[ijet v2i5p21] authors: sirgireddy chinnaanki reddy, n.keerthi

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

ISSN: 2395-1303 http://www.ijetjournal.org 46

Design Modification and Analysis of Flywheel Using in Thresher Machine

SIRGIREDDY CHINNAANKI REDDY1, N.KEERTHI2

1 M.Tech Student, Department of Mechanical Engineering, 2 Assistant Professor, Department of Mechanical Engineering, Annamacharya Institute of Technology and sciences, Rajampet

ABSTRACT :

I. INTRODUCTION

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

Material

Density (kg/m3)

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.


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

CAST IRON

7810 240000 0.37

ALUMINIUM

ALLOY 6061

2700 68900 0.33

S-GLASS 2.46 86900 0.28

III. MODELING 3.1 INTRODUCTION TO CATIA

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. DESIGN CALCULATIONS FOR

DIFFERENT TYPES OF FLY WHEELS BY

USING THRESHER MACHINE

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 (vs) = π×D×N / 60 = π×0.500×738/ 60 vs= 19.32 m/s

Energy stored in flywheel (Ek) = ½ × I total× ω2 = ½ × 2.865 ×77.28 2 Ek = 8.555KJ

Specific energy (Ek, m) = Ek/ Mtotal = 8.555/ 85.938. (Ek, m) = 0.099kJ/kg

Energy Density (Ek, v) = (Ek/ Mtotal) × ρ = 0.099×7810 (Ek, v) = 777.48KJ/m3



CAST IRON:

TABLE1

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 ANALYSIS5.1 STRUCTURAL ANALYSIS OF

FLYWHEEL 5, 6 SPOKES

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 STRUCTURAL ANALYSIS OF

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


(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

RESULTS TABLE FOR STRUCTURAL

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


(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


(mm)

Stress

(N/mm2

Cast iron 0.00076355 1.4135

Aluminum

alloy 6061

0.00091828 0.49595

S-Glass 0.00066215 0.45897


TABLE 8


(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 Sglass 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


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



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. CONCLUSION

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.

REFERENCES

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3. “Design & Development Of Maize Thresher For Rural Dwellers By Human Pedal Power” by mr.praveen



kiran mali, volume2, issue4, oct-2015 (IJNTSE), ISSN 2349-0780.

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