Design Modification and Analysis of Flywheel Using in Thresher Machine

International Journal of Engineering and Techniques - Volume 2 Issue 5, Sep – Oct 2016

ISSN: 2395-1303 http://www.ijetjournal.org Page 146

Design Modification and Analysis of Flywheel Using in Thresher Machine

SIRGIREDDY CHINNAANKI REDDY

, N.KEERTHI

1 M.Tech Student, Department of Mechanical Engineering,

2 Assistant Professor, Department of Mechanical Engineering, Annamacharya Institute of Technology and sciences, Rajampet

ABSTRACT :

I. I

A flywheel is an inertial energy- storage device. It absorbs mechanical energy and serves as a reservoir, storing energy during the period when the supply of energy is more than the requirement and releases it during the period when the requirement of energy is more than the supply. Focuses on exploring the effects of flywheel geometry on its energy storage/deliver capability per unit mass, further defined as Specific Energy. Proposed computer aided analysis and optimization procedure results show that smart design of flywheel geometry could both have a significant effect on the Specific Energy performance and reduce the operational loads exerted on the shaft/bearings due to reduced mass at high rotational speeds. FE analysis is carried out for different geometry of the flywheel and maximum von misses stresses and total deformations are determined.

Thresher machine much popular in Indian agriculture sector for threshing grains.

Thresher machine are power driven constructed for separate the comb from grain.

Thresher machine take power from electric motors or diesel engines. These machine are

easily available in number of models by different output capacity. These machines used to separate the cob from grains. Now in India most of the farmer’s used thresher’s machine for threshing grain like soybean, maize, wheat, jawar, etc. In previous year farmer resort manual means of threshing, which results into less efficiency, more wastage and much cost spend on labor. Thresher machine constructed for separate cob from the grain. It was constructed from locally available and its cost is very low, affordable, easy transportable.

II. MATERIAL SELECTION Due to the high density of cast iron the weight of the component is high. so it is necessary to reduce the weight of the component by considering high strength to weight ratio materials like aluminum alloy 6061 and s- glass. The material properties of these alternatives are shown in table 2.1.

Table 2.1: Material Properties Materi

al Density (kg/m

)

Young’s modulus

(MPa)

Poisson’

s ratio

RESEARCH ARTICLE OPEN ACCESS

Abstract:

A flywheel is a mechanical device with a significant moment of inertia used as a storage device for rotational energy. Flywheels resist changes in their rotational speed, which helps steady the rotation of the shaft when a fluctuating torque is exerted on it by its power source such as a piston-based engine, such as a piston pump, is placed on it. The flywheel are different types such as solid disk, Spoke type, rim type, tapered type. In solid disk flywheel type it is provided with hub and disk. Solid disk flywheels are less capable of storing energy. Then spoke type flywheel are capable of storing more energy with greater moment of inertia than any other type of flywheel.

In this work solid disk, spoke type flywheel are designed by using CATIA software. The spoke type flywheel is

modeled with 6 spokes and 5 spokes with and without taper. Structural analysis and Modal analysis by using

ANSYS software is done to determine the stresses and frequencies respectively by considering the different

materials Cast iron, Aluminum Alloy 6061 & S-glass materials. From the above analysis, the better material for

the flywheel is determined.

International Journal of Engineering and Techniques - Volume 2 Issue 5, Sep – Oct 2016

ISSN: 2395-1303 http://www.ijetjournal.org Page 147

IRON

7810 240000 0.37 ALUMINI

UM ALLOY

6061

2700 68900 0.33

S-GLASS 2.46 86900 0.28

III. MODELING

CATIA is a one of the world’s leading high-end CAD/CAM/CAE software packages.

CATIA (Computer Aided Three dimensional Interactive Application) is a multi-platform PLM/CAD/CAM/CAE commercial software suite developed by Dassault Systems and marketed world-wide by IBM.CATIA is written in the C++ programming language.

CATIA provides open development architecture through the use of interfaces, which can be used to customize or develop applications. The application programming interfaces supported Visual Basic and C++

programming languages. Commonly referred to as 3D Product Lifecycle Management (PLM) software suite, CATIA supports multiple stages of product development.

Fig (3a): Solid Disk Fig (3b): 5SpokeWith Taper

Fig (3c): 5spoke without taper Fig (3d): 6 spoke with taper

Fig (3e): 6 spoke without taper

IV.

1. Various Functional values of solid disk flywheel

Material: Cast iron

Angular velocity (ω) = 2×π×N/ 60 = 2×π×738 / 60 ω = 77.28 rad/sec

Surface speed (v

) = π×D×N / 60 = π×0.500×738/ 60 v

= 19.32 m/s

Energy stored in flywheel (E

) = ½ × I

× ω

= ½ × 2.865 ×77.28 2 E

= 8.555KJ

Specific energy (E

, m) = Ek/ M

= 8.555/

85.938. (E

, m) = 0.099kJ/kg

Energy Density (E

, v) = (E

/ M

) × ρ =

0.099×7810 (E

, v) = 777.48KJ/m

International Journal of Engineering and Techniques - Volume 2 Issue 5, Sep – Oct 2016

ISSN: 2395-1303 http://www.ijetjournal.org Page 148 CAST IRON:

Funct ional value s

Sol d Fly whe el

Optimi zed Five Spoke withou t taper Flywhe el

Optim ized Five Spoke with taper Flywh eel

Optim ized Six Spoke witho ut taper Flywh eel

Optimized Six Spoke with taper Flywheel

Mass(

Kg) 85.9 38

30.98 31.48 31.778 32.378

Mom ent of inerti a(I) Kg- m2

2.86 5

1.41 1.429 1.427 1.45

N (R.P.

M.)

738 738 738 738 738

Kinet ic energ y(E) store d KJ

8.55 5

4.210 4.267 4.261 4.329

Spe.

Energ y KJ/kg

0.09 9

0.135 0.135 0.134 0.133

Spe.

Densi ty KJ/

m³

777.

48

1061.3 3

1058.6 5

1046.5 4

1044.41

ALUMINUM ALLOY 6061:

TABLE2

Functio nal values

Solid Flywh eel

Optimi zed Five

Optimi zed Five

Optimi zed Six Spoke

Optimi zed Six Spoke

Spoke withou t taper Flywhe el

Spoke with taper Flywhe el

withou t taper Flywhe el

with taper Flywhe el

Mass(K g)

29.71 10.71 31.48 10.986 11.193

Momen t of inertia(I ) Kg-m2

0.991 0.487 1.429 0.493 0.501

N (R.P.M.

)

738 738 738 738 738

Kinetic energy(

E) stored KJ

2.959 1.454 1.475 1.472 1.496

Spe.

Energy KJ/kg

0.0996 0.135 0.135 0.134 0.133

Spe.

Density KJ/ m³

268.92 366.61 365.97 361.80 360.87

S-GLASS:

Functio nal values

Solid Flywh eel

Optimi zed Five Spoke withou t taper Flywhe el

Optimi zed Five Spoke with taper Flywhe el

Optimi zed Six Spoke withou t taper Flywhe el

Optimi zed Six Spoke with taper Flywhe el

Mass(g) 27.069 9.758 9.915 10.01 10.198 Momen

t of inertia(I ) Kg-m2

0.903 0.444 0.45 0.449 0.457

N (R.P.M.

)

738 738 738 738 738

Kinetic energy(

26964 1.325 1.343 1.340 1.364

International Journal of Engineering and Techniques

ISSN: 2395-1303

E) stored KJ Spe.

Energy KJ/kg

0.099 0.135 0.135 0.133

Spe.

Density KJ/ m³

245.05 334.24 332.1 329.49

TABLE 3

V. STRUCTURAL ANALYSIS

WITHOUT TAPER MATERIAL IRON, ALUMINUM ALLOY AND S

5.1a: Total Deformation 5.1b: Total Deformation

5.1c: Total Deformation 5.2a: stress

5.2b: stress 5.3c: stress

International Journal of Engineering and Techniques - Volume 2 Issue 5, Sep –

http://www.ijetjournal.org

0.133 0.133

329.49 329.18

ANALYSIS

WITH &

MATERIAL – CAST , ALUMINUM ALLOY AND S-GLASS

5.1b: Total Deformation

: stress

5.3c: stress

5.3a: strain 5.3b: strain

5.3c: strain 5.4a: Total Deformation

5.4b: Total Deformation 5.4c: Total Deformation

5.5a: stress 5.5b: stress

– Oct 2016

Page 149

5.3b: strain

5.4a: Total Deformation

5.4c: Total Deformation

5.5a: stress 5.5b: stress

International Journal of Engineering and Techniques

ISSN: 2395-1303

5.5c: stress

RESULTS TABLE FOR STRUCTURAL

ANALYSIS SOLID TYPE FLY WHEEL

TABLE 4

Material Deformation (mm)

Stress (N/mm² Cast iron 0.00015504 0.4205 Aluminum

alloy 6061

0.00019786 0.14474

S-Glass 0.00015274 0.13125

FLY WHEEL 5 SPOKES WITH OUT TAPER TABLE 5

Material Deformation (mm)

Stress (N/mm²) Cast iron 0.00087526 1.5117 Aluminum

alloy 6061

0.0010512 0.52656

S-Glass 0.00075682 0.48468

International Journal of Engineering and Techniques - Volume 2 Issue 5, Sep –

http://www.ijetjournal.org

SOLID TYPE FLY WHEEL

2)

Strain

1.7559e-6 0.14474 2.1123e-6

0.13125 1.5592e-5

SPOKES WITH OUT TAPER

Strain

6.9587e-6 8.5049e-6

6.2483e-6

FLY WHEEL 5SPOKES WITH TAPER TABLE 6

Material Deformation (mm)

Stress (N/mm Cast iron 0.00085004 1.2511 Aluminum

alloy 6061

0.0010211 0.43619

S-Glass 0.0007353 0.40124

FLY WHEEL 6 SPOKES WITH OUT TAPER

TABLE 7

Material Deformation (mm)

Stress (N/mm² Cast iron 0.00076355 1.4135 Aluminum

alloy 6061

0.00091828 0.49595

S-Glass 0.00066215 0.45897

FLY WHEEL 6SPOKES WITH TAPER TABLE 8

Material Deformation (mm)

Stress (N/mm²) Cast iron 0.00072998 1.1306 Aluminum

alloy 6061

0.00087853 0.3917

S-Glass 0.00079954 0.35808

5.7 COMPARISION OF DEFORMATION

The comparison of maximum deformation in all the cases considered here shows that’s S glass epoxy gives the least deformation while the aluminum alloy 6065 gives largest deformation.

– Oct 2016

Page 150

Stress (N/mm²)

Strain

1.2511 5.7912e-6 0.43619 7.0661e-6

0.40124 5.18e-6

SPOKES WITH OUT TAPER

2)

Strain

6.9717e-6 0.49595 8.409e-6

0.45897 6.093e-6

FLY WHEEL 6SPOKES WITH TAPER

Strain

5.2326e-6 6.3579e-6

5.8558e-6

COMPARISION OF DEFORMATION

The comparison of maximum deformation in

all the cases considered here shows that’s S-

glass epoxy gives the least deformation while

the aluminum alloy 6065 gives largest

International Journal of Engineering and Techniques - Volume 2 Issue 5, Sep – Oct 2016

ISSN: 2395-1303 http://www.ijetjournal.org Page 151

Fig: 5.7: Comparison Of Deformation

5.8 COMPARISION OF STRESS

The comparison of stress in all cases considered here shows that’s. The stress values are less for solid type. When the weights are considered by using solid type, flywheel is heavier which results in mechanical losses.

The weight of flywheel with 5 spokes without taper is less and also its stress values are within range, using flywheel with 5 spokes without taper is good.

Fig: 5.8 Comparison Of Stress

VI.

By observing the weight of the flywheels for different materials, flywheel with 5 spokes without taper and by using material S – Glass has less weight.

By observing the structural analysis results, the stress values for all materials and for all

models of flywheel are less than the respective yield stress values of all materials. So using all materials and all models are safe under given working conditions.

By comparing the results between models of flywheel, the stress values are less for solid type. When weights are considered by using solid type, the flywheel is heavier which results in mechanical losses. The weight of flywheel with 5 spokes without taper is less and also its stress values are within range, using flywheel with 5 spokes without taper is good. By comparing the results between materials S – Glass is good due to its less stresses and deformations.

By observing the modal analysis results, the deformation values are less for Solid type flywheel but the frequencies are more. If the frequencies are more, vibrations will increase.

The flywheel with 5 spokes without taper has fewer frequencies, so using this model is good.

By using the material Aluminum alloy 6061 is better since its frequencies are less than Cast Iron and S – Glass.

So it can be concluded that flywheel with 5 spokes without taper is good and S – Glass material is good.

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