M46 Design Project
M46 Design Project
PROJECT REPORT
Submitted by
ABHINAV G (18G003)
PRANNAV M (18G085)
2019-2020
i
THIAGARAJAR COLLEGE OF ENGINEERING: MADURAI- 625 015
BONAFIDE CERTIFICATE
Dr. V BALASUBRAMANI
ii
ABSTRACT
A flywheel is the heavy rotating mass which is placed between the power source and the driven
machine to act as a reservoir of energy. It is used to store the energy when the demand of energy
of energy is less and deliver it when the demand of energy is high. The current report is focused
on the analytical design of arm type of flywheel which is used for automobile engine operation.
Now in regard to the design of flywheel it is required to decide the mean diameter of the
flywheel rim, which depends upon two factors such as availability of space and the limiting
value of peripheral velocity of the fly wheel.
However the current design problem is formulated for automobile engine which has to spin at a
speed of 900 rpm and with the moment-torque ratio of 70 N and 4.5 °, hence it can be observed
that the design of the flywheel is to be carried out (based) on the availability of space limitation
and accordingly the fluctuation of energy, dimensions of the flywheel, stresses induced in the
flywheel are determined. Finally after detail analysis it is observed that the induced diameter of
the flywheel is less than the allowable/permissible diameter and hence it can be concluded that
the design is safe from availability of space point of view.
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ACKNOWLEDGEMENT
We express our deep sense of gratitude to our faculty In-charge of Design of Machine
elements, Dr. V. BALASUBRAMANI, Associate Professor of Mechanical Engineering for
his unstinting guidance and continuous support which enabled us to complete this project
with great success.
We also like to convey our sincere thanks to all the Faculty & Staff Members and all the
customers for helping and guiding us to complete this project with great success.
We also express our special thanks to our parents who have sacrificed greatly in our
education and welfare. We thank all those who have helped us directly and indirectly in
doing this project and bringing out this report successfully.
Above all we are very much thankful to THE ALMIGHTY for his marvelous grace towards
us.
ABHINAV G (18G003)
PRANNAV M (18G085)
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Table of Contents
Chapter No Title Page No
ABSTRACT iii
LIST OF TABLES Vi
LIST OF FIGURES vii
1. INTRODUCTION 1
2. PROBLEM FORMULATION 2
3. OBJECTIVES 3
4. METHODOLOGY 4
5. PRESENT WORK 5
6. RESULT AND DISCUSSION 19
7. CONCLUSION 20
REFERENCE 21
v
LIST OF TABLES
vi
LIST OF FIGURES
vii
CHAPTER 1
INTRODUCTION
Several hundred years ago pure mechanical flywheels where used solely to keep machines
running smoothly from cycle to cycle, thereby render possible the industrial revolution. During
that time several shapes and designs where implemented, but it took until the early 20th century
before flywheel rotor shapes and rotational stress were thoroughly analyzed. Later in the 1970s
flywheel energy storage was proposed as a primary objective for electric vehicles and stationary
power backup. At the same time fiber composite rotors where built, and in the 1980s magnetic
bearings started to appear. Thus the potential for using flywheels as electric energy storage has
long been established by extensive research. More recent improvements in material, magnetic
bearings and power electronics make flywheels a competitive choice for a number of energy
storage applications. One of the major advantages of flywheels is the ability to handle high
power levels. This is a desirable quality in e.g. a vehicle, where a large peak power is necessary
during acceleration and, if electrical breaks are used, a large amount of power is generated for a
short while when breaking, which implies a more efficient use of energy, resulting in lower fuel
consumption.
The flywheel is an energy storing element whose main function is to reduce fluctuation of speed
and increase energy output. The main aim of the design is to reduce the mass and to increase the
energy output gained in the flywheel.
REDUCE THE
MASS
INCREASE
THE ENERGY
STORED
Fig 2.1: Aim of the Design
2
CHAPTER 3
OBJECTIVES
The main objective of this problem is to design an optimal flywheel with reduced mass and to
increase the energy output for the selected materials. Design of an optimum flywheel for the
suitable application with specific constraints. Design of a flywheel the intercepted areas between
the output torque curve and the mean resistance line of a turning moment diagram for a Multi
cylinder engine, taken in order from one end are as follows: –35, + 410, –285, + 325, –335, +
260, –365, + 285, –260 mm2.
The scale of 1 mm = 70 N-m and 1 mm = 4.5°. The engine speed is 900 rpm and the fluctuation
in speed is not to exceed 2% of the mean speed. Factor of Safety = 4
No of Arms = 4, 5 & 6
Cross-section of the Rim = b = 2t, 3t, 4t
Assumptions = we consider diameter of the rim as 650 mm and thickness as 200 mm.
3
CHAPTER 4
METHODOLOGY
This design is selected and analyzed by using Taguchi Experimental software which is handling
with L9 orthogonal array. This software is mainly used for designing components and analyzing
with the possible affecting factors of the component. We used L9 orthogonal array for the design
we made and took three important factors as material, cross-section and number of arms with
three entries each. This software uses S/N ratio and a specified calculation for choosing 9 best
outcomes. From these outcomes, the best result can be decided and calculated.
The Taguchi method involves reducing the variation in a process through robust design of
experiments. The overall objective of the method is to produce high quality product at low cost
to the manufacturer. The experimental design proposed by Taguchi involves using orthogonal
arrays to organize the parameters affecting the process and the levels at which they should be
varied. Instead of having to test all possible combinations like the factorial design, the Taguchi
method tests pairs of combinations. This allows for the collection of the necessary data to
determine which factors most affect the product quality with a minimum amount of
experimentation, thus saving time and resources.
4
CHAPTER 5
PRESENT
WORK
CALCULATION
The masses are analyzed on different materials.
5
Fig 5.1 Multi cylinder engine Flywheel
6
CALCULATION OF ΔE
TORQUE
Energy at A = E
Energy at B = E -35
Energy at C = E – 35 + 410 = E + 375
Energy at D = E + 375 – 285 = E + 90
Energy at E = E + 90 + 325 = E + 415
Energy at F = E + 415 – 335 = E + 80
Energy at G = E + 80 + 260 = E + 340
Energy at H = E + 340 – 365 = E - 25
Energy at I = E – 25 + 285 = E + 260
Energy at J = E + 260 – 260 = E
7
As per the turning moment
diagram 1mm2 = 70 * 4.5 * (π /
180)
= 5.497Nm
ΔE = 440 * 5.497
ΔE = 2419.25 Nm
Case 1
Assuming
D = 650mm = 0.65m
t = 200mm = 0.2m
1. To find mass
We know that
(𝜎𝑡 ) s = 250 / 4 = 62.5
N/mm2 m = 𝜌 x v
= 7100 * b * t * 2πr
= 7100 * 2t2 * 2π * 0.325
= 7100 * 2 * (0.2)2 * 2π * 0.325
m = 1159.87 Kg
2. To find Velocity
v = πDN / 60
v = π * 0.65 * 900 / 60
v = 30.36 m/s
3. Design of Flywheel Rim
8
b = 2t
9
b = 2 * 0.2
b = 0.4 m
We know that
Stress in Rim:
𝜎𝑡 = 𝜌 x v
= 7100 X (30.36)2
𝜎𝑡 = 6.54 X 106 N/m2
𝜎𝑏 = 19.74 𝑋2 𝜌 𝑋 𝑣2 𝑋 𝑅
𝑛 𝑋𝑡
4 𝑡 +4 𝑏
Case 2
Assuming
D = 650mm = 0.65m
t = 200mm = 0.2m
1. To find mass
We know that
(𝜎𝑡 ) s = 250 / 4 = 62.5
N/mm2 m = 𝜌 x v
= 7100 * b * t * 2πr
= 7100 * 3t2 * 2π * 0.325
= 7100 * 3 * (0.2)2 * 2π * 0.325
m = 1739 Kg
2. To find Velocity
v = πDN / 60
v = π * 0.65 * 900 / 60
10
v = 30.36 m/s
3. Design of Flywheel Rim
b = 3t
b = 3 * 0.2
b = 0.6 m
We know that
Stress in Rim:
𝜎𝑡 = 𝜌 x v
= 7100 X (30.36)2
𝜎𝑡 = 6.54 X 106 N/m2
𝜎𝑏 = 19.74 𝑋2 𝜌 𝑋 𝑣2 𝑋 𝑅
𝑛 𝑋𝑡
4 𝑡 +4 𝑏
Case 3
Assuming
D = 650mm = 0.65m
t = 200mm = 0.2m
1. To find mass
We know that
(𝜎𝑡 ) s = 250 / 4 = 62.5
N/mm2 m = 𝜌 x v
= 7100 * b * t * 2πr
= 7100 * 4t2 * 2π * 0.325
= 7100 * 4 * (0.2)2 * 2π * 0.325
m = 2319 Kg
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2. To find Velocity
v = πDN / 60
v = π * 0.65 * 900 / 60
v = 30.36 m/s
3. Design of Flywheel Rim
b = 4t
b = 4 * 0.2
b = 0.8 m
We know that
Stress in Rim:
𝜎𝑡 = 𝜌 x v
= 7100 X (30.36)2
𝜎𝑡 = 6.54 X 106 N/m2
𝜎𝑏 = 19.74𝑛𝑋2𝑋
𝜌𝑋𝑣 𝑋𝑅
2
𝑡
4 𝑡 +4 𝑏
12
Case 1
Assuming
D = 650mm = 0.65m
t = 200mm = 0.2m
1. To find mass
We know that
(𝜎𝑡 ) s = 400 / 4 = 100 N/mm2
m=𝜌xv
= 7800 * b * t * 2πr
= 7800 * 3t2 * 2π * 0.325
= 7800 * 3 * (0.2)2 * 2π * 0.325
m = 1911 Kg
2. To find Velocity
v = πDN / 60
v = π * 0.65 * 900 / 60
v = 30.36 m/s
3. Design of Flywheel Rim
b = 3t
b = 3 * 0.2
b = 0.6 m
We know that
Stress in Rim:
𝜎𝑡 = 𝜌 x v
= 7800 X (30.36)2
𝜎𝑡 = 7.18 X 106 N/m2
𝜎𝑏 = 19.74 𝑋2 𝜌 𝑋 𝑣2 𝑋 𝑅
𝑛 𝑋𝑡
4 𝑡 +4 𝑏
13
= ¾ * (7.18 X 106) + ¼ * (14.4 x 106)
Total stress, 𝜎 = 8.98 x 106 N/m2
Hence the Total stress < Allowable stress. So, the design holds good.
Case 2
Assuming
D = 650mm = 0.65m
t = 200mm = 0.2m
1. To find mass
We know that
(𝜎𝑡 ) s = 400 / 4 = 100 N/mm2
m=𝜌xv
= 7800 * b * t * 2πr
= 7100 * 4t2 * 2π * 0.325
= 7100 * 4 * (0.2)2 * 2π * 0.325
m = 2548 Kg
2. To find Velocity
v = πDN / 60
v = π * 0.65 * 900 / 60
v = 30.36 m/s
3. Design of Flywheel Rim
b = 4t
b = 4 * 0.2
b = 0.8 m
We know that
Stress in Rim:
𝜎𝑡 = 𝜌 x v
= 7800 X (30.36)2
𝜎𝑡 = 7.18 X 106 N/m2
14
𝜎𝑏 19.74 𝑋 𝜌 𝑋 𝑣2 𝑋 𝑅
= 𝑛 2𝑋 𝑡
4 𝑡 +4 𝑏
Case 3
Assuming
D = 650mm = 0.65m
t = 200mm = 0.2m
1. To find mass
We know that
(𝜎𝑡 ) s = 400 / 4 = 100 N/mm2
m=𝜌xv
= 7800 * b * t * 2πr
= 7800 * 2t2 * 2π * 0.325
= 7100 * 2 * (0.2)2 * 2π * 0.325
m = 1274 Kg
2. To find Velocity
v = πDN / 60
v = π * 0.65 * 900 / 60
v = 30.36 m/s
3. Design of Flywheel Rim
b = 2t
b = 2 * 0.2
b = 0.4 m
We know that
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Stress in Rim:
𝜎𝑡 = 𝜌 x v
= 7800 X (30.36)2
𝜎𝑡 = 7.18 X 106 N/m2
𝜎𝑏 = 19.74 𝑋2 𝜌 𝑋 𝑣2 𝑋 𝑅
𝑛 𝑋𝑡
4 𝑡 +4 𝑏
Case 1
Assuming
D = 650mm = 0.65m
t = 200mm = 0.2m
1. To find mass
We know that
(𝜎𝑡 ) s = 710 / 4 = 177.5 N/mm2
m=𝜌xv
= 7850 * b * t * 2πr
= 7850 * 4t2 * 2π * 0.325
= 7850 * 4 * (0.2)2 * 2π * 0.325
16
m = 2564 Kg
2. To find Velocity
v = πDN / 60
v = π * 0.65 * 900 / 60
v = 30.36 m/s
3. Design of Flywheel Rim
b = 4t
b = 4 * 0.2
b = 0.8 m
We know that
Stress in Rim:
𝜎𝑡 = 𝜌 x v
= 7850 X (30.36)2
𝜎𝑡 = 7.23 X 106 N/m2
𝜎𝑏 = 19.74 𝑋2 𝜌 𝑋 𝑣 𝑋𝑅
2
𝑛 𝑋𝑡
4 𝑡 +4 𝑏
Case 2
Assuming
D = 650mm = 0.65m
t = 200mm = 0.2m
17
1. To find mass
We know that
(𝜎𝑡 ) s = 710 / 4 = 177.5 N/mm2
m=𝜌xv
= 7850 * b * t * 2πr
= 7150 * 2t2 * 2π * 0.325
= 7150 * 2 * (0.2)2 * 2π * 0.325
m = 1282 Kg
2. To find Velocity
v = πDN / 60
v = π * 0.65 * 900 / 60
v = 30.36 m/s
3. Design of Flywheel Rim
b = 2t
b = 2 * 0.2
b = 0.4 m
We know that
Stress in Rim:
𝜎𝑡 = 𝜌 x v
= 7850 X (30.36)2
𝜎𝑡 = 7.23 X 106 N/m2
𝜎𝑏 = 19.74 𝑋2 𝜌 𝑋 𝑣2 𝑋 𝑅
𝑛 𝑋𝑡
4 𝑡 +4 𝑏
18
Case 3
Assuming
D = 650mm = 0.65m
t = 200mm = 0.2m
1. To find mass
We know that
(𝜎𝑡 ) s = 710 / 4 = 177.5 N/mm2
m=𝜌xv
= 7850 * b * t * 2πr
= 7850 * 3t2 * 2π * 0.325
= 7150 * 3 * (0.2)2 * 2π * 0.325
m = 1923 Kg
2. To find Velocity
v = πDN / 60
v = π * 0.65 * 900 / 60
v = 30.36 m/s
3. Design of Flywheel Rim
b = 3t
b = 3 * 0.2
b = 0.6 m
We know that
Stress in Rim:
𝜎𝑡 = 𝜌 x v
= 7850 X (30.36)2
𝜎𝑡 = 7.23 X 106 N/m2
𝜎𝑏 = 19.74 𝑋2 𝜌 𝑋 𝑣2 𝑋 𝑅
𝑛 𝑋𝑡
19
𝜎𝑏 = 6.47 x 106 N/m2
Total stress, 𝜎 = 𝜎 𝜎
3 1
4 𝑡 +4 𝑏
20
CHAPTER 6
RESULTS & DISCUSSION
From the above results and with the formulated problem, we can conclude that the minimum
mass and lower stress can be chosen as the best design for the flywheel. Optimum design is as
follows: Material: Grey Cast Iron (GCI 25)
Mass: 1160 kg
Breadth: 0.4 m
Thickness: 0.2 m
Stress obtained: 8.185 × 10^6 N/m2
No of arms: 4
The flywheel designed with the above specifications can yield maximum energy with minima
stress and thus a safe flywheel can be manufactured.
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CHAPTER 7
CONCLUSION
It can be conclude that in case of flywheel design it is first important to know the design
requirement such as material, type, application, desired speed (peripheral velocity), availability
of space, and dimensions of the flywheel. The peripheral velocity of the flywheel is governed by
allowable strength of the flywheel material, generally for grey cast iron it should be less than or
greater than 25m/s.
In case of arm type of flywheel the numbers of arms selection depends upon the diameter of the
flywheel, generally four numbers of arms are selected for diameter of flywheel which should be
less than 0.75m.As the current problem is related to the design of flywheel with consideration
that, with lower mass, maximum energy would be obtained with lower stress. The stress
obtained is
8.185 N/mm2 which is less than the required condition, hence can be concluded as design is safe.
22
REFERENCE
1. "Flywheels move from steam age technology to Formula 1". Archived from the original
on 2012-07-03. Retrieved 2012-07-03.;"Flywheels move from steam age technology to
Formula 1"; Jon Stewart | 1 July 2012, retrieved 2012-07-03.
2. "Flywheel Energy Calculator". Botlanta.org. 2004-01-07. Archived from the original on
2011-07-25. Retrieved 2010-11-30.
3. "Density of Steel". Hypertextbook.com. 1998-01-20. Archived from the original on 2010-
11-25. Retrieved 2010-11-30.
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