OPTIMIZATION AND ANALYSIS OF FLY WHEEL

A Major Project Report Submitted

To

Jawaharlal Nehru Technological University, Hyderabad.

In partial fulfilment for the requirement of the award of the degree of

BACHELOR OF TECHNOLOGY

IN

MECHANICAL ENGINEERING

Submitted by

Ch. Ramesh 20831A0313

K. Shravan Kumar 20831A0329

Rangaraju Rohan 20831A0355

Y. Santhosh Reddy 20831A0369

Under the Esteemed Guidance of

Mrs. K. Deepika

Assistant professor

DEPARTMENT OF MECHANICAL ENGINEERING

GURU NANAK INSTITUTE OF TECHNOLOGY
(Approved by AICTE, NBA accredited & Affiliated to JNTU Hyderabad)

Ibrahipatnam, Rangareddy Dist-501506(T.S)

2020-2024

i
 CERTIFICATE

This is to certify that the mini project entitled “OPTIMIZATION AND ANALYSIS OF FLY
WHEEL ” is being presented with report by CH.RAMESH (20831A0313) , K.SHRAVAN
KUMAR (20831A0329) , RANGARAJU ROHAN (20831A0355) , Y.SANTHOSH
REDDY (20831A0369) in partial fulfilment for the award of Degree of Bachelor of
Technology in Mechanical Engineering to Guru Nanak Institute of Technology (Autonomous)
affiliated to Jawaharlal Nehru Technological University, Hyderabad during the academic Year
2023-2024.

Mrs. K. DEEPIKA Dr. B. VIJAYA KUMAR

INTERNAL GUIDE HOD,ME & COE

EXTERNAL EXAMINER

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 ACKNOWLEDGEMENT
We own our immense thanks to Mrs. K. DEEPIKA our project guide, Assistant
Professor in Department of Mechanical Engineering, Guru Nanak Institute of
Technology for the sustained interest, constructive criticism, and constant
encouragement at every stage of his Endeavour.

We extend our deep sense of graduate to Dr. B. VIJAYA KUMAR, Professor, Head of
the Mechanical Department and Controller of Examinations, Guru Nanak Institute of
Technology for his masterly supervision and valuable suggestions for the successful
completion of our project.

We wish to express our candidate gratitude to Dr. S. SREENATHA REDDY, Principal

and the Management of the Guru Nanak Institute of Technology for providing us the
best amenities which enabled us to complete our project in the stipulated time. Finally,
yet importantly, we are very thankful to our parents, friends, and other faculty of
Mechanical Engineering Department for their constant support in completion of this
project.

CH. RAMESH 20831A0313

K. SHRAVAN KUMAR 20831A0329

R. ROHAN 20831A0355

Y. SANTHOSH REDDY 20831A0369

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 TABLE OF CONTENTS

DESCRIPTION PAGE NO

CERTIFICATE ii

ACKNOWLEDGEMENT iii

TABLE OF CONTENTS iv

LIST OF FIGURUES vi

ABSTRACT viii

CHAPTER - 1 INTRODUCTION

1.1 Introduction 1
1.2 Flywheels as energy storage 3
1.3 Goals and objective 3
1.4 Proposed model 5
1.5 Material strength 5
1.6 Geometry 7
1.7 Flywheel moment 8

CHAPTER- 2 LITERATURE REVIEW 9

CHAPTER- 3 EXPERIMENTATION

3.1 Modelling solidworks 13

3.2 Solidworks components 13
3.3 Feature manager / Design tree 15
3.4 Modelling of wheel 16

CHAPTER- 4 MASTERING ANSYS

iv
 4.1 Analysing Process 21
4.2 Project objective 22
4.3 Finite Element Analysis (FEA) 24
4.4 Elements and elements shapes 25
4.5 Problem statement 26
4.6 General procedure to conduct finite element analysis
4.6.1 Pre processor 27
4.6.2 Components types 28
4.6.3 Post processor 28
CHAPTER- 5 MODAL ANALYSIS
5.1 Introduction 30
5.2 Performing the modal analysis 31
5.3 Adding modal analysis system to Ansys work bench 31
5.4 Starting the mechanical window 32
5.5 Generating the mesh for model 32
5.6 Setting the boundary conditions 33
CHAPTER- 6 STATIC STRUCTURAL ANALYSIS
6.1 Project objective 35
6.1.1 Pre-Processing 36
6.1.2 post processing 37
6.2 Equivalent stress analysis 38
6.3 Specifying boundary conditions 39
6.4 Static thermal analysis temperature 40
6.4.1 Heat flux 41
RESULTS AND DISCUSSIONS 43
CONCLUSION 45
FUTURE SCOPE 46
REFERENCES 47

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 LIST OF FIGURES

NAME OF FIGURES PAGE NO

Fig 1.1 Fly wheel movement 8
Fig 3.1 Components of solid works 14
Fig 3.2 Specification tree 15
Fig 3.3 Sketch for the flywheel 16
Fig 3.4 Revolve 17
Fig 3.5 Extrude cut 17
Fig 3.6 Extrude cut and circular pattern 18
Fig 3.7 Sketch for teeths 18
Fig 3.8 Sketch for teeth 19
Fig 3.9 Extrude cut 19
Fig 3.10 Model 1 with 152 teeths 20
Fig 3.11 Model 2 with 146 teeths 20
Fig 4.1 Node and an Element 25
Fig 4.2 Line Element 25
Fig 4.3 The Area Elements 26
Fig 4.4 Volume Elements 26
Fig 4.5 Fea through Software 27
Fig 5.1 Project schematic window with modal 31
analysis system added
Fig 5.2 Mechanical window tree outline 32
Fig 5.3 Safety factor 33
Fig 5.4 Total deformation 34
Fig 6.1 Static Structural analysis added to project schematic 35
Fig 6.2 Equivalent elastic strain 36
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Fig 6.3 Environmental contextural tool bar 36
Fig 6.4 Solution contextural tool bar 37
Fig 6.5 Equivalent stress analysis 38
Fig 6.6 Connections 39
Fig 6.7 Loads drop down 40
Fig 6.8 steady state thermal analysis 41
Fig 6.9 total heat flux 42

vii
 ABSTRACT
Our project presents a comprehensive optimization framework for the design of flywheel
energy storage systems (FESS). The optimization process involves the selection of
materials, geometrical parameters, and operational parameters to maximize energy
storage capacity while minimizing system weight and cost. Various analytical and
numerical techniques are employed to analyze the dynamic behavior of the flywheel
under different loading conditions. The proposed optimization approach aims to enhance
the performance and efficiency of FESS for diverse applications in renewable energy
integration and grid stabilization. This paper presents a detailed analysis of composite
flywheel rotors, focusing on material selection, manufacturing techniques, and structural
optimization. Finite element analysis (FEA) is utilized to evaluate the mechanical
behavior and performance of composite rotors under various loading conditions.

These abstracts provide a glimpse into the diverse research efforts focused on optimizing
and analyzing flywheel systems for various applications in energy storage and mechanical
energy management. This study explores the effects of tooth reduction in transmission
systems on the performance of flywheel energy storage systems (FESS). By reducing the
number of teeth in gears or pulleys within the transmission system, the rotational speed of
the flywheel can be increased, leading to enhanced energy storage capacity and efficiency.

Optimization algorithms are utilized to identify the optimal tooth reduction ratio that
maximizes energy storage while minimizing system weight and cost. Experimental
validation is conducted to assess the practical feasibility and performance improvements
achieved through tooth reduction in FESS.

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 CHAPTER 1

INTRODUCTION

1.1 INTRODUCTION
The concept of flywheels as a method of energy storage traces back to antiquity, with its
roots entwined with the earliest mechanical devices such as the axe grinder’s wheel. However,
contemporary advancements have revitalized interest in flywheel technology owing to
achievements in achieving high specific energy densities. A flywheel, essentially, serves as an
inertial energy-storage device, capable of absorbing mechanical energy during periods of
surplus and dispensing it when demand surpasses supply. This pivotal function is especially
pertinent in systems characterized by fluctuating torque, where the flywheel acts as a
stabilizing force, smoothing out variations in shaft speed. Notably, engines with one or two
cylinders, piston compressors, and other machinery subject to torque fluctuations greatly
benefit from the presence of a flywheel.

In the realm of engineering analysis and design, the Finite Element Method (FEM) stands
as a cornerstone numerical technique. Offering the ability to approximate solutions to a
myriad of engineering challenges, FEM is particularly favored for its versatility. It can
accommodate complex geometries, diverse material properties, varied boundary conditions,
and diverse loading scenarios. This adaptability renders it an indispensable tool in addressing
the intricate demands of mechanical engineering applications, including the design and
optimization of flywheel systems.

The outlined project embarks on a journey to explore the potential of flywheels as energy
storage solutions, with a specific focus on material feasibility, design, analysis, and
optimization. Setting forth clear objectives, the endeavor aims to assess the viability of
different materials for high-speed flywheel applications, subsequently translating findings into
the design phase. Utilizing sophisticated software such as ANSYS, the project endeavors to
subject the flywheel to rigorous analysis under diverse operating conditions, thereby ensuring
its structural integrity and performance reliability. Ultimately, the project culminates in the
optimization of the flywheel design, leveraging insights gleaned from material studies and
analytical assessments.

For the proposed model, the Maruti Suzuki Swift serves as a tangible foundation, with
specifications meticulously outlined. Parameters including mass, material composition (Mild
1
Steel), dimensions, and performance metrics such as maximum power and torque are
stipulated. Additionally, the discourse delves into the critical aspect of material strength,
underscoring the significance of selecting materials capable of withstanding operational
stresses and rotational speeds. Through the exploration of various materials—Gray Cast Iron,
Al Alloy, Cast Alloy, and Steel—the project aims to ascertain the optimal material
composition for maximizing flywheel performance. Moreover, attention is directed towards
geometric considerations, highlighting the potential for mass reduction through innovative
design, all while ensuring structural integrity and operational safety.

A flywheel is a mechanical gadget particularly intended to effectively store rotational

vitality. Flywheels oppose changes in rotational speed by their snapshot of dormancy. The
measure of vitality put away in a flywheel is relative to the square of its rotational speed. The
best approach to change a flywheel's put away vitality is by expanding or diminishing its
rotational speed applying a torque lined up with its hub of symmetry,

Basic employments of a flywheel include:

• Smoothing the power yield of a vitality source. For instance flywheels are utilized
as a part of responding motors in light of the fact that the dynamic torque from the
individual cylinders is irregular.
• Energy stockpiling frameworks Flywheel vitality stockpiling
• Delivering vitality at rates past the capacity of a vitality source. This is
accomplished by gathering vitality in a flywheel after some time and afterward
discharging it rapidly, at rates that surpass the capacities of the vitality source.
• Controlling the introduction of a mechanical framework, spinner and response
wheel
• Flywheels are normally made of steel and turn on customary orientation; these are
by and large constrained to a greatest upheaval rate of a couple of thousand RPM.
High vitality thickness flywheels can be made of carbon fiber composites and
utilize attractive course, empowering them to rotate at speeds up to 60,000 RPM (1
kHz).
• Carbon-composite flywheel batteries have as of late been made and are ended up
being suitable in genuine tests on standard autos. Moreover, their transfer is more
eco-accommodating

2
1.2 FLYWHEELS AS ENERGY STORAGE
Flywheels represent a fundamental concept in the realm of kinetic energy storage, tracing
their origins back to ancient times. In essence, any object rotating around an axis inherently
possesses kinetic energy. However, the term "flywheel" typically denotes structures
specifically engineered for the primary purpose of storing kinetic energy through rotational
motion. This distinction arises from the fact that flywheels are meticulously designed to
optimize energy storage capacity and facilitate efficient energy transfer within mechanical
systems.

Central to the concept of flywheels is their role in augmenting the moment of inertia within a
given system. The moment of inertia, a measure of an object's resistance to changes in its
rotational motion, is crucial for stabilizing rotational speed and mitigating fluctuations in
torque. By virtue of their considerable mass and cylindrical configuration, flywheels excel in
enhancing the moment of inertia, thereby contributing to the stability and smooth operation of
machinery.

The conventional image of a flywheel often conjures the mental picture of a robust, rotating
cylinder. This archetype underscores the emphasis placed on mass and rotational motion in
flywheel design. Typically, these cylindrical objects are engineered to possess sufficient mass
to store significant amounts of kinetic energy, ensuring their efficacy as energy reservoirs.
Through meticulous design and engineering, flywheels are crafted to optimize energy storage
capacity while adhering to constraints such as size, weight, and operational requirements.

In summary, flywheels epitomize the synergy between ancient principles and modern
engineering, embodying the timeless concept of kinetic energy storage through rotational
motion. Their distinct design and purposeful construction reflect a longstanding commitment
to harnessing and optimizing the inherent properties of rotating objects for efficient energy
management in mechanical systems.

1.3 GOALS AND OBJECTIVES

The outlined goals form a structured framework for evaluating the progression of work in
the development of a high-speed flywheel system. Firstly, the investigation into the feasibility
of materials as the primary energy storage medium underscores the importance of selecting
materials capable of withstanding high-speed rotational forces while efficiently storing kinetic

3
energy. This initial phase involves thorough research and experimentation to identify
materials that strike a balance between strength, density, and other relevant properties.

Upon confirming the feasibility of suitable materials, the next step involves initiating the
design phase of the flywheel. This encompasses not only determining the general geometry of
the flywheel but also entails addressing factors such as operating loads and manufacturing
processes. By meticulously crafting the design, engineers aim to optimize the flywheel's
performance, ensuring structural integrity and operational efficiency while adhering to
practical constraints and specifications.

Subsequent to the design phase, the flywheel undergoes rigorous analysis utilizing
advanced software tools like ANSYS. This crucial step involves subjecting the flywheel to
various forces and operating conditions to assess its structural response and performance
characteristics. Through detailed simulation and analysis, engineers gain insights into areas of
potential improvement and refinement, guiding iterative design iterations.

The final stage in the development process entails optimization of the flywheel design.
Drawing upon insights gleaned from material feasibility studies, design iterations, and
analytical assessments, engineers refine and fine-tune the flywheel's geometry, material
composition, and operating parameters to maximize its energy storage capacity, efficiency,
and reliability. By iteratively optimizing the flywheel design, engineers aim to achieve an
optimal balance between performance, cost-effectiveness, and practical feasibility, thereby
realizing the full potential of the high-speed flywheel system

4
1.4 PROPOSED MODEL
Table 1. Specifications of Model
Model Maruthi Suzuki Swift

Mass of Flywheel 7.5 kg

Material Aluminium alloy

Outer Diameter 260mm

Inner Diameter 31mm

Width 40mm

Maximum Power 6000rpm

Maximum Torque 3500rpm

Capacity 796 cc

1.5 MATERIAL STRENGTH

In the pursuit of enhancing the performance and efficiency of flywheel systems, the
choice of materials plays a pivotal role. The inherent strength and density of materials dictate
their suitability for withstanding the substantial operating stresses encountered during high-
speed rotational motion. Recognizing this critical aspect, the present study embarks on a
comprehensive exploration, evaluating the merits of four distinct materials: Gray Cast Iron,
Aluminum Alloy (Al Alloy), Cast Alloy, and Steel. Each material offers unique properties that
influence its ability to endure the demanding conditions inherent in flywheel operation. Gray
Cast Iron, renowned for its excellent damping properties and high compressive strength,
presents a compelling option for flywheel applications. Its ability to withstand large operating

5
stresses makes it an attractive candidate, particularly in scenarios where stability and
durability are paramount. Conversely, Aluminum Alloy, characterized by its lightweight
nature and corrosion resistance, offers a contrasting yet equally appealing alternative. Despite
its lower density compared to other materials, Aluminum Alloy exhibits commendable
strength-to-weight ratio, making it well-suited for applications demanding reduced mass
without compromising structural integrity.

In contrast, Cast Alloy and Steel present more conventional choices, leveraging their robust
mechanical properties to withstand high rotational speeds and operating stresses. Cast Alloy,
renowned for its superior tensile strength and durability, embodies a balance between strength
and versatility, making it a preferred option for a wide range of engineering applications.
Meanwhile, Steel, celebrated for its exceptional strength, hardness, and ductility, remains a
steadfast choice for demanding environments where resilience to wear and fatigue is
paramount.

Through systematic evaluation and comparative analysis, the study endeavors to identify
the optimal material candidate capable of bearing maximum stress and rotational speed,
thereby unlocking the full potential of flywheel technology. By scrutinizing the unique
attributes of each material and assessing their performance under simulated operating
conditions, engineers aim to inform informed decisions in material selection, paving the way
for the advancement of high-performance flywheel systems.

Flywheels are produced using a wide range of materials; the application decides the decision
of material. Little flywheels made of lead are found in youngsters' toys. Cast press flywheels
are utilized as a part of old steam motors. Flywheels utilized as a part of auto motors are made
of thrown or nodular iron, steel or aluminum. Flywheels produced using high-quality steel or
composites have been proposed for use in vehicle vitality stockpiling and stopping
mechanisms.

The proficiency of a flywheel is dictated by the most extreme measure of vitality it can
store per unit weight. As the flywheel's rotational speed or rakish speed is expanded, the put
away vitality increments; be that as it may, the burdens likewise increment. On the off chance
that the loop push outperform the elasticity of the material, the flywheel will break separated.
Accordingly, as far as possible the measure of vitality that a flywheel can store.

6
 In this unique situation, utilizing lead for a flywheel in a tyke's toy is not effective; in
any case, the flywheel speed never approaches its burst speed in light of the fact that the point
of confinement for this situation is the pulling-energy of the tyke. In different applications, for
example, a vehicle, the flywheel works at a predetermined rakish speed and is compelled by
the space it must fit in, so the objective is to boost the put away vitality per unit volume. The
material choice hence relies upon the application.

The table underneath contains computed values for materials and remarks on their
reasonability for flywheel applications. CFRP remains for carbon-fiber-strengthened polymer,
and GFRP remains for glass-fiber fortified polymer.

1.6 GEOMETRY
The specific energy storage capacity of a flywheel is intricately linked to its mass,
presenting a crucial consideration in its design and optimization. To enhance the specific
energy stored within a flywheel, reducing its mass becomes imperative. This reduction can be
achieved through the exploration and implementation of different geometries, each tailored to
minimize weight while maintaining structural integrity and performance. By judiciously
adjusting the dimensions and shape of the flywheel, engineers strive to strike an optimal
balance between mass reduction and energy storage capacity, thereby maximizing efficiency
and effectiveness.

However, the pursuit of mass reduction must be coupled with a thorough investigation
into the stresses induced within the flywheel during operation. As the flywheel rotates,
centrifugal forces come into play, exerting considerable loads on the structure. These forces
give rise to tensile and bending stresses within the flywheel, potentially compromising its
integrity and safety. Therefore, a comprehensive analysis of these stresses under various
operating conditions is essential to ensure the durability, reliability, and safety of the flywheel
design.

By scrutinizing the interplay between mass reduction strategies, geometric optimization,

and stress analysis, engineers endeavor to improve the overall quality of the flywheel product.
This holistic approach not only enhances energy storage efficiency but also fosters the
development of safe, reliable, and high-performance flywheel systems. Through meticulous
design iteration and refinement, engineers strive to achieve an optimal balance between mass
reduction, energy storage capacity, and structural robustness, thus advancing the state-of-the-
art in flywheel technology.
7
 1.7 FLYWHEEL MOVEMENT

Figure 1. 1 Flywheel Movement

The moment of a flywheel refers to its capacity to store rotational energy. When a flywheel is
set in motion, such as by an engine or motor, it accumulates kinetic energy due to its
rotational speed. This energy is then available to do work when needed. The moment of a
flywheel is important in various applications where smooth and continuous energy delivery is
required, such as in engines, power generators, and even in some mechanical systems like
clocks and bicycles. In practical terms, a larger moment of inertia in a flywheel means it can
store more energy and maintain its rotational speed more effectively, thereby providing
smoother operation and better stability in the system it's a part of. This is why flywheels are
often used in applications where consistent energy delivery or rotational stability is crucial.

8
 CHAPTER 2

LITERATURE REVIEW
ImafidonA.Lawani [1] have proposed, a PC supported plans of programming for
flywheels utilizing object-arranged programming methodology of Visual Basic. The
different setups of flywheels (rimmed or strong) framed the reason for the improvement of
the product. The product's graphical highlights were utilized to give a visual understanding
of the arrangements. The product's viability was tried on various numerical illustrations,
some of which are sketched out in this work.

Sushama G Bawane [2] had proposed flywheel outline, and investigation the material
determination process. The FEA demonstrate is depicted to accomplish a superior
comprehension of the work sort, work size and limit conditions connected to finish a viable
FEA show.

Saeed Shojaei [3] have proposed calculations in view of dynamic examination of wrench
shaft for planning flywheel for I.C.engine , torsional vibration investigation result by AVL\
EXCITE is contrasted and the rakish relocation of a want free hased of wrench
shaft ,likewise thought of exhaustion for weariness examination of flywheel are given.

S.P. Srikanth [4] have propose [4] the significance of the flywheel geometry outline choice
and its commitment in the vitality stockpiling execution. This commitment is exhibited on
illustration cross-areas utilizing PC helped investigation and enhancement system.
Proposed Computer supported examination and advancement methodology comes about
demonstrate that keen outline of flywheel geometry could both significantly affect the
Specific Energy execution and decrease the operational burdens applied on the pole/course
because of lessened mass at high rotational velocities.

Bedier B. EL-Naggar [5] had is proposed the plate edge flywheel for light weight. The
mass of the flywheel is limited subject to limitations of required snapshot of inactivity and

9
permissible burdens. The hypothesis of the turning circles of uniform thickness and
thickness is connected to each the plate and the edge autonomously with reasonable
coordinating condition at the intersection..

Sagar M. Samshette [6] Works on design solid, Rim, Section-cut and six arm type
flywheel maintaining constant weight. And simultaneously we calculate moment of inertia
and kinetic energy of respective fly wheel. He conclude that six arm type fly wheel store
more amount of kinetic energy as compare to solid, rime and section of fly wheel.

Yongjie Hana [7] works on General Design Method of Flywheel Rotor for EnergyStorage
System. This paper discussed the general design methodology flywheel rotor base on
analyzing these influence, and given a practical method of determine the geometric
parameters. It was applied to determine flywheel rotor parameters of 600Wh flywheel
energy storage system in developing.

Tae-Hyun Sung [8] works on Optimum design of multi-ring composite flywheel rotor
using a modified generalized plane strain assumption. The introduction of the modified
generalized plane strain assumption which considers thermally induced residual stress is
much more efficient and easier to use than the finite element approach.

K. Takahash [9] works on Development of high speed composite flywheel rotors for
energy storage systems. The rotor, whose outer circumference was re-wound, burst at a
peripheral speed of1310 m/ s. The rotor stored energy of 354 Wh. The vibration in the spin
test indicated good agreement with the stress in the analysis.

TANG et al [10] The auxiliary support was removed until the flywheel passed the first
critical speed. The flywheel is kept at rigid state in sub critical condition and tested at high
speed. Discussed the lower damper’s effect on the modal damping ratios and forced
vibrations. The sub critical rotor dynamics design and pivot jewel bearing to be good
solutions to the spin test for the composite flywheel.

YU et al [11] Proposed novel flywheel energy storage for marine systems. The purpose was
to improve the power quality of a marine power system (MPS) and strengthen the energy
recycle. The electrical machine electromagnetism design was further optimized by the FEA
in the temperature field, to find the local overheating point under the normal operation
condition and provide guidance for the cooling system.

10
Pietraszek [12] Presented to automotive industry optimization problem the fuzzy
regression approach. They summarized problem definition, measured data presentation and
analysis of the final with classical and fuzzy regression approach. He also shows the benefit
of fuzzy regression approach.

Jiang [13] Established a flywheel rotor system for design flexibility. Analyzed the force of
PMB through FEM and verified experimentally. Introduced a squeeze film damper to
support bottom rolling bearing, enhance stability of the rotor system and suppress lateral
vibration. They showed that the flexibility design and hybrid bearing for the system allow
for the use of a small rolling bearing to reduce power loss.

Wen et el [14] Obtained the stress analysis of anisotropic flywheel rotor under high speed
rotation. They derived maximum radial stress location equation by Newton Iteration
Method. They studied the effects of flywheel anisotropy degree and the symmetricity of the
maximum radial stress location.

Rupp [15] Analyzed the introduction of flywheel energy storage systems in a light rail
transit train. Mathematical models of the train, driving cycle and flywheel energy storage
system are developed. Results suggest that maximum energy savings of 31% can be
achieved using flywheel energy storage systems.

Deb.K[16] provide a number of optimization algorithms which are commonly used in

computer-aided engineering design. The book begins with simple single-variable
optimization techniques, and then goes on to give unconstrained and constrained
optimization techniques in a step-by-step format so that they can be coded in any user-
specific computer language. In addition to classical optimization methods, the book also
discusses Genetic Algorithms and Simulated Annealing, which are widely used in
engineering design problems because of their ability to find global optimum solutions.

Mouleeswaran Senthil [17] Proposed novel flywheel energy storage for marine systems.
The purpose was to improve the power quality of a marine power system (MPS) and
strengthen the energy recycle. The flywheel is kept at rigid state in sub critical condition
and tested at high speed. Discussed the lower damper’s effect on the modal damping ratios
and forced vibrations. The sub critical rotor dynamics design and pivot jewel bearing to be
good solutions to the spin test for the composite flywheel. He also shows the benefit of
fuzzy regression approach.

11
Kiyoshi [18] Hand book by mechanical design torsional vibration investigation result by
AVL\EXCITE is contrasted and the rakish relocation of a want free hased of wrench
shaft ,likewise thought of exhaustion for weariness examination of flywheel are given. The
product's graphical highlights were utilized to give a visual understanding of the
arrangements. The product's viability was tried on various numerical illustrations, some of
which are sketched out in this work. This commitment is exhibited on illustration cross-
areas utilizing PC helped investigation and enhancement system. Proposed Computer
supported examination and advancement methodology comes about demonstrate that keen
outline of flywheel geometry could both significantly affect the Specific Energy execution.

Michael [19] Materials Selection in Mechanical Design The approach emphasizes design
with materials rather than materials ‘‘science’’, although theunderlying science is used,
whenever possible, to help with the structuring of criteria for selection.The first eight
chapters require little prior knowledge: a first-year grasp of materials and mechanicsis
enough. The chapters dealing with shape and multi-objective selection are a little more
advancedbut can be omitted on a first reading. As far as possible the book integrates
materials selection withother aspects of design; the relationship with the stages of design
and optimization and with themechanics of materials, are developed throughout.

Lynn white [20] published Medieval Technology and Social Change in 1962. A
reflection of his lifelong interest in the Middle Ages, combined with his realization of the
benefits of studying a civilization through its material culture, White's work helped to
create the field of the history of medieval technology. Controversial, inspiring, and
accessible, the influence of this book continues to affect the work of a wide variety of
scholars. White's contentious ‘stirrup thesis’ suggested that the stirrup's introduction to
Europe from Asia in the Carolingian period enabled the development of feudalism, which
concept was itself highly problematic. His work on the plow, the horse harness, and three-
field crop rotation, and the degree to which they affected Europe's post-Roman population
shift, is still debated. Mechanical power may not have led to a medieval industrial
revolution as White claimed, but wind, water, and chemical power developments, along
with the development of the crank, still substantially altered medieval agricultural and
industrial production.

12
 CHAPTER 3
EXPERIMENTATION

3.1 Modelling Solidworks

SolidWorks is a powerful 3D solid modelling software package that enables users to create
comprehensive solid models within a simulated environment, catering to both design and
analysis needs. With SolidWorks, users can conceptualize ideas and explore different
design possibilities through the creation of detailed 3D models. This versatile software is
widely utilized by a diverse range of professionals, including college students, designers,
engineers, and other experts, across various industries. Whether it's producing simple or
complex components, assemblies, or drawings, SolidWorks provides the necessary tools
and functionalities to meet the demands of modern design projects. One of the key
advantages of designing in SolidWorks is its ability to streamline the design process,
ultimately saving valuable time, effort, and resources that would otherwise be spent on
prototyping and iteration. By offering a user-friendly interface and robust features,
SolidWorks empowers users to bring their design ideas to life efficiently and effectively,
contributing to enhanced productivity and innovation in the field of engineering and design

3.2 Solid Works Components

SolidWorks components comprise a versatile set of features and tools integral to the
SolidWorks software suite, facilitating the creation of intricate 3D models for design and
analysis purposes across various industries. These components play a pivotal role
throughout the product development lifecycle, offering functionalities from
conceptualization to manufacturing. Solid modeling stands as a cornerstone feature,
empowering users to craft detailed 3D models by sketching 2D profiles and transforming

13
them into solid geometry through extrusions, revolutions, and other operations. Assembly
design capabilities enable the seamless integration of multiple components into complex
assemblies, allowing designers to simulate real-world interactions and ensure proper fit and
function. Part design tools provide the means to refine individual components, incorporating
features like fillets, chamfers, and patterns to meet specific design criteria. SolidWorks
further extends its functionality with specialized tools for sheet metal design, surface
modeling, and drawing documentation, catering to diverse design requirements. Moreover,
its integrated simulation and analysis capabilities empower users to evaluate structural,
thermal, and fluid flow performance directly within the software, facilitating optimization
and validation of designs. With SolidWorks, engineers and designers can efficiently bring
their ideas to fruition, from initial concept to final production, thanks to its comprehensive
suite of components and tools.

Fig. 3.1 components of solid works

14
3.3 Feature Manager /Design Tree
Shows the shape of the element, assembly, or drawing. Pick out an object from the feature
manager design tree to edit the underlying sketch, edit the characteristic, and suppress and
un suppress the function or element, for example.

Figure 3.2 Specification Tree

Displays the structure of the part, assembly, or drawing. Select an item from the feature
manager design tree to edit the underlying sketch, edit the feature, and suppress and un
suppress the feature or component, for example.

15
An meeting is a aggregate of or extra components, additionally known as components,
inside one solid works record. You role and orient components the use of mates that form
family members among additives.

 This lesson discusses the following:

 Adding components to an meeting
 Transferring and rotating additives in an assembly
 Growing display states in an assembly

3.4 Modeling: Modeling Of wheel

 Go to solid works software and select file on top then it will ask the file type or
module type part, assembly and drawing.
 Then select part module then click ok.
 On part module go to sketch. And select sketch, then create sketch as shown in figure
in below.
 Later select on exit sketcher.

Figure 3. 3 Sketch For The Flywheel

 After sketch. Go to features and select revolved boss/base .

 In revolved boss, sketch above profile as a object to revolve and specify axis of
revolutions
 Then click ok or click on right mark.

16
 Figure 3. 4 Revolve

 On part module go to sketch. And select sketch, then create sketch as shown in figure
in below
 Later select on exit sketcher.

Figure 3. 5 Extrude Cut

 In extrude cut boss, sketch above profile as a object to depth and specify direction
 Then click ok or click on right mark.

17
 Figure 3. 6 Extrude Cut And Circular Pattern

 After extrude cut, go to plane in reference and select front plane as a reference and
specify offset distance 0.45metre.

Figure 3. 7 Sketch For Teethes

 On part module go to sketch. And select sketch, then create sketch as shown in figure
in below
 Later select on exit sketcher.

18
 Figure 3. 8 Sketch For Teeth

 After sketch. Go to features and select extrude cut boss/base .

 In extrude cut boss, sketch above profile as a object to depth and specify direction
 Then click ok or click on right mark.

Figure 3. 9 Extrude Cut

19
  final modal with 152 teethes

Figure 3. 10 Model 1 With 152 Teethes

 similary i also create 146 teethes fly wheel

Figure 3. 11 Modal 2 With 146 Teeths

20
 CHAPTER 4

MASTERING ANSYS

4.1 Analysing Process

ANSYS, a product of ANSYS Inc., stands as a preeminent, widely utilized commercial

CAE (Computer-Aided Engineering) software package globally. Its extensive adoption
spans across various industries including aerospace, automotive, manufacturing, nuclear,
electronics, biomedical, and beyond. ANSYS offers a comprehensive simulation solution
that empowers engineers to accurately replicate design performance directly on their
desktops. This capability facilitates rapid, efficient, and cost-effective product development,
spanning from the conceptual design phase to the validation stage of the product
development cycle.

The software serves as a catalyst for accelerating and streamlining the product
development process by enabling engineers to address a wide array of issues related to
structural, thermal, fluid flow, electromagnetic, and multiphysics phenomena. ANSYS
equips engineers with the tools and capabilities to simulate and analyze complex
engineering problems with precision and reliability. Through its intuitive interface and
robust features, ANSYS Workbench facilitates the application of fundamental FEA (Finite
Element Analysis) concepts, modeling techniques, and engineering analysis methods.

In ANSYS, engineers can seamlessly perform various types of structural analyses,

including static structural analysis, modal analysis to assess natural frequencies and mode
shapes, and transient structural analysis to analyze dynamic responses over time.
Additionally, the software enables thermal analyses such as steady-state thermal analysis to
evaluate temperature distributions under constant conditions and transient thermal analysis
to study temperature variations over time.

The versatility of ANSYS extends beyond structural and thermal analyses to encompass
a multitude of engineering disciplines, offering solutions for fluid flow simulations,
electromagnetic analyses, and multiphysics simulations. Through its robust capabilities and
comprehensive toolset, ANSYS empowers engineers to address diverse engineering
challenges, ultimately facilitating the development of innovative and optimized products
across industries.

21
 1. Structural analysis
Static structural analysis
Modal analysis
Transient structural analysis
2. Thermal analysis
Steady state thermal analysis
Transient thermal analysis

4.2 Project Objectives

Upon completion of this chapter, readers will have gained a comprehensive understanding of
the fundamental principles and workings of Finite Element Analysis (FEA), a powerful
computational technique widely employed in engineering disciplines. The chapter begins by
elucidating the basic concepts underlying FEA, providing insights into its theoretical
foundations and practical applications. Readers will grasp the essence of how FEA operates
by discretizing complex geometries into finite elements, each representing a small portion of
the overall structure or system. Through this discretization process, the behavior of the entire
system can be accurately simulated and analyzed using numerical methods.

Furthermore, readers will delve into the advantages and limitations inherent to FEA. They
will come to appreciate the numerous benefits FEA offers, including its ability to provide
detailed insights into the behavior of structures under various loading conditions, its capacity
for cost-effective design optimization, and its role in facilitating the exploration of design
alternatives without the need for physical prototypes. However, the chapter also sheds light on
the limitations of FEA, such as the assumptions and simplifications inherent in the modeling
process, the potential for numerical errors, and the computational resources required for
complex simulations.

Additionally, readers will develop a thorough understanding of different types of analyses

commonly performed using FEA. These include structural analyses, which assess the
response of structures to external loads, thermal analyses, which investigate temperature
distributions and heat transfer phenomena, and other specialized analyses such as modal
analyses to determine natural frequencies and mode shapes. By familiarizing themselves with
these analysis types, readers will be equipped to apply FEA effectively in a variety of

22
engineering contexts, gaining insights into the behavior and performance of mechanical
systems, components, and materials.

Finally, the chapter emphasizes the importance of comprehending key terms and definitions
associated with FEA. Readers will be introduced to essential terminology such as boundary
value problems, meshing, boundary conditions, convergence, and post-processing.
Understanding these terms is essential for effectively communicating and interpreting FEA
results, enabling engineers to make informed decisions during the design and analysis
process. Overall, by mastering these concepts and principles, readers will be well-equipped to
harness the capabilities of FEA for solving complex engineering problems and advancing
innovation in their respective fields.

After complete of this chapter,

 The basic concept and general working of fea

 Understand the advantage and limitations of fea
 Understanding the analysis type
Understanding important terms and definition of fea

4.3 Finite Element Analysis

23
 Finite Element Analysis (FEA) stands as a computational technique utilized extensively
across various engineering disciplines to approximate solutions to boundary value problems
encountered in structural, thermal, fluid flow, electromagnetic, and multiphysics domains. At
its core, FEA leverages a numerical method known as the Finite Element Method (FEM) to
discretize complex geometries into smaller, manageable elements. These elements collectively
form a mesh, allowing engineers to represent the entire system or structure within a computer
model.
In FEA, the process begins with the creation of a computer model representing the design
under consideration. This model is then subjected to specific loading conditions, such as
forces, pressures, temperatures, or displacements, corresponding to real-world operating
conditions. The software analyzes the response of the model to these loads, providing insights
into various parameters such as stress, deformation, deflection, natural frequencies, mode
shapes, temperature distributions, and more.
The concept of FEA can be elucidated through a simple analogy to measuring dimensions.
Just as dimensions provide insights into the size and shape of an object, FEA simulates the
response of a design to different loading conditions, thereby facilitating the determination of
its performance characteristics. This simulation-driven approach enables engineers to evaluate
design responses accurately and efficiently, aiding in both the development of new products
and the refinement of existing ones.

4.4 Elements And Elements Shapes

 Elements is an entity into which the system under study is divided. An element shape is
specified by nodes. The shape (area, length, and volume) of elements depends on the
nodes with which it is made. An element (triangular shape) is shown in the figure.

24
 Figure 4.1 A Node And An Element

 Element shape there are many types of elements shapes that are further divided into
various classes depending on their uses. The following are some basic elements shape
 Line element a line element has a shape of line or curve. Therefore, a minimum of
two nodes is required to define it. The higher order elements that additional nodes at
the middle of the line or curve. An element the does not have a node in between its
edges are called linear element.

Figure 4. 2 Line Element

 Area elements an area elements have a shape of triangular or a quadrilateral, therefore
it's required a minimum of three or four nodes to define it.

Figure 4.3 The Area Elements

 Volume elements A volume elements have the shape of a hexahedron, wedge,

tetrahedron, or a pyramid.

25
 Figure 4.4 Volume Elements

4.5 Problem statement

In response to the imperative to reduce the weight of the flywheel, an industry initiative was
undertaken to innovate its design. The conventional approach of adding grooves to the surface
of the flywheel proved to be less effective than anticipated. Consequently, the decision was
made to pursue a more substantial alteration in the casting process itself. By implementing
changes in the design of the flywheel, such as modifying its shape or altering its internal
structure, manufacturers were able to achieve significant reductions in weight without
compromising performance. This strategic shift not only addressed the core objective of
weight reduction but also yielded additional benefits. By streamlining the manufacturing
process, the new design reduced manufacturing time, as it entailed less machining work and
generated fewer material cuts. Moreover, the efficiencies gained translated into tangible cost
savings, making the production of the redesigned flywheel more economically viable.
Overall, this innovative approach exemplifies the industry's commitment to continuous
improvement and optimization in pursuit of enhanced performance, efficiency, and cost-
effectiveness

4.6 General Procedure To Conduct Finite Elements Analysis

To conduct the finite elements analysis you need to follow certain steps that are given next.
1. Set the type of analysis to used.
2. Create model
3. Define the elements type
4. Divide the elements types
5. Divide the given geometry into nodes and elements
6. Apply material properties and boundary conditions
7. Drive elements matrices and equations
26
 8. Solve the unknown parameters at nodes
9. Interpret the results
The general process fea by using software is divided into three main phases:
4.6.1 Preprocessor
The preprocessor is a phase that process input data to produce an output which is used as
input in the subsequent phase (solution). Following are the input data that need to be given
to the preprocessor.

Figure 4.5 Fea Through Software

Types of analysis (structural or thermal, static or dynamics, and linear or non-linear)

4.6.2. Components Type

• Real constants for components (cross-sectional zone, snapshots of idleness, shell
thickness and soon )
• Material properties (youthful's modulus, poisson's proportion, spring consistent,
warm conductivity, coefficient of warm development, and soon)
• Geometry show (either made in fea programming or imported from miscreant
bundle)
• Fea display (disparaging the geometric model into little components)
• Loading and limit conditions (characterizing loads, weights, minutes, temperature,
conductivity, convection, imperatives (settled, stuck or frictionless/symmetrical )),
et cetera.

27
 • The input information are preprocessed for the yield information and the
preprocessor creates the information documents consequently with help of
employments.

4.6.3 Post processor

In addition to exploring the advantages and limitations of Finite Element Analysis

(FEA), readers will delve into a nuanced examination of the various types of analyses
frequently conducted using this powerful computational technique. This exploration will
provide readers with a comprehensive understanding of the diverse applications and
capabilities of FEA in engineering contexts.

One key area of focus is structural analysis, which involves scrutinizing how structures
respond to external loads. By employing FEA, engineers can gain detailed insights into the
behavior of structures under diverse loading conditions, allowing for the assessment of
factors such as stress distribution, deformation, and structural integrity. This capability is
invaluable in the design and optimization of mechanical components, ensuring that they
meet performance requirements and safety standards.

Furthermore, readers will explore thermal analysis, which delves into temperature
distributions and heat transfer phenomena within structures or systems. Through FEA-
based thermal analyses, engineers can evaluate thermal gradients, heat fluxes, and thermal
stresses, enabling them to optimize designs for thermal performance, mitigate overheating
issues, and enhance overall efficiency.

Moreover, specialized analyses such as modal analyses are examined, focusing on the
determination of natural frequencies and mode shapes of structures. By conducting modal
analyses using FEA, engineers can identify critical modes of vibration, resonance
frequencies, and mode shapes, aiding in the design of structures that exhibit desirable
dynamic characteristics and avoiding potential vibration-induced failures.

Equipped with a comprehensive understanding of these analysis types, readers will be

empowered to apply FEA adeptly across a spectrum of engineering contexts. Whether
analyzing mechanical systems, components, or materials, FEA provides engineers with
28
valuable insights into their behavior and performance, enabling informed decision-making
and driving innovation in product development processes. Overall, the exploration of these
analysis types enhances readers' proficiency in utilizing FEA as a powerful tool for
engineering simulation and design optimization

CHAPTER 5

MODAL ANALYSIS

29
 5.1 INTRODUCTION
I tool in engineering for evaluating the vibration characteristics of structures or machine
components, particularly in scenarios where dynamic behavior is of concern. By calculating
parameters such as natural frequency and mode shape (deformed shapes), modal analysis
provides valuable insights into how a structure will respond to dynamic loading conditions.
For instance, consider a scenario where a beam is attached to a machine vibrating at a specific
frequency. It becomes imperative for the designer to ascertain whether the beam can
withstand the induced vibrations without failure.
During vibration, structures assume various shapes at specific frequencies, known as mode
shapes. These mode shapes represent graphical depictions of the deformation experienced due
to vibration. The primary objective of modal analysis is to determine whether the natural
frequency of the component aligns closely with the induced vibrations. In practice, modal
analysis often yields multiple mode shapes, typically represented through the display of the
first, second, third, and subsequent modes.
If the natural frequency of a system closely matches the excitation frequency, resonance
can occur, potentially leading to structural failure. To mitigate the risk of resonance-induced
failure, designers may opt to reinforce the component based on the identified mode shape.
However, there are instances where strengthening the component may not be feasible due to
design constraints. Additionally, in real-world scenarios, the displacement experienced at
resonance is not infinite due to the presence of damping.
To address these challenges, engineers may need to evaluate the response of the system
under time- or frequency-based loads. By assessing stress, strain, and displacement responses
against permissible limits, engineers can determine whether strengthening or redesigning the
component is necessary. Ultimately, the insights gleaned from modal analysis enable
engineers to make informed decisions regarding the design, optimization, and safety of
structures and machine components, thereby enhancing overall performance and reliability

5.2 Performing The Modal Analysis

The modal analysis is performed to find out the natural frequencies of a model. You can
find out more than one natural frequency of a model depending upon the degrees of
freedom available.
30
The following steps are involved to perform a modal analysis:
1. Set the analysis preference.
2. Create or import the geometry into ansys workbench.
3. Define element attributes (element types, real constants, and material properties).
4. Define meshing attributes.
5. Generate a mesh for the model.
6. Specify the analysis type, analysis options, and apply loads.
7. Obtain the solution.
8. Review the results.

5.3 Adding Modal Analysis System To Ansys Workbench

To perform a modal analysis in ansys workbench, you need to add the modal analysis
system from the analysis systems toolbox in the toolbox window to the project schematic
window.

Figure 5.1 Project Schematic Window With The Modal Analysis System Added

5.4 Starting The Mechanical Window

To start the analysis, double-click on the model cell of the modal analysis system to display
the mechanical window. The components of the mechanical window displayed by using the

31
model cell of the modal analysis system are similar to the components of the mechanical
window displayed by using the static structural analysis system.
In the mechanical window, you can set the number of modes or natural frequencies you
need. To find Shows the tree outline of the mechanical window.

Figure 5.2 The Mechanical Window Tree Outline

5.5 Generating The Mesh For The Model

Now, you need to generate the mesh of the model.;

1. Double click on model cell will enter into mechanical window. Also, you will notice
that in the outline window, the mesh node is displayed in the tree outline with a yellow
thunderbolt attached to it.
2. Click on mesh in the tree outline; the details of “mesh” window is displayed.

32
 Figure 5.3 safety factor
3.In the details of “mesh” window, expand the sizing node, if not already expanded
4. In the sizing node in the details of “mesh” window, (inter 2-5 in the element size edit box.
5. Right-click on mesh in the tree outline and then choose the preview > surface mesh from
the shortcut menu displayed; the preview of the mesh for the model is displayed.
5.6 Setting The Boundary Conditions
After the mesh is generated, you need to set the boundary conditions under which the analysis
is to be performed.
1. Right—click on modal node in the tree outline and then choose insert >fixed support
from the shortcut menu displayed; fixed support with a question symbol is added
under the modal node in the tree outline. Also, the details of “fixed support window is
displayed.
2. In the details of “fixed support” window, click on the geometry cell to display the
apply and cancel buttons, if not already displayed.

33
 Figure 5. 4 total deformation

3. Select the side face of the model, as shown in figure.

4. Next, choose the apply button from the geometry selection box in the details of “fixed
support’ window, fixed support is applied to the selected face.

34
 CHAPTER 6
STATIC STRUCTURAL ANALYSIS AND THERMAL
ANALYSIS
6.1 PROJECT OBJECTIVE

In this project, we will be able to define total deformation and stress, etc
 Create the static structural analysis system
 Apply different types of materials
 Applying of boundary conditions
 Apply a different type of constraints
 Apply different loads
 Generate the results as per required
 Generate project reports
In this project, we imported the geometry of the component show the dimensions for the
component with respect to the load applications. The material to be applied on the model is
stainless steel. Next, you will run the analysis under two conditions and evaluate the total
deformation, directional deformation, equivalent stress, maximum principal stress, and
minimum principal stress.
The static structural analysis is one of the important analyses in ansys workbench. It is
available as static structural analysis system under the analysis system toolbox in the
toolbox window, this system analyses the structural components for displacements
(deformation), stresses, strains, and forces under different loading conditions. The loads in
this analysis system are assumed not to have damping characteristics (time dependent).
Steady loading and damping conditions are assumed in this type of analysis system.

Figure 6.1 The Static Structural Analysis Added To The Project Schematic

35
 Figure 6. 2 Equivalent Elastic Strain
As discussed in previous chapters, analysis can be carried out in three major steps: pre-
processing, solution, and post-processing. The tools required to carry out these steps are
discussed next.

6.1.1. Pre-Processing
The pre-processing of an analysis system involves specifying the material, generating a
mesh, and defining boundary conditions.
In ansys workbench, the various tools related to boundary conditions are available in the
environment contextual toolbar, which is displayed when you select the static structural
node in the tree outline

Figure 6. 3 The Environment Contextual Toolbar

In order to provide a support to the model, you need to choose the required tool from the
supports drop-down. Similarly, to add a load, choose the desired tool from the loads drop-
down in the environment contextual toolbar. Also, when you choose any tool from the
environment contextual toolbar; the corresponding entity is placed under the static
structural node in the tree outline.
The main purpose of an analysis is to evaluate the results. After the boundary condition is
set and loads are applied, you need to specify the desired outcomes of the analysis. In ansys
36
workbench, you can analyze various parameters such as deformation, stresses, strains, and
so on. To do so, you need to specify the results required and then evaluate them. You can
use the tools available in the solution contextual toolbar to specify results. Alternatively,
right-click on the solution node in the tree outline and then use the desired option from the
shortcut menu displayed.

Figure 6. 4 The Solution Contextual Toolbar

6.1.2 Post-Processing

After completing the analysis in ANSYS, the next step is to generate a comprehensive
report summarizing the findings and results of the analysis. This report serves as a crucial
document for communicating the analysis outcomes to stakeholders, including team
members, supervisors, or clients. In ANSYS, generating the report is a straightforward
process. Users can navigate to the report preview tab located at the bottom of the graphics
screen within the mechanical window. Upon selecting this tab, the ANSYS software
initiates the report generation process, indicated by the "ANSYS report generation in
progress" message displayed on the screen. The software systematically compiles the
analysis data, including input parameters, simulation results, and any relevant plots or
graphs. Depending on the complexity of the analysis and the amount of data involved, this
process may take some time. However, once the report generation is complete, the
"ANSYS report generation in progress" message disappears, signaling that the report is
ready for preview or export. Users can then review the generated report to ensure its
accuracy and completeness before sharing it with stakeholders. Overall, the report
generation feature in ANSYS streamlines the documentation process, facilitating clear and
concise communication of analysis findings for informed decision-making.6.1.3 Solution

In an analysis, after pre-processing (meshing, specifying material, and specifying

boundary condition) is done, the next step is to solve the analysis. In ansys workbench, you
will use the solve tool from the standard toolbar to run the solver. The solver runs in the
background of a software and acquires results of an analysis, based on the specified
boundary conditions.
37
6.2 Equivalent stress analysis

After the model is created in the design modeler window, you need to generate the mesh for
the model in the mechanical window.
1. In the project schematic window, double-click on the model cell in the static structural
analysis system; the mechanical window is displayed.
2. Select mesh in the tree outline to display the details of "mesh" window.
3. In the details of "mesh" window, expand the sizing node, if it is not already
expanded.Also, notice that default is displayed in the element size edit box.
The element size edit box is used to specify the size of an element. The element size
specified in this edit box is according to the size of the geometry. However, this edit box
will not be visible when the
 On: proximity End
 On: proximity and curvature
Options are selected from the use advanced size function drop-down list. When default is
displayed in the element size edit box, it indicates that a default value, based on the size of
the geometry, is already specified by the software.
 Choose the generate mesh tool from the mesh drop-down in the mesh contextual
toolbar; the mesh is generated.

Figure 6.5 Equivalent Stress Analysis

38
 4. Expand the statistics node in the details of "mesh" window to display the total number
of elements created. On doing so, you will find that the total number of elements.
6.3 Specifying The Boundary Conditions

After you mesh the model, it is required to specify the boundary and loading conditions.
1. In the mechanical window, select the static structural node from the tree outline; the
details of “static structural” window is displayed along with the environment
contextual toolbar.
2. Go to environment contextual toolbar- select connection in outline- click on the
contact region and select required suitable face for friction contact
3. Go to environment contextual toolbar select body to ground then go to details of body
to ground connection and select revolute connection then select face as shown in
below - click on mobile reference
4. Go to environment contextual toolbar select body to ground then go to details of body
to ground connection and select fixed connection then select face as shown in below -
click on mobile reference.

Figure 6.6 Choosing The Fixed Support Tool From The Supports Drop-Down

1. Select faces on the model. Next, choose the apply button in the geometry selection
box; the selected faces turn purple indicating that fixed support is applied
2. Choose the joint load tool from the loads drop-down in the environment contextual
toolbar; joint load is added under the static structural node in the tree outline. Also,
the details of “joint load ” window is displayed

39
 3. Click on the geometry selection box to display the apply and cancel buttons, if they
are not already displayed.
4. Choose the apply button from the geometry selection box; the cylindrical face turns
red indicating that the joint load is applied.
5. In the details of “joint load ” window, expand the definition node, if it is not already
expanded. Specify magnitude 10 oc.

Figure 6.7 The Loads Drop-Down

6.4 Static Thermal Analysis - Temperature
Performing thermal analysis on a flywheel involves assessing how heat affects its
performance and durability. Factors such as material properties, rotational speed, and
environmental conditions are crucial. Tools like finite element analysis (FEA) can simulate
heat generation and dissipation, aiding in optimizing design for thermal management.
Thermal analysis plays a critical role in the design and optimization of flywheels, especially
in high-performance applications such as energy storage systems and automotive kinetic
energy recovery systems (KERS). By accurately assessing how heat is generated and
dissipated within the flywheel during operation, engineers can make informed decisions
regarding material selection, cooling strategies, and overall design configuration. This
analysis helps ensure that the flywheel can effectively manage temperature fluctuations,
minimizing the risk of thermal degradation and mechanical failure. Moreover, by integrating
thermal analysis with stress analysis, designers can evaluate the impact of temperature
40
changes on structural integrity, ensuring the flywheel can withstand the rigors of dynamic
loading conditions over its operational lifespan. Ultimately, the insights gained from thermal
analysis not only enhance the durability and reliability of the flywheel but also contribute to
optimizing its performance and efficiency, thus advancing the development of sustainable and
resilient energy storage solutions.

Figure 6.8 Steady state thermal analysis

6.41 heat flux analysis

Heat flux analysis on a flywheel involves examining the distribution of heat transfer across its
surface during operation. This analysis helps identify areas of high heat generation and
assesses the effectiveness of cooling mechanisms in dissipating heat. By understanding the
heat flux distribution, engineers can optimize the design of cooling systems and material
selection to ensure efficient thermal management and prevent overheating, thereby enhancing
the performance and longevity of the flywheel. Computational tools such as finite element
analysis (FEA) are commonly used to simulate heat flux patterns and aid in the design
optimization process.

41
Figure 6.9 Total Heat Flux

42
 RESULTS AND DISCUSSION
The results obtained from the experimentation were largely favourable and aligned with the
anticipated outcomes. Both the stresses and deformations observed provided valuable insights
into the parameters that should be considered when defining the design specifications of the
flywheel. Notably, the decision to decrease the number of teeth on the flywheel yielded
significant improvements in both the longevity and efficiency of the system.

Types Units Maximum Minimum

Equivalent strain m/m 1.5588e-6 2.0676e-10

Equivalent stress pa 3.1174e-5 14.907e

Total deformation m 5.2385e-8 0

Safety factor - 15 15

Steady state thermal ℃ 180 150

(temperature)
Heat flux w/m2 8.4035e-6 4.7603e-10

A key advantage stemming from the reduction in the number of teeth was the notable
decrease in mechanical stress concentrations, particularly evident at the tooth-root fillet
regions. This reduction played a pivotal role in minimizing the risk of fatigue failure, thereby
extending the lifespan of the flywheel system. By alleviating stress concentrations, the
system's reliability and durability under cyclic loading conditions were markedly enhanced.

Furthermore, the decreased number of teeth facilitated a more uniform distribution of load
across the circumference of the flywheel. This uniform distribution helped mitigate localized
wear and diminished the likelihood of premature component failure. As a result, the flywheel
system exhibited improved mechanical integrity and demonstrated prolonged service life.

In summary, the decision to reduce the number of teeth on the flywheel proved to be
advantageous, as evidenced by the reduction in stress concentrations, the enhanced uniformity
of load distribution, and the consequent improvements in reliability and durability. These
findings underscore the importance of carefully considering design parameters to optimize the
performance and longevity of engineering systems like flywheels.

43
Table : Structural and thermal analysis

CONCLUSION
From the analysis it is completely shown that the design of new flywheel is better than
the previous on because of it reduction in weight of 3 kilograms and increase in efficiency.
Different type of flywheels are designed and analyzed for high reliability and long life.
Smart design of flywheel geometry has significant effect on its specific energy
performance. Amount of kinetic energy stored by wheel –shaped structure flywheel is
greater than any other flywheel. we also consider in this task to discover the change made
in fly wheel by teeths. In this task we consider a fly wheel of 152 teethes and later re
adjusted to 146 teethes so we can locate any unique in stress and aggregate distortion.
In this we utilized Ansys and watch red that as a result of the teethes lessening we got add
up to disfigurement are same yet a slight change in stress and life of fly wheel.
Consequently i can state that quality and life do fly wheel is relies upon speed and no of
teethes.

44
 FUTURE SCOPE
The "Flywheel Energy Storage Systems Market" is poised for significant growth in the
foreseeable future, primarily propelled by increasing demand across various sectors such as
UPS, electricity grid stabilization, and transportation. This growth is fueled by the rising
adoption of renewable energy sources and electric vehicles, which have underscored the
importance of energy storage technologies. While conventional battery technology remains a
dominant player in the energy storage landscape, there is a growing interest in alternative
approaches, notably flywheel technology.

In recent years, there has been a surge in interest in flywheel energy storage systems due
to their unique capabilities and advantages. A notable development in this space is the
prototype flywheel storage system developed by a project team from Graz University of
Technology (TU Graz). This system demonstrates the ability to store electrical energy
efficiently while offering fast charging capabilities, addressing key challenges faced by
traditional energy storage solutions.

The market research report on the global Flywheel UPS industry offers a comprehensive
analysis of various techniques and materials utilized in the production of Flywheel UPS
products. The report delves into industry chain analysis and cost structure analysis, providing
insights into production processes and economic considerations. Moreover, it examines both
production and end-use segments of Flywheel UPS products, offering a holistic view of the
market landscape.

Furthermore, the report highlights the latest trends in the pharmaceutical industry and their
potential impact on the production of Flywheel UPS products. By identifying and analyzing
emerging trends, the report aims to provide stakeholders with valuable insights into market
dynamics and opportunities for growth and innovation.

Overall, the increasing demand for energy storage solutions, coupled with advancements in
flywheel technology and ongoing research and development efforts, is expected to drive the
growth of the Flywheel Energy Storage Systems Market in the coming years.

45
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