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

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 easily available in number of models by

different output capacity. These machines used
A flywheel is an inertial energy-
to separate the cob from grains. Now in India
storage device. It absorbs mechanical energy
most of the farmer’s used thresher’s machine
and serves as a reservoir, storing energy during
for threshing grain like soybean, maize, wheat,
the period when the supply of energy is more
jawar, etc. In previous year farmer resort
than the requirement and releases it during the
manual means of threshing, which results into
period when the requirement of energy is more
less efficiency, more wastage and much cost
than the supply. Focuses on exploring the
spend on labor. Thresher machine constructed
effects of flywheel geometry on its energy
for separate cob from the grain. It was
storage/deliver capability per unit mass,
constructed from locally available and its cost
further defined as Specific Energy. Proposed
is very low, affordable, easy transportable.
computer aided analysis and optimization
procedure results show that smart design of
II. MATERIAL SELECTION
flywheel geometry could both have a
significant effect on the Specific Energy Due to the high density of cast iron the
performance and reduce the operational loads weight of the component is high. so it is
exerted on the shaft/bearings due to reduced necessary to reduce the weight of the
mass at high rotational speeds. FE analysis is component by considering high strength to
carried out for different geometry of the weight ratio materials like aluminum alloy
flywheel and maximum von misses stresses
6061 and s- glass. The material properties of
and total deformations are determined.
these alternatives are shown in table 2.1.
Thresher machine much popular in
Indian agriculture sector for threshing grains. Table 2.1: Material Properties
Thresher machine are power driven
constructed for separate the comb from grain. Materi Density Young’s Poisson’
Thresher machine take power from electric al (kg/m3) modulus s ratio
motors or diesel engines. These machine are (MPa)

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

CAST 7810 240000 0.37

IRON
ALUMINI 2700 68900 0.33
UM
ALLOY
6061
S-GLASS 2.46 86900 0.28

III. MODELING
3.1 INTRODUCTION TO CATIA
Fig (3c): 5spoke without taper Fig (3d): 6 spoke with 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,
Fig (3e): 6 spoke without taper
which can be used to customize or develop
applications. The application programming IV. DESIGN CALCULATIONS FOR
interfaces supported Visual Basic and C++ DIFFERENT TYPES OF FLY WHEELS BY
programming languages. Commonly referred USING THRESHER MACHINE
to as 3D Product Lifecycle Management 1. Various Functional values of solid disk
(PLM) software suite, CATIA supports flywheel
multiple stages of product development.
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 Spoke withou with

withou with t taper taper
t taper taper Flywhe Flywhe
TABLE1
Flywhe Flywhe el el

Funct Sol Optimi Optim Optim Optimized el el

ional d zed ized ized Six Mass(K 29.71 10.71 31.48 10.986 11.193

value Fly Five Five Six Spoke g)

s whe Spoke Spoke Spoke with taper Momen 0.991 0.487 1.429 0.493 0.501
el withou with witho Flywheel t of
t taper taper ut inertia(I
Flywhe Flywh taper )
el eel Flywh Kg-m2
eel N 738 738 738 738 738
Mass( 85.9 30.98 31.48 31.778 32.378 (R.P.M.
Kg) 38 )
Mom 2.86 1.41 1.429 1.427 1.45 Kinetic 2.959 1.454 1.475 1.472 1.496
ent of 5 energy(
inerti E)
a(I) stored
Kg- KJ
m2 Spe. 0.0996 0.135 0.135 0.134 0.133
N 738 738 738 738 738 Energy
(R.P. KJ/kg
M.) Spe. 268.92 366.61 365.97 361.80 360.87
Kinet 8.55 4.210 4.267 4.261 4.329 Density
ic 5 KJ/ m3
energ S-GLASS:
y(E)
store Functio Solid Optimi Optimi Optimi Optimi
d KJ nal Flywh zed zed zed Six zed Six
Spe. 0.09 0.135 0.135 0.134 0.133 values eel Five Five Spoke Spoke
Energ 9 Spoke Spoke withou with
y withou with t taper taper
KJ/kg t taper taper Flywhe Flywhe
Spe. 777. 1061.3 1058.6 1046.5 1044.41 Flywhe Flywhe el el
Densi 48 3 5 4 el el
ty KJ/ Mass(g) 27.069 9.758 9.915 10.01 10.198
m3 Momen 0.903 0.444 0.45 0.449 0.457
t of
inertia(I
)
ALUMINUM ALLOY 6061:
Kg-m2
N 738 738 738 738 738
TABLE2
(R.P.M.
)
Functio Solid Optimi Optimi Optimi Optimi
nal Flywh zed zed zed Six zed Six Kinetic 26964 1.325 1.343 1.340 1.364

values eel Five Five Spoke 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 0.135 0.133 0.133
Energy
KJ/kg
Spe. 245.05 334.24 332.1 329.49 329.18
Density
KJ/ m3

TABLE 3 5.3a: strain 5.3b: strain

V. STRUCTURAL ANALYSIS
5.1 STRUCTURAL ANALYSIS OF
FLYWHEEL 5, 6 SPOKES WITH &
WITHOUT TAPER MATERIAL – CAST
IRON,, ALUMINUM ALLOY AND S-GLASS
S

5.3c: strain 5.4a: Total Deformation

5.1a: Total Deformation 5.1b: Total Deformation

5.4b: Total Deformation 5.4c: Total Deformation

5.1c: Total Deformation 5.2a:: stress

5.5a: stress 5.5b: stress

5.2b: 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 Deformation Stress Strain

(mm) (N/mm2)
Cast iron 0.00085004 1.2511 5.7912e-6

5.5c: stress Aluminum 0.0010211 0.43619 7.0661e-6

alloy 6061
RESULTS TABLE FOR STRUCTURAL
ANALYSIS S-Glass 0.0007353 0.40124 5.18e-6
SOLID TYPE FLY WHEEL

TABLE 4
FLY WHEEL 6 SPOKES WITH OUT TAPER
Material Deformation Stress Strain TABLE 7
2
(mm) (N/mm )
Material Deformation Stress Strain
Cast iron 0.00015504 0.4205 1.7559e-6
(mm) (N/mm2)
Aluminum 0.00019786 0.14474 2.1123e-6 Cast iron 0.00076355 1.4135 6.9717e-6
alloy 6061
Aluminum 0.00091828 0.49595 8.409e-6

S-Glass 0.00015274 0.13125 1.5592e-5 alloy 6061

S-Glass 0.00066215 0.45897 6.093e-6

FLY WHEEL 5 SPOKES WITH OUT TAPER

FLY WHEEL 6SPOKES WITH TAPER
TABLE 5
TABLE 8
Material Deformation Stress Strain
(mm) (N/mm2) Material Deformation Stress Strain
2
(mm) (N/mm )
Cast iron 0.00087526 1.5117 6.9587e-6
Cast iron 0.00072998 1.1306 5.2326e-6
Aluminum 0.0010512 0.52656 8.5049e-6
Aluminum 0.00087853 0.3917 6.3579e-6
alloy 6061
alloy 6061
S-Glass 0.00079954 0.35808 5.8558e-6
S-Glass 0.00075682 0.48468 6.2483e-6

5.7 COMPARISION OF DEFORMATION

The comparison of maximum deformation in

all the cases considered here shows that’s S
S-
glass 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
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
ISSN: 2395-1303 http://www.ijetjournal.org
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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1. “Design Optimization of Flywheel
Thresher Using Fem” advanced
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characterization BY Mr. D.Y.Shahare
vol3 issue2 (2013) IJETAE, ISSN
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2. “Design Optimization & Experiments
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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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