WEEK # 08-09

FLY WHEEL INSTRUCTOR: Haseeb Ahmed

SPRING 2020
 INTRODUCTION
A flywheel used in machines serves as a reservoir which stores energy during
the period when the supply of energy is more than the requirement and
releases it during the period when the requirement of energy is more than
supply.

• The flywheel absorb excess energy developed in power Stroke and

its speed increases.
• The flywheel release the energy to the crankshaft during the non-
power stroke and its speed deceases.
Examples

• Steam Engines
• Internal Combustion Engines
• Reciprocating Compressor
• Pumps
• Machine Tools
 INTRODUCTION
▪Many machines have load patterns that cause the
torque-time function to vary over the cycle like Piston
compressors, punch presses, rock crushers, etc.

▪The prime mover can also introduce torque oscillations to

the transmission shaft. Internal-combustion engines with
one or two cylinders are an example.

▪Systems may have both smooth torque sources and

smooth loads, such as an electrical generator driven by a
steam turbine.
INTRODUCTION

Smooth-acting devices have no need for a

flywheel.

If the source of the driving torque or the load

torque has a fluctuating nature, then a
flywheel is usually called for.
 EQUATION OF MOTION-FLYWHEELS
Load
Torque
The torque is dependent Driving
on its angular (-ve)
Torque
displacements and (+ve)
angular velocity.

Moment of Inertia for circular disk

Here 𝛾 is material’s
weight density
Double
Derivative
CONCEPT-4 STROKE ENGINE

https://www.youtube.com/watch?v=M1h9eU9YH5o
 WORK AND KINETIC ENERGY
An input power source subjects a
flywheel to a constant torque Ti
while the shaft rotates from θ1 to
θ2. In turn the shaft velocity
increases from ω1 to ω2.
As shown, the shaft now rotates
from θ2 to θ3 with zero torque and
hence with zero acceleration.
Therefore ω3 = ω 2.
From θ3 to θ4 a load, or output
torque, of constant magnitude is
applied, causing the shaft to slow
down from ω3 to ω4.
 WORK AND KINETIC ENERGY
The work input to the
flywheel is the area of
the rectangle between
θ1 and θ2

The work output to the

flywheel is the area of
the rectangle between
θ3 and θ4.
 change in shaft
speed during a
cycle is called its
COEFFICIENT OF FLUCTUATION fluctuation.

This coefficient of fluctuation is a design

parameter to be chosen by the designer. It
is typically set to a value between 0.01
and 0.05 for precision machinery, and as
high as 0.20 for crushing or hammering
machinery, which correspond to a 1 to 5%
fluctuation in shaft speed.
The smaller this chosen value, the larger the
flywheel will have to be. This presents a
design trade-off.
A larger flywheel will add more cost and
weight to the system, which are factors that
have to be considered against the
smoothness of operation desired.
DETERMINING INTERTIA OF FLYWHEEL

The physical flywheel’s mass

moment of inertia Im is set
Moment of equal to the required system Is.
Inertia of But, if the moments of inertia of
Complete the other rotating elements on
System the same shaft (such as the
motor) are known, the physical
flywheel’s required Im can be
reduced by those amounts.
DESIGN OF FLYWHEEL-DISCUSSION
The most efficient flywheel design in terms of maximizing Im for
minimum material used is one in which the mass is concentrated in its
rim and its hub is supported on spokes, like a carriage wheel.

This puts the majority of the mass at the largest radius possible and
minimizes the weight for a given Im.

Dense materials such as cast iron and steel are the obvious choices for
a flywheel.
 DESIGN OF FLYWHEEL-DISCUSSION

Fig. A shows the change in the torque of Fig. B after the addition of a flywheel
sized to provide a coefficient of fluctuation of 0.05.
The peak value is now 8,730 lb-in instead of 34,200 lb-in. A much smaller
horsepower motor can now be used because the flywheel is available to
absorb the energy returned from the load during the cycle.
ENERGY VARIATION IN A ROTATING SYSTEM
In Fig. flywheel, designed as a flat circular disk, attached to a motor shaft. The motor
supplies a torque magnitude Tm, which we would like to be as constant. Assume that the
load on the other side of the flywheel demands a torque Tl, which is time varying. This
torque variation can cause the shaft speed to vary depending on the torque speed
characteristic of the driving motor. We need to determine how much Im to add in the
form of a flywheel to reduce the speed variation of the shaft to an acceptable level.

=E
EXAMPLE # 01
The nominal speed of the engine is to be 250 rad/s.
(a) Integrate the torque-displacement function for one cycle and find the energy that can
be delivered to a load during the cycle.
(b) Determine the mean torque Tm.
(c) Find energy fluctuation is approximately between 0° and 180° on the torque diagram.
Using a coefficient of speed fluctuation Cs = 0.1, find a suitable value for the flywheel
inertia.
(d) Find ω2 and ω1
 SOLUTION
(a) Use Simpson’s Approximation to calculate area under the curve of torque
displacement diagram. This will give us the total energy.

𝟒𝝅 𝒃−𝒂
Here n = 48 intervals, ∆θ = ; ∆θ =
𝟒𝟖 𝒏

(b) Divide the value of Energy by angular displacement to calculate Tm.

(c) Calculate the area under the curve for T-Tm for duration 0° to 180°. This
will give us E2-E1. Eventually we can calculate Im.
(d) Calculate the values for w2 and w1 respectively.
STRESSES IN FLYWHEEL
As a flywheel spins, the centrifugal force acts upon its distributed mass and
attempts to pull it apart. The stress state in a spinning flywheel is analogous
to a thick walled cylinder under internal pressure.

γ = material weight density, ω = angular velocity in rad/sec, ν = Poisson’s

ratio, r is the radius to a point of interest, and ri, ro are inside and outside
radii of the solid-disk flywheel.
STRESSES IN FLYWHEEL
The tangential stress is a maximum at the
inner radius.

The radial stress is zero at inside and outside

radii and peaks at an interior point but is
everywhere less than the tangential stress.
The forces causing the stress are a function of
rotational speed i.e. there will always be some
speed that will fail the flywheel. A safety factor
against over speeding can be determined as the
quotient of the speed that will cause yielding over
the operating speed:
CASE OF FLYWHEEL IN PUNCH PRESS
Punch-press torque demand often takes the form
of a severe impulse and the running friction of
the drive train.

The motor overcomes the minor task of

overcoming friction while attending to the major
task of restoring the flywheel’s angular speed.

Neglecting the running friction, Euler’s equation

can be written as:
(a) Punch-press torque demand during punching.
(b) Squirrel cage electric motor torque speed characteristic.
CASE OF FLYWHEEL IN PUNCH PRESS
Punch presses can have the motor and flywheel on one shaft, then, through a
gear reduction, drive a slider-crank mechanism that carries the punching
tool.

The motor can be connected to the punch continuously, creating a punching

rhythm, or it can be connected on command through a clutch that allows one
punch and a disconnect.

The motor and flywheel must be sized for the most demanding service,
which is steady punching. The work done is given by:
CASE OF FLYWHEEL IN PUNCH PRESS
Punch presses can have the motor and flywheel on one shaft, then, through a
gear reduction, drive a slider-crank mechanism that carries the punching
tool.

The motor can be connected to the punch continuously, creating a punching

rhythm, or it can be connected on command through a clutch that allows one
punch and a disconnect.

The motor and flywheel must be sized for the most demanding service,
which is steady punching. The work done is given by:
 CASE OF FLYWHEEL IN PUNCH PRESS
Torque Characteristics of an Induction Motor

Consider a motor with name plate rating of 5 Hp at 1170 RPM, 230 V 50 Hz, 4 pole. then
the synchronous speed is Ns=120*50/4=1500 RPM and its base speed is=1170 RPM

For Interval from t1 to t2

CASE OF FLYWHEEL IN PUNCH PRESS

When motor is
accelerating
the flywheel

For
deceleration
cycle
CASE OF FLYWHEEL IN PUNCH PRESS
 EXAMPLE # 02
Design a suitable flywheel for the system as shown. An overspeed
safety factor of at least 2 is desired. The shaft ω = 800 rad/sec.
 EXAMPLE # 02
Step 1: Since we have total energy of the system, we can start off
by calculating moment of inertia for complete system:

Step 2: We will assume a steel material with γ = 0.28 lb/in3 and

an inside radius ri = 1 in and calculate moment of inertia of
flywheel

Solid disk geometry with inside

radius ri and outside radius ro
constant thickness t and having a
central hole
 EXAMPLE # 02
Step 3: Assume σt = Sy / Ny and derive the relationship via known values

For a design safety factor against yielding of 2.5 we get ro = 8.06 in

and t = 0.172 in.
 EXAMPLE # 02
Step 4: Calculate the yield angular velocity

Step 5: Find Current overspeed safety factor

 EXAMPLE # 02
Step 6: Through iterations, we find the value of outer radius as 6.36 in.

Step 7: In next step, we calculate the thickness of flywheel.

EXAMPLE # 03
A punch-press geared 10:1 is to make six punches per minute under
circumstances where the torque on the crankshaft is 1300 lbf.ft for
1/2s.

The motor’s nameplate reads 3 bhp at 1125 rev/min for continuous

duty. Design a satisfactory flywheel for use on the motor shaft to the
extent of specifying material and rim inside and outside diameters as
well as its width.

As you prepare your specifications, note Wmax, Wmin, the coefficient

of speed fluctuation Cs, energy transfer, and peak power that the
flywheel transmits to the punch-press. Note power and shock
conditions imposed on the gear train because the flywheel is on the
motor shaft.
EXAMPLE # 03
Given:
t1 = 0.5 seconds
t2 = 10 seconds
Nr = 1125 RPM
Ns = 1200 RPM
Tl = 1300 for 0.5 sec
 EXAMPLE # 03
Step 1: Calculate the load torque
𝐏 ℎ𝑝 . (6600 (𝑖𝑛. 𝑙 𝑏Τ𝑠 𝑒𝑐))
𝐓(𝑙𝑏. 𝑖𝑛) =
Step 2: Calculate Rated Motor Torque 2𝜋 𝑟𝑎 𝑑Τ𝑠 𝑒𝑐
𝛚 𝑟𝑝𝑚 . 60 ( 𝑟𝑝𝑚 )

Step 3: Calculate Rated and Synchronous Angular Velocity

Step 4: Calculate Mean squirrel-cage motor characteristic Torque

 EXAMPLE # 03
Step 5: Calculate moment of inertia

Step 6: Calculate Angular Velocity

Step 7: Calculate the total Energy

 EXAMPLE # 03
Step 8: Calculate Peak Power

Step 9: Calculate Weight by taking initial guess about mean dia. &
thickness

Step 10: Calculate the length incorporating volume and density.

THE END