in-house training done at kyambogo university

8/10/2019 In-House Training Done At Kyambogo University

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KYAMBOGO UNIVERSITY

FACULTY OF ENGINEERING

DEPARTMENT OF MECHANICAL AND PRODUCTION

PROGRAMME: BACHELOR OF ENGINEERING MECHANICAL AND MANUFACTURING ENGINEERING

TOPIC: IN-HOUSE TRAINING REPORT FOR THE PERIOD 4TH

JUNE - 30TH

AUGUST 2012

NAME: ORTEGA IAN

REG. N0: 11/U/11049/EMD/PD

SIGNATURE: . DATE: ..

INSPECTOR: MR. OKELLO PETER

SIGNATURE: . DATE: ..

SUPERVISOR: MR. OKELLO PETER

SIGNATURE: DATE: .

INSTRUCTOR: MR. BOSSO BERNARD

SIGNATURE: DATE: .


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Table of Contents

Cover Page............................................................................................................................................................1

Table of Contents ............................................................................................................................................. 3

Abstract ........................................................................................................................................................ 4

Declaration ...........................................................................................................................................................4

Acknowledgment .............................................................................................................................................. 4

Appendix ....................................................................................................................................................... 5

Section A :Introduction6

Section One:Machine Shop...............8

Section Two: Foundry.16

Section Three:Motor Vehicle..20

Conclusion..25

Recommendation.25

References.26


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ABSTRACT

The report was written to give a detailed coverage of the activities that transpired during the In-House In-

dustrial training at Kyambogo University organized by the Faculty of Engineering. It is hoped that the report

is precise yet not lost on detail.

The industrial training activity took-place at the mechanical engineering department workshop for a period

stretching three months and a great hands-on training was achieved. The assigned tasks included recording

daily activities in a Log-book, making mini reports for the various sections and getting involved in the weekly

cleaning activities.

A great deal of experience was obtained, practical skills that span a lifetime in the engineering career were

acquired and with such Knowledge, I can comfortably compete in any mechanical engineering career around

the world. Though it served as basic training, it built the foundation upon which a mega-skyscraper is being

erected.

Declaration

I declare that the report is a work of my own hands, free of any erroneous description and coverage and ex-

cept in purposes of books for reference, the report is free of any sort of plagiarism. I declare the following to

be my own work, unless otherwise referenced, as defined by the Universitys policy on plagiarism.

ACKNOLEDGMENT

It is always a pleasure to remind the fine people in the Engineering Workshops for their sincere guidance I

received to uphold my practical as well as theoretical skills in engineering.

Firstly I would like to thank my supervisor, Mr. Okello Peter for ensuring that everything is in control, with-

out his seal, there would be no proof that I even partook of the training exercise.

Secondly I would like to thank Mr. Bosso Bernard, a man in whose ingenuity I pride in. For always allow-

ing me to put my creativity to work and challenging me with activities that tickled my imagination.

It would also be a show of poor upbringing if I dont send a note of appreciation to Mr. Yusuf

Kamulegeya, Mr. Ochola Samson, and Mr. Gerald Mukasa for the great guidance provided in the motor-

vehicle workshop.

Finally I apologize all other unnamed who helped me in various ways to have a good training. And with-out mincing my words, I thank God for providing me with wonderful parents, two mothers and a father

who went to be with the Lord. They remind me of a proverb Train up a child in a way he should go such

that even while an adult, he wont depart from this way.


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APPENDIX

Symbols Used

Mass-Kilograms (Kg)

Length- Inches and Metre (m)

Time (s)

Temperature-kelvin(K)


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SECTION A: INTRODUCTION

Background to Kyambogo University

Although Kyambogo is a new university started, it has a rich history that dates back as far back as 1928. UPK

started in 1928 as a small technical school on the Makerere Hill and was transferred to Kyambogo Hill in

1958 as Kampala technical Institute. It was renamed Uganda technical College and finally UPK. ITEK started

as a Government Teacher training college in 1948 in Nyakasura, Fort Portal and transferred to Ruharo and

then Ntare Hill all in Mbarara, western Uganda. It transformed into a National teachers college and later

ITEK as per the statue of parliament in1989. UNISE on the other hand started as a Department of Special Ed-

ucation at ITEK in 1988, and later became an autonomous institution bu act of parliament in 1998.

Vision

To be a Centre of Academic and Professional Excellence.

Mission

To advance and promote knowledge and development of Skills in Science, Technology and Education, and in

such other fields having regards for quality, equity, progress and transformation of society.

SERVICES AND MAJOR FUNCTIONS

The infrastructure of the Engineering Workshops could provide the following listed services to its consumers

both in academic and non-academic terms.

- Machining of metals

-Welding

- Foundry work

-Smith and fitting work

- Woodwork

- Vehicle repair

Subject to the rules established by the Faculty and the University, deploying the following functions was ex-

pected from it.

-Provide above mentioned services to the engineering undergraduates to carry out their academic activities

such as practicals, experiments and etc.

-Provide above mentioned services to the Faculty of Engineering and the University as a whole if requested.


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DIFFERENT SECTIONS

1. Metal Workshop

The Metal Workshop is the place for machining metals. It comprises the following prominent ma-

chine tools with other supporting machines and equipment;

- Drilling machines- Engraving machines

-Gear shapers

-Grinding machines

- Lathe machines

- Milling machines

-Planers

-Shaping machines

- Slotting machines

* Several varieties of some of these machine tools could be found for specialized operations.

2. Welding and Foundry Shop

The Welding and Foundry shop comprised equipment to deploy following services:

- Arc welding

-Metal casting

- Mig welding

-Oxyacetylene welding

-Spot welding

-Tig welding

3. Smithy and Fitting Shop

The Smithy And Fitting Shop mostly comprised hand tools (anvils, hammers, chisels, etc.) and some

machine tools (Electric hammer and sheet metal rollers, benders and cutters).

4. Woodwork shop

5. Motor vehicle workshop

Organization Structure of the University

-Chancellor

-Vice Chancellor

-Deans of faculties

-Heads of Departments

-Heads of sections


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SECTION ONE: Development and Testing of a Hammer Mill

1.0AbstractThe hammer mill was designed and constructed from locally available materials for grinding grain

particles such as maize, millet, guinea corn and other coarse materials of cassava tuber, yam tuber,

beans, etc. into small size enough to pass through the holes of the cylindrical sieve positioned be-

neath the hammer assembly.

The grinding process is achieved by the use of a hammer in beating the material fed into fine

particles; the fineness aimed depends on the detachable screen with aperture sizes ranging

from 87m to 2 mm. Based on the power ratings and output shaft speed of the existing grind-

ing machines in industries like flour mill, it was found that the main shaft speed of 700 rpm

transmitted by a belt drive from a one-horse-power electric motor is suitable to mill effective-ly.

The machine was designed to be power-operated and portable with overall dimensions of 380 x

200 x 344 mm.


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1.1 IntroductionThe hammer mill, which can otherwise be referred to as Cereal Miller, is designed for processing, grind-

ing, and sieving all kinds of cereal grains, such as maize, wheat, millet, corn, sorghum, wheat. It can also

process non-cereal materials such as dry cassava tuber and yam tuber.

Cereal processing is complex. The principal procedure is milling; that is, the grinding of the grain so that

it can be cooked and rendered into an attractive foodstuff.

The machine is of hammer mill type. In this case, there is hammer-like projection mounted on a shaft.

The hammer revolves at high speed and grinds the materials fed into pieces by beating. Moreover, the

machine can mill only the dry materials.

The machine is incorporated with a detachable sieving mechanism to ensure fineness of cereal grain

ground. The industrial screen - the main components responsible for sieving - is made of wire cloth withaperture sizes ranging from 870 m to 2 mm.

The machine cannot be operated manually. The electrical operation is effected by the use of one horse-

power electric motor with speed of 1,400 rev/mm. The machine can handle 5 kg of cereal grains in a

single operation lasting 15 min.

The entire construction is brought about by locally sourced material thereby making the cost not pro-

hibitive. The machine elements are easily accessible and detachable to facilitate assembling and

maintenance process. Although the machine is sufficiently rugged to function properly for a reasonable

long period.

NO PART QUANTITY SIZE

BUSH 2 61 x DIA 38.5

BUSH 24 DIA 19.6

SHAFT 1 38.2

SHAFT 4 DIA 18

KEYWAY 1 73 x 6HAMMER 24 11


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1.2 Design Analysis

Determination of the Shaft Speed

To calculate the shaft speed, the following parameters are used:

1.........................................1221NNDD=

Where

N1

= revolution of the smaller pulley, rpm.

N2

= revolution of the larger pulley, rpm.

This shaft speed is only obtained when there is no slip condition of the belt over the pulley. When

slip and creep condition is present, the value (700 rpm) is reduced by 4% (Spolt 1988)

Determination of Length of the Belt

Assume the center distance between the larger pulley and the smaller pulley = 600 mm, the pitchlength of the belt is given by (John and Stephens 1984)

2......4)()(57.122112CDDDDCL++++=

Where

L = length of the belt, mm

C = center distance between larger pulley and the smaller one, mm

From the standard table, a belt designated as A60 was selected.

Determination of the Belt Contact Angle

The belt contact angle is given by equation 3:

3.........................)(1CrRSin=

Where

R = radius of the large pulley, mm

R = radius of the smaller pulley, mm

The angles of wrap for the pulleys are given by:4....................)(18011CrRSin=

5......................)(18012CrRSin+=

Where

1

= angle of wrap for the smaller pulley, deg

2

= angle of wrap for the larger pulley, deg

Comparing the capacities, e a/sin

of the pulley,


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Using = 0.25; = 40o

For the smaller pulley e0.25 x 3.04/sin20

= 9.22

For the larger pulley e

0.25 x 3.04/sin20

= 10.68

Since that of smaller pulley is smaller, the smaller pulley governs the design.

Determination of the Belt Tension

The belt tension can use equation 6 below (Maitra and Prasad 1985):

6.............................21exp) (212=SinMVTTAnd

7............................................1SAT=

Where

T1

= the tension in the tight side of belt, N

T2

= the tension in the slack side of belt, N

S = the maximum permissible belt stress, MN/m2

A = area of belt,

M = mass per unit length of belt

v = linear velocity of belt

mv2

= centrifugal force acting on the belt

Determination of the Torque and Power Transmitted to the Shaft

Power transmitted to the shaft is given by

8..................................)(21VTTP=

Torque at the main shaft is given by Spolt (1988)

9................................)(21RTTT=

Determination of the Hammer Weight

10........................................gmWhh=

It can be seen that the action of the weight of hammer shaft on the main shaft is negligible.

Determination of the Centrifugal Force Exerted by the Hammer


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Centrifugal force exerted by the hammer can be calculated from equation 11 as given by:

11................................rmvFc=

The angular velocity of the hammer is given by

12..............................602rN=

Determination of the Hammer Shaft Diameter

The bending moment on the shaft is given by (Ryder 1996)

13.........................82(max)WlMb=

Since the bending moment that can be carried by a beam is a measure of the strength of the

beam and this depend upon, I/y a (Ryder 1996).

14.................max)(IYMballowables=

15.................)(maxZMZYIballowables=

=

Where

Ymax

= distance from neutral axis to outer fibers

I = moment of inertia

Z = Section modulus

For a solid round bar:

16.........................................644dI=

17................................323dZ=

Determination of the Maximum Bending Moment

The position of the electric motor in relation to the main shaft is such that T1

and T2

act vertically down-

ward and T1+

T2

= 148N.

The overall loading system on the shaft is as shown in Fig. 1

From the shear force diagram of Fig. 1, it is obvious that b is the point of maximum bending moment.

Determination of the Shaft Diameter

The ASME code equation for a solid shaft having little or no axial loading is:

()()18.......16223ttbbsMKMKd+=

1.3 Construction Details of Major Parts


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1.4 TestingTesting is a vital step in the process of machine development. After the design and construction, testing is

necessary in order to:

a. determine the performance of the machine,

b. expose defect and area of possible improvement, and

c. appreciate the level of success in the research.Thus, it is important to test run a machine to determine its work ability and efficiency.


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1.5 Challenges

-We were not able to test the hammer mill since time was not on our side, however had it been pos-

sible then two different tests using cassava dry tubers and dry maize were to be carried out. This

would imply us getting the results in both cases and taking averages before finally drawing a conclu-

sion.


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SECTION TWO: WELDING AND FABRICATION WORK

Although we were not directly involved with work in this Foundry section, our day to day work dur-

ing the development of a hammer mill required frequent movements to this section as far as elec-

tric-arc welding of certain components is concerned plus progressive bending and cutting.

Among the expertise acquired from this section included:

2.1. Learning how to operate a bending machine

The plate bending machine in the workshop is similar to the one shown in the picture below.

The 3 ROLL PYRAMID TYPE MECHANICAL PLATE BENDING is designed to cater for the basicrequirements of bending & forming of metal plates. In this machine, the bottom rolls are active rollsdriven by electric motor & gear box. The upper roll is passive roll having manual up & down adjust-ment to achieve desired bending radius. This is a very simple & robust design machine suitable forlight to medium jobs.

Align the plate using the alignment grooves in the lower rolls or against the rear roll. The pre-bending is ac-

complished by clamping the plate between the top roll and one of the lower rolls.


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The plate is bent towards the top roll by the other roll; and the plate edge is pre-bent to minimum flat end

possible. A length of the plate is rolled and radius is checked.

Roll the plate through the machine and bend to desired diameter.

Lower the clamping roll and raise the other roll until the plate is clamped again. Roll the plate into a closed

cylinder and pre-bend the second plate edge.

Finished cylinder is released from the machine by lowering the drop end.

2.2. Welding Expertise


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Materials used to make patterns include wood, plastics, aluminum, fiberglass, cast iron and some

other metals. Wood is a common pattern material because it is easily worked into shape. Its disad-

vantages are that it tends to warp and the sand being compacted around it abrades it, thus limiting

the number of times it can be reused (used for a small number casting).


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SECTION THREE: MOTOR VEHICLE WORKSHOP

In this section, the mechanical engineering students on a bachelors level concentrated on the engine part of

a motor vehicle. Our training in this section revolved around overhauling an engine for the two weeks we

spent here.

3.1 ECI-MULTI ENGINE OVERHAUL

Due to the absence of a manufacturers manual, I kept referring to a copy of the Haynes Users manual. The

engine had ECI-Multi inscribed on its top and this basically means Electronically Controlled Multi-Point Fuel

Injection. ECI means that it is an electronic carburetor injection.

It is an engine mainly built by Mitsubishi Motors and used in its semi-luxury vehicle; the Mitsubishi Lancer.

ECI or advanced electronically-controlled fuel injection gives an engine more power and economizes fuel.

Specifically the cyclone ECI-Multi engine usually powers the 4-door Sedan with (66-86Kw)

3.2 Original Condition of the Engine

The engine had clearly been standing for some time as the casings had become oxidized. Some of the engine

mounting lugs had been damaged in the pre-process to rebuilding the lug to the rear of the number 4 cylin-

der block and the pair of lugs underneath the rear of the gearbox.

All coolant pipe work and inlet/exhaust parts were plugged with clean cloths. The spark plugs and drainplugs were not in Situ. The engine oil filler cap and combined dipstick were present with holes plugged.


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3.3 Equipment, Tools and Aids Used

-Torque wrench, Puller, Valve spring compressor

-Sets of ring, open, and socket spanners

-Sets of star and flat screw driver

-Engine stands (an old car tire)

-Instruction Manual

3.4 Strip-down/Dismantling of the Engine

Having mounted the engine on its stand, we proceeded as follows;

-Cylinder head was removed

-All external accessories like the alternator, starter motor and ignition units were taken off

-Timing gear covers were stripped after removing the pulleys

-Clutch unit was removed


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-Con-rod caps, pistons and connecting rods were removed

-Taking off timing chain and removing sprockets

-Removing the crankshaft with flywheel having taken off main bearing caps

All parts were labeled to ensure correct replacements in right positions. This was particularly important for

valve end caps, piston/con-rod assemblies and main bearing shells.

3.5 Examination

It had originally been envisaged that the piston rings would be replaced with re-bore if necessary, but on

stripping the engine down , it became apparent from the gasket sealant used and engravings on the under-

sides of the piston crowns that it had been previously rebuilt.

The Piston rings end gaps were checked by me against the specifications detailed in the Haynes manual and

were found to be within the specified standard tolerances, and well within service limits. L ikewise the pis-

ton rings to the groove gaps were in the limits.

The cylinder bores were in perfect condition with criss-cross honing marks from the previous rebuild clearly

visible. There was less scoring of the bores and no discernible lip at the top of the cylinder. Similarly the main

bearings and crank journals were inspected and found to be in as new condition. The little end bearings were

also within tolerances.

The clutch assembly was examined. The clutch basket was in good condition. The pressure plates were in as

new condition with no signs of blueing or warping. The friction plates were within service limits and so

were the clutch spring lengths.

3.6 Tolerances

Part Standard Tolerances Service Limits Measured

Top Piston ring #1 0.008- 0.014 0.02 0.012

Top Piston ring #2 0.008- 0.014 0.02 0.014

Top Piston ring #3 0.008- 0.014 0.02 0.013

Top Piston ring #4 0.008- 0.014 0.02 0.014Clutch Plates 0.115- 0.121 0.102 0.118

****All in inches

3.7 Cleaning the engine components

This was done to free the engine components from dust, dirt, oil, grease and to facilitate examination and

measurement.

The cleaning was undertaken using paraffin, scrubbing with a wire and brittle brush to remove all dirt. After

the cleaning, all parts were placed on a slab to dry. For small delicate parts, petrol was used as it not only

dissolves all oil and removes dirt quickly, but the parts dry practically instantly.


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3.8 Rebuild/ Assembly

Had it been possible, a full gasket set should have been acquired. This would have included paper gaskets,

new cylinder head gaskets, new seals for main output shaft and gear change shaft etc.

New and old copper/aluminium sealing washers were used throughout the reassembly of the crankcase. Thecrankshaft, con-rod/piston assemblies and gear clusters and shift mechanism were replaced and the crank-

case rejoined using silicon based sealant.

The cylinder head was not replaced. Valve clearances were all checked and were found to be within the re-

quired specifications.

3.9 Step by step Assembly

-Soak the new lifters in engine oil for at least five to six hours-but preferably overnight. While the new lifters

are soaking, line up all the new parts and the nuts and bolts and get all the tools you will need to put the en-

gine together.

-Install the piston rings. Coat the cylinder walls with STP oil treatment.

-Flip the block over and install the top-half of main and rod bearings.

-Flip the block over back over. Put the rod bearing in the bearing caps on one of the piston-rod assemblies.

-Put the bearings on the bearing caps, coat them with STP oil treatment and install pursuant to the engines

spacing and torque specifications.

-Install the crankshaft, the camshaft and the timing chain and cover.

-Install the lifters.

-Install the push rods and rocker arms

-Install the valve covers. The engine is now ready to be set back into the car, The rest of the accessories (fuel

pump, carburetor and distributor) can be installed once the engine is bolted securely into the engine com-

partment.


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FINAL CHAPTER: CONCLUSION

The 3 months training was worth it and one would be correct to say that without it, I would be consider my-

self less of an engineering student.

1. I became well versed with the skill of manufacturing a high speed hammer mill on top on gainingmastery on certain machines like the Milling, lathe, power saw, angle grinder and many other ma-

chines.

2. The industrial training also helped me embed time management and organization skills into my daily

routine as a person, appreciating the role of every section, every office and interpersonal relation-

ships.

3. On top on turning the theoretical knowledge acquired into the practical sense, I was able to become

diverse, having extensive knowledge on the engine, welding matters and other fabrication process-

es.

RECOMMENDATIONS

1. The university should supply the workshops with more machines that are up-to date, for example

Computer Numerical Controls are nowhere in the workshops yet they are the machines that are in

most industries.

2. The industrial training should be more research based and invention oriented. This would help stu-

dents to compete favorably in the ever changing world.


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REFERENCE

Donnel, H. 1983. Farm Power and Machinery. McGraw Hill, New Delhi, India.

Anon. 1980. Encyclopedia Britanica, Vol. 21, pp.1157-72. William Benton, Chicago, IL, USA.

Maitra, G.M.; and Prasad, L.V. 1985. Handbook of Mechanical Design, pp. 89-108. McGraw Hill, New Delhi,

India.

John, H.; and Stephens, R.C. 1984. Mechanic of Machines, 4th ed., pp. 213-24. Edward, London, England.

Mott, I.C. 1980. Engineering Drawing and Construction, 2nd ed., Oxford Univ. Press, Oxford, England.

Ryder, G.H. 1969. Strength of Material, 3rd ed. Catalogue 300E/EB 666, SKF General Catalogue. Macmillan,

New York, USA.

Spolt, M.F. 1988. Design of Machines Element, 6th ed. Prentice Hall, New Delhi, India.

129

Haynes Repair Manual ISBN 1859607098

in-house training done at kyambogo university

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