

Fig 7.21 Final assembly of bending machines

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AKSUM UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

HOSTING COMPANY; Amara Metal Industry and Machine Technology

PROJECT TITLE:- Design and manufacturing of manually operated pipe bending

DONE BY; EYOB SISAY

Advisor; Mr. Kibrom M.

September 24, 2018

BY: EYOB SISAY MECHANICAL ENGINEERING I

BY: EYOB SISAY MECHANICAL ENGINEERING II

Acknowledge ment .......................................................................................................................... I

Exclusive Summary ...................................................................................................................... II

List of Table ................................................................................................................................ VIII

List of symbols/Nomenclature ...................................................................................................... IX

1.1 Back Ground of the Company .................................................................................................. 1

1.2.1 Objectives of the Enterprise ............................................................................................... 2

1.2.2 Main Products or Services.................................................................................................. 2

1.2.3 Main Customer or End Users ............................................................................................. 2

1.2.4 Vision of the Company ...................................................................................................... 2

1.2.5 Mission of the company ..................................................................................................... 3

1.2.6 Values of the company ....................................................................................................... 3

1.2.7 The Section of the Agency I Have Been Working ............................................................. 3

1.2.8 Working flow of the company ........................................................................................... 4

1.2.9 Major challenges faced during stay.................................................................................... 5

1.2.10 over all benefits I gained from the internship .................................................................. 5

1.3 Location of the Company.......................................................................................................... 6

1.4 Problem Statement and Justifications ....................................................................................... 7

BY: EYOB SISAY MECHANICAL ENGINEERING III

1.5 Objective ............................................................................................................................... 8

1.5.1 General Objective............................................................................................................... 8

1.5.2 Specific Objective .................................................................................................................. 8

1.6 Significance and advantages of the project............................................................................... 8

1.6.1 Significance of the project ..................................................................................................... 8

1.6.2 Advantages of the project................................................................................................... 8

1.7 Introduction of the Machine...................................................................................................... 9

1.8 Components of Pipe Bending Machine .................................................................................. 11

1.9 Scope of the Project ................................................................................................................ 12

1.9.1 Scope ................................................................................................................................ 12

2 Literature Review ............................................................................................................... 13

3 Detail Design ...................................................................................................................... 14

3.1 Methodology ........................................................................................................................... 14

3.2 Material Selection ................................................................................................................... 16

3.3 Hydraulic bottle jack selection................................................................................................ 17

3.4 Design of Shaft........................................................................................................................ 21

3.5 Bearing Selection .................................................................................................................... 31

3.6 Design of Key ......................................................................................................................... 33

3.7 Design of Housing .................................................................................................................. 36

3.8 Design of C-Channel Support ................................................................................................. 37

3.9 Design of Handle .................................................................................................................... 38

3.10 Bolt and Nut Selection .......................................................................................................... 41

BY: EYOB SISAY MECHANICAL ENGINEERING IV

3.11 selection of Washer ............................................................................................................... 44

CHAPTER FOUR ................................................................................................................. 49

4 Result And Discussion........................................................................................................ 49

CHAPTER FIVE ................................................................................................................... 50

5 Conclusion And Recommendation ..................................................................................... 50

5.1 Conclusion .............................................................................................................................. 50

5.2 Recommendation .................................................................................................................... 50

CHAPTER SEVEN ............................................................................................................. 56

BY: EYOB SISAY MECHANICAL ENGINEERING V

BY: EYOB SISAY MECHANICAL ENGINEERING VI

Fig 7.6 Rotating Bender Shaft ..................................................................................................... 61

BY: EYOB SISAY MECHANICAL ENGINEERING VII

c/d = Clearance ratio