* STRESSES IN A FLYWHEEL RIM

A flywheel, as shown in Fig, consists

of a rim at which the major portion of
the mass or weight of flywheel is
concentrated, a boss or hub for fixing
the flywheel on to the shaft and a
number of arms for supporting the rim
on the hub.
The following types of stresses are
induced in the rim of a flywheel:
1. Tensile stress due to centrifugal
force. This is also called as centrifugal
or hoop stress.
2.Bending stress induced to the
restraint of the arms, and
3. The shrinkage stresses due to
unequal rate of cooling of casting.
* 1. Tensile stress due to the centrifugal force(𝝈𝒕 ): The tensile stress
in the rim due to the centrifugal force, assuming that the rim is unstrained by
the arms, i.e the arms are completely flexible
Let
. b = Width of rim,
t = Thickness of rim,
A = Cross-sectional area of rim
= b × t,
D = Mean diameter of flywheel
R = Mean radius of flywheel,
ρ = Density of flywheel material,
ω = Angular speed of flywheel,
v = Linear velocity of flywheel, and
σt = Tensile or hoop stress.
Fig shows the upper half of the rim, in
equilibrium under the centrifugal force , and
resisting force due to hoop stress. Consider a
small element of the rim, located at an angle,
𝜃 from the horizontal, and subtending an
angle, 𝑑𝜃 𝑎𝑡 𝑡ℎ𝑒 𝑤ℎ𝑒𝑒𝑙 center. This is acted
upon by the centrifugal force, dF acting
radially outward, which is given by,
Centrifugal force, dF=mR⍵2 (v=R ⍵)
𝑣2
=m .R.
𝑅2
Where, m=mass of the element=lA⍴
= R. 𝑑𝜃.b.t ⍴
𝑣2 𝑃 𝑃
=𝐴 =𝐴
=(R. 𝑑𝜃.b.t)⍴ x
𝑅
dF =b.t.⍴.𝑣 2 . 𝑑𝜃
dN, the vertical component of dN= dF sinθ
dN =b.t.⍴.𝑣 2 sinθ.d 𝜃
The total vertical force, N causing rupture at section X-X is given by
𝜋
N= b.t.⍴.𝑣 2 0 𝑠𝑖𝑛𝜃. 𝑑𝜃 =2.b.t.⍴.𝑣 2 --------------------------(i)
This vertical force is resisted by a force of 2P, such that (P= σt × b. t )
2P = 2σt × b. t ----------------------------------------(ii)
From equations (i) and (ii), we have
2.b.t.⍴.𝑣 2 = 2σt × b. t

σt = ρ.v2
* 2. Tensile bending stress caused by restraint of the arms:
* If the arms are assumed to be rigid, then the portion of the rim between two
arms can be regarded as a beam, fixed at the arm and subjected to uniformly
distributed load, because of centrifugal effect.
The uniformly distributed load (w) per metre length
will be equal to the centrifugal force between a pair of
arms. i.e w= centrifugal force and which is equal
𝑣2
to=b.t ⍴ x from first statement.
𝑅
𝑣2
w=b.t ⍴ x , N/m
𝑅
𝑤𝑙 2
Maximum Bending moment, Mmax=
12
2π𝑅
Where l=length of the rim between two arms=
𝑛
n= No. of arms
2
b.t ⍴ x𝑣𝑅 𝑥(2π𝑅)2
Mmax= 𝑛
12
𝑀 𝑏𝑡 2
Bending stress induced in the rim is given by, 𝜎𝑏 = where Z=
2 2 2 𝑍 6
1 𝑏𝑡𝜌𝑣 4𝜋 𝑅 6
𝜎𝑏 = 𝑥 𝑥 𝑥
12 𝑅 𝑛2 𝑏𝑡 2
2 2
2 4𝜋 𝑅
𝜎𝑏 =𝜌𝑣 ( 2 )
𝑛
3. The shrinkage stresses due to unequal rate of cooling of casting.
The magnitude of this stress may be very high but difficulty to
determine. Hence, this is usually neglected by using a very high
factor of safety
4.RESULTANT STRESS IN THE RIM:
In the practice, the arms are neither completely flexible nor rigid.
Hence, the resultant stress in the rim lies in-between two extreme
cases considered above, and is given by
𝜎𝑟𝑖𝑚 =0.75𝜎𝑡 +0.25𝜎𝑏
DESIGN OF FLYWHEEL ARM:
1) No. of arms:
a) 4 arms are used when diameter of pulley lies in between 200mm to 600mm
b) 6 arms are used when diameter of pulley lies in between 600mm to 1500mm
* Note: For pulleys less than 200mm diameter, the pulley is made with a solid
disc instead of arms.
2)Cross sections of arms:
The cross-section of the arms is usually elliptical with major axis as twice the
minor axis, as shown in Fig., and it is designed for the maximum bending
stress. a1=2 b1
a1 = Major axis, and
b1 = Minor axis.
π
Section modulus, Z= 32
𝑥 𝑏1𝑥 𝑎12
Let, T= Torque transmitted
𝑇
Tangential force acting on each arm(F)= 𝑛
𝑅2
Where, n= No. of arms
It is assumed that power is transmitted from
the hub to the rim or vice-versa through half of
the total no. of arms for safety.
* In design, each arm is considered as a cantilever beam
fixed at the hub and loaded at the rim.
* For safe design the length of arm may be taken as equal to
radius of flywheel pulley.
* It is usual to assume that about half of the no. of are
loaded, since the angle of lap is 1800.
Maximum bending moment at the hub, Mmax= tangential load acting on
each arm x Radius of F.W
𝑇
Mmax= 𝑛 𝑥 𝑅
𝑅2
2𝑇
Mmax=
𝑛
𝑀
Then the bending stress, 𝜎𝑏 =
𝑍
2𝑇
𝑛
𝜎𝑏 = π
𝑥 𝑏1𝑥 𝑎12
32
* DESIGN PROCEDURE:
* The following steps are involved in design of flywheel rim and arms
1.Calculate the Fluctuation of energy (∆E): It can be calculate from T-θ diagram
2. Calculate diameter of flywheel: It can be obtained by 𝜎ℎ𝑜𝑜𝑝 = 𝜌𝑣 2
Where 𝜎ℎ𝑜𝑜𝑝 is hoop stress in rim, N/mm2
𝑣 = linear velocity of flywheel,m/see
𝜋𝐷𝑁
𝑣 = Where N= Mean speed
60
Above relations are useful to determine the diameter of fly wheel rim (D)
3. Calculation of mass of rim
∆E
from step No.1 ∆𝐸=ICs𝜔2 ; I= ; But I= mass moment of flywheel=mk2
Cs𝜔2
𝐷
Where k= Radius of gyration= 2
Assumption :Mass of rim is always 0.9 times of mass of rim only
Irim=0.95Iflywheel ;
4.Calculation of cross sections of flywheel rim (b=? & t=?)
m= 𝜌AL
Where A=C/S od flywheel rim & L=Length of flywheel rim =𝜋D
m= 𝜌 𝑥 𝑏 𝑥 𝑡 𝑥 𝜋D
Where b=width of rim & t= thickness of rim
Above relations are useful to determine the cross sections of flywheel rim.
Take b=2t, if not given
* 5.Hub Design:
Where do = outer diameter of hub
di= inner diameter of hub
From line diagram di is equal to
the diameter of shaft (d) i.e di=d
From the basics of DME subject
do=2d & length of hub=2.5d

6. Key Design:
We know that U=d+13
Where U is Unit of proportion
𝑈 𝑈
width of key= ; Thickness of key = ; 𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑘𝑒𝑦 = 1.5U
4 6
7. Arm Design:
𝑀
𝜎𝑏 =
𝑍
2𝑇
Where Mmax= 𝑛
Where T= torque
π
Z= 𝑥 𝑏1𝑥 𝑎12
32
a1 = Major axis, and
b1 = Minor axis.
* Design and draw a cast iron flywheel used for a four stroke I.C engine
developing 180 kW at 240 r.p.m. The hoop or centrifugal stress developed in
the flywheel is 5.2 MPa, the total fluctuation of speed is to be limited to 3% of
the mean speed. The work done during the power stroke is 1/3 more than
the average work done during the whole cycle. The maximum torque on the
shaft is twice the mean torque. The density of cast iron is 7220 kg/m3.Take
no.of arms are 6 and safe bending stress is15MPa.
Ans: Given: P = 180 kW = 180 × 103 W; N = 240 r.p.m. ; σt = 5.2 MPa = 5.2 × 106
N/m2 ; N1 – N2 = 3% N ; ρ = 7220 kg/m3.
𝑃𝑥60
Work done per cycle=
𝑛
𝑁
n= for-stroke I.C.E
2
240
n= =120 rpm
2
180𝑥103𝑥60
work done per cycle=
120
=90 000 N-m

But, workdone per cycle = Tmean × θ

90000= Tmean × θ
90000= Tmean x4π
Tmean=7163.32 N-m
* from the given data, workdone during
the power stroke is 1/3 more than the
average workdone during the whole cycle
* Workdone during the power (or working)
stroke=1.33333xworkdone per cycle
* =1.333333x90000
* Workdone during the power (or working)
stroke = 120000N-m
* The workdone during the power stroke
is shown by a triangle ABC in Fig. in
which the base AC = π radians and height
BF = Tmax.
Workdone during power stroke= Area above T- θ diagram= Area of ∆le ABC
1
= = x AC xBF
2
1
120000 = x π x Tmax
2
Tmax=76 408.8N-m
Excess turning moment (Height above the mean torque line)
BG = BF – FG Texces = Tmax – Tmean = 76408.8– 7163.32= 69 245.48 N-m.

Since the area BDE shown shaded in Fig. above the mean torque line
represents the maximum fluctuation of energy (Δ E), therefore from
geometrical relation,
* Since the area BDE shown shaded in Fig.
above the mean torque line represents the
maximum fluctuation of energy (ΔE),
therefore from geometrical relation,
* From the Similar ∆le ABC & DBE
𝐴𝐶 T𝑚𝑎𝑥 π
* 𝐷𝐸
𝐴𝐶 𝐵𝐹
=
𝐵𝐺
=
𝐷𝐸 Texces 𝐷𝐸
=
76408.8
69245.48
* DE=2.846 rad
maximum fluctuation of energy (ΔE)= Area of ∆le DBE
1
ΔE= 2 x DE x BG
1
ΔE= x 2.846 x 69245.48 ΔE = 98536.32 N-m
2

1.Diameter of the flywheel Rim(D):

We know that the hoop stress developed in the flywheel rim (σt)= ρ.v2
5.2 × 106 = ρ.v2 = 7220 × v2
5.2 × 106
∴ v2 = = 720 or v = 26.8 m/s
7220
πxD×N π x D × 240
We also know that peripheral velocity, v= 26.8=
60 60
D=2.129m
* 2. Mass of the flywheel:
We know that Fluctuation of energy (∆𝐸)=ICs𝜔2
2𝑥π𝑥𝑁 2𝑥π𝑥240
𝜔= = =25.128 rad/sec
60 60
𝑁 −𝑁
Cs= 𝑀𝑎𝑥 𝑀𝑖𝑛 =0.03
𝑁𝑀𝑒𝑎𝑛
Then, 98536.32 =Ix 0.03 x (25.128)2
I=5201.86 kg-m2
But I=mk2 where k=D/2
5201.86 =m x1.06452
m=4590kg
* 3. Cross-sectional dimensions of the rim
Let t = Depth or thickness of the rim in metres, and
b = Width of the rim in metres = 2 t ...(Assume)
∴ Cross-sectional area of the rim A = b.t = 2 t × t = 2 t2
We know that mass of the flywheel rim (m),
4590 = A × πD × ρ = 2 t2 × π × 2.129 × 7220
4590= 96563 t2
∴ t = 0.218 m say 0.220 m = 220 mm
and b = 2 t = 2 × 220 = 440 mm
* Hub design:
* a) Determination of diameter of shaft:
* Since the maximum torque on the shaft is twice the mean torque, therefore
maximum torque acting on the shaft,
* T = 2 × Tmean = 2 × 7163.32 = 14 326 N-m = 14 326 × 103 N-mm
* We know that the maximum torque acting on the shaft (Tmax),
* π
T= d3𝜏𝑠
16
take 𝜏𝑠 =40MPa
* π
14326x103= d3 40
16
* diameter of shaft, d=122.19mm say 125 mm
* b) Inner diameter of hub di=d=125mm
* c) outer diameter of hub do=2d=125x2=250mm
* d) length of hub=2.5d=2.5x125=312.5mm
* Key design:
* Unit of proportion U=d+13=125+13=138mm
* Width of key=𝑈4=1384
= 34.5𝑚𝑚

* Thickness of key=𝑈6=138
6
=23 mm
* Length of key=1.5U=1.5x138=207 mm
* Arm Design: 2𝑇
Mmax= (relation from design of hub slide no.7)
𝑛

2 𝑥 14 326 × 103
* Mmax= =4775333.33 N-mm
6
𝑀
* But 𝜎𝑏 =
𝑍
Where 𝜎𝑏 =15MPa (From given data)
* π
Z= 32 𝑥 𝑏1𝑥 𝑎12
4775333.33
* 15= π Take 𝑎1=2b1
32
𝑥 𝑏1𝑥 𝑎12

4775333.33
* 15= π 3
32
𝑥 𝑏1

*By solving, we get

*𝑏1=148 mm
*𝑎1=296mm