ME 1601: Mechanical System Design

Design of Flywheel

Dr. Vineet Sahoo

Dept. of Mechanical Engineering
National Institute of Technology Jamshedpur

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Flywheel
• A flywheel acts as an energy reservoir, which stores energy during the
period when the supply of energy is more than the requirement and
releases energy during the period when the requirement is more than
the supply.

Power Press
Dr. Vineet Sahoo, MED, NIT Jamshedpur
 Basic Operation of IC Engine
• In internal combustion engines, the energy is developed during the
power (expansion) stroke and the engine runs for the whole cycle on the
energy supplied during that stroke

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Basic Operation of IC Engine
• Pressure and temperature rapidly increases during the combustion and
hence the piston is pushed down. Therefore, there is a significant
fluctuation of energy during once engine cycle

Dr. Vineet Sahoo, MED, NIT Jamshedpur

IC Engines: Turning Moment
• The torque at the crank shaft or the
turning moment is largely dependent on;
• The in-cylinder gas pressure
• The inertia force of the reciprocating
parts
• As explained above the gas pressure
fluctuates over a complete cycle
• The acceleration and deceleration of the
piston assembly also changes during the
motion over a cycle
• Therefore the Turning Moment also
fluctuates over an engine cycle

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 IC Engines: Turning Moment
• The Fluctuation Turning Moment can be controlled to some extent by
increasing number of cylinders (Multi-cylinder engines)

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 IC Engines: Turning Moment
• Practically it is not possible to build engines with cylinders beyond a
certain number. (depends on the capacity)
• Therefore, a complete smoothness can not be achieved by only
increasing the number of cylinders
• A flywheel is usually coupled to the crank shaft to limit the fluctuation
of turning moment and hence the fluctuation of speed.

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Procedure
• Selection of the engine
• Data tables will be provided and select the problem based on the serial number

• Calculation of Turning Moment

• calculation of torque due to inertia forces
• calculation of torque due to pressure forces
the indicator diagram of the engine will be provided

• Obtain the turning moment and hence find the mean torque
• Calculation of the Moment of Inertia of the Flywheel to limit the speed
fluctuation to given value
• Design of the flywheel with the required Moment of Inertia

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Procedure
Calculation of torque due to inertia forces

The total Inertia force 𝑄 = 𝑀𝑥ሷ

where M is the mass of the reciprocating
parts

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Procedure
Calculation of torque due to inertia forces

The total Inertia force 𝑄 = 𝑀𝑥ሷ

where M is the mass of the reciprocating
parts

𝑄 = 𝑀𝑥ሷ

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Procedure
Calculation of torque due to inertia forces

• Mass of the reciprocating parts

are largely due to
• Mass of the piston
• Contribution from the connecting
rod

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Procedure
Calculation of torque due to inertia forces

• Contribution from the connecting rod

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Procedure
Calculation of torque due to inertia forces

Equivalent Mass System

If the mass of the connecting rod = m

Therefore the total mass

M = piston mass + m2

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Procedure
Calculation of torque due to pressure forces

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Procedure
Calculation of torque due to pressure forces

• Calculation of pressure force (P)

• Use of Indicator Diagram

The pressure force at given

crank angle can be obtained
using the indicator diagram

The indicator diagram of an engine

can experimentally be obtained by
measuring the in-cylinder gas
pressure and plotting the variation of
pressure against the volume over one
cycle
Dr. Vineet Sahoo, MED, NIT Jamshedpur
 Design of a Flywheel: Procedure

Calculation of Resultant Torque

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Design of a Flywheel: Fluctuation of Energy

• Consider the given maximum pressure and the stroke of the engine

• Draw the configuration diagram to obtain h at each crank position

• Tabulate the pressure and the value of h at each crank position.

• Tabulate the gas torque, inertia torque and the total torque at each
crank position.

• Draw the Turning Moment diagram and the mean torque line

• Calculate the scale factors for pressure axis and displacement axis

• Calculate the maximum fluctuation of energy

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Design of a Flywheel: Fluctuation of Energy

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Design of a Flywheel: Fluctuation of Energy

• The area under the TMD gives the work done per cycle.

• The work done per cycle when divided by the crank angle per cycle
gives the mean torque Tm

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Design of a Flywheel: Fluctuation of Energy

• The area under the TMD gives the work done per cycle.

• The work done per cycle when divided by the crank angle per cycle
gives the mean torque Tm

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Fluctuation of Energy

• The power consumed by the machine or delivered by the engine is

Power, P = Tmxω

Where ω= angular velocity of the crank.

• The area of the TMD above the mean torque line represents the excess
energy that may be stored by the flywheel, which helps to design the
dimensions & mass of the flywheel.

• Flywheels help in smoothening out the fluctuations of the torque on the

crankshaft & maintain the speed within the prescribed limits.

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Types of flywheel

Disc Type Flywheel Rim Type Flywheel

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Types of flywheel
• Flywheels posess inertia due to its heavy mass.
Mass moment of inertia of a flywheel is given by
I=mk2 where, m= Mass of the flywheel
k is the radius of gyration

𝑫
• For Rim type, k= D= Mean diameter of the flywheel
𝟐
𝑫
• For Disc type, k= D= Outer diameter of the flywheel
𝟐 𝟐
• Hence, 2 2
𝐷 𝐷
𝐼 = 𝑚𝑟𝑖𝑚 𝐼 = 𝑚𝑑𝑖𝑠𝑐
2 2 2
Hence for a given diameter & inertia, the mass of the rim type flywheel
is half the mass of a disk type flywheel

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Different Parameters
• Maximum fluctuation of speed :

It is the difference between the maximum & minimum speeds in a

cycle. (=N1-N2 )

• Coefficient of fluctuation of speed: (Cs or Ks):

It is the ratio of maximum fluctuation of speed to the mean speed. It

is often expressed as a % of mean speed

𝑁1 − 𝑁2 𝜔1 − 𝜔2
𝐶𝑠 (𝑜𝑟 𝐾𝑠 ) = =
𝑁𝑚𝑒𝑎𝑛 𝜔𝑚𝑒𝑎𝑛
𝜔1 + 𝜔2
𝜔𝑚𝑒𝑎𝑛 =
2

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Different Parameters
• Coefficient of fluctuation of Energy (Ce or Ke):

It is the ratio of maximum fluctuation of energy to the mean energy.

It is often expressed as a % of mean energy

𝐸1 − 𝐸2 𝛥𝐸
𝐶𝑒 (𝑜𝑟 𝐾𝑒 ) = =
𝐸𝑚𝑒𝑎𝑛 𝐸𝑚𝑒𝑎𝑛
* * It is often expressed as the ratio of excess energy ΔE to the work
done per cycle.

• Coefficient of steadiness :

It is the reciprocal of coefficient of fluctuation of speed

𝜔1 − 𝜔2
𝜔𝑚𝑒𝑎𝑛
Dr. Vineet Sahoo, MED, NIT Jamshedpur
Design of a Flywheel: Energy Stored By A Flywheel

Let

I=be the mass moment of inertia of the flywheel

ω1 & ω2 be the max & min speeds of the flywheel

ωmean = Mean speed of the flywheel

m=Mass of the flywheel, k=Radius of gyration of flywheel

Cs =Coefficient of fluctuation of speed

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Design of a Flywheel: Energy Stored By A Flywheel
The max fluctuation of energy (to be stored by the flywheel)
1 2 1 2
𝛥𝐸 = 𝐸1 − 𝐸2 = 𝐼𝜔1 − 𝐼𝜔2
2 2
1 2 2
1
𝛥𝐸 = 𝐼 𝜔1 − 𝜔2 = 𝐼 𝜔1 − 𝜔2 𝜔1 + 𝜔2
2 2
2
𝜔1 − 𝜔2
𝛥𝐸 = 𝐼𝜔𝑚𝑒𝑎𝑛 𝜔1 − 𝜔2 = 𝐼𝜔𝑚𝑒𝑎𝑛
𝜔𝑚𝑒𝑎𝑛
2
𝛥𝐸 = 𝐼𝜔𝑚𝑒𝑎𝑛 𝐶𝑠
Again, if mean kinetic energy,

1 2
𝐸𝑚𝑒𝑎𝑛 = 𝐼𝜔𝑚𝑒𝑎𝑛
2
2
⇒ 𝐼𝜔𝑚𝑒𝑎𝑛 = 2𝐸𝑚𝑒𝑎𝑛 , ⇒ 𝛥𝐸 = 2𝐸𝑚𝑒𝑎𝑛 𝐶𝑠
𝐶𝑒
⇒ =2
𝐶𝑠
Dr. Vineet Sahoo, MED, NIT Jamshedpur
Design of a Flywheel: Mass Of Flywheel In Terms Of
Density & Crossectional Area
Mass of the fly wheel, m= Density(ρ)x Volume

Volume of the flywheel

𝜋 2
For Disc type, Volume= 𝐷 x𝑏 Where b= width of the disc
4
For Rim type, Volume= 𝜋𝐷x𝑏x𝑡 Where b= width of rim

t= rim thickness and (bxt)= Cross-section of rim

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Tutorial

Problem 1

A single cylinder 4 stroke gas engine develops 18.4 KW at 300 rpm

with work done by the gases during the expansion being 3 times the

work done on the gases during compression. The work done during

the suction & exhaust strokes is negligible. The total fluctuation of

speed is 2% of the mean. The TMD may be assumed to be triangular

in shape. Find the mass moment of inertia of the flywheel.

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Design of a Flywheel: Tutorial

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Tutorial
Given Data

Power P=18.4 KW=18.4 10 W, Mean speed Nmean =300 rpm

Work done during expansion,W= 3xWork done during compression

Cs= 2% =0.02

Given 4-stroke cycle engine

Crank angle per cycle= 4π radians( 2 rev of crank shaft)

Solution:

Mean angular velocity

2𝜋𝑁𝑚𝑒𝑎𝑛 2𝜋x300 𝑟𝑎𝑑

𝜔𝑚𝑒𝑎𝑛 = = = 31.416
60 60 𝑠

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Tutorial
2𝜋𝑁𝑚𝑒𝑎𝑛 𝑇𝑚𝑒𝑎𝑛
𝑃𝑜𝑤𝑒𝑟, 𝑃 = 𝑘𝑊
60000
60000x𝑃 60000x18.4
𝑇𝑚𝑒𝑎𝑛 = = = 585.7 𝑁 − 𝑚
2𝜋𝑁𝑚𝑒𝑎𝑛 2𝜋𝑥300

Work Done Per Cycle= Tmean x Crank Angle per Cycle

585.7x4π = 7360.12 joule

Work done per cycle =Work done in expansion-Work done in Compression

Wnet= WEX- Wcomp (As work done in suction and exhaust is neglected)

But WEX=3 x Wcomp

Wnet=2x Wcomp ⇒ WEX = 7360*3/2=11040 Joule

This work done, WEX is is the area under tringle for expansion stroke.
Dr. Vineet Sahoo, MED, NIT Jamshedpur
 Design of a Flywheel: Tutorial
This work done, WEX is is the area under tringle for expansion stroke.

𝟏
𝑾𝑬𝑿 = 𝝅𝑻𝒎𝒂𝒙 , 𝑻𝒎𝒂𝒙 =7028.3 N-m
𝟐

Excess energy stored in the flywheel

ΔE= Triangular area above mean torque line in expansion stroke

1
𝛥𝐸 = 𝑥 𝑇max − 𝑇mean
2
From the triangle

𝑥 𝑇max − 𝑇mean 7028.3 − 585.7

= ⇒𝑥= 𝜋 = 2.88 𝑟𝑎𝑑
𝜋 𝑇max 7028.3
1
⇒ 𝛥𝐸 = x2.88x 7028.3 − 585.7 = 9276.67 𝑗𝑜𝑢𝑙𝑒
2

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Tutorial
From Excess of energy,
2
𝛥𝐸 = 𝐼𝜔𝑚𝑒𝑎𝑛 𝐶𝑠
9276.67 2
⇒𝐼= = 470 𝐾𝑔 − 𝑚
31.4162 x0.02

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Tutorial

Problem 2

The crank effort diagram for a 4-stroke cycle gas engine may be assumed

to for simplicity of four rectangles, areas of which from line of zero

pressure are power stroke =6000 mm2 , exhaust stroke =500 mm2 ,

Suction stroke=300 mm2 , compression stroke = 1500 mm2 . Each Sq mm

represents 10 Nm. Assuming the resisting torque to be uniform, find

a) Power of the engine

b) Energy to be stored by the flywheel

c) Mass of a flywheel rim of 1m radius to limit the total fluctuation of

speed to 2% of the mean speed of 150 rpm.

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Design of a Flywheel: Tutorial

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Design of a Flywheel: Tutorial

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Punching Press
• Flywheel controls the fluctuation of speed where load on the crank
shaft is constant but the applied torque varies during the cycle

• Flywheel can also be used when driving

torque is constant but the load varies during
the cycle.

Ex: Punching Press

Energy is determined by the size of the hole,

thickness and properties of the material to be
punched.

• For stable operation, energy supplied to the

crank per revolution should be E.

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Punching Press

• The energy supplied to the crank from the motor during punching
operation (assuming the power of the motor is constant)

𝐸(𝜃2 − 𝜃1 )
=
2𝜋
• The excess energy that is stored in the flywheel

𝜃2 − 𝜃1 1 2 2 2
𝛥𝐸 = 𝐸 1 − = 𝐼 𝜔max − 𝜔min = 𝐼𝜔mean 𝐶𝑠
2𝜋 2
𝜃2 − 𝜃1 𝑡 𝑡
≈ =
2𝜋 2𝑠 4𝑟
Where, s is the stroke of the punch(=2r), and r= radius of crank.

t=thickness of plate to be punched.

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Punching Press

Problem 3

A machine punching 3.8 cm diameter holes in 3.2cm thick plate does

600 joule of work per square cm of sheared area. The punch has a

stroke of 10.2cm and punches 6 holes per minute. The maximum

speed of the flywheel at its radius of gyration is 27.5 m/s. Find the

mass of the flywheel so that its speed at the same radius doesn’t fall

below 24.5 m/s. Also determine the power of the motor driving this

machine.

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Punching Press

Solution:

Sheared area per punch is As= 𝝅 (dxt)=38.2 cm2

d=diameter of the hole=3.8cm

t=thickness of the plate=3.2 cm

Thus energy required per punch is E=600x38.2=22920 J

𝜃2 − 𝜃1 𝑡 3.2
However, = =
2𝜋 2𝑠 20.4
Excess energy
3.2 1 2 2 2
𝛥𝐸 = 22920 1 − = 𝑚𝑘 𝜔max − 𝜔min
20.4 2

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Punching Press
• Where k is the radius of gyration
Vmax= kωmax=27.5 m/s
Vmin= kωmin=24.5 m/s

17.2 1 2 2
1
22920x = 𝑚 27.5 − 24.5 = 𝑚x158
20.4 2 2
𝑚 = 244 𝐾𝑔
The energy required per minute for one hole is 22920 J
For making 6 holes, energy required per minute=6x22920 J

6x22920
Hence, Motor Power= 𝑘𝑊 = 2.292 𝑘𝑊
60000

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Design of a Flywheel: Problems

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Design of a Flywheel: Problems

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Design of a Flywheel: Problems

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Design of a Flywheel: Problems

1. The turning moment diagram for an engine consist of a curve represented by the
equation

T= (19614 + 9316.7sin2θ - 5590cos2θ) N-m

where θ is the angle moved by the crank from inner dead centre. If the resisting torque
is constant, determine-

(a)Power developed by the engine.

(b)Moment of inertia of the flywheel in kg-m2, if the total fluctuation os speed is not to
exceed one percent of mean speed which is 180 rpm

(c)Angular acceleration of the flywheel when the crank has turned through 450 from the
inner dead centre.

Ans: 369.7kW; 3058.2 kg-m2; 3.046 rad/s2

Dr. Vineet Sahoo, MED, NIT Jamshedpur
 Design of a Flywheel: Problems
1. Turning moment curve for one revolution of a multi-cylinder above and below the line of
mean resisting torque are given by -0.32; +4.06; -2.71; +3.29; -3.24; +2.4; -3.74; +2.71; -
2.45 sq. cm. The vertical and horizontal scales are 1 cm=588420 N-cm, and 1cm= 240
respectively. The fluctuation of speed is limited to ±1.5% of mean speed which is 250
rpm. The hoop stress in the rim material is limited to 549.2 N/cm2. Neglecting effect of
boss and arms, determine suitable diameter and cross-section of the flywheel rim. Weight
density of the rim material is 0.0706 N/cm3. Assume width of rim equals to four times its
thickness. Ans:- [d=2.08 m; t=5.23 cm; b=20.9 cm]

Dr. Vineet Sahoo, MED, NIT Jamshedpur