1

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 4
TH
JUNE - 30
TH
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: .



2

Table of Contents
Cover Page............................................................................................................................................................ 1
Table of Contents ............................................................................................................................................. 3
Abstract ........................................................................................................................................................ 4
Declaration ........................................................................................................................................................... 4
Acknowledgment .............................................................................................................................................. 4
Appendix ....................................................................................................................................................... 5
Section A :Introduction 6
Section One :Machine Shop...............8
Section Two: Foundry.16
Section Three :Motor Vehicle..20
Conclusion..25
Recommendation.25
References.26

3

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.

4

APPENDIX
Symbols Used
Mass-Kilograms (Kg)
Length- Inches and Metre (m)
Time (s)
Temperature-kelvin(K)
5


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.

6

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
7



SECTION ONE: Development and Testing of a Hammer Mill

1.0 Abstract
The 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.

8


1.1 Introduction
The 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 with
aperture 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 6
HAMMER 24 11
9


1.2 Design Analysis
Determination of the Shaft Speed
To calculate the shaft speed, the following parameters are used:
1.........................................1221NNDD=
Where
N
1
= revolution of the smaller pulley, rpm.
N
2
= 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 pitch
length 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,
10

Using = 0.25; = 40
o

For the smaller pulley e
0.25 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=SinMVTT
And
7............................................1SAT=
Where
T
1
= the tension in the tight side of belt, N
T
2
= the tension in the slack side of belt, N
S = the maximum permissible belt stress, MN/m
2

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
11

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
Y
max
= 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 T
1
and T
2
act vertically down-
ward and T
1+
T
2
= 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
12

Main Shaft: A 32 mm diameter rod was cut to a 480 mm length using power hacksaw. The shaft was
then faced and center drilled. It was held between its centers and step turned to 25 and 30 mm. Keyway
was cut on it using milling machine.
Beater Shaft: 5 mm diameter rod was cut, faced and turned to 12 mm diameter. The length of the shaft
is 70 mm.
Hammer: A 3 mm thick bar of 30 mm width was cut into 70 mm pieces. A hole of 13 mm was drilled at
the bottom of each hammer, using twist drill, to enable it to be put into position on the hammer shaft.
Hopper: It is pyramidal in shape and it was made from 1.8 mm thick plate. It was dimensioned 204 x 204
mm top opening, 50 x 50 mm base opening and height 240 mm. The plate was marked and cut to sizes
and then welded together.
Collar: A hollow pipe of internal diameter of 13 mm was cut to 10 mm length.
Supporting Bar (Stand): Two 100 x 40 mm mild steel bar was cut on 3 mm thick plate using hacksaw.
Three holes of 25, 12 and 12 mm were drilled.

13



1.4 Testing
Testing 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.
14


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.




15

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 basic
requirements of bending & forming of metal plates. In this machine, the bottom rolls are active rolls
driven 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 for
light 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.


16



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

17

An electric arc between the electrode and the work piece generates heat. Sufficient heat
is generated to melt the work pieces together. During my training I became well versed with the
dangers of welding without the necessary equipment plus the importance of ensuring the safety
precautions. Not once or twice, I was down with arc- eyes due to the absence of welding glasses.



2.3. Introduction to Sand Casting Techniques
Sand Casting is simply melting the metal and pouring it into a preformed cavity, called mold, allow-
ing (the metal to solidify and then breaking up the mold to remove casting. In sand casting expand-
able molds are used. So for each casting operation you have to form a new mold.

Basic Requirements for metal casting

1. A mold cavity
2. Melting process
3. Pouring technique
4. Solidification process
5. Removal of casting
6. Finishing draft allowance

Sand Casting is the most important and mostly used casting technique. To perform sand casting we
have to form a pattern (a full sized model of the part), enlarged to account for shrinkage and ma-
chining allowances in the final casting.

18

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).


19

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 drain
plugs were not in Situ. The engine oil filler cap and combined dipstick were present with holes plugged.

20


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
21

-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. Likewise 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 0.014
Clutch 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.
22

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. The
crankshaft, 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.

23




24

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 gaining
mastery 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.



25

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