Flywheels

• Flywheel is a device that acts as an energy reservoir by

Storing and supplying mechanical energy when required.

• For example, in reciprocating engines, the flywheel restore

some amount of energy during power stroke, and deliver it
back during the intake stroke

• Flywheels help in smoothening out the fluctuations of the

torque on the crankshaft & maintain the speed within the
prescribed limits.
Flywheels
An input power source subjects a flywheel to a constant torque Ti while the shaft
rotates from θ1 to θ 2. This is a positive torque and is plotted upward. Equation (b)
indicates that a positive angular acceleration will be the result, and so the shaft
velocity increases from ω1 to ω2.

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 Hypothetical Flywheel Case

Fig. 16–27

An input power source subjects a flywheel to a constant torque Ti while the shaft
rotates from θ1 to θ2.

From θ3 to θ4 a load, or output torque, of constant magnitude is applied, causing the

shaft to slow down from ω3 to ω4.
Shigley’s Mechanical Engineering Design
The work output of the flywheel is the area of the rectangle from θ3 to θ4, or

If U is greater than Ui , the load uses more energy than has been delivered
o

to the flywheel and so ω4 will be less than ω . If Uo = Ui , ω4 will be equal to

1

ω because the gains and losses are equal; we are assuming no friction
1

losses. And finally, ω4 will be greater than ω1 if Ui > Uo.

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 Kinetic Energy

At 𝜃 = 𝜃1 , the flywheel has a velocity of 𝜔1 rad/s, and so its kinetic energy is

At 𝜃 = 𝜃2 , the flywheel has a velocity of 𝜔2 rad/s, and so its kinetic energy is

The change in kinetic energy is

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Engine Torque for One Cylinder Cycle

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Fig. 16–28
The fluctuation of energy may be determined by the turning moment diagram for one
complete cycle of operation.

Consider the turning moment diagram for a single cylinder double acting steam engine as
shown

We see that the mean resisting torque line AF cuts the turning moment diagram at points B, C, D
and E.

When the crank moves from a to p, the work done by the engine is equal to the area aBp,
whereas the energy required is represented by the area aABp.
In other words, the engine has done less work (equal to the area a AB) than the
requirement. This amount of energy is taken from the flywheel and hence the speed
of the flywheel decreases.

Now the crank moves from p to q, the work done by the engine is equal to the area
pBbCq, whereas the requirement of energy is represented by the area pBCq.

Therefore, the engine has done more work than the requirement. This excess work
(equal to the area BbC) is stored in the flywheel and hence the speed of the
flywheel increases while the crank moves from p to q.

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Coefficient of Speed Fluctuation, Cs

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Energy Change

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Example 16–6

Shigley’s Mechanical Engineering Design

Example 16–6

Table 16–6
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Example 16–6

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Punch-Press
• The function of a flywheel in an engine is to reduce the fluctuations of speed, when the
load on the crankshaft is constant and the input torque varies during the cycle.

• The flywheel can also be used to perform the same function when the torque is constant
and the load varies during the cycle.

• Such an application is found in punching press machine. The crank is driven by a motor
which supplies constant torque and the punch is at the position of the slider in a slider-
crank mechanism.

• From the figure, we see that the load acts only during the rotation of the crank from θ
= θ1 to θ = θ2, when the actual punching takes place and the load is zero for the rest of
the cycle.

• Unless a flywheel is used, the speed of the crankshaft will increase too much during the
rotation of crankshaft will increase too much during the rotation of crank from θ = θ2 to
θ = 2π or θ = 0 and again from θ = 0 to θ = θ1, because there is no load while input
energy continues to be supplied.
• On the other hand, the drop in speed of the crankshaft is very large during
the rotation of crank from θ = θ1 to θ = θ2 due to much more load than the
energy supplied.

• Thus, the flywheel has to absorb excess energy available at one stage and
has to make up the deficient energy at the other stage to keep to fluctuations
of speed within permissible limits.

• This is done by choosing the suitable moment of inertia of the flywheel.

• Let E1 be the energy required for punching a hole. This energy is
determined by the size of the hole punched, the thickness of the material
and the physical properties of the material.
Example: punching press is driven by a constant torque electric motor. The press is provided with a
flywheel that rotates at maximum speed of 225 rpm. The radius of gyration of the flywheel is 0.5 m. The
press punches 720 holes per hour; each punching operation takes 2 second and requires 15 kN-m of
energy. Find the power of the motor and the minimum mass of the flywheel if the speed well not fall
below 200 r. p. m.

Given N1 = 225 rpm ; k = 0.5 m ; Hole punched = 720 /hr; E1= 15 kN-m= 15 × 103 N-m ; N2= 200 rpm

• The total energy required per second= 𝐸𝑛𝑒𝑟𝑔𝑦 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑/ℎ𝑜𝑙𝑒 × 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 ℎ𝑜𝑙𝑒𝑠/𝑠𝑒𝑐𝑜𝑛𝑑
= 15000 × 720/3600 =3000 N-m/s=3000 W

• Since each punching operation takes 2 seconds, therefore energy supplied by the motor in 2
seconds,

⟹ Energy to be supplied by the flywheel during punching or maximum fluctuation of energy

 𝜔2 −𝜔1
The maximum fluctuation of energy (ΔE)= 𝐶𝑠 𝐼𝜔2 = × 𝐼 × 𝜔2 = 𝜔2 − 𝜔1 × 𝐼 × 𝜔
𝜔

𝑟𝑒𝑣 𝑟𝑒𝑣 2𝜋 2𝜋
△ 𝐸 = 225 − 220 × 𝑚 × 𝑘 2 × 212.5 = 225 − 220 × 𝑚 × 0.52 × 212.5
𝑚𝑖𝑛 𝑚𝑖𝑛 60 60