Machine Design II

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

Flywheel

flywheel

energy
when
it

is

and
the

during

an

inertial

serves

supply
the

as

of

energy-storage

energy

period

when

device.

reservoir,

storing

is

than

more

the

absorbs

energy

the

requirement

It

of

during

requirement
energy

is

mechanical
the

and

more

period
releases

than

the

supply.

Flywheels-Function need and Operation

The main function of a fly wheel is to smoothen out variations in the
speed

of

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

torque

time

engines

for.

Many

function

with

compressors,

one
punch

to
or

machines
vary
two

presses,

have

over

the

cylinders
rock

load

patterns

cycle.

are

crushers

etc.

that

cause

Internal
typical
are

combustion

example.

the

the

Piston

other

systems

its

angular

that have fly wheel.

Flywheel

absorbs

mechanical

energy

by

increasing

velocity and delivers the stored energy by decreasing its velocity

1 CYCLE

T2
Tm
T1

C D

max
min

Figure 3.3.1

Indian Institute of Technology Madras

Machine Design II

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

Design Approach
There are two stages to the design of a flywheel.
First,

the

smoothening

amount
must

of

be

energy

found

required

and

the

for

(mass)

the

desired

moment

of

degree

of

inertia

needed

caters

the

required

and

safe

to absorb that energy determined.

Then

flywheel

moment

of

geometry

inertia

in

must

be

reasonably

defined
sized

that

package

is

against

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

cycle

is

called

the

dividing

it

speed

fluctuation and is equal to max- min

Fl = max min
We

can

normalize

this

to

dimensionless

ratio

by

by

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 =

Indian Institute of Technology Madras

max min

the

Machine Design II

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

Where
shaft

is

speed

nominal

angular

desired.

This

velocity,

and

coefficient

is

ave
a

the

design

average
parameter

or

mean
to

be

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

machinery

set

and

as

to

value

high

as

between
0.20

0.01

for

to

0.05

applications

for

precision

like

crusher

entire

rotating

hammering machinery.

Design Equation
The kinetic energy Ek in a rotating system
=

( )

1
I 2
2

Hence the change in kinetic energy of a system can be given as,

EK =

Im 2max 2min
2

E K = E 2 E1
avg =

( max + min )
2

1
I 2avg
2 s
E 2 E1 = Cf I2
Ek
Is =
2
Cf avg

EK =

Thus
system

the
in

mass

moment

order

to

obtain

determined using the relation

Indian Institute of Technology Madras

of

inertia
selected

)( Cf avg )

Im

needed

coefficient

in
of

the
speed

fluctuation

is

Machine Design II

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

EK =
Is =
The
Im

above

equation

corresponding

can

to

the

1
I 2avg
2 s
Ek

)( Cf avg )

2
Cf avg

be

used

known

to

obtain

appropriate

energy

change

energy

Ek

Ek

for

flywheel
a

specific

inertia
value

coefficient of speed fluctuation Cf,

Torque Variation and Energy

The

required

change

in

kinetic

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

mechanical

punching

press without a fly wheel in shown in the figure.

In

the

initially
during

absence
and

can

fly

intermedialty

punching

fluctuation

of

and
be

wheel
and

stripping

noted.

surplus

or

positive

enery

absorbtion

operations.

large

out

the

To

smoothen

enregy
or

is

avalible

negative

energy

magitidue
speed

of

speed

fluctuation

fly

wheel is to be added and the fly wheel energy needed is computed as

illustrated below

Indian Institute of Technology Madras

Machine Design II

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

Torque
Area
+20 073

34 200

Area
+15 388
D

rms

Average

7 020
0
Shaft angle
time t

max

min

Area
-26 105

-34 200

Area
-9 202

360

Figure 3.3.2
Accumulation of Energy pulses under a Torque- Time curve
From

Area= E

Accumulated sum =E

Min & max

A to B

+20 073

+20 073

B to C

-26 105

-6 032

C to D

+15 388

D to A

-9 202

min

@B

max

@C

+9 356
+154
Total Energy= E @min- E@min
=(-6 032)-(+20 073)= 26 105 Nmm2

Figure 3.3.3

Indian Institute of Technology Madras

Machine Design II

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

Torque Time Relation with Flywheel

Torque
Cf =0.05

8730

Average

7020

Time t

Shaft angle

360
Figure 3.3.4

Geometry of Flywheel
The geometry of a flywheel may be as simple as a cylindrical disc of
solid

material,

wheels

with

wheels

are

to

may

hub

solid

requirements
changes

or

discs

and
disc

and

be

of

rim

connected

of

size
of

central

hollow
of

circular

the
hub

and to hollow wheels with multiple arms.

Indian Institute of Technology Madras

spoked

and

construction
by

spokes

cross

flywheel
peripheral

or

section.

increases
rim

like

conventional

arms
As

Small
the

the

connected

fly

energy

geometry
by

webs

Machine Design II

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

D
D0

do

Figure 3.3.5

D0

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

since the mass moment of inertia is proportional to mr2

Indian Institute of Technology Madras

contributes

much

more

Machine Design II

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

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=

= ro2 ri2 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

upon

its

similar

to

assuming inside to out side radius ratio and radius to thickness ratio.

Stresses in Flywheel
Flywheel

being

rotating

distributed

mass

and

attempts

disc,
to

centrifugal
pull

it

apart.

stresses
Its

acts

effect

is

those caused by an internally pressurized cylinder

t =

2 3 + v 2 2 1 + 3v 2

r
ri + ro
g 8
3+ v

r =

2 3 + v 2 2 ri2 ro2
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

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:

Indian Institute of Technology Madras

Machine Design II

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

Radius

t
Tang. stress

Radial stress
r

Radius
The

point

of

most

maximum.

What

stress

at

that

fragments

can

Since

forces

speed

the
also,

interest

causes
point

failure

from

explode

the

inside

in

where

the

of

flywheel

for

where

is

are

the

typically

originated

extremely

stresses

checking

radius

fracture

resulting

causing

instead

is

and

stress
the

is

tangential

upon

fracture

dangerous

consequences,

function

the

stresses,

the

of

maximum

rotational
speed

at

which the stresses reach the critical value can be determined and safe
operating
factor.

speed

Generally

can
some

be

calculated

means

to

or

specified

preclude

its

speed is desirable, for example like a governor.

Consequently

F.O.S (N) = Nos =

yield

Indian Institute of Technology Madras

based
operation

on

beyond

safety
this

Machine Design II

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

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

Indian Institute of Technology Madras

Machine Design II

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

600 825 * 0.075 ( 21.88 * 6 * * 0.15 )

538.125Nm
Ek
I=

Cf avg

538.125

960

0.02 2 *

60

= 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=

2 .6622
= 0.0445
59.805

or
45 mm

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
t =

= 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

= 164.65

Indian Institute of Technology Madras

16544
32