Turning Moment (Crank Effort) Diagram

Torque N-m for a 4-stroke I C engine

Excess Energy
T (Shaded area)
max

Expansion
T
mean

0    

Crank Angle 
Exhaust
Suction Compression
 Turning Moment (Or Crank Effort) Diagram (TMD)
Turning moment diagram is a graphical
representation of turning moment or torque
(along Y-axis) versus crank angle (X-axis) for
various positions of crank.
Uses of TMD
1. The area under the TMD gives the work done
per cycle.
2. The work done per cycle when divided by the
crank angle per cycle gives the mean torque Tm.
 Uses of TMD
3. The mean torque Tm multiplied by the angular
velocity of the crank gives the power consumed by
the machine or developed by an engine.
4. The area of the TMD above the mean torque
line represents the excess energy that may be
stored by the flywheel, which helps to design the
dimensions & mass of the flywheel.
 FLYWHEEL
Flywheel is a device used to store energy when
available in excess & release the same when
there is a shortage.
Flywheels are used in IC engines, Pumps,
Compressors & in machines performing
intermittent operations such as punching,
shearing, riveting, etc.
A Flywheel may be of Disk type or Rim Type
Flywheels help in smoothening out the
fluctuations of the torque on the crankshaft &
maintain the speed within the prescribed limits.
 DISK TYPE FLYWHEEL

DISK TYPE FLYWHEEL

 X X
D

t
b

Section X-X
RIM TYPE FLYWHEEL
Comparision between Disk Type & Rim Type Flywheel :
Flywheels posess inertia due to its heavy mass.
Mass moment of inertia of a flywheel is given by
I = mk 2 , where m=Mass of the flywheel.
k=Radius of gyration of the flywheel.
D
For rim type, k= where D=Mean diameter of the flyheel
2
D
For Disk type, k= where D=Outer diameter of the flywheel
2 2
 D2   D2 
Hence I=m Rim   and I=m Disk  
 4   8 
Hence for a given diameter & inertia, the mass of the
rim type flywheel is half the mass of a disk type flywheel
 Important Definitions
(a) Maximum fluctuation of speed :
It is the difference between the maximum & minimum speeds
in a cycle. (=n1  n2 )
(b) Coefficient of fluctuation of speed : (C s or K s )
It is the ratio of maximum fluctuation of speed to the mean speed.
It is often expressed as a % of mean speed.
 n1  n2   1  2 
Cs (or K s )    
 n    
 2 n 
where  =Angular velocity=  
 60 
 Important Definitions
(c) Coefficient of fluctuation of energy : (C e or K e )
It is the ratio of maximum fluctuation of energy to the
mean kinetc energy.
 E1  E2   E   e 
Ce (or K e )     
 E   E  E
* * It is often expressed as the ratio of excess energy
 e 
to the work done per cycle. C e (or K =)e  
W.D / cycle 
(d) Coefficient of steadiness :
It is the reciprocal of coefficent of fluctuation of speed.
  
 Coefficient of steadiness=  
 1  2 
 EXPRESSION FOR ENERGY STORED BY A FLYWHEEL
Let
I be the mass moment of inertia of the flywheel
1 & 2 be the max & min speeds of the flywheel
  Mean speed of the flywheel
m=Mass of the flywheel, k=Radius of gyration of the flywheel
Cs =Coefficient of fluctuation of speed

The max fluctuation of energy (to be stored by the flywheel)

e  E1  E2  I 1  I 2  I 12  22 
1 2 1 2 1
2 2 2
1
 e  I 1  2  (1  2 )
2
 EXPRESSION FOR ENERGY STORED BY A FLYWHEEL
1
Putting the mean agular speed  = 1  2  ,
2
We get e = Iω(ω1 - ω2 ) Multiplying & dividing by  ,
(ω1 - ω2 )
e = Iω2

(ω1 - ω2 )
Also  Cs , the coefficient of fluctuation of speed

Hence e = Iω2C s
Putting I=mk 2 , we get e = mk 2 ω2C s
1 2
Note: 1.Alternatively, if Mean kinetic energy E= I  ,
2
 I  2  2 E , e=2EC s
e e C
  2Cs But  Ce OR e = 2
E E Cs
 EXPRESSION FOR ENERGY STORED BY A FLYWHEEL
1 2
e= I Cs , Putting mean Kinetic energy E= I 
2

2
and expressing C s as a percentage,
2EC s
e
100
 e  0.02 ECs
1
Note: 2. Alternatively, if Mean kinetic energy E= mk 2 2 ,
2
1 2
 (k )  v , E= mv
2 2

2
 e  mv 2 cs
 MASS OF FLYWHEEL IN TERMS OF
DENSITY & CROSSECTION AREA
We know that
mass m=Density   Volume
 D2
For Disk type flywheel, Volume = t
4
For Rim type flywheel, Volume= D( A)
where A= Cross section of the rim =b  t
b= width of rim & t= thickness of the rim
Note:
 Dn
(i)Velocity of the flywheel v= m / sec
60
(ii) Hoop Stress (Centrifugal stress) in the flywheel
 = v 2 where  = density of flywheel material
 Problem 1
A single cylinder 4 stroke gas engine develops
18.4 KW at 300 rpm with work done by the
gases during the expansion being 3 times the
work done on the gases during compression.
The work done during the suction & exhaust
strokes is negligible. The total fluctuation of
speed is 2% of the mean. The TMD may be
assumed to be triangular in shape. Find the
mass moment of inertia of the flywheel.
 TURNING MOMENT DIAGRAM
Torque N-m

T Excess Energy
max

Expansion
T
x mean

0    
Suction Exhaust
Crank Angle 
Compression
Data :
Power P=18.4 KW=18.4 103 W, Mean speed n=300 rpm
Work done during expansion WE  3  Work done during compression
Cs  2%  0.02
Given 4-stroke cycle engine
 Crank angle per cycle=4π radians( 2 rev of crank shaft)
Solution :
2 n
Angular Velocity of flywheel  =
60
2  300
i.e.    31.416 rad/sec
60
Also power P=Tm    18.4 103  Tm  31.416
18.4 103
 Mean torque Tm   585.7 N-m
31.416
Work done per cycle
Work done per cycle=Tm  Crank angle per cycle
i.e. W.D/Cycle =Tm  4  585.7  31.416
 W.D/Cycle  7360 N-m
W.D/Cycle  W.D during expansion  W.D during compression
(As the W.D during suction & compression are neglected)
 7360=(WE  WC )
WE
Given WE  3WC Or WC  , we can write
3
 WE  2
7360=  WE    WE  WE  11040 N-m
 3  3
This work represents the area under triangle for expansion stroke
1
i.e. 11040     Tmax
2
 Max torque Tmax  7028.3 N-m
Excess energy stored by the flywheel
The shaded area represents the excess energy.
1
i.e.excess energy stored by flywheel e=  x  (Tmax  Tmean )
2
where x is the base of shaded triangle, given by
x (Tmax  Tmean )

 Tmax
(Tmax  Tmean ) (7028.3  585.7)
x      2.88rad
Tmax 7028.3
1
Hence e=  2.88  (7028.3  585.7)  9276.67 N-m
2
We know that excess energy is given by
e=I Cs  9276.64  I  (31.416)  0.02
2 2

Hence mass moment of inertia of flywheel

2
I=470 Kg-m
 Problem 2
A single cylinder internal combustion engine
working on 4-stroke cycle develops 75 KW at
360 rpm. The fluctuation of energy can be
assumed to be 0.9 times the energy
developed per cycle. If the fluctuation of
speed is not to exceed 1% and the maximum
centrifugal stress in the flywheel is to be 5.5
MN/m2, estimate the diameter and the cross
sectional area of the rim. The material of the
rim has a density 7.2 Mg/m3.
Data :
Power P=75 KW=75 103 W, Mean speed n=360 rpm
Fluctuation of energy e =0.9  W.D/cycle
4 stroke cycle  Crank angle per cycle=4π radians
Density  =7.2 Mg/m 3  7200 Kg/m 3 , Hoop stress  =5.5 MPa
Solution :
2 n
Angular Velocity of flywheel  =
60
2  360
i.e.    37.7 rad/sec
60
Also power P=Tm    75 103  Tm  37.7
75 103
 Mean torque Tm   1989.4 N-m
37.7
Work done per cycle :
Work done per cycle=Tm  Crank angle per cycle
i.e. W.D/Cycle =Tm  4  1989.4  4
 W.D/Cycle  25000 N-m
Also given e = 0.9 × W.D / cycle = 22500 N - m
Diameter of the flywheel :
Hoop stress  = v 2  5.5 106 =7200  (v 2 )
Hence, velocityof flywheel v = 27.64m / sec
 Dn   D  360
Also v =  27.64 =
60 60
 Diameter of the flywheel = 1.466 m
The energy stored by the flywheel is given by
e = mk 2 2C s .
D 1.466
For rim type, radius of gyration k=   0.733m
2 2
 22500 = m (0.733) (  37.7)  0.01
2 2

Hence, Mass of the flywheel m = 2946.4 Kg

But , for rim type, mass m= DA  
(where A=cross section area of the rim)
 2946.4   1.466  A  7200
 A = 0.09m 2
Note :
If it is given that the rectangular cross section of the
rim has width (b)=3  thickness ( t),
Then A=b  t=3t  t=3t 2

0.09  3t 2  t=0.1732m  173 mm

b=3t=520 mm
 Problem 3
The crank effort diagram for a 4-stroke cycle gas
engine may be assumed to for simplicity of four
rectangles, areas of which from line of zero
pressure are power stroke =6000 mm2, exhaust
stroke =500 mm2, Suction stroke=300 mm2,
compression stroke = 1500 mm2. Each Sq mm
represents 10 Nm. Assuming the resisting torque
to be uniform, find
a) Power of the engine
b) Energy to be stored by the flywheel
c) Mass of a flywheel rim of 1m radius to limit the
total fluctuation of speed to ±2% of the mean
speed of 150 rpm.
Torque N-m

Excess energy
T (Shaded area)
max

Expansion
T
mean

0    

Suction Crank Angle  Exhaust

Compression
Data :
4 stroke cycle  Crank angle per cycle=4π radians
Radius of gyration k  1 meter, Mean speed n=150 rpm
C s  2%  4%  0.04 ( Total fluctuation=2  Fluctuation on either side)
2 n
Solution : Angular Velocity of flywheel  =
60
2 150
i.e.    15.71 rad/sec
60
WD/cycle=W.D during Expansion-(W.D during other strokes)
 W.D/cycle= 6000-(300  1500  500)  3700mm 2
W.D/cycle  3700  scale of diagram=3700 10=37000 N-m
W.D/cycle 37000
 Mean Torque Tm    2944.4 N-m
Crank angle/cycle 4
(i) Power developed by engine :
P  Tm    2944.4  15.71  46.256 KW

Torque N-m
Excess energy
T
(ii) Energy stored by flywheel : max (Shaded area)

e = Shaded area = π(Tmax -Tm ) Expansion

T
mean

But W.D during expansion =Tmax  

0    
 6000  10  Tmax  
 Tmax = 19098.6N - m Suction Crank Angle  Exhaust
Compression
Substituting for Tmax ,
e   (Tmax  Tm )   (19098.6  2944.6)
e = 50749.27 N - m
(iii) Mass of flywheel
We know that energy stored by flywheel
e  mk  Cs
2 2

50749.27  m  (1) (15.71)  0.04

2 2

 Mass of flywheel m = 5140.64 Kg

 Problem 4
A multi cylinder engine is to run at a speed of
600 rpm. On drawing the TMD to a scale of
1mm=250 Nm & 1mm=30, the areas above &
below the mean torque line are +160, -172,
+168, -191, +197, -162 mm2 respectively.
The speed is to be kept within ±1% of the mean
speed. Density of Cast iron flywheel=7250
kg/mm3 and hoop stress is 6 MPa. Assuming
that the rim contributes to 92% of the
flywheel effect, determine the dimensions of
the rectangular cross section of the rim
assuming width to be twice the thickness.
 197
Turning Moment 160 168

1 2 3 4 5 6 7

Mean Torque
162 line
172 191

Crank angle
Let the energy at 1=E
Energy at 2=(E+160)
Energy at 3=(E+160)-172=(E-12)
Energy at 4=(E-12)+168=(E+156)
Energy at 5=(E+156)-191=(E-35)
Energy at 6=(E-35)+197=(E+162)
Energy at 7=(E+162)-162=E= Energy at 1

Hence, Maximum fluctuation of energy

(in terms of area) = (E+162)-(E-35)=197 Sq mm
Energy stored by the flywheel :
2 N 2  600
Angular velocity  =   62.84rad / sec,
60 60
Cs  1%  2%  0.02
Scale of the diagram is
 3 
1mm  250  
2
  13.1Nm
 180 
Max Fluctuation of energy e  (Max.K.E-Min K.E)
 e=(E+162)-(E-35)=197 mm 2
e = 197 ×13.1 = 2581Nm
i.e.2581=I 2Cs  I  (62.84) 2  0.02
 Mass moment of inertia I = 32.7Kg - m 2
Diameter of the flywheel :
Using  = v 2 ; 6 106  7250  v 2
 Velocity v=28.8 m/sec
 DN   D  600
Also v=  28.8=
60 60
 Mean dia of flywheel D=0.92 m
Given 92% of the flywheel effect is provided by the rim,
erim  0.92  2581  2375 Nm
erim  mk 2 2 cs  m(k ) 2 cs  mv 2cs
 2375  m  (28.8) 2  0.02
 Mass of rim m = 143 kg.
Dimensions of the crossection of the rim :
We know that mass of the flywheel rim
m=Volume of rim  density=( DA)  
 143  (  0.92  A)  7250
 A=0.006824m 2
As cross section of rim is rectangular with b=2t,
A=(b  t)=2t  0.006824  2t
2 2

Hence t = 58.4 mm, b = 2t = 116.8 mm.

 Problem 5
Torque –output diagram shown in fig is a
single cylinder engine at 3000 rpm. Determine
the weight of a steel disk type flywheel
required to limit the crank speed to 10 rpm
above and 10 rpm below the average speed of
3000 rpm. The outside diameter of the
flywheel is 250 mm. Determine also the
weight of a rim type flywheel of 250 mm
mean diameter for the same allowable
fluctuation of speed.
 100

T 75
N-m
50

25

90 180 360 450 540 630 720

0

-25  (Degrees)

-50

-75

-100
Data :
Crank angle per cycle=7200 = 4π radians
Mean speed n=3000 rpm,
250
Radius of gyration k= =125 mm =0.125 m (For rim type)
2
0.25
Radius of gyration k= =0.0884 m (For disk type)
2 2
10 20
Cs    0.00667
3000 3000
2 n
Solution : Angular Velocity of flywheel  =
60
2  3000
i.e.    314.16 rad/sec
60
WD/cycle=Net area under TMD
           
=75    50    100  75    50    100    75  
2 2 2 2 2 2
W.D / cycle = 87.5π N - m
W.D per cycle 87.5
Mean torque Tm  
Crank angle per cycle 4
T m = 21.875N - m
 100

T 75
N-m
50

25 5 Tmean
1 2 3 4 6 7 8

0
90 180 360 450 540 630 720
-25  (Degrees)

-50

-75

-100
Excess energy stored by flywheel
Let the energy at 1=E
 
Energy at 2=E+(75-21.875)    E  26.5625
2
 
Energy at 3=(E  26.5625 ) - (71.875)    E  9.735
2
Energy at 4=(E  9.735 )+(100-21.875)  E  68.75
 
Energy at 5=(E  68.75 )-(96.875)    E  20.3125
2
 
Energy at 6=(E  20.3125 )  (50-21.875)    E  34.375
2
 
Energy at 7=(E  34.375 )-(121.875)    E  26.5625
2
 
Energy at 8=(E  26.5625 )+(75-21.875)    E
2
Excess energy e = Max Energy-Min energy
e=(E+68.75 )  (E-26.5625 )  299.43Nm
Mass of flywheel
We know that energy stored by Rim type flywheel
e  mk  Cs
2 2

299.43  m  (0.125) 2 (314.16) 2  0.00667

 Mass of flywheel m = 29.11 Kg
Fordisk type, k = 0.0884 m
 Mass of flywheel m = 58.221 Kg
 Problem 6
The torque required for a machine is shown in
fig. The motor driving the machine has a mean
speed of 1500 rpm and develop constant
torque. The flywheel on the motor shaft is of
rim type with mean diameter of 40 cm and
mass 25 kg. Determine;
(i) Power of motor
(ii) % variation in motor speed per cycle.
2000 N-m
Torque

400 N-m

    
Crank angle 
Data :
Crank angle per cycle= 2π radians
Mean speed n=1500 rpm,
40
Radius of gyration k= =20 cm =0.2 m (For rim type)
2
m=25 kg
2 n
Solution : Angular Velocity of flywheel  =
60
2  1500
i.e.    157.08 rad/sec
60
(i) Power developed by the engine :
W.D/cycle  area 1+area 2+area 3
   1  
=400  2  (2000  400)          (2000  400)
 4  2  2 
W.D / cycle = 1600π N - m
W.D per cycle 1600
Mean torque Tm  
Crank angle per cycle 2
T m = 800 N - m
 Power developed by the engine
P=Tm    800 157.08  125.664 KW
 Excess energy e
2000 N-m
(shaded area)
Torque

 mean
800 N-m x
2 3
400 N-m
1

    
Crank angle 
(ii) Coefficent of fluctuation of speed C s
x 1200
  x  1.178rad
 2
From the similar triangles,
 1600

Energy stored by flywheel e = Shaded area

 1
e=  2000  800    1.178   2000  800 
4 2
e = 1649.28Nm
We know that energy stored by the flywheel
e  mk 2 2Cs
1649.28  25  (0.2) 2 (157.08) 2  Cs
Coefficient of fluctuation of speed = 0.0668 = 6.68%
 Problem 7
A 3 cylinder single acting engine has cranks set
equally at 1200 and it runs at 600 rpm. The TMD
for each cylinder is a triangle, for the power
stroke with a maximum torque of 80 N-m at 600
after dead center of the corresponding crank.
The torque on the return stroke is zero. Sketch
the TMD & determine the following;
(i) Power developed
(ii) Coefficient of fluctuation of speed if mass of
flywheel is 10 kg and radius of gyration is 8 cm.
(iii) Maximum angular acceleration of flywheel.
80N-m

T (N-m)

0
60 120 180 240 300 360
 degrees
Data :
Crank angle per cycle=2π radians
Mean speed n=600 rpm,
Radius of gyration k=8cm =0.08 m
m=10 kg
2 n
Solution : Angular Velocity of flywheel  =
60
2  600
i.e.    62.83 rad/sec
60
(i) Mean torque Tm :
W.D/cycle  area of 3 triangles
1
=3       80  377 N - m
2
W.D per cycle 377
Mean torque Tm  
Crank angle per cycle 2
T m = 60 N - m
As the maxim um torque (Tmax ) is 80 Nm,
and Tmean = 60 Nm, the minimum torque (Tmin )
will be = 40 N - m. Hence the modified TMD
may be drawn as shown in fig.
80 N-m

T (N-m)

60 Nm

40 Nm

0
60 120 180 240 300 360
 degrees

Modified TMD for 3 Cylinder engine

(i) Power developed :
P  Tmean    60  62.83  3.77 Kw

 x   rad
x 20

 2 3 
From the similar triangles,
40 3

Due to symmetry,the energy stored by flywheel

=Area of any one traingle (Shaded portion)
1 
 e=    80  60   e = 10.47 N - m
2 3
(ii) Coefficeint of fluctuation of speed :
We know that energy stored by the flywheel
e  mk 2 2Cs
10.47  10  (0.08) (62.83)  Cs
2 2

 Coefficient of fluctuation of speed = 0.0414 = 4.14%

(iii) Maximum angular acceleration of flywheel
We know that T=I ,where
T=Max fluctuation of torque=(Tmax  Tmean )
I=mk 2 , the mass moment of inertia of flywheel
 = Max angular acceleration, rad/sec 2
 20  10(0.08) 2    ∴ α = 312.5 rad / sec 2
 Problem 8
A torque delivered by a two stroke is represented
by T=(1000+300 sin 2 cos 2 Nm where 
is the angle turned by crank from IDC. The engine
speed is 250 rpm. The mass of the flywheel is 400
kg and the radius of gyration is 400 mm. Determine
(i) The power developed
(ii) Total percentage fluctuation of speed
(iii) The angular acceleration and retardation of
flywheel when the crank has rotated through an
angle of 600 from the IDC
(iv) Max & Min angular acceleration & retardation of
flywheel.
Data :
As the torque is a function of 2 ,
equate 2  360    180
0 0

The crank angle per cycle = 180  π radians

0

Mean speed n=250 rpm,

Radius of gyration k=400mm =0.4 m
m=400 kg
2 n
Solution : Angular Velocity of flywheel  =
60
2  250
i.e.    26.18 rad/sec
60
(i) Power developed by engine :
W.D per cycle
Mean torque Tm  
Crank angle per cycle
 
1 1

  Td   (1000  300sin 2  500 cos 2 ) d
0
 0

 Mean torqueT m = 1000 N - m

 Power developed by engine P = T m  
P  1000  26.18  26.18 KW
Sl Angle Torque
No  T N-m  mean )
1 0 500 T
2 30 1010 (N-m) Excess
 Energy  T mean =1000 N-m
3 60 1510
4 90 1500
5 120 990
500 Nm
6 150 490
7 180 500

0 180
Crank Angle
(ii) Coefficient of fluctuation of speed :
The excess energy stored by the flywheel is
given by integrating ΔT between the limits 1
&  2 where 1 &  2 correspond to points where
T=Tmean Or (T-Tmean ) =ΔT = 0
(As the torque curve intercepts the mean torque line at these points)
i.e. (300sin 2  500 cos 2 )  0
 500 
Hence tan2 =    1.667
 300 
 2θ1 = 59 0 & 2θ 2 =(180 0 + 59 0 =) 2 39 0
Hence θ1 = 29.5 0 & θ 2 = 119.5 0
(ii) Coefficient of fluctuation of speed (contd.....)
2
Excess energy e =  T .d
1
119.5
e= 
29.5
(300sin 2  500 cos 2 )d

(The above integration may be performed using

calculator by keeping in radian mode and substituting
the limits of integration in radians)
 e = 583.1 N - m
Also e=mk 2 2Cs  583.1  400  (0.4) 2  (26.18) 2  Cs
 Coefficient of fluctuation of speed Cs  0.0133  1.33%
(iii) Angular acceleration at 60 0 crank position
Acceleration (or retardation) is caused by excess (or deficit)
torque measured from mean torque at any instant. i.e T.
At  =600 , ΔT  300sin(2  60)  500 cos(2  60)
 ΔT  509.8 N  m
Now, ΔT  I
 509.8  400  (0.4) 2   
Hence Angular acceleration at 600crank position
α 60 0 = 7.965 rad / sec 2
(iv) Maximum angular acceleration :
Maximum acceleration (or retardation) is caused by
maximum fluctuation of torque from mean, i.e ΔT max
(To find ΔTmax first find the crank positions at which
ΔT is maximum & then substitute those values in the
equation of ΔT.)
d
For max value of T, (T)  0
d
d
 (300sin 2  500 cos 2 )  0
d
i.e 600 cos 2 +1000 sin2  0
Hence tan2 =-0.6  2 =-310 &
2  (1800  (310 )  1490
(iv) Maximum angular acceleration (contd) :
At 2 =-31 , T  583.1N-m (causes retardation)
0

At 2 =149 , T  583.1 (Causes acceleration)

0

 Max angular acceleration of flywheel

Tmax 583.1
 max   2
 9.11 rad / sec 2

I 400(0.4)
 Max angular retardation of flywheel
Tmin 583.1
 min   2
 -9.11 rad / sec 2

I 400(0.4)
(-ve sign indicates retardation)
 Problem 9
A machine is coupled to a two stroke engine which
produces a torque of (800+180 Sin 3 N-m where  is
the crank angle. The mean engine speed is 400 rpm.
The flywheel and the rotating parts attached to the
engine have a mass of 350 kg at a radius of gyration of
220 mm. Calculate;
(i) The power developed by the engine
(ii) Total percentage fluctuation of speed when,
(a) The resisting torque is constant
(b) The resisting torque is (800+80 Sin
Sl No Angle Torque
 T N-m
(a) When the resisting torque is Constant
1 0 800
2 30 980
3 60 800 T
E
4 90 620 T
(N-m) Excess Energy
5 120 800
T
m  Nm

00 30 0 60 0 90 0 120
0

Crank Angle

T = Engine torque
E
T
m =mean Torque
Data :
As the torque is a function of 3 ,
equate 3  360    120
0 0

2π
The crank angle per cycle = 120  radians
0

3
Mean speed n=400 rpm, m=350 kg
Radius of gyration k=220mm =0.22 m
2 n
Solution : Angular Velocity of flywheel  =
60
2  400
i.e.    41.89 rad/sec
60
(i) Power developed by engine :
W.D per cycle
Mean torque Tm 
Crank angle per cycle
2 2
3 3
1 1

2  Td  2  (800  180sin 3 )d
3 0 3 0
 Mean torqueT m = 800 N - m
 Power developed by engine P = T m  
P  800  41.89  33.51 KW
(ii) Coefficient of fluctuation of speed :
(a) When the resisting torque is constant
The excess energy stored by the flywheel is
given by integrating ΔT between the limits 1
&  2 , where To find 1 &  2 are crank positions
at which T=Tmean Or (T-Tmean ) = ΔT = 0
(As the torque curve intercepts the mean torque line at these points)
i.e. (800  180sin 3  800)  0
 180sin 3  0  3  0 & 3  180
0 0

 θ1 = 0 & θ 2 = 60
0 0
(ii) Coefficient of fluctuation of speed (contd.....)
2
Excess energy e =  T .d
1
60
 e =  (180sin 3 )d
0

(The above integration may be performed using

calculator by keeping in radian mode and substituting
the limits of integration in radians)
 e = 120 N - m
Also e=mk 2 2Cs  120  350  (0.22) 2  (41.89) 2  Cs
 Coefficient of fluctuation of speed Cs  0.00404  0.404%
(b) When the resisting torque is (800 + 80sin )

T Excess Energy
E
T
(N-m)  T
 M


00 300 600 90 0 120

0
180
0

Crank Angle

T = Engine torque
E
T
M =Machine Torque
(ii) Coefficient of fluctuation of speed :
(b) When the resisting torque is (800 + 80sin )
The excess energy stored by the flywheel is
given by integrating ΔT between the limits 1
&  2 , where To find 1 &  2 are crank positions
at which TE =TM Or (TE -TM =) ΔT = 0
(As the engine torque curve intercepts the
machine torque curve at these points)
i.e. (800  180sin 3 )  (800  80sin  )  0
 180(3sin   4sin 3  )  80 sin  =0
(460-720sin    0  sin   0.799
2

 θ1 = 53 0 & θ 2 =(180 - 53)= 127 0

(ii) Coefficient of fluctuation of speed (contd.....)
2
Excess energy e =  T .d
1
127
e=  (180sin 3  80sin  )d
53

(The above integration may be performed using

calculator by keeping in radian mode and substituting
the limits of integration in radians)
 e = -208.3 N - m (Take absolute value)
Also e=mk 2 2Cs  208.3  350  (0.22) 2  (41.89) 2  Cs
 Coefficient of fluctuation of speed C s  0.007  0.7%
 Problem 10
A certain machine requires a torque of
(500+50sin N-m to drive it, where  is the
angle of rotation of the shaft. The machine is
directly coupled to an engine which produces a
torque of (500+60 sin2 Nm. The flywheel and
the other rotating parts attached to the engine
have a mass of 500 kg at a radius of 400 mm. If
the mean speed is 150 rpm. Find;
(a) The maximum fluctuation of energy
(b) Total % fluctuation of speed
(c) Max & Min angular acceleration of the flywheel
& the corresponding shaft positions.
 T
T M
E
Excess Energy
T
(N-m)


 

00 180
0

Crank Angle

TE = Engine torque
T
M =Machine Torque
Data :
As the torque is a function of 2 ,
equate 2  360    180
0 0

The crank angle per cycle = 180  π radians

0

Mean speed n=150 rpm,

Radius of gyration k=400mm =0.4 m
m=500 kg
2 n
Solution : Angular Velocity of flywheel  =
60
2 150
i.e.    15.71 rad/sec
60
(i) Excess energy stored by flywheel :
The excess energy stored by the flywheel is
given by integrating ΔT between the limits 1
&  2 , where To find 1 &  2 are crank positions
at which TE =TM Or (TE -TM ) = ΔT = 0
i.e. (500  60sin 2 )  (500  50sin  )  0
 (60sin 2  50sin  )=0
Put sin2θ = 2sinθcosθ
sin  12 cos   5  0. Either sin   0  00 ,1800
or 12 cos   5  0  cos   5    65.37 0
12
Considering max difference between consecutive crank positions,
θ1 = 65.37 0 &θ2 = 180 0
 2
Excess energy e =  T .d
1
180
e= 
65.37
(60sin 2  50sin  ) d

(The above integration may be performed using

calculator by keeping in radian mode and substituting
the limits of integration in radians)
 e = -120.42 N - m (Take absolute value)
(ii) Coefficient of fluctuation of speed :
Also e=mk 2 2Cs  120.42  500  (0.4) 2  (15.71) 2  Cs
 Coefficient of fluctuation of speed Cs  0.0061  0.61%
(iii) Maximum & Minimum angular acceleration :
Maximum acceleration (or retardation) is caused by
maximum fluctuation of torque from mean, i.e ΔT max
(To find ΔTmax first find the crank positions at which
ΔT is maximum & then substitute those values in the
equation of ΔT.)
d
For max value of T, (T)  0
d
d
 (60sin 2  50sin  )  0
d
i.e.12 cos 2 - 5cos  0
i.e.12 cos 2 - 5cos  0
Put cos 2  (2 cos 2   1), we get
12(2 cos 2   1) - 5cos  0
24cos 2 θ - 5cosθ -12 = 0
 = 35 0 &  = 127.6 0
At  = 35 0 :
T=60 sin(2  35)-50sin(35)= 27.7 N - m
27.7
 Maximum acceleration  max =  0.346 rad / sec 2
80
At  = 127.6 0 :
T=60 sin(2 127.6)-50sin(127.6)=-97.62 N - m
97.62
 Maximum retardation  max =  1.22 rad / sec 2
80
Flywheel for Punch press
Flywheel

Crank shaft

Crank

connecting
rod

Plate
Punching
tool d
t Die

Flywheel for Punch Press

 Flywheel for Punch press
• If ‘d’ is the diameter of the hole to be punched in
a metal plate of thickness ‘t’ , the shearing area
A= d t mm2
• If the energy or work done /sheared area is
given, the work done per hole =W.D/mm2 x
Sheared area per hole.
• As one hole is punched in every revolution,
WD/min=WD/hole x No of holes punched /min
• Power of motor required P=WD per min/60
Excess energy Stored by Flywheel :
e =(E 1 E
 2)
where;
E 1 = Energy required per hole
E 2 = Energy supplied during actual punching
(E2 = Energy supplied per sec× Actual time of punching)
 Problem 11
A punching machine carries out 6 holes per min.
Each hole of 40 mm diameter in 35 mm thick
plate requires 8 N-m of energy/mm2 of the
sheared area. The punch has a stroke of 95 mm.
Find the power of the motor required if the
mean speed of the flywheel is 20 m/sec.
If the total fluctuation of speed is not to exceed
3% of the mean speed, determine the mass of
the flywheel.
Data :
Mean speed of flywheel v=20m/sec
Cs  3%  0.03, Diameter of hole d=40 mm
Thickness of plate t=35 mm, Energy/mm 2 =8 N-m
Stroke length =95 mm,
No of holes/min=6  Speed of crank=6rpm
 Time required to punch one hole= 10 secs
Solution :
Sheared area per hole = πdt = π × 40 × 35 = 4398.23 mm 2
 W.D/hole= 4398.23  8 = 35186 N - m
W.D/hole  holes/min
Power of motor= KW
60 10 3

35185.4  6
P  3.5186KW
60 10 3
 As the punch travels 95 × 2 = 190 mm in 10 secs
⇒ actual time taken to punch one hole
Thickness of plate
T actual =  Time taken per cycle
2×stroke length
35
T actual = 10=1.842 Secs
190
Excess energy supplied by flywheel
e=Energy required/hole  Energy supplied during actual punching
e=35186  (3518.6 1.842)= 28705 N - m
Also e = mv 2 C s  28705  m (20) 0.0
2
 3
 m = 2392 Kg
 Problem 12
A constant torque 2.5 KW motor drives a riveting
machine. The mass of the moving parts including
the flywheel is 125 kg at 700 mm radius. One
riveting operation absorbs 10000 J of energy and
takes one second. Speed of the flywheel is 240
rpm before riveting. Determine;
(i) The number of rivets closed per hour
(ii) The reduction in speed after riveting operation.
Data :
2  240
Maximum speed of flywheel n1 =240 rpm  1   25.133 rad / sec
60
Energy required per rivet =10000 J
Time taken to close one rivet =1 sec
Energy supplied by motor=Power of motor =2.5KW=2500 J/sec
Mass of flywheel m=125 kg, Rad. of gyration k=700 mm
 Mass M.O.I of flywheel I=125  (0.7) 2  61.25 Kg  m 2
(i) Number of rivets closed per hour :
Energy supplied by motor =2.5KW=2500 J/sec
 Energy supplied per hour =2500  3600 J
Energy required per rivet =10000 J
2500  3600 J
 Number of rivets closed per hour will be=  900 rivets / hr
10000
(ii) Excess energy supplied by flywheel :
e=Energy required/rivet-Energy supplied by motor
e=(10000  2500)  7500 J

Also e = I 1  2 
1 2 2

2
1
 7500   61.25  (25.13)  2 
2 2

2
 19.66  60 
2  19.66rad / sec  n2     188rpm.
 2 
Reduction in speed after riveting=(n 1 n2 )
 (240 - 188) = 52 rpm