DESIGN AND FABRICATION OF

ENERGY GENERATION

SYSTEM FOR ELECTRIC VEHICLES

A PROJECT REPORT

Submitted By

ABISHAKE. S. M 161001003

AKASH KANNAN. J 161001006

DAVID ALLEN VAZ. L 161001023

HEMPRAKASH. P 161001038

In partial fulfilment for award of the degree

of

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

SRI VENKATESWARA COLLEGE OF ENGINEERING

SRIPERUMBUDUR

ANNA UNIVERSITY: CHENNAI 600 025

APRIL 2019
i
 ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE
Certified that this project report “DESIGN AND FABRICATION OF
ENERGY GENERATION SYSTEM FOR ELECTRIC VEHICLES” is the
bonafide work of ABISHAKE. S.M(161001003), AKASH KANNAN.J
(161001006), DAVID ALLEN VAZ. L (161001023), HEMPRAKASH.P
(161001038) who carried out the project work under my supervision.

SIGNATURE SIGNATURE

Dr. S. RAMESH BABU Mr.M. MAHESWARAN

HEAD OF THE DEPARTMENT SUPERVISOR

Professor Assistant Professor

Department of Mechanical Engineering Department of Mechanical Engineering

Sri Venkateswara College of Engineering Sri Venkateswara College of Engineering

Pennalur Pennalur

Sriperumbudur – 602 117 Sriperumbudur – 602 117

Submitted for viva-voce held on……..

INTERNAL EXAMINER EXTERNAL EXAMINER

ii
 ACKNOWLEDEMENT

First and foremost we owe our heartfelt thanks to our parents for their
blessings and their encouragement and support to do this project.

We sincerely thank our principal Dr. S. GANESH VAIDYANATHAN,

for giving us permission to carry out the project in our college.

We express our sincere thanks to Head of the department Dr. S. RAMESH

BABU, Department of Mechanical Engineering, for the constant encouragement
given to us for carrying our project so as to gain practical knowledge in the field
of study.

We are grateful to thank Mr. M. MAHESWARAN, Assistant Professor,

Department of Mechanical engineering for his guidance and motivation during
the course of our project.

We would like to express our sincere thanks to the faculty of Mechanical

Engineering department of SRI VENKATESWARA COLLEGE OF
ENGINEERING for the facilities that we have availed during the course of our
project.

iii
 ABSTRACT

Energy is usually produced by non-renewable sources such as petrol, Kerosene

and nuclear which unfortunately create pollution, this is the main reason the

idea of producing energy for charging the Electric car or electric vehicles for

upcoming vehicles. Electric vehicles are taking very important part in today’s

Indian and national market. Energy generation using flywheel is renewable.

This can increase the range of electric vehicles.

Most of the electric cars today have a range of 80-100 miles before the battery

runs flat. The two major disadvantages of electric vehicles are short range and

long duration of recharging time. To increase the range of the electric vehicle is

the aim of our project. Just imagine you stopped your car for speed breaker

and still your battery is charging. Here kinetic energy is used for the charging of

vehicle battery. Initially the kinetic energy is stored in the flywheel and then its

rotation is used to generate energy using generator / dynamo to store it back

to the battery. This is theme of our project.

iv
 TABLE OF CONTENTS

CHAPTER TITLE PAGE NO.

NO.

ABSTRACT

1 INTRODUCTION

1.1 - ELECTRIC VEHICLES 1

1.2 - ADVANTAGES OF ELECTRIC VEHICLES 3

1.3 - DISADVANTAGES OF ELECTRIC 5

VEHICLES

1.4 – PROBLEM IN ELECTRIC VEHICLES 6

1.5 - SCOPE OF THE PROJECT 6

2 PROJECT DESCRIPTION

2.1 - CONSTRUCTION AND WORKING 7

2.2 - PARTS

2.2.1 - SHAFT 8

2.2.2 - CHAIN AND SPROCKETS 9

2.2.3 - BEARING BLOCK 10

2.2.4 - FLYWHEEL 11

2.2.5 - FREEWHEEL 12
3 DESIGN CALCULATIONS

3.1 - COMPONENTS USED IN THE PROJECT 13

3.2 - CHAIN DRIVE 2 13

3.3 - CHAIN DRIVE 1 & 3 16

3.4 - SHAFT 1 20

3.5 - SHAFT 2 23

3.6 - FLYWHEEL 27

4 CAD MODEL

4.1 - FRONT VIEW 29

4.2 - TOP VIEW 29

4.3 - SIDE VIEW 30

4.4 - ISOMETRIC VIEW 30

5 MANUFACTURING PROCESSES

5.1 - ARC WELDING 31

5.2 – TURNING 33

5.3 – MILLING 34

5.4 – THREADING 34
6 CONCLUSION 36

7 COST ESTIMATION 37

8 REFERENCE 38
 CHAPTER 1

INTRODUCTION

1.1 ELECTRIC VEHICLES

An electric car (also battery electric car or all-electric car) is a plug-in

electric automobile that is propelled by one or more electric motors, using energy
typically stored in rechargeable batteries. Just as there are a variety of technologies
available in conventional vehicles, plug-in electric vehicles (also known as electric
cars or EVs) have different capabilities that can accommodate different drivers’
needs. A major feature of EVs is that drivers can plug them in to charge from an
off-board electric power source. This distinguishes them from hybrid electric
vehicles, which supplement an internal combustion engine with battery power but
cannot be plugged in.

There are two basic types of EVs: all-electric vehicles (AEVs) and plug-in
hybrid electric vehicles (PHEVs). AEVs include Battery Electric Vehicles (BEVs)
and Fuel Cell Electric Vehicles (FCEVs). In addition to charging from the
electrical grid, both types are charged in part by regenerative braking, which
generates electricity from some of the energy normally lost when braking. Which
type of vehicle will fit your lifestyle depends on your needs and driving habits.
Find out which BEVs and PHEVs are available to suit your needs.
All-electric vehicles (AEVs) run only on electricity. Most have all-electric ranges
of 80 to 100 miles, while a few luxury models have ranges up to 250 miles. When
the battery is depleted, it can take from 30 minutes (with fast charging) up to

1
nearly a full day (with Level 1 charging) to recharge it, depending on the type of
charger and battery.

If this range is not sufficient, a plug-in electric vehicle (PHEV) may be a

better choice. PHEVs run on electricity for shorter ranges (6 to 40 miles), then
switch over to an internal combustion engine running on gasoline when the battery
is depleted. The flexibility of PHEVs allows drivers to use electricity as often as
possible while also being able to fuel up with gasoline if needed. Powering the
vehicle with electricity from the grid reduces fuel costs, cuts petroleum
consumption, and reduces tailpipe emissions compared with conventional vehicles.
When driving distances are longer than the all-electric range, PHEVs act like
hybrid electric vehicles, consuming less fuel and producing fewer emissions than
similar conventional vehicles. Depending on the model, the internal combustion
engine may also power the vehicle at other times, such as during rapid acceleration
or when using heating or air conditioning. PHEVs could also use hydrogen in a
fuel cell, biofuels, or other alternative fuels as a back-up instead of gasoline.

2
1.2 ADVANTAGES OF ELECTRIC VEHICLES:

1. No Required gas: Electric cars are entirely charged by the electricity you
provide, meaning you don’t need to buy any gas ever again. Driving fuel based
cars can burn a hole in your pocket as prices of fuel have gone all time high.
Though electricity isn’t free, an electric car is far cheaper to run.

2. Savings: These cars can be fuelled for very cheap prices, and many new cars
will offer great incentives for you to get money back from the government
for going green. Electric cars can also be a great way to save money in your own
life.

3. No Emissions: Electric cars are 100 percent eco-friendly as they run on

electrically powered engines. It does not emit toxic gases or smoke in the

3
environment as it runs on clean energy source. They are even better than hybrid
cars as hybrids running on gas produce emissions. You’ll be contributing to a
healthy and green climate.

4. Popularity: EV’s are growing in popularity. With popularity comes all new
types of cars being put on the market that are each unique, providing you with a
wealth of choices moving forward.

5. Safe to drive: Electric cars undergo same fitness and testing procedures test as
other fuel powered cars. In case an accident occurs, one can expect airbags to open
up and electricity supply to cut from battery. This can prevent you and other
passengers in the car from serious injuries.

6. Cost Effective: Earlier, owing an electric car would cost a bomb. But with more
technological advancements, both cost and maintenance have gone down. The
mass production of batteries and available tax incentives have further
brought down the cost, thus, making it much more cost effective.

7. Low Maintenance: Electric cars runs on electrically powered engines and

hence there is no need to lubricate the engines. Other expensive engine work is a
thing of past. Therefore, the maintenance cost of these cars has come down. You
don’t need to send it to service station often as you do a normal gasoline powered
car.

8. Reduced noise pollution: Electric cars put curb on noise pollution as they are
much quieter. Electric motors are capable of providing smooth drive with higher
acceleration over longer distances.

4
1.3 DISADVANTAGES OF ELECTRIC VEHICLES:

1. Recharge points: Electric fuel stations are still in the development stages. Not a
lot of places you go to on a daily basis will have electric fuel stations for your
vehicle, meaning that if you’re on a long trip and run out of a charge, you may be
stuck where you are.

2. Electricity isn’t Free: Electric cars can also be a hassle on your energy bill if
you’re not considering the options carefully. If you haven’t done your research into
the electric car you want to purchase, then you may be making an unwise
investment. Sometimes electric cars require a huge charge in order to function
properly – which may reflect poorly on your electricity bill each month.

3. Short Driving Range and Speed: Electric cars are limited by range and speed.
Most of these cars have range about 50-100 miles and need to be recharged again.
You just can’t use them for long journeys as of now, although it is expected to
improve in future.

4. Longer Recharge Time: While it takes couple of minutes to fuel your gasoline
powered car, an electric car take about 4-6 hours to get fully charged. Therefore,
you need dedicated power stations as the time taken to recharge them is quite long.

5. Silence as Disadvantage: Silence can be a bit disadvantage as people like to

hear noise if they are coming from behind them. An electric car is however silent
and can lead to accidents in some cases.

5
6. Battery Replacement: Depending on the type and usage of battery, batteries of
almost all electric cars are required to be changed every 3-10 years.

1.4 PROBLEM IN ELECTRIC VEHICLES

The major drawbacks of the electric vehicles are the less range, longer
charging time and less charging points. Most of the electric vehicles can run upto
average range of about 80 – 100 miles if charged once. For instance, in a regular
IC engine vehicles, when you see you’re running out of fuel, you can go to your
nearest fuel station pump in fuel and be back on the road in a matter of minutes.
But in EV in the same scenario will take at least 3-4 hours if fast charger is
available ad if at all a charging station is available in close vicinity. You cannot go
500-1000 kms like you do in petrol or diesel cars in single full tank. So it is
necessary to increase the range of EVs.

1.5 SCOPE OF THE PROJECT:

The main aim of the project is to increase the range of the electric vehicle.
This can be done by partially charging the battery while driving the electric vehicle
using flywheel. Since freewheel mechanism is used, even after braking or slowing
down the vehicle in traffic, flywheel continues to rotate and partially charge the
battery. During recharging in charge points, recharging time is also reduced
because the battery is being charged partially already while driving.

6
 CHAPTER 2

PROJECT DESCRIPTION

2.1 CONSTRUCTION AND WORKING

Frame is the base on which all parts are mounted. There is a wheel shaft
which is mounted on the frame through bearing blocks. The vehicle's wheel shaft is
driven by an electric motor powered by a battery. It is done by chain drive. In
parallel to this wheel shaft an another shaft is placed on which the flywheel is
mounted. When the vehicle wheel shaft rotates it rotates the flywheel shaft which
is connected parallelly with the help of freewheel sprocket and chain. As the break
apply or wheel stops, here the flywheel takes a part still it rotates as its work to
save energy, we are utilizing this rotary energy of flywheel to generate electricity
through a generator/dynamo and then it is stored back to the battery.

7
2.2 PARTS

2.2.1 SHAFT

A shaft is a rotating machine element, usually circular in cross section, which is

used to transmit power from one part to another, or from a machine which
produces power to a machine which absorbs power. The various members such as
pulleys and gears are mounted on it.Shaft is a common and important machine
element. It is a rotating member, in general,has a circular cross-section and is used
to transmit power. The shaft may be hollow or solid. The shaft is supported on
bearings and it rotates a set of gears or pulleys for the purpose of power
transmission. The shaft is generally acted upon by bending moment, torsion and
axial force. Design of shaft primarily involves in determining stresses at critical
point in the shaft that is arising due to aforementioned loading. Other two similar
forms of a shaft are axle and spindle. Axle is a non-rotating member used for
supporting rotating wheels etc. and do not transmit any torque. Spindle is simply
defined as a short shaft. However, design method remains the same for axle and
spindle as that for a shaft.

8
2.2.2 CHAIN AND SPROCKETS

Chain drive is a way of transmitting mechanical power from one place to

another. It is often used to convey power to the wheels of a vehicle, particularly
bicycles and motorcycles. It is also used in a wide variety of machines besides
vehicles. Most often, the power is conveyed by a roller chain, known as the drive
chain or transmission chain passing over a sprocket gear, with the teeth of the gear
meshing with the holes in the links of the chain. The gear is turned, and this pulls
the chain putting mechanical force into the system. Sometimes the power is output
by simply rotating the chain, which can be used to lift or drag objects. In other
situations, a second gear is placed and the power is recovered by attaching shafts or
hubs to this gear. Though drive chains are often simple oval loops, they can also go
around corners by placing more than two gears along the chain; gears that do not
put power into the system or transmit it out are generally known as idler-wheels.
By varying the diameter of the input and output gears with respect to each other,
the gear ratio can be altered.

9
2.2.3 BEARING BLOCK

A bearing block or pillow block is used to provide support for a rotating

shaft with the help of compatible bearings & various accessories. Housing material
for a pillow block is typically made of cast iron or cast steel. A pillow block
usually refers to a housing with an included anti-friction bearing. A pillow block
refers to any mounted bearing wherein the mounted shaft is in a parallel plane to
the mounting surface, and perpendicular to the center line of the mounting holes, as
contrasted with various types of flange blocks or flange units. A pillow block may
contain a bearing with one of several types of rolling elements, including ball,
cylindrical roller, spherical roller, tapered roller, or metallic or synthetic bushing.
The type of rolling element defines the type of pillow block. These differ from
"plummer blocks" which are bearing housings supplied without any bearings and
are usually meant for higher load ratings and a separately installed bearing.

10
2.2.4 FLYWHEEL

A flywheel is an inertial energy-storage device. It absorbs mechanical

energy and serves as a reservoir, storing energy during the period when the supply
of energy is more than the requirement and releases it during the period when the
requirement of energy is more than the supply. The main function of a fly wheel is
to smoothen out variations in the speed of a shaft caused by torque fluctuations. If
the source of the driving torque or load torque is fluctuating in nature, then a
flywheel is usually called for. Many machines have load patterns that cause the
torque time function to vary over the cycle. Internal combustion engines with one
or two cylinders are a typical example. Piston compressors, punch presses, rock
crushers etc. are the other systems that have fly wheel. Flywheel absorbs
mechanical energy by increasing its angular velocity and delivers the stored energy
by decreasing its velocity .

11
2.2.5 FREEWHEEL

A freewheel or overrunning clutch is a device in a transmission that

disengages the driveshaft from the driven shaft when the driven shaft rotates faster
than the driveshaft. The simplest freewheel device consists of two saw-toothed,
spring-loaded discs pressing against each other with the toothed sides together,
somewhat like a ratchet. Rotating in one direction, the saw teeth of the drive disc
lock with the teeth of the driven disc, making it rotate at the same speed. If the
drive disc slows down or stops rotating, the teeth of the driven disc slip over the
drive disc teeth and continue rotating, producing a characteristic clicking sound
proportionate to the speed difference of the driven gear relative to that of the
(slower) driving gear.

12
 CHAPTER 3

DESIGN CALCULATIONS

3.1 COMPONENTS USED IN THE PROJECT

• Chain drive and sprocket

• Shaft 1
• Shaft 2
• Flywheel

3.2 CHAIN DRIVE 2:

P = 120 W
N1 = 2000 rpm
N2 = 2000 rpm
(i) Calculation of number of teeth
i = 2000/2000 = 1
Taking Z1 = 20
Z2 = i X Z1 = 1X 20 = 20
Z2 = 20

(II) Calculation of standard pitch

a = 30 to 50 p
Take a = 200 mm
Pmax = 200/30 = 6.67
Pmin = 200/50 = 4
So, standard pitch, p = 9.525 mm
13
(iii) Selection of chain
For pitch, p = 9.525 mm
Selecting simplex chain
So ISO/DIN is 06B-1, R957
Bearing area = 0.28 cm2
Weight per meter = 0.41 kgf
Bearing load min = 910 kgf

(iv) Breaking load

𝑸𝒗
N= kW
𝟏𝟎𝟐𝒏𝑲𝒔

V = Z1N1P/60 = (20X2000X9.525X10-3)/60 = 6.35 m/s

n = 14.8
Ks = K1 x K2 x K3 x K4 x K5 x K6
Load factor, K1,
Variable load = 1.25
Factor for distance regulation,
Fixed center distance = 1.25
Factor for center distance of sprocket, K3
ap = 30 to 50p
Factor of position of sprocket K4
Horizontal = 1
Lubrication factor, K5
Drop lubrication = 1

14
 Rating factor, K6
Double shift of 16 hours a day = 1.25

Ks = 1.25 x 1.25 x 1 x 1 x 1 x 1.25 = 1.953

0.12 = (Q x 6.35)/ (102 x 14.8 x 1.953)
Q = 55.714 kgf
Actual factor of safety
[n] = Q/∑P
∑P = Pt + Pc + Pa
Pt = 102 x 0.12/6.35 = 1.927 kgf
Pc = Wv2/g = 0.41 x (6.35)2/9.81 = 1.68 kgf
Pa = kWa = 6 x 0.41 x 200 = 492 kgf
∑P = 495.612 kgf
[n] = 910/492.612 = 1.836

Bearing stress
N = σAV/ (102 x Ks)
σ = (0.12 x 102 x 1.953)/(0.28 x 6.35)
σ = 13.444 kgf/cm2

Length of chain
Lp = 2ap + (Z1 + Z2)/2 + [(Z2-Z1)/2π]2/ap
ap = ao/P = 200/9.525 = 20.997
Lp = 2(15.74) + (20 + 20)/2 + [(20-20)/2π]2/15.74
= 61.98 mm ~ 62 mm
Final centre distance
a = (e + √ (e2 – 8m))/4

15
 e = Lp – (Z1 + Z2)/2 = 62 – (20 + 20)/2
e = 42
m = 3.647
a = [ 42 + √ (422 – 8(3.647))] x 9.525/4
= 199.02 ~ 200 mm
Length of chain L = Lp.P
= 62 x 9.525
= 590.35 mm

Pitch diameter of sprockets

Sprocket 1
d1 = P/sin(180/Z1) = 9.525/ sin (180/20) = 60.8 mm ~ 60mm
sprocket 2
d2 = P/sin(180/Z2) = 9.525/sin (180/20) = 60.8 ~ 60 mm

3.3 CHAIN DRIVE 1& 3:

P = 120 W
N1 = 2000 rpm
N2 = 2000 rpm
(i) Calculation of number of teeth
i = 2000/2000 = 1
Taking Z1 = 20
Z2 = i X Z1 = 1X 20 = 20
Z2 = 20

(II) Calculation of standard pitch

a = 30 to 50 p
16
 Take a = 150 mm
Pmax = 150/30 = 5
Pmin = 150/50 = 3
So, standard pitch, p = 9.525 mm

(iii) Selection of chain

For pitch, p = 9.525 mm
Selecting simplex chain
So ISO/DIN is 06B-1, R957
Bearing area = 0.28 cm2
Weight per meter = 0.41 kgf
Bearing load min = 910 kgf

(iv) Breaking load

𝑸𝒗
N= kW
𝟏𝟎𝟐𝒏𝑲𝒔

V = Z1N1P/60 = (20X2000X9.525X10-3)/60 = 6.35 m/s

n = 14.8
Ks = K1 x K2 x K3 x K4 x K5 x K6
Load factor, K1,
Variable load = 1.25
Factor for distance regulation,
Fixed center distance = 1.25
Factor for center distance of sprocket, K3
ap = 30 to 50p
Factor of position of sprocket K4
Horizontal = 1

17
 Lubrication factor, K5
Drop lubrication = 1
Rating factor, K6
Double shift of 16 hours a day = 1.25

Ks = 1.25 x 1.25 x 1 x 1 x 1 x 1.25 = 1.953

0.12 = (Q x 6.35)/ (102 x 14.8 x 1.953)
Q = 55.714 kgf

Actual factor of safety

[n] = Q/∑P
∑P = Pt + Pc + Pa
Pt = 102 x 0.12/6.35 = 1.927 kgf
Pc = Wv2/g = 0.41 x (6.35)2/9.81 = 1.68 kgf
Pa = kWa = 6 x 0.41 x 150 = 369 kgf
∑P = 372.612 kgf
[n] = 910/372.61 = 2.4422

Bearing stress
N = σAV/ (102 x Ks)
σ = (0.12 x 102 x 1.953)/(0.28 x 6.35)
σ = 13.444 kgf/cm2

Length of chain
Lp = 2ap + (Z1 + Z2)/2 + [(Z2-Z1)/2π]2/ap
ap = ao/P = 150/9.525 = 15.74
Lp = 2(15.74) + (20 + 20)/2 + [(20-20)/2π]2/15.74

18
 = 51.48 mm ~ 52 mm
Final centre distance
a = (e + √ (e2 – 8m))/4
e = Lp – (Z1 + Z2)/2 = 52 – (20 + 20)/2
e = 32
m = 3.647
a = [ 32 + √ (322 – 8(3.647))] x 9.525/4
= 148.81 ~ 150 mm
Length of chain L = Lp.P
= 32 x 9.525
= 490.347 mm

Pitch diameter of sprockets

Sprocket 1
d1 = P/sin(180/Z1) = 9.525/ sin (180/20) = 60.8 mm ~ 60mm
sprocket 2
d2 = P/sin(180/Z2) = 9.525/sin (180/20) = 60.8 ~ 60 mm

TORQUE CALCULATION:
P = 2πNT/60
T = P x 60/ 2πN
= 120 x 60 / (2π x 1000)
= 1.145 Nm = 1.145 x 103 Nmm

19
3.4 SHAFT 1

P=120W
P=2πNT/60
T= (P ×60)/(2πN)
= 120×60/(2×π×1000)
T = 1.145 Nm.

For Chain drive:

T = T1× RC
T1=T/RC = 1.145/0.030 = 38.166 N
WCH= 38.166N
WCV= 10 N

T = T3× RD
T3=T/RD = 1.145/0.030 = 38.166 N
WDH= 38.166N
WDV= 10 N
Vertical Loading:
Reactions at Bearings
RAV+RBV= 20 N
Moment at A,
RBV ×0.5 = (10×0.15 + (10 × 0.35)
RBV = 10 N
RAV = 20 - 10 = 10 N

20
Bending moment at A & B,
MAV = MBV = 0
B.M at C ➔ MCV = RAV × 0.15 = 10 × 0.15 = 1.5 N
B.M at D ➔ MDV = RBV × 0.15 = 10 × 0.15 = 1.5 N
Horizontal Bending:
Reactions at bearing,
RAH + 38.166 = RBH + 38.166
RAH = RAH
Moment at A,

(RBH × 0.5) + (38.166 × 0.15) = (38.166 × 0.35)

RBH = 15.2664 N

RAH = 15.2664 N

B.M at A&B ➔ MAH = MBH = 0

B.M at C ➔ MCH = RAH × 0.15 = 15.2664 × 0.15 = 2.289 Nm

B.M at D➔ MDH = RBH × 0.15 = 15.2664 × 0.15 = 2.289Nm

Resultant B.M at C & D

MC =√(MCV)2+(MCH)2 = √ (1.5)2+(2.289)2

MC = 2.7366 Nm

MD = √(MDV)2+(MDH)2 = √(1.5)2+(2.289)2

MD = 2.7366 Nm

Maximum bending moment

21
M= MC = 2.7366 Nm

Material used is C45. Its Yield Strength is 380 N/mm2

Syt = 380 ×106 N/m2

Taking Factor of Safety as 2

FOS = Syt/σ

σ = Syt/FOS = 380 × 106/2 = 190 × 106 /m2

For solid shaft, Maximum shear stress is

Τmax = [T× d] /[(π/32) ×(d4)]
Τmax = [32× T]/[π × d3]

M/I = σ/y

2.1366/[(π/64) ×(d4)] = (190 × 106)/(d/2)

d = 0.00527 m = 5.27 mm
τmax = (32 × 1.145)/ (π × 0.00843)
= 76.68 MPa.
Take Km =1.5, Kt = 1.5
Equivalent twisting moment,

Te = √ [(Km × M)2+(Kt × T)2]

= √ [(1.5 × 2.2736)2+(1.5 × 1.145)2]

= 3.81845 Nm.

22
Te = (π/16) × τmax × [d3]

3.81845 = (π/16) × 10.09 × 106 × [d3]

d = 0.00624m = 6.24 mm

Equivalent bending moment,

Me= (1/2) × [(Km × M) +(Tc)]

= (1/2) × [(1.5 × 2.2736) + 3.81845]

Me 3.6144 Nm.

Me = (π/32) × σ × [d4]

3.6144 = (π/32) × 190× 106 × [d4]

d= 0.0106m = 10.6mm ~ 12mm

Taking Larger diameter value

d = 12mm

3.5 SHAFT 2

For chain drive:

Flywheel [D]:
WDV=50N
WDH=0
P=120W

23
P=2πNT/60
T= (P ×60)/(2πN)
= 120×60/(2×π×1000)
T = 1.145 Nm.

For Chain drive:

T = T1× RC
T1=T/RC = 1.145/0.030 = 38.166 N
WCH= 38.166N
WCV= 10 N

T = T3× RD
T3=T/RD = 1.145/0.030 = 38.166 N
WEH= 38.166N
WEV= 10 N
Flywheel [D]:
WDV=60N
WDH=0

Vertical Loading:
Reactions at Bearings
RAV+RBV= 80 N
Moment at A,
RBV ×0.5 = (10×0.15 + (10 × 0.35) + (60 × 0.25)
RBV = 40 N
RAV = 80 - 40 = 40 N

24
Bending moment at A & B,
MAV = MBV = 0
B.M at C ➔ MCV = RAV × 0.15 = 40 × 0.15 = 6 N
B.M at D ➔ MDV = RAV × 0.25 = 40 × 0.25 = 10 N
B.M at E ➔ MEV = RBV × 0.25 = 40 × 0.15 = 6 N
Horizontal Bending:
Reactions at bearing,
RAH + 38.166 = RBH + 38.166
RAH = RAH
Moment at A,

(RBH × 0.5) + (38.166 × 0.15) = (38.166 × 0.35)

RBH = 15.2664

RAH = 15.2664 N

B.M at A&B ➔ MAH = MBH = 0

B.M at C ➔ MCH = RAH × 0.15 = 15.2664 × 0.15 = 2.289 Nm

B.M at D➔ MDH = RBH × 0.15 = 15.2664 × 0.15 = 2.289Nm

Resultant B.M at C & D

MC =√(MCV)2+(MCH)2 = √ (6)2+(2.289)2

MC 6.421 Nm

ME = √(MDV)2+(MDH)2 = √(6)2+(2.289)2

ME = 6.421 Nm

25
MD = 10 Nm

Maximum bending moment

M= MD = 10 Nm

Material used is C45. Its Yield Strength is 380 N/mm2

Syt = 380 ×106 N/m2

Taking Factor of Safety as 2

FOS = Syt/σ

σ = Syt/FOS = 380 × 106/2 = 190 × 106 /m2

For solid shaft, Maximum shear stress is

Τmax = [T× d] /[(π/32) ×(d4)]
Τmax = [32× T]/[π × d3]

M/I = σ/y

10/[(π/64) ×(d4)] = (190 × 106)/(d/2)

d = 0.01023 m 10.23 mm
τmax = (32 × 1.145)/ (π × 0.010233)
= 44.47 MPa.
Take Km =1.5, Kt = 1.5
Equivalent twisting moment,

Te = √ [(Km × M)2+(Kt × T)2]

26
 = √ [(1.5 × 10)2+(1.5 × 1.145)2]

= 15.09Nm.

Te = (π/16) × τmax × [d3]

15.09 = (π/16) × 10.09 × 106 [d3]

d = 0.01189m = 11.89 mm ~ 12mm

Equivalent bending moment,

Me= (1/2) × [(Km × M) +(Te)]

= (1/2) × [(1.5 × 10) + 15.09]

Me =15.045 Nm.

Me = (π/32) × σ × [d4]

15.045 = (π/32) × 190× 106 × [d4]

d= 0.0093m = 9.3mm

Taking Larger diameter value

d = 12mm

3.6 - FLYWHEEL

Type: Solid disc flywheel

Material used: Mild steel (ρ = 7850 kg/m3)
Taking Mass of flywheel = 6 kg
Assume b = D/6

27
 Where b = Thickness of flywheel
D = Diameter of flywheel
We know that, Density = mass/volume
ρ = 6/(πR2b)
R2× (1/6) ×R×2 = 6/(π×7850)
R3 = (6×6)/(π×7850×2)
R = 0.090m
R = 90mm
Diameter, D = 180mm
Thickness, b = D/6 = 180/6 = 30mm
Radius of gyration
k = R/√2 = 90/√2 = 63.63mm
Moment of inertia:
I = mk2
= 6×63.632
I = 24292.66 kg/mm2
Angular velocity:
ω= 2πN/60
= 2×π×2000/60
ω = 209.43 rad/s
Kinematic Energy stored:
E = Iω2/2
= (24292.66×10-6×209.43)/2
E = 2.543 J (or) Nm.

28
 CHAPTER 4
CAD MODELS

4.1 – FRONT VIEW

4.2 – TOP VIEW

29
4.3 – SIDE VIEW

4.4 – ISOMETRIC VIEW

30
 CHAPTER 5

MANUFACTURING PROCESS

5.1 ARC WELDING

Arc welding is a welding process that is used to join metal to metal by using
electricity to create enough heat to melt metal, and the melted metals when cool
result in a binding of the metals. It is a type of welding that uses a welding power
supply to create an electric arc between a metal stick ("electrode") and the base
material to melt the metals at the point of contact. Arc welders can use either direct
(DC) or alternating (AC) current, and consumable or non-consumable electrodes.
The welding area is usually protected by some type of shielding gas, vapor, or slag.
Arc welding processes may be manual, semi-automatic, or fully automated. First
developed in the late part of the 19th century, arc welding became commercially
important in shipbuilding during the Second World War. Today it remains an
important process for the fabrication of steel structures and vehicles.Here we used
manual metal arc welding (MMAW) or stick welding. An electric current is used
to strike an arc between the base material and a consumable electrode rod or stick.
The electrode rod is made of a material that is compatible with the base material
being welded and is covered with a flux that gives off vapors that serve as a
shielding gas and provide a layer of slag, both of which protect the weld area from
atmospheric contamination. The electrode core itself acts as filler material, making
a separate filler unnecessary. The process is very versatile, requiring little operator
training and inexpensive equipment. However, weld times are rather slow, since
the consumable electrodes must be frequently replaced and because slag, the
residue from the flux, must be chipped away after welding.Furthermore, the
process is generally limited to welding ferrous materials, though specialty

31
electrodes have made possible the welding of cast iron, nickel, aluminium, copper
and other metals. The versatility of the method makes it popular in a number of
applications including repair work and construction.

32
5.2 TURNING:

Turning is a form of machining, a material removal process, which is used to

create rotational parts by cutting away unwanted material. The turning process
requires a turning machine or lathe, workpiece, fixture, and cutting tool. The
workpiece is a piece of pre-shaped material that is secured to the fixture, which
itself is attached to the turning machine, and allowed to rotate at high speeds. The
cutter is typically a single-point cutting tool that is also secured in the machine,
although some operations make use of multi-point tools. The cutting tool feeds into
the rotating workpiece and cuts away material in the form of small chips to create
the desired shape.

Turning is used to produce rotational, typically axi-symmetric, parts that have

many features, such as holes, grooves, threads, tapers, various diameter steps, and
even contoured surfaces. Parts that are fabricated completely through turning often
include components that are used in limited quantities, perhaps for prototypes, such
as custom designed shafts and fasteners. Turning is also commonly used as a
secondary process to add or refine features on parts that were manufactured using a
different process. Due to the high tolerances and surface finishes that turning can
offer, it is ideal for adding precision rotational features to a part whose basic shape
has already been formed.

33
5.3 MILLING:

Milling is the process of machining using rotary cutters to remove material by

advancing a cutter into a workpiece. This may be done varying direction on one or
several axes, cutter head speed, and pressure. Milling covers a wide variety of
different operations and machines, on scales from small individual parts to large,
heavy-duty gang milling operations. It is one of the most commonly used processes
for machining custom parts to precise tolerances.
Milling can be done with a wide range of machine tools. The original class of
machine tools for milling was the milling machine (often called a mill). After the
advent of Computer Numerical control (CNC) in the 1960s, milling machines
evolved into machining centers: milling machines augmented by automatic tool
changers, tool magazines or carousels, CNC capability, coolant systems, and
enclosures. Milling centers are generally classified as vertical machining centers
(VMCs) or horizontal machining centers (HMCs).
The integration of milling into turning environments, and vice versa, began
with live tooling for lathes and the occasional use of mills for turning operations.
This led to a new class of machine tools, multitasking machines (MTMs), which
are purpose-built to facilitate milling and turning within the same work envelope.

5.4 THREADING:
Threading is the process of creating a screw threads. More screw threads are
produced each year than any other machine elements. There are many methods of
generating threads, including subtractive methods (many kinds of thread cutting
and grinding, as detailed below); deformative or transformative methods (rolling
and forming; molding and casting); additive methods (such as 3D printing); or
combinations.

34
There are various methods for generating screw threads. The method chosen for
any one application is chosen based on constraints—time, money, degree of
precision needed (or not needed), what equipment is already available, what
equipment purchases could be justified based on resulting unit price of the
threaded part (which depends on how many parts are planned), etc.

In general, certain thread-generating processes tend to fall along certain portions of

the spectrum from toolroom-made parts to mass-produced parts, although there can
be considerable overlap. For example, thread lapping following thread grinding
would fall only on the extreme toolroom end of the spectrum, while thread rolling
is a large and diverse area of practice that is used for everything from micro
lathe leadscrews (somewhat pricey and very precise) to the cheapest deck screws
(very affordable and with precision to spare).
Threads of metal fasteners are usually created on a thread rolling machine. They
may also be cut with a lathe, tap or die. Rolled threads are stronger than cut
threads, with increases of 10% to 20% in tensile strength and possibly more in
fatigue resistance and wear resistance.

35
 CHAPTER 6

CONCLUSION

All the components were fabricated and assembled. The assembled system was run
using a battery checked for energy generation. The kinetic energy stored in the
flywheel was efficiently converted into electrical energy through generator. The
device was able to achieve the desired output.

36
 CHAPTER 7

COST ESTIMATION

COMPONENTS COST
FRAME 1500
SHAFT 1200
DC MOTOR 3000
DC GENERATOR 1500
CHAIN SPROCKET 600
CONNECTING CHAIN 450
BEARING 400
12V BATTERY 800
WHEEL 600
BEARING HOUSING 1000
FLYWHEEL 600

37
 CHAPTER 8

REFERENCE

KHURMI R S, “THEORY OF MACHINES”, 14th ed.; S. Chand & Co. Ltd., New
Dehli 2005.

38