FLYWHEELS

Flywheel - an energy reservoir in a mechanical system. It stores rotational

kinetic energy and distributes it when needed by the system thus, reducing
speed fluctuation.
*Rotational Kinetic energy of a body
1 2
K rot ' l= I M I M =[ I M +mr 2 ]
2

Im = mass moment of inertia based on the axis of the rotation

(body).

= angular speed

For a solid cylinder

of mass m &
radius r
1
I M= m k2
2

For any rotating body in general

2
I M =mk

Where:
k = radius of gyration based on the axis of rotation
2 2 2
(usually, K o : where) k 0 =k x + ky

*Rimmed Flywheel
 Dm = mean diameter in rim

t trim = thickness of rim

brim = width of rim

Note:
Rimmed flywheel has a maximized radius of gyration since its mass is
concentrated on its rim.
Kinetic Energy available, KE1;
1 1
K E1= I m 1 = (m k 2 ) 2
2
2 2

=k

Dm
Since k= [an estimation for a rimmed flywheel]
2

1
K E1= m v 2 or
2

1 f
K E1= V 2
2 g 1

V1 = mass linear speed based on the mean diameter of the rim.

Flywheel Weight, Wf;
W f =W rim +W H A
Weight of hub &
arms

Weight of rim

Note:
Dm
To support the estimation formula, K the weight of the hub &
2

arms is usually taken to be only about 5% to 10% of the weight of the

rim.
 KE
Change of Kinetic Energy of the Flywheel, ;
1
KE= I m ( 12 22 ) , in general
2

Dm
K
2
For a rimmed flywheel, with
1 f
KE=
2 g
( V 12 V 22)

V1 = max. Linear sped based on the mean diameter of rim

V 1= Dm n1

V2 = min. linear speed

V 2= Dm n2

Where:
Subscripts 1 & 2 denote the conditions before & after discharging

KE
, respectively.
Also,
2 gKE
f 2 2
v1 v2
reqd flywheel weight
Introducing the coefficient of fluctuation, Cf ;
change of speeds V 1 V 2 v
Cf= = =
ave . speed v v

Where: V=
V 1V 2
v [ ]
; V 2=V 1
2C f
2+C f

(V 1V 2 )
2 g KE (V +V )
f = 1 2
(V 1+V 2 )(V 1V 2 ) C
 g KE KE
f = wf
C f v2 (fly wheel reqd in terms of , Cf &

average speed (v)

Note:

Recommended vales of C f for some machines are shown

in Table 20.
KE
The change in kinetic energy in a flywheel is usually

KE
due to a certain process (e.g. in a punch press, this is
usually the energy reqd in punching one hole, the flywheel
is usually assumed to supply this energy requirement)

KE process

*Energy for Shearing a Plate

(a) Punching one hole from a plate

Estimated relationship of F vs tp
1
E punching Ft p
2

Where:
F
Ss = S us
As
Ultimate shearing stress of
plate
Shear area of one
hole

A s = dh t p
 Thickness of
plate
Hole
diameter

F=Sus ( A s)

Force necessary for

punching one whole

(b) Shearing a Plate

(b) Shearing a Plate

A s =L(t p )

Plate thickness

Lengt

Also,
1
Eshearing= t
2 F p

*Estimation for flywheel weight , W f ;

W f =W rim +W H A
 The rim weight is generally estimated as (based on Dm )

rim
b
rim = Dm (t rim )

*Flywheel mats :
Cast iron
V limit=6000 fpm

3 3
P=0.26 lb/ 7200 kg /m

Cast steel
V limit=10000 fpm

P=0.284 lb/3 7860 kg/m3

*Tensile stress at the rim :

From MDB, the tensile stress in rotating thin ring is

s t =pv 2

P = matl density of ring

V= linear velocity based on the mean diameter
Note:
Some formula is used in a rimmed flywheel (effect of arms is not
considered)
EX. 1
A punching machine is to punch a 25 mm diameter hole from a 19
mm thick steel plate. The plate has an ultimate shearing strength of 400
MPa. The flywheel to be used has a mean diameter of 1m & is to operate
at a maximum speed of 200 rpm & at a coefficient of fluctuation of 0.1.
 The weight of the hub & arms can be taken to be 10% of that of the rim,
with the rim width equal to the five times the rim thickness.
Determine the ff:
(a) Energy reqd to punch one hole.

(b) Flywheel wt reqd.

(c) Rim dimensions necessary in mm.

(d) Energy left at the flywheel after punching a hole.

(e) Solve ( ), if a solid disk flywheel is used with equal weight & equal
outside diameter.
*Use a cast iron flywheel.
Solution:

Flywheel:
Dm= 1m

n1= 200 rpm

C f = 0.1

W H A = 0.10 W rim

brim =5 t rim

(a) E punching=?

1
E punching= F t p
2

1
E punching=
2
[ dht p] t p

25 19
400 19
1
E punching =
2
 E punching=5670574 N mm

E punching=5670.6 N m

(b) W f = ?

1 f 2
KE 2

v1 v2 E punching 1 f
V 12 V 22) =E punching
2 g KE=
2 g
(

200
V 1= Dm n1= (1 m)( rps )
60

m
V 1=10.47
s

V 2=V 1
[ ]
2C f
2+ C f

m
V 2=9.47
s

C f =0.1

1 f [
10.472 9.472 ] =5670. 6
2 9.81

1 kg f
f =5579.6 N
9.81 N

f =568.8 kg f

(c) brim t rim = ? (D = 1m, given)

m

f = rim + H A : 0.1 rim = H A

568.8 = 1.1 rim

rim = 517.1 kgf
thus from,
 + rim D rim
rim =
V rim= D m

: D rim = 5trim
kg 2
517.1kg = 7200 m3 [(1)( 5 t rim )]

t rim = 0.0676m or
t rim = 67.6mm &
brim = 5 t rim = 338mm

(e) Eavailable=?
f
Eavail . = K = [V12]
g
m2
2
= 568.8 kgm [10.47 s2 ]
Eavail . = 31,176.2 N-m

(d) E punching a hole

E = K = mV22 = 25505.2 N-m
E punching = K = K K
1 2

(f) Eavail . using a solid disk flywheel = ?

Eavail . using a rimmed flywheel = 31176.2 N-m
 Ky = Im 2
D
Im = mr2 : r = 2
1.068 2 200 2
1(
Ky = [ 2 568.8 )
2 (
60 )(
x2 )
ra d 2
= kgm (m ) ( s 2
2

Ky(solid disk) = 17786.9 N-m

(g) S trim = ?
S trim = V2
m
V = 10.47 s (based on Dm)
2
3 1N 1m
kgm ( 2m
S trim = 7200 10.47 ) 2 m ( 1000 mm )2
m3
s 1 kg 2
s
N
S trim = 0.789 2 or MPa
mm
or Strim = 114.7 psi

Flywheels cont.
*Tensile stress in the rim
(a) MDB formula for a rotating thin ring

St = V2

= density of material
= linear velocity at the pitch or mean circle
 ( = Dm n

(b) Textbook formula

Max stress is at the inner surface (where r = ri)

2
S t = [ ( 3+ ) r 2o + ( 1 ) r 2i ]
4g
= Poissons ratio of matl
= angular speed in rad/time
g = local gravity acceleration
note:
for a solid disk, take r =0
2
S t = [ ( 3+ ) r 2o ]
4g
(tensile stress is max at the center of the disk)
*computation for the mass moment of inertia, Im
For a solid circular cylinder

I m= m v 2

For a hollow cylinder of mass m

1 2
I m= m(r o +r i2)
2
 For a slender rod of mass m, rotating about its transverse axis

1
I m= mL2
2

For a rod of defined radius r rotating about its transverse axis

Transfer
1 formula for Im
I m= m [3r2 + L2]
2

I m=I m + md2

d= radial distance between the centroid axis and the axis of rotation.

Note:
For composite bodies or shapes in an assembled flywheel, the ff formula
applies:
Im = [ I m + md2]
*some design recommendation of a rimmed flywheel
- no. of spokes or arms is usually 6 (for larger sizes, eight or more spokes are
used; i.e Dm > 10ft)
- spokes are of elliptical section w/ D = 2d
- Cross sectional area at rim side should not be less than 2/3 that at the hub side
2
[ A rim side A
3 hub side ]
-design bending moment for each spoke is equal to the total torque transmitted
divided by the no. of spokes.
Ttotal
M = no . of spokes

Example No. 2
 A sheet metal working company purchased a shearing machine from a
surplus dealer without a flywheel. It is estimated that the amount of energy
in cutting a 4mm thick steel sheet is 2300 Joules. The mean diameter of the
rim of the flywheel should be about 90cm with a width of 25cm. the max
operating speed is 180rpm and slows down to 160rpm during the shearing
process. The flywheels hub & arms account for about 12% of the flywheels
weight. Calculate the ff:
(a) weight of the flywheel reqd, in kg
(b) Rim thickness necessary, in cm
(c) Max width of steel plate that can be cut.
(d) Power of motor, in hp, required if actual cutting time is 0.1sec & the
mechanical efficiency is about 75%
(e) Tensile stress on the rim in psi (solve using the available formulas)
(f) Bending moment to be used in designing each spoke.
assume a cast iron flywheel with = 0.211.

SOLUTION:

a) f =?
From
f
Eshearing [K = (V12 V22)]
g
180
V1 = Dmn1 = (0.9) m ( 60 )rps
m
V1= 8.48 s
160
V2 = Dmn2 = (8.48) ( 180 )

m
V2= 7.54 s
f
2300 N-m = 9.81 (8.482 7.542)

f =2996.7 N 305.5 kg

(b) t rim=?
f =rim + H A
 305.5=rim + (0.12 x 305.5)
rim =268.84= V rim
(0.9)m(t rim )
kg
268.84 kg=7200 3 )(0.25)m
m
t rim= 0.0528m or 5.28cm

(c) L = ?
1
Eshearing= [ s ( As)] tp
2 us
s us =50 ksi=345 MPafor steel plate
N
2300000 N-mm = [(345 mm2 L(4mm)](4mm)

L = 833.3mm
(d) Pmotor =?
E shearing 2300 Nm
1 hp
time = 0.1 x
Pmotor = 746 W
mech ' l 0.75
Pmotor = 41.11 hp or 30.69 kW

(e) St = ?
Considering thin ring:
m
St = V2 ; V = 8.48 s
kg
= 7200 m
3

kg m2
2
St = 7200 m3 [8.48 ] s2
St = 517,755 Pa = 0.518 MPa or 75.11 psi
*cast iron flywheels have a limiting stress of 1ksi

Using textbook formula

2 ( 2 2
St = 4 g [ 3+ ) r o + ( 1 ) r i ]

= 2n
 180 rad
= 2 ( = 18.85
60 s
Dm+ t rim
r i= =0.4764 m
2
r i= ro trim = 0.4236m
7200(18.85 2)
St = [( 3+ 0.211 ) 0.47642 + ( 10.211 ) 0.42362 ]
4( 9.81)
kgf 9.81 N
S t =56743 x =556,649
m 1 kgf
S t =S t =

(f) M/spoke
30.69
T total (9.59 x 106 )
M/spoke = = 180
6
6

M/spoke = 271,351 N-mm

Example No. 3
Compute the following for the flywheel with the given dimensions below:
(a) Mass moment of inertia based on its axis of rotation.

(b)Its radius of gyration, and

(c) Available kinetic energy at 200 rpm

Dimension in inches material cast iron- = 0.26 lb/in3

SOLUTION: (a) =?
 2
I m + md

I m=

1.) m1=? m=V

m1=0.26 [ ( 202182 ) 6 ]=372.5 lb

1
I m = ( 372.5 ) [ 20 2+18 2 ]=134845
1
2

( 3222 )

2.) m2=?
m 2=0.26

1 2 2
I m = ( 32.67 ) [ 3 + 2 ] =212.4
2
2

3.) m3=? m1=0.26 [ ( 18232 ) ] 1=372.5 lb

1 2 2
I m = ( 372.5 ) [20 +18 ] 1=251.3 lb
2
3

1
I m = ( 257.3 ) [18 2+3 2 ]=42840
2
3

4.) m4=? (hole)

m4=0.26 [ ( 1.5 ) 1 ]=1.838lb

2

2
I m =[ I m +m4 ]( d ) 6
4 4

1
[ (1.838 ) ( 1.52 ) +1.838 ( 10 )2 ]6
2
I m =115.2
4

I m= [I m +m d 2]

I m=176,782lb2
 2
(b) I m=m k

k=
Im
m ; M T =657.442

k =16.47
1
(c) K T =? K T = I m w 2
2
144 2
1 200 2 rad 2 1lbf 1 ft 2
[ 176782 ] lb2 ( ) 2
2 60 s lbmft
32.174 2
s

K T =8361.9 ft lb