1. A flywheel absorbs mechanical energy by increasing its angular velocity when the load torque is lower than the source torque, and delivers energy by decreasing its angular velocity when the load torque is higher.
2. The turning moment diagram graphs the torque on the crankshaft against the crank angle, showing how torque varies over each cycle. The fluctuations in torque cause corresponding speed variations unless balanced by a flywheel.
3. The flywheel absorbs energy when the engine delivers more work than required, increasing its speed, and provides energy when the engine delivers less work than required, decreasing its speed. The maximum energy fluctuations determine the required flywheel size.
1. A flywheel absorbs mechanical energy by increasing its angular velocity when the load torque is lower than the source torque, and delivers energy by decreasing its angular velocity when the load torque is higher.
2. The turning moment diagram graphs the torque on the crankshaft against the crank angle, showing how torque varies over each cycle. The fluctuations in torque cause corresponding speed variations unless balanced by a flywheel.
3. The flywheel absorbs energy when the engine delivers more work than required, increasing its speed, and provides energy when the engine delivers less work than required, decreasing its speed. The maximum energy fluctuations determine the required flywheel size.
1. A flywheel absorbs mechanical energy by increasing its angular velocity when the load torque is lower than the source torque, and delivers energy by decreasing its angular velocity when the load torque is higher.
2. The turning moment diagram graphs the torque on the crankshaft against the crank angle, showing how torque varies over each cycle. The fluctuations in torque cause corresponding speed variations unless balanced by a flywheel.
3. The flywheel absorbs energy when the engine delivers more work than required, increasing its speed, and provides energy when the engine delivers less work than required, decreasing its speed. The maximum energy fluctuations determine the required flywheel size.
1. A flywheel absorbs mechanical energy by increasing its angular velocity when the load torque is lower than the source torque, and delivers energy by decreasing its angular velocity when the load torque is higher.
2. The turning moment diagram graphs the torque on the crankshaft against the crank angle, showing how torque varies over each cycle. The fluctuations in torque cause corresponding speed variations unless balanced by a flywheel.
3. The flywheel absorbs energy when the engine delivers more work than required, increasing its speed, and provides energy when the engine delivers less work than required, decreasing its speed. The maximum energy fluctuations determine the required flywheel size.
Dr. S. P. Harsha Mechanical & Ind. Engg. Deptt, INDIAN INSTITUTE OF TECHNOLOGY ROORKEE S. No. Contact Hours Particulars 1. Force Analysis of Mechanisms: Review of basic principle of statics, Concept of free body and its 10 equilibrium, static force analysis; friction effects; forces on gear teeth, D’Alembert’s principle; dynamic force analysis; force analysis of cam-follower system, equivalent dynamical systems; dynamic analysis of reciprocating engines; practical examples from actual machines.
Flywheels and Governors: Fluctuation of energy and speed; calculation of 06
2. flywheel size. Analysis of different types of governors; effect of friction; controlling force curves; sensitivity; stability; governor effort and power. 3. Balancing: Balancing of rotating masses on one plane and in different parallel planes. 07 Balancing of slider crank mechanisms; balancing of in-line, V- and locomotive engines; principles of balancing machine. 4. Friction Devices: Coulomb friction; belt drive system, pivots and collars, power screws; 06 plate and cone clutches; band and block brakes. 5. Gyroscope: Gyroscopic action, equation for regular precession and gyroscopic torque. 02 6. Mechanical Vibration: Simple Harmonic motion, Conservative systems, Free vibrations 11 of systems without damping; equilibrium and energy methods for determining natural frequency; Rayleigh’s method, free vibrations of system with viscous damping; over damped, critically and under damped systems; logarithmic decrement; Forced vibrations of systems with viscous damping; equivalent viscous damping; impressed forces due to unbalanced masses and excitation of supports; vibration isolation; transmissibility; whirling of shaft, Introduction to multi degree of freedom system vibrations: discrete and continuous systems.
Total 42 Flywheel A flywheel is an energy storage device. It absorbs mechanical energy by increasing its angular velocity and delivers energy by decreasing its angular velocity. Commonly, the flywheel is used to smooth the flow of energy between a power source and its load. If the load happens to be a punch press, the actual punching operation requires energy for only a fraction of its motion cycle. If the power source happens to be a two-cylinder four- cycle engine, the engine delivers energy during only about half of its motion cycle. Introduction In practice, there are two following types of cases where reciprocating engine mechanism is used : 1) An internal combustion engine or a steam engine which is used as a prime mover to drive generators, centrifugal pumps, etc. 2) A punching machine which is driven by a prime mover like electric motor. In both these cases either a variable torque is supplied where demand is a constant torque or demand is variable torque whereas constant torque is supplied. In both these cases there is mismatch between the supply and demand. This results in speed variation. Flywheel’s-Function The main function of a flywheel is to smoothen out variations in the speed of a shaft caused by torque fluctuations. If the source of the driving torque or load torque is fluctuating in nature, then a flywheel is usually called for. Many machines have load patterns that cause the torque time function to vary over the cycle. Rim Type Flywheel
Tapered Disc Flywheel Cont…
In other words, a flywheel controls the speed variations
caused by the fluctuation of the engine turning moment during each cycle of operation. In machines where the operation is intermittent like punching machines, shearing machines, riveting machines, crushers, etc., the flywheel stores energy from the power source during the greater portion of the operating cycle and gives it up during a small period of the cycle.
Thus, the energy from the power source to the machines is
supplied practically at a constant rate throughout the operation. Turning moment diagram The turning moment diagram (also known as crank effort diagram) is the graphical representation of the turning moment or crank-effort for various positions of the crank. It is plotted on Cartesian co-ordinates, in which the turning moment is taken as the ordinate and crank angle as abscissa. 1. Turning Moment Diagram for a Four Stroke Cycle Internal Combustion Engine, Multi-cylinder Engine, Single Cylinder Double Acting Steam Engine. Turning Moment Diagram
The diagram which is
plotted for ‘M’ against crank angle ‘’ is called turning moment diagram. Turning Moment Diagram There are two forces, i.e. gas force and inertia force. Gas force = p x Piston area The variation in the gas where p is the gas pressure. force will be due to the change in pressure. The gas force and inertia force have been plotted for all the four strokes. The net force is the resultant of gas force and inertia force. It can be plotted in reference to as
The value of O2D is given by
For various values of , O2D can be determined and then
plotted. Turning Moment Diagram The approximate turning moment ‘M’ = Net force x O2D
The turning moment in the suction stroke and exhaust stroke is very small. In case of compression stroke and expansion stroke turning moment is higher. In compression stroke, energy is to be supplied and in expansion stroke, large amount of energy is available. At the same time it is observed that there is large variation of turning moment during the cycle. The variation in the turning moment results in corresponding variation in speed of the crank. Use of Turning Moment Diagram Cont… The turning moment of the crank shaft is given by,
Where, FP = Piston effort, r = Radius of crank, n = Ratio of the connecting rod length and radius of crank, and θ = Angle turned by the crank from inner dead centre. • Cont…
If
M = Torque on the crankshaft at any instant, and
Mmean = Mean resisting torque.
• Then, accelerating torque on the rotating parts of the engine,
= M – Mmean
If (M – Mmean) is positive, the flywheel accelerates and if (M – Mmean) is
negative, then the flywheel retards. Fluctuation of Energy The fluctuation of energy may be determined by the turning moment diagram for one complete cycle of operation. Consider the turning moment diagram for a single cylinder double acting steam engine as shown in Fig.
We see that the mean resisting torque line AF cuts the turning moment diagram at points B, C, D and E. When the crank moves from a to p, the work done by the engine is equal to the area aBp, whereas the energy required is represented by the area aABp.
In other words, the engine has done less work (equal to the area aAB) than the requirement. This amount of energy is taken from the flywheel and hence the speed of the flywheel decreases. Cont.. Now the crank moves from p to q, the work done by the engine is equal to the area pBbCq, whereas the requirement of energy is represented by the area pBCq. Therefore, the engine has done more work than the requirement. This excess work (equal to the area BbC) is stored in the flywheel and hence the speed of the flywheel increases while the crank moves from p to q. Similarly, when the crank moves from q to r, more work is taken from the engine than is developed. This loss of work is represented by the area C c D. To supply this loss, the flywheel gives up some of its energy and thus the speed decreases while the crank moves from q to r. Cont.. As the crank moves from r to s, excess energy is again developed given by the area D d E and the speed again increases. As the piston moves from s to e, again there is a loss of work and the speed decreases. The variations of energy above and below the mean resisting torque line are called fluctuations of energy. The areas BbC, CcD, DdE, etc. represent fluctuations of energy. Cont.. A little consideration will show that the engine has a maximum speed either at q or at s. This is due to the fact that the flywheel absorbs energy while the crank moves from p to q and from r to s.
On the other hand, the engine has a minimum speed either at p or
at r. The reason is that the flywheel gives out some of its energy when the crank moves from a to p and q to r.
The difference between the maximum and the minimum energies is
known as maximum fluctuation of energy. Determination of Maximum Fluctuation of Energy
Turning moment diagram for a multi-cylinder engine.
A turning moment diagram for a multi-cylinder engine is shown
by a wavy curve in Fig. The horizontal line AG represents the mean torque line. Cont… Let a1, a3, a5 be the areas above the mean torque line and a2, a4 and a6 be the areas below the mean torque line. These areas represent some quantity of energy which is either added or subtracted from the energy of the moving parts of the engine. Let the energy in the flywheel at A = E, then from Fig., we have Energy at B = E + a1 Energy at C = E + a1– a2 Energy at D = E + a1 – a2 + a3 Energy at E = E + a1 – a2 + a3 – a4 Energy at F = E + a1 – a2 + a3 – a4 + a5 Energy at G = E + a1 – a2 + a3 – a4 + a5 – a6 = Energy at A (i.e. cycle repeats after G) Cont… Let us now suppose that the greatest of these energies is at B and least at E. Therefore, Maximum energy in flywheel = E + a1 Minimum energy in the flywheel = E + a1 – a2 + a3 – a4 Therefore, Maximum fluctuation of energy,
Δ E = Maximum energy – Minimum energy
= (E + a1) – (E + a1 – a2 + a3 – a4) = a2 – a3 + a4 Coefficient of Fluctuation of Energy (CE) • It may be defined as the ratio of the maximum fluctuation of energy to the work done per cycle. • Mathematically, coefficient of fluctuation of energy,
• The work done per cycle (in N-m or joules) may be obtained by using the following two relations : 1. Work done per cycle = Tmean × θ • Where, Tmean = Mean torque, and θ = Angle turned (in radians), in one revolution. = 2π, in case of steam engine and two stroke i. c. engines, = 4π, in case of four stroke internal combustion engines. Cont… • The mean torque (Tmean) in N-m may be obtained by using the following relation :
• Where, P = Power transmitted in watts, N = Speed in r.p.m., and ω = Angular speed in rad/s = 2 πN/60
2. The work done per cycle may also be obtained by using the following relation:
• Where, n = Number of working strokes per minute, = N, in case of steam engines and two stroke i. c. engines, = N/2, in case of four stroke internal combustion engines. Note: The following table shows the values of coefficient of fluctuation of energy for steam engines and internal combustion engines. Coefficient of Fluctuation of Speed (CS) The difference between the maximum and minimum speeds during a cycle is called the maximum fluctuation of speed.
The ratio of the maximum fluctuation of speed to the mean speed is
called the coefficient of fluctuation of speed.
Let,
N1 and N2 = Maximum and minimum speeds in r.p.m. during the cycle,
and
Therefore, coefficient of fluctuation of speed
Cont..
The coefficient of fluctuation of speed is a limiting factor in the
design of flywheel. It varies depending upon the nature of service to which the flywheel is employed.
Note: The reciprocal of the coefficient of fluctuation of speed is known as coefficient of steadiness and is denoted by m. Energy Stored in a Flywheel
A flywheel is shown in Fig. We know that in fluctuation of energy that
when a flywheel stores energy, its speed increases and when it gives up energy, its speed decreases. Let, m = Mass of the flywheel in kg, k = Radius of gyration of the flywheel in metres, I = Mass moment of inertia of the flywheel about its axis of rotation in kg-m2 = m.k2, N1 and N2 = Maximum and minimum speeds during the cycle in r.p.m., ω1 and ω2 = Maximum and minimum angular speeds during the cycle in rad/s,
We know that the mean kinetic energy of the flywheel,
Cont… As the speed of the flywheel changes from ω1 to ω2, the maximum fluctuation of energy,
= m.v2.CS Note: Since ω = 2 π N/60, therefore equation (i) may be written as DIMENSIONS OF THE FLYWHEEL RIM Consider a rim of the flywheel as shown in Fig. Let, D = Mean diameter of rim in metres, R = Mean radius of rim in metres, A = Cross-sectional area of rim in m2, ρ = Density of rim material in kg/m3, N = Speed of the flywheel in r.p.m., ω = Angular velocity of the flywheel in rad/s, v = Linear velocity at the mean radius in m/s = ω .R = π D.N/60, and σ = Tensile stress or hoop stress in N/m2 due to the centrifugal force. Cont…. Consider a small element of the rim as shown shaded in Fig. Let it subtends an angle δθ at the centre of the flywheel. Volume of the small element = A × R.δθ Therefore, mass of the small element dm = Density × volume = ρ.A.R.δθ And centrifugal force on the element, acting radially outwards, dF = dm.ω2.R = ρ.A.R2.ω2.δθ Vertical component of dF = dF.sin θ = ρ.A.R2.ω2.δθ.sin θ Cont…. Therefore, total vertical upward force tending to burst the rim across the diameter X Y.
= 2ρ.A.R2.ω2 . . . (i)
This vertical upward force will produce tensile stress or hoop
stress (also called centrifugal stress or circumferential stress), and it is resisted by 2P, such that 2P = 2 σ·A . . . (ii) Cont…. Equating equations (i) and (ii), 2.ρ.A.R2.ω2 = 2σ.A or σ = ρ.R2.ω2 ; σ = ρ.v2 ....( v = ω.R) ...(iii) We know that mass of the rim, m = Volume × density = π D. A. ρ ...(iv)
From equations (iii) and (iv), we may find the value of the mean radius and cross-sectional area of the rim. If the cross-section of the rim is a rectangular, then A=b×t Where, b = Width of the rim, and t = Thickness of the rim FLYWHEEL IN PUNCHING PRESS We have discussed that the function of a flywheel in an engine is to reduce the fluctuations of speed, when the load on the crankshaft is constant and the input torque varies during the cycle. The flywheel can also be used to perform the same function when the torque is constant and the load varies during the cycle. Such an application is found in punching press or in a rivetting machine. A punching press is shown diagrammatically in Fig. The crank is driven by a motor which supplies constant torque and the punch is at the position of the slider in a slider-crank mechanism. From Fig. we see that the load acts only during the rotation of the crank from θ = θ1 to θ = θ2, when the actual punching takes place and the load is zero for the rest of the cycle. Cont… Unless a flywheel is used, the speed of the crankshaft will increase too much during the rotation of crank from θ = θ2 to θ = 2π or θ = 0 and again from θ = 0 to θ = θ1, because there is no load while input energy continues to be supplied. On the other hand, the drop in speed of the crankshaft is very large during the rotation of crank from θ = θ1 to θ = θ2 due to much more load than the energy supplied. Thus the flywheel has to absorb excess energy available at one stage and has to make up the deficient energy at the other stage to keep to fluctuations of speed within permissible limits. Cont… This is done by choosing the suitable moment of inertia of the flywheel. Let E1 be the energy required for punching a hole. This energy is determined by the size of the hole punched, the thickness of the material and the physical properties of the material. Let,
d1 = Diameter of the hole punched,
t1 = Thickness of the plate, and τu = Ultimate shear stress for the plate material. Maximum shear force required for punching,
FS = Area sheared × Ultimate shear stress
= π d1 t1 τu Cont… It is assumed that as the hole is punched, the shear force decreases uniformly from maximum value to zero.
Work done or energy required for punching a hole,
Assuming one punching operation per revolution, the energy
supplied to the shaft per revolution should also be equal to E1. The energy supplied by the motor to the crankshaft during actual punching operation, Cont… Balance energy required for punching,
This energy is to be supplied by the flywheel by the decrease in its
kinetic energy when its speed falls from maximum to minimum. Thus maximum fluctuation of energy, Cont… The values of θ1 and θ2 may be determined only if the crank radius (r), length of connecting rod (l) and the relative position of the job with respect to the crankshaft axis are known. In the absence of relevant data, we assume that
Where, t = Thickness of the material to be punched, s = Stroke of the punch = 2 × Crank radius = 2r. By using the suitable relation for the maximum fluctuation of energy (ΔE), we can find the mass and size of the flywheel.
