design & modal analysis of multi cylinder petrol engine...

International Journal of Electrical Electronics Computers & Mechanical Engineering (IJEECM)

ISSN: 2278-2808 www.ijeecm.org Volume 3 Issue8 ǁ Aug. 2016

IJEECM journal of Mechanical Engineering (ijeecm-jme)

www.ijeecm.org

Design & Modal Analysis of Multi Cylinder Petrol Engine Flywheel using Different Materials

P.Manoj kumar 1, K.Baba Saheb 2, D.Madhava reddy3 1,2,3 Mechanical Engineering Department,

1,2,3 AVN Institute of Engineering and Technology, Koheda Road, Ibrahimpatnam, Ranga Reddy Dist., T.S(India)

Abstract— A flywheel used in machines serves as

a reservoir which stores 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 supply. For example, in I.C. engines,

the energy is developed only in the power stroke which is

much more than engine load, and no energy is being

developed during the suction, compression and exhaust

strokes in case of four stroke engines. The excess energy

is developed during power stroke is absorbed by the

flywheel and releases its to the crank shaft during the

other strokes in which no energy is developed, thus

rotating the crankshaft at a uniform speed.

The flywheel is located on one end of the

crankshaft and serves two purposes. First, through its

inertia, it reduces vibration by smoothing out the power

stroke as each cylinder fires. Second, it is the mounting

surface used to bolt the engine up to its load The aim of

the project is to design a flywheel for a multi cylinder

petrol engine flywheel using the empirical formulas. A

parametric model of the flywheel is designed using 3D

modeling software Creo. The forces acting on the

flywheel are also calculated. The strength of the flywheel

is validated by applying the forces on the flywheel in

analysis software ANSYS. Structural analysis, modal

analysis and fatigue analysis are done on the flywheel.

Structural analysis is used to determine whether

flywheel withstands under working conditions. Fatigue

analysis is done for finding the life of the component.

Modal analysis is done to determine the number of mode

shapes for flywheel. Analysis is done for two materials

Gray Cast Iron and S Glass Epoxy to compare the

results.

Keywords: Spur gear, Contact stress, Involute, Pro/Engineer, ANSYS 14.5.

I. INTRODUCTION

A flywheel is a heavy disk or wheel that is

attached to a rotating shaft Flywheels are used for storage

of kinetic energy. The momentum of the flywheel causes it

to not change its rotational speed easily. Because of this,

flywheels help to keep the shaft rotating at the same speed.

This helps when the torque applied to the shaft changes

often. Uneven torque can change the speed of rotation.

Because the flywheel resists changes in speed, it decreases

the effects of uneven torque. Engines which use pistons to

provide power usually have uneven torque and use

flywheels to fix this problem. It takes energy to get a wheel

(any wheel) to rotate. If there is little friction (good

bearings) then it will keep rotating a long time. When

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energy is needed, it can be taken from the wheel again. So

it is a simple mechanical means of storing energy. The

amount of energy stored is a function of the weight and the

speed of rotation - making a heavier wheel rotate faster

takes more energy.

2.DESIGN

PRO-E INTRODUCTION(3D CAD)

Three-dimensional (3D) CAD programs come in a

wide variety of types, intended for different applications and

levels of detail. Overall, 3D CAD programs create a realistic

model of what the design object will look like, allowing

designers to solve potential problems earlier and with lower

production costs. Some 3D CAD programs include

Autodesk Inventor, Co-Create Solid Designer, Pro/Engineer

Solid Edge, SolidWorks, Unigraphics NX and VX CAD,

CATIA V5.

Pro/ENGINEER Wildfire is the standard in 3D

product design, featuring industry-leading productivity tools

that promote best practices in design while ensuring

compliance with your industry and company standards.

Integrated Pro/ENGINEER CAD/CAM/CAE solutions

allow you to design faster than ever, while maximizing

innovation and quality to ultimately create exceptional

products.

3.ANALYSIS

The basic concept in fem is that the body or

structure may be divided into smaller elements of finite

dimensions called “Finite Elements”. The original body or

the structure is then considered as an assemblage of these

elements connected at a finite number of joints called

“nodes” or “nodal points”. Simple functions are chosen to

approximate the displacements over each finite element.

Such assumed functions are called “shape functions”. This

will represent the displacement with in the element in terms

of the displacement at the nodes of the elements.

The Finite Element method is a mathematical tool

for solving ordinary and partial differential equation

because it is a numerical tool, it has the ability to solve the

complex problem that can be represented in differential

equation from. The application of FEM are limitless as

regards the solution of practical design problems.

Due to high cost of computing power of years gone

by, FEM has a history of being used to solve complex and

cost critical problems.

The finite element method is a very important tool

for those involved in engineering design; it is a now used

routinely to solve problems in the following areas:

Fig. 1. Structural analysis

Fig. 2. Thermal analysis

Fig. 3. Vibrations and dynamics

Fig. 4. Buckling analysis

Fig. 5. Acoustics

Fig. 6. Fluid flow simulations

Fig. 7. Crash simulations

Fig. 8. Mould flow simulations

4.RESULTS & DISCUSSION

STRUCTURAL ANALYSIS OF FLYWHEEL

CAST IRON

Imported Model from Pro/Engineer

Figure :4.1 Imported Creo Model

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Element Type: Solid 20 node 186

Material Properties: Youngs Modulus (EX) :

103000N/mm2

Poissons Ratio (PRXY) : 0.211

density : 0.0000071 kg/mm3

Meshed Model

Figure:4.21MESHED MODEL

Loads

Pressure values – 0.64398e-01,0.86604e-

01,0.19221,0.25849,0.51714e-01,0.618646e-01.

Solution

Solution – Solve – Current LS – ok

Post Processor

General Post Processor – Plot Results – Contour

Plot - Nodal Solution – DOF Solution –

Displacement Vector Sum

Figure :4.3 DISPLACEMENT


Plot – Nodal Solution – Stress – Von Mises Stress

Figure: 4.4VONMISES STRESS

General Post Processor – Plot Results – Contour Plot –

Nodal Solution – Strain – Total mechanical Strain

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Figure :4.5 MECHANICAL

STRAIN


ALUMINIUM-A360


Figure :4.6 IMPORTED MODEL



80000N/mm2


Density : 0.00000268 kg/mm3

Meshed Model

Figure: 4.7 MESHED MODEL

Loads


01,0.19221,0.25849,0.51714e-01,0.618646e-01.

Solution


Post Processor





Nodal Solution – Stress – Von Mises Stress

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Figure :4.8 VONMISES STRESS

General Post Processor – Plot Results – Contour Plot – Nodal Solution – Strain – Total mechanical Strain

Figure :4.9MECHANICAL STRAIN


E-GLASS FLIBER


Figure: 4.10 IMPORTED MODAL



72000N/mm2


Density : 0.00000255 kg/mm3

Meshed Model

Figure:4.11 MESHED FILE

Loads

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01,0.19221,0.25849,0.51714e-01,0.618646e-01.

Solution


Post Processor




Figure :4.12DISPLACEMENT VECTOR SUM


Nodal Solution – Stress – Von Mises Stress

Figure :4.13 VONMISES

STRESS


Nodal Solution – Strain – Total mechanical Strain

Figure :4.14 MECHANICAL STRAIN

FLYWHEEL MODAL ANALYSIS FOR CAST IRON

Import Model

Figure:4.15 IMPORTED

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MODEL

Material Properties Cast Iron

Young’s Modulus – 103000Mpa

Poisson’s ratio – 0.211

Density – 0.0000071Kg/mm3

MESHED MODEL

Figure :4.16 MESHED FILE

Solution>analysis type>new analysis>select model

analysis>ok Analysis options>no of modes to extract>5

No of modes to expand 5>ok Frequency range>0 to1000

Modal Analysis 1

Figure :4.17 FIRST MODE

SHAPE

Modal analysis 2

Figure:4.18 SECOND MODE SHAPE

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Modal Analysis 3

Figure:4.19 THIRD MODE SHAPE

Modal Analysis 4

Figure:4.20 FOURTH MODE SHAPE

Modal Analysis 5

Figure:4.21 FIFTH MODE

SHAPE

FLYWHEEL

MODAL ANALYSIS FOR AL-A360

Import Model

Figure:4.22 IMPORTED MODEL

Material Properties Cast Iron

Young’s Modulus – 80000Mpa

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Poisson’s ratio – 0.33

Density – 0.00000268Kg/mm3

Solution>analysis type>new analysis>select model

analysis>ok Analysis options>no of modes to extract>5

No of modes to expand 5>ok Frequency range>0 to1000

Modal Analysis 1

Figure :4.23FIRST FREQUENCY

Modal analysis 2

Figure :4.24 SECOND FREQUENCY

Modal Analysis 3

Figure :4.25 THIRD FREQUENCY

Modal Analysis 4

Figure :4.26 FOURTH FREQUENCY

Modal Analysis 5

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Figure :4.27 FIFTH FREQUENCY

FLYWHEEL

MODAL ANALYSIS FOR E-GLASS FLIBER

Import Model

Figure :4.28 IMPORTED MODEL

Material Properties

Cast Iron Young’s Modulus – 72000Mpa

Poisson’s ratio – 0.21 Density – 0.00000255Kg/mm3

Solution>analysis type>new analysis>select model analysis>ok Analysis options>no of modes to extract>5 No of modes to expand 5>ok Frequency range>0 to1000

Modal Analysis 1

Figure :4.29 FIRST FREQUENCY

Modal analysis 2

Figure :4.30 SECOND FREQUENCY

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Modal Analysis 3

Figure :4.31 THIRD FREQUENCY

Modal Analysis 4

Figure :4.32 FOURTH FREQUENCY

Modal Analysis 5

Figure ;4.33 FIFTH FREQUENCY

Table 1 Numerical values obtained during analysis:

si.no material displacement von-mises stress strain min max min max min

1 CAST IRON 0

5.48E-05 0.011865 0.313296

1.70E-07

2 A360 0 6.12E-

05 0.014586 0.281982 2.29E-

07

3 E-

GLASS 0 7.85E-

05 0.011855 3.14E-01 2.44E-

07

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Table 2 material modes

5.CONCLUSION

In our project we have designed a flywheel used in

a multi cylinder petrol engine using theoretical calculations.

2d drawing is created and modeling of flywheel is done

using Pro/Engineer. We have done structural and modal

analysis on flywheel using two materials Gray Cast Iron,

Aluminum A360 and S Glass Epoxy to validate our design.

By observing the results, for all the materials the

strength values are less than their respective yield strength

values. So our design is safe. We have also done modal

analysis for number of modes to see the displacement of

flywheel for number of frequencies. By comparing the

results for three materials, the strength value for Aluminum

A360 and S Glass Epoxy is less than that of Cast Iron.

So we conclude that for our design, Gray Cast Iron

is better material for flywheel. In this project mainly we did

material optimization.

6.REFERENCES

"Flywheels move from steam age technology to Formula

1"; Jon Stewart | 1 July 2012, retrieved 2012-07-03 Jump

up, "Breakthrough in Ricardo Kinergy ‘second generation’

high-speed flywheel technology"; Press release date: 22

August 2011. retrieved 2012-07-03

1. Janse van Rensburg, P.J."Energy storage in

composite flywheel rotors". University of

Stellenbosch.

2. Jump up rosseta Technik GmbH, Flywheel

Energy Storage, German, retrieved February 4,

2010.

3. Zhang Da-lun, Mechanics of Materials, Tongji

University Press, Shjanghai, 1993

4. Huang Xi-kai, Machine Design, Higher Education

Press, Beijing, 1995

5. Robert L. Norton, Design of Machinery, McGraw-

Hill Inc, New York, 1992

6. K. Lingaiah, Machine Design Data Handbook,

McGraw-Hill Inc, New York, 1994

7. R. S. Khurmi, J. K. Gupta, Machine Design,

Eurasia Publishing House, NewDelhi, 1993

8. ANSYS User's Manual, Swanson Analysis

Systems, Inc., Houston

si.no material mod 1

mode 2 mode 3

mode 4 mode 5

1 CAST IRON

9.19E+01

122.813

1.24E+02

137.039 1.76E+02

2 A360 125.95

5 174.59

4 1.77E+

02 197.1

88 243.984

3 E-

GLASS 128.23

3 171.35

7 1.73E+

02 191.1

85 246.273

design & modal analysis of multi cylinder petrol engine...

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