Design and Analysis of a Euro-7 13-Litre Heavy Duty Engine Flywheel Housing under Static and Vibration Loads

The forthcoming Euro-7 emission framework has redefined performance and durability standards for commercial diesel engines, compelling manufacturers to enhance drivetrain structures without compromising on mass efficiency or NVH (Noise, Vibration, and Harshness) characteristics. This study presents the design and finite-element analysis of a flywheel housing developed for a 13-litre Euro-7-compliant heavy-duty diesel engine. A parametric 3D model was constructed in CATIA V5 and evaluated in ANSYS Workbench 2024 R2 for combined torque, clutch thrust, and gearbox overhung loads. Modal and harmonic response analyses were employed to verify frequency separation from engine firing orders and to assess the damping potential of compacted graphite iron (GJV-450). The optimised design achieved a 17 percent weight reduction, a minimum factor of safety of 1.75, and a first-mode frequency of 173 Hz, well above the sixth firing order (≈ 120 Hz at 2400 rpm). The results affirm that a well-ribbed CGI flywheel housing satisfies Euro-7 durability and NVH targets while remaining castable and lightweight.