Flywheels

Item (1-27) MD2 Reviewer by Jas Tordillo.

1. A cast iron flywheel is rotated at a speed of 1200 rpm and having a mean rim radius of 1 foot. If the
weight of the rim is 30 lbs, what is the centrifugal force? Use C = 41. (ME Bd. Oct 95).

2. What pressure is required to punch a whole 2 inches diameter through a 1⁄4 in steel plate? (ME Bd.
Apr 95).

3. A flywheel for a punching press must be capable of furnishing 3400 N-m of energy during the 25%
revolution while the hole is being punched. The flywheel maximum speed is 200 rpm and the speed
decreases 8.7% during the load stroke. The mean radius of the rim is 1016 mm and contributes 90% of
the energy requirements. Approximate total weight of the flywheel to be 1.20 times the weight of the
rim. Compute the total weight of the flywheel. (ME Bd. Oct 94).

4. A shearing machine requires 150 kg-m of energy to shear a steel sheet, and has a normal speed of 3
rev/sec, slowing down to 2.8 rev/sec during the shearing process. The flywheel has a mean diameter of
75 cm and weighs 0.018 kg/cm^3. The width of the rim is 30 cm. If the hub and arms of the flywheel
account for 15% of its total weight, find the thickness of the rim. (ME Bd. Oct 2006)

5. A flywheel weighing 910 kg has a radius of gyration of 1524 mm. The shaft journals are 304.8 mm in
diameter and have a coefficient of friction of 0.06. After the wheel reaches 120 rpm, the driving force is
withdrawn and the wheel slows to 60 rpm. How much energy thus the wheel loss? (ME Bd. Oct 92).

6. How many 5/16 inch holes can be punch in one motion in a steel plate made of SAE 1010 steel, 7/16
inch thick using a force of 55 tons. The ultimate strength for shear is 50 ksi and use 2 factor of safety.
(ME Bd. Oct 2006)

7. A flywheel rotates at 120 rpm or 12.57 rad/sec slowed down to 102 rpm or 10.68 rad/sec during the
punching operation that requires second of the punching portion of the cycle. Compute the angular
acceleration of the flywheel in rad/sec2. (ME Bd. Apr 2006)

8. The flywheel on a press rotating at 100 rpm is slowed down to 90 rpm during a punching operation
that requires 1 second for punching portion of the system cycle. Compute the angular deceleration in
rad/sec-sec the flywheel undergoes. Given the angular velocities for 120 rpm is 10.47 rad/sec. And for
90 mph 9.42 rad/sec. (ME Bd. Apr 2003)

9. A punching machine flywheel accelerates from rest with α = 5 radians/sec-sec. In 5 seconds, how
many revolutions are achieved? (ME Bd. Apr 2003)

10. Find the working pressure required to punch 4" diameter hole on ¼ " thick steel plate. (ME Bd. Apr
2002)

11. A mechanical press is used to punch 6 holes per minute on a 25 mm thick plate. The hole is 25 mm in
diameter and the plate has an ultimate strength in shear of 420 MPa. The normal operating speed is 200
rpm and it slows down to 180 rpm during the process of punching. The flywheel has a mean diameter of
one meter and the rim width is 3 times the mean diameter and the density of cast iron is 7,200 kg per
cubic meter. Find the power in thickness. Assume that the hub and arm account for 5% of the rim
weight concentrated at KW required to drive the press.

12. From the previous problem, find the width and thickness of the flywheel rim in millimeters.

13. It is found that the shearing machine requires 205 joules of energy to shear a specific gauge of sheet
metal. The mean diameter of the flywheel is to be 76.2 cm. The normal operating speed is 200 rpm, and
slows down to 180 rpm during shearing process. The rim width is 30.48 cm and the weight of the cast
iron is 7,196.6 kg/m^3. find the thickness of the rim, assuming that the hub and arms account for 10% of
the rim weight concentrated on the mean diameter.

14. A sheet metal working company purchased a shearing machine from a surplus dealer without a
flywheel. It is calculated that the machine will use 2380 joules of energy to shear a 1.2 mm thick sheet
metal. The flywheel to be used will have a mean diameter of 91.44 cm with a width of 25.4 cm. The
normal operating speed is 180 rpm and slows down to 160 rpm during the shearing process. Assuming
that the arms and the hub will account for 12% of the rim weight concentrated at the mean diameter
and that the material density is 0.26 lb/cu. in. Compute the weight of the flywheel.

15. From the previous problem, determine the thickness of the rim.

16. A 48 inch (121.9 cm) diameter spoked steel flywheel having a 12 inch wide x 10 inches (30.5 x 25.4
cm) deep rim rotates at 200 rpm. How long a cut (in inches) can be stamped in one (1) inch (2.5 cm)
thick aluminum plate if ultimate shearing strength of aluminum is 40,000 lb/in^2 (275,789.9 KPa).
During stamping, the force exerted by the stamp varies from a maximum F lb at the point of contact to
zero lb when the stamp emerges from the metal. Neglect the weight of the flywheel and spokes and use
0.28 lb/in^3 density for flywheel material.

17. Determine the mass moment of inertia with respect to the axis of rotation, the flywheel effect, and
the radius of gyration of cast iron flywheel having the following specifications:

Rim: OD 1300 mm; ID = 1150 mm;

Face Width = 310 mm

Hub: OD 220 mm; ID = 110 mm

Length = 260 mm

Arms: 6 with 50 x 80 mm in cross-section and considered as slender rods, L = 480 mm.

Density of cast-iron is 7.10 x 10 kg/mm2

18. A cast-iron flywheel has an outside diameter of 3 meters and a rim 110 mm thick, 480 mm wide. The
ultimate tensile stress of good grade cast-iron is 230 MPa. If it runs at 220 rpm, determine the hoop
tension in rim assuming no flows in manufacture and tension in the arms negligible.

19. From the previous problem, determine the bursting speed assuming no flows in manufacture and
tension in the arms negligible.

20. An energy of 2900 N-m is required to cut 25-mm steel bars by a shearing machine. The cutting
operation is 1/10 of a revolution and the maximum cut per minute is 15. The 21. An energy of 2900 N-m
is required to cut 25-mm square steel bars by a shearing machine. The mean diameter of the machine
flywheel is 950 mm and rotating at 120 rpm. Considering the flywheel. Assume that the flywheel slowed
down 10% while delivering energy. Considering the mass of the wheel to be concentrated entirely at the
rim, calculate the weight of the flywheel. Assume that the flywheel slowed down 10% while delivering
energy.

21. It is desired to determine the dimensions of two solid flywheels, built up of plate discs bolted
together, which will have the same energy stored as in a car weighing 18kN and travelling 95 kph. The
flywheel has an outside diameter of 1200 mm and the tire diameter is 710 mm. If the flywheel is driven
from direct peripheral contact with the wheels, determine the necessary kinetic energy of one flywheel.

22. From the previous problem, determine the moment of inertia of one flywheel.

23. From the previous problem, determine the radius of the gyration.

24. From the previous problem, determine the thickness of the flywheel.

25. A press is designed to punch 24 mm-diameter holes through 12 mm thick steel plates. Ultimate
shear strength of steel plate is 360 MPa. It has been proved that the force required at the punch is 25%
greater than that required to remove the slug because of friction between the tool and die. The press is
operated at 30 rpm through gears having a ratio of 7 to 1, and because of the location of the shaft, the
wheel may not be larger than 850 mm in diameter. The punching operation takes place over 75 degree
of eccentric travel and the speed fluctuation is to be limited to 15%. The overall mechanical efficiency is
80%. Determine the cross section of the rim if the rim provides 95% of the flywheel effect. Assume the
rim has square cross-section.

26. from the previous problem, what would be the motor power supplied to the press with the flywheel,
if the maximum number of punching is 30 per minute?

27. from the previous problem, what would be the motor power supplied to the without the flywheel, if
the maximum number of punching is 30 per minute?

Item (28-30) MD2 Reviewer Class Examples.

28. A flywheel for a punching press must be capable of furnishing 3400 N m of energy during the 25%
revolution while the hole is being punched. The flywheel maximum speed is 200 rpm and the speed
decreases 8.7% during the load stroke. The mean radius of the rim is 1,016 mm. compute the weight of
the flywheel in N.

29. A shearing machine requires 150 kg-m of energy to shear a steel sheet, and has a normal speed of 3
rps, slowing down to 2.8 rps during the shearing process. The flywheel has a mean diameter of 75 cm
and weighs 0.018 kg/cm^3. The width of the rim is 30 cm. If the hub and arms of the flywheel account
for 15% of its total weight, find the thickness of the rim in cm.

30. A mechanical press is used to punch 6 holes per minute on a 25 mm thick plate. The holes is 25 mm
in diameter and the plate has an ultimate strength in shear of 420 MPa. The normal operating speed is
200 rpm and it slows down to 180 rpm during the process of punching. The flywheel has a mean
diameter of 1 meter and the width is 3 times the thickness. Assume that the hub and arm account for
5% of the rim weight kg concentrated at the mean diameter and the density of cast iron is 7,200
kg/m^3.