Design Analysis and Weight Reduction of Car Flywheel … Analysis and Weight...Sushama G Bawane et al. (2012) [3] had proposed flywheel design, and analysis the material selection

International Journal of Advance Engineering and Research Development

Volume 2,Issue 5, May -2015

@IJAERD-2015, All rights Reserved 1550

Scientific Journal of Impact Factor(SJIF): 3.134 e-ISSN(O): 2348-4470

p-ISSN(P): 2348-6406

Design Analysis and Weight Reduction of Car Flywheel using Finite Element

Analysis Palak J Patel

1, Arvind S. Sorathiya

2

1 PG Scholar, Mechanical Engg. Department, Govt. Engg. College, Bhuj-370001, India

2 Associate Professor, Mechanical Engg. Department, Govt. Engg. College, Bhuj-370001, India,

Flywheel is a rotating mechanical device that is used to store rotational energy. Flywheels have a significant moment of

inertia and thus resist change in rotational speed. Flywheel development has been dominated by mobile application

where minimizing mass is critical. The main problem with flywheel is its higher weight which results in lower rotational

speed. Flywheel is designed using 3 dimensional modelling software. Then the 3-D model was imported into ANSYS

using the IGES format. Using finite element analysis, static structural analysis carried out by considered three different

materials namely Gray cast iron, 5059 H321 aluminium alloy and Kevlar carbon fiber and their relative performance

have been observed respectively.

The finite element idealization of this model was then produced using the tetrahedron solid element. The analysis was

performed in a static condition. We find out the total deformation, normal stress and equivalent stress by using FEA

software. In this paper by observing the results of static analysis obtained carbon fiber is suggested as better material for designing of wheel as it has lower weight.

KEYWORDS: - Flywheel, 3-dimensional model; Finite element analysis; Static structural analysis.

I. INTRODUCTION

Flywheels serve as a kinetic energy storage and retrieval device that stores twisting or spinning motion and then release it

as rotational kinetic energy to provide motion when the requirement of the energy is more than supply. The amount of

energy stored in a flywheel is proportional to square of its rotational speed. The main function of flywheel is to smoothen

out variation in the speed of a shaft caused by torque fluctuation [7]. Flywheels are typically made of steel and rotate on

conventional bearings having a higher weight. These are generally limited to a revolution rate of a few thousand RPM.

As it is necessary to modify or design advanced flywheel having a lighter weight and less fracture possibilities with

composite material. For that stress analysis are carried out to flywheel for di fferent composite materials [8].

II. TYPES OF WHEEL

The geometry of a flywheel may be as simple as a cylindrical disc of solid material, or may be of spoke construction like

conventional wheels with a hub and rim connected by spokes or arms Small fly wheels are solid discs of hollow circu lar

cross section. As the energy requirements and size of the flywheel increases the geometry changes to disc of c entral hub

and peripheral rim connected by webs and to hollow wheels with multiple arms.[9]

I.

Fig 1 Types of flywheel [9]

III. LITERATUTRE REVIEW

International Journal of Advance Engineering and Research Development (IJAERD) Volume 2,Issue 5, May -2015, e-ISSN: 2348 - 4470 , print-ISSN:2348-6406


Mofid Mahdi et al. (2011) [1] worked on three solid flywheel d isk profiles that are constructed using functions of cubic

splines. Using FEM, the cubic splines parameters are analysed systematically to seek a maximum stored kinetic energy

per unite mass. All FEM computations were carried out using ANSYS. Three flywheels thickness profiles were analysed

based on cubic splines functions. The study concluded that thinner flywheel disk has a higher capability of kinetic energy

storing the corresponding maximum effect ive stresses are found near the centre of flywheels where thickness should be

maximum.

Mauleeswaran Senthil Kumar et al. (2012) [2] had put forward discussion of composite flywheel design. Based on

analytical approach for calculating stresses in flywheel using genetic algorithm. The problem was solved for a sample

flywheel with varying materials. Min imum mass required is found out for different value of energy storage and

corresponding other parameters are found out for five different materials cast iron, aluminium alloy, marging steel,

carbon fiber composite and E Glass fiber epoxy . Finally, from the analysis, it is clear that, among five materials carbon

fibre composites have lowest mass 0.001 kg and highest angular velocity 354 rad/sec for 500 j energy storage. It can be

also used in high speed applications, as the values of angular velocities obtained are higher than that of other materials.

Sushama G Bawane et al . (2012) [3] had proposed flywheel design, and analysis the material selection process. The

Gray cast iron, ASTM 30.SAE 111 was selected for the flywheel of MARUTI SUZUKI OMNI. The FEA model is

described by using CATIA software to achieve a better understanding of the mesh type, mesh size and boundary

conditions applied to complete an effective FEA model. Gray cast iron model was compared with alumin ium alloy. After

analysis the total deformation of Gray cast iron including equivalent stress Mpa, Normal stress Mpa and shear stress Mpa

was 0.00001419 mm while in alumin ium alloy the total deformation was 0.0000224 mm. Hence Gray cast iron can be

used to reduce stress and weight of flywheel.

Akshay P. Punde, et al. (2013) [4] has presented the investigation of a flywheel, A flywheel model is prepared by

CATIA software, and analyzed by using Finite Element Analysis method. Further it is used to calculate the Stresses

inside the flywheel by ANSYS; finally the comparison study between the Design and analysis with existing flyw heel is

carried out . The total deformation in Gray cast iron is 1.0484 x 10 ̄ ³ while in S Glass epoxy total deformation is 5,3399 x

10 ̄ ³. Hence s glass epoxy can be used in flywheel to store higher energy with less mass.

Lavakumar et al. (2013) [5]gives the design and optimize the flywheel for the best material. The flywheel is modelled

with solid 95 (3-D element), the modelled analyses using free mesh.Von-misses stress for both materials (mild steel and

mild steel alloy) is compared. The flywheel is modelled with solid elements. To reduce stress and deflection flywheel

40% titanium element is added as alloying element to the mild steel. The maximum deflection of mild steel alloy is

0.444E-05 meters which is less than maximum deflection of mild steel which is found to be 0.369E-03 meters. Thus mild

steel alloy is best, from rig idity point of view. Maximum von-misses stress in flywheel is 332288 N/m² for mild steel

alloy which is less than the maximum von-misses stress of flywheel which is found to be 352405 N/m². Hence design is

much safe based on strength point of view for mild steel alloy than for mild steel.

Kishor D. Farde et al. (2014) [6]reducesthe weight of automobile by using composite material. In this research Work

taking Flywheel as an Automobile component and applying FEA analysis using ANSYS to optimize weight and strength

of flywheel. Here Performing Analysis on metal flywheel, carbon fibre flywheel and composite i.e. metal and carbon

fibre flywheel. By using ANSYS stresses obtained & compared with analytical calculat ions, also weight is compared. A

composite material allows a higher rotational speed and this result in flywheel rotors with hig h specific energy and light

in weight. Composite materials are therefore a better choice than metals when designing flywheel rotors. The theoretical

specific energy of composite rotors is around five times higher than metallic ones. Composite materials als o have safety

advantage over metallic material.

IV. MODELING OF WHEEL

Creo is software which is used for creation and modifications of the objects. In Creo design and modeling feature is

available. Design means the process of creating a new object or modifying the existing one. Drafting means the

representation or idea of the object. Modeling means create and converting 2D to 3D. By using Creo software, c reate the

model of the Flywheel.

Step Involved In Design

1. Draw the profile d iagram of the Flywheel.

2. Now revolve the profile body about respect to axis.

3. By selecting the face of rim, the required design is drawn on the surface and teeth are obtained by pattern operation.



Fig 1Flywheel Model of Maruti Suzuki swift

V. FINITE ELEMENT ANALYS IS

The Finite Element Technique produces many simultaneous algebraic equations, which are generated and solved on a

digital computer. The Finite Element Method originated as a method of stress analysis. The Finite Element Method is

firmly established as a powerful and popular analysis tool. It is a numerical procedure for analyzing structures and

continua. Finite element procedures are used in design of buildings, electric motors, heat engines, ships, airfra mes and

space crafts.

The Fin ite Element Method, in general, models a structure as an assemblage of s mall elements. FEA has become a

solution to the task of predicting failure due to unknown stresses by showing problem areas in a material and allowing

designers to see all of the theoretical stresses within. This method of product design and testing is far superior to the

manufacturing costs, which would accrue if each sample was actually built and tested. FEA consists of a computer model

of a material or design that is stressed and analyzed for specific results.

It is used in new product design, and existing product refinement. In case of structural failure, FEA may be used to

help determine the design modificat ions to meet the new condition. FEA uses a co mplex system of points called nodes,

which make a grid called a mesh. This mesh is programmed to contain the material and structural properties, which

define how the structure will react to certain loading conditions.

A. Mesh Generation

B. Material Properties

Fig.2 Flywheel Model in Creo

The mesh was meshed with tetrahedron

structural solid elements. The wheel was

meshed using an element edge length is 2mm.

The total number of nodes and elements are

156933 and 92484 respectively. The finite

element realization of the wheel obtained is

shown in fig.3.

Fig.3 Meshing of Flywheel



Static structural analysis of flywheel using Fin ite element analysis is carried out to analyse zones with higher stress

concentration. For analysis, three materials are selected Gray cast iron, 5059 H321 aluminium alloy and Kevlar carbon

fiber and to show their relat ive performance using finite element analysis. This materials properties are shown in table 2.

Table I. Material Properties

Properties

Gray cast iron 5059 H321 Al alloy(11)

Kevlar Carbon

Fiber(9)

Density (g/cm3)

7.650 2.6 1.4

Ult imate Tensile Strength (MPa) 176.79

310 480

Poisson‟s ratio 0.23

0.33 0.2

Young's Modulus (Gpa) 101

69 30

C. Static Structural Analysis

Import developed Creo model into Ansys

Select the type of analysis require.

Applying the material

Create the mesh for the imported model

Fixing the geometry

Apply the loads and angular velocity

Run the analysis

1. Gray cast iron Results

Equivalent stress

Fig.4 Equivalent stress in gray cast iron

Total deformation



Fig 5 Total deformation in gray cast iron

Normal stress

Fig 6 Normal stress in gray cast iron

2. 5059 H321 AlAlloy Results

Equivalent stress



Fig.7 Equivalent stress in 5059 H321 Al alloy

Total deformation

Fig.8 Total deformation in 5059 H321 Al alloy

Normal stress



Fig. 9 Normal stress in 5059 H321 Al alloy

3. Kevlar carbon fiber

Equivalent stress

Fig. 10 Equivalent stress in Kevlar carbon fiber

Total deformation



Fig. 11 Total deformation in Kevlar carbon fiber

Normal stress

Fig. 12 Normal stress in Kevlar carbon fiber



D. Result Comparison

Material

Total

Deformation(mm)

Equivalent Stress

(MPa)

Normal Stress

(MPa)

Mass

(Kg)

Max.

Min.

Max.

Min.

Max.

Min.

Gray cast iron 35.084 0 52.045 0.05955 34.099 -26.962 5.6373

5059 H321 Al Alloy 15.122

0 13.306 0.051723 11.922 -8.6263 1.916

Kevlar Carbon

Fiber

13.506 0 8.2519 0.3265 5.1856 -4.2779 1.0317

In table II result of static structural analysis is given. After complet ion of meshing we apply fixed support at rim. For

gray cast iron and 5059 H321 Al Alloy, The total deformation of flywheel maximum is 35.084mm at hub portion and

minimum 0 mm at rim of flywheel. The equivalent stress is 52.045 Mpa and 0.05955 MPa. The normal stress maximum

is 34.099 MPa and minimum is -26.962 MPa. For 5059 Al alloy, the total deformat ion of flywheel maximum is 15.122

mm at hub portion. The equivalent stress is 13.306 Mpa and 0.051723 MPa.The norma l stress maximum is 11.922 MPa

and minimum is -8.6263 MPa. For Kevlar carbon fiber, the total deformation of wheel maximum is 13.506mm and

minimum is 0 at hub portion. The equivalent stress is 8.2519 Mpa and 0.3265 MPa. The normal stress maximum is

5.1856 Mpa and minimum is -4.2779 MPa. For three of materials, total deformat ion maximum at shaft hole and

minimum at rim and equivalent stress maximum at the centre of the flywheel and min imum at rim.

VI. CONCLUS IONS

Model of the flywheel is generated in Cre-o and this is imported to ANSYS for processing work. An angular velocity

471 rad/sec is applied in the direction of the rotation of flywheel made of gray cast iron, 5059 H321 Al Alloy & kev lar

Carbon Fiber and rim of the flywheel is fixed. Fo llowing are the conclusions from the results obtained:

1. Gray cast iron flywheel is subjected to more total deformation compared to 5059 Al alloy and carbon fiber.

2. Gray cast iron wheel is subjected more von-misses stress and normal stress compared to 5059 H321 Al alloy and

carbon fiber.

3. Weight of kevlar carbon fiber is 80 % less compared to gray cast iron and 5059 H321 Al alloy. 4. Kevlar carbon fiber has no erosion and corrosion problems.

5. By comparing all result we are suggested that kevlar carbon fiber is better material than gray cast iron and 5059

H321 Al alloy for designing of wheel.

REFERENCES

[1] Mofid Mahdi “An optimal two dimensional geometry of flywheel for kinetic energy storage” international journal of

thermal and environmental engineering (IJTEE) - vol 3 issue- 2 2011, page no. 67-72.

[2] Mauleeswaran senthil kumar, yogesh kumar “optimization of flywheel material using genetic algorithm” -2012.

[3] Sushama G Bawane , A P Ninawe and S K Choudhary, Analysis and optimization of flywheel, Intern ational Journal

of mechanical engineering and robotics Vol. 1, No. 2, Ju ly 2012.

[4] Akshay P. Punde, G.K.Gattani, Analysis of Flywheel, International Journal of Modern Engineering Research

(IJMER), Vol.3, Issue.2, March-April. 2013 pp-1097-1099.

[5] Lavakumar, R.prasanna Srinivasan, Design and analysis of light weight motor vehicle flywheel, International Journal

of Computer Trends and Technology (IJCTT) – volume 4 Issue -7July 2013.

[6] Kishor D Farde, Dr Dhiraj S Deshmukh [2014] “composite flywheel for h igh speed application” IJIRAE ISSN 2349-

2163 vol 1 issue 6 (July 2014).

[7] Sudipta Saha, Abhik Bose, G. Sai Tejesh, S.P. Srikanth, “Computer aided design & analysis on flywheel for greater

efficiency” International Journal of Advanced Engineering Research and Studies, IJAERS/Vol. I/ Issue II/January-

March, 2012/p-299-301.

[8] “Breakthrough in Ricardo Kinergy „second generation‟ high - speed flywheel technology”, press release date 22

august 2011.

Table II.Results Comparison



[9] Machine design –ІІ, Prof K. Gopinath and M.M Mayuram.

[10] http://www.performance-composites.com/carbonfibre/mechanicalp roperties_2.asp

[11] http://www.alcotec.com/us/en/solutions/-Understanding-the-Aluminum-Alloy-Designation-System.cfm

[12] http://www.efunda.com/materials/alloys/aluminum/temper.cfm

[13]Text book of Finite Element Analysis by P.Shesu.

[14] http://www.performance-composites.com/carbonfibre/mechanicalp roperties_2.asp

[15] http://www.carwale.com/m/marutisuzuki-cars\swift20052010/vxi-168/

[16] Jigar car pvt. Ltd. Himmatnagar.

[17] Devine metallurgical services and pvt. Ltd. Ahmedabad.

http://www.performance-composites.com/carbonfibre/mechanicalproperties_2.asp

http://www.alcotec.com/us/en/solutions/-Understanding-the-Aluminum-Alloy-Designation-System.cfm

http://www.efunda.com/materials/alloys/aluminum/temper.cfm

http://www.performance-composites.com/carbonfibre/mechanicalproperties_2.asp

http://www.carwale.com/m/marutisuzuki-cars/swift20052010/vxi-168/

Design Analysis and Weight Reduction of Car Flywheel … Analysis and Weight...Sushama G Bawane et al. (2012) [3] had proposed flywheel design, and analysis the material selection

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