International Journal of Engineering and Advanced Technology (IJEAT)

ISSN: 2249-8958 (Online), Volume-3 Issue-4, April 2014

A Case Study on Design of a Flywheel for

Punching Press Operation
Rathod Balasaheb S, Satish. M. Rajmane

of power is generated for a short while when breaking, which

Abstract— A flywheel is the heavy rotating mass which is placed implies a more efficient use of energy, resulting in lower fuel
between the power source and the driven machine to act as a consumption.
reservoir of energy. It is used to store the energy when the demand Individual flywheels are capable of storing up to 500MJ and
of energy of energy is less and deliver it when the demand of
peak power ranges from kilowatts to gigawatts, with the
energy is high. The current paper is focused on the analytical
design of arm type of flywheel which is used for punching press higher powers aimed at pulsed power applications.
operation. Now in regard to the design of flywheel it is required to Stress analysis is the complete and comprehensive study of
decide the mean diameter of the flywheel rim, which depends upon stress distribution in the specimen under study. To improve
two factors such as availability of space and the limiting value of the quality of the product and in order to have safe and
peripheral velocity of the fly wheel. However the current design reliable design, it is necessary to investigate the stresses
problem is formulated for punching machine which has to be induced in the component during working condition.
make holes of 30 holes/minute in a steel plate of 18mm thickness Flywheel is an inertial storage device which acts as reservoir
with space limitation that is the diameter of flywheel should not of energy. When the flywheel rotates, centrifugal forces acts
exceed 1000mm, hence it can be observed that the design of the
on the flywheel due to which tensile and bending stress are
flywheel is to be carried out (based) on the availability of space
limitation and accordingly the fluctuation of energy, dimensions induced in a rim of flywheel.
of the flywheel, stresses induced in the flywheel are determined.
Finally after detail analysis it is observed that the induced
diameter of the flywheel is less than the allowable/permissible
diameter and hence it can be concluded that the design is safe
from availability of space point of view.

Keywords- Flywheel, peripheral velocity, fluctuation of energy,

stresses, stored energy.

I INTRODUCTION
Several hundred years ago pure mechanical flywheels
where used solely to keep machines running smoothly from
cycle to cycle, thereby render possible the industrial
revolution. During that time several shapes and designs
where implemented, but it took until the early 20th century Fig.1.1Arm type of flywheel
before flywheel rotor shapes and rotational stress were The current paper is focused on the analytical design of arm
thoroughly analyzed [1].Later in the 1970s flywheel energy type of flywheel which is used for punching press operation.
storage was proposed as a primary objective for electric Now in regard to the design of flywheel it is required to
vehicles and stationary power backup. At the same time fiber decide the mean diameter of the flywheel rim, which depends
composite rotors where built, and in the 1980s magnetic upon two factors such as availability of space and the limiting
bearings started to appear [2]. Thus the potential for using value of peripheral velocity of the fly wheel. However the
flywheels as electric energy storage has long been established current design problem is formulated for punching machine
by extensive research. More recent improvements in which has to be make holes of 30 holes/minute in a steel plate
material, magnetic bearings and power electronics make of 18mm thickness with space limitation that is the diameter
flywheels a competitive choice for a number of energy of flywheel should not exceed 1000mm, hence it can be
storage applications. observed that the design of the flywheel is to be carried out
One of the major advantages of flywheels is the ability to (based) on the availability of space limitation.
handle high power levels. This is a desirable quality in e.g. a
vehicle, where a large peak power is necessary during II. PRESENT THEORIES AND PRACTICES
acceleration and, if electrical breaks are used, a large amount A literature review of some relevant research work was
conducted in related with the current study as stated below
Akshay P. Punde, G.K.Gattani (2013) has presented the
Manuscript published on 30 April 2014. investigation of a flywheel, to counter the requirement of
* Correspondence Author (s) smoothing out the large oscillations in velocity during a cycle
Rathod Balasaheb.S*, Department of Mechanical Engineering- BIGCE, of an I.C. Engine, a flywheel is designed, and analyzed by
Solapur, India. using Finite Element Analysis method.
Satish M. Rajmane, Assistant Professor of Department of Mechanical
Engineering - BIGCE, Solapur, India.

© The Authors. Published by Blue Eyes Intelligence Engineering and

Sciences Publication (BEIESP). This is an open access article under the
CC-BY-NC-ND license http://creativecommons.org/licenses/by-nc-nd/4.0/

Published By:
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Retrieval Number D2794043414/14©BEIESP and Sciences Publication (BEIESP)
Journal Website: www.ijeat.org 32 © Copyright: All rights reserved.
 A Case Study on Design of a Flywheel for Punching Press Operation

Further it is used to calculate the Stresses inside the flywheel; result. Based on the dynamic functions, specifications of the
finally the comparison study between the Design and analysis system the main features of the flywheel are initially
with existing flywheel is carried out. [1] determined; the detail design study of flywheel is done. Then
Bjorn Bolund, Hans Bernhoff, Mats Leijon (2007) The early FEA ANALYSIS for more and more designs in diverse areas
models where purely mechanical consisting of only a stone of engineering is being analyzed through the software. FEA
wheel attached to an axle. Nowadays flywheels are complex provides the ability to analyze the stresses and displacements
constructions where energy is stored mechanically and of a part or assembly, as well as the reaction forces other
transferred to and from the flywheel by an integrated elements are to impose. This thesis guides the path through
motor/generator. The stone wheel has been replaced by a flywheel design, and analysis the material selection process.
steel or composite. Rotor and magnetic bearings have been The FEA model is described to achieve a better
introduced. Today flywheels are used as supplementary understanding of the mesh type, mesh size and boundary
UPS storage at several industries world over. Future conditions applied to complete an effective FEA model. At
applications span a wide range including electric vehicles, last the design objective could be simply to minimize cost of
intermediate storage for renewable energy generation and flywheel by reducing material. [5]
direct grid applications from power quality issues to offering Mofid Mahdi (2011) the consumption of energy is increasing
an alternative to strengthening transmission. One of the key drastically. The available resources of energy are limited
issues for viable flywheel construction is a high overall therefore; the search of new sources is a vital issue. This has
efficiency, hence a reduction of the total losses. By increasing to be done with efficient energy consumption and saving. A
the voltage, current losses are decreased and otherwise flywheel may provide a mechanical storage of kinetic energy.
necessary transformer steps become redundant. So far A capable flywheel must have a very high rotational speed
flywheels over 10kV have not been constructed, mainly due which may lead to a high stresses. The stress state relies on
to isolation problems associated with high voltage, but also the flywheel material properties, geometry and rotational
because of limitations in the power electronics. Recent speed. On the other hand, the stored kinetic energy relies on
progress in semi-conductor technology enables faster the mass moment of inertia and rotational speed. This paper
switching and lower costs.The predominant part of prior considered three solid flywheel disk profiles that are
studies has been directed towards optimizing mechanical constructed using functions of cubic splines. Using FEM, the
issues whereas the electro technical part now seems to show cubic splines parameters are analyzed systematically to seek
great potential for improvement. An overview of flywheel a maximum stored kinetic energy per unite mass. Subjected
technology and previous projects are presented and moreover to maximum permissible effective stress, favorable flywheel
a 200kW flywheel using high voltage technology is disk profiles were achieved. All FEM computations were
simulated. [2] carried out using ANSYS. [6] S. M. Dhengle, Dr. D. V.
Sudipta Saha, Abhik Bose, G. Sai Tejesh, S.P. Bhope, S. D. Khamankar (2012) there is many causes of
Srikanth(2013) the performance of a flywheel can be flywheel failure. Among them, maximum tensile and bending
attributed to three factors, i.e., material strength, geometry stresses induced in the rim and tensile stresses induced in the
(cross-section) and rotational speed. While material strength arm under the action of centrifugal forces are the main causes
directly determines kinetic energy level that could be of flywheel failure. Hence in this work evaluation of stresses
produced safely combined (coupled) with rotor speed, this in the rim and arm are studied using finite element method
study solely focuses on exploring the effects of flywheel and results are validated by analytical calculations .The
geometry on its energy storage/deliver capability per unit models of flywheel having four, six and eight no. arms are
mass, further defined as Specific Energy. Proposed Computer developed for FE analysis. The FE analysis is carried out for
aided analysis and optimization procedure results show that different cases of loading applied on the flywheel and the
smart design of flywheel geometry could both have a maximum Von mises stresses and deflection in the rim are
significant effect on the Specific Energy performance and determined. From this analysis it is found that Maximum
reduce the operational loads exerted on the Shaft/bearings stresses induced are in the rim and arm junction. Due to
due to reduced mass at high rotational speeds. This paper tangential forces, maximum bending stresses occurs near the
specifically studies the most common five different hub end of the arm. It is also observed that for low angular
geometries (i.e., straight/concave or convex shaped2D). [3] velocity the effect gravity on stresses and deflection of rim
M.lavakumar, R .prasanna srinivas (2013) This paper and arm is predominant. [7] D.Y. Shahare, S. M. Choudhary
involves the design and analysis of flywheel to minimize the (2013) This study solely focuses on exploring the effects of
fluctuation in torque, the flywheel is subjected to a constant flywheel geometry on its energy storage/deliver capability
rpm. The objective of present work is to design and optimize per unit mass, further defined as specific energy. In this paper
the flywheel for the best material. The flywheel is modeled we have studied various profiles of flywheel and the stored
with solid 95 (3-D element), the modeled analyses using free kinetic energy is calculated for the respective flywheel
mesh. The FEM mesh is refined subject to convergence .various profiles designed are solid disk, disk rim
criteria. Preconditioned conjugate gradient method is adopted ,webbed/section cut, arm/spoke flywheel. It shows that smart
during the solution and for deflections. Von-misses stress for design of flywheel geometry could both have a significant
both materials (mild steel and mild steel alloy) are compared, effect on the Specific Energy performance and reduce the
the best material is suggested for manufacture of flywheel. operational loads exerted on the shaft/bearings due to
[4] Sushama G Bawane , A. P. Ninawe and S. K. reduced mass at high rotational speeds.
Choudhary(2012) By using optimization technique various
parameter like material, cost for flywheel can be optimized
and by applying an approach for modification of various
working parameter like efficiency, output, energy storing
capacity, we can compare the result with existing flywheel
Published By:
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Retrieval Number D2794043414/14©BEIESP and Sciences Publication (BEIESP)
Journal Website: www.ijeat.org 33 © Copyright: All rights reserved.
 International Journal of Engineering and Advanced Technology (IJEAT)
ISSN: 2249-8958 (Online), Volume-3 Issue-4, April 2014

Efficient flywheel design used to maximize the inertia of 60

moment for minimum material used and guarantee high =11.3m/s…which is less than the maximum
reliability and long life. FE analysis is carried out for permissible velocity for grey cast iron
different cases of loading on the flywheel and maximum ✓ Mass of flywheel, m=fluctuation of energy
von-mises stresses and total deformation are determined. [8] V2 × Cs
= 3233.3 = 253.3 Kg
III. PROBLEM DEFINITION 11.32×0.1
The design of arm type flywheel is to be carried out for ✓ Assuming mass of rim as 90%of total mass,
punching press machine with the consideration of space mrim =0.9×253.2=227.88Kg
requirement or with the condition that the diameter of ✓ mrim= πDhp ….used to determine dimensions of rim
flywheel should not exceed than 1000mm. The fly wheel is to Where, p=7100kg/m3for C.I.
de design which is used to punch 30 holes/minute on a steel Therefore, h=90mm, b=150mm
plate of 18 mm thickness. In concern this geometrical ✓ Outer diameter of flywheel=Do=D+h=0.89m, which
dimension, material, and function values of flywheel as is less than the maximum space of 1m, hence the
stated below design dimensions are within limit.
✓ To determine Shaft diameter
➢ Geometrical Dimensions and material condition: ✓ Bending moment M =weight of flywheel× overhang
✓ Flywheel should not exceed the diameter of 1000mm =253.2×9.81× 0.2=496.78N-m
✓ Coefficient of fluctuation of speed :0.1 ✓ Average torque =Energy required/min
✓ Mean speed of flywheel : 270 rpm 2πN
✓ Mass of flywheel : 254 kg = 107778
✓ Material of flywheel : Grey cast iron with density 2π×270
7100kg/m3
➢ Functional values of flywheel: =63.53N-m
✓ The following table shows the details about flywheel ✓ Assuming suddenly applied load condition with
design parameters. shock and fatigue factor of 1.5 and 2
✓ Equivalent torque =((Cm×M)2 +(Ct× T)2)1/2
Flywheel Total Fluctuation of Rim =755.92N-m
energy energy (N-M) velocity ✓ Shaft is made of medium carbon steel, with shear
(N-M) strength 360N-mm2, Factor of safety is 4,therefore
(m/s) shaft diameter can be determined by using torsion
equation
Arm type 3592.6 3233.3 11.3
✓ Shaft diameter,ds =34.96 say=40mm
✓ Hub diameter, dh= 2ds=80mm
Table 1.1 Flywheel Parameters
✓ Length of hub, lh = 2.5 ds=100mm
✓ To determine the Stresses in the rim of flywheel
IV. METHODOLOGY
✓ Stresses in unstrained rim = pv2
The method adopted for the design of flywheel for = 7100×11.32 =0.9066MN/m2
punching machine is Analytical method. Now let us ✓ Stresses in restrained rim = pv2(2πR2/ i2h)
determine the various parameters in regard with flywheel =4.97 MN/m2
design. ✓ Total Stress in the rim ,
✓ Mean speed of flywheel N= 9 Number of strokes/min ✓ = 0.75 Stresses in unstrained rim+0.25 Stresses in
=9×30=270rpm restrained rim
✓ Maximum shear stress required to punch a hole ✓ =1.922 MN/m2….which is less than the allowable
=Shear strength ×resisting area strength of C.I, hence design of rim is safe
=fs× π dt ✓ To determine stress in arm of flywheel
=240× π×25×18 Considering arm type flywheel of four arms
1000 Bending stress in the arm =10N/mm2
=339.3kN =T(D-dh)
✓ Energy required to punch one hole iDz
=average force × distance travelled by punch Where, Z=modulus of elasticity=1429.4mm3
=0.5×339.3× 18=3053.7N i=numbers of arms=4
✓ Since mechanical efficiency is less than 100%, ✓ Direct stress due to centrifugal force =pv2=0.9066N/
assuming as 85% ,therefore mm2
Total energy required, E=3053.7/0.85 ✓ Total stress = Bending stress+ Direct stress
=3592.6N-m =10+0.9066=10.9066N/mm2
✓ Actual punching operation lasts for the 1/10 th of the ✓ Total stress is less than the allowable strength
cycle period. Therefore, during remaining period 20N/mm2, hence the design of the arms are safe.
9/10th of the cycle period, the energy is stored by the
flywheel. Thus fluctuation of energy =9/10× E=
3233.3Nm
✓ Maximum space available is 100mm,therefore
considering as D=800mm to carry out design
✓ Rim Velocity= π× 0.8×270
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Journal Website: www.ijeat.org 34 © Copyright: All rights reserved.
 A Case Study on Design of a Flywheel for Punching Press Operation

V. CONCLUSIONS
✓ It can be conclude that in case of flywheel design it is
first important to know the design requirement such as
material, type, application, desired speed (peripheral
velocity), availability of space, and dimensions of the
flywheel.
✓ The peripheral velocity of the flywheel is governed by
allowable strength of the flywheel material, generally
for grey cast iron it should be less than or greater than
25m/s.
✓ In case of arm type of flywheel the numbers of arms
selection depends upon the diameter of the flywheel,
generally four numbers of arms are selected for
diameter of flywheel which should be less than 0.75m.
✓ As the current problem is related to the design of
flywheel with consideration(limitation) of the space
availability that is maximum space should be less than
1m, but after carrying out design the outer diameter of
flywheel obtained is of 0.89m which is less than the
required condition, hence can be concluded as design is
safe.

ACKNOWLEDGMENT
I am thankful to Principal, Management & Head of
Mechanical Engineering Department- Bharat Ratna
IndiraGandhi College of Engineering, Solapur, for their
support during this work. I would also likes to thanks Prof.
Satish M. Rajmane for giving me the valuable guidance as an
when required. Last but not the least; I will also thanks to
Prof. Mahendra Gaikwad for his motivational support
throughout the completion of this work.

REFERENCES
1. Akshay P. Punde, G.K.Gattani , Analysis of Flywheel, International
Journal of Modern Engineering Research (IJMER) , Vol.3, Issue.2,
March-April. 2013 pp-1097-1099
2. Bjorn Bolund , Hans Bernhoff, Mats Leijon , Flywheel energy and
power storage systems,international journal of Renewable and
Sustainable Energy Reviews 11 (2007) 235–258
3. Sudipta Saha, Abhik Bose, G. Sai Tejesh, S.P. Srikanth , computer
aided design & analysis on flywheel for greater efficiency,
International Journal of Advanced Engineering Research and Studies,
IJAERS/Vol. I/ Issue II/January-March, 2012/299-301
4. M.lavakumar, R.prasanna srinivas, Design and analysis of light
weight motor vehicle flywheel, International Journal of Computer
Trends and Technology (IJCTT) – volume 4 Issue -7July 2013
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engineering and robotics Vol. 1, No. 2, July 2012
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Thresher using FEM, Advanced Materials Manufacturing &
Characterization Vol3 Issue 1 (2013)

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