CHAPTER 1

INTRODUCTION

1.1 GENERAL

A material is a substance or mixture of substances that constitutes an object. Materials can be

pure or impure, living or non-living matter. Materials can be classified based on their physical
and chemical properties, or on their geological origin or biological function. These are the some
of the materials used in vehicles

Fig.1.1: Classification of materials

The engineering materials can broadly be classified as:

a) Ferrous Metals

b) Non-ferrous Metals (aluminum, magnesium, copper, nickel, titanium)

c) Plastics (thermoplastics, thermosets)

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d) Ceramics and Diamond

e) Composite Materials &

f) Nano-materials.

The engineering materials are often primarily selected based on their mechanical, physical,
chemical and manufacturing properties.

1.11 Ferrous Metal

A ferrous metal is any metal that is primarily composed of iron and has magnetic
properties. A ferrous metal is known for its hardness, durability and tensile strength. Some
common ferrous metals include Alloy steel, Carbon steel, Cast iron, Wrought iron.

1.12 Non-Ferrous Metal

Non-ferrous metals, including aluminum, nickel, lead, tin, brass, silver, and zinc, are
known for their tensile strength and present characteristics that hold an advantage over ferrous
metals, mainly by their malleability, lighter weight, and corrosion resistivity.

1.13 Composite Material

A composite material is a combination of two materials with different physical and

chemical properties. When they are combined they create a material which is specialized to do a
certain job, for instance to become stronger, lighter or resistant to electricity. They can also
improve strength and stiffness. Some common composite materials include: Mud Bricks, Wood
,Fiberglass, Translucent Concrete, Absorbent Concrete ,Kevlar, Carbon Fiber, Pykrete

1.14 Alloy materials

An alloy is a combination of a metal with at least one other metal or nonmetal. The
combination must be part of a solid solution, a compound, or a mixture with another metal or
nonmetal in order for it to be considered an alloy. The most common way to combine metals into

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an alloy is by melting them, mixing them together, and then allowing them to solidify and cool
back to room temperature.
Examples of alloys are steel, solder, brass, pewter, duralumin, bronze, and amalgams.

1.15 Aluminum

Aluminum is a silvery-white, lightweight metal. It is soft and malleable. Aluminum is used

in a huge variety of products including cans, foils, kitchen utensils, window frames, beer kegs and
aeroplane parts. This is because of its particular properties

Table 1.1 : Properties of Aluminum

Properties Aluminum
Density 2.70 g/cm^3

Poisson Ratio 0.33

Young's Modulus 68.9 GPa

Shear Modulus 26 GPa

Thermal 279 W/m K

Conductivity

1.16 Cast iron

the cast iron is a brittle material, therefore, it cannot be used in those parts which are subjected to
shocks. The properties of cast iron which makes it a valuable material for engineering purposes
are its low cost, good casting characteristics, high compressive strength, wear resistance and
excellent machinability. The compressive strength of cast iron is much greater than tensile
strength.

Table 1.2 : Properties of cast iron

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 properties Cast iron
density 7150 kg/m^3
Youngs modulus 80 GPa
Tensile strength 500 MPa
Compressive strength 650 MPa
Thermal conductivity 45 w/mk

1.17 Steel

Steel is any iron-based alloy containing less than 1.5 percent carbon. Steel, an alloy consisting
mostly of iron and a small amount of carbon, is one of the most common materials in the world
Carbon steels have carbon as the key alloying element in their composition. They also contain up
to 0.4% silicon and 1.2% manganese. In addition, the residual elements such as copper,
molybdenum, aluminum, chromium and nickel are present in these steels.
AISI 1035 is a water resisting carbon steel whose wear resistance and hardenability are increased
by the addition of small quantity of chromium.

Table 1.3 : Properties of steel

properties steel
density 7850 kg/m^3
Youngs modulus 210 GPa
Tensile strength 600 MPa
Elastic modulus 200 GPa
Poisson ratio 0.30

1.2 NEED OF THE PROJECT

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 The need of every customer is both performance and fuel efficiency of the vehicle. It is achieved
by reducing the weight of the flywheel by changing the conventional material to the best suited
material

1.3 AIM

To reduce the weight of the flywheel and to increase the performance and fuel efficiency of the
car.

1.4 OBJECTIVES

1. To design and analyse the flywheel of the car

2. To fabricate the flywheel
3. Analysis of the flywheel

1.5 METHODOLOGY

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1.6 ORGANISATION OF THE REPORT

Chapter 1: It tells the basic explanation of the materials

Chapter 2: The report is analysed and modified under this literature review. A literature review is
a survey of scholarly sources on a specific topic. It provides an overview of current knowledge,
allowing you to identify relevant theories, methods, and gaps in the existing research.
Chapter 3: The Materials required for the construction of flywheel are discussed and mentioned.
Chapter 4: The process of construction of flywheel is undergone from design to real product.
Chapter 5: Different materials are compared under its varied properties. They are represented
using pictures.
Chapter 6: In this chapter the cost that was spent for various tasks is tabulated.

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Chapter 7: Here we say where the experimentals and how it can be improvised and also have
mentioned about the references used for this project.

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 CHAPTER 2

LITERATURE REVIEW

2.1 SURVEY OF LITERATURE

[1] Kishor D. Farde , Dr Dhiraj S Deshmukh – International Journal of Innovative Research in

Advanced Engineering ISSN: 2349-2163, Volume 1, Issue 6, July 2014.. composite flywheel for
high speed application. From this article, composite materials are better choice for high speed
application is found

[2] Mofid Mahdi – international journal of thermal and environmental engineering volume 3
issue 2 (2011). An optimal two dimensional geometry of flywheel for kinetic energy storage.

From this article, effective stresses on the flywheel is known.

[3] Nagraj R. M. – International Journal Of Modern Engineering Research.volume 4 issue 6

(2016). Suitability of composite material for flywheel analysis. From this article, material for
high energy storing purpose is known.

[4] Sushama G Bawane, A P Ninawe and S K Choudhary– International Journal of mechanical

engineering and robotics volume 1 no 2 (2012), Analysis and optimization of flywheel. From this
article, materials used to reduce stress and weight is known

[5] M.Lavakumar , R.Prasanna Srinivas - International Journal of Computer Trends and

Technology – Volume 4 Issue 7– july 2013 - Design and analysis of light Weight motor vehicle
flywheel-. From this article, material to decrease the fluctuation in torque is known

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2.1 PROBLEM STATEMENT

Heavy flywheel stores more energy but some of the power is lost due to move the weight
of the flywheel and the amount of fuel injected in combustion chamber is also increased to move
the flywheel. Heavy flywheel has a high rotational inertia, which reduces how fast engine
revolution can come up, or slow down, So it takes longer time to reach full rpm. Hence a suitable
material is required to increase the performance of the flywheel and fuel efficiency

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 CHAPTER 3
MATERIAL
3.1 Aluminum alloy

Aluminum alloys are alloys in which aluminum (Al) is the predominant metal. The typical
alloying elements are copper, magnesium, manganese, silicon, tin and zinc. There are two
principal classifications, namely casting alloys and wrought alloys, both of which are further
subdivided into the categories heat-treatable and non-heat-treatable. About 85% of aluminum is
used for wrought products, for example rolled plate, foils and extrusions.

Cast aluminum alloys yield cost-effective products due to the low melting point, although they
generally have lower tensile strengths than wrought alloys. The most important cast aluminum
alloy system is Al–Si, where the high levels of silicon (4.0–13%) contribute to give good casting
characteristics. Aluminum alloys are widely used in engineering structures and components where
light weight or corrosion resistance is required

Aluminum alloys with a wide range of properties are used in engineering structures. Alloy systems
are classified by a number system or by names indicating their main alloying constituents.
Selecting the right alloy for a given application entails considerations of its tensile strength,
density, ductility, formability, workability, weldability, and corrosion resistance, to name a few.
Aluminum alloys are used extensively in aircraft due to their high strength-to-weight ratio.

On the other hand, pure aluminum metal is much too soft for such uses, and it does not have the
high tensile strength that is needed for airplanes and helicopters.
Aluminum alloys are widely used in automotive engines, particularly in cylinder blocks and
crankcases due to the weight savings that are possible

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3.1.1 Aluminum alloy (7068)

Fig 3.1 aluminum alloy

7068 aluminum alloy is one of the strongest commercially available aluminum alloys, with a
tensile strength comparable to that of some steels. This material, also known as an aircraft alloy,
is heat treatable.

7068 has typical ultimate tensile strength of 710 MPa (103 ksi) versus a similar product
produced from 7075 that would have a typical ultimate tensile strength of 640 MPa (93 ksi).
Typical yield strength for alloy 7068 is 683 MPa (99.1 ksi) versus 590 MPa (86 ksi) for a similar
product produced from 7075.

The main alloying elements are zinc (7.3 to 8.3%), magnesium (2.2 to 3.0%), copper (1.6 to
2.4%) and zirconium (0.05 to 0.15%), with traces of silicon, iron, manganese, chromium, and
titanium. Aluminum alloys are 1/3 the weight of carbon and stainless steels

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Table 3.1 : Chemical Composition
Element Weight Percenatge
Aluminum, Al 85.43
Zinc, Zn 8.3
Magnesium, Mg 3
Copper, cu 2.4
Iron, fe 0.15
Zirconium 0.15
Silicon, Si 0.12
Manganese, Mn 0.1
Titanium, Ti 0.1
chromium, Cr 0.05
other 0.2

3.1.2 Properties of aluminum alloy

aluminum is a light-weight metal with a bright silvery luster. This metal along with its alloys are
in high demand worldwide. aluminum 7068 alloy is a heat treatable wrought alloy with good
fatigue strength, good anodizing response, and high thermal conductivity. It was designed as a
higher strength. It also provides the highest mechanical strength of all aluminum alloys.

Table 3.2 :

Properties Aluminum alloy

Density 2.85g/cm^3

Tensile strength 641 MPa

Yield strength 590 MPa

Melting point 476-635 ºC

Thermal Conductivity 190 W/m K

3.2 Aluminum

Aluminum is the main part of this chemical composition. Aluminum has a low specific
weight if 2.7g/cm^3, because of its specific weight it is one of the light weight material. It has a

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modulus of elasticity of 69 GPa, which helps aluminum on easy shaping, rolling, extrusion,
welding, etc. It is also an electric conductor.

The thermal conductivity of Aluminum is 279 W/m K, which makes it an excellent thermal
conductor. Aluminum has a tensile strength between 40MPa to 700MPa and has a yield strength
of 250 MPa, which makes it a high weight to strength ratio material. It is a low dense material of
2.7 g/cm³. So it can be used for high energy storing purpose

3.2.1 Properties of aluminum

Aluminum is lightweight, durable, malleable and corrosion-resistant. This metal is widely used
for components in the aerospace, transportation and construction industries.
 Non-corrosive
 Easily machined and cast
 Lightweight yet durable
 Non-magnetic and non-sparking
 Good heat and electrical conductor

Table 3.3
properties Aluminum, Al
density 2700 kg/m^3
Youngs’s modulus 68 GPa
Poisson ratio 0.33
Thermal conductivity 210 W/mk
Shear modulus 25 GPa

3.3 Zinc

Zinc is a bluish-white metal with a lustrous appearance. It is brittle by nature, but exhibits good
malleability and ductility at higher temperatures. The atomic number of zinc is 30 and is
represented by the symbol Zn. It belongs to the d-block, period 4 and group 12 of the periodic
table. Zinc is used in automotive applications and cathode in batteries

3.3.1 Properties of zinc

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Strength: Zinc is a weak metal with less than half the tensile strength of mild carbon steel. It
is generally not used in load-bearing applications, although inexpensive mechanical parts can
be die cast from zinc.

Toughness: Pure zinc has low toughness and is generally brittle, but zinc alloys generally
have high impact strength compared to other die casting alloys.

Ductility: Between 212 and 302 degrees Fahrenheit, zinc becomes ductile and malleable, but
at elevated temperatures, it reverts to a brittle state. Zinc alloys greatly improve on this
property over the pure metal, allowing more complex fabrication methods to be used.

Conductivity: Zinc’s conductivity is moderate for a metal. Its strong electrochemical

properties, however, serve well in alkaline batteries and during the galvanizing process.

Table 3.4
properties Zinc, Zn
density 7.10g/cm^3
Tensile strength 37 MPa
Thermal conductivity 112.2 W/mk
Modulus of elasticity 96.5 GPa

3.4 Magneisum, Mg

Magnesium is a chemical element with the symbol Mg and atomic number 12. It is a shiny gray
solid magnesium (Mg), chemical element, one of the alkaline-earth metals of Group 2 of the
periodic table, and the lightest structural metal. Its compounds are widely used in construction
Elemental magnesium is a gray-white lightweight metal, two-thirds the density of aluminium.
Magnesium has the lowest melting (923 K (1,202 °F)) and the lowest boiling point 1,363 K (1,994
°F) of all the alkaline earth metals.

3.4.1 Properties of magnesium

Magnesium (Mg) is the lightest structural metal in the world. Therefore, Mg alloys hold great
promise for weight-saving applications in the automotive and aerospace industries. However, the
hexagonal close-packed (HCP) structure of Mg alloys results in limited dislocation plasticity and
alternative deformation mechanisms such as deformation twinning that leads to poor formability

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and mechanical performance of Mg alloys. This inherent low ductility in Mg restricts its broad
applicability as a high performance structural material

Table 3.5
properties Zinc, Zn
density 1.73 Mg/m^3
Tensile strength 175 MPa
Modulus of elasticity 45 GPa
Thermal conductivity 150 W/mk

CHAPTER 4
EXPERIMENTAL PROCESS

4.1 DESIGN OF FLYWHEEL

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 The initial stage for this experimental analysis starts with the design of the flywheel using
the designing software like CATIA, Solidworks etc. Initially the design includes the selection of
materials which is explained. The designing software used here is Solidworks and inside it there
are various designing tools like line, circle, extrude, hole, fillet etc. With the help of these design
tools the flywheel is designed.
Following up on this project, selection of material stands in the way after designing the
flywheel. Mostly flywheel is made up of steel or cast iron. Due to the weight of cast iron and steel
and its properties like lesser thermal conductivity it is not considered.
As a result aluminum alloy is mostly used over a wide variety of automobiles. It has a greater
thermal conductivity as mentioned earlier. The main reason for the selection of aluminum alloy is
that it positioned 3rd place as a lightweight material. As a result it has greater weight to strength
ratio by one third of steel. Since conventional flywheel weigh a lot, it is a positive thing for
choosing aluminum alloy as a flywheel material. Along side the cost of aluminum alloy is cheaper
than cast iron. On the contrary due to its greater thermal conductivity it can transfer more heat
than cast iron.
.

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 Fig.4.1 3D- flywheel Design

4.2 FABRICATION OF FLYWHEEL

4.2.1 Lathe turning machine

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 Fig.4.2.1 turning opertaion
A lathe is a machining tool that is used primarily for shaping metal or wood. It works by rotating
the workpiece around a stationary cutting tool. The main use is to remove unwanted parts of the
material, leaving behind a nicely shaped workpiece.

There are many types of lathes that are specialized for different materials and techniques. Here at
All Metals Fabricating, we have four different kinds of lathes, including a lathe with live tooling
capabilities for multitasking jobs.

People have used lathes to make parts for other machinery, as well as specialty items like bowls
and musical instruments. Whatever the type and function, they all operate using this basic holding
and rotating mechanism.
The lathe machine is used here for turning operation.
it is used to convert the alloy block to the cylinder shape. Here the first operation for machining
flywheel take place.

4.2.2 Jig boring machine

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 Fig.4.2.2 boring process
The jig boring is the most accurate machine of all machine tools. This was first developed in the
year 1910 in Switzerland and used as a locating machine. The real jig borer was first built in the
year 1917 by Pratt and Whitney.

Jig boring machine is used for the production of jigs, fixtures, tools, and other parts. That requires
a high degree of accuracy. They are defined by terms of highest accuracy through rigidity, low
thermal expansion, and precise means of measuring distance for locating and spacing holes.

Jig Borer or Jig Boring Machine, The machining accuracy is high, within a range of 0.0025 mm. A
jig boring machine looks like a vertical milling machine. But so far its operation and accuracy are
concerned that there cannot be any comparison between the two.

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The spindle and other parts of the machine are much hard to resist deflection and the vibration is
low. A Spindle runs in preloaded antifriction bearings.
The jig boring machine is used here to bore the inner area according to the given dimension

4.2.3 VMC Machine for profile machining

Fig 4.2.3 generating gear

CNC machines use a 3D Cartesian coordinate system. shows a typical Vertical Milling Center
(VMC). Parts to be machined is fastened to the machine table. This table moves in the XY-Plane.
As the operator faces the machine, the X-Axis moves the table left-right. The Y-Axis moves the
table forward-backward. The machine column grips and spins the tool. The column controls the Z-
axis and moves up-down.

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 Fig 4.2.4 flywheel

The vertical milling centre is used here to remove the material on the outer surface to generate the
gear according to the given dimension

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 CHAPTER 5
RESULTS AND DISCUSSION

5.1 RESULTS
5.1.1 Weight Comparison
The Weight of flywheel for aluminum alloy, cast iron and steel are compared and the results are
tabulated.
The data’s employed are,
1.Total Volume of flywheel : 2226121.3mm^3.
2.Density of aluminum :2850 kg/m^3.
3.Denstiy of gray cast iron :7200 kg/m^3.
4.Density of steel :7850 kg/m^3.

Formula Applied is Mass = Volume*Density

Table 5.1 Weight details of used materials

Material Weight (kg)

steel 17.5

Gray cast iron 16

Aluminum alloy 6.3

From this we can observe a 64% weight reduction by using aluminum alloy material

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5.1.5 ANALYSIS

Stress analysis

Through solidworks static structural analysis is performed. Total deformation and von mises stress
are obtained.

1. steel

Fig.5.1 steel - Von Mises Stress

2.Gray cast iron

Fig.5.6 Gray cast iron - Von Mises Stress

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3.aluminum alloy

Fig.5.8. aluminum alloy - Von Mises

The following trend was observed for stress analysis:

Al < steel< Cast iron

The maximum stress occurs in gray cast iron flywheel while the minimum occurs in Aluminum
alloy flywheel. One of the reason for this behavior can be attributed to the low strength to the
density ratio for cast iron and in the case of the aluminum alloy, it can be proposed that as the
strength to the density ratio is sufficiently high and the properties of aluminum alloy like light
weight, high strength and high value of elastic modulus contribute towards minimum stress. In
general, stiffer and lighter design can be achieved using aluminum alloys. Figure 8, Figure 9,
Figure 10, and Figure 11 depict the stress for the different materials employed in structural
simulation of the flywheel.

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DEFORMATION ANALYSIS

1 steel

2 gray cast iron

3 aluminum alloy

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The following trend was observed for the radial deformation:

Al < Cast iron<steel

The maximum deformation due to centrifugal force occurs in cast iron and the minimum in Al
alloy, the reason for which can be contributed to their respective strength to the density ratio
which was found to be the highest in case of Al and lowest for steel. The yield strength of Al is
relatively less, so the elastic modulus determines such behavior of aluminum alloys. The
deformation is found to be maximum near the periphery and minimum near the center of the
flywheel. This is because the centrifugal forces increase as we move towards the outer periphery
of the flywheel from the center. Figure 4, Figure 5, Figure 6 and Figure 7 show the deformation
for the different materials employed in structural simulation of the flywheel.

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 CHAPTER 6

COST ESTIMATION

The following particulars were used to complete the project successfully and cost of the
components purchased and fabrication charges are listed below.
Table 6.1 Cost estimation of the flywheel project.
s.no component cost
1 material 3000
2 machining 3000
3 Total cost 6000

CHAPTER 7

CONCLUSIONS

In this project, The modeling of the flywheel was performed using Solid-works. The
Analysis was also carried out using solid-works for the three materials, aluminum alloy, cast iron
and steel. The structural analysis of the original flywheel made of cast iron and steel was carried
out and the deformation, radial stress was reported. Material of the flywheel was changed to
Aluminum alloy 7068 and the structural analysis on solid-works was reported for each of the
materials. The results of the deformation and stress analysis were found to be within safe limits.
However, the deformation and stress developed for aluminum alloy flywheel was found to be the
least among the three materials under consideration. Al alloy also has an added advantage of
higher strength-to-weight ratio compared to the other materials. By using Al alloy flywheel, 64%
of the weight can be reduced as compared to cast steel flywheel which can help in reducing the
weight of the vehicle and increase the performance and fuel economy Thus, Al was found to be
the best suited material for constructing the flywheel.

REFERENCES

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[1]The effect of selected operational factors on the vibroactivity of upper gearbox housings made
of composite materials.TomaszFiglus, Mateusz and ŁukaszKutyński.

[2]Analysis of two stage reduction gearbox.Swapnilkharkar and Saurabh shinde – International

journal of scientific research in science, Engineering and technology.

[3]3D printing technique applied to rapid casting.ElenaBassoli, Andrea gatto and Luca Luliano –
Rapid prototyping journal, 2007.

[4]Design and analysis of a two stage reduction gearbox.AYVGopi Krishna and RV Kiran –
International research journal of Engineering and technology (IRJET).

[5]How to vacuum bagTech hobby –https://youtu.be/C-iL9eLh50O.

[6]Long fibre reinforced thermoplastics continue growth in the Automotive

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[7]Recycled copper filled epoxy composites : the effect of mixed particle size.Mohammad Nur
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[8]Thermal and Electrical conductivity of unsaturated polyester resin filled with copper filler
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