FLY WHEEL TYPES AND DESIGN

MECHANICS OF MACHINES

DONE BY,
VIGNESHWARAN R
19P131
INTRODUCTION :
FLYWHEEL :
 A flywheel is an inertial energy storage device.

 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.
FUNCTION NEED:
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 sourcing 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.
Internal combustion engines with one or two cylinders
are a typical example.
Piston compressors, punch press, rock crushers etc.,
are the other systems that have fly wheel.
OPERATION :
Flywheel absorbs mechanical energy by increasing its
angular velocity and delivers the stored energy by
decreasing its velocity.
Flywheel & Governor :
Reduces the unavoidable Controls the mean speed
fluctuation of speed, arising of the engine by varying
from fluctuations of turning the fuel supply to the
moment on the crankshaft.
engine.
Always remains in
Only operates when the
operation when the engine
is running. engine is running away
Energy stored is in the form from its mean speed.
of kinetic energy and is It involves frictional
100% convertible to work losses.
without friction.
Flywheel materials:
Traditionally, Flywheel are made of cast iron. From
design consideration, cast iron flywheel offer the
following advantages :-
Cast iron flywheels are the cheapest.
Cast iron flywheels can be given any complex shape
without involving machining operations.
Cast iron flywheel has excellent ability to damp
vibration.
However, the machinability of cast iron flywheel is
poor compared to steel flywheel.
Solid disk flywheel:
The simple type of flywheel is a solid circular disk. The
mass moment of inertia of this disk is given by ,
I = mR2/2. ---------(1)
where, I=mass moment of inertia of disk(kg ⋅m 2)
m=mass of disk (kg)
R=outer radius of disk(m)
The mass of the disk is given by ,
m=πR2ρt.-----------(2)
t=thickness of disk(m)
ρ=mass density of flywheel material(kg/ kg/m–3)
From (1) & (2) ,
I= (π/2) ρt R4
solid disk flywheel;
Rimmed flywheel :
Construction:
Rimmed flywheel consists of following components,
1)Rim(outer ring) 2)Hub(inner hub) 3)Arms
Arms possesses elliptical cross section for increased
stress absorption, while the rim
has rectangular c/s.
It is difficult to determine the mass
moment of inertia of rimmed flywheel
due to its complicated shape.
Design of flywheel :
Analysis of flywheel is made by using any one of the
following assumptions
1) The spokes, the hub, and the shaft do not contribute
any moment of inertia, entire moment of inertia is
due to the rim alone.
2) The effect of shaft hub, spokes is to contribute 10%
while the arm contributes 90% of the required
moment of inertia.
The mass moment of inertia of the rim is given by
Ir = C×I
Ir =mass moment of inertia of the rim about its axis
of rotation.
c =factor of mass moment of inertia
I =mass moment of inertia of the entire rimmed
flywheel.
Stresses in rimmed flywheel :
The following types of stresses are induced in the rim of
a flywheel :
Tensile stress due to centrifugal force.
Tensile bending stress caused by the restraint of the
arms
The shrinkage stresses due to unequal rate of cooling
of casting. It is taken care of by a factor of safety.
DESIGN :

SPLIT FLYWHEEL:
Arms have elliptical c/s. In small flywheels, the arms
are replaced by a solid web.
In large flywheels stresses are induced in arms due to
casting process. Heavy concentration of mass at the
rim and at the hub results in unequal cooling rates,
which in cooling stresses.
These are taken care by using split type costruction.
Torque analysis:
A flywheel mounted on a relatively stiff shaft is shown.
When the flywheel absorbs energy its speed increases
and vice versa.
This reduces speed fluctuations.
Considering the equilibrium of torques,
I(dω/dt) = Ti – T0--------(1)
 Where,
I=mass moment of inertia of flywheel(kg-m2)
Ti=driving or input torque(N-m)
T0=load of output torque(N-m)
ω= angular velocity of the shaft(rad/s)
 when (Ti-T0) is positive then the flywheel is
accelerated.
 when (Ti-T0) is negative then the flywheel is
retarded.
Coefficient of fluctuation of speed (Cs :)
It is defined as the ratio of maximum fluctuation of
speed to the mean speed.
Cs = maximum fluctuation of speed/mean speed.

Cs=(ω max- ω min)/ω.

Fluctuation of energy in flywheel:

The turning moment diagram for a multi cylinder

engine is shown above.
The intercepted areas between the torque developed
by the engine and the mean torque line is taken in
order from one end are,
=+a1,-a2,+a3,-a4,+a5,-a6
Let the energy in the flywheel at A=U.
Then from fig we have,
Energy at B=U+a1
Energy at C=U+a1-a2
Energy at D=U+a1-a2+a3
Energy at E=U+a1-a2+a3-a4
Energy at F=U+a1-a2+a3-a4-a5
Energy at G=U+a1-a2+a3-a4-a5+a6=U
Let the maximum and minimum energy occurs at points E and B
Maximum energy in the flywheel,
=U+a1-a2+a3-a4
Minimum energy in the flywheel,
=U+a1
Maximum fluctuation of energy(U0) is defined as the difference
between the maximum kinetic energy and minimum kinetic
energy in the cycle.
(U0)=UE-UB
=(U+a1)-(U+a1-a2+a3-a4)
=+a2-a3+a4.
Advance and modern flywheel:
Flywheels have also been proposed as a power booster
for electric vehicles . Speeds of 1,00,000 rpm have been
used to achieve very high power densities.
Modern high energy flywheels use composite rotors
made with carbon fibre materials. The rotors have a
very high strength to density ratio, and rotate at speeds
upto 1,00,000 rpm in a vacuum chamber to minimize
aerodynamic losses.
Conclusion:
Recent advances in the mechanical properties of
composites has regained the interest in using the
inertia spinning wheel to store energy.

Carbon composite flywheel batteries have recently

been manufactured and are proving to be viable in real
world tests on mainstream cars. Additonally, their
disposal is more eco-friendly.