This document presents a case study on the design of a flywheel. It discusses the functions, materials, design approach, stresses, and methodology for designing a flywheel. The design is for a flywheel for a punching machine. The required energy is 3,592.6 N-m and the fluctuation in energy is 3,233.3 N-m. Using a rim velocity of 11.3 m/s, the mass of the flywheel is determined to be 253.5 kg. The stresses in the rim and arm are calculated and found to be less than the allowable strength of the material.
This document presents a case study on the design of a flywheel. It discusses the functions, materials, design approach, stresses, and methodology for designing a flywheel. The design is for a flywheel for a punching machine. The required energy is 3,592.6 N-m and the fluctuation in energy is 3,233.3 N-m. Using a rim velocity of 11.3 m/s, the mass of the flywheel is determined to be 253.5 kg. The stresses in the rim and arm are calculated and found to be less than the allowable strength of the material.
This document presents a case study on the design of a flywheel. It discusses the functions, materials, design approach, stresses, and methodology for designing a flywheel. The design is for a flywheel for a punching machine. The required energy is 3,592.6 N-m and the fluctuation in energy is 3,233.3 N-m. Using a rim velocity of 11.3 m/s, the mass of the flywheel is determined to be 253.5 kg. The stresses in the rim and arm are calculated and found to be less than the allowable strength of the material.
This document presents a case study on the design of a flywheel. It discusses the functions, materials, design approach, stresses, and methodology for designing a flywheel. The design is for a flywheel for a punching machine. The required energy is 3,592.6 N-m and the fluctuation in energy is 3,233.3 N-m. Using a rim velocity of 11.3 m/s, the mass of the flywheel is determined to be 253.5 kg. The stresses in the rim and arm are calculated and found to be less than the allowable strength of the material.
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Gokhale Education Society's R. H.
Sapat College Of Engineering, Management Studies And Research,
Prin. T.A. Kulkarni Vidyanagar, College Road, Nashik – 5 Mechanical Department A Presentation On Case Study on Design of Flywheel Presented By- Guided By- Mr. Mahesh Mandlik Prof. M. K. Ghode Mr. Shubham Mali Mr. Yash Nikam Mr. Kalpesh Patil Content Introduction Function Material Design approach Design of flywheel Geometry of flywheel Stresses in flywheel Geometrical dimensions methodology conclusion Introduction • Flywheel is a heavy rotating body that acts as a reservoir of energy. Energy is stored in the form of kinetic energy. • Flywheel is extensively used in applications like “Punching Press’ (power is supplied at constant rate)and I/C Engines” (Power is generated at variable rate) Functions
To store and release energy when needed during the work cycle
To reduce the power capacity of electric motor
To reduce the amplitude of speed fluctuations.
Materials for flywheel
It is generally made of cast iron, as it has following advantages:
1) C.I Flywheels are cheapest 2) C.I Flywheels can be given any complex shape without involving machining operations. 3) Excellent ability to damp vibrations However it has poor tensile strength, and its failure is sudden and total. Design Approach There are two stages to the design of a flywheel. • First, the amount of energy required for the desired degree of smoothening must be found and the (mass) moment of inertia needed to absorb that energy determined. • Then flywheel geometry must be defined that caters the required moment of inertia in a reasonably sized package and is safe against failure at the designed speeds of operation. Design Parameters:- • It depend upon acceptable changes in the speed. Speed fluctuation:- • The change in the shaft speed during a cycle is called the speed fluctuation and it is given by 𝐹1 = 𝜔𝑚𝑎𝑥 − 𝜔𝑚𝑖𝑛 Design Of Flywheel Design Equation:-
𝐸𝑘 𝐼𝑆 = 2 𝐶𝑓 ∗ 𝜔𝑎𝑣𝑔 where, “𝐶𝑓 ” is the co-efficient of speed fluctuation and “𝐸𝑘 ” is the kinetic energy and “𝜔𝑎𝑣𝑔 ” is the average rotational motion. Torque Variation and Energy:- The required change in kinetic energy 𝐸𝑘 is obtained from the known torque time relation or curve by integrating it for one cycle and it is given by,
It can be like conventional wheel design. But energy requirements and size of the flywheel increases the geometry changes to disc of central hub and peripheral rim connected by webs and to hollow wheels with multiple arms. Geometry Of Flywheel • For a solid disc geometry with inside radius 𝑟𝑖 and out side radius 𝑟𝑜 , mass moment of inertia 𝐼𝑚 is 𝑚 2 𝐼𝑚 = 𝑚𝑘 2 = 𝑟𝑜 + 𝑟𝑖2 2 • The mass of a hollow circular disc of constant thickness t is
𝑊 𝛾 2 𝑚= = 𝜋 𝑟𝑜 − 𝑟𝑖2 𝑡 𝑔 𝑔 • Combing the two equations we can write
𝜋𝛾 4 𝐼𝑚 = 𝑟𝑜 − 𝑟𝑖4 𝑡 2𝑔 • Where “𝛾” is material’s weight density Stresses In Flywheel • Flywheel being a rotating disc, centrifugal stresses acts upon its distributed mass and attempts to pull it apart. Its effect is similar to those caused by an internally pressurized cylinder. There are two principle stresses tangential & radial.
Where, 𝛾 = material weight density, ω= angular velocity in rad/sec. ν= Poisson’s ratio, is the radius to a point of interest, 𝑟𝑖 and 𝑟𝑜 are inside and outside radii of the solid disc flywheel. Geometrical Dimensions and material condition: • Flywheel should not exceed the diameter of 1000mm • Coefficient of fluctuation of speed : 0.1 • Mean speed of flywheel : 270rpm • Mass of flywheel : 250kg • Material of flywheel : Grey cast iron with density 7100kg/m3
Details about flywheel design parameters :
Flywheel Total Energy(N-m) Fluctuation in Rim velocity(M/s)
energy(N-m) Arm type 3592.6 3233.3 11.3 Methodology • Design of Flywheel for punching machine. 1. Energy required to punch one hole =3053.7 Total energy =3592.6N 𝜋𝐷𝑁 2. Rim velocity = =11.2m/s 60 3. Mass of flywheel = 253.5kg 4. Assuming mass of rim as 90% of total mass mrim =0.9*253.3=277.88kg 5. Outer diameter of flywheel =Do =D+h=0.89m 6. Total stress in rim =0.75*unstrained rim +0.25 strained rim =1.922 MN/m2 7. To determine stress in arm pf flywheel • Direct stress due to centrifugal force =0.9066N/mm2 • Bending stress =10n/mm2 Total stress =BS+DS =10+0.9066 =10.906N/mm2 Hence, total stress is less than allowable strength 20N/mm2 Hence design of the arm are safe CONCLUSION
• It can be conclude that in case of flywheel design it is first important to
know the design requirements such as material, application, desired speed and dimensions. THANK YOU
