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

ISSN: 2395-1303

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 farmers used threshers 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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Youngs
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 worlds 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 () = 2N/ 60 = 2738

/ 60 = 77.28 rad/sec
Surface speed (vs) = DN / 60 =
0.500738/ 60 vs= 19.32 m/s
Energy stored in flywheel (Ek) = I total 2
= 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) =
0.0997810 (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

Flywhe

Flywhe

el

el

el

el

29.71

10.71

31.48

10.986

11.193

0.991

0.487

1.429

0.493

0.501

738

738

738

738

738

2.959

1.454

1.475

1.472

1.496

0.0996

0.135

0.135

0.134

0.133

268.92

366.61

365.97

361.80

360.87

TABLE1
Funct

Sol

Optimi

Optim

Optim

Optimized

ional

zed

ized

ized

Six

Mass(K

value

Fly

Five

Five

Six

Spoke

g)

whe

Spoke

Spoke

Spoke

with taper

Momen

Flywheel

t of

el

withou

with

witho

t taper

taper

ut

inertia(I

Flywhe

Flywh

taper

el

eel

Flywh

Kg-m2

30.98

31.48

31.778

eel
Mass(

85.9

Kg)

38

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

738

738

738

Energy
KJ/kg

(R.P.

Spe.

M.)
Kinet

8.55

ic

4.210

4.267

4.261

4.329

Density
KJ/ m3

S-GLASS:

energ
y(E)
store

Functio

Solid

Optimi

Optimi

Optimi

Optimi

d KJ

nal

Flywh

zed

zed

zed Six

zed Six

values

eel

Five

Five

Spoke

Spoke

Spoke

Spoke

withou

with

withou

with

t taper

taper

KJ/kg

t taper

taper

Flywhe

Flywhe

Flywhe

Flywhe

el

el

el

el

Spe.

0.09

Energ

0.135

0.135

0.134

Spe.

777.

1061.3

1058.6

1046.5

Densi

48

0.133

1044.41

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

738

738

738

738

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

Optimi

Optimi

Optimi

nal

Flywh

zed

zed

zed Six

zed Six

Kinetic

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

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

5,

ANALYSIS
SPOKES

OF

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 thats 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 thats. 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

ISSN: 2395-1303

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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