Flywheel

Flywheel is a rotating mechanical device that is used to store rotational energy.

• A flywheel used in machines serves as a reservoir, which stores 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.
(Makinelerde kullanılan volan, enerji arzının ihtiyaçtan fazla olduğu
dönemde enerjiyi depolayan, enerji ihtiyacının arzdan fazla olduğu
dönemde ise enerjiyi serbest bırakan bir depo görevi görmektedir.)

 Flywheels are typically made of steel and rotate on

conventional bearings; these are generally limited to a
revolution rate of a few thousand RPM. Some modern
flywheels are made of carbon fiber materials and
employ magnetic bearings, enabling them to revolve at
speeds up to 60,000 RPM
 Flywheel
Consider a foot operated sewing machine. It consists of two wheels one big, other small. The wheels

are connected by a rope.When motion is imparted to the bigger wheel, the rope transfers this motion

to the smaller wheel . This smaller wheel acts as a pulley and runs the sewing machine. We see that

even when we stop supplying driving force to the bigger wheel it still continues to run for a short time

because of inertia it possesses. Flywheel is a device acts as an Energy Reservoir by storing and

supplying mechanical Energy when required.

https://www.youtube.com/watch?v=EMazLuxpzxE
 Flywheel

https://youtu.be/7K4W4hA6aV4
 Flywheel

Flywheel Battery

https://www.youtube.com/watch?v=yhu3s1ut3wM
Internal combustion engines with one or two cylinders are a typical example. Piston compressors, punch
presses, rock crushers etc. are the other systems that have fly wheel.

The function of a flywheel in an engine is entirely different from that of a governor. It controls
the speed variation caused by the fluctuations of the engine turning moment during each cycle
of operation.

In a machine, Turning moment versus crank angle graph is drawn. In this graph, energy
overbalance is determined by calculating mean torque. Then mass moment of inertia of
flywheel is determined to balance fluctuations. Sometimes mean torque graph is given. If it is
not given, one must first calculate mean torque graph from the energy fluctuation graph.
 Ekzantrik Preste Volan
Eksantrik preste iş yapmak için gerekli olan enerji elektrik
motorundan alınır. Fakat iş çevirimlerinde sürekli olarak motorun
durup tekrar çalısması ve yeterli enerjiyi tek başına saglayabilmesi
için yüksek maliyetli bir motora ihtiyaç vardır. Bunun yanında presin
elektrik tüketimi konusunda oldukça yüksek meblağlar elde edilir.

Bu tip makinelerde bir enerji düzensizligi olmaması ve gerektiginde

yüksek güçlerin karşılanabilmesi için enerji depolayan akülere ihtiyaç
vardır. işte mekanik anlamda bu akülere volan denmektedir ve
eksantrik preste baş rol bu elemanındır.

Volanın geometrisi itibariyle sürekli dönüp bir enerji

depolayacagından dairesel formda olması kaçınılmazdır. Dönme
hareketinden kaynaklanan açısal hız ve kütlesinden kaynaklanan
ataletle dönme kinetik enerjisini depolar. Depolanan bu enerji preste
iş yapmak amacıyla kullanılır. Preste iş yapılmadığı anlarda
dönmesine devam ederek bir enerji sürekliliği meydana getirir.

https://www.youtube.com/watch?v=D1FktaJauFU
Eccentric Press with capacity of 100 kg
Animation of Eccentric Press- https://www.youtube.com/watch?v=zqW6PPfWgCE
A portable rock crusher from the early 20th century
 Hand operated rock crusher
https://www.youtube.com/watch?v=UIG5xOiIhQc

Simple Rock Crusher - https://www.youtube.com/watch?v=0ApTDRt7ZLY

 Flywheels
The turning moment diagram (also known as crank effort diagram) is the graphical
representation of the turning moment or crank-effort for various positions of the crank
It is plotted on Cartesian co-ordinates, in which the turning moment is taken as the
ordinate and crank angle as abscissa.

A turning moment diagram for a four stroke cycle internal combustion engine is shown
in Figure. We know that in a four stroke cycle internal combustion engine, there is one
working stroke after the crank has turned through two revolutions, i.e 720 (or 4 pi
radians)

9
 Flywheels

The variations of energy above and below the mean resisting torque line are called
fluctuations of energy. The difference between the maximum and the minimum
energies is known as maximum fluctuation of energy
Turning Moment

Mean Torque Line

Crank Angle

10
 d d d d
T  I  T  I T  I Noting that 
dt dt d dt

d
T I   Td  I d and take the integral of both sides
d
2 2
 Td   I d
1 1

2 2 
1 2 2 1
Let  Td  U  A;  I d  I  I ( 22  12)
1 1 2 1 2
 2 2 
1 2 2 1
Let  Td  U  A;  I d  EK ; EK  I  I ( 22  12)
1 1 2 1 2
1 2
1 2
Emax  Imax Emin  Imin
2 2
1  min ; 2  max ;  2max   2min  (max  min )(max  min )
1 (  min )
 I (max  min )(max  min )  EK  I (max  min ) max
2 2
Multiply the numerator and denominator by mean , we get as follow
(max  min ) mean
E K  I (max  min )
2 mean
( max  min ) ( max  min )
Notice that  mean ;  Cs
2 mean
A
EK  A  IC smean
2
I  , where Cs  Coefficient of fluctuation of speed
Csmean
2

I is mass moment of inertia of flywheel. A is energy overbalanc e.

 Flywheel

Coefficient of fluctuation of speed

System Permissible Cs

Pumps, Shearing machines 1/5 – 1/30

Machine Tools, Textile Machines 1/40 – 1/50

Generators 1/100 – 1/300

Automobiles 1/200 – 1/300

Aircraft Engines 1/1000 – 1/2000

13
 min  Minimum speed during the cycle
max  Maximum speed during the cycle
mean  Averagespeed during the cycle

(nmax  nmin ) ( max   min )

 Cs 
nmean  mean

nmin  Minimum rotating speed (rpm)during the cycle

nmax  Maximum rotating speed (rpm) during the cycle
nmean  Averagespeed during the cycle
Turning Moment Diagram and Flywheels
Consider the Torque angle diagram
again. A and B are the points where
the diagram passes through the
mean. For convenience move the
start of the cycle to point A.
 Determination of Maximum Fluctuation of
Energy Total amount of energy

E   M ( )d
4
E 1
M resisting  M ave  
4 4  Md
0

Let the energy at A be E A , we have

B
Energy at B, E B  E A   ( M  M ave )d
A
C
Energy at C , EC  E B   ( M  M ave )d
B
D
Energy at D, E D  EC   ( M  M ave )d
C
E
Energy at E , EE  E D   ( M  M ave )d
D
F
Energy at F , E F  EE   ( M  M ave )d
E
G
Energy at G, EG  EF   ( M  M ave )d  Energy at A
F
17
 Example
An engine is running at a speed of 600 rpm. If the total
fluctuation speed is not to exceed 1.5 % of the mean, find the
coefficient of fluctation of speed.
1.5
nmax  600  600x  nmax  609 rpm
100
1.5
nmin  600  600x  nmax  591 rpm
100

609  591
nmean   600 rpm
2

n    min C
max  nmin 609  591  C  0.03  0.03
max
ave
s
 s
nmean 600

18
 A3
A2

U  E  A  800 J Reference line

A4

A1
 Example
Given:
  62.84 rad / s
Cs  0.03
1 mm2 =31.42Nm

Let the energy at A is E A

Energy at B, EB  E A  52 Maximum Energy
Energy at C, EC  EB 124  EA  72 E  E A  52  E A  120  172
Energy at D, ED  EC  92  EA  20 E  172 * 31.42  5404 Nm
Energy at E , EE  ED  140  E A  120 Minimum Energy E  Iave
2
Cs
Energy at F , EF  EE  85  E A  35
Energy at G, EG  EF  72  EA 107 5404  I * 62.822 * 0.03
Energy at H , EH  EG  107  EA I  45.64 kgm2
I  45.64 kgm2  m * k 2
22
m  182.58 kg
Example The torque diagram of a machinery for one cycle is given in the
figure. The average angular speed and the coefficient of
fluctuation of speed are 100 rad/s and 2% respectively. Calculate
the mass moment of inertia of the flywheel.
 Tmean

Checking the summation of the mean torque that it should be zero.

Example The deviation with crank angle of the provided torque to the crank is
given in the figure so that it can rotate constant angular velocity of 25
rad/s. The minimum value of the angular velocity of the crank should be
24.5 rad/s. Calculate the mass moment of inertia of the flywheel.

As it is shown that the graph doesn’t include mean torque (Tmean). So, first it
must be obtained.
Example

A1 A2 A3
A5 A6
A4

A4 A5 A6
A1 A2 A3
Example

   4.603 A5
   2.727
A2
A1
A3
. ... A6 791.7 Nm
791.7

. A4

A3
A2
A1

=A4
A6

A5
Example
E1=1342,1 1342,1
E1=1680,6
Reference Line
E=1342,1+338,5
E3=338,5 338,5
=1680,6 J

791.7 Nm
 Example 2
A shaft fitted with a flywheel rotates at 250 rpm and drives a machine. The torque
of machine varies in a cyclic manner over a period of 3 revolutions. The torque rises
from 750 Nm to 3000 Nm uniformly during ½ revolution and remains constant for
the following revolution. It then falls uniformly to 750 Nm during the next ½
revolution and remains constant one revolution, the cycle being repeated
thereafter. Determine the power required to drive the machine and percentage
fluctuation in speed, if the driving torque applied to the shaft is constant and the
mass of the flywheel is 500 kg with radius of gyration of 600 mm.
Turning moment diagram for one cycle is shown in figure
3000 Given:
Turning Moment(Nm)

N  250 rpm
2
 250  26.2 rad / s
60
750 m  500 kg
k  0 .6 m
 2 3 4 5 6
½ rev. 1 rev. ½ rev. 1 rev.
30 Crank angle
 B C
Example 2
3000
Turning Moment (Nm)

2
 T
Tmean  0
 A1  A2  A3  A4
6
A2
A1 A3
750 E
A G H D
A4 750  3000 
F A1   1875
2
O  2 3 4 5 6
½ rev. 1 rev. ½ rev. 1 rev. A2  30003     6000
Crank angle 3000  750 4  3 
A3   1875
2
A4  7506  4   1500

1875  6000  1875  1500  11250

Tmean    1875 Nm
6 6

31
 Example 2
3000
B C M ave  1875 Nm
Turning Moment (Nm)

A4 Power  49.125 kW
A3 A6
1875 K L M N P Tmean
BM  CN  3000 1875  1125Nm
A2 A7
750 A5 E
A G H D The area above the mean torque
A1 A8 A9
F represents the maximum
0
 2 3 4 5 6
fluctuation of energy.
½ rev. 1 rev. ½ rev. 1 rev.
Crank angle
From the similarity of thetriangles, BMˆ L and AKˆ L
BM LM 3000  1875 LM 1125 LM KM
 0.5
      LM  LK  LM  LK 
AK LK 1875  750  LK 1125 LK 2

From the Similarity of Triangles CHˆ D and CNˆ P

CH HD 3000  750  4  3  LM 2250 
      NP  0.5
CN NP 3000  1875 NP 1125 NP
 Example 2
3000
B C M ave  1875 Nm
Turning Moment (Nm)

A3 Power  49.125 kW
A2 A4 LM  0.5
1875 K L N P Tmean
A1
M
A5 NP  0.5
A6
BM  CN  3000 1875  1125Nm
750 E
A D The area above the mean torque
represents the maximum
0
 2 3 4 5 6
fluctuation of energy.
½ rev. 1 rev. ½ rev. 1 rev.
Crank angle

A1 
 1875  750 ( 0.5 )
 281.25 J A2 
3000  18750.5  281.25 J
2 2
A3  3000  18753    2250 J A4 
3000  18750.5  281.25 J
2

A5  
3000  18750.5  281.25 J A6  1875  750 ( 6  4 )  2250 J
2

33
 B C
3000 Example 2
Turning Moment (Nm)

A2 A3 A4
K Tmean
1875 A1 L M N P A A1  281.25 J A2  281.25 J
5 A6
750 A A3  2250 J A4  281.25 J
D E
A5  281.25 J A6  2250 J
0
 2 3 4 5 6
½ rev. 1 rev. ½ rev. 1 rev.
Crank angle

E1  A1  281.25 J
E2  A2  A3  A4  281.25  2250  281.25  2812.5 J
E3  A5  A6  281.25  2250  2531.25 J

E3=2531.25
E=2531.25+281.25 E2=2812.5 2531.25
=2812.5 J Reference Line
E1=281.25 281.25

34
  =2812.5 J= 2812.5x(3.14159)=8835.7 Nm

E  I2Cs  mk 2 2Cs
8835.7  500( 0.6 )2 ( 26.2 )2 Cs  8835.7  123559.2Cs
8835.7
Cs   0.0715
123559.2
 B C Example 2
3000 M ave  1875 Nm
Turning Moment Nm

E Power  49.125 kW
1875 Tmean LM  0.5
L M N P NP  0.5
BM  CN  3000 1875  1125Nm
750
A G H D E
The area above the mean torque
F represents the maximum
O  2 3 4 5 6 fluctuation of energy.
½ rev. 1 rev. ½ rev. 1 rev.
Crank angle

E  Area LBCP
1 1 E  I 2Cs  mk 2 2Cs
 * 0.5 *1125  2 *1125  * 0.5 *1125
2 2 8837  500 * (0.6) 2 * (26.2) 2 * Cs
 8837 Nm
8837
Cs   0.071
123559

36
 Punch Press
A punching press is shown diagrammatically in Figure. The
crank is driven by a motor which supplies constant torque
and the punch is at the position of the slider in a slider- 1
2
crank mechanism. From Figure, we see that the load acts
only during the rotation of the crank from   1 to   2, ,
when the actual punching takes place and the load is zero
for the rest of the cycle. Unless a flywheel is used, the
speed of the crankshaft will increase too much during the
rotation of crankshaft   2 to   2 or   0 and again
from   0 to   1 because there is no load while input
energy continues to be supplied. On the other hand, the punch
plate
drop in speed of the crankshaft is very large during the die
rotation of crank from   1 to   2 due to much more
t
load than the energy supplied. Thus the flywheel has to
absorb excess energy available at one stage and has to
make up the deficient energy at the other stage to keep to
fluctuations of speed within permissible limits. This is done
by choosing the suitable moment of inertia of the flywheel.

37
1 2
Let
Punch Press
E1 be the energy required for punching a hole,
d1 = Diameter of the hole punched,
t = Thickness of the plate. and 1
2
tu= Ultimate shear stress for the plate material.

Maximum shear force required for punching.

Fs = Area sheared*Ultimate shear stress = *d1*t*tu

Work done or energy required for punching a hole,

punch
plate
1 die
E1  * FS * t t
2

38
1 2
 Punch Press
Assuming one punching operation per revolution, the
energy supplied to the shaft per revolution should also be
equal to E1. The energy supplied by the motor to the
1
crankshaft during actual punching operation. 2

  2  1 
E2  E1  
 2 
Balance energy required for punching
   
 E1  E2  E1  E1  2 1 
 2  punch
   
plate
 E1 1  2 1  die

 2  t

This energy is to be supplied by the flywheel by the

decrease in its kinetic energy when its speed falls from
maximum to minimum. Thus maximum fluctuation of
energy
  2  1 
E  E1  E2  E1 1  
 2 
39
1 2
 Punch Press
   
E  E1  E2  E1 1  2 1 
 2  1
2

The values of 1 and 2 may be determined only if the

crank radius (r), length of connecting rod (l) and the
relative position of the job with respect to the crankshaft
axis are known. In the absence of relevant data, we assume
that
 2  1 t t
  punch
2
plate
2 s 4r die

s = Stroke of the punch = 2 x Crank radius t

40
1 2
 Example 3
A punching press is driven by a constant torque electric motor. The press is provided
with a flywheel that rotates at maximum speed of 225 rpm. The radius of gyration of
the flywheel is 0.5 in. The press punches 720 holes per hour, each punching
operation takes 2 second and requires 15 kN-m of energy. Find the power of the
motor and the minimum mass of the flywheel if speed of the same is not to fall
below 200 rpm.
Given:

N1  225 rpm, N 2  200 rpm, k  0.5 m, E1  15 *103 Nm,

Hole punched  720 per hr
We know that the total energy required per second

Energy required Number of holes

Power of the motor  *
Hole s
720
 15 *103 *  3000 Nm / s  3 kW
3600

41
 Example 3
A punching press is driven by a constant torque electric motor. The press is provided
with a flywheel that rotates at maximum speed of 225 rpm. The radius of gyration of
the flywheel is 0.5 in. The press punches 720 holes per hour, each punching
operation takes 2 second and requires 15 kN-m of energy. Find the power of the
motor and the minimum mass of the flywheel if speed of the same is not to fall
below 200 rpm.
Given: N1  225 rpm, N 2  200 rpm, k  0.5 m, E1  15 *103 Nm,
Hole punched  720 per hr

Since each punching operation takes 2 seconds, therefore energy supplied by the
motor in 2 seconds
E2  3000* 2  6000Nm
Energy to be supplied by the flywheel during punching or maximum fluctuation of energy
E  E1  E2  15 *103  6000  9000Nm
Mean speed of the flywheel,
N1  N 2 225  200
N   212.5 rpm
42 2 2
 Example 3
A punching press is driven by a constant torque electric motor. The press is provided
with a flywheel that rotates at maximum speed of 225 rpm. The radius of gyration of
the flywheel is 0.5 in. The press punches 720 holes per hour, each punching
operation takes 2 second and requires 15 kN-m of energy. Find the power of the
motor and the minimum mass of the flywheel if speed of the same is not to fall
below 200 rpm.
Given: N1  225 rpm, N 2  200 rpm, k  0.5 m, E1  15 *103 Nm,
Hole punched  720 per hr
Let
m = Minimum mass of the flywheel.
We know that maximum fluctuation of energy (E).
2
9000  * m * k 2 N N1  N 2 
900
2
 * m * 0.52 * 212.5 * 225  200  14.565m
900
m  9000 / 14.565  618 kg

43
 Example 4
A machine punching 38 mm holes in 32 mm thick plate requires 7N-m of energy per square mm of sheared
area, and punches one hole in every 10 seconds. Calculate the power of the motor required. The mean
speed of the flywheel is 25 meters per second. The punch has a stroke of 100 mm. Find the mass of the
flywheel required, if the total fluctuation of speed is not to exceed 3% of the mean speed. Assume that the
motor supplies energy to the machine at uniform rate.
Given:
d  38 mm, t  32 mm, E1  7 Nm / mm 2 of sheared area, v  25m / s,
s  100 mm, v1  v2  %3v  0.03v
We know that sheared area,

A   * d * t   * 38* 32  3820 mm2

Since the energy required to punch a hole is 7 Nm/mm2 of sheared area, therefore total energy required per
hole,

E1  7 * 3820  26740Nm
Also the time required to punch a hole is 10 second, therefore energy required for punching work per second

 26740/ 10  2674 Nm / s
Power of the motor required
 2674W  2.674 kW
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 Example 4
A machine punching 38 mm holes in 32 mm thick plate requires 7N-m of energy per sq. mm of sheared area,
and punches one hole in every 10 seconds. Calculate the power of the motor required. The mean speed of
the flywheel is 25 meters per second. The punch has a stroke of 100 mm. Find the mass of the flywheel
required, if the total fluctuation of speed is not to exceed 3% of the mean speed. Assume that the motor
supplies energy to the machine at uniform rate.

Since the stroke of the punch is 100 mm and it punches one hole in every 10 seconds, therefore the time
required to punch a hole in a 32 mm thick plate
10
 * 32  1.6 s
2 *100
Energy supplied by the motor in 1.6 seconds.  32 
E2  2674*1.6  4278 Nm E  267401    22462 Nm
 2 *100 
Energy to be supplied by the flywheel during punching or the maximum fluctuation of energy,
E  E1  E2  26740  4278  22462 Nm   2  1 
E  E1  E2  E1 1  
Coefficient of fluctuation of speed.  2 
v1  v2
Cs   0.03   2  1   t 
v E  E1 1    E1 1  
 2   2s 
We know that maximum fluctuation of energy (E)

22462
45
 m * v 2
* C s  m * 252
* 0.03  18.75 m m  22462/ 18.75  1198 kg
 Example 5
A riveting machine is driven by a constant torque 3 kW motor The moving parts including the flywheel are
equivalent to 150 kg at 0.6 m radius. One riveting operation takes 1 second and absorbs 10 000 Nm of energy The
speed of the flywheel is 300 rpm before riveting. Find the speed immediately after riveting. How many rivets can be
closed per minute.
Given:
P  3 kW , m  150 kg, k  0.6 m, N1  300 rpm,1  2 * 300 / 60  31.42 rad / s
We know that energy supplied by the motor.
E2  3 kW  3000 W  3000 Nm / s
But energy absorbed during one riveting operation which takes 1 second.
E1  10000 Nm
Energy to be supplied by the flywheel for each riveting operation per second or the maximum fluctuation of
energy.

E  E1  E2  10000  3000  7000 Nm

We know that maximum fluctuation of energy (E).

2  26.98 rad / s
1
  1

7000  mk 1  2  *150 * 0.6 * 31.42  2
2 2 2 2 2 2

2 2 N 2  257.6 rpm
Energy to be supplied by the flywheel for each riveting operation per second or the maximum fluctuation of
energy.
E2 3000
46
 * 60  * 60  18 rivets
E1 10000