Class MD 2 Lec 6 FlyWheel

Design of Machine Elements

Course Outline Ch-22 Khurmi
Ch-16 Shigley
• Spur, Helical, Bevel and Worm Gears

• Selection of bearings
• Design of Power Screws / Translation Screws
• Design of fly wheel
• Design of Belt and chain drives
• Design of Brakes / Clutches
FlyWheel
What is FlyWheel?
FlyWheel
What is FlyWheel?
A flywheel is an energy-storage device in a machine.

It absorbs mechanical energy and serves as a reservoir
It store energy during the period when the supply of energy is

more than the requirement, and releases it during the period
when the requirement of energy is more than the supply.
Internal combustion engines, Piston compressors, punch

presses, rock crushers etc.
FlyWheel
Punching Machine
Design of Machi ne Elements
FlyWheel
IC Engine
For example, in I.C. engines, the energy is

developed only during power stroke which is
much more than the engine load, and no
energy is being developed during suction,
compression and exhaust strokes.
The excess energy developed during power
stroke is absorbed by the flywheel and releases
it to the crankshaft during other strokes in
which no energy is developed.
FlyWheel
FlyWheel
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.
When a flywheel absorbs energy, its

speed increases and when it releases,
the speed decreases.
Hence a flywheel does not maintain a
constant speed, it simply reduces the
fluctuation of speed.
Design of Machine El ements
FlyWheel
Flywheels-Function need and Operation
Many machines have load patterns that cause the torque time
function to vary over the cycle.
FlyWheel
Design Approach
1. First, the amount of energy required for the desired
degree of smoothening must be found and the (mass)
moment of inertia needed to absorb that energy
determined.
2. Then flywheel geometry must be defined that caters the

required moment of inertia in a reasonably sized
package and is safe against failure at the designed
speeds of operation.
Flywheel inertia (size) needed directly depends upon the

acceptable changes in the speed.
FlyWheel
Moment Of Inertia (I )
i=n
I =  mi ri I = mr 2
2
i=1
I ?? …… Higher or lower?
Additional Power
1 2 required for higher “I”
E K = I
Energy can be
increased by
2
“”
High  means high stresses !!

FlyWheel
Speed Fluctuation
The change in the shaft speed during a
cycle is called the speed fluctuation
and is equal to (ωmax – ωmin).
Fl = max −min
Co-oefficient of Speed Fluctuation
We can normalize this to a
dimensionless ratio by dividing it by the
average or nominal shaft speed
Cf =
max − min Eq. (A)
avg Dr. S
FlyWheel
max − min
Cf =
avg
➢ This coefficient is a design parameter to be chosen by the
designer.
➢ The smaller the Cf, 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.
max − min
Cf =
avg FlyWheel
FlyWheel
Design Equation
The kinetic energy EK in a rotating system
1 2
E K = I
2
Hence the change in kinetic energy of a system
EK = E2 − E1
1
2
2
(
E K = I max − min
2
) I = mr 2
FlyWheel
Design Equation
1
2
2
(
E K = I max − min
2
)
Using Eq. (A)
EK =
1
2
( )(
I 2avg C f avg ) Eq. (B)
The above equation can be used to obtain appropriate

flywheel inertia I corresponding to the known energy change.
E K
I= Eq. (C)
C f avg
2
FlyWheel
Torque Variation and Energy
The required change in kinetic
energy E is obtained from the
known torque time relation or
curve by integrating it for one cycle
 @max
EK =
@
 (T − T )d
avg
min
FlyWheel
FlyWheel
FlyWheel
FlyWheel
FlyWheel
Stresses in Flywheel
Flywheel being a rotating disc, centrifugal stresses acts upon
its distributed mass and attempts to pull it apart.
Its effect is similar to those caused by an
internally pressurized cylinder
FlyWheel
Stresses in Flywheel
v = Poisson ratio,  = avg , r is variable(ri -> ro)
r = ri => t is maximum (figure)
t > r at any radius, so check only t

FlyWheel
Maximum Linear speed (v)
 all
vmax =

 all
rmax =

Design Steps FlyWheel
1. Select material for flywheel.
2. Decide allowable strength of material (all ) and density ().
max − min
3. Decide/Calculate the co-efficient of speed fluctuation (Cf). Cf =
avg
4. Calculate the energy requirement for a given Torque verses
crank angle diagram (IA).
5. Find out minimum and maximum angular speed by speed
verses crank angle diagram (IA). EK
I=
6. Calculate the mass moment of inertia (I ). C f  avg
2
 all
7. Calculate maximum linear speed (v). v=

8. Calculate diameter (D) for given space constraints.
9. Calculate mass. I = mr2
10. Compare hoop and radial stresses with allowable stress.
IA = If Applicable
FlyWheel
Example
A multi-cylinder engine is to run at a constant load at a speed of 600
r.p.m. On drawing the crank effort diagram to a scale of 1 mm = 250 N-m
and 1 mm = 3⁰, the areas in sq mm above and below the mean torque line
are as given. The speed is to be kept within ± 1% of the mean speed of the
engine.
Determine suitable dimensions for cast iron flywheel. The density of cast
iron is 7250 kg/m3, and its working stress in tension is 6 MPa.
FlyWheel
Solution
1. Material for flywheel is given – Cast iron
2. all = 6 MPa and  = 7250kg/m3
3. Decide the co-efficient of speed fluctuation (Cf)
N = 600 rpm
 = avg = 2  N/60 = 62.84rad/sec
max - min = 2% of avg = 0.02 x avg ( ± 1% )
max − min
Cf =
Cf = (max - min)/avg = 0.02 avg
4. Calculate the energy requirement for a given load pattern or

by Torque verses crank angle diagram (IA).
FlyWheel
Solution (cont.)
4. Calculate the energy requirement for a given Torque verses
crank angle diagram (IA).
Let the total energy at A = E
Maximum Energy = E + 162

Minimum Energy = E – 35
E = Max – Min = (E + 162) – (E - 35) = 197 mm2
But, 1 mm2 = 250 x (3⁰ =  /60 rad) = 13.1 N-m
So, E = 197 mm2 = 2581 N-m
Solution (cont.) FlyWheel
6. Calculate the mass moment of inertia (I ) E K
I = 32.7 kg–m2 I=
C f  avg
2
7. Calculate maximum linear speed (v).

 all
v=
6106
= 28.76 m/sec
v=
7250 
8. Calculate diameter (D) for given space constraints.
v = r
Do
28.76 =  62.84
2
Do = 915 mm ro
9. Calculate mass.(For a disc type flywheel as shown)
ri
Di =150 mm
Mass = m = 304 kg
FlyWheel
Design Steps
Now width (b) of the flywheel
b ro
 = m /V
ri
 (ro2 − ri 2)b = m
b = 16.5 mm
10. Compare hoop stress with allowable stress.
r = ri => t is maximum
t = 0.066 Mpa << all = 6Mpa

FlyWheel
Home Work
Design a flywheel for a petrol engine ( N = 1800 rpm ) having turning
moment variation with respect to crank-angle as follow. Choose
appropriate values for any missing data
Turning moment, 1 mm = 5 N-m ; Crank angle, 1 mm = 1 ⁰
FlyWheel
Thank you

Class MD 2 Lec 6 FlyWheel

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Class MD 2 Lec 6 FlyWheel

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Design of Machine Elements

Design of Machine Elements

• Spur, Helical, Bevel and Worm Gears

A flywheel is an energy-storage device in a machine.

It store energy during the period when the supply of energy is

Internal combustion engines, Piston compressors, punch

For example, in I.C. engines, the energy is

When a flywheel absorbs energy, its

2. Then flywheel geometry must be defined that caters the

Flywheel inertia (size) needed directly depends upon the

High  means high stresses !!

The above equation can be used to obtain appropriate

v = Poisson ratio,  = avg , r is variable(ri -> ro)

r = ri => t is maximum (figure)

t > r at any radius, so check only t

4. Calculate the energy requirement for a given load pattern or

Maximum Energy = E + 162

7. Calculate maximum linear speed (v).

t = 0.066 Mpa << all = 6Mpa

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