The document summarizes an internship project to design an adjustable oil and fuel filter wrench. The interns conducted research at Belayab Motors PLC on common vehicle maintenance tasks. They observed issues with accessing filters on some vehicle models. The project aims to develop a wrench that can loosen filters more easily. The interns designed components like the socket, extension arm, and belt to withstand necessary torques. Materials were selected based on properties like strength and wear resistance. Stresses on parts were calculated. The new wrench was tested and found to successfully loosen filters while avoiding damage. Interns recommend further improvements to optimize the design.

1. Bahir Dar University
Bahir Dar Institute of Technology
Faculty of Mechanical and industrial engineering
mechanical and engineering department
Internship presentation
Hoisting company: Belayab Motors Plc.
Project title: Adjustable oil and fuel filter wrench
Students-name: id
Ephrem Ababiya 1103315
Elshaday Tariku 1103007
Mentor: Birhanu
Company Supervisor: Ephrem Melese
Date: November 2-2022

2. General information about the hosting company
 Company background:- Belayab Motors Plc. Was established in 2006,with a registered capital of 5 million USD to import
and distribute light, medium, and heavy-duty trucks and industrial equipment.
 Belayab Motors PLC has imported and introduced a number of vehicles to Ethiopian market. Furthermore, the enterprise
has a maintenance shops located in Addis Ababa, Akaki, and Adama to give maintenance and support for its customers.

3. Work flow
In belayab motors compound there are 3 different working sections and
departments. They are :-
 Maintenance shop
 Body shop
 Electrical shop
section of the company we have been working

4. work tasks we have been executing

5. Clutch
maintenance

6. Clutch highlight Symptoms of a failing clutch plate include:
 The vehicle’s clutch slipping
 Reduced engine power to the wheels
 Lack of pressure required to press the clutch pedal
 Shaking/chattering noises when the clutch is engaged/disengaged

7. Causes of clutch
failure
 Worn clutch plate
 Loose/missing springs
 Overheating
 Incorrect installation

8. How to replace a clutch

9.  Incorrect use of the clutch can increase the likelihood of problems. There are
several things to do while driving to extend the life of clutch. These include:
✓ Always start accelerating the vehicle in first gear
✓ Avoiding aggressive downshifts
✓ Trying not to skip gears
✓ Changing gears smoothly
✓ Do not ride the clutch, to make it slip unnecessarily

10. Changing filters
 Car filters are a must if you want your beloved car to run smoothly. When one of your filters
gets clogged, it can cause problems and affect performance. You may notice a loss of power,
dirty smoke, oil light or even engine failure.
Every car has four main filters:
• cabin filter
• oil filter and fuel filter
• air filter.
 The function of all these filters is to enable flows
and catch impurities

11. CABIN FILTERS
Common Reasons to change your cabin filter
on time:
 To breathe fresher air
 To avoid safety and visibility issues
 To increase the life of your car’s A/C heating
system

12. AIR FILTER
Common Reasons to change your air filter:
 For a better car performance
 To save on fuel
 To avoid black smoke
Effects of clogged air filter:
 Lack of Acceleration
 Engine misfire
 Strange Engine Noises
 Illuminated Check Engine Light
 Black Smoke Coming from Tailpipe
 Reduced Gas Mileage

13. Benefits of fresh oil changes :
 Reduce Harmful Emissions
 Gas Mileage
 Extended Engine Life
OIL CHANGES

14. OIL FILTER
These Contaminants can affect the engine by
• Increased wear of the different parts of the engine that
leads to frequent rebuilds or repairs
• Reduced life of the lubricant, which causes shorter oil
change intervals
• Reduced fuel combustion efficiency and lowered engine
performance
• Low fuel economy which increases vehicle operation costs,
and
• Higher exhaust emissions that harm the environment

15. Oil filter highlight

16. maintenance of Brakes
Disc and drum brakes are based on a
hydraulic pressure system. Braking starts
with a mechanical force — your foot
pressing the brake pedal.
Disc brake
Drum brake

17. Wheel
alignment
An alignment is the process
of adjusting the angles of
your vehicle’s wheels back
within original
specifications to improve
their contact with the road.

18.  What types of Engineering methods, tools and
techniques you have been using while
performing your work tasks.
 What major challenges and problems you have
been facing and identifying while performing your
work tasks.
 What we gained in terms of improving our
practical skills
 What we gained in terms of upgrading our
theoretical knowledge
 What we gained in terms of improving our team
playing skills
 What we gained in terms of improving your
interpersonal communication skills
 What we gained in terms of improving our
leadership skills.
 What we gained in terms of understanding about
work ethics issues, industrial psychology and
related issues.
 What we gained in terms of entrepreneurship
skills:
 Problem solving and decision making
 Listening
 Assertiveness
 Negotiation

19. The project is focused on developing an oil and
fuel filter wrench based on available materials
around the compound for the accomplishment
of tasks easily. It simplifies the work load of
mechanics when faced with different vehicles.
Some cars like lifan jelly, zna, bishoftu rich and
some others vehicles have their oil and fuels
filter positions undesirable for mechanics to
change them.
Summary of the project Problem statement
 Oil filter wrenches are of a class of tool that is
indispensable in automotive garages. An automotive type
oil filter canister, even when secured to an automotive
engine in a hand-tight torquing procedure, the normal
heating and contraction of the oil filter cannister in use of
the automobile tends to tighten the oil filter to the
automobile engine making manual removal very difficult.
Consequently, oil filter wrenches are necessary. Different
automobiles have different oil filter positions. Modern
automobiles in the evolution of development are currently
utilizing oil filters of varying diameters.
 These vehicles came with different oil filter torque ranges.

20. About to be
Old way New way

21. Objectives
Main objective
 The primary aim of this work is to design an
adjustable oil filter wrench that meets
multiple objectives such as easy to handle,
and that can withstand stresses induced to it.
This project is concerned with the design of
oil filter wrench which can operate on up to
36.6 N/m2 torqued oil/fuel filters without
braking.
Specific objective
 This project is concerned on designing
components of oil filter wrench such as:
➢ Socket
➢ Moment arm
➢ Extension arm
➢ Circular pipe
➢ belt

22. methodology
o Data gathering
To gather the information required for the
project, we have used different methods to
Collect data. Including:-
• Interviews
• Observation
• Document analysis
Material selection
 To select the best material for the gear and shaft following are the
factors which must be consider during the selection process.
1. Mechanical Properties
 Tensile strength
 Density
 Ductility
 Wear resistance
2. Manufacturing Properties
3. Environmental Properties
4. Economic Factors

23. material selection for the socket
• Hardness
• Ductility
 Impact sockets are made of more ductile steel than standard sockets to prevent
them from shattering under the greater forces impact wrenches are able to apply to
them.
In the market there are mainly two types materials that sockets are
made of. They are 860 steel and chrome vanadium steel.
o 8650 steel is very similar to chrome vanadium in its properties, although
it contains a lower percentage of chromium
o Chrome vanadium is a type of spring steel that was pioneered by Henry
Ford for use in the Model T in 1908. It contains approximately 0.8%
chromium and 0.1-0.2% vanadium, which improves the strength and
toughness of the material when it is heat-treated.
One of the things that makes chrome vanadium
particularly suited to use as a socket material is its excellent
resistance to wear and fatigue.
Therefore, we have selected socket that is made from chrome
vanadium steel

24. force analysis
The magnitude of the moment is directly proportional to the magnitude of F
and the perpendicular distance or moment arm d. The larger the force or
the longer the moment arm, the greater the moment or turning effect
The magnitude of MO
MO = Fdsinθ
where d is the moment arm or perpendicular distance from the axis at point O to
the line of action of the force. Units of moment magnitude consist of force times
distance.

25. Minimum length of moment arm
Typically oil filters are tightened on a car around 25 – 27 ft lbs. by taking
the maximum amount that oil filters are tightened, we can calculate
the length of minimum moment arm required to create a turning effect
on the oil filter.
We know
MO = Fdsinθ
27 ft lbs. = 36.6 nm
An average human being can exert a force of 65N with his/her one arm
according to international Encyclopedia of Ergonomics and human
factors.
 However most mechanics can exert a little more than the
average person.
So taking average mechanics’ arm force 100N
Using the above values the moment arm length can be calculated.
MO = Fdsinθ
36.6 nm = 100N * d *
sin(90) d= 0.3m
therefore, arm length should be greater or equal to 0.6 meters to
get task done easily.

26. Extension arm
They are commonly employed to help reach bolts that are recessed or
otherwise unreachable with a standard wrench. They are often used by
mechanics and other related professions, who must loosen stiff or rusted
bolts and work in compact spaces, like engine compartments.
Material selection of extension arm
The material which are used for the extension arm should have following
properties:
1. Material should possess high strength.
2. Material should have high wear resistance.
3. Material should possess heat treatment properties.
4. Material should possess good mechanization.
5. Material must have low notch sensitivity factor.
Steel is the best choice for this purpose because of the advantages below.
• its high stiffness
• consistency and durability.
• High torsional load resistance (twists much less on off-
center hits for better directional control).
• Steel also stands up to good wear resistance
• steel cost considerably less than other metals.
Allowable stress of a typical ASME carbon steel SA-105 at
normal temperature of ≤ 1000C from data table is 138Mpa.

27. Stress calculation
Shear stress for a solid bar or shaft is given by
𝜏 = 𝑇 ∗ 𝐶 / 𝐽
Where T = torque C= radius J=second polar moment of inertia and it is given by
𝐽 = 𝜋 32 (𝐷^4 )
for solid shaft As discussed earlier the diameter of extension bar commonly is 2cm. By
substituting the radius and the torque in the shear stress formula to get the amount of shear
stress induced on the extension bar.
𝜏 = 𝑇 ∗ 𝐶 / 𝐽
𝜏 = 36.6 ∗ 0.01/ 𝜋 32 (0.02^4 )
𝝉 = 𝟑𝟕𝟐, 𝟕𝟎𝟖, 𝟕𝟓𝟕. 𝟔𝑵/𝒎𝟐
find the factor of safety of the extension arm
𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦 = 𝑢𝑙𝑡𝑖𝑚𝑎𝑡𝑒 𝑠𝑡𝑟𝑒𝑠𝑠/𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
❖ Allowable stress of a typical ASME carbon steel SA-105 at normal temperature of ≤ 1000C is
from data table is138Mpa.
𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦 = 𝟑𝟕𝟐, 𝟕𝟎𝟖, 𝟕𝟓𝟕. 𝟔𝑵/𝒎𝟐 /138,000,000𝑁/𝒎𝟐
Factor of safety = 2.7
 Therefore, our design is safe!

28. Shear stress on a circular pipe
The shear stress of a hallow shaft and pipe is the highest on the outside. As an
engineer it is the best option to know the worst-case scenario. Therefore,
studying the shear stress on the outside radius of the circular pipe rather than the
inside is necessary and the best option.
𝜏 = 𝑇 ∗ 𝑐 / 𝐽 , 𝐽 = 𝜋 32 (D0 ^4 – Di ^4 )
𝐽 = 𝜋 / 32 (0.02^4 -0.017^4 )
𝑱 = 𝟕. 𝟓 ∗10^-8
𝜏 = 𝑇 ∗ 𝑐 / 𝐽 = 36.6 ∗ 0.01/ 7.5 ∗ 10^−8
𝝉 = 𝟒, 𝟖𝟖𝟎, 𝟎𝟎𝟎𝑵/𝒎^2
Find the Factor of safety of the steel pipe
𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦 = 𝑢𝑙𝑡𝑖𝑚𝑎𝑡𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 / 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦 = 4,880,000N/m^2 / 2,757,900N/m^2
𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦 =1.8
❖ Therefore, the design is safe!

29. Material selection of the belt
the different properties of a fabric which
are considered for design are
1. Tensile Strength
2. Tear Strength
3. Adhesion Strength
4. Flame Retardancy
5. Flexibility
We have found a material inside belayab company that satisfies the above
requirement. It was not serving any business so it was unwanted and had been in
the garbage until we reused it.
proposed solution
The designed adjustable oil and fuel filter wrench has been implemented and
executed practically. Using our new filter wrench,
• oil and fuel filters cannot be damaged.
• Filters can be reused if necessary.
• The proposed filter wrench can fit in tight spots and be able to loosen filters
which are difficult for mechanics to operate.
• Creates clean environment

30. comparison
 Old way  New way
old way and the new way of loosening filters

31. Conclusion and recommendation
Conclusion
we conclude that the Designed and implemented
oil and fuel filter wrench satisfied the planed
objective of the project. The wrench can loosen car
filters easily. It has high torsional strength and very
good mechanical property. The light and small size
of the wrench made it portable. This adjustable
filter can improve the efficiency of mechanics
around the world.
Recommendation
The following are recommended to further improve the
design and operation of the wrench.
• The belt of the wrench should be improved to the best
quality so that it would not snap off.
• The length of the wrench could be decreased to fit for
other types of car models that we had not faced during our
internship period.
• The belt should be fastened with finer fastener in the
market

32. THANK YOU !