Flywheel

flywheel and the

is

an

inertial as a

energy-storage reservoir, is more

device.

It

absorbs during

mechanical the period

energy when

serves

storing than the

energy

supply

of energy

requirement is

and releases the

it during theperiod supply.

when the requirement

of energy

more than

Flywheels-Function need and Operation

The main function of a fly wheel is speed of a shaft caused by torque to smoothen out If the variations in the source of the

fluctuations.

driving torque or load usually torque engines called time with

torque is

fluctuating in nature, then a flywheel is have the are load patterns that cause the

for. Many function one punch or to

machines vary two over

cycle. a etc.

Internal typical are

combustion Piston

cylinders rock

example.

compressors,

presses,

crushers

the other systems

that have fly wheel. Flywheel absorbs mechanical energy by increasing its angular

velocity and delivers the stored energy by decreasing its velocity

T2 Tm T1 A B max C D
1 CYCLE

min

Figure 3.3.1

Indian Institute of Technology Madras

Design Approach
There are two stages to the design of a flywheel. First, the amount must be of energy and required the for the desired degree of to

smoothening

found

(mass)

momentof inertia needed

absorb that energy determined. Then moment flywheel of geometry in a must be defined sized that caters and is the safe required against

inertia

reasonably

package

failure at the designed speeds of operation.

Design Parameters
Flywheel inertia (size) needed directly depends upon the acceptable

changes in the speed.

Speed fluctuation
The change in the shaft speed during a cycle is called the speed

fluctuation and is equal to max- min Fl = We can normalize this to a max min ratio by dividing it by the

dimensionless

average or nominal shaft speed (ave) . max min Cf = Where avg is nominal angular velocity

Co-efficient of speed fluctuation

The above ratio is termed as coefficient of speed fluctuation Cf and it is defined as max min Cf =

Machine Design II

Prof. K.Gopinath & Prof. M.M.Mayuram

Where shaft

is

nominal desired.

angular This

velocity,

and is a

ave

the

average parameter

or to

mean be

speed

coefficient

design

chosen by the designer. The smaller more the this chosen and value, the larger to be added the flywheel to the have to be and the

cost

weight

system.

However

smaller this value more smoother the operation of the device It is typically and set as to a high value as between 0.20 for 0.01 to 0.05 for like precision crusher

machinery

applications

hammering machinery.

Design Equation
The kinetic energy E in a rotating system k =
1 2 I

( 2)
= 1 I 2 max 2 2 m min

Hence the change in kinetic energy of a system can be given as,

E K

E K = E 2 E1 avg = max + min 2

E K

I 2 avg 2

)( C )
f avg

2 s

E E = C I 2 1 f E I = k s 2 C av f g

Thus system

the in

mass order

moment to

of

inertia selected

Im

needed

in of

the speed

entire

rotating is

obtain

coefficient

fluctuation

determined using the relation

Machine Design II

Prof. K.Gopinath & Prof. M.M.Mayuram

E K

I 2

)( C )
f avg

avg 2 s I = Ek s 2 C av f vg The above equation to can the be used to

obtain change

appropriate Ek for a

flywheel specific

inertia value

Im corresponding

known

energy

coefficient of speed fluctuation Cf,

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.

@ @

max

( Tl Tavg )d = EK

min

Computing the kinetic energy Ek needed is illustrated in the following example

Torque Time Relation without Flywheel A typical torque time relation for example of a mechanical punching

press without a fly wheel in shown in the figure. In the absence and of fly wheel and surplus enery operations. To smoothen or positive or enregy isavalible energy speed fly

initially during

intermedialty and be

absorbtion A out large the

negative of

punching can

stripping

magitidue speed

fluctuation

noted.

fluctuation

wheel is to be added and the fly wheel energy needed is computed as illustrated below

Torque Area +20 073 C rms Area +15 388 D B A

34 200 A

7 020

Average

min

max

Shaft angle time t

-34 200 0

Area -26 105

Area -9 202 360

Figure 3.3.2
Accumulation of Energy pulses under a Torque- Time curve From Area= E Accumulated sum =E +20 073 -6 032 +9 356 +154 Total Energy= E @min- E@min Min & max

A to B B to C C to D D to A

+20 073 -26 105 +15 388 -9 202

min

@B @C

max

=(-6 032)-(+20 073)= 26 105 Nmm

Figure 3.3.3

Torque Time Relation with Flywheel

Torque 8730 7020 C =0.05 f Average

0 360
Figure 3.3.4

Time t Shaft angle

Geometry of Flywheel
The geometry of a flywheel may solid wheels wheels material, with are a solid and disc of or hub may and be rim of be as spoked by simple as a cylindrical construction spokes or like arms As the disc of

conventional Small the fly

connected circular

discs size

of hollow of the

cross

section.

energy geometry

requirements changes to

flywheel peripheral

increases rim

central

hub and

connected

by

webs

and to hollow wheels with multiple arms.

WORKED OUT EXAMPLE 1

A 2.2 kw, 960 rpm motor powers the cam driven ram of a press through a gearing of 6:1 ratio. The rated capacity of the press is 20 kN and has a stroke of 200 mm. Assuming that the cam driven ram is capable of delivering the rated load at a constant velocity during the last 15% of a constant velocity stroke. Design a suitable flywheel that can maintain a coefficient of Speed fluctuation of 0.02. Assume that the maximum diameter of the flywheel is not to exceed 0.6m.

Work done by the press= 3 U = 20 *10 * 0.2 * 0.15 = 600Nm

Energy absorbed= work done= 600 Nm Mean torque on the shaft: 3 2.2 *10 = 21.88Nm 960 2* * 60 Energy supplied= work don per cycle = 2 * 21.88 * 6 = 825 Nm Thus the mechanical efficiency of the system is = 600 = = 0.727 = 72% 825 There fore the fluctuation in energy is =

E = Energy absorbed - Energy supplied k

Indian Institute of

600 825 * 0.075 ( 21.88 * 6 * * 0.15 ) 538.125Nm Ek I= C f 538.125 960 0.02 2 60 * = 2.6622 kg m I= 2 2

avg

r 2 2 . r r .t 2 g o i

ri = 0.8 r o 78500 4 4 2.6622 = * 0.30 0.24 t 2 9.86 = 59.805t Assuming

t= or

2 .6622 59.805

= 0.0445

45 mm 2 = 3+ 2 2 1 + 3 2 r +r r i o 3+ g 8 7 8 5 0 0 2 3 + 0.3 2 2 1.9 * 0.242 t = . 0.24 + 0.3 9.81 8 3.3 2 960 t = 0 .5 4 * 2 * 3 60 2 = 55667 N / m = 0.556MPa t = r or if t = 150 MPa

6 2 150 *10 = 7961.4 ( 0.4125 )( 0.0376 )( 0.090 )( 0.0331) = 0.5482 = 16544 rad / sec2

OS =

yield 16544 = 32

= 164.65

Indian Institute of Technology Madras