[IJET V2I5P21]

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

OPEN ACCESS

Design Modification and Analysis of Flywheel Using in Thresher Machine SIRGIREDDY CHINNAANKI REDDY1, N.KEERTHI2 1

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

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 aABSTRACT 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.

I. INTRODUCTION A flywheel is an inertial energystorage 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

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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/m3)

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Young’s modulus (MPa)

Poisson’ s ratio

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International Journal of Engineering and Techniques - Volume 2 Issue 5, Sep – Oct 2016 CAST IRON ALUMINI UM ALLOY 6061 S-GLASS

7810

240000

0.37

2700

68900

0.33

2.46

86900

0.28

III. MODELING 3.1 INTRODUCTION TO CATIA

Fig (3c): 5spoke without taper

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 (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 Fig (3a): Solid Disk

Fig (3b): 5SpokeWith Taper

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

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

CAST IRON:

Spoke

withou

with

withou

with

t taper

taper

t taper

taper

Flywhe

29.71

10.71

31.48

10.986

11.193

0.991

0.487

1.429

0.493

0.501

738

2.959

1.454

1.475

1.472

1.496

0.0996

0.135

0.134

0.133

268.92

366.61

365.97

361.80

360.87

TABLE1 Funct

Sol

Optimi

Optim

Optimized

ional

zed

ized

Six

Mass(K

value

Fly

Five

Six

Spoke

whe

Spoke

with taper

Momen

Flywheel

t of

withou

with

witho

t taper

taper

inertia(I

Flywhe

Flywh

taper

)

eel

Flywh

Kg-m2

30.98

31.48

31.778

eel Mass(

85.9

Kg)

Mom

2.86

ent of

32.378

(R.P.M. )

1.41

1.429

1.427

1.45

Kinetic energy(

inerti

E)

a(I)

stored

Kg-

KJ Spe.

m2 738

738

Energy KJ/kg

(R.P.

Spe.

M.) Kinet

8.55

4.210

4.267

4.261

4.329

Density KJ/ m3

S-GLASS:

energ y(E) store

Functio

Solid

Optimi

d KJ

nal

Flywh

zed

zed Six

values

eel

Five

Spoke

withou

with

withou

with

t taper

taper

KJ/kg

t taper

taper

Flywhe

Spe.

0.09

Energ

0.135

0.134

Spe.

777.

1061.3

1058.6

1046.5

Densi

0.133

1044.41

ty KJ/

Mass(g)

27.069

9.758

9.915

10.01

10.198

Momen

0.903

0.444

0.45

0.449

0.457

738

26964

1.325

1.343

1.340

1.364

t of inertia(I )

ALUMINUM ALLOY 6061:

Kg-m2 N

TABLE2

(R.P.M. )

Functio

Solid

Optimi

nal

Flywh

zed

zed Six

Kinetic

values

eel

Five

Spoke

energy(

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International Journal of Engineering and Techniques - Volume 2 Issue 5, Sep – Oct 2016 E) stored KJ Spe.

0.099

0.135

0.133

245.05

334.24

332.1

329.49

329.18

Energy KJ/kg Spe. Density KJ/ m3

TABLE 3

5.3a: strain

5.3b: strain

V. STRUCTURAL ANALYSIS 5.1

STRUCTURAL

FLYWHEEL

ANALYSIS SPOKES

WITH

WITHOUT TAPER MATERIAL – CAST IRON,, ALUMINUM ALLOY AND S-GLASS S

5.3c: strain

5.1a: Total Deformation

5.1b: Total Deformation

5.4b: Total Deformation

5.1c: Total Deformation

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5.4c: Total Deformation

5.2a:: stress

5.5a: stress

5.2b: stress

5.4a: Total Deformation

5.5b: stress

5.3c: stress

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International Journal of Engineering and Techniques - Volume 2 Issue 5, Sep – Oct 2016 FLY WHEEL 5SPOKES WITH TAPER TABLE 6 Material

5.5c: stress

Deformation

Stress

(mm)

(N/mm2)

Strain

Cast iron

0.00085004

1.2511

5.7912e-6

Aluminum

0.0010211

0.43619

7.0661e-6

0.0007353

0.40124

5.18e-6

alloy 6061

RESULTS TABLE FOR STRUCTURAL ANALYSIS

S-Glass

SOLID TYPE FLY WHEEL TABLE 4 Material

Deformation

FLY WHEEL 6 SPOKES WITH OUT TAPER Stress

TABLE 7

Strain

(mm)

(N/mm )

Cast iron

0.00015504

0.4205

1.7559e-6

Aluminum

0.00019786

0.14474

2.1123e-6

Material

Deformation

Stress

(mm)

(N/mm2)

Strain

Cast iron

0.00076355

1.4135

6.9717e-6

Aluminum

0.00091828

0.49595

8.409e-6

0.00066215

0.45897

6.093e-6

alloy 6061 S-Glass

0.00015274

0.13125

1.5592e-5

alloy 6061 S-Glass

FLY WHEEL 5 SPOKES WITH OUT TAPER

FLY WHEEL 6SPOKES WITH TAPER

TABLE 5 Material Cast iron Aluminum

Deformation

Stress

(mm)

(N/mm2)

0.00087526 0.0010512

1.5117 0.52656

TABLE 8 Strain Material

alloy 6061 S-Glass

Stress

Strain 2

(mm)

(N/mm )

Cast iron

0.00072998

1.1306

5.2326e-6

Aluminum

0.00087853

0.3917

6.3579e-6

0.00079954

0.35808

5.8558e-6

6.9587e-6 8.5049e-6

Deformation

alloy 6061 0.00075682

0.48468

6.2483e-6

S-Glass

5.7 COMPARISION OF DEFORMATION

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

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

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.

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

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

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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

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International Journal of Engineering and Techniques - Volume 2 Issue 5, Sep – Oct 2016 kiran mali, volume2, issue4, oct-2015 (IJNTSE), ISSN 2349-0780. 4. “Stress Analysis Of Flywheel” by Mr. tony. A, tony kurian, vol 2, issue3, (July-Sep 2015) IJARET, ISSN: 23942975. 5. “Fem Analysis of Flywheel Used in Press- a Review” by ms.Snehal R.raut, proof .N.P DOSHI, volume1, issue3 (mar-apr 2014) IORD, ISSN: 23480831. 6. “Analysis and optimization of flywheel” by sushama, g bawane, a p ninawe and s k choudhary, volume no.2 ISSN 2278-0149(IJMER) JULIY 2012.

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