Flywheels-Function Need and Operation

Machine Design II
Prof. K.Gopinath & Prof. M.M.Mayuram
Flywheel
flywheel and the
is
an
inertial as a
energy-storage reservoir, is the more
device.
It
absorbs during
mechanical the period releases than the
energy when it
serves of
storing than the of
energy
supply the
energy when
requirement energy is
and
during
period
requirement
more
supply.
Flywheels-Function need and Operation

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 torque engines called time with for. Many to or machines vary two have the are load patterns that cause the
function one punch
over
cycle. a etc.
Internal typical are the
combustion Piston systems
cylinders rock
example. other
compressors,
presses,
crushers
that have fly wheel. Flywheel absorbs mechanical energy by increasing its angular
velocity and delivers the stored energy by decreasing its velocity

T 2 T m T 1 A max min C D B C D
1 CYCLE
Figure 3.3.1
Indian Institute of Technology Madras
Machine Design II
Design Approach
There are two stages to the design of a flywheel. First, the amount must be of energy and required the for the moment desired of degree of
smoothening
found
(mass)
inertia
needed
to absorb that energy determined. Then moment flywheel of geometry in a must be defined sized that caters and is the safe required against
inertia
reasonably
package
failure at the designed speeds of operation.
Design Parameters
Flywheel inertia (size) needed directly depends upon the acceptable
changes in the speed.
Speed fluctuation
The change in the shaft speed during a cycle is called the speed
fluctuation and is equal to max- min
Fl = max min
We can normalize this to a dimensionless ratio by dividing it by the
average or nominal shaft speed (ave) .

Cf = max min
Where avg is nominal angular velocity
Co-efficient of speed fluctuation
The above ratio is termed as coefficient of speed fluctuation Cf and it is defined as

Cf = max min
Machine Design II
Where shaft
is
nominal desired.
angular This
velocity,
and is a
ave
the
average parameter
or
mean to be
speed
coefficient
design
chosen by the designer. The smaller this chosen value, the larger the flywheel have to be and more the cost and weight to be added to the system. However the
smaller this value more smoother the operation of the device It is typically and set as to a high value as between 0.20 for 0.01 to 0.05 for like precision crusher
machinery
applications
hammering machinery.
Design Equation
The kinetic energy Ek in a rotating system =
1 I 2 2
( )
1 Im 2max 2 min 2
Hence the change in kinetic energy of a system can be given as,

EK =
E K = E 2 E1 avg =
( max + min )
2
EK =
1 I 2avg 2 s E 2 E1 = Cf I2 Ek Is = 2 Cf avg
)( Cf avg )
Thus system
the in
mass order
moment to
of
inertia selected
Im
needed
in of
the speed
entire
rotating is
obtain
coefficient
fluctuation
determined using the relation
Machine Design II
EK = Is =
The Im above equation to can the be
1 I 2avg 2 s Ek
)( Cf avg )
obtain change appropriate Ek for a flywheel specific inertia value
2 Cf avg
used to
corresponding
known
energy
coefficient of speed fluctuation Cf,
Torque Variation and Energy

The required change in kinetic energy Ek is obtained from the known
torque time relation or curve by integrating it for one cycle.
@ max Tl Tavg d = E K @ min
Computing the kinetic energy Ek needed is illustrated in the following example
Torque Time Relation without Flywheel A typical torque time relation for example of a mechanical punching
press without a fly wheel in shown in the figure. In the absence and of fly wheel and surplus enery operations. To smoothen or positive or enregy is avalible energy speed fly
initially during
intermedialty and be
absorbtion A out large the
negative of
punching can
stripping
magitidue speed
fluctuation
noted.
fluctuation
wheel is to be added and the fly wheel energy needed is computed as illustrated below
Machine Design II
Torque Area +20 073 C rms Area +15 388 D B A
34 200 A
7 020 0
Average
min
max
Shaft angle time t
-34 200 0
Area -26 105
Area -9 202 360
Figure 3.3.2
Accumulation of Energy pulses under a Torque- Time curve From A to B B to C C to D D to A Area= E +20 073 -26 105 +15 388 -9 202 Accumulated sum =E +20 073 -6 032 +9 356 +154 Total Energy= E @min- E@min =(-6 032)-(+20 073)= 26 105 Nmm2 Min & max
min
@B @C
max
Figure 3.3.3
Machine Design II
Torque Time Relation with Flywheel
Torque 8730 7020 Cf =0.05 Average
0 360
Figure 3.3.4
Time t Shaft angle
Geometry of Flywheel
The geometry of a flywheel may be as simple as a cylindrical disc of solid wheels wheels material, with are a solid and disc of or hub may and of be rim of spoked by construction spokes or like arms As the conventional Small the fly
connected circular
discs size
hollow of the hub
cross
section.
energy
requirements changes to
flywheel peripheral
increases rim
geometry by webs
central
and
connected
and to hollow wheels with multiple arms.
Machine Design II
D d D0 D do
Figure 3.3.5
D0 D
d
a
Arm Type Flywheel

Figure 3.3.6
The
latter
arrangement
is
more
efficient
of
material
especially
for
large flywheels, as it concentrates the bulk of its mass in the rim which is at the largest radius. Mass at largest radius contributes much more
since the mass moment of inertia is proportional to mr2
Machine Design II
For a solid disc geometry with inside radius ri and out side radius ro, the mass moment of inertia I is
Im = mk 2 = m 2 2 (r + r ) 2 o i
The mass of a hollow circular disc of constant thickness t is
m=
W 2 2 = ro ri t g g
Combing the two equations we can write
Im =
4 4 r r t 2g o i
Where is materials weight density The equation is better solved by geometric proportions i.e by
assuming inside to out side radius ratio and radius to thickness ratio.
Stresses in Flywheel
Flywheel distributed being mass a and rotating attempts disc, to centrifugal pull it apart. stresses Its acts is upon similar its to
effect
those caused by an internally pressurized cylinder
t = r =
2 3 + v 2 2 1 + 3v 2 r ri + ro g 8 3+ v
2 2 3 + v 2 2 ri2 ro 2 + r r r o i g 8 r2
= material weight density, = angular velocity in rad/sec. = Poissons ratio, is the radius to a point of interest, ri and ro are inside and outside radii of the solid disc flywheel. Analogous to a thick cylinder under internal pressure the tangential
and radial stress in a solid disc flywheel as a function of its radius r is given by:
Machine Design II
Radius
t Tang. stress
Radial stress r
Radius
The point of most interest is the in inside a radius is where the stress the upon is a
maximum. stress at
What that can forces
causes point
failure
flywheel
typically and
tangential fracture
from
where resulting the
fracture
originated
fragments Since speed the also,
explode causing of
extremely are a
dangerous function the of
consequences, the rotational speed at
stresses for
instead
checking
stresses,
maximum
which the stresses reach the critical value can be determined and safe operating factor. speed can some be calculated to or specified its based operation on a safety this
Generally
means
preclude
beyond
speed is desirable, for example like a governor. Consequently
F.O.S (N) = Nos = yield
Machine Design II
WORKED OUT EXAMPLE 1

A 2.2 kw, 960 rpm motor powers the cam driven ram of a press through a gearing of 6:1 ratio. The rated capacity of the press is 20 kN and has a stroke of 200 mm. Assuming that the cam driven ram is capable of delivering the rated load at a constant velocity during the last 15% of a constant velocity stroke. Design a suitable flywheel that can maintain a coefficient of Speed fluctuation of 0.02. Assume that the maximum diameter of the flywheel is not to exceed 0.6m.
Work done by the press=
U = 20 *103 * 0.2 * 0.15 = 600Nm
Energy absorbed= work done= 600 Nm Mean torque on the shaft:
2.2 *103 = 21.88Nm 960 2** 60

Energy supplied= work don per cycle
= 2 * 21.88 * 6 = 825 Nm Thus the mechanical efficiency of the system is = 600 = = 0.727 = 72% 825
There fore the fluctuation in energy is =
E k = Energy absorbed - Energy supplied
Machine Design II
600 825 * 0.075 ( 21.88 * 6 * * 0.15 ) 538.125Nm Ek I= Cf avg 538.125 960 0.02 2 * 60 2
= 2.6622 kg m2
r 2 2 . r ri .t 2 g o r Assuming i = 0.8 ro 78500 2.6622 = * 0.304 0.244 t 2 9.86 = 59.805t I=
t= or
2 .6622 = 0.0445 59.805
45 mm
t = t =
r 2 3 + 2 2 1 + 3 2 r r + ro g 3+ 8 i
78500 2 3 + 0.3 2 2 1.9 * 0.242 . 0.24 + 0.3 9.81 3.3 8 960 2 t = 0.543* 2 * 60 = 55667N / m 2 = 0.556MPa
or if t = 150 MPa 150 *106 = 7961.42 ( 0.4125 )( 0.0376 )( 0.090 )( 0.0331) = 0.5482 = 16544 rad / sec2
N OS = yield = 16544 32
= 164.65

Flywheels-Function Need and Operation

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Flywheels-Function Need and Operation

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Machine Design II

Prof. K.Gopinath & Prof. M.M.Mayuram

flywheel and the

energy-storage reservoir, is the more

mechanical the period releases than the

storing than the of