Finite Element Analysis of Inertia Dynamometer

R. A. Gujar1, S. V. Bhaskar2 & N. U. Yewale3

1,2&3

Department of Mechanical Engineering,

Pimpri Chinchwad College of Engineering,
2
Sanjivani Rural Education Society College of Engineering
E-mail : ragujartpopune@gmail.com1, santoshbhaskar12002@yahoo.co.in2, na.624@rediffmail.com3
1&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.

Table I : Material Properties for Shaft

Physical Properties
Values
Ultimate Strength
410 Mpa (N/mm2)
Yield Strength
230 Mpa (N/mm2)
Youngs Modulus (E)
2.1x105 N/mm2
Poissons Ratio ()
0.3
Density
7850 kg/ m3
Table II : Chemical Properties for Shaft

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.

Grade
Qua
Desig
lity
nation

FE
A
410 W

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.

Method
of
(CE)
DeoxidaMax
tion

Ladle Analysis, % Max

C

Mn

0.23

1.5

S
0.045

Si

0.045 .40

0.42

SemiKille
d/ Killed

Table III : Mechanical Properties of Shaft

Grade
Quality
Designation
FE 410 W

Syt
MPa

t
MPa

% Elongation,
A at Gauge
Length, LO
5.65S ,Min

Internal
diam.
Min.

410

230-250

23

3t

B. ANALYSIS OF SHAFT BY USING FEA

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
Fig.1 : CAD Geometry of Shaft
ISSN : 2319 3182, Volume-2, Issue-4, 2013

55

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

C. STATIC ANALYSIS OF BUSH

FIG. 5 : CAD GEOMETRY OF BUSH

Fig. 2 : Deformation in Shaft

Fig.6 : Deformation in Bush

Fig. 3 : Von-Mises Stresses in Shaft

Fig.7 : Von-Mises Stresses in Bush

Fig.4 : Max.Shear Stress in Shaft
ISSN : 2319 3182, Volume-2, Issue-4, 2013

56

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

D. STRUCTURAL ANALYSIS OF PEDESTAL

BEARING

E. STRUCTURAL ANALYSIS OF BASE FRAME

Fig. 8 : CAD Geometry of Pedestal Bearing

Fig.11 : CAD Geometry of Base Frame

Fig. 9 : Deformation in Pedestal Bearing

Fig. 12 : Deformation in Base Frame

Fig. 10 : Von-Mises Stresses in Pedestal Bearing

Fig.13 : Von-Mises Stresses in Base Frame

ISSN : 2319 3182, Volume-2, Issue-4, 2013

57

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

III. MODAL ANALYSIS OF DYNAMOMETER

Operating Frequency of Dynamometer

Rotating Speed (N)

= 1000 rpm.

Angular Velocity () = 2N/60

= 2 x x 1000/60
= 104.71 rad/s
Operating Frequency = / 2
= 104.71 / 2
= 16.66 Hz

Fig.14 : Model Shape II

C. Model Shape III

Natural Frequency of Dynamometer

Natural Frequency: 117.14 Hz

The product is been solved in ANSYS to find the

Natural Frequency upto first three natural modes.

Max. Amplitude: 1.09 mm

CASE I Shaft & Fixed Flywheel

A. Model Shape I
Natural Frequency: 47.539 Hz
Max. Amplitude: 1.1 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.13 : Model Shape I

B. Model Shape II
Natural Frequency: 112.25 Hz
Max. Amplitude: 1.09 mm

Fig.15 : Model Shape I

ISSN : 2319 3182, Volume-2, Issue-4, 2013

58

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

B. Model Shape II
Natural Frequency: 48.711 Hz
Max. Amplitude: 1.077 mm

Fig. 16 : Model Shape II

Fig.19 : Deformation in flywheel due to centrifugal stress

C. Model Shape III

Natural Frequency: 69.494 Hz

Max. Amplitude: 0.5788 mm

CASE II Shaft, Fixed Flywheel & Removable

Flywheel.

Fig. 17 : Model Shape III

D. DYNAMIC ANALYSIS OF DYNAMOMETER
(High Speed Effect)

1.
2.

Fig. 20 : Deformation in flywheel & Removable

Flywheel due to centrifugal stress

Assumption
The Fixed, Removable Flywheel & Shaft is
perfectly balanced.
This Analysis will consider the centrifugal forces
developed due to high speed.
CASE I Shaft & Fixed Flywheel

Fig.21 : Deformation in flywheel & Removable

Flywheel due to centrifugal stress

Fig.18 : Stress developed due to centrifugal stress

ISSN : 2319 3182, Volume-2, Issue-4, 2013

59

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

.
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 doesnt meet to natural frequency.

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

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.Coordinator & 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.

ISSN : 2319 3182, Volume-2, Issue-4, 2013

60

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

Controlled
Chassis
Dynamometer
University of Cincinnati, 2004.
[5]

[6]

B.S;

[7]

Brian J. Schwarz & Mark H. Richardson,

Experimental Modal Analysis, Vibrant
Technology, Inc.1999.

S.Vijayaraja, S.Vijayaragavan, Finite Element

Analysis of Critical Components of the 2.6L
Gasoline EngineAVTEC Ltd.

[8]

V.B.Bhandari, Design of Machine Element; Tata

McGraw-Hill
Publication
Co.Ltd.
New
Delhi,2004.

J Michael Robichaud, P.Eng, Reference

Standards for Vibration Monitoring and Analysis.

ISSN : 2319 3182, Volume-2, Issue-4, 2013

61