Non linear analysis and optimization of flywheel

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 04 Issue: 02 | Feb -2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 925
Non Linear Analysis And Optimization Of Flywheel
Dinesh Patil, Prof. Gayatri S.Patil
1PG Student, Mechanical Engineering Department, KJCOE & MR , SPPU, Pune.
2Professor, Mechanical Engineering Department, KJCOE & MR , SPPU, Pune.
Maharashtra, India
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Abstract - Flywheels serve as kinetic energy storage and
retrieval devices with the ability to deliver high output power
at high rotational speeds as being one of theemergingstorage
energy technologies is available today in various stages of
development feild, especially in advanced technologicalareas.
Many causes are there of flywheel failure among them and
one of is the non-linear behavior of the flywheel. Hence this
work evaluation is done of non-linear stresses in the flywheel
for different material . The solid work software used fordesign
of flywheel. The ANSYS software is used for analysisandapply
forces for validation of flywheel is. The FEA of flywheel is
considering centrifugal forces on its comparative non-linear
analysis von-mises stress is done, shearstress anddeformation
of the flywheel made of Cast iron and aluminum alloy. The
paper gives too topology optimization approach in the mass
of flywheel reducing.
1. INTRODUCTION
1.1 Flywheel Detail
The word ‘flywheel’ appeared first during the start of
industrial revolution. There were two important
developments during this period, one is the use of flywheels
in steam engine and other is widespread use of iron. Iron
material has high integrity that flywheels made up of wood,
stone or clay.
Flywheel is a device (mechanical) which is used as a storage
device for rotational energy due to its significantly high
moment of inertia. Flywheels are required where there is a
fluctuation in input power and output load is constant or
there where is a fluctuation in output load and the input
power remains constant Flywheel is like as a reservoir to
store energy when supply is more than requirement and to
release the energy when requirement is more than supply.
Flywheel provides an effective way to smooth out the
fluctuation of speed.
1.2 Problem Statement
The flywheel is dynamic part hence the non-linear static
analysis does not gives the exact value of stresses developed
in flywheel. It is difficult to find out such type of stresses
with the help of numerical analysis to overcome these
problems. Modern technologies are used such as FEA
software. The paper deals with the study of stressesinduced
in a flywheel made of different material by using non-linear
analysis.
1.3 Objectives
1. To study the stress induced in Subaru EJ25D
gasoline engine flywheel..
2. FEM Modeling of Flywheel
3. Perform Non-Linear Analysis using ANSYS.
4. Consideration of flywheel model for shape
optimization.
5. Experimental Validation.
1.4 Scope
Considering the overall importance ofFlywheel asanenergy
storage device, we focus on nonlinear analysis by using step
loading apply & shape optimization of flywheel. Hence the
main concentration will be:
1. To use FEA/FEM as method andsoftwaretofindthe
stresses in the flywheel.
2. Optimize the flywheel for reduction in cost & high
fuel efficiency.
3. Perform non linear analysis to find the bestsuitable
material for flywheel manufacturing.
4. And most important is dynamometer test perform
on flywheel, etc.
2. COMPUTER ADDED MODELLING & FEA
2.1 Introduction to Solid works
Solid works is based on a single database, parametric, and
modular process-oriented PLM system. Today all over the
world as businesses, small, SMEs and large industrial
companies from all sectors to all types of design processes
and product development,
production machinery, moulds, household appliances,
automotive, agricultural machinery,shipbuilding,electrical /
electronics, medical products, telecommunications,
household appliances, metal products, heating and cooling
and the manufacturing sectors such as defence and
aerospace design and product development processes of all
types of co lateral industries, universities , institutes of
technical education institutions and R&D is the software
used. This is the result of the different sectors to respond to
the modular structure.

Fig. Fig 01- Flywheel Model
2.2 Introduction to Structural analysis
Finite element analysis process is divided into three main
phase’s
a) Pre-processor,
b) Solution,
c) Postprocessor.
1. Pre-processor
The user constructs a model of the part to be analyzed in
which the geometry is divided into a number of discrete sub
regions or elements," connected at discrete points called
nodes." Certain of these nodes will havefixeddisplacements,
and others will have prescribed loads. These models can be
extremely time consumingto prepare,andcommercial codes
with one another to have the most user- friendly graphical
pre-processor" to assist in this rather tediouschore.Someof
these pre-processors can overlay a mesh on a pre-existing
CAD file, so that finite element analysis can be done
conveniently as part of the computerized drafting-and-
design process. The pre-processor is a program that
processes the input data to produce the output that is used
as input to the subsequent phase (solution). Following are
the input data that needs to be given to the pre-processor:
2. Solution
Solution phase is completely automatic. The FEA software
generates the element matrices, computes nodal values and
derivatives, and stores the result data in files. These files are
further used by the subsequent phase (postprocessor) to
review and analyze the results through the graphic display
and tabular listings. The dataset prepared by the pre-
processor is used as input to the finite element code itself,
which constructs and solves a system of linear or nonlinear
algebraic equations.
Kijuj = fi
3. Post-processor
In the earlier days of finite element analysis, the user would
pass through of numbers generated by the code, listing
displacements and stresses at discrete positions within the
model. It is easy to miss important trends and hot spots this
way and modern codes use graphical displays to assist in
visualizing the results. Typical postprocessor display
overlays colored contours representing stress levels on the
model, showing a full field picture similar to that of photo
elastic or moire experimental results.
2.3 Finite Element Analysis (FEA) Software –
Finite Element Analysis is one of several numerical methods
that can be used to solve complex problems and is the
dominant method used today. As the name implies,ittakesa
complex problem and breaks it down into a finite number of
simple problems. A continuousstructuretheoreticallyhasan
infinite number of simple problems, but finite element
analysis approximates the behavior of a continuous
structure by analyzing a finite number of simple problems.
Each element in a finite element analysis is one of these
simple problems. Each element ina finite elementmodel will
have a fixed number of nodes that define the element
boundaries to which loads and boundary conditions can be
applied. The finer the mesh, the closer we can approximate
the geometry of the structure, the load application,aswell as
the stress and strain gradients. However, thereisa trade-off:
the finer the mesh, the more computational powerisneeded
to solve the complex problem. The strategyofoptimizing the
mesh size can greatly reduce an analyst’s t ime without
compromising on the quality of analysis results
3. SOFTWARE ANALYSIS OF FLYWHEEL
3.1 Meshing Method
The element is defined by 4-nodes with 6 DOFs at each node
and well suitable to create irregular meshes. It also has
stress stiffening capability. Free mesh with smart element
sizing is adopted to automatically and flexibly mesh the
model. Compared to mapped mesh, which is restricted to
only quadrilateral (area) or only hexahedron (volume)
elements; free mesh has no restrictions in terms of element
shapes. Smart sizing gives the meshes a greater opportunity
to create reasonably shaped element during automatic
element generation.

Fig. 02- Meshed Model
3.2 Boundary Conditions and Load
A Cylindrical support is given at the shaft and flywheel
contact, that is, the shaft-hole of the flywheel.Theflywheel is
radially and axially made fixed while it is free to rotate
tangentially. The flywheel is rotated by 418.67 radians/s
with the axis of rotation being theperpendicularlinepassing
through the centre of the flywheel, outwards of the plane of
flywheel. The rotational velocity of 418.67 radians/s is
applied in steps of every 1 second linearly.
Fig. 03- Boundary Condition on Flywheel
3.3 FEA Analysis
1. Analysis of FLYWHEEL as Aluminum alloy, Cast Iron,
Titanium & E-glass material
a) Radial Deformation Analysis
Fig. 04- Radial deformation of Al 6063 T6 flywheel.
Fig. 05- Radial deformation of cast alloy steel flywheel.
b) Radial Stresses Analysis
Fig. 06- Radial stress developed in Al 6063 T6
flywheel

Fig. 07- Radial stress developed in cast alloy flywheel.
c) Factor of Safety Analysis
The factor of safety for the differentmaterialsoftheflywheel
are found to be within safe limits, which depicts that the
flywheel designs are feasible and theirmanufacturingcan be
carried out for real time simulation.
Fig. 08- Factor of safety of Al 6063 T6 flywheel.
Fig. 09- Factor of safety of cast alloy flywheel.
d) Step loading Chart
Table 01: Step loading Chart
Time Rotational Velocity
0. 0.
1. 100.
2. 200.
3. 300.
4. 418.67.
Fig. 10- Non-Linear Radial stress developed in Al 6063
flywheel.
Fig. 11- Total Deformation developed in Al 6063 flywheel.

Fig. 12- Shear stress developed in Al 6063 flywheel.
As with step loading formulation, the actual stress and
deformation were plotted for Al Alloy and Gray CI.
It is seen that the difference the stress and deformation is
very large and we could say that with linear analysis the
results plotted are following the linear stress – strain
relation, but in actual practice the relation is not linear.
Fig. 13- Non-Linear Radial stress developed in Gray CI
flywheel.
Fig. 14- Non-Linear Radial stress developed in Gray CI
flywheel.
Fig. 15- Shear stress developed in Gray CI flywheel.
2. Shape Optimization of flywheel
At last through the software for reduction of 20%weight of
material can be removed from the periphery of the flywheel.
In optimization process a comparative study was made and
cost wise efficient material is considered as Al alloy.
Table 02: Structural Optimization
Scope
Geometry All1 Bodies
Definition
Target Reduction 20%
Result
Original Mass 5.5006 kg
Optimized Mass 4.4004 kg
Marginal Mass 0.0000 kg
Fig. 16- Optimization result for Al Alloy Flywheel.

4. EXPERIMENTAL VALIDATION
4.1 Experimental Setup –
As shown in below fig. The setup of flywheel testing.
In this set up we are going to check deflection at
different point. The point where we get deflection
value can show in Fig. As below.
(A)
(B)
Fig. 17- Experimental setup of flywheel
Deflection reading of flywheel is taken at 8 different Points.
This 8 different reading is as below. The original thicknessof
flywheel is 29 mm.
Table 03: Defection Reading For Al Alloy & Cast Iron
Sr.
no
Defection Reading For
Al Alloy
Defection Reading For
Cast Iron
1 29.14 mm 29.175 mm
2 28.97 mm 29.112 mm
3 29.097 mm 29.159 mm
4 28.972 mm 29.070 mm
5 29.196 mm 28.995 mm
6 29.134 mm 28.998 mm
7 29.19 mm 29.099 mm
8 28.984 mm 29.160 mm
1) Final length For Aluminium Alloy:
Final length =
Final length = 29.085mm
2) Final length For Cast Iron:
Final length =
Final length = 29.096mm
Deflection Calculation:
1) Deflection For Aluminium Alloy:
Deflection = Final length Original length
Deflection = 29.085 29
Deflection = 0.085 mm
2) Deflection For Cast Iron:
Deflection = Final length Original length
Deflection = 29.096 29
Deflection = 0.096 mms

Table 4.2: Defection Results For Al Alloy & Cast Iron
Experimental Stress Calculation:
1) stress For Aluminium Alloy:
ɛ
202.24 Mpa.
2) Stress For Cast Iron:
ɛ
331.034 Mpa.
5. CONCLUSION
The modelling of the flywheel was performed using Solid
works 2013. The Finite Element Analysis (FEA) was carried
out using ANSYS workbench 16.0 for the four materials:
The linear analysis was carried out on Aluminium alloy,Cast
Iron, Titanium & E-glass materials that's shows the less
stress developed in cast Iron & Al alloy, so that non-linear
analysis is carried on the same materials.
The Finite Element Analysis (FEA) for non- linear was
carried out using ANSYS workbench 16.0 for the two
materials: Cast iron, Al 6063-T6,
The nonlinear analysis of Al Alloy and Gray CIshowsthatthe
stress developed with Al Alloy is less than that of Gray CI.
Experimental validation conducted on both materials and
results are compared with FEA analysis and percentage
error lies between 3-4%. Thus, Al was found to be the best
suited material for constructing the flywheel due to
minimum stress and low weight as compared to cast iron.
REFERENCES
[1] Phanindra Mudragadda1 , T. Seshaiah,‖ Analysis of
flywheel used in petrol engine car‖, International Journal of
Engineering Research & Technology,ISSN:2278-0181,Vol.3
Issue 5, May – 2014.
[2] Nagaraj.R.M,‖ Suitability of composite material for
flywheel analysis ―, International Journal Of Modern
Engineering Research , ISSN: 2249 6645 Vol. 4,iss. 6, June.
2014.
[3] Snehal.R.Raut, Prof .N.P.Doshi,prof .U.D.Gulhane,‖ FEM
Analysis of flywheel used for punching press operation‖,
IORD Journal Of Science & Technology, E-ISSN: 2348-0831
Volume 1, Issue V JULYAUGUST 2014.
[4] Kishor D.Farde, Dr.Dheeraj.S.Deshmukh, ―Review:
Composite flywheel for high speed application‖,
International Journal of Innovative Research in Advanced
Engineering, ISSN: 2349-2163, Volume 1, Issue 6, July 2014.
[5] S.M.Choudhary, D.Y.Shahare2,‖ Design optimization of
flywheel of thresher using FEM ―, International Journal of
Emerging Technology and Advanced Engineering , ISSN
2250-2459, ISO 9001:2008CertifiedJournal,Volume3,Issue
2, February 2013 .
Sr. no Material Experimental Deflections
1. Al Alloy 0.085mm
2. Cast Iron 0.096mm

Non linear analysis and optimization of flywheel

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