FLYWHEELS: Case Studies (problems)

1. A four-stroke single cylinder I.C engine develops 80 kW at 300 rpm. The fluctuation
of energy can be assumed to be 0.9 times the energy developed per cycle. If the
coefficient of fluctuation of speed is not to exceed 2 percent and the maximum
centrifugal stress in the rim of the flywheel is limited to 6MN/m2, estimates the mean
diameter of the rim and the moment of inertia of the flywheel. The density of flywheel
material is 7500 kg/m3.

2. A four-stroke engine develops 20 kW at 240 rpm. The TM diagram is rectangular for

the expansion and compression strokes. The TM for expansion stroke is 3 times that of
the compression stroke (negative). Assuming constant load, determine the M.I of the
flywheel to keep the total fluctuations of the crank shaft speed within 1% of the average
speed of 240 rpm.

3. The TMD for a four-stroke engine may be assumed for the sake of simplicity to be
represented by four triangles in each stroke. The area of these triangles is expansion
stroke 9cm2, exhaust stroke 0.8cm2 (–ve), suction stroke 0.5cm2(–ve) and compression
stroke 1.7cm2(–ve). Where 1cm2 represents 1400 J of work. Assuming constant
resistance determine the MI of the flywheel to keep the speed between 98 rpm and 102
rpm. Find the size of the rim type flywheel based on the minimum material criterion,
given that the density of the flywheel material is 7.5 kg/m3. The allowable tensile stress
of the material is 7.5 MPa and the rim cross section is rectangular with one side being
four times the length of the other.

4. The cranks of a three-cylinder two stroke engine run at 600 rpm and they are 120o apart.
The turning moment diagram for each cylinder is represented by a triangle for one
stroke with a maximum value of 600 N.m at 60o from the top dead-centre. The turning
moment in the remaining stroke is zero for all the cylinders. Determine (i) the power
developed by the engine. (ii) The coefficient of fluctuation of energy. (iii) Coefficient
of fluctuation of speed with a flywheel of mass 16 kg and radius of gyration 0.25 m.

5. A machine punching 40 mm diameter holes 30 mm thick plate requires 7 Nm of energy

per mm2 of shear area. The punch has a stroke of 100 mm and it takes 10 sec to complete
one cycle. The mean speed of the flywheel is 25 m/sec, and the fluctuation of speed
should not exceed 3% of the mean speed. Assuming that the motor supplies energy to
the machine at a uniform rate, determine the power of the motor and the mass of the
flywheel required.

6. A punch press fitted with a flywheel having a radius of gyration of 0.5 m runs at 270
rev/min. The press is capable of punching 600 holes per hour. Each punching operation
take 1.5 seconds and requires a work of 10,000 Nm. The rating of the electric motor
used is 2kW. Determine the mass of the flywheel, if the speed of the flywheel should
not drop below 30 rev/min.
7. The resisting torque on the crank of a riveting machine is as shown in figure. The
duration of the cycle is 2 seconds. The motor driving the machine however has a speed
of 1500 rpm and it delivers constant torque... The crank shaft of the machine is geared
to the motor shaft. Neglecting the frictional loss, determine (i) The power of the motor
and (ii) the moment of inertia of the flywheel mounted on the motor shaft to keep the
speed fluctuation with in ±2% of the average speed.

8. A machine requiring a driving torque of (2000+300 Sin Θ) N-m is driven by a directly

coupled two stroke engine whose turning moment is given by (2000+400 Sin 2 Θ) N-
m. where Θ is the angle of rotation of the shaft with reference to a certain datum. The
average speed is 150 rpm. Determine (i) the moment of inertia of the flywheel required
to limit the fluctuation of speed within ±2% of the average speed. (ii) The maximum
angular acceleration of the flywheel and (iii) the maximum angle by which the flywheel
leads or lags an imaginary flywheel which rotates at a constant speed of 150 rpm.