Flywheel Design

The force due to gas pressure on piston creates a turning moment on the crankshaft.
Also, the inertia force due to connecting rod and reciprocating masses cause a torque to act
on the crankshaft. The inertia-torque curve is similar for each rotation of the crank whereas
the torque on crankshaft due to gas pressure repeats itself after 2 rotations of crank in case of
4-s engine. The net turning moment diagram is obtained by superimposing the 2 curves and
the difference between the ordinates at any angle, plotted. The TMD is drawn for 1 complete
cycle.

This net TMD can be seen to vary continuously during each cycle of operation. To
control the speed variations of engine crankshaft caused by the fluctuation of TM during a
cycle, flywheel is used. Note that a flywheel does not control the speed variations due to
varying load. This is the function of a governor which it accomplishes by varying the fuel
supply. The flywheel, or governor, does not maintain a constant speed. They only reduce the
fluctuation of speed and keep the mean speed within certain limits.

A flywheel is a fairly heavy steel wheel (disc) attached to the rear end of the
crankshaft. Its size depends upon the number of cylinders and the general construction of the
engine.
The flywheel is also used as a part of clutch mechanism and has teeth on its outer
peiphery to mesh with the electric cranking-motor pinion.

The permissible speed variation is an important factor in all flywheel designs. The rim
section is generally quite heavy and is connected to the hub by disc-shaped plate.
Fluctuation of Speed and Fluctuation of Energy:
Let, N1 = maximum speed of flywheel
N2 = minimum speed of flywheel
N = mean speed of flywheel = N1+N2
2
Then, (N1-N2) is called fluctuation of speed and (N1-N2) is called the coefficient of
N
fluctuation of speed, CS.
The following table shows the permissible values of CS for some engines.

S. No. Type of Engine CS 4s CE % 4s CE % 2s

1. single cylinder 0.093 2.35 - 2.40 0.95 - 1.00
2. 4-cylinder 0.066 0.15 - 0.20 0.075 - 0.100
3. 6-cylinder 0.031 0.10 - 0.12 0.016 - 0.02

(In general, CS is between 0.05 and 0.1)

Now, let E = Energy of the flywheel at its mean speed

a1 = energy absorbed by the flywheel in one cycle
a2 = energy withdrawn from the flywheel in one cycle
Then maximum energy in flywheel = E+a1, and
minimum energy in flywheel = E-a2
Fluctuation of energy of flywheel = (a1 + a2) = e
Coefficient of fluctuation of energy = CE= e
E
Alternatively, the coefficient of fluctuation of energy is defined as the ratio of maximum
fluctuation of energy to the work done per cycle.
Ce = e/work done/cycle
Work done per cycle can be obtained as follows:
wd / cycle = Tmean xθ
where Tmean = mean torque
θ = angle turned in radian / cycle
= 4π in case of 4s engine
= 2π in case of 2s engine
Tmean kgfm = Px 4500
2πN
where P = BHP
wd / cycle may also be obtained as,
wd / cycle = Px 4500 , where n = number of power strokes / min.
2πn

Energy stored in flywheel:

When a flywheel absorbs energy its speed increases and when it gives up energy its speed
decreases. The mean kinetic energy of flywheel is given by,

E = 1 Iω2 = 1 mk2 ω2 = W k2 ω2
2 2 2g
where, I = mass moment of inertia of flywheel about the axis of rotation
= W. k2 , kg m/s2
g
(I is the moment of inertia of the mass about the center of rotation. The moment of
inertia is the measure of resistance to torque applied on a spinning object (i.e. it is the inertia
of a rotating body), hence the higher the moment of inertia, the slower the object will spin
after being applied a given force.)

m = mass of flywheel, kg
W = weight of flywheel, kg
k = radius of gyration, m

2
 ω = mean angular speed of flywheel, rad/s
= 2πN
60

In the above expression only the mass-moment of inertia of the rim is considered and
the M.I. of hub and disc is neglected. This is because the major portion of weight of flywheel
is in the rim and a small portion is in the hub and disc. Also, the hub and disc are nearer to the
axis of rotation, therefore M.I. of the hub and disc is small.
As the speed of rotation of flywheel changes from ω1 to ω2, the maximum fluctuation
of energy,
e = 1 I(ω12-ω22)
2
= 1 I (ω1+ω2)( ω1-ω2)
2
= Iω (ω1-ω2)
= Iω2 (ω1-ω2)
ω
= Iω2 CS
= mk2ω2 CS

The radius of gyration may be taken equal to the mean radius of the rim, r, because thickness
of rim is very small as compared to diameter of rim.

e = mr2ω2 CS
= mv2 CS
= W v2 CS
g
Now, K.E. = 1 mv2
2
= W v2
2g
2E = W v2 = e
g CS
. 2
. . e = 2E CS = W v CS,
g
substituting in above expression.

From this expression weight of flywheel rim may be determined. The actual weight of rim
may be taken 10% less than calculated to allow for the flywheel effect of the hub and disc.

In the above expression we must know r and ω to calculate m. But if r and ω are not known
then we may proceed as follows -

We obtain the mean diameter of the flywheel by considering the centrifugal force in the rim.
f = ρ v2 kg/cm2
g
where, f = permissible stress
ρ = density of material
v = mean linear velocity of rim
g = acceleration due to gravity

3
Thus knowing v we can calculate D because,
v = rw = r 2πN = πDN
60 60
Thus D = 60v
πN

Now, the mass of flywheel is given by

mass = volume X density
= (2πr)A ρ
From this we may find the cross-sectional area of the rim, A.
Assuming the cross-section to be rectangular, A= bt, where b = width of rim and t = thickness
of rim.
Knowing the ratio b which is usually 2, we find the dimensions of the rim. Thus we
t
find r, b, and t of the flywheel.