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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 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.
International Journal of Engineering and Techniques - Volume 2 Issue 5, Sep – Oct 2016
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
International Journal of Engineering and Techniques - Volume 2 Issue 5, Sep – Oct 2016
ISSN: 2395-1303 http://www.ijetjournal.org Page 148
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
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
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
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 Sglass epoxy gives the least deformation while the aluminum alloy 6065 gives largest deformation.
– Oct 2016
Page 150
FLY WHEEL 5SPOKES WITH TAPER
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. 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
1. “Design Optimization of Flywheel Thresher Using Fem” advanced materials manufacturing & characterization BY Mr. D.Y.Shahare vol3 issue2 (2013) IJETAE, ISSN 2250-2459.
2. “Design Optimization & Experiments On Flywheel Using Thresher Machine” by mr.sagar m.samshette, mr.Mahesh c. swami volume 04, issue10, oct-2015(IJRET) eISSN: 2319-1163.
3. “Design & Development Of Maize Thresher For Rural Dwellers By Human Pedal Power” by mr.praveen
International Journal of Engineering and Techniques - Volume 2 Issue 5, Sep – Oct 2016
ISSN: 2395-1303 http://www.ijetjournal.org Page 152
kiran mali, volume2, issue4, oct-2015 (IJNTSE), ISSN 2349-0780.
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