FLYWHEELS

Flywheels can also be used to perform the same function when the torque
is constant and the load varies during the cycle like punching press or in a
riveting machine. A punching press is shown diagrammatically below,

The crank is driven by a motor which supplies constant torque and the
punch is at the position of the slider in a slider-crank mechanism. The load acts
only during the rotation of the crank from 𝜃 = 𝜃1 to 𝜃 = 𝜃2 , 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 will increase too much during the rotation of crank from
𝜃 = 𝜃2 to 𝜃 = 2𝜃 or 𝜃 = 0 and again from 𝜃 = 0 to 𝜃 = 𝜃1 , because there is no load
while input energy continues to be supplied. On the other hand, the drop in
speed of the crankshaft is very large during the rotation of crank from 𝜃 = 𝜃1 to
𝜃 = 𝜃2 due to much more load than the energy supplied.
Energy Required for Punching a Hole

1
𝐸1 = 𝑥 𝐹𝑆 𝑥 𝑡
2

where: 𝐹𝑆 = maximum shear force required for punching

𝑡 = thickness of the plate

Maximum Fluctuation of Energy

𝜃2 − 𝜃1
∆𝐸 = 𝐸1 (1 − )
2𝜋

Types Flywheels
Based on types of constructions, the flywheel has different types;
1. Disc Type

Flywheels up to 600 mm
diameter are commonly of this type.
They may be manufactured by
casting or fabrication where hub and
rim are connected through rim of
web.

2. Rim and Arm

Flywheels or larger size (600
mm to 2500 mm) are mostly of this
type. In this type, the rim and hub is
connected by the number of arms.
 3. Split

Flywheels with a very

large size (greater than 2500
mm diameter) are
manufactured in split form
where flywheels are divided
into to two, three, four or
more sectors.

Rim and Arm Flywheel

Mass of a Flywheel

𝑚𝐹 = 𝑚𝑅 + 𝑚𝐴𝐻
where: 𝑚𝐹 = total mass of flywheel
𝑚𝑅 = mass of the flywheel rim
𝑚𝐴𝐻 = mass of the arm and hub

Stresses in a Flywheel Rim

A flywheel consists of a rim at which the major portion of the mass or
weight of flywheel is concentrated, a boss or hub for fixing the flywheel on to the
shaft and a number of arms for supporting the rim on the hub.

The following types of stresses are induced in the rim of a flywheel:

1. Tensile stress due to centrifugal force

𝜎𝑡 = 𝜌 𝑥 𝑅 2 𝑥 𝜔2
2. Tensile bending stress caused by the restraint of the arms
19.74 𝑥 𝜌 𝑥 𝜔2 𝑥 𝑅 3
𝜎𝑏 =
𝑛2 𝑥 𝑡
3. The shrinkage stresses due to unequal rate of cooling of casting.
These stresses may be very high but there is no easy method of
determining. This stress is taken care of by a factor of safety.
Stresses in Flywheel Arms

The following stresses are induced in the arms of a flywheel;

1. Tensile stress due to centrifugal force acting on the rim.

3
𝜎𝑡 𝑎 = 𝜎𝑡
4
2. Bending stress due to the torque transmitted from the rim to the
shaft or from the shaft to the rim
𝑇
𝜎𝑏𝑎 = (𝑅 − 𝑟)
𝑅𝑥𝑛𝑥𝑍
3. Shrinkage stresses due to unequal rate of cooling of casting. These
stresses are difficult to determine

Design of Flywheel Arms

From the equation of maximum bending stress

𝑇
𝜎𝑏𝑎 = (𝑅 − 𝑟)
𝑅𝑥𝑛𝑥𝑍

where: 𝑍 = section modulus

𝜋
𝑍 = 32 𝑥 𝑏1 (𝑎1 )2

Design of Shaft, Hub and Key

𝑑𝑠
𝜏𝑚𝑎𝑥 = 𝐿 𝑥 𝑤 𝑥 𝜏 𝑥
2
Split Flywheels

A split flywheel has the advantage of relieving the shrinkage stresses in

the arms due to unequal rate of cooling of casting. A flywheel made in two halves
should be spilt at the arms rather than between the arms, in order to obtain
better strength of the joint. The two halves of the flywheel are connected by
means of bolts through the hub. The two halves are also joined at the rim by
means of cotter joint or shrink links. The width or depth of the shrink link is
taken as 1.25 to 1.35 times the thickness of link. The slot in the rim into which
the link is inserted is made slightly larger than the size of link.

The relative strength of a rim joint and the solid rim are given in the
following table;