Design of Flywheel

DESIGN OF FLYWHEEL
Name :- Rahul Gujar

Class :- C division
Roll No. :- BEMEC20373
Seat No. :- B150080962
PRN No. :- 71702327D
Table of contents:
SR NO. CONTENT PAGE NO.
1. Introduction 3
2. Material selection 5
3. Design consideration for flywheel 6
4. Problem statement 7
5. Reference 15
INTRODUCTION
• A flywheel is a mechanical device
specifically designed to use the conservation
of angular momentum so as to efficiently
store rotational energy; a form of kinetic
energy proportional to the product of its
moment of inertia and the square of its
rotational speed.
• It absorbs mechanical energy and serves as
a reservoir, storing 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
the supply.
• The main function of a fly wheel is to smoothen out variations in the speed of
a shaft caused by torque fluctuations. Many machines have load patterns that
cause the torque time function to vary over the cycle. Flywheel absorbs
mechanical energy by increasing its angular velocity and delivers the stored
energy by decreasing its velocity.
• Internal combustion engines with one or two cylinders are a typical example.
Piston compressors, punch presses, rock crushers etc. are the other systems
that have fly wheel.
MATERIAL SELECTION:
• Flywheels are made from many different materials. The application determines the choice of
material.
• Flywheels are typically made of steel and rotate on conventional bearings. High energy density
flywheels can be made of carbon fiber composites and employ magnetic bearings. Carbon-
composite flywheel batteries have recently been manufactured and are proving to be viable in
real-world tests on mainstream cars.
• Flywheels used in car engines are made of cast or nodular iron, steel or aluminum.
• Flywheels made from high-strength steel or composites have been proposed for use in vehicle
energy storage and braking systems.
• Traditionally, flywheel are made of cast iron.

DESIGN CONSIDERATION FOR FLYWHEEL
Flywheels are rotating devices that store rotational energy in applications such as automotive
transmissions.
It must be stores maximum energy per unit volume/mass at a specified angular velocity.
The stresses must not exceed the limit value.
It should good machinability.
Good fatigue resistance.
Cheap in cost.
PROBLEM STATEMENT
The design of arm type flywheel is to be carried out for punching press machine with the
consideration of space requirement or with the condition that the diameter of flywheel should not
exceed than 1000mm. The fly wheel is to de design which is used to punch 30 holes/minute on a
steel plate of 18 mm thickness. In concern this geometrical dimension, material, and function values
of flywheel as stated below :
Geometrical Dimensions and material condition:

Flywheel should not exceed the diameter of 1000mm
Coefficient of fluctuation of speed :0.1
Mean speed of flywheel : 270 rpm
Mass of flywheel : 254 kg
Material of flywheel : Grey cast iron with density 7100kg/𝑚3

Functional values of flywheel:
The following table shows the details about flywheel design parameters.
Flywheel Total energy (Nm) Fluctuation of energy Rim velocity (m/s)

(Nm)
Arm type 3592.6 3233.3 11.3
Figure:- The table shows the flywheel parameters

Methodology
The method adopted for the design of flywheel for punching machine is Analytical method.
1)Mean speed of flywheel N= 9
Number of strokes/min =9×30=270rpm
Maximum shear stress required to punch a hole =Shear strength ×resisting area
= fs× π dt =(240× π×25×18) /1000 =339.3kN
Energy required to punch one hole =average force × distance travelled by punch
=0.5×339.3× 18=3053.7N
Since mechanical efficiency is less than 100%, assuming as 85% ,therefore
Total energy required, E=3053.7/0.85 =3592.6N-m
2)Actual punching operation lasts for the 1/10th of the cycle period. Therefore, during remaining
period 9/10th of the cycle period, the energy is stored by the flywheel.
Thus fluctuation of energy =9/10× E= 3233.3Nm

3)Maximum space available is 100mm,therefore considering as D=800mm to carry out design
Rim Velocity= (π× 0.8×270)/60
=11.3m/s (which is less than the maximum permissible velocity for grey cast iron)
Mass of flywheel, m= (fluctuation of energy)/V2 × Cs = 3233.3 /(11.32 ×0.1) = 253.3Kg
4) Assuming mass of rim as 90%of total mass,

mrim=0.9×253.2=227.88Kg
mrim = πDhp (used to determine dimensions of rim Where, p=7100kg/𝑚3 for C.I.)
Therefore, h=90mm, b=150mm
5) Outer diameter of flywheel=Do=D+h=0.89m, which is less than the maximum space of 1m,
hence the design dimensions are within limit.
6) To determine Shaft diameter
Bending moment M =weight of flywheel× overhang =253.2×9.81× 0.2=496.78N-m
Average torque =(Energy required/min) /2πN = 107778 /(2π×270) =63.53N-m
7)Assuming suddenly applied load condition with shock and fatigue factor of 1.5 and 2
Equivalent torque =((Cm × M)^2 +(Ct× T)^2)1/2 =755.92N-m
Shaft is made of medium carbon steel, with shear strength 360N-𝑚𝑚2 ,

Factor of safety is 4,therefore shaft diameter can be determined by using torsion equation.
8)Shaft diameter ,ds =34.96 say=40mm

Hub diameter, dh= 2ds=80mm
Length of hub, lh = 2.5 , ds=100mm

9) To determine the Stresses in the rim of flywheel
Stresses in unstrained rim = p𝑣2 = 7100×11.32 =0.9066MN/𝑚2
Stresses in restrained rim = p 𝑣2 (2πR2/ i2h) =4.97 MN/ 𝑚2
Total Stress in the rim ,
= 0.75 Stresses in unstrained rim+0.25 Stresses in restrained rim

=1.922 MN/ 𝑚2 (which is less than the allowable strength of C.I, hence
design of rim is safe)
10)To determine stress in arm of flywheel

Considering arm type flywheel of four arms
Bending stress in the arm =10N/ 𝑚𝑚2 =T(D-dh) /iDz where,

Z=modulus of elasticity=1429.4𝑚𝑚3
i=numbers of arms=4
11) Direct stress due to centrifugal force =p V2 =0.9066N/ 𝑚𝑚2
Total stress = Bending stress+ Direct stress =10+0.9066=10.9066N/ 𝑚𝑚2
Total stress is less than the allowable strength 20N/ 𝑚𝑚2 ,hence the design of the arms
are safe.
Figure:- Arm type flywheel
REFERENCES:-
https://en.wikipedia.org/wiki/Flywheel#Design
https://www.slideshare.net/dhirenppatel1994/design-of-flywheel-50095336
https://www.ijeat.org/wp-content/uploads/papers/v3i4/D2794043414.pdf
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DESIGN OF FLYWHEEL

Name :- Rahul Gujar

3. Design consideration for flywheel 6

• Traditionally, flywheel are made of cast iron.

Geometrical Dimensions and material condition:

Material of flywheel : Grey cast iron with density 7100kg/𝑚3

Flywheel Total energy (Nm) Fluctuation of energy Rim velocity (m/s)

Arm type 3592.6 3233.3 11.3

Figure:- The table shows the flywheel parameters

Thus fluctuation of energy =9/10× E= 3233.3Nm

4) Assuming mass of rim as 90%of total mass,

Shaft is made of medium carbon steel, with shear strength 360N-𝑚𝑚2 ,

8)Shaft diameter ,ds =34.96 say=40mm

Length of hub, lh = 2.5 , ds=100mm

= 0.75 Stresses in unstrained rim+0.25 Stresses in restrained rim

10)To determine stress in arm of flywheel

Bending stress in the arm =10N/ 𝑚𝑚2 =T(D-dh) /iDz where,

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