\\pradeep\D\pune\Patil\rev2009\msd\chp1\chap-1.doc Final

  Chapter

1
Design of Flywheels
 TOPICS

1.
1.1
1 In
Intr
tro
odu
duct
ctio
ion
n tto
o Fly
Flywh
whee
eell
1.2 Torque A
An
nalysis

1.
1.3
3 Ma
Maxi
ximu
mum
m Fluc
Fluctu
tuat
atio
ion
n of En
Ener
ergy
gy

1.
1.
 !o
!oef
effi
fici
cien
entt of F
Flu
luct
ctua
uati
tion
on o
off Ener
Energy
gy

1.
1."
" !o
!oef
effi
fici
cien
entt of Fluc
Fluctu
tuat
atio
ion
n of
of #$ee
#$eed
d

1.% #i&e of Flywheel

1.' #tresses in #olid (is) Flywheel

1.* #tresses in +immed Flywheel

1., (esign of #olid (is) Flywheels

1.1- (esign of +immed Flywheels

1.11 !onstructions
!onstruction s of Flywheels
1.12 ist of Formulae
 Exercise
 

Mechanical #ystem (esign /0 12 (esign of Flywheels

1.1 INTR
NTRODU
ODUCTIO
CTION
N TO
TO FL
FLYWH
YWHEEL
 Flywheel is a heavy rotating body which serves as an energy reservoir.

 he !lywheel stores the energy in the !orm o! "inetic energy during the period when the
supply o! energy !rom the prime mover is more than the re#uirement o! energy by the
machine$ and releases it during the period when the re#uirement o! energy by the
machine is more than the supply o! energy by the prime mover.
1.1.
1.1.1
1 Types
ypes o
off Fly
Flywh
whee
eell A
App
ppli
lica
cati
tion
ons
s:
here are three distinct types o! applications o! !lywheels %

1. Cons
Consta
tant
nt driv
drivin
ing
g ttor
orqu
quee and
and vari
variab
able
le loa
load
d ttor
orqu
quee
2. Varia
ariabl
blee d
dri
rivi
ving
ng to
torq
rque
ue and
and cons
consta
tant
nt lo
load
ad torq
torque
ue
3. Varia
ariabl
blee d
dri
rivi
ving
ng to
torq
rque
ue and
and vari
variab
able
le loa
loadd ttor
orqu
quee

Fig. 1.1 : Constant Driving Torque and Variable Load Torque

1. Cons
Consta
tant
nt dri
drivi
ving
ng to
torq
rque
ue an
and
d var
varia
iabl
ble
e load
load tor
torqu
que
e:
 &n this type o! !lywheel application$ the energy is supplied by the prime mover at
uni!orm rate$ while the re#uirement o! the energy by machine is at variable rate$ as
shown in Fig. 1.1.
 he !lywheel absorbs the energy !rom the prime mover during the greater portion o! the
cycle and delivers it during the very short duration o! the cycle.
 he e'amples o! this type o! !lywheel application are % electric motor driving punching
machine$ riveting machine$ shearing machine$ press$ etc.
et c.
 (y application o! !lywheels to such machines the smaller capacity prime mover is
re#uired.
 

Mechanical #ystem (esign /0 13 (esign of Flywheels

. !ar
aria
iabl
ble
e driv
drivin
ing
g tor
torqu
que
e an
and
d cons
consta
tant
nt loa
load
d torq
torque
ue::

 &n this type o! !lywheel application$ the energy is supplied by the prime mover at
variable
variable rate$ while the re#u
re#uiremen
irementt o! the energy
energy by the machine is at uni!orm
uni!orm rate$ as
shown in Fig. 1.2.
 he e'ample o! this type o! !lywheel application is$ !our stro"e diesel engine driving the
centri!ugal pump.

Fig. 1.2 : Variable Driving Torque and Constant Load Torque

". !ar
aria
iabl
ble
e dri
drivi
ving
ng to
torq
rque
ue an
and
d var
varia
iabl
ble
e load
load tor
torqu
que:
e:

Fig. 1.3 : Variable Driving Torque and Variable Load Torque

 

Mechanical #ystem (esign /0 1 (esign of Flywheels

 &n this type o! !lywheel application$ the energy is supplied by the prime mover at
variable rate$ while the re#uirement o! the energy by the machine is also at variable rate$
as shown in Fig.1.).
 he
he e'
e'am
ampl
ples
es o! th
this
is type
type o! !lyw
!lywhe
heel
el ap
appl
plic
icat
atio
ion
n ar
aree % &.*.
&.*. en
engin
ginee dr
driv
iving
ing the
the
reciprocating compressor$ &.*. engine driving the stone crusher$ etc.

1.2 TORQUE ANALYI

 +hen !lywheel absorbs the energy$ its speed increases and when it releases the energy$
its speed decreases. ,ence$ a !lywheel does not maintain the speed constant$ but it
simply reduces the !luctuation o! speed.

Fig. 1. : Torque !nalysis

Fig. 1. shows the prime mover driving the machine through the !lywheel.
et$ i / input
input or driv
driving
ing tor#u
tor#ue$
e$ -m
o / outpu
outputt or lo
load
ad tor#u
tor#ue$
e$ -m
-m
& / mass
mass mom
momen
entt o! in
iner
erti
tiaa o!
o! !lyw
!lywhe
heel "g-m2
el$$ "g-m
 / angula
angularr speed
speed o! sha!t
sha!t$$ rads
rads
 / angular
angular acc
accelerat
eleration
ion o!
o! sha!t$ rads2 
sha!t$ rads
 *onsidering the e#uilibrium o! tor#ues$
&  / i  o ...31.14
  " Ti # To ...31.24
 +hen the driving
+hen driving tor#ue
tor#ue is greate
greaterr than the load tor
tor#u
#ue$
e$ $Ti  # To%  is positive and
hence the !lywheel gets accelerated. +hen the driving tor#ue is less than the load tor#ue$
$Ti # To% is negative and hence the !lywheel gets retarded.

1.! "A#I"U" FLUCTUATION OF ENER$Y % E&

 Fig. 1.53a
1.53a44 shows     diagram !or a typical !lywheel application. &n this case$ the
driving tor#ue is variable whereas the load tor#ue is constant.
 

Mechanical #ystem (esign /0 1" (esign of Flywheels

Fig. 1.& : Torque and '(eed Diagra)s

 he cycle consists o! !ive parts % 6($ (*$ *D$ DF and F7.

1. *art !+ :

During the !irst part 6($ the energy supplied by the prime mover is less than the energy
re#uir
re#uired
ed by the machine
machine by an amount
amount ,-1 and hence the angular speed o! the !lywheel
decreases to , )in.

2. *art +C :
During the second part (*$ the energy supplied by the prime mover is more than the
energy re#uired by the machine by an amount ,-2 and hence the angular speed o! the !lywheel

increases to , )a/.
3. *art CD :
During the third part *D$ the energy supplied by the prime mover is les
lesss than the energy
re#uir
re#uired
ed by the machine
machine by an amount
amount ,-3 and hence the angular speed o! the !lywheel
decreases.
. *art DF :
During the !ourth part DF$ the energy supplied by the prime mover is more than the
energy re#uired by the machine by an amount ,- and hence the angular speed o! the !lywheel
increases.
&. *art F0 :
 

Mechanical #ystem (esign /0 1% (esign of Flywheels

During the !i!th part F7$ the energy supplied by the prime mover is less than the energy
re#uir
re#uired
ed by the machine
machine by an amount
amount ,-& and hence the angular speed o! the !lywheel
decreases.

et$ 8 / energy in !lywheel at 6.

 ,ence !rom Fig. 1.53a4
8nergy in !lywheel at ( / 8  8 1 
8nergy in !lywheel at * / 8  8 1 : 82 
8nergy in !lywheel at D / 8  8 1 : 82  8)
8nergy in !lywheel at F / 8  8 1 : 82  8) : 8
8nergy in !lywheel at 7 / 8  8 1 : 82  8) : 8  85
 et us consider that the ma'imum o! these energies is at * and minimum o! 
these energies is at (.
 a/i)u) luctuation o energy :
;a'imum energy in !lywheel$

8 ma' / 8  81 : 82  ...3a4

;inimum energy in !lywheel$

8 min / 8 min / 8  81  ...3b4

  ;a'imum !luctuation o! energy is given by
by$$

8 / 8 ma'  8 min 

/ 38  81 : 824  38  814

or 8 / 82  ...3c4

1.
1.'
' COEF
COEFFI
FICI
CIEN
ENT
T OF
OF FLU
FLUCT
CTUA
UATI
TION
ON OF ENER
ENER$Y
$Y %Ce&

 Coei
Coeicie
cient
nt o lu
luctu
ctuati
ation energy  is defi
on o energy define
ned
d as the
the rati
ratio
o of the
the
maximum fluctuation of energy to the work done per cycle. &t is usually denoted by ,Ce.
here!ore$

*e /

or  Ce " ...31.)4

where$ 8 / ma'i
ma'imu
mum
m !lu
!luctu
ctuat
atio
ion
n o! en
ener
ergy
gy$$ <
+ / wor" do
done pe
per cy
cycle$ <
 elations or wor4 done :
he wor" done per cycle may be obtained by using one o! the !ollowing relations 31.4$
31.54 or 31.=4 %
 

Mechanical #ystem (esign /0 1' (esign of Flywheels

5or4
or4 done
done (er
(er cycl
cycle6
e6 5 " T    ...31.4

where$  / mean tor#ue$ -m

 / rot
rotatio
ation
n o! sha!
sha!tt in one
one cyc
cycle$
le$ rrad
ad
or 

5or4 done (er cycle6

cycle6 5 " ...31.54

where$ P / power$ +

ns / number
number o! cyc
cycles
les per minute
minute
or 

5or4
or4 done
done (er
(er cycl
cycle6
e6 5 " Td  ...31.=4

where$  / driving tor#ue or load tor#ue$ -m

/ i or o

1.( COEFFICIENT OF FLUCTUATION OF )EED %C s&

 +hen !lywheel absorbs the energy$ its speed increases and when it releases
the energy$
energy$ its speed decreases. ,owever$ the !lywheel reduces the !luctuation o! speed.
s peed.

 Coeicient o luctuation o s(eed   is defined as the ratio of the difference

between maximum and minimum angular speeds of the flywheel to the mean speed of the
 flywheel during the cycle.
cycle. &t is usually denoted by ,Cs. here!ore$
Cs "
Cs "
or  ...31.>4
  "
n"
and ...31.?4
where$ ma' / ma'imum
ma'imum angular
angular speed
speed o! the
the !lywheel
!lywheel during
during the the cy
cycle$
cle$ rads
rads
min / minimum
minimum angular
angular speed
speed o! the !lywheel
!lywheel during
during the cycle$
cycle$ rads
rads
 / mean angula
angularr speed
speed o! the !lywhee
!lywheell dur
during
ing ththee cycle$
cycle$ rads
rads
nma' / ma'imum
ma'imum speed
speed o! the !lywhe
!lywheelel during
during the
the cycle$
cycle$ r.p.m.
nmin / minimum
minimum speed
speed o! the !lywhee
!lywheell during
during ththee cycle$
cycle$ r.p.m.
r.p.m.
n / mean
mean spee
speed
d o! the
the !ly
!lywh
whee
eell duri
during
ng tthe
he cyc
cyclele$$ r.p
r.p.m
.m..
 he ma'imum permissible values o! coe!!icient o! !luctuation o! speed !or 
di!!erent applications are given in able
able 1.1.
 

Mechanical #ystem (esign /0 1* (esign of Flywheels

Table 1.1 : Coeicient o Fluctuation o '(eed $Cs%

!((lication Cs
 *rushing machinery$ ,ammers 0.200
 Punching machines$ @hearing machines$ Presses 0.150
 Pumps$ &.*. engines 0.0)0
 ;achine tools$ e'tile machines 0.025
 D.*. 7enerators 0.010
 6.*. 7enerators 0.005

1.* I+E OF FLYWHEEL

 6s already discussed$ the !unction o! the !lywheel is to act as an energy
reservoir which absorbs the energy during the period when the supply o! energy is more
than the re#uirement and releases it during the period when the re#uirement o! energy is
more than the supply.
 6bsorption o! energy is necessarily accompanied by an increase o! the
speed$ whereas release o! energy is accompanied by a decrease o! speed.
 he siAe o! the !lywheel should be !i'ed such that the !luctuation o! the
speed or the coe!!icient o! !luctuation o! speed does not e'ceed the permissible limit.
 ;a'imum !luctuation o! energy is given by$
8 / ...3a4
/ &  &
/ &
or 8 / 3ma'  min4 ...3b4
@ubstituting 8#uation 31.?4 in 8#uation 3b4$
8 / & 3ma'  min4

or 8 / ...3c4
 @ubstituting 8#uation 31.>4 in 8#uation 3c4$ we get$
 - " 7 2   Cs ...31.94
where$ 8 / ma'i
ma'imu
mum
m !lu
!luctu
ctuat
atio
ion
n o! en
ener
ergy
gy$$ <
& / mass
mass mom
momen
entt o! ine
inert
rtia
ia o!
o! the
the !lyw
!lywhe
heel
el abo
about
ut
the a'is o! rotation$ "g-m2
 / mean angula
angularr speed o! the !lywheel$
!lywheel$ rads
rads
*s / coe!!icien
coe!!icientt o! !luctuation
!luctuation o! speed.
speed.
 (y using
using 8#uatio
8#uation
n 31.
31.94$
94$ the re#uir
re#uired
ed mass
mass mom
moment
ent o! inerti
inertiaa o! the
 

Mechanical #ystem (esign /0 1, (esign of Flywheels

!lywheel can be determined. he !lywheel can be either a solid dis" !lywheel or a
rimmed !lywheel.

1.#.1 $olid %is& Flywheel :

 he solid dis" !lywheel is a solid circular dis" as shown in Fig. 1.=.

Fig. 1.8 : 'olid Dis4 Flywheel

et$
et$ & / mass
mass moment
moment o! inerti
inertiaa o! the solid
solid dis" !lywhe
!lywheelel
  about the a'is o! rotation$ "g-m2
m / mass
mass o! th
thee sol
solid
id di
dis"
s" !lyw
!lywheheel
el$$ "
"g
g
" / radius
radius o! gyratio
gyrationn o!
o! the
the solid
solid dis
dis" " !lyw
!lywhee
heell about
about
the a'is o! rotation$ m
B / ou
oute
terr radi
radius
us o! th
thee soli
solidd dis"
dis" !lyw
!lywhe heel
el$$ m
 b / width o! the solid dis" !lywheel$ m
 / mass density
density o!
o! the !lywhee
!lywheell material$ "gm).
material$ "gm
 he mass moment o! inertia
i nertia o! the solid dis"
dis " !lywheel is given by$
7 " )42   ...31.104
 he mass o! the solid dis" !lywheel is$
m / Col
olum
umee o!
o! tthe
he solid
solid di
dis"
s" !lywh
!lywhee
eell  ;ass density
/ 3B 24 3b4  
or ) "  2 b  ...31.114
 he radius o! gyration o! the solid dis" !lywheel is$
9 " ...31.124
 @ubstituting 8#uations 31.114 and 31.124 in 8#uation 31.104$ we get$
& / 3B 2 b 4
or 7 " ...31.1)4
 

Mechanical #ystem (esign /0 11- (esign of Flywheels

 able 1.2 gives the mass density o! materials used !or !lywheel.
Table 1.2 : ass Density o Flywheel aterials

3
aterial ass Density6 4g)
1. 0ray cast iron :

 F7 150 >000

 F7 200 >050

 F7 220 >100

 F7 2=0 >150

 F7 )00 >200

2. Carbon steels : >?00

 

Mechanical #ystem (esign /0 111 (esign of Flywheels

1.#. 'i((ed Flywheel :

 he solid dis" !lywheel$ discussed in section 1.=.1$ is not commonly used in practice.
he rimmed !lywheel$ which is commonly used$ consists o! %
$i% ri)6
$ii% hub6 and
$i
$iii
ii%% thre
threee tto
o ssi/
i/ ar)
ar)s.
s.
 Due to the complicated shapes o! its parts$ it is di!!icult to determine analytically the
e'act mass moment o! inertia o! the rimmed !lywheel.
 ,enc
,ence$
e$ th
thee an
anal
alys
ysis
is o! a rimm
rimmed
ed !lyw
!lywhe
heel
el 3F
3Fig
ig.. 1.>4
1.>4 is do
done
ne by us
usin
ing
g on
onee o! the
the
!ollowing two assumptions %

1. The
The ri) contr
contribu
ibutes
tes ;<=
;<= o the
the total
total )ass
)ass )o)en
)o)entt o inert
inertia
ia o the
the lywhee
lywheel6
l6 while
while
the ar)s6 hub and shat contribute 1<= o the total )ass )o)ent o inertia o the
lywheel.
2. The
The ri) contr
contribu
ibutes
tes the
the en
entir
tiree )as
)asss )o)ent
)o)ent o
o inerti
inertia
a o the
the lywh
lywheel6
eel6 whil
whilee the
ar)s6 hub and shat do not contribute any )ass )o)ent o inertia.

Fig. 1.> : i))ed Flywheel

 he mass moment o! inertia o! the rim is given by$

7r " C   7  ...31.14
 

Mechanical #ystem (esign /0 112 (esign of Flywheels

  where$ &r  / mass moment o! inertia o! the rim about the a'is o! "g-m 2
o! rotation$ "g-m
& / mass moment
moment o! inertia
inertia o!
o! the
the !!lywhee
lywheell about rotation$ "g-m2
about the a'is o! rotation$
* / 0.9 when
when rim
rim contrib
contributes
utes 90
90 o! the total
total ma
mass
ss moment
moment o!o! ine
inertia
rtia o!
o!
!lywheel
/ 1.0 when rim contributes entire
entire mass moment o! inertia o! !lywheel
  et6 mr  / mass
mass o! the rim$
rim$ "g
" rr   / radius
radius o! gyration o!
o! the rim about the a'is
a'is o! rotation$
rotation$ m
B m / mean
mean radius
radius o! the
the rim$
rim$ m
 b / width o! the rim$ m
t / th
thic
ic"n
"nes
esss o!
o! tthe
he ri
rim$
m$ m
 / mass density
density o! the !lywheel material$$ "gm)
!lywheel material
 he mass moment o! inertia o! the rim can be e'pressed as$
7r " )r    ...31.154
 he mass o! the rim is$

mr  / Col
olum
umee o! the
the ri
rim
m  ;ass density
/ 32
32
 B m4  bt    
or  )r " 2   ) b t   ...31.1=4
 he radius o! gyration o! the rim is$
4 r "  ) 31.1>4
 @ubstituting 8#uations 31.1=4 and 31.1>4 in 8#uation 31.154$ we get$
&r  / 2 B m b t   
or  7r " 2   b t   ...31.1?4
 he width ,b o! the rim is usually ta"en as two times the thic"ness ,t o! the rim. &! the
!lywheel is also used as a pulley$ the rim width is ta"en as 20 to 0 mm wider than the
 belt.

1.#." )i(iting 'i( $peed :

 ;any a times$ in the design o! the !lywheel$ it is necessary to select the mean radius o! 
the rim. From 8#uations 31.1=4 and 31.1?4$ it is seen that !or the re#uired mass moment
o! inertia$ the mass o! the !lywheel rim can be considerably reduced by increasing the
mean radius. ,owever$ the mean radius is limited by the availability o! the space and the
linear rim speed.
 a"ing
a"ing int
into
o accoun
accountt the !actor
!actor o! sa!ety
sa!ety$$ the limitin
limiting
g lin
linear
ear rim spe
speed
ed !or rimmed
rimmed
!lywheel is given by the !ollowing relations %
V ? 3< )s @ or cast iron lywheel
E31.194
and V ? &< )s@ or cast steel lywheel
 

Mechanical #ystem (esign /0 113 (esign of Flywheels

 +hen the linear rim speed e'ceeds this limit$ the rim may burst due to high centri!ugal
!orce.

Exa(ple 1.1 :
he load cycle !or a machine consists o! three parts %
3i4 he tor#ue
tor#ue is constant and e#ual to
to 12 -m during  / 0 to  radians 
3ii4 he tor#ue
tor#ue is constant
constant and e#ual
e#ual to
to 1 -m during
during  /  to radians  and
3iii4 he tor#ue
tor#ue is constant
constant and e#ual
e#ual to 12 -m during
during  / to 2 radians.
he machine is driven by a constant tor#ue electric motor. he mean speed is =00 r.p.m. while
the coe!!icient o! !luctuation o! speed is 0.05. Determine the outer diameter o! the !lywheel$ i! 
it is made o! a solid circular steel dis" o! 25 mm width. he mass density o! the steel is
>?00 "gm)
$olution :
0iven : n / =00 r.p.m.  *s / 0.05
 b / 0.025 m      / >?00 "gm).
1. a
a/
/i)u
i)u) F
Flu
luct
ctua
uati
tio
on o
o -
-n
ner
ergy
gy :

Fig. 1.1.1
From    diagram shown in Fig. 1.1.1
+or" done
done per
per cycle
cycle$$ + / 6rea
6rea under
under drivi
driving
ng tor#u
tor#uee diagram
diagram
/ i  2
 2

or + / =.2?) i$ -m 3or <4 ...3a4
6gain$
+or" done
done per cycle$
cycle$ + / 6rea
6rea under
under load
load tor
tor#ue
#ue diagra
diagram
m
 

Mechanical #ystem (esign /0 11 (esign of Flywheels

/ 12   : 1   : 12  
/ 90 
or + / 2?2.>) -m 3or <4 ...3b4
Form 8#uations 3a4 and 3b4$

=.2?) i / 2?2.>)

 i / 5 -m
et the energy stored in !lywheel at point 6 is ,-.
here!ore$
8nergy in !lywheel at ( / 8 : 81 / 8 : 35  124   / 8 : ))
)) 
8nergy in !lywheel at * / 8 : 81  82 / 8 : ))
))  31  54   / 8  1=.5
1=.5 
8nergy in !lywheel at D / 8 : 81  82 : 8) / 8  1=.5  : 35  124   / 8

  ;a'imum energy in the !lywheel is$ 8ma' / 8 : ))  <

and$ ;inimum energy in the !lywheel is$ 8min / 8  1=.5  <

;a'imum !luctuation o! energy$
8 / 8ma'  8min / 38 : )) 4  38  1=.5 4
/ 9.5 
or    - " 1&&.&<; A
2. Flywheel Dia)eter :

;ean angular speed$  / / / =2.?)

2.?) ra
rad
ds

 ow$$
 ow   8 / & 2 *s
  1 55.509 / &  3=2.?)42  0.05
15

 & / 0.>?>? "g-m2

For a solid dis" !lywheel$
& /
/

  or & /

0.>
.>?>
?>?
? /

  B / 0.2252 m

 B / 225.2 mm
mm or
or 2
22
2= mm
mm
Diameter o! the !lywheel$

D / 2B / 2  22= / 52 mm
 

Mechanical #ystem (esign /0 11" (esign of Flywheels

D " &2 )) ...!ns.

Exa(ple 1. :
)
6 rimmed !lywheel made o! gray cast iron 3   / >100 "gm 4 is used on a punching press
runnin
run ningg at a mean
mean speed
speed o! 200 r.p.m.
r.p.m. he punchi
punching
ng operat
operation
ion consists
consists o! one #uarte
#uarter 
r 
revolu
rev olution
tion during
during which
which the !lywhe
!lywheel
el is re#uir
re#uired
ed to supply
supply )00
)000
0 -m o! eneenerg
rgy
y. he
coe!!icient o! !luctuation o! speed is limited to 0.2. he rim$ which contributes 90 o! the
re#uired mass moment o! inertia$ has a mean radius limited to 0.5 m due to space limitations.
&! the cross-section o! the rim is s#uare$ determine its dimensions.
$olution :
0iven :    / >100 "gm)  ns / 200 r.p.m. 
8 / )000 -m.  *s / 0.2 
* / 0.9  Bm / 0.5
  m
 bt / 1.
1. ass
ass o)e
o)en
nt o
o 7ne
7nert
rtia
ia o Flyw
Flywhe
heel
el i)
i) :

;ean angular speed$  / / / 20.9

0.9 ra
rad
ds
8 / & 2 *s

)000 / &  320.942  0.2

   & / ).19= "g-m2

For a !lywheel rim$
&r  / *& / 0.9  ).19=
or  4gB)2
7r " 3<.>> 4g
2. Di)en
i)enssions
ions o Fly
Flywhee
eell i) :
 ow$$
 ow &r  / mr    
/ 32
32
 B m b t 4

or &r  / 2  b t 
)0.>> / 2  30.54)  t  t  >100

 t2 / 5.5191  10  ) m2

   t / 0.0>) m

t / >.) mm or
or >5 mm
mm

and b / t / >5 mm

 ) " &<< ))

b " >& ))
 

Mechanical #ystem (esign /0 11% (esign of Flywheels

t " >& )) ...!ns.

Exa(ple 1." :

he    diagram !or a multi-cylinder diesel engine is drawn with a scale o! 1 mm / 5 5 on the
cran" angle a'is and 1 mm / >5 -m on the tor#ue a'is. he intercepted areas between the
variable engine tor#ue and the constant load tor#ue during one cycle$ ta"en in order are : 0$
  ?5$ : >9$  =?$ : 9= and  =2 mm 2. he mean speed is 500 r.p.m. 6 rimmed !lywheel made
3  / >200 "gm)4 is used to limit the !luctuation o! speed to 2 o! the
o! gray cast iron F7 )00 3
mean speed. he limiting linear rim speed at mean radius is )0 ms. he rim has a rectangular 
cross section with width to thic"ness ratio o! 1.5. eglecting the e!!ect o! arms and hub !or 
moment o! inertia$ determine the dimensions o! a !lywheel rim.
$olution :
0iven : 'cale on cr
cran4 an
angle a/
a/is % 1mm / rad 
'cale on torque a/is   % 1 mm / >5 -m 
n / 500 r.p.m.    / >200 "gm)
*s / 0.02  C   )0 ms
 bt / 1.5  * / 1.

Fig. 1.3.1
1. a
a/
/i)u
i)u) F
Flu
luct
ctua
uati
tio
on o
o -
-n
ner
ergy
gy :
@cale !or area on    diagram
1 mm2 /   >5 / =.55 -m 3or <4
he    diagram is shown in Fig. 1.).1. et the energy stored in the !lywheel at point
6 is ,-. here!ore$
8nergy in !lywheel at ( / 8 : 0
8nergy in !lywheel at * / 8 : 0  ?5 / 8  5 / ;inimum energy
8nergy in !lywheel at D / 8  5 : >9 / 8 : )
 

Mechanical #ystem (esign /0 11' (esign of Flywheels

8nergy in !lywheel at F / 8 : )  =? / 8  )
8nergy in !lywheel at 7 / 8  ) : 9= / 8 : =2 / ;a'imum
;a'imum energy

8nergy in !lywheel at , / 8 : =2  =2 / 8
he ma'imum and minimum energy levels in the !lywheel are at points 7 and *
respectively.. here!ore$ the ma'imum !luctuation o! energy is$
respectively

  8 / 8ma'  8min  

/ 38
38 : =2
=244  38  
54
54GG  scale

/ 38
38 : =2
=244  38  
54
54GG  =.55

/ 10>  =.55

or    8 / >00.)15 <

2. Di)en
i)enssions
ions o Fly
Flywhee
eell i) :
;ean angular speed$  / / / 52.)
52.)=
= ra
rad
dss
 ow$$
 ow   8 / & 2 *s
>00.)15 / &  352.)=42  0.02
 & / 12.>>2 "g-m2
For a !lywheel rim$
&r  / *&
/ & 33si
sin
nce * / 14
or &r  / 12.
2.>>
>>2 g-m2
2 "g-m
C    )0 ms
B m     )0

 B m   
 or B m    0.5>) m

here!ore the mean rim radius is ta"en as$

B m / 0.5> m
 ow$$
 ow &r  / mr    
/ 32  B m b t 4
or &r  / 2   b t $ "g-m2
12.>>2 / 2   30.5>4)  1.5 t  t  >200
 t2 / 1.01=)  10  ) m2
 t / 0.0)1?? m
 t / )1.?? mm or )2 mm
and b / 1.5 t / 1.5  )2 / ? mm
 

Mechanical #ystem (esign /0 11* (esign of Flywheels

 ) " &>< ))

t " 32 ))
b "  )) ...!ns.

Exa(ple 1.* :
6 three cylinder diesel engine running at a mean speed o! 500 r.p.m. has its three cran"s set at
120 to each other. he tor#ue-cran" angle diagram !or each cylinder is a triangle with the
120
!ollowing values !or one cycle %
Cran4 !ngle6   $deg% 0 =0 1?0 1?0  )=0
Torque6 T $B)% 0 =00 0 0
6 rimmed !lywheel made o! gray cast iron F7 2=0 3 3   / >150 "gm)4 is used to limit the
!luctuation o! speed to  1.5. he resisting tor#ue o! the machine is constant throughout the
cycle. he mean radius o! the rim should not e'ceed 250 mm. he rim has a s#uare cross
section. &! the rim contributes 90 o! the re#uired mass moment o! inertia$ determine %
3i4 he dimensions o! a !lywheel rim  and

3ii
3ii44 he powe
powerr develo
developed
ped by
by the engine
engine..
$olution :

0iven : n / 500 r.p.m.      / >150 "gm) 

*s / 0.0) 3  1
 1..5  i.e. )4  Bm  / 250 mm 
 b / t  * / 0.9.

1. a
a/
/i)u
i)u) F
Flu
luct
ctua
uati
tio
on o
o -
-n
ner
ergy
gy :

Fig. 1..1 shows the    diagram !or the individual cylinders$ while Fig. 1..2 shows
the combined    diagram !or the three cylinder engine. he combined    diagram is
obtained by ta"ing the sum o! the tor#ues developed by each individual cylinder at a given
cran" angle.
 

Mechanical #ystem (esign /0 11, (esign of Flywheels

Fig. 1..2

Form    diagram shown in Fig. 1..1

+or
or"
" done
done per
per cycl
cycle$
e$ + / )  6rea o! each triangle
/ )  
or + / 2?2>.)) < ...3a4
6gain !rom Fig. 1..2
+or" done
done per
per cycle
cycle$$ + / 6rea
6rea under
under load
load tor#ue
tor#ue diag
diagram
ram
/ o  2 
or + / =.2?) o$ < ...3b4
From 8#uations 3a4 and 3b4$
=.2?) o / 2?2>.))

 o / 50 -m
From Fig. 1..2

82 / 8) / 8 / 85 / 8= /  3=00  504  =0  

/ >?.5 <
and 81 / 8> /  350  )004  )0   / )9.2> <
et the energy stored in !lywheel at point 6 is ,-. here!ore$
8n
8ner
erg
gy iin
n !!ly
lywh
whee
eell aatt ( / 8  81 / 8  )9.2>
8n
8ner
erg
gy iin
n !!ly
lywh
whee
eell aatt * / 8  81 : 82 / 8  )9.2> : >?.5 / 8 : )9.2>
8n
8ner
ergy
gy in !l
!lyw
ywh
hee
eell at
at D / 8  81 : 82  8) / 8 : )9.2>  >?.5 / 8  )9.2>
8n
8ner
ergy
gy in !ly
lywh
whee
eell at
at F / 8  81 : 82  8) : 8 / 8  )9.2> : >?.5 / 8 : )9.2>
8n
8ner
ergy
gy in !l
!lyw
ywh
hee
eell at
at 7 / 8  81 : 82  8) : 8  85 
 

Mechanical #ystem (esign /0 12- (esign of Flywheels

/ 8 : )9.2>
)9.2>  >?.5
>?.5
 / 8 : )9.2>
)9.2>
8n
8ner
ergy
gy in !l
!lyw
ywh
hee
eell at
at , / 8  81 : 82  8) : 8  85 : 8= 

/ 8  )9.2>
)9.2> : >?.5
>?.5 / 8 : )9.2
)9.2>>
8n
8ner
ergy
gy in !l
!lyw
ywh
hee
eell aatt & / 8  81 : 82  8) : 8  85 : 8=  8> 
/ 8 : )9
)9.2
.2>
>  )9
)9.2
.2>
> /8

 ;a'imum energy in the !lywheel is$ 8ma' / 8 : )9

)9.2
.2>
><

and$ ;inimum energy in the !lywheel is$ 8 min / 8  )9

)9.2
.2>
><
;a'imum !luctuation o! energy$
8 / 8ma'  8min  
/ 38 : )9
)9.2
.2>4
>4  38  )9
)9.2
.2>4
>4
or  - " >.& A
2. Di)en
i)enssions
ions o Fly
Flywhee
eell i) :
;ean angular speed$  / / / 52.)
52.)=
= ra
rad
dss
 ow$$
 ow   8 / & 2 *s
>?.5 / &  352.)=42  0.0)
 & / 0.955 "g-m2
For a !lywheel rim$

&r  / *& / 0.9  0.955 / 0.?595 "g-m 2

 ow$$
 ow &r  / mr  

/ 32  B m b t 4
or &r  / 2   b t $ "g-m2
0.?595 / 2   30.254)  t  t  >150
  t2 / 1.225  10  ) m2

  t / 0.0)5 m
or t / )5 mm
and b / t / )5 mm
 ) " 2&< ))
t " 3& ))
b " 3& )) ...!ns.
3. *ower Develo(ed by
by -n
-ngine
ine :
Power developed by the engine is given by$
by$
P / +or"
or" don
onee pe
perr cy
cycl
clee   umber o! cycles per second
/ +  
 

Mechanical #ystem (esign /0 121 (esign of Flywheels

/ +   3since ns / n4
/ 2?
2?2>
2>.
.)
))  
/ 2)
2)5=
5=1
1.9
.9
+
or * " 23.&82 45 ...!ns.

Exa(ple 1.+ :
6 two stro"e gas engine develops )>.5 "+ at a mean speed o! 1200 r.p.m. he resisting load
tor#uee is constant
tor#u constant throughout
throughout the cycle.
cycle. he coe!!icien
coe!!icientt o! !luctuat
!luctuation
ion o! energy
energy is 0.2>.
)
6 rimmed !lywheel made o! gray cast iron F7 2=0 3 3   / >150 "gm 4 is used to limit the
coe!!icient o! !luctuation o! speed to 0.02. he linear rim speed at mean radius is limited to )0
ms. he rim has a rectangular cross-section with width to thic"ness ratio o! 2.0. &! the rim
 provides the 90 o! the !lywheel e!!ect$
e!!ect$
determine %
3i4
3i4 ;ass
;ass o!
o! tthe
he !lyw
!lywhe
heel
el rim
rim an
and
d
3ii
3ii44 Dimensi
Dimensions
ons o! the
the !lyw
!lywhee
heell rim.
rim.
$olution :
0iven : ns / n  P / )>500 + 
n / 1200 r.p.m.  *e / 0.2> 
 / >150 "gm )   *s / 0.02 
C  )0 ms  b / 2t 
* / 0.9.

1. a
a/
/i)u
i)u) F
Flu
luct
ctua
uati
tio
on o
o -
-n
ner
ergy
gy :
For two stro"e engine$
 umber o! cycles per second / umber o! revolutions per second
/
  ns / n
+or" done per cycle$ + /
/ /
or + / 1?>5 <
 ow$$
 ow *e /
  0.2> /
0.
   - " &<8.2& A
2. ass o Flywheel i
i) :
 / /
or     / 125
25.=
.==
= rad
rads
s
 

Mechanical #ystem (esign /0 122 (esign of Flywheels

8 / & 2 *s
50=.25 / &  3125.==42  0.02
  & / 1.=0) "g-m2
For a !lywheel rim$

&r  / *& / 0.9  1.=0) / 1.2> "g-m 2

C    )0 ms

  B m   )0

 B m     

or B m    0.2)?? m
here!ore$ the mean rim radius is ta"en as$
B m / 0.2)5 m
 ow$$
 ow &r  / mr
2
1.2> / mr   30.2)54
  )r " 28.12 4g ...!ns.
3. Di)en
i)enssions
ions o Fly
Flywhee
eell i) :
mr  / 2  B m b t 
 2
 2=
=.12 / 2   0.2)5  2 t  t  >150
  t2 / 1.2)>2  10  ) m2 
 t / 0.0)51> m
 t / )5.1> mm or )= mm
  b / 2t / 2  )= / >2 mm$
 ) " 23& ))
t " 38 ))

b " >2 )) ...!ns.

Exa(ple 1.# :
he tor#ue developed by a three cylinder engine and the resisting tor#ue on a machine are
given by the !ollowing e'pressions %
i  / 19000 : >000 sin
sin )
) -m
o  / 19000 : )000 sin  -m
+here$  is the cran" angle
he mean speed o! the engine in ?00 r.p.m.$ while the coe!!icient o! !luctuation o! speed is
limited to 0.0). he rimmed !lywheel is made o! gray cast iron F7 200 3  / >100 "gm)4. he
rim contributes 90 o! the re#uired mass moment o! inertia. he cross-section o! the rim is
 

Mechanical #ystem (esign /0 123 (esign of Flywheels

rectangle with the width to thic"ness ratio o! 1.5. &! the limiting mean rim velocity is )0 ms$
determine the dimensions o! the rim.
$olution :
0iven :   n / ?00 r.p.m.  *s / 0.0) 
   / >100 "gm)  * / 0 .9 
 bt / 1.5  C  )0 ms.
1. a
a/
/i)u
i)u) F
Flu
luct
ctua
uati
tio
on o
o -
-n
ner
ergy
gy :
Fig. 1.=.1 shows the    diagram. 6s the driving tor#ue ,Ti is a !unction o! sin 3  and
load tor#ue ,To is a !unction o! sin  6 the cycle duration is o! )=0
)=0  cran" sha!t rotation i.e. one
rotation o! the cran" sha!t.
he driving tor#ue and load tor#ue diagrams will intersect each other$ when i / o.
i.e. 19000 : >000 sin ) / 1900
19000
0 : )00
)000
0 sin
sin 
>000 sin )
) / )000 sin 

  / or sin ) / sin  / 0

 / or   / 0$ 1?0
1?0 or )=0
)=0
)   sin2  / or  / 0$ 1?0
1?0 or )=0
)=0 

 sin2  / or  / 0$ 1?0

1?0 or )=0
)=0

sin2  / or  / 0$ 1?0

1?0 or )=0
)=0

    sin  /    0
 0..?01>? or  / 0$ 1?0
1?0 or )=0
)=0
   / 5).)
5).)$ 12=.>
12=.>$ 2)).)
2)).) or )0=.)
)0=.) or  / 0
0$ 1?0
1?0 or )=0
)=0
 

Mechanical #ystem (esign /0 12 (esign of Flywheels

Fig. 1.8.1

here!ore$  6 / 0 ( / 5).)

* / 12=.> D / 1?0

F / 2)).) 7 / )0=.)

, / )=0
;a'imum !luctuation o! energy$

8 / o d
 d  i d
 d
/ 3o  i4 d
d
/ 31
31900
9000
0 : )000
)000 sin 4  319000 : >000 sin )
)4G d
d  
/ )00
)000
0 sin
sin   >000 sin )
)G d
d  

/
/

/ H)9?
H)9?.09G
.09G   )9?.09G
)9?.09GI
I

or  - " >;8.2 A

or 
2. Di)en
i)enssions
ions o Fly
Flywhee
eell i) :

;ean angular speed$  / / / ?)

?).>
.>>
> rad
ads
s
he limiting rim speed at mean radius is )0 ms

C    )0 ms

B m   )0 ms

 B m  ?).>>    )0 ms
   B m    0.)5? m
here!ore$ mean rim radius is ta"en as$

B m / 0.)55 m

 ow$$
 ow   8 / & 2 *s

>9=?.2 / &  3?).>>42  0.0)

  & / )>.?9= "g-m2

For a !lywheel rim$
 

Mechanical #ystem (esign /0 12" (esign of Flywheels

&r  / *& / 0.9  )>.?9= / ).0= "g-m2

 ow$$
 ow &r  / mr    

/ 32  B m b t 4
or &r  / 2   b t 
 ).0= / 2   30.)554)  1.5 t  t  >100
  t2 / 0.011)>?=
  t / 0.10==> m
  t / 10=
0=.=
.=>
> mm or 10
10>
> mm
 b / 1.5 t / 1.5  10> / 1=0.5 mm
 ) " 3&& ))
t " 1<> ))
b " 18<.& )) ...!ns.

Exa(ple 1., :
6 twin cylinder engine$ with cran"s at right angles$ develops >5 "+ power at a mean speed o! 
00 r.p.m. he coe!!icient o! !luctuation o! speed is limited to 0.0). he mean diameter o! the
!lywheel is 1.2 m. he ma'imum variation o! energy per cycle is !ound to be 20 o! the
energy per cycle. &! the arms and hub contribute 5 o! the !lywheel e!!ect$ determine the
necessary dimensions o! a s#uare rim section o! cast iron which has a density o! >000 "gm ).
$olution :
0iven : P / >5 "+  n / 00 r.p.m. 
*s / 0.0)  Dm / 1.2 m 
8 / 0.2 8  * / 0.95 
 bt / 1     / >000 "gm).
1. a
a/
/i)u
i)u) F
Flu
luct
ctua
uati
tio
on o
o -
-n
ner
ergy
gy :
For twin cylinder engine 
 umber o! cycles per minute$
ns / umber
umber o! rota
rotatio
tions
ns per
per minut
minutee
/ n
or ns / 00
+or" done per cycle$
cycle$ + /

or + / 11250 <

8n
8neergy pe
perr cy
cyccle
le$$ 8 / +

or 8 / 11250 <
 

Mechanical #ystem (esign /0 12% (esign of Flywheels

;a'imum !luctuation o! energy$

8 / 0.2 8 / 0.2  11250
or  - " 22&< A
2. Di)en
i)enssions
ions o Fly
Flywhee
eell i) :
;ean angular speed$  / / / 1
1.?
.?9
9 rad
ads
s
B m / / / 0.= m
 ow$$
 ow   8 / & 2 *s
2250 / &  31.?942  0.0)
   & / 2.> "g-m2
For a !lywheel rim$
&r  / *&
/ 0.95  2.>
or &r  / 0.=0 "g-m2
&r  / mr    
/ 32  B m b t 4
or &r  / 2   b t $ "g-m2
0.=0 / 2   30.=4)  t  t  >000
   t2 / .2>  10  ) m2
   t / 0.0=5)> m
   t / =5.)> mm or == mm
and b / t / == mm
 ) " 8<< ))
t " 88 ))
b " 88 )) ...!ns.

Exa(ple 1.- :
6 punching press e'ecutes 20 holes o! 20 mm diameter per minute in a plate o! 15 mm
thic"ness.
thic"ness. he actual
actual punching
punching operation ta"es 1.5 second
second per hole. he energy
energy re#uired !or 
 punching operation is 5 < per s# mm o! shear area and the !rictional losses are 15 o! the
energy re#uired !or shearing operation. he punching press is powered by a rimmed !lywheel
o! mean
mean radi
radius
us 0.
0.5
5 m anand
d s#ua
s#uare
re cr
cross
ossec
ectio
tion.
n. he
he de
dens
nsity
ity o! the
the !lyw
!lywhe
heel
el ma
mater
teria
iall is
)
>100 "gm . he rim contributes 90 o! the re#uired mass moment o! inertia. &! the !lywheel
speed varies between 250 r.p.m. and 225 r.p.m$ determine %
3i4 the p
powe
owerr re#uir
re#uired
ed to oper
operate
ate the
the punch
punching
ing pres
presss  and
3ii
3ii44 the dimensi
dimensions
ons o! !lyw
!lywhee
heell rim.
rim.
$olution :
0iven :   n p / 20 r.p.m  d p  / 20 mm 
 

Mechanical #ystem (esign /0 12' (esign of Flywheels

  t p / 15 mm  Bm  / 0.5 m 
 bt / 1  * / 0.9 

  nma' / 250 r.p.m.  nmin / 225 r.p.m.

   / >100 "gm)
1. a
a/
/i)u
i)u) F
Flu
luct
ctua
uati
tio
on o
o -
-n
ner
ergy
gy :
he shear area o! hole is$
6 /    d p t p  
/     20  15
or 6 / 92.? mm2
he energy re#uired to punch each hole is$
81 /
/ 5  92.?
or 81 / >12. <
he !rictional losses are 15. ,ence$ the mechanical e!!iciency punching press is$
m / 0.?5
 he energy input to punching press per stro"e 3hole4 is$
8 / / / 55).99 <

20 holes are punched per minute 3i.e. in =0 seconds4. ,ence$ time re#uired !or each
 punching stro"e / / )s

he time re#uired !or actual punching operation / 1.5s

Fig. 1.?.1 shows    diagram !or punching machine. he punching operation ta"es
 place during 12 o! rotation o! the punching press
press cran" sha!t. ,ence$ during 12 o! the rotation
o! the cran" sha!t$ the energy is stored in the !lywheel.

here!ore$ the ma'imum !luctuation o! energy is$

8 / /  55).99

or    - " 2>>2 A

 

Mechanical #ystem (esign /0 12* (esign of Flywheels

Fig. 1..1

2. Di)en
i)enssions
ions o Fly
Flywhee
eell i) :
;ean speed o! !lywheel$ n /
/
or n / 2)>.5 r.p.m.
;ean angular speed$  / / / 2.?
2.?>
> ra
rad
ds.
s.
  *oe!!icient o! !luctuation o! speed$ *s /
/
or *s / 0.1052
 ow$$
 ow 8 / & 2 *s
2>>2 / &  32.?>42  0.1052
 & / 2.= "g-m2
For a !lywheel rim$
&r  / *& / 0.9  2.= / )?.) "g-m 2
 ow$$
 ow &r  / mr    
/ 32  B m b t 4

or &r  / 2   b t 

)?.) / 2  30.54)  t  t  >100

  t2 / =.?>5  10  ) m2
  t / 0.0?29 m
  t / ?2.9 mm or
or ?) mm
mm
 b / t / ?) mm
t " 3 ))
b " 3 )) ...!ns.
3. *ower equire)ent :
Power input to punching press is$
P p / 8nergy
8nergy input
input to
to punching
punching press per stro"e
stro"e  umber o! punching stro"es per second
 

Mechanical #ystem (esign /0 12, (esign of Flywheels

/ 8  
/ 55).99  

/ 1?? +
or *( " 1. 45 ...6ns.

1., TREE IN OLID DI- FLYWHEEL

Fig. 1. : 'tresses in 'olid Dis4 Flywheel

here are two types o! stresses induced in the solid dis" !lywheel %
1. Tan
ang
gen
enti
tial
al stress66  t 
tress
2. adial stress6  r

 he tangential and radial stresses at any radius ,r are given by$
t /    C2  ...31.204

and r  /    C2  ...31.214

+here$ t / tangential
tangential stress radius r$ m2
stress at radius
2
r  / radial
radial stress
stress at
at radius
radius r$
r$ m
C / peperrip
iphe
hera
rall sp
spee
eeddmms
s / B 
B / ou
oute
terr rrad
adiu
iuss o!
o! tthe
he soli
solid
d dis
dis"$
"$ m
 / mass density
density o!
o! the solid
solid dis" material$ "gm)
dis" material$
 / Poiss
Poisson
onJJs rati
ratio
o
/ 0.21
0.211 !or
!or cast
cast iron
iron
/ 0.
0.29
292
2 !!or
or ste
steel
el
 he ma'imum tangential and radial stresses which occur at the centre 3i.e at r / 04 are
given by$
 

Mechanical #ystem (esign /0 13- (esign of Flywheels

 t )a/ " r )a/ "   V2  ...31.224

+here$ t ma' / ma'imu

ma'imum
m tange
tangenti
ntial
al stres
stress$
s$ m2
m

r ma' / ma'imu
ma'imum
m radi
radial
al stress m2
stress$$ m

1. TREE
TREE IN RI""ED FLYWHEEL

Fig. 1.; : i))ed Flywheel

6 rimmed !lywheel$ as shown in Fig. 1.9$ consists o! a rim at which the maKor portion o! 
the mass o! !lywheel is concentrated$ a hub !or mounting the !lywheel on the sha!t and a
number o! arms !or supporting the rim on the hub.

1.-.1 $tresses in Flywheel 'i( :

he !ollowing stresses are induced in the !lywheel rim %

1. Tens
ensile
ile str
stress
ess $hoo
$hoo(
( stress
stress%% due
due to centr
centriu
iuga orce $ t%
gall orce
2. +e
+end
ndin
ing
g stre
stress
ss due
due to rest
restra
rain ar)s $ b%
intt o ar)s

1. Tensile
ensile stress
stress $hoo(
$hoo( str
stress
ess%% due
due to centri
centriug
ugal orce $  t% :
al orce

 he centri!ugal !orce due to the rotational motion o! the !lywheel rim induces the
direct tensile stress in a rim. he tensile stress may be assumed to be uni!orm$ i! the
cross-sectional dimensions o! the rim are small as compared to its radius.
 

Mechanical #ystem (esign /0 131 (esign of Flywheels

Fig. 1.1< : Tensile 'tress

'tress in Flywheel i)

et$ t / tensile stress

stress in !lywheel
!lywheel rim due
due to centri!ug
centri!ugal !orce$ m2
al !orce$
B m / mean
mean radiu
radiuss o! the
the rim$
rim$ m
 / angular
angular spe
speed
ed o! the !lywhee
!lywheel$
l$ rads
rads
C / li
line
near
ar rim
rim spe
speed
ed at mean
mean radi
radius
us$$ ms
ms / B m 
6 / cr
cros
oss-
s-se
sect
ctio
iona
nall aare
reaa o! rim$$ m2 / bt
o! rim
)
 / mass density
density o! the
the !lywhee
!lywheel$
l$ "gm
"gm
 

Mechanical #ystem (esign /0 132 (esign of Flywheels

 *onsider a small element o! the !lywheel rim subtending an angle ,  at the centre
o! the !lywheel as shown in Fig. 1.10.

 *entri!ugal !orce acting on the rim element is given by$

dF / ;ass o! tth he eellement  *entripetal acceleration
/ Colume
olume o! the
the elemen
elementt  ;ass density  *entripetal acceleration
/ 3B m    
   64    B m 2
or dF /      6      2     ...3a4
 his centri!ugal !orce is acting in radial outward direction and hence induces the
tensile stress , t in the rim element.
 Form Fig. 1.10$ considering the e#uilibrium o! !orces acting on the rim element in
radial direction$

dF  2 t  6 sin / 0

  F / 2 t   6   sin
dF
d ...3b4
 @ubstituting 8#uation 3a4 in 8#uation 3b4$ we get$

   6      2    / 2 t   6   sin ...3c4

 6s is very small$ sin  

,ence 8#uation 3c4 becomes$

   6      2    / 2 t   6   

 t /     2

or    t "  V2  ...31.2)4

 &t is important to note that 8#uation 31.2)4 is obtained by assuming that the arms
have no restraining e!!ect on the rim and rim is !ree to e'pand.
2. +e
+end
ndin
ing
g str
stres
esss due
due to rest
restra
rain
intt o ar)ss $ b% :
o ar)

 Due to the rigidity o! the arms$ the portion o! the rim between the arms acts li"e a beam
!i'ed at both ends and subKected to uni!ormly distributed !orce$ as shown in Fig. 1.11.
his induces bending stress in the rim.
 

Mechanical #ystem (esign /0 133 (esign of Flywheels

Fig. 1.11 : +ending 'tress in Flywheel i)

 ength o! the rim between the !i'ed ends is$

 / ...3a4

wher
where$
e$  / le
leng
ngth
th o! th
thee rim
rim be
betw
twee
een
n the !i'e
!i'ed
d en
ends
ds$$ m
  / number o! arms.
 Lni!ormly distributed !orce on the rim per unit length is$
 p / centri!ugal !orce per unit length
2
/ 3bt  1  4  B m   
or p /    b t B m 2 ...3b4
where$
where$ p / uni!or
uni!ormly
mly distri
distribut
buted
ed load
load on the rim per unit
unit len
length
gth$$ m
 +e "now that$ !or a !i'ed beam subKected to the uni!ormly distributed !orce$ the
ma'imum bending moment is given by$
; / ...3c4
 @ubstituting 8#uations 3a4 and 3b4 in 8#uation 3c4$ we get$
; /
or ; / ...3d4
 he section modulus o! the rim cross-section 3section MM4 is$
N / ...3e4
 ,ence$ the ma'imum bending stress induced in the rim due to restraint o! the arms
is given by$
 b / /
/
or b " ...31.24
where$  b / bending
bending stress in the !lywhee
!lywheell rim due to restraint rms$ m2
restraint o! aarms$
 his 8#uation 31.24 is obtained by assuming that 3i4 the arms are rigid and do not
stretch$ and 3ii4 the arms are placed very close to each other.
 From 8#uation 31.24$ it is seen that the bending stress can be reduced by increasing
th
thee nu
numb
mber
er o! ar
arms
ms.. &t can
can be to tota
tall
lly
y elim
elimin
inat
ated
ed by usin
using
g a web
web type
type
 

Mechanical #ystem (esign /0 13 (esign of Flywheels

construction.
 &! the arms are !le'ible and !ree to stretch$ the 8#uation 31.2)4 gives the stress
induced in the rim and in such case  b / 0.
 On the other hand$ i! the arms are rigid$ and do not stretch$ the 8#uation 31.24
gives the stress induced in the rim and in such case t / 0.
 ,owever$ the arms are neither completely !le'ible nor completely rigid and hence
the actual condition lies between the two e'treme cases.
". 'esu
'esult
ltan
antt str
stres
ess
s in
in fly
flywh
whee
eell ri(  ri(/:
ri(

 6ccording to Pro!. anAa$ the stress in the !lywheel rim may be assumed to t o be e#ual
to three-!ourths o! the tensile stress due to centri!ugal !orce plus one-!orth o! the
 bending stress due to the restraint o! the arms.
 ,ence the resultant stress in the !lywheel rim is given by$

 ri) " ...31.254

@ubstituting 8#uations 31.2)4 and 31.24 in 8#uation 31.254$ we get$

rim /

or    ri) " ...31.2=4

where$ rim / resultant

resultant stress
stress in
in the !lywheel rim$ m2
!lywheel rim$
 / mass density
density o!
o! the !lywhee
!lywheell material$ "gm)
material$ "gm
C / li
line
near
ar rim
rim spe
speed
ed at mean
mean radi
radius
us$$ ms
ms / B m 
B m / mean
mean radiu
radiuss o! the
the rim$
rim$ m
 / angular
angular spe
speed
ed o! the !lywhee
!lywheel$
l$ rads
rads
t / th
thic
ic"n
"nes
esss o! th
thee ri
rim$
m$ m
  / number o! arms.

1.-. $tresses in Flywheel Ar(s :

he !ollowing stresses are induced in the !lywheel arms %

1. Tens
ensile
ile str
stress
ess due to centr
centriu
iugal
gal orce
orce acti
acting
ng on ri) $ ta%
on ri)
2. +endin
+endingg stress
stress due
due to torque
torque trans
trans)is
)issio
sion
n ro
ro)
) hub to ri)
ri) or ro)
ro) ri) to
to hub
$ ba%
1. centri ugal orce acting on ri) $ ta% :
Tensile stress due to centriugal

 Due to the centri!ugal !orce acting on the rim$ the arms will be subKected to the
direct tensile stress.
 he magnitude o! the tensile stress in the arm is same as the tensile stress in the rim
 

Mechanical #ystem (esign /0 13" (esign of Flywheels

and is given by$

 ta " ...31.2>4
where$
ta / tensile
tensile stress in the arm
arm due to centri!ug
centri!ugal
al !orce acting the rim$ m2 
acting on the
2. +ending stress due to torque trans)ission $ ba% :

 +hen the !lywheel receives the energy$ the accelerating tor#ue is transmitted !rom
the hub to the rim through the arms and when the !lywheel releases the energy$
the retarding tor#ue is transmitted !rom the rim to the hub through the arms.
 8ach arm is assumed to act as a cantilever beam !i'ed at the hub and carrying a
concentrated load at the rim$ as shown in Fig. 1.12.
et$ a / ma'imum
ma'imum accelerating
accelerating or retarding
retarding tor#ue
tor#ue acting
acting on the !lywheel
!lywheel
3i.e. ma'imum tor#ue di!!erence between the driving and load tor#ues
during the cycle4$ -m
B m / mean
mean radiu
radiuss o! the
the rim$
rim$ m
r  b / radius
radius o! the
the hub 3gener
3generally
ally ta"en
ta"en as
as 2r4$ m
r / ra
rad
diu
iuss o! th
thee sh
sha!
a!t$
t$ m
  / number o! arms

Fig. 1.12 : +ending 'tress in Flywheel !r)

 

Mechanical #ystem (esign /0 13% (esign of Flywheels

Na / section
section modulus
modulus o! the arms cross-sect
cross-section hub end$ m) 
ion at the hub
 he !orce acting on each arm at the rim is$

F / ...3a4

 he ma'imum bending moment acting on the arm at the hub end is$

; / F 3Bm   r  b4

or ; / 3Bm  r  b4   ...31.2?4

 ,ence$ the ma'imum bending stress induced in the arm at the hub end is given by$
by$

 ba / ...3b4

or  ba "  ...31.294

where$  ba / ma'imum

ma'imum bending
bending stress induced
induced in the arm
arm at the hub end
end
2

due to the tor#ue transmitted$ m

". 'esu
'esult
ltan
antt tten
ensi
sile
le st
stress in ar(  ar(/ :
ress

 he resultant tensile stress in the arm at the hub end is$
 ar) "  ta E  ba
or    ar) " E E31.)04

 he arms o! the !lywheel are usually o! elliptical cross-section with maKor a'is
twice the minor a'is.
 he maKor a'is o! the ellipse is in the plane o! rotation to give the arms greater 
resistance to bending and reduce the air resistance.
 he arms usually have a taper !rom the hub to the rim. he taper on the maKor a'is
is usually 1 in 50 while on the minor a'is it is 1 in 100.

 he number o! arms are usually =. ,owever$ !or large siAe !lywheels the number o! 
arms can be ?$ 10 or 12.
 From Fig. 1.12$ the section modulus o! the arm cross-section at the hub end is$

a " ...31.)14

where$ a1 / maKor a'is o!

o! the arm cross-s
cross-section
ection$$ m
 b1 / minor a'is o!
o! the arms cross-s
cross-section
ection$$ m
 he !actor o! sa!ety used in the design o! the !lywheel is between ? to 15.

1./ DEI$N OF OLID DI- FLYWHEEL

 

Mechanical #ystem (esign /0 13' (esign of Flywheels

he !ollowing procedure is adopted in the design o! a solid dis" !lywheels %

1. Deter)
Deter)ina
inatio
tion
n o Flyw
Flywhee
heell Di)
Di)ens
ension
ionss +ased
+ased on
on Fu
Funct
nction
ional
al equ
equire
ire)en
)entt :

3i4
3i4 he
he mat
mater
erial
ial is sel
selec
ected
ted !or
!or tthe
he !lyw
!lywhe
heel
el..
3ii4
3ii4 he
he ma'i
ma'imu
mum m !luc
!luctu
tuat
atio
ionn o! en
ener gy , - is determined !or the given application.
ergy
3iii4
3iii4 he re#u
re#uire
ired
d mass
mass moment
moment o! o! inerti
inertiaa o! !lywh
!lywheel
eel ,7 is determined$ "nowing the
 permissible value o! coe!!icient o! !luctuation
!luctuation o! speed.
3iv4
3iv4 (ased
(ased on th
thee re#u
re#uir
ired
ed mass mome
moment
nt o! iner
inerti
tia$
a$ the
the !lyw
!lywhe
heel
el dimen
dimensio
sions
ns are
are
determined.
2. Deter)ination o 'tresses in Flywheel :
3i4 he !!act
actor
or o! sa!et
sa!ety
y is selecte
selected
d !or the
the given
given appli
applicat
cation
ion.. he
he !ac
!actor
tor o!
o! sa!ety
sa!ety used
used
in the design o! !lywheel is between ? to 15.
3ii4
3ii4 he all
allowa
owable
ble stress
stress !or
!or the
the !lyw
!lywhee
heell is dete
determi
rmined
ned..
3iii4 he ma'imum
ma'imum tangentia
tangentiall or radial
radial stress
stress induced
induced in the !lywhe
!lywheel
el is determined
determined..
3iv4 For the
the sa!ety o! the !lywheel$
!lywheel$ the
the ma'imum
ma'imum tangenti
tangential
al or rradial
adial stress
stress induced
induced in
the !lywheel must be less than the allowable stress.
he procedure is elaborated through the subse#uent
s ubse#uent solved e'ample.
Exa(ple 1.0 :
6 machine is to be driven at >20 r.p.m. by an electric motor which e'erts a constant tor#ue.
he variation o! the load tor#ue on the machine during one cycle is shown in Fig.1.9.1. 6 solid
dis"
dis" !ly
!lywhe
wheelel made
made o! plain carbon steel 15*? 3@ut  / 250 mm24 is used to limit the
plain carbon
!luctuation o! speed to  2.0  o! the mean speed. he density o! the !lywheel material is
>.? gmcm) while the PoissonJs ratio is 0.292. he width o! the !lywheel is )5 mm. he !actor 
o! sa!ety is 10.
Design the !lywheel and estimate the necessary power o! an electric motor.

Fig. 1.;.1
$olution :
0iven : n / >20 r.p.m.  @ut / 250 mm2 
 

Mechanical #ystem (esign /0 13* (esign of Flywheels

*s / 0.0 3
3 2  i.e.
i.e. 4
4   / >?00 "gm) 
 / 0.292  b / 0.0)5 m 

 !  / 10.
1. a
a/
/i)u
i)u) F
Flu
luct
ctua
uati
tioon o
o -
-n
ner
ergy
gy :
From    diagram shown in Fig. 1.9.2
+or" done
done per cycle$
cycle$ + / 6rea
6rea unde
underr drivin
driving
g tor
tor#ue
#ue diag
diagram
ram
/ i  2
 2
 
or + / =.2?) i$ < ...3a4
6gain$
+or" done
done per cycle$
cycle$ + / 6rea
6rea under
under load
load tor
tor#ue
#ue diagra
diagram
m
/
/ )00 
or + / 92.>? < ...3b4
From 8#uations 3a4 and 3b4$

=.2?) i / 92.>?

i / 150 -m

Fig. 1.;.2
From Fig. 1.9.2$
/
  6( / 0.)>5  rad
@i
@imi
mila
larl
rly
y$ *D / 0.)
.)>5
>5  rad
  6
 6*
* / 6D  *D / 2   0.)>5   / 1.=25  rad
and (* / 6*  6( / 1.=25   0.)>5  / 1.25  rad
81 / 8) / 3150  0.)>5 4 / ??.)5>) <
and 82 / 320
200
0  15
150
04 3
3 : (*4
 

Mechanical #ystem (esign /0 13, (esign of Flywheels

/ 3202000  15
15004 3
3 : 1.25 4 / 1>=.>1= <
et the energy stored in the !lywheel at point 6 is ,-. here!ore$

8ner
8nergy
gy in !l
!lyw
ywheel at ( / 8 : 81 / 8 : ??.)5>)
heel
8ner
8nergy
gy in !l
!lyw
ywhe
heel
el at * / 8 : 81  82 / 8 : ??.)5>)  1>=.>1=
/ 8  ??.)5>)
8n
8ner
ergy
gy in !l
!lyw
ywhe
heel
el at D / 8 : 81  82 : 8)
/ 8  ??.
??.)5
)5>)
>) : ??.)
??.)5>
5>)
)/8
 ;a'imum energy in the !lyw
!lywheel
heel is$ 8ma' / 8 : ??.)
??.)5>
5>)
)<

and ;inimum energy in the !lywheel is$ 8min / 8  ??.)

??.)5>
5>)
)<
;a'imum !luctuation o! energy$

8 / 8ma'  8min

/ 38 : ??.)5>
??.)5>)4
)4  38  ??.)5>
??.)5>)4
)4

or    - " 1>8.>18 A

2. Flywheel Dia)eter :

;ean angular speed$  / / / >5.

5. ra
rad
ds

 ow$$
 ow 8 / & 2 *s

1>=.>1> / &  3>5.42  0.0

& / 0.>>>1 "g-m2

For a solid dis" !lywheel$
& /
/

or & /
0.>
.>>>
>>1
1 /
 B / 0.20=) m
  B / 20=.) mm
mm or
or 2
20
0> mm
mm
 " 2<> )) ...!ns.
3. 'tresses iin
n Fl
Flywheel :
he allowable stress !or the !lywheel is$
all /
/ / 25 mm2
C / B
 

Mechanical #ystem (esign /0 1- (esign of Flywheels

/ 0.20>  >5. / 15.=0>? ms

he ma'imum tangential or radial stress induced in the solid dis" !lywheel is$
t ma' /   r ma' /  C2  m2 

/ >?00  315.=0>?42 

/ 0.>?2  10= m2

or    t )a/ " <.>2 

))2 ? 2& ))2 ...!ns.
6s$ t ma'  all$ !lywheel is sa!e$
. *ower equire)ent :

P / +or"
or" don
onee pe
perr cy
cycl
clee  umber o! cycles per second
/ +  
he cycle duration o! the machine is o! 2
2   radians i.e. one revolution o! the sha!t.
,ence$ the number o! cycles per second is e#ual to the number o! revolutions o! sha!t per 
second.
 P / +  
/ 92.>?  
/ 11)10 +
or  * " 11.31 45 ...!ns.

1.10 DEI$N OF RI""ED FLYWHEEL

he !ollowing procedure is adopted in the design o! a rimmed !lywheels %

1. Deter)
Deter)ina
inatio
tion
n o Flyw
Flywhee
heell i) DDi)e
i)ensi
nsions
ons +as
+ased
ed on Fun
Functi
ctiona
onall equir
equire)e
e)ent
nt :
3i4
3i4 he
he mat
mater
erial
ial is sel
selec
ected
ted !or
!or tthe
he !lyw
!lywhe
heel
el..
3ii4
3ii4 he
he ma'i
ma'imu
mum
m !luc
!luctu
tuat
atio
ion
n o! en
energy Q -J is determined !or the given application.
ergy
3iii4
3iii4 he re#u
re#uire
ired
d mass momen
momentt o! inerti
inertiaa o! !lywhe
!lywheel
el Q 7J is determined$ "nowing the

 permissible value o! coe!!icient o! !luctuation

!luctuation o! speed.
3iv4
3iv4 (as
(ased
ed on the re#uire
re#uired d mass moment
moment o! inertia
inertia$$ the !lywheel
!lywheel rim di
dimen
mensio
sions
ns are
determined
2. Dete
Deter)
r)ininat
atio
ion
n o
o 'tr
'tres
esse
sess iin
n Fly
Flywh
whee
eell i)
i) :
3i4 he !!act
actor
or o! sa!et
sa!ety
y is selecte
selected
d !or the
the given
given appli
applicat
cation
ion.. he
he !ac
!actor
tor o!
o! sa!ety
sa!ety used
used
in the design o! !lywheel is between ? to 15.
3ii4
3ii4 he aallo
llowab
wable
le tensile
tensile stre
stress
ss !or the
the !lywh
!lywheel
eel rim
rim is dete
determi
rmined
ned..
3iii4 he resulta
resultant
nt stress
stress induced
induced in the
the !lywheel
!lywheel rim
rim is determined.
determined.
3iv4For the sa!ety o! the !lywhe
!lywheel el rim$ the
the resultant
resultant stress
stress induced
induced in the !lywheel
!lywheel rim
rim
must be less than the allowable tensile stress.
3. Dete
Deter)
r)in
inat
atio
ion
n o
o Di)
Di)enensi
sion
onss o
o Fly
Flywh
whee
eell !r)s
!r)s :
 

Mechanical #ystem (esign /0 11 (esign of Flywheels

Finally the dimensions o! !lywheel arms are determined by e#uating the resultant stress
in the arm with the allowable tensile stress.
he procedure is elaborated through the subse#uent
s ubse#uent solved e'amples.
Exa(ple 1.1 :
he    diagram !or a !our stro"e gas engine can be assumed to be consists o! !our triangles.
he areas measured are =00$ 50$ )0 and 150 mm 2 !or power$ e'haust$ suction and compression
stro"es respectively. he scale !or the    diagram is 1 mm 2 / 10 <. he engine is running at
a mean speed o! 500 r.p.m. he load tor#ue is constant throughout cycle. 6 rimmed !lywheel
made o! gray cast iron F7 150 33  / >000 "gm)4 is used to limit the !luctuation o! speed to )
o! the mean speed. he mean diameter o! the !lywheel rim is limited to 1 m. he rim
contributes 90 o! the re#uired mass moment o! inertia. he rim has a rectangular cross-
section with width to thic"ness ratio o! 2. he number o! arms are = having elliptical cross-
section with maKor a'is twice the minor a'is. &! the !actor o! sa!ety is 5$ design the !lywheel
and !ind the power developed by the engine.
he allowable shear stress !or the !lywheel sha!t is ta"en as 0 mm 2.

$olution :
0iven : 'cale or T #   diagra) : 1 mm2 / 10 <
n / 500 r.p.m.  @ut / 150 mm2 
 / >0
>00
00 "gm)
"gm  * s / 0 .0 ) 
Dm    1m  * / 0 .9 
 bt / 2   / =
a1 / 2 b1  ! / 5 
 / 0 mm2.
1. a
a/
/i)u
i)u) F
Flu
luct
ctua
uati
tio
on o
o -
-n
ner
ergy
gy :
For the !our stro"e engine$ one cycle consists o!   radians or two revolutions o! cran" 
sha!t. Fig. 1.10.1 shows the    diagram.
From Fig. 1.10.1

+or" done
done per cycle$
cycle$ + / =00
=00  350 : )0 : 1504G
1504G  scale
/ =00
=00  350
350 : )
)0
0 : 150
1504G
4G  10

or + / )>00 < ...3a4

6gain$

+or" done
done per cycle$
cycle$ + / 6rea
6rea under
under load
load tor
tor#ue
#ue diagra
diagram
m

/ o  
  ...3b4
From 8#uations 3a4 and 3b4$

o  
  / )>00
 

Mechanical #ystem (esign /0 12 (esign of Flywheels

  o / 29
9.
.)>
)> -m
-m

et$ ma' / ma'imum

ma'imum tor#ue
tor#ue produced
produced by the engine$
engine$ -m
-m

Fig. 1.1<.1
From Fig. 1.10.1$
+or
or"
"ddon
onee in
in pow
power
er stro
stro"e
"e /  ma'  
=00  s
 sccale /  ma'  
  =00  1
 100 /  ma'  
   ma' / )?1
?199.>
.>1?
1? -m
-m
6gain$ /
/
 6( / 2.?99 rad
;a'imum !luctuation o! energy$
8 / 6rea o!  6(*

/ 3ma'  o4  6(

/ 3)?1
3)?19.
9.>1
>1?
?  29.
29.)
)>4
>4  2.?99
 

Mechanical #ystem (esign /0 13 (esign of Flywheels

or  - " &11<.8& A
2. Di)en
i)enssions
ions o Fly
Flywhee
eell i) :

;ean angular speed$  /

/ / 52
52.)
.)=
= rad
rads
s
B m / / / 0.5 m
8 / & 2 *s 
5110.=5 / &  352.)=42  0.0)
 & / =2.1)? "g-m2
For a !lywheel rim$ &r  / *&
/ 0.9  =2.1)? / 55.922 "g-m2
 ow$$
 ow &r  / mr   / 32  B m b t 4 
or &r  / 2   b t 
55.922 / 2   30.54)  2t  t  >000
  t2 / 5.0?=  10  ) m2 
 t / 0.0>1) m
 t / >1.) mm or
or >2 mm
mm
and b / 2t / 2  >2 / 1 mm
 ) " &<< ))
t " >2 ))
b " 1 )) ...!ns.
3. 'tresses iin
n Fl
Flywheel i)
i) :

he allowable tensile stress !or the !lywheel is$

all /

/ / )0 mm2 

/ )0  10= m2

C / B m  / 0.5  52.)= / 2=.1? ms

he resultant stress induced in !lywheel rim is$

rim /    C2 

/ >000  32=.1?42  m2 

/ ?.1=5  10= m2

or  ri) " .18& 

))2 ? 3< ))2 ...!ns.
 

Mechanical #ystem (esign /0 1 (esign of Flywheels

6s rim  all$ !lywheel rim is sa!e.

. Di)en
i)enssions
ions o Fly
Flywhee
eell !r)s
r)s :

he ma'imum tor#ue acting on the sha!t is$

ma' / )?1?199.>
.>1?
1? -m
-m
/ )?1
?19
9>1
>1?
? -m
-mm
m
ma' /

)?
)?1
19>
9>1
1? /

  d / >?.=5 mm or ?0 mm
 d / 0.0? m
 r / / 0.0 m

 Badi
Badius
us o! sha!
sha!t$
t$ r / 0.
0.0
0 m

and Badius o! hub$ r b   / 2r / 2  0.0 / 0.0? m

he ma'imum accelerating tor#ue acting on the
t he !lywheel is given by$
a / ma'  o  
/ )?
)?19.>1?  29.)>
or a / )52
5255.2
.2?1
?1 -m
-m
he resultant stress induced in the !lywheel arm is
arm / $ m2 
/  >000  32=.1?42 : $ m2 
or arm / )5
)59?
9?)1
)10.
0.1
1 : $ m2
m
For the sa!ety o! the !lywheel arms$
arm /   all

)59?
)59?)1
)10.1 : / )0  10=
0.1
 / 2=
=0
01=
1=?
?9.9
9.9
  Na / 1.?=9)5  10  5 m)
,ence the re#uired section modulus o! the arm cross-section at the hub end is$

Na / 1.?=9)5  10  5 m) ...3c4

For the elliptical cross-section o! the arm at the hub end shown in Fig. 1.10.2
  Na /
/
or Na / ...3d4 Fig. 1.1<.2
 

Mechanical #ystem (esign /0 1" (esign of Flywheels

From 8#uations 3c4 and 3d4$

  / 1.?=9)5  10  5

  b1 / 0.0)=2 m
    b1 / )=.2
)=.2
 mm
mm or
or )
)>
> mm
mm
and a1 / 2 b1 / 2  )> / > mm
a1 " > ))
b1 " 3> )) ...!ns.
&. *ower Develo(ed by
by -n
-ngine
ine :
For !our stro"e engine$
 umber o! cycles per minute /
ns / / / 250
250 cy
cycl
cles
es pe
perr minu
minute
te
P / +or"
or" don
onee pe
perr cy
cycl
clee  umber o! cycles per second
/ +  

/ )>00  
/ 151=.== +
or * " 1&.18 45 ...!ns.
Exa(ple 1.11 :
6 machine is driven by a constant tor#ue electric motor running at a mean speed o! >20 r.p.m.
he load tor#ue o! the machine is given by 1000 : 00 sin  -m$ where$  is the angle o! 
rotation o! sha!t. 6 rimmed !lywheel made o! gray cast iron F7 200 3  / >050 "gm)4 is used
to limit the coe!!icient o! !luctuation o! speed to 0.02. he rim contributes 90 o! the !lywheel
e!!ect. he rim has a rectangular cross-section with width to thic"ness ratio o! 1.5. he number 
o! arms are = having elliptical cross-section with maKor a'is twice the minor a'is. he !actor o! 
sa!ety is ?. Design the !lywheel and draw its dimensional s"etch. 6lso !ind the re#uired power 
rating o! an electric motor.
2

he allowable shear stress !or the !lywheel sha!t is ta"en as 115mm .
$olution :
0iven : n / >20 r.p.m.  o / 100
100 : 00
00 sin
sin  -m
2
@ut / 20
200
0 m
mm     / >0
>050
50 "gm)
"gm
*s / 0.02  * / 0.9
 bt / 1.5   / =
a1 / 2 b1  !  / ?
mm2.
 / 115 mm
1. a
a/
/i)u
i)u) F
Flu
luct
ctua
uati
tio
on o
o -
-n
ner
ergy
gy :
Fig. 1.11.1 shows the    diagram. 6s load tor#ue ,To is a !unction o! sin , $ the
 

Mechanical #ystem (esign /0 1% (esign of Flywheels

cycle duration is o! )=0

)=0 sha!t rotation i.e. one revolution o! the sha!t.

Fig. 1.11.1