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Finite Element Analysis of Inertia Dynamometer

R. A. Gujar

1, S. V. Bhaskar

2 & N. U. Yewale

3

1,2&3

Department of Mechanical Engineering, 1&3

Pimpri Chinchwad College of Engineering, 2Sanjivani Rural Education Society College of Engineering

E-mail : ragujartpopune@gmail.com1, santoshbhaskar12002@yahoo.co.in

2, na.624@rediffmail.com

3

Abstract – The Dynamometer is a LOAD device. It applies

a load to an engine so we can test the performance of the

engine under a variety of circumstances. System operates

where load (dyno) torque equals that of the Engine. By

varying the engine throttle and load we can test any point

under the engines max torque curve. We design and

modify engines for improved fuel economy and emissions

We need DATA to quantify the improvements in Fuel

savings and Emissions reductions. This data will be used to

help us “tune in” our design.

The Dynamometer is operated at 1000 rpm to generate the

necessary inertia. For different kind of conditions, there is

need of having variable inertia. So the dynamometer is

constructed with removable flywheel.

I. INTRODUCTION

The Dynamometer is a LOAD device. It applies a

load to an engine so we can test the performance of the

engine under a variety of circumstances. System

operates where load (dyno) torque equals that of the

Engine. By varying the engine throttle and load we can

test any point under the engines max torque curve. We

design and modify engines for improved fuel economy

and emissions. We need DATA to quantify the

improvements in Fuel savings and Emissions reductions.

This data will be used to help us “tune in” our design.

The Dynamometer is operated at 1000 rpm to

generate the necessary inertia. For different kind of

conditions, there is need of having variable inertia. So

the dynamometer is constructed with removable

flywheel

II. STATIC ANALYSIS

A. ANALYSIS OF SHAFT

Material Properties for shaft : Steel : FE 410 WA :

IS 2062

Table I : Material Properties for Shaft

Physical Properties Values

Ultimate Strength 410 Mpa (N/mm2)

Yield Strength 230 Mpa (N/mm2)

Young‟s Modulus (E) 2.1x105 N/mm

2

Poisson‟s Ratio (µ) 0.3

Density 7850 kg/ m3

Table II : Chemical Properties for Shaft

Grade Desig

nation

Qua

lity Ladle Analysis, % Max

(CE)

Max

Method

of

Deoxida-tion

C Mn S P Si

FE

410 W A 0.23 1.5 0.045 0.045 .40 0.42

SemiKille

d/ Killed

Table III : Mechanical Properties of Shaft

Grade Designation

Quality Syt

MPa σt

MPa

% Elongation,

A at Gauge Length, LO

5.65√S ,Min

Internal

diam.

Min.

FE 410 W A 410 230-250 23 3t

B. ANALYSIS OF SHAFT BY USING FEA

Fig.1 : CAD Geometry of Shaft

International Journal on Theoretical and Applied Research in Mechanical Engineering (IJTARME)

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Fig. 2 : Deformation in Shaft

Fig. 3 : Von-Mises Stresses in Shaft

Fig.4 : Max.Shear Stress in Shaft

C. STATIC ANALYSIS OF BUSH

FIG. 5 : CAD GEOMETRY OF BUSH

Fig.6 : Deformation in Bush

Fig.7 : Von-Mises Stresses in Bush

International Journal on Theoretical and Applied Research in Mechanical Engineering (IJTARME)

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D. STRUCTURAL ANALYSIS OF PEDESTAL

BEARING

Fig. 8 : CAD Geometry of Pedestal Bearing

Fig. 9 : Deformation in Pedestal Bearing

Fig. 10 : Von-Mises Stresses in Pedestal Bearing

E. STRUCTURAL ANALYSIS OF BASE FRAME

Fig.11 : CAD Geometry of Base Frame

Fig. 12 : Deformation in Base Frame

Fig.13 : Von-Mises Stresses in Base Frame

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III. MODAL ANALYSIS OF DYNAMOMETER

Operating Frequency of Dynamometer

Rotating Speed (N) = 1000 rpm.

Angular Velocity (ω) = 2πN/60

= 2 x π x 1000/60

= 104.71 rad/s

Operating Frequency = ω / 2π

= 104.71 / 2π

= 16.66 Hz

Natural Frequency of Dynamometer

The product is been solved in ANSYS to find the

Natural Frequency upto first three natural modes.

CASE I – Shaft & Fixed Flywheel

A. Model Shape – I

Natural Frequency: 47.539 Hz

Max. Amplitude: 1.1 mm

Fig.13 : Model Shape – I

B. Model Shape – II

Natural Frequency: 112.25 Hz

Max. Amplitude: 1.09 mm

Fig.14 : Model Shape – II

C. Model Shape – III

Natural Frequency: 117.14 Hz

Max. Amplitude: 1.09 mm

Fig.14 : Model Shape – III

CASE II – Shaft, Fixed Flywheel & Removable

Flywheel.

A. Model Shape – I

Natural Frequency: 36.007 Hz

Max. Amplitude: 0.51 mm

Fig.15 : Model Shape – I

International Journal on Theoretical and Applied Research in Mechanical Engineering (IJTARME)

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B. Model Shape – II

Natural Frequency: 48.711 Hz

Max. Amplitude: 1.077 mm

Fig. 16 : Model Shape – II

C. Model Shape – III

Natural Frequency: 69.494 Hz

Max. Amplitude: 0.5788 mm

Fig. 17 : Model Shape – III

D. DYNAMIC ANALYSIS OF DYNAMOMETER

(High Speed Effect)

Assumption

1. The Fixed, Removable Flywheel & Shaft is

perfectly balanced.

2. This Analysis will consider the centrifugal forces

developed due to high speed.

CASE I – Shaft & Fixed Flywheel

Fig.18 : Stress developed due to centrifugal stress

Fig.19 : Deformation in flywheel due to centrifugal stress

CASE II – Shaft, Fixed Flywheel & Removable

Flywheel.

Fig. 20 : Deformation in flywheel & Removable

Flywheel due to centrifugal stress

Fig.21 : Deformation in flywheel & Removable

Flywheel due to centrifugal stress

International Journal on Theoretical and Applied Research in Mechanical Engineering (IJTARME)

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. IV. RESULTS

XXXX

V. CONCLUSION

The result of Static Analysis for shaft, Pedestal

Bearing & Base frame confirms the safety &

overall rigidity of dynamometer assembly.

The Modal Analysis confirms the safety of product

to operate at 1000 rpm speed, as the operating

frequency doesn‟t meet to natural frequency.

The dynamic analysis confirms the strength

validation of the product. The average induced

stress is lower than the yield strength of material,

the product is safe.

VI. ACKNOWLEDGMENT

I wish to express my sincere thanks to

Prof.S.V.Bhaskar for their technical support and helpful

attitude gave us high moral support .

I am also thankful to Prof. A.G.Thakur (P.G.Co-

ordinator & HOD of Mechanical Department) who had

been a source of inspiration.

Finally, I specially wish to thank my father &

Mother, wife kirti and sweet daughter Sanskriti and all

those who gave me valuable inputs directly or

indirectly.

VII. REFERENCES

[1] Min-Soo Kim, “Vibration Analysis of Tread

Brake Block in the Brake Dynamometer for the

High Speed Train” „International Journal of

Systems Applications, Engineering &

Development‟, 2011, Volume 5, Issue 1.

[2] J. Naga Malleswara Rao, A. Chenna Kesava

Reddy & P.V. Rama Rao, “Design and

fabrication of new type of dynamometer to

measure radial component of cutting force and

experimental investigation of optimum

burnishing force in roller burnishing process”

„Indian Journal of Science and Technology‟,

2010, Vol. 3 No.7, ISSN: 0974- 6846.

[3] Min-Soo Kim, Jeong-Guk Kim, Byeong-Choon

Goo, & Nam-Po Kim, “Frequency Analysis of

the Vibration of Tread Brake Dynamometer for

the High Speed Train” „Vehicle Dynamics &

Propulsion System Research Department‟, Korea

Railroad Research Institute, ISSN: 1792-4618,

ISBN: 978-960-474-217-2.

[4] Ryan Douglas Lake, “Integration of a small

Engine Dynamometer into an eddy Current

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Controlled Chassis Dynamometer” B.S;

University of Cincinnati, 2004.

[5] Brian J. Schwarz & Mark H. Richardson,

“Experimental Modal Analysis”, Vibrant

Technology, Inc.1999.

[6] J Michael Robichaud, P.Eng, “Reference

Standards for Vibration Monitoring and Analysis.

[7] S.Vijayaraja, S.Vijayaragavan, “Finite Element

Analysis of Critical Components of the 2.6L

Gasoline Engine”AVTEC Ltd.

[8] V.B.Bhandari, Design of Machine Element; Tata

McGraw-Hill Publication Co.Ltd. New

Delhi,2004.