Afro - Asian International Conference on Science, Engineering & Technology
AAICSET-2015
ISBN: 9-780993-909238
Reduction in Mass of an Existing Punch-Press Flywheel
Using Advance Modelling and Finite Element Techniques
(Paper ID: Bharuch2k15C0220)
Nilesh V. Rana
Brijesh K. Gotawala, Vijay Parekh
Student, M.E.(CAD/CAM),
Department of Mechanical Engineering
Shree S ’ad Vidya Mandal Institute of Technology,
Bharuch, Gujarat, India
[email protected]
Assistant Professor
Department of Mechanical Engineering
Shree S ’ad Vidya Mandal Institute of Technology,
Bharuch, Gujarat, India
[email protected],
[email protected],
Abstract: Flywheel energy storage (FES) can have energy fed in the
rotational mass of a flywheel, store it as kinetic energy, and release
out upon demand. For example, in I.C. engines, the energy is
developed only in the power stroke which is much more than engine
load, and no energy is being developed during the suction,
compression and exhaust strokes in case of four stroke engines. The
excess energy is developed during power stroke is absorbed by the
flywheel and releases its to the crank shaft during the other strokes in
which no energy is developed, thus rotating the crankshaft at a
uniform speed. The current paper is focused on the analytical design
of flywheel & FEM analysis flywheel used in Press. Different types
of forces acting on flywheel & design parameters has taken into
consideration for optimizing design of flywheel by using ANSYS
stresses obtained & compared with analytical calculations, also
weight is compared.
are a typical examples. Piston compressor, Punch presses, rock
crusher etc. are the other system than have flywheel [3].
Keywords: Flywheel, Composite, FEA.
I.
INTRODUCTION
Flywheels have been used for a so many time as Mechanical
Energy Storage (MES) devices. The past form of a flywheel is
Potter’s wheel that uses stored energy to aid in Shaping [6].
The word ‘flywheel’ appeared first during the start of
industrial revolution. During this period, there were two
important developments, one is the use of flywheels in steam
engine and other is widespread use of iron. Iron material has
high integrity that flywheels made up of wood, stone, or clay
[6]. Mainly the performance of a flywheel can be attributed to
three factors i.e. Material strength, Geometry and Rotational
speed [5]. A flywheel is a mechanical device with a significant
moment of inertia used as a storage device for rotational
energy. Flywheels have become the subject of extensive
research as power storage devices for uses in vehicles [1].
Flywheel is like as a reservoir to store energy when supply is
more than requirement and to release the energy when
requirement is more than supply [2]. Flywheel provides an
effective way to smooth out the function of speed. Flywheel
energy storage are considered to be an alternative to
electromechanical batteries due to higher stored energy
density, high life time and deterministic state of change and
ecologically clean nature [2]. Many machines have a load
patterns that cause the torque time function to vary over the
cycle. Internal combustion engine with one or two cylinders
Akshar Publication © 2015
Fig. 1 Solid disc flywheel [16]
The amount of stored energy is determined by the size, weight
and the maximum allowed rotational speed of the flywheel
within its centrifugal strength limit. In order to maximize
energy storage capacity the rotor has to be designed to rotor as
fast as possible without any material failure thereby high
strength fiber reinforced polymer composite have been widely
used to fabricate flywheel rotor [10]. Composite flywheel is
currently being developed for energy storage. To satisfy the
high performance and low weight constraints, high strength
carbon fiber composites are the material of choice for flywheel
construction. Recently, several composite flywheels have been
developed for commercial power generation and vehicles,
such as buses and trains. Composite flywheels are crucial
component of the system. There have been numerous R & D
programs of composite flywheel in the past [8].
A. Function of flywheel
 Flywheel is like as a reservoir to store energy when
supply is more than requirement and release the
energy when requirement is more than supply.
 Flywheel provides the effective way to smooth out
the function of speed.
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ISBN: 9-780993-909238
 The amount of stored energy is determined by the
size, weight and the maximum allowed rotational
speed of the Flywheel within it centrifugal strength
limit.
 Recently, several composite Flywheels have been
developed for commercial power generation and
vehicles such as buses and trains.
Fig.2 Function of flywheel [16]
II.
LITERATURE REVIEW
Phanindra Mudragadda et.al.[1] have designed a four wheeler
Flywheel used in a petrol engine using theoretical calculation.
They have validated the design of Flywheel on A360 & Cast
iron. For all the materials the stress values are less than their
respective permissible yield stress values. By comparing the
results for two materials, the stress value for aluminum alloy
A360 is less than that of Cast iron. Nagraj R. M. [2] has
presented a work on comparison of existing Flywheel material
with composite one. They got a result from design & analysis
methods that for energy storage low density and high strength
is required in turns stresses and deformation should be low. So
the Existing Gray cast iron Flywheel are having more stress
and deformation whereas the test material is comparatively
low. Therefore they suggest to use aluminum in Flywheel for
high energy storing purpose with low density and less mass.
Snehal R. Raut et.al.[3] have discuss the different parameter
like material stress acting on the Flywheel efficiency, cost of
the Flywheel, output energy storing capacity of existing
Flywheel. They have made a model in Pro-E as Web type
Flywheel and 4,6,8 arm Flywheel. They conclude that web
construction having maximum weight. All taper arm
respectively 4,6,8 arm are having mass less than elliptical arm
flywheel. Kishore D. Farde et.al. [4] Have observed that the
speed of the Flywheel would increase during periods of excess
of torque during the cycle and speed will fail during the period
of the deflect torque during the cycle. In their paper work they
have used the composite material which allow a higher
rotational speed and are better choice than metals when
designing Flywheel rotors. The theoretical specific energy of
composite rotor is around five times higher than metallic ones.
Akshar Publication © 2015
In future they are going to design & analyze the composite
Flywheel i.e. Steel (Rim) and Flywheel body to reduce weight
for space aircraft & F1 race car application. S.M.Choudhary
et.al [5] have studied various profiles of Flywheel and the
stored kinetic energy is calculated for the respective flywheel.
Results shows that efficient Flywheel design maximize the
inertia of moment for minimum material used and guarantee
high reliability and long life. Amount of Kinetic energy stored
by wheel-shaped structure Flywheel is greater than any other
flywheel. They found that certain amount of energy stored in
Spoke/Arm Flywheel is less than the other Flywheel, thus
reduce the cost of the Flywheel. M. Lavakumar et.al. [6] have
establish the design and analysis of Flywheel to minimize the
fluctuation in torque. The Flywheel is subjected to a constant
rpm. The objective of this work is to design and optimize for
the best material. Akshay P. Pundey et.al. [7] have presented
the investigation of a Flywheel to counter the requirement of
smoothing out the large oscillation in velocity during a cycle
of an I.C. Engine. A Flywheel is designed and analyzed by
using FEA method. They have calculated the stresses inside
the Flywheel. Finally the comparison study between the
design and analysis with existing Flywheel is carried out.
Francisco Diaz-Gonzalez et.al. [8] have formulate the
optimum operation to determine storage. The main objective
of the Flywheel is to smooth the net power flow injected to the
grid by a variable speed wind turbine. The result show that the
higher mean wind power, the higher mean rotating speed of
the Flywheel. The simulation results for the Flywheel with
proposed energy management algorithm are able to achieve a
91.9 % of the turbulent energy component reduction in the
high frequency components of the wind power. This result is
close to the 91.7 % obtained by the optimal operation of the
Flywheel. Sushama G. Bawane et.al [9] have used
optimization technique for various parameters like material,
cost for Flywheel. These parameters are optimized and by
applying an approach for modification of various working
parameter like efficiency, output, energy storing capacity and
compare the result with existing Flywheel result. At last the
design objective could be simply to minimize cost of Flywheel
by reducing material [9]. Sudipta Saha et.al [10] has done
work on the performance of the Flywheel. They found that the
performance can be attributed to three factors (1) Material
strength, (2) Geometry, (3) Rotational Speed. The material
strength is directly determines the Kinetic energy level that
could be produced safely combines with rotor speed. The CAE
Analysis and optimization procedure result show that smart
design of Flywheel geometry could both have a significant
effect on the performance and reduce the operational loads
exerted on the shaft due to reduced mass at high rotational
speed. S. M. Dhengle et.al. [11] have discussed the many
cases of Flywheel failure. Among them maximum tensile
stress and bending stress induced in the Rim and tensile stress
induced in the Arm under the action of centrifugal forces are
the main cause of the Flywheel failure. The Finite Element
Analysis is carried out for different cases of loading applied
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ISBN: 9-780993-909238
on the Flywheel and maximum Von-Misses stress and
deflection in the rim are determined. From this Analysis they
have found that Maximum stresses induced are in the rim &
arm junction. Jerome Tzeng et.al. [13] Have studied with the
intent of implement composites in high performance
Flywheels. The potential failure mechanism of Flywheel
constructed with fiber composites was evaluated. They have
used Analytical method to predict creep and pre-load loss due
to the time dependent behavior of composites. Then they have
test the material of T1000G Graphite / Epoxy composite. They
have check the fracture toughness which is a critical property
of for the composite Flywheel subjected to a very high
operating stress. The material test matrix performance
Flywheel was proposed from a design point of view of high
performance Flywheels. S. M. Arnold et.al. [14] Have
observed the problem in a Flywheel rotating disk. They have
make a analytical model to performing elastic stress analysis
for single/ multiple, annular / solid, anisotropic / isotropic
disk, which is subjected to pressure surface traction, body
force is summarized. They have considered the important
parameters like mean radius, thickness, material property,
load gradation and speed, all of which must be simultaneously
optimized to achieve the best and most reliable design. They
have made analysis with material PMC and TMC with either
and annular or solid geometry. They observed that an annular
anisotropic disk is more efficient than its solid counterpart.
Haichang Liu et.al. [15] Have offers significant operating cost
saving to the internal storage system, the commercialization of
Flywheel Energy Storage (FES) was not very successful. They
have implemented new technologies, Flywheel energy storage
will continue to develop and key issue will be solved and
reduced gradually. They considered three major advancement
for next technique. Their objective is enhancing the following
performance characteristics: - specific energy =200 Wh/Kg
and specific power = 30Kw/kg. The second is to improve its
efficiency by reduction of loss. Helium-air mixture gas
condition or vacuum enclose with better heat exchangers will
be selected according to different operation condition. They
have found that if the cost of FES can be lowered, they will be
widely used both in civil and military industries and play a
significant role in securing global energy sustainability.
III.




OBJECTIVES

The flywheel is modeled from geometric design data
and structural analyzed in FEA tool.
IV.
DESIGN PROCEDURE OF FLYWHEEL
A. Co-efficient of Fluctuation of speed.
The difference between maximum and minimum speeds
during a cycle is called the maximum fluctuation of speed.[19]
C =
N −N
ω −ω
=
N
ω
(1)
=
. .
=
. .
.
.
ℎ
Akshar Publication © 2015
.
.
.
A. Energy stored in Flywheel
Energy is stored in the rotor as kinetic energy or more
specifically as rotational energy[19].
m= Mass of the flywheel in kg,
k = Radius of gyration of the flywheel in meters,
I= Mass moment of inertia of the flywheel about the axis of
rotation in kg=m
We know that mean kinetic energy of the flywheel,
=
=
1
2
×
×
×
(in N-m or joules)
(2)
Where ω is mean angular speed during cycle in rad/s
And I is the moment of inertia of the mass about the centre of
rotation.
B. Mass of the flywheel
The mass of the flywheel rim is given by
m = Volume x Density
= 2πR x Ax ρ
The main objective is to reduce the weight of the
Flywheel with considering same mechanical
efficiency of Machine.
Structural analysis of flywheel by changing the cross
Section and geometry of the flywheel.
The analysis also consists of change of material with
Composite material for better reduction of weight.
The parameters are used for flywheel analysis such as
Rotating speed, diameter and thickness of flywheel,
Mass.
ℎ
(3)
C. Cross sectional area of Rim
A= b x t
b = Width of the rim, and
(4)
t = Thickness of the rim.
D. Stresses in a Flywheel
As a flywheel spins, the centrifugal force acts upon its
distributed mass and attempts to pull apart. These centrifugal
forces are similar to those caused by internal pressure in a
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ISBN: 9-780993-909238
cylinder. The tangential stress of a solid-disk flywheel as a
function of its radius r is
3+
8
=
+
+
−
= 2949.46/0.05*8002
= 0.092 kg-m2
+
−
TABLE I – Variation in stresses with geometry change.
−
(6)
Thickness
Diameter
Weight
Stress
In mm
(mm)
(Kg)
(N/mm2)
Safety
factor
yielding
3.175
441.96
3.69
199.38
2.1
6.35
371.60
5.22
141.16
3.0
9.525
335.78
6.34
115.38
3.7
12.7
312.67
7.29
100.00
4.3
15.87
295.65
8.14
89.52
4.8
19.05
282.44
8.86
81.77
5.2
22.22
271.78
9.58
75.76
5.6
25.4
262.89
10.21
70.91
6.0
28.57
255.27
10.8
66.89
6.4
31.75
248.66
11.34
63.49
6.7
Where ρ= material weight density,
ω= angular velocity in rad/sec
υ = Poisson’s ratio
r = radius to point of interest
ri, ro = inside and outer radius of the solid disc flywheel.
The tangential stress is a maximum at the inner radius. The
radial stress is zero at inside and outside radii and peaks at an
internal point but it is everywhere less than the tangential
tensile stress. The tangential tensile stress at that point is what
fails a flywheel, and when it fractures at that point, it typically
fragments and explodes with extremely dangerous results [20].
V.
FAILURE CRITERIA
If the flywheel spends most of the its life operating at
essentially constant speed, then it can be considered to be
statically loaded and yield strength used as a failure criterion.
The number of start-stop cycles in its operating regime will
determine whether a fatigue-loading situation needs to be
considered.
If number of these start- stop cycles is large enough over the
projected life of the system, then fatigue – failure criteria
should be applied [20].
VI.
(9)
From equation (3), (5) and (6) find the value of outer diameter
with vary in thickness and different stress value.
Where the radial stress is
3+
8
Is = E/ Cs ω2
1+3
3+
(5)
=
Mass moment of inertia for the system
GENERAL DESIGN CALCULATIONS OF SIMPLE DISC
FLYWHEEL
ω= 800 rad/sec
From the table we can conclude that the weight increases as
the outside diameter decreases and the thickness increases.
The maximum tangential stress at the inside radius stress
decreases with decreasing ro, the safety factor against yielding
increasing from 1.5 to 2.6
VII. MODELING AND SIMULATION
The geometrical design dimensions are taken from the
table and made a 3D model in Parametric Software (Creo
Element/Pro.) with detailed drawings views. The finite
Element Analysis is done with FEA tool.
A. Sequential steps in modeling and simulation
The geometrical design dimensions are taken from the
table no. I and made a 3D model in Parametric Software (Creo
Element/Pro.) with detailed drawings views.
ri = 25.4 mm
Cs = 0.05
Material property:- Steel
Density = 7750 Kg/m3
υ = Poisson’s ratio = 0.28
Sy = 427.8 MPa
Energy variation per cycle
E = 2949.46 N-m (J)
From the given data:Akshar Publication © 2015
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ISBN: 9-780993-909238
ANALYTICAL
STUDYOF
FLYWHEEL
DESIGN
MODELING OF
FLYWHEEL
FEA ANALYSIS
OF FLYWHEEL
COMAPRATIVE
STUDY
MODIFYING THE
STRUCTURAL &
GEOMETRICAL
DESIGN
ANALYSIS FOR
WEIGHT
REDUCTION
Fig. 5 – Normal stress in Ansys
B. Comparison of stresses
TABLE-2 Validation of design with software
Thickn
ess
Diamet
er
In mm
(mm)
31.75
248.66
Weight
Stress
(Kg)
(N/mm2)
11.34
63.49
Norm
al
Stress
(N/m
m2 )
Von
misses
stress
(N/mm2
)
62.29
50.76
From comparative study analyzed that the result of stress
obtained from mathematical method is somewhat higher than
the result obtained from the FEM method. So the result
obtained from FEA tool is quite accurate & further used for
modified design of flywheel.
VIII. ACTUAL FLYWHEEL MODEL AND ANALYSIS
In this study the simple solid disc flywheel is consider for
validation but for a constant inertia application it is not used in
practice such a that for analysis consider a power press
machine flywheel for better mass reduction.
Fig. 3 – Detail drawing of solid disc flywheel.
TABLE -3 Given data from flywheel used in power press
machine
Fig. 4 – 3D model of solid disc flywheel
Akshar Publication © 2015
Sr.
No.
Data
Value
1
Mass moment of inertia
1.47Kg-m2
2
Mass
62.63 Kg
3
Speed of flywheel
266 RPM
4
Energy required per stroke
1707.7 N-m
5
Power required
0.75 KW
6
Material
Gray cast Iron
7
Density of Material
7200 kg/m3
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8
Young’s Modulus
1.1 x 105 MPa
TABLE – 4 Structural analysis of the web type flywheel
9
Poisson’s ratio
0.28
Sr.
No.
Data
Value
1
Mass moment of inertia
1.47Kg-m2
2
Mass
62.63 Kg
3
Deflection
0.00028 mm
4
Von misses stress
0.276 N/mm2
5
Normal stress
0.271 N/mm2
6
Density of Material
7200 kg/m3
7
Young’s Modulus
1.1 x 105 MPa
8
Poisson’s ratio
0.28
9
Speed of flywheel
266 RPM
Fig. 6 – Web type Flywheel
IX.
POSSIBLE MODIFIED DESIGN OF FLYWHEEL
A. Modelling of modified flywheel design
Modification in design of flywheel have done in two following
session.
Session-1. Change in cross section of rim
TABLE 5- Change in design of Rim
Fig. 7 – Meshing in Ansys
Sr.
No.
Change in C/s of Rim
Correspond
ing M.I. in
Kg-m2
Correspon
ding Mass
in Kg.
1
Rectangle rim (Actual)
1.47
62.36
2
Fillet of 10 mm at outer
1.44
61.97
3
Fillet of 15 mm at outer
1.42
61.72
4
Fillet of 10 mm at inside
1.46
62.50
5
Fillet of 15 mm at inside
1.46
62.32
6
Taper 7 deg. at Rim profile
1.42
60.79
7
Taper 15 deg. at rim profile
1.47
57.43
Session – 2. Change in design between Rim and Hub.
TABLE-6 Change in design between Rim and Hub.
Fig. 8 – Maximum Von-Misses stress
Akshar Publication © 2015
Sr.
No.
Change in C/s of Rim
Correspond
ing M.I. in
Kg-m2
Correspon
ding Mass
in Kg.
1
Rectangle rim (Actual)
1.47
62.36
2
No. of hole-5
1.46
61.59
3
No. of holes-6
1.46
61.10
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4
No. of hole-8
1.45
6.12
5
No. of arm-3
1.24
44.83
6
No. of arm-5
1.6
46.61
7
No. of arm-6
1.27
47.7
8
Curved
Web
trapezoidal cut
with
1.47
57.95
9
Curved web with no. of
holes-8
1.47
58.92
10
Curved Web with three
outer ring on rim.
1.47
57.33
From Session -1 and Session – 2 data select the models for the
better mass reduction for Moment of inertia as 1.47 kg-m2 for
analysis.
Case -1
Fig. 11 – Curved web with trapezoidal holes
Case – 4
Fig. 9 – Curved Web Flywheel
Fig. 12 – Concave web with 8 no. of holes
Case – 2
TABLE- 7 Effect of Mass with changing different cross
section of rim and web.
Fig. 10 – Tapered Rim type flywheel
Case -3
Akshar Publication © 2015
Sr.
No.
Different
Cross
section of flywheel
Corresponding
Mass moment of
inertia in Kg-m2
Correspon
ding Mass
in kg.
1
Web Type
1.47
62.63
2
Taper Rim C/s
1.47
57.43
3
Curved Web
Flywheel
1.47
57.33
4
Curved web with
trapezoidal hole
1.47
57.95
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5
Concave Web With
no. of holes 8
1.47
58.92
From the comparative study of different cross section of
flywheel, it is observed that the mass of the flywheel is
reduced due to change in cross section of rim and web.
B. Finite Element analysis for different modified design
Section - 1
For Mass moment of inertia I= 1.47 kg/m2
Material – Gray Cast Iron
Without effect of gravity.
Fig. 15 – Von misses stress in Curved web with trapezoidal
hole
Fig. 13 – Von misses stress in Taper rim cross section
Fig. 16 – Von misses stress in Concave Web With no. of holes
8
TABLE -8 Comparison of von misses stress of different
geometry without effect of gravity
Sr
.
N
o.
Different
Cross
section of
flywheel
Corresp
onding
Mass in
kg.
Deflectio
n
1
Web Type
62.63
2
Taper Rim
C/s
3
4
Fig. 14 – Von misses stress in Curved web flywheel
Akshar Publication © 2015
Norm
al
Stress
in
MPa
Von
Misses
Stress in
MPa
0.00028
0.271
0.276
57.43
0.00048
0.308
0.303
Curved
Web
Flywheel
57.33
0.00011
0.57
0.58
Curved
web with
trapezoidal
hole
57.95
0.00009
6
0.56
0.53
in mm
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5
Concave
Web With
no. of
holes 8
58.92
0.00032
0.474
X.
0.478


Section-2
For Mass moment of inertia I= 1.47 kg/m2
With consideration of standard gravity g=9.81 m/s2


RESULT AND DISCUSSION
In this study, first simple solid disc flywheel model is
taken for design and analysis. From the analysis is
the value of mass and stresses are different for
different thickness and outer radius value.
The solid disc flywheel is modified for use in practice
such that the web flywheel with hub is modeled in
parametric software and analyzed in FEA tool. From
the analysis the value of maximum stress is 0.276
MPa.
The web flywheel is modified with no. of changes in
structure of web and rim so that the mass is reduced.
All the modified design is analyzed in FEA tool for
checking a safe stress condition without and with
effect of standard gravity.
XI.


Fig. 17 – Von misses stress in Web type with effect of gravity
TABLE -9 Comparison of von misses stress of different
geometry with effect of gravity
Sr
.
N
o.
Different
Cross
section of
flywheel
Corres
pondin
g Mass
in kg.
Deflection
1
Web
Type
62.63
0.00042
2
Taper
Rim C/s
57.43
0.000729
0.397
0.359
3
Curved
Web
Flywheel
57.33
0.000390
1.16
1.074
4
Curved
web with
trapezoid
al hole
57.95
0.00019
0.93
0.88
5
Concave
Web
With no.
of holes 8
58.92
0.00096
1.04
1.039
in mm
Norm
al
Stress
in
MPa
Von
Misses
Stress in
MPa
0.36
0.367

CONCLUSION
From the comparative study the value of mass is
reduced 10% with changing the rim cross section and
shape of web. The curved web flywheel having very
less mass with respect to other flywheel. The value of
deflection is also less. In the curved web flywheel
have very less mass value as 57.33 kg.
The maximum von misses’ stress generated is less
than the ultimate stress such that the design of
flywheel is safe.
From the FEA analysis the curved flywheel have
very less mass and stress with respect to existing web
flywheel.
XII. FUTURE WORK


In the next study the modified model analysis include
the change of parameter as rotating speed, diameter
of flywheel and thickness of rim.
The analysis will also carry out by changing the
material property with composite material as Carbon
fiber, MMC (Metal Matrix Composite) for better
performance of flywheel with less mass.
XIII. ACKNOWLEDGEMENT
The authors would like to thank Principal, H.O.D. and
teaching staff of mechanical engineering department for
providing their valuable guidance and support to carrying out
this work.
REFERENCES
[1]
[2]
[3]
Akshar Publication © 2015
Phanindra Mudragadda, T. Seshaiah,” Analysis of flywheel used in
petrol engine car”, International Journal of Engineering Research &
Technology, ISSN: 2278-0181, Vol. 3 Issue 5, May – 2014.
Nagaraj.R.M,” Suitability of composite material for flywheel analysis
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