GEARBOX LIFT STAND

UNIVERSITY OF GONDAR

INSTITUTE OF TECHNOLOGY

SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERIN

INTERNSHIP REPORT INREFERENCE TO ORGANISATION

FORREHABILITATION AND DEVELOPMENT IN AMHARA [ORDA]

DONE BY;

NAME OF STUDENT ID NO
MIERAF AMDEMICHAEL 5750/08
ELSABET ADANE 07459/09
YOSEF MULUALEM

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ADVISOR NAME; MR NETSANET

MR YHUN

MR ANWAR

DATE OF SUBMISION;

DECLARATION
This report is our original work and has not been published or presented for award of any degree
in any university there before.

Signed…………………………………….Date………………….

Supervisor

This report has been submitted by the above students for examination with my approval as a
university lecturer and supervisor of the project

Signed……………………………………….Date…………………

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ACKNOWLEDGMENT

First and foremost we would like to express my deepest gratitude to my lord GOD that gave me
strength and wisdom in every step of our life. we also like to extend my greatest thank to
university of Gondar for providing me such kind of opportunity to stretch our knowledge skill
and attitude on how a given work is carried out in real work field In respect of our studies/
mechanical Engineering/.

Secondly we like to address my thanks to our mentor, Mr.Netsanet, Mr.Anwar, MrYihun

Forourdevotion in attending supporting and kind advises for our successful completion of
ourinternship project work.

In addition we would like to say thank you to ORDA for its hospitality and welcoming me;
MissMeaza. /the immediate head of technical department and work shop/ for her kind acceptance
and serious assistance in leading the day today internship program.

Finallywe would like to express my appreciation and thanks to Mr yibeltal,

MrAmlaku,MrDawit,MrTadele,Mr Sintayehu, MrMulat who are technicians working in the work
shop for their clear and knowledgeable demonstrations and provisions of equipment and make
our fully participating on each technical activities .

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ABSTRACT

This report involves the major accomplishments of our tasks in the internship time that wewere
attending in ORDA.Mainly the report presents the new easily manupulatable idea of design and
functional concepts of GEARBOX LIFT STAND which can lift 150kg of gearbox that can
operate by manually So we designed each parts with solid works and Assembly from the
software SOLID WORKS. This has made the project simpler and smarter to understand. Beside
that we have faced financial problem to produce the proto type. In addition we have used direct
observation to collect the data.Finally it has got conclusion with well supported
recommendation; it also deals the possible justifications for solutions as well.

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CHAPTER ONE

INTRODUCTION

1.1 Over view of the project

In modern daily work routine either in our domestic chores or in industrial work place
manual lifting of both heavy and light loads is a common practice. These practices of
manual lifting have been characterized by height input under taking in terms of labor
energy and time investment.
This has proven to health of the individuals due to poor work experiences, exhaustion,
inefficiencies and strenuous tasks involved. Although different loads have their own way
of lifting, most of them have to be hooked to the equipment through a winch of rope for
appropriate lifting. Then an efficient lifting mechanism is required.
Over the years, lifting activities were heavily depending to manual labor. During this
period various mechanisms such as pulley and gear were used.
In addition, gears are important elements in a variety of industrial applications such as
machine tool and gear boxes, an unexpected failure of gear may cause significant
economic losses.
Furthermore and in particular, gear box is important part of many engineering systems. It
is used for various applications like power transmission, motion control, speed reduction
and torque multiplication.
To sum up, this paper deals with the introduction of better mechanical design and
function of gear box lift .In the presentation the statement of the problem , the objective
of the project, the methodology, the literature review ,the design of each component ,the

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results and discussions and final states a conclusion and recommendations have already
been stated .
Thus the idea ,the design---- etc…of the paper are validated by the organization /ORDA/

to be a problem solving for the timely problems of the workshop , beyond the knowledge,

skill and attitude results I get in my internship.

1.2 PROBLEM OF STATEMENT

We all want to maintain the gearbox without spending so much time while removing (dis
assembling) and assembling it, from and to the shaft. In addition to solve all the risk, the danger
that mechanics or technicians face in carrying and moving heavy duties in the work shop. But if
we ignore this problem, they will have many failures that results time wastages and make
ineffective maintenance. The problem mainly affect the mechanics directly because it takes so
much labor force to dis assemble at first because they hooked to the equipment through a winch
of the rope for appropriate lifting and this also requires a good manual labor.

In other way the customer indirectly Waite so much times to take his or her car.

But if we solve this problem, we can avoid time wastage, we can increase the mechanic’s safety
and we can protect unexpected clashes and break therefore we design of the gearbox lift stand by
using solid works with calculating different analysis.

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1.3 OBJECTIVES OF THE STUDY

1.3.1 Main objective of the study

 Lifting heavy duties like machine/vehicles/gearbox that can loaded up to 150 kg by a

newly designed gear box lift stand which is suitable for all types of gearbox.

1.3.2 Specific objective of the study

Specific objective of our projects are:-

Designing and numerical analysis of each components

 Design of teeth
 Design of gears
 Design of shaft
 Design of key
 Design of bearing
 Design of keys
 Design of handle
 Design of cap (plate)
 Design of caster wheel
Software analysis with sold woks
 Animation
 Motion
Cost analysis

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1.4 SCOPE AND LIMITATION OF THE STUDY

1.4.1 Scope of the study

This project is done under the scope of designing gear box lift stand with its components. Giving

each component part design with geometric analysis

1.4.2 Limitation of the study

We have taken out most care while working on this project, but that doesn’t mean we were
perfect. There was limitation due to various factors. The major limitation factor in these projects
is listed below.

 Lack of financial support to produce our project; due to this we are unable to make

our design in real object.

1.4 METHODOLOGY OF THE STUDY

Primary data collection

 Direct observation
 Interview concerned people

Secondary data collection

 Searching internet
 Referring different guide books, manual, written document related to the project.

In the work shop the gear box is lifted up and down manually which is fully difficult and risky.
To solve this problem the new mechanical and technical solution with its procedures have been
set as follow-

1-OBSERVATION-Identify the problem of the hosting company by observation

2-DESIGNING-Design the new gear box liftsstand and each component with SOLIDWORKS.

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GEARBOX LIFT STAND

3-ANALYSIS;-Stress, displacement and strain analysis of the design

-Cost Analysis
4-MATIMATICAL ANALYSIS-numerical computing of each component with
Safety factor,
-Determine lifting capacity and maximum height.

5-MODELING-detail drawing of the gear box lift stand with solid works.

6-SELECTION OF PROPER MATERIAL

7-REPORT: write the final thesis, draw conclusion and recommendation

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CHAPTER TWO

LITERATURE REVIEW

2.1introduction to gearbox

In the most basic sense, a gearbox functions like any system of gear; it alter torque and speed
between a driving device like a motor and load.

The gearbox is a mechanical method of transferring energy from one device to another and is
used to increase torque while reducing a speed.

The most basic definition of a gearbox is that it is a contained gear train, or a mechanical unit or
component consisting of a series of integrated gear within housing. In fact the name itself defines
what it is; a box containing gear. In the most basic sense, a gearbox function like any system of
gears; it alters torque and speed between a driving device like a motor and a load.[3]

Figure 1 Gear box [3]

The gears inside of a gearbox can be any one of a number of types from bevel gears and spiral
bevel gears to worm gears and other such as planetary gears. The gear is mounted on the shafts.
Which are supported by and rotate via rolling element bearings. The gearbox is a mechanical

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method of transferring energy from one device to another and is used to increase torque while
reducing speed.

Gearboxes are used in many applications including machine tools, industrial equipment,
conveyors, and really any rotary motion power transmission application that requires changes to
torque and speed requirements. [3]

2.2 The need of gearbox

Most modern gearboxes are used to increase torque while reducing the speed of a prime mover
output shaft. This means that the output shaft of gearbox rotates at a slower rate than the input
shaft, and this reduction in speed produces a mechanical advantage and increasing torque.

The need of different torque and different speed due to the continuously change in road condition
has led us to the development of theintermediate device that can provide different speed or gear
ratios in order to keep the vehicle moving. [3]

 When a car starts, the torque provided by the engine output shaft is not
enough to overcome the weight of the vehicle which make it difficult to
move the car initially, so to solve this problem a gearbox is required which
can provide high torque initially in order to move the vehicle.

When we go to hill station it is essential that the vehicles should be equipped with device that
can provide a wide range of high torque, to fulfill this need a gearbox is required so that a vehicle
can go to the hills.

 When a vehicle is going at high speed, torque is not at all effective so a

gearbox is needed that can also provide a high speed low torque ratio so that
vehicle can maintain the high speed.[3]

2.3 Types of gearbox

There are mainly 2 types of transmission used these days that are

1, Manual transmission or manual gearbox

2, Automatic transmission or automatic gearbox [1]

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1 Manual transmission

A manual transmission is the type of gearbox used in most of the vehicle on the road due to its
low cost. It is the type of gearbox in which there are limited gear or speed ratios therefore,
maximum of 6-speed and 1-reverse is there, and the shifting of gears is a manual task performs
by the driver by pushing or pulling the gear lever in predefined fashion. This transmission always
requires the use of clutch.[1]

Types of manual transmission are

a) sliding mesh gearbox

It is the oldest types of gearbox used, in sliding mesh gearbox the gears of main shaft and lay
shaft are not in mesh i.e., independent only a single gear is in continues mesh with the gear
on the clutch shaft that rotates the lay-shaft and the meshing of gear with the appropriate gear
on the lay shaft occurs due to the left or right siding of the gears of the main shaft.

Figure 2 Sliding mesh gearbox[1]

b) constant mesh gear

It is modified gearbox introduced to overcome the limitation of the sliding mesh gearbox. In
these types of gearbox all the gear of the lay-shaft,main-shaft and clutch-shaft are in constant
mesh with each other and the shifting of gear is obtained by the sliding of dog clutches over
the splined main shaft in order to obtain high speed or torque output.[1]

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GEARBOX LIFT STAND

Figure 3 Constant mesh gearbox[1]

c) synchromesh gearbox
This is the latest of all types of manual gearbox which provides the smooth and quiet shifting
of gear due to the use of special devices known as synchromesh devise, these helps in
bringing the speed of the shafts to the same (using friction contact) before the meshing of the
appropriate gears which causes less wear and tear to the gears.[1]

Figure 4 Synchromesh gear box[1]

2. Automatic transmission or gearbox

It is used in high end cars due to its high cost in this types of gearbox infinite gear ratios can
be obtained by just pressing the accelerator the driver just need to select the mode of the
drive i.e. forward or reverse park neutral, drive and spot and the required gear ratios along
with the timing of the meshing is obtained automatically. It doesn’t require clutch pedal, so
all the car with automatic transmission comes with only two pedals.[1]

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Types of automatic gearbox

a) Epicyclic gearbox
Sun and planetary gears along with annular ring and a carrier is used in these types of
gearbox. The clutch shaft is connected to the sun gear which are in constant mesh with the
number of planetary gear which freely rotates on the their axis and are in constant mesh in
with the ring gear which has the teeth at its inner side, the rotation of the planet gears is
carried by the carrier used which is connected to the main shaft.

Figure 5 Epicyclic gearbox[1]

b) hydraulic torque converter

It is the special type of the automatic gearbox that is based on the fluid coupling, in this type
an impeller, a turbine, a highly compressed fluid and a stator is used for obtaining the
different speed or gear ratio that is controlled by the accelerator pedal. The impeller of the
torque convertor is connected to the engine shaft, the turbine is connected to the output shaft
and the stator is placed in between these two to direct the flow of the fluid.[3]

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GEARBOX LIFT STAND

Figure 6 Hydraulic torque converter[3]

2.4 Gearbox lift stand

This equipment used for the lifting up and down of the gear from the car after removal or
disconnect from the shaft to change or to maintain it.

The gearbox stand will be developed by using several models for the component. The models
used are directed at a specific aspect of the stand’s response to loading. We are attempted to
identify several basic loading and resultant responses. The stand consists of different
components. Mainly it consists of about six components. [5]

Several gearbox stands were developed up to this time. The stand models first developed were
flat tables. Such a stands are not suitable for the workers, needs more labor and waste more time.
In addition to this, these stands are not manufactured in our county. The price of the tool is too
expensive when it is imported from abroad. The stand developed in this project has a sliding and
roiling for transporting purpose and have a very cheap costs.[5]

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GEARBOX LIFT STAND

CHAPTER THREE

DETAILED DESIGN OF GEARBOX LIFT STAND

Given design condition are assigned by us by measuring and considering.

Specification

Table 1 Specification

PARAMETER VALUE UNIT

Power (W) 20 W

Input speed 20 RPM

Driving machine hand power HAND POWER

Length of rack 1000 MM

Gravity 10 M/S2

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General design consideration

3.1 Design of Teeth

There are two types of teeth

1, cycloidal teeth

2, Involute teeth[1]

For our design we have used involutes teeth because for smooth running and less wear of gear.

 First determine the number of teeth

The minimum number of teeth on the pinion without interference is given by the following
formula.

Before using this formula first determine the value of “k” and ∅

Therefore k=1 for Full depth teeth and m is module.

There are four systems of gear teeth.We have used 20 degree full depth involute, so the value of
∅=20° since it is more compact than the other degree .(1)

Thesmallestspurpinionthat willoperatewithrackwithoutinterferenceis

N 2(k)
p= 2
sin φ

For a20° pressureanglefull-depthtooththesmallestnumber ofpinionteethtomeshwitharack is

N 2 (1 ) =17.6=18 teeth
p= 2 °
sin 20

Calculate the input, and output torque

P × 60
T=
2 πN

60× 0.02 KW
Ti¿ =37.68
2 × π × 20

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3.2 Design of Gear

3.2.1 Definition of gear

GEAR:-a toothed wheel that works with other to alter the relation between the speed of a driving

mechanism (such as the engine of a vehicle) and the speed of the driven parts (wheels).[1]

3.2.2Classification of Gears

The gears or toothed wheels may be classified as follow.

1. According to the position of axes of the shafts

 The axes of the two shafts between which the motion is to be transmitted may be
(a) Parallel,
(b) Intersecting, and
(c) Non-intersecting and non-parallel.
The two parallel and co-planar shafts connected by the gears. These gears are called
spur gears and the arrangement is known as spur gearing. [1]
 So we have used spur gear due to availability to the company
2. According to the peripheral velocity of the gears
 The gears, according to the peripheral velocity of the gears, may be classified as:

(a) Low velocity

(b)Medium velocity

(c) High velocity

 The gears having velocity less than 3 m/s are termed as low velocity gears.
 Gears having velocity between 3 and 15 m / s are known as medium velocity
gears.
 If the velocity of gears is more than 15 m / s, then these are called high speed
gears.[1]
3. According to the type of gearing
a. External gearing
b. Internal gearing

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GEARBOX LIFT STAND

c. Rack and pinion[1]

Figure 7 Internal gearing

Figure 8 External gearing

Figure 9 Rack and pinion gearing [1]

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GEARBOX LIFT STAND

 For our design we have used rack and pinion type.

3.2.3 Given design specification for gear

 Value unit

Length of the 1000 mm

rack
Teeth 1 18
Teeth2 70
No of revolution 20 Rpm

Table 2 Specification of gear

Selective design specification

D
M= where M=module
T

D=M*T

Let m=4

T=18 from above equation

D=4*18=72mm……..D=diameter of the gear

Then to know how many rotation of gear rotate to finish the rack

1000-120=880,

880
No of rev= =12.22 rev
72

Therefore,

For 20 rev=60 sec

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GEARBOX LIFT STAND

12.22rev=?

12.22rev × 60 sec
20 sec

=36.66sec

D 880
v 2= =
t 36.66

M
= 0.024
S

We select module let =4mm

3.2.3.1 Geometric analysis of spur gear

Figure 10 Spurs gear [1]

°
S. No particular 1 20° full depth 20° stub
14 composite
2
involutes system involutes system
or full depth
involutes system
1 Addendum 1m 1m 0.8m
2 Dedendum 1.25m 1.25m 1m
3 Working depth 2m 2m 1.6m
4 Minimum total 2.25m 2.25m 1.80m
depth
5 Tooth thickness 1.5708m 1.5708m 1.5708m

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6 Minimum 0.25m 0.25m 0.2m

clearance
7 Fillet radius at 0.4m 0.4m 0.4m
root

Table 3 Standard gear tooth [1]

The standard proportion of the gear tooth in terms of module m for 20° full depth system are as
follows [1]

 Addendum =1m = 1×4 =4mm

 Duodenum =1.25m = 1.25×4 =5mm
 Clearance =0.25m = 0.25×4 =1mm
 Working depth =2m =2×4=8mm
 Whole depth=2.25m =2.25×4=9mm
 Total thickness=1.5708m =1.5708×4=6.28mm
 Tooth space =1.5708m =1.5708×4=6.28mm
 Fillet radius =0.4m = 0.4×4=1.6mm

 Width (b) =12m =12×4=48mm

Figure 11Geometry analysis of spur gear [1]

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3.2.3.2 Force Analysis Spur Gear

Calculate tangential load [1]

3
F t = 10 ∗P but
V
π d 1 n1 π∗72∗20 rpm
v= =
60∗10 3
60∗103

m
= 0.075
s

103∗0.02
∴ Ft = m
0.075
s

= 266.66 N

F ta 1 = F t =266.66 N

F t a1 266.66
Fa1 = = = 283.77 N
cos 20 cos 20

F ra 1 = F ta 1∗tan ∅ = 266.66 * tan20 = 97.05 N

∴ F r a1 =−Fr 1 aOnly opposite in direction but equal in magnitude

F ta 1 = - F t1 a

F a 1 = - F 1a

In rack gear they have the same normal and tangential force but have no radial force

3.2.3.3 Gear materials

 The cast iron is widely used for the manufacture of gears due to its good wearing
properties, excellent machinability and ease of producing complicated shapes by casting

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method. The cast iron gears with cut teeth may be employed, where smooth action is not
important.

 The steel is used for high strength gears and steel may be plain carbon steel or alloy steel.
The steel gears are usually heat treated in order to combine the properly toughness and
tooth hardness.
 The phosphor bronze is widely used for worm gears in order to reduce wear of the worms
which will be excessive with cast iron or steel. The following table shows the properties
of commonly used gear materials.[1]

We can select carbon steel grade 40 C 8 and its Brinell hardness number and minimum tensile
strength is as follows, [4]

Material Condition Brinell hardness Minimum tensile

number
N
strength( ¿
mm2
Carbon steel Hardened and 460 540.6
tempered
40 C 8

Table 4 Standards of gear material[1]

3.2.3.4 Strength analysis of spur gear

Consider the each tooth as a cantilever beam loaded by a normal load (WN) as shown below

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Figure 12 Tooth of a gear[1]

The tangential component (WT) induces a bending stress which tends to break the tooth.

The radial component (WR) induces a compressive stress of relatively small magnitude;
therefore its effect on the tooth may be neglected.

The maximum value of the bending stress (permissible working stress) at the section “BC” is
given by

σ M ∗y
w=
I

Where M= Maximum bending moment at the critical section BC = W T ×h,

W T = Tangential load acting at the tooth,

h= Length of the tooth,

y = Half the thickness of the tooth (t) at critical section BC= t/2,

I = Moment of inertia about the center line of the tooth = b*t3/12,

b= Width of gear face. [1]

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t
( W T × h ) 2 W × h ×6
σ w=
( T )
3 = 2
b∗t b∗t
12

But, from the geometrical analysis the valve of h, b and t as follows

h=9mm b=48mm t=6.28mm Wt. =0.265KN then

Wt × h× 6 0.265× 1000 ×9 ×6
σ w= = =7.912 N/mm2
bt 2 48 ×(6.28)2

3.2.3.5Permissible working stress for gear teeth in the Lewis equation

The permissible working stress (σ w) in the Lewis equation depends on the material for which an
allowable static stress (δo) may be determined.[1]

σ w=σ o × C v

Where δo=allowable static stress

C v=velocity factor

The value of the velocity factor (c v ) are given as follows

3
C v= For ordinary cut gears operating at velocities up to 12.5 m/sec since the pitch line
3+v
velocity (v) is given by [1]

P P 0.02 Kw
Wt = , v= = =0.0755m/sec then It is less than 12.5 m/sec therefore
v Wt 0.265 KN

3 3
C v= = =0.975
3+0.0755 3.0755

The material of the gear is carbon steel then the allowable static stress (δo) 140 Mpa or N/mm2
from the table is 140 N/mm2 therefore the permissible working stress is

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σ w =σ o ×C v

=140N/mm2 ×0.975

¿ 136.937 N / mm2

σ w=136.937N/mm2

3.2.3.6 Dynamic Tooth Load For the spur

In the previous article, the velocity factor was used to make approximate allowance for the
effect of dynamic loading. The dynamic loads are due to the following reasons:

1. Inaccuracies of tooth spacing

2. Irregularities in tooth profiles, and
3. Deflections of teeth under load[1]

W D = WT + W I

WhereW D =¿total dynamic load,

W T = Steady load due to transmitted torque, and

W I = Increment load due to dynamic action.

The increment load (W I ) depends upon

 The pitch line velocity,

 The face width,
 material of the gears,
 The accuracy of cut and
 The tangential load. [1]

For average conditions, the dynamic load is determined by using the following Buckingham
equation, i.e.

21 V (b∗C+ W T )
W D = WT + W I = WT +
21 V + √ b∗C+W T

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GEARBOX LIFT STAND

Where

v = Pitch line velocity in m/s,

b=Facewidth of gears in mm.

C= A deformation or dynamic factor in N/mm.

The value of C in N/mm may be determined by using the following relation:

K∗e
C= 1 + 1
E P EG
Where K = A factor depending upon the form of the teeth.
= 0.107, for 141/2 ° full depth involute system.
= 0.111, for 20° full depth involutes system.
= 0.115 for 20° stub system.
E P = Young's modulus for the material of the pinion in N/mm2 . (207GPa)
EG = Young's modulus for the material of gear in N/mm2. (207GPa)
e = Tooth error action in mm. [1]
We take K=0.111, for 20° full depth involutes system.
m
Our calculated pitch line velocity is v=0.06998
s
We get the value of e from the table=0.0925

K∗e 0.111∗0.0925
1
C= + 1 = 1 1 = 1062.686 N /mm
+
E P EG 207∗10 207∗103
3

W D = WT + W I
21∗1.256 (48∗1062.686+266.66)
= 266.66+
21∗1.256+ √ 48∗1062.686+ 266.66
= 266.66+5349.45

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=5616.15N

3.2.3.7 Static Tooth Load for the spur

The static tooth load (also called beam strength or endurance strength of the tooth) is obtained
by Lewis formula by substituting flexural endurance limit or elastic limit stress ( σ e) in place of
permissible working stress (σ w). ∴ Static tooth load or beam strength of the tooth,

W S = σ e*b* pc *y = σ e*b*π* m*y

Where σ e= flexural endurance limit
b= face width
y= Lewis form factor or tooth form factor [1]

The value of y in terms of the number of teeth may be expressed as follows

0.912
Y=0.154 -–
T3
0.912
=0.154 -
16
=0.097
For steel, the flexural endurance limit (σ e) may be obtained by using the following relation:
σ e = 1.75 × B.H.N. (in Mpa)
= 1.75*460 Mpa =805 Mpa
W S=σ e*b*π* m*y
= 805 Mpa *48* π*4*0.097
= 47,075.88 N

3.2.3.8 Wear Tooth Load for spur gear

The maximum load that gear teeth can carry, without premature wear, depends upon the radii
of curvature of the tooth profiles and on the elasticity and surface fatigue limits of the materials.

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The maximum or the limiting load for satisfactory wear of gear teeth is obtained by using the
following Buckingham equation.[1]

W W = D P*b*Q*K
Where
W W = Maximum or limiting load for wear in newtons,
D P= Pitch circle diameter of the pinion in mm,
b = Face width of the pinion in mm,
Q = Ratio factor
N
K = Load-stress factor (also known as material combination factor) in . [1]
mm2
2∗V . R 2T G
Q= = Where V.R=Velocity Ratio
V . R+1 T p +T G
2∗70
= = 1.590
70+18
The load stress factor depends upon the maximum fatigue limit of compressive stress, the
pressure angle and the modulus of elasticity of the materials of the gears. According to
Buckingham, the load stress factor is given by the following relation, [1]

1 1
K= ¿ ¿( + ) Whereσ es=surface endurance limit .
EP EG

The surface endurance limit for steel may be obtained from the following equation
σ es= (2.8 × B.H.N. – 70) N/mm2
=2.8*460 -70
=1218 N/mm2
1 1
K= ¿ ¿( + ) = 3.5
207∗10 207∗103
3

W W = D P*b*Q*K
D p = M∗T P
Where m=module=4

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GEARBOX LIFT STAND

Tp =pinion teeth
4*18=72
b=14*m for spur gear
14*4=56
W W = 72*56*1.590*3.5
= 22,450.90 N
So the static load is greater than dynamic load.
For safety, against tooth breakage, the static tooth load (W S) should be greater than the dynamic
load (W D). Buckingham suggests the following relationship between W S andW D.
For steady loads, W S ≥ 1.25 W D
For pulsating loads, W S≥ 1.35 W D
For shock loads, W S ≥ 1.5 W D
The maximum limiting wear load (W W ) must be greater than the dynamic load (W D).[1]

3.3 Design of Shaft

3.3.1 Definition of shaft
A shaft is a rotating machine element which is used to transmit power from one place to another.
In order to transfer the power from one shaft to another, the various members such as pulleys,
gears etc., are mounted on it. The shafts are usually cylindrical, but may be square or cross-
shaped in section.

3.3.2Material Used for Shafts

The material used for shafts should have the following properties:

1. It should have high strength.

2. It should have good machinability.

3. It should have low notch sensitivity factor.

4. It should have good heat treatment properties.

5. It should have high wear resistant properties.[1]

pg. 31
GEARBOX LIFT STAND

The material used for ordinary shafts is carbon steel of grades 40 C 8, 45 C 8, 50 C 4 and 50
C 12.

From the above explanation we choice carbon steel (40 C 8) [6]

Materials Ultimatetensile strength Yield tensile strength

M pa M pa
For spur gear 560 – 670 320
40 C 8

Table 5 Mechanical property of steel[6]

3.3.3 Design of Drive Shaft

The load applied on the shaft are listed below

1. The normal load (WN)

WN=1500 N (the load of gearbox is 150 kg and the weight will be M*g) where the gravity
(10m/s2)

2. Wight of slide bare or the rack

Where the mass of the rack will be 10 kg

Ws=10×10=100 N

3. Bending moment on the shaft due to the resultant load,

W R=1500+100=1600 N(the total weight)

M =RA × y

M = 800 × 200 =160000 N-mm

4. Since the shaft is under the combined effect of torsion and bending, therefore we shall
determine the equivalent torque

Te = √ M 2+T 2

T = Twisting moment = WT × D P/2

pg. 32
GEARBOX LIFT STAND

= 266.66 × 72/2

=9599.76 N-mm

Te = √ 1600002+ 9599.762

=160287.73 N-mm

5. Now the diameter of the pinion shaft (d) is determined by using the following relation [1]

π
Te = × d3× τ
16

π
160287.73= × d 3 × 42
16

d=39.37≈ 40 mm

3.3.4 Strength analysis of the shaft

 Shafts subjected to twisting moment or torque
 Shafts subjected to bending moment only
 Shafts subjected to combined twisting and bending[1]

1, Shaft subjected to twisting moment

T τ
For round solid shaft: =
J r

πd 4
But J= =251327.41 mm 4
32

Where d=40mm , r=20mm, T=9599.76(from the previous solved equation)

9599.76∗20
¿
Torsional shear stressτ =T*r/J π
∗40 4
32

τ =0.764 Mpa

2. Shaft subjected to bending moment

M δb
=
I r

pg. 33
GEARBOX LIFT STAND

160000× 20
M ×r
σb= = π
I × 40 4
64

=25.5 Mpa

3, Shaft subjected to combined twisting and bending moment

According to maximum shear stress theory the maximum shear stress in the shaft is given by[1]

1
τ max ¿
2
√(σb)2 +4 τ 2
1
τ max ¿
2
√ ( 25.5 )2+( 4 ×0.764 2)
τ max=¿12.8 Mpa

 Therefore τ max¿ τ i.e 12.8Mpa< 42 Mpa it is safe.

3.4 Design of keys

3.4.1 Definition of keys
A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to connect
these together in order to prevent relative motion between them. It is always inserted parallel to
the axis of the shaft. Keys are used as temporary fastenings and are subjected to considerable
crushing and shearing stresses.[1]

3.4.2 Types of keys

The following types of keys are important from the subject point of view:

1. Sunk keys,

1.1.1 Rectangular sunk key

1.1.2 Square sunk key

1.1.3 Parallel sunk key

2. Saddle keys,

3. Tangent keys,

pg. 34
GEARBOX LIFT STAND

4. Round keys, and

5. Splines.

 For our design we used parallel sunk key.

Parallel sunk key; theparallelsunkkeys may be of rectangular or square section uniform
in width and thickness throughout. It may be noted that a parallel key is a taper less and is
used where the pulley, gear or other mating piece is required to slide along the shaft.[1]

3.4.3 Specification

Shaftdiameter =40mm,

By considering the shaft material and the keys material are the same.

d d
W= and t= [1]
4 6

 Width of key

40
W=
4

=10mm

 Thickness of key

40
t=
6

=6.666 say 7mm

The length of key is obtained by considering the key in shearing and crushing.

Let l = Length of key.

 Considering the shearing of the key.

We know that shearing strength (or torque transmitted) of the key,

pg. 35
GEARBOX LIFT STAND

40
T= l ×10×42× =8400l N mm…………………… (i)
2

And torsional shearing strength (or torque transmitted) of the shaft,

π
T= × τ ×d 3
16

π
T= × 42× 40 3=527787.6 N-mm…………………… (ii)
16

From equations (i) and (ii), we have

527787.6
l= =62.8 say 63 mm
8400

 Now considering crushing of the key. We know that shearing strength (or torque
transmitted) of the key,

t d
T=l × ×σ c ×
2 2

Where σ c=2*τ =2*42=84

7 40
T=l × × 84 × =5880l N-mm………………. (iii)
2 2

From equations (ii) and (iii), we have

527787.6
l= =89.7 say 90mm
5880

Taking larger of the two values, we have length of key,

l=90 mm

pg. 36
GEARBOX LIFT STAND

3.5 Design of Bearing

Figure 13 Bearing [1]

3.5.1 Definition of Bearing

In rolling contact bearings, the contact between the bearing surfaces is rolling instead of
sliding.
Advantages
1. Low starting and running friction except at very high speeds.
2. Ability to withstand momentary shock loads.
3. Accuracy of shaft alignment
4. Low cost of maintenance, as no lubrication is required while in service.
5. Small overall dimensions.
6. Reliability of service.
7. Easy to mount and erect.
8. Cleanliness.
Disadvantages
1. More noisy at very high speeds.
2. Low resistance to shock loading.
3. More initial cost.
4. Design of bearing housing complicated.[1]

pg. 37
GEARBOX LIFT STAND

Objective Types of bearing

Rolling contact Sliding contact
Cost High Low
Shaft arrangement Accurate Not accurate
Lubrication No Yes
Maintenance cost Low High
Overall dimension Small Large
Assembly Easy Difficult

Table 6 Bearing type [1]

 From the above table we choose a roller contact bearing [1]

3.5.2 Analysis of bearing

Basic dynamic radial load:

W = X. V. WR + Y. WA

V = 1, for all types of bearings when the inner race is rotating,

.The values of radial load factor (X) and axial or thrust load factor (Y) for the dynamically
loaded bearings may be taken from table:

WA
For deep groove ball bearing with ≤ e X=1, Y=0
WR

The basic dynamic load rating C can be calculated from the following equation.
pg. 38
GEARBOX LIFT STAND

1
L
C=W ( )
106
k

The relationship between the life in revolutions (L) and the life in working hours (LH) is given
by

L = 60 N. LH revolutions [1]

W= X. V. WR + Y. WA

SinceWA = 0

The equation reduces to

W = X¿V¿ RA

X= 1

W =0.8*1*1=0.8 KN

By multiplying this load with a factor of safety Ks = 2 for Moderate shock load

W = 0.8*2=1.6 KN

k = 3 for ball bearings

N = 20rpm, rotational speed of the shaft

L = 60NLh rev

L = 60(20)6000 rev

L = 7200000 rev

7200000
C = 1.6¿
√
3

1000000

C = 22.8 KN

Therefore according to this value from table for single row deep grove ball bearing, bearing
number 208 is selected.

pg. 39
GEARBOX LIFT STAND

Roller bearing number 208 satisfies this requirement

Do =80mm, Di = 40mm, W=18 mm …from table

3.6 Design of beam

The beam is the material which supports the gearbox and the shaft, rack and gear.

3.6.1 Material selection of beam

We have selected the suitable material for our project depending on the following criteria’s.
Those are:
 Availability of the material
 Suitability of the material for the working condition
 The cost of the material
 Property of the material [5]
 Recommendation from the company or availability of the material in the company
Generally the material selected and its property is shown in the table below;

3.6.2. Design of upper beam

The upper beam is the part that holds the overall weight of the object.

Wnet=WG.B+WRACK

pg. 40
GEARBOX LIFT STAND

Where, W net =total weight that is applied on the beam

WG.B=weight of the gearbox

Wrack=weight of rack

Hence, the gearbox mass is 150kg we can calculate the weight of the gear box and the weight of
the rack is 10kg.

WG.B=M*g

=150 kg*10m/s2

=1500N

Where g=10m/s

Wrack=M*g

=10kg*10m/s2

=100N

Now we can calculate the total weight.

W net =W G .B +W Rack

=1500N+100N

=1600N

Now find moment of beam

W net
P=
2

1600 N
=
2

=800N

pg. 41
GEARBOX LIFT STAND

Where P=force at the center.

Moment at point 1

M 1 = P*l

=800N*180

=144000N/m

M2 =p*l

=R2*(180+180)

At equivalent

M1=M2

M1-M2 =0

=800N*180 - R2*360 ; OR R1=R2

R2 = 400N 2*R1=800N

M C =¿ 400N*180mm R1=400N

=72000Nm

pg. 42
GEARBOX LIFT STAND

Where, M=moment of the load

R1 and R2=radius

L=distance

P=force

From the standard table we select square tube of 40mm width and 3mm thickness

│--3-│mm

h=34mm

│…………..40mm………...│

4 4 4 4
My 72000∗20
I xx = b −h = 40 −34 = 101,972mm4 δ= =
12 12 I 101972

=14.12Mpa < 300Mpa so, our design is safe

Checking shear

P 800
τ= =
As ( 40 )2− (34 )2

=1.8Mpa < 150Mpa, so our design is safe

pg. 43
GEARBOX LIFT STAND

Stage two

Find moment of inertia

 MA = 0

= 200mm*400N+400*400 – 600* R B

(image)

My
R B= 400Nδ= but first get moment
I

Ra = 400N at point c and d

4 4 4 4
I xx = b −h = 40 −34 = 101972mm4 m c = 400*200 = 80000
12 12

m d = 400*200 = 80000

My 80000∗20
δ= = = 15.70Mpa
I 101972

Checking shear

P 400
τ= =
As ( 40 )2− (34 )2

= 0.90Mpa

pg. 44
GEARBOX LIFT STAND

3.6.2.2 Design of leg

Similar to beam we select from the standard table, it is square tube of 40mm width and 3mm
thickness

│3--│mm

│------- 40mm-------│
Length of leg = 400mm

Compressive stress

P P
σc = =
A Ao −Ai 2
2

W =W GB +W Ub +W lb +W sb+ W SB

= (1500+20+20+20+100) N

=1660N

W 1660
P= = = 415N
4 4

415
σ c= = 0.934Mpa
402−342

It is less than 173.3Mpa, so our design is safe

The leg also subjected to buckling, due to that we have to check for buckling

IE ( π )2
P cr= 2
( L)

pg. 45
GEARBOX LIFT STAND

4 4 2 2
π ( Co −C i )∗E∗π ( Di )
=
4 ( L )2

π 3∗190∗10 9∗( 404 −34 4 )

=
4∗(8602)

= 8.84*1011N

Since Pcr of the material greater than the critical applied load, the design is safe.

3.6.2.3 Design of lower beam

First of all we have to calculate the overall weight applied on the beam [1]

W =W engine +W sb=1500N+100N

Now find moment of beam

P=1600N

180
180

R1 R2

M=P*l=1600N*80 => R1+R2=1600N ; R1=R2

=128000Nmm 2*R1=1600N

R1=800N

From the standard table we select square tube of 40mm width and 3mm thickness

│3--│mm

pg. 46
GEARBOX LIFT STAND

│------- 40mm-------│

b4 −h 4 40 4−34 4 My 128000∗20
Ixx= = = 101972mm4 δ= =
12 12 I 101972

=25.10Mpa < 300Mpa so, our design is safe

Checking shear

P 1600
τ= =
As ( 40 )2− (34 )2

=3.60Mpa < 50Mpa, so our design is safe

3.7 Design of slide bar (rack)

To design the rack which is the vertical component we choose a material which is the same as
that of the pinion. This is gray cast iron class 60.its properties are.[7]

E = young’s modulus = 103.4Gpa

Compressive strength = 1289Mpa

Ultimate strength =427Mpa

Brinell hardness = 302

By using the ultimate strength of the material and by taking factor of safety

(F.S) 4
σu
σ all=
4

pg. 47
GEARBOX LIFT STAND

427 Mpa
= =106.75Mpa
4
Note the geometrical parameters of the rack are the same as that of the pinion in order to mesh
properly and safely.

Figure 14 Geometric analysis of rack and pinion [1]

The rack which is the vertical component should resist compressive load that applied
perpendicular to it.
F = M*G =150Kg*10 +10Kg*10
F = 1600N
On rim thickness factor the backup ratio ( M b) is the ratio of rim thickness (r t ) to whole depth of
the tooth (ht ).or its ratio is limited between (0.5≤mb≤1.2)

rt
Mb =
ht

H t = addendum+deddendum

= 4+5 =9mm

Let the value of m b from the above interval is 1 that is m b = 1

pg. 48
GEARBOX LIFT STAND

Rt = mb*ht = 1*9

= 9mm

The same of r t and ht is thickness of the rack

T = r t + ht

=9 + 9

=18mm

F
Compressive stress (σ ¿ = but A = b*t
A

= 90mm*27mm

=2430 mm2

F 1600 N
(σ ¿ = = =0.65Mpa
A 2430 mm2

Which is less than 320.75Mpa it is safe

The leg also subjected to buckling, due to that we have to check for buckling

IE ( π )2
Pcr = 2
( L)

The length of the rack is 1000mm

Find moment of inertia

b h3 90∗273
Along I xx axis, I xx = = = 1.48*105 mm4
12 12

b h3 27∗903
Along I yy axis, I yy = = = 1.64*106 mm4
12 12

Since inertia along yy-axis is stronger than along xx-axis. We will have to consider smaller
inertia is I xx .

pg. 49
GEARBOX LIFT STAND

IE ( π )2 103.4∗103∗( π )2∗1.48∗105
Pcr = 2 =
( L) 10002

= 151036.53N

Wcr 151036.53 N N
Buckling stress(σcr ¿ can be defined as σcr = = = 62.15
A 90∗27 mm2

Since Pcr of the material greater than the critical applied load, the design is safe

1 Holding and lower plate: these is a rectangular plates used to support the applied load, and
transmit the load to the screw. Since the plates are subjected to bending stress and shear
stress, we have to check the above two types of stress.
Bending stress

M σ
=
I y

Where M = Bending moment acting at the given section,

σ = Bending stress,

I = Moment of inertia of the cross-section about the neutral axis,

y = Distance from the neutral axis to the extreme fiber, [1]

Shear stress

τ P WhereP= applied load

avg=¿ ¿
A

A= shear area

M=P*L

=1500N*0.200m

=300Nm

M σ
=
I y

pg. 50
GEARBOX LIFT STAND

300 173.3
bt 3 = t
12 2

12∗420000 12∗300000
t2 = = = 27.4
b∗2∗173.3 0.40∗2∗173.3

t = 5.2m = 6m

V =l∗w∗h=0.53∗0.56∗0.006 = 1.7808*10-3m3

W =ρ∗v∗g = 7.920∗1.7808∗10−3∗9.81 = 140N

│ ─────────400mm │

400mm

6mm

WT=1500+140=1640N=1.64kN

Checking for shear stress

P P P 1500 N
τ= = = = = 0.47Mpa
As t∗0.53 6 m∗530 m 6∗530

There for it is less than 50Mpa, so our design is safe

3.8Selection of wheel

Wheels are other key components of the stand, which provides the technician to move the stand
in any required place even including the engine. All four wheels are rotated 360 degree. The

pg. 51
GEARBOX LIFT STAND

wheels are directly selected according to the maximum load the engine stand can subjected. The
wheels are directly purchased from the market. [1]

These wheels must carry a maximum amount of weight which is the sum of the maximum
applied engine weight and the weights of the engine stand parts.

Total weight applied on the wheel,

W=1500+20+20+20+20=1580N

Each of these four wheels carries one over forth of the applied load (W/4). So the wheels are
directly purchased from the market which carries a weight of 1580N.

3.8.1 Welded joint analysis

We use a weld of minimum size(s) 6mm from table

A welded joint is used between each horizontal & vertical hollow tube of 40mm diameter beams.

This weld is subjected to a direct shear stress and bending stress due to the applied eccentric
load.

W
τ= , A=π∗D∗t where, A=area of weld
A

D=diameter of tube [1]

t=throat thickness of weld=0.707 s

A=π∗40∗0.707∗6 =533mm2

1500
τ= =2.814Mpa
533

Z=π∗D 2∗t /4,where, z=section modules

=5330.6mm3

M 375 375
δb= = W× =1500* = 175.8Mpa
z z 5330.6

pg. 52
GEARBOX LIFT STAND

The maximum normal stress is calculated as follows;

1
σ max= (σ b + √ σ b2+ 4∗τ 2 )=176Mpa
2

According to maximum normal stress theory;

σy
σ t 1=
FS

Since the maximum normal stress is much lower than the yield strength of the material, the weld
is capable of withstanding the applied loadδmax<δy.

3.9Design of Bolt and Nut

A bolt is a threaded fastener designed to pass through holes in the mating members and to be
secured by tightening a nut from the end opposite the head of the bolt.

In machine design, most fasteners are made from steel because of its high strength, high
stiffness, good ductility, and good machinability and form ability. But varying composition s and
conditions of steel are used. The strength of steels used for bolts and screws is used to determine
its grade, according to one of several standards. Three strength ratings are frequently available:
the familiar tensile strength and yield strength plus the proof strength. The proof strength, similar
to the elastic limit, is defined as the stress at which the bolt or the screw would undergo
permanent deformation. It usually ranges between 0.90 and 0.9 5 Times the yield strength.[1]

We select bolt and nut material steel that have tensile strength 100MPa and the factors safety of
bolt and nut are 5 then the design tensile stress are

100 MPa 20 N
σd= =20 MPa= And also load of the gear box are 1500N
5 mm 2

3.10 Design of handle or lever

When a shaft of high strength is required, then alloy steel such as nickel, nickel-chromium or
chrome-vanadium steel is used and we selected the material have the strength 45C8 ultimate
tensile strength 610-700MPa and yield strength 350Mpa respectively. [1]

pg. 53
GEARBOX LIFT STAND

Taking a factor of safety of 5 due to the nature of the application and is given compression stress
= 700 MPa and crushing strength 350MPa and also the weight of the gear box are
150 kg ≈ 1500 N

σ 700
Design ultimate tensile stress is σd= = MPa=140 MPa
f.s 5

σc 350
Design yield strength σc= = MPa=70 MPa
f .s 5

The diameter of the handle/lever, D may be obtained by considering bending effects. We know
that bending moment;

D3 σc 350 MPa 70 N
M =π ×σ × While σd= = =70 MPa=
32 f.s 5 mm2

And maximum bending moment on the lever/handle

M =applied forces ×length of handle

M =100 N ×0.75 m=75 Nm

D3
Then, 75 Nm=π ×70 MPa × → D=22.18 mm ≈ 22mm
32

W 4 W 4 ×1500 N
Stress analysis σ = A = 2
= 2
=3.945 Mpa=4 MPa
π D π (22 mm)

Since, the induced stress is less than the allowable stress, so design is safe

3.11 Cost Analysis

All the component of our project are directly purchased from the market.

 Cost of rectangular holding steel plate ;

6mm thickness580*560=800ETB

 Cost of rectangular base steel plate;

6mm thickness580*560

pg. 54
GEARBOX LIFT STAND

=800ETB

 COST of wheels;

Four sets of small caster wheel=250*4

=1000ETB

 Cost of bearing

Two set of bearing=2*100

=200ETB

 Cost of spurs gear=3500ETB

 Cost of circular steel tube=4*100

=400ETB

 Cost of rectangular steel tube=100ETB

 Manufacturing and labor cost=1300ETB
 Cost of busing=4*60

=240ETB

 Cost of baring=14*65
=910ETB
 Total cost= Cost of rectangular holding steel plate+ Cost of rectangular base steel plate+
COST of wheels+ Cost of bearing+ Cost of spurs gear+ Cost of circular steel tube+ Cost
of rectangular steel tube+ Manufacturing and labor cost+ Cost of busing+ Cost of baring
=800+800+1000+200+3500+400+100+1300+240+560=9250

pg. 55
GEARBOX LIFT STAND

CHAPTER 4

SOLUTION TECHNIQUE

In this project we design a gearbox lift stand and we present our design with solid works.

4.1 Part Design

Figure 15 Beam

Figure 16 Bearing

pg. 56
GEARBOX LIFT STAND

Figure 17 Driving shaft with handle

Figure 18 Bearing house

pg. 57
GEARBOX LIFT STAND

Figure 19 Spur gear

Figure 20 Wheel

Figure 21 plate

pg. 58
GEARBOX LIFT STAND

Figure 22 Wheel house

Figure 23 stud

pg. 59
GEARBOX LIFT STAND

Figure 24 Rack

Figure 25 Bolt

pg. 60
GEARBOX LIFT STAND

Figure 26 Nut

Figure 27 rack plate

pg. 61
GEARBOX LIFT STAND

4.2 Assembly

Figure 28 Assembly

pg. 62
GEARBOX LIFT STAND

Figure 29 Assembly and Bill of Material

pg. 63
GEARBOX LIFT STAND

4.3 Part drawing

Figure 30 Part drawing

pg. 64
GEARBOX LIFT STAND

CHAPTER FIVE

RESULT AND DISCUSSION

5.1 RESULT

In this section the designed parameters are presented in tabular format. And will discussed
accordingly.

5.1.1 GEAR

PARAMETERS value unit Abbreviation

Wear tooth load Ratio factor 1.627 - Q
for spur gear Load stress 3.5 - K
factor
Surface 1218 N/mm2
endurance limit
Max load for 17493.5 N Ww
wear
Static tooth load
for spur gear Lewis factor 0.097 Y
Flexural 805 Mpa
endurance limit
Static load 47075.88 N WS
Dynamic tooth Total load of 5616.15 N Wd
load for spur dynamic
gear Deformation 1062.686 N/mm C
factor
Permissible WORKING 136.937 N/mm2
working stress STRESS
VELOCITY 0.975 Cv
FACTOR
Strength analysis …….. 7.912 N/mm2
of spur gear
Force analysis of Tangential force 266.66 N Ft
spur gear
Radial force 283.77 N Fa1
Diameter of gear Diameter of gear 72 mm

Number of teeth Number of teeth 18

pg. 65
GEARBOX LIFT STAND

5.1.2 SHAFT

PARAMETERS VALUE UNIT

momentum 160000 N-mm
Diameter 40 Mm
Shear 0.764 Mpa
Bending stress 25.5 Mpa
Maximum shear 12.8 Mpa

5.1.3 Key

parameters value Unit

Width 10 Mm
Thickness 7 Mm

5.1.4 Bearing

parameter value unit

Outer diameter 80 MM
Inner diameter 40 mm
Width 18 mm

5.1.5 Beam

parameter value Unit

pg. 66
GEARBOX LIFT STAND

Momentum 72000 Nm
Stress 14.12 Mpa
Shear 1.8 Mpa
For leg 0.934 stress Mpa
8.84*1011 critical force N

5.1.6 Rack

Parameter Value unit

Allowable stress 106.75 Mpa

Tooth depth 9 Mm
Rim thickness 9 Mm

Compressive stress 0.65 Mpa

Bulking stress 62.15 N/mm2

5.1.7 Handle or lever

parameter value Unit

Tensile stress 140 Mpa
Yield stress 70 Mpa
Bending moment 70 Mpa
Stress analysis 4 Mpa

5.18 bolt and nut

Parameter value unit

Tensile stress 20 Mpa

pg. 67
GEARBOX LIFT STAND

5.2 Discussion of the study

From the design data’s presented above, the designed gearbox lift stand has the ability to lift a
1500N of load 1m high without incurring any failure, i.e. without buckling and maintaining its
position by self-lock.

To do this, we have used different methods like

 Inert gas Welding

 Grinding
 Electric arc welding
 Cutting

We have faced financial problem so we couldn’t assemble the pinion and rack gear to the beam.
Beside this the following picture will show our work in ORDA.

pg. 68
GEARBOX LIFT STAND

Figure 31

CHAPTER 6

CONCLUTION AND RECOMMENDATION

6.1 conclusion

All the analyses in this project are done by considering all the parts as different structural model
for a better design purpose such as beam, shaft, rack,bearing and other models. These models
help us to meet our proposed objectives. The work performed in this project is designed to help
the workers by creating a comfortable working condition, highly decrease the labor force and
time. The strength of the stand is checked by design concept, so there is no fear of failure and
nothing keeps them from using the stand. So we conclude that the designed gear box stand can
lift a gear box up to a weight of 150kg and can be manufactured with low cost.

All the works performed in this tool is very safe, because in addition to manual calculations
solidworkalso used to make the tool is surly designed. So, this stand can be manufactured
according to the design parameters/dimensions and perform all works using this tool without any
frustrations.

6.2 RECOMMENDATIONS

When we design some part we have to collect information from different source. This means the
design is performed by using many references and web sites.

The gearbox stand should be manufactured forthe company and it should be put into practice for
the desired work task.

 Safety stands should be used in repair shop

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 A clean and proper table should be made for putting disassembled parts
 The garage area is full of gravel and dust, so it should be clean
 The vehicles should be park orderly

As we can see the total cost of the stand, it is not much high according to the material used. But
we do not analysis the cost of gearbox stand because of the shortage of industries and
information of gearboxstand price that imported from foreign to our country. Therefore we
recommended that to future we are design or analysis the cost of gearbox stand by asking some
information from industry and other organization that imported gearbox stand from foreign
courtiers.

We would like to recommend students who join the internship program for the future to use their
time effectively and change their theoretical knowledge to practical.

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REFERENCES
[1] R.S.Kuhrmi, J.K.Gupta, A text book of machine design, fourteenth edition: Eurasia publisher,
2005.
[2] Beer, Ferdinand, P., Mechanics of Materials, Second Edition, McGraw-Hill, Inc.: Santa Fe,
NM 1992.
[3], https://WWW.google.com
[4], https://WWW.asme.org(The American Society of )
[5], Internship report guideline manual
[6], Machine design data book
[7], Text book of physical properties of engineering material
[8], https://www.wikipidia.com

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