Optimizing Energy Storage Capacity Metallic Flywheel Rotor Stress Concentration Reduction

Technique

Adham Samanoudy
School of Engineering
University of the West of England (UWE) Bristol, UK
Student ID: 18045371
Abstract-Flywheel and other energy storage devices stressed monolithic rotors are eliminated with the steel
can be used for load levelling and short-term energy laminated rotor design. Compared to a composite
storage. Nevertheless, the energy storage capacity of KES (Kinetic Energy) flywheel system with lead acid
metallic flywheel rotors is limited due to their batteries, it has a far longer service life and far less
susceptibility to material failure and stress Parameter Flywheel Technology Lead Acid
concentration. To optimize flywheel rotors design Steel Composite Battery
by lowering stress concentration, a novel technique 30Wh/kg Mechanical Chemical
is proposed in this work. Regions with large Lifespan >20 years 5 –15 years
concentrations of stress are identified and rotor Lifecycle 8x103 cycles (for 20-year 1000
life) Cycles
stresses are modelled using finite element analysis.
Losses Very High (5% per hour) Very Low
Effective reduction of peak stress levels is (2-5% per
demonstrated by selective rotor shape adjustments month)
based on fillet introduction. Reduced stress Tolerance to Very High Very Low
concentration allows for a higher rotating velocity overcharge and
in the rotor design, which increases the amount of deep discharge
Cost/kWh $400-800 $50-100
energy stored. An increase of 12% in stored energy
Environmental Very Low Low High
is shown when the suggested technique is applied Impact
to a sample metallic rotor shape. By reducing the Specific Energy 70Wh/Kg 14Wh/kg (e- 30Wh/kg
focused stress concentration, this offers a workable (Plain disc glass)
method of flywheel optimization for energy storage rotor)
applications. 75.7Wh/kg 300Wh/kg
(Rotor disc (Carbon
Keyword - Flywheel, reduced stress concentration, with AS4C)
elliptical
optimization, metallic rotor shape. NC holes)
environmental impact.
I. Introduction
Table 1 Cost Benefit Analysis of Steel flywheel technology (Lamare
A) Flywheel Energy Storage Background et al, 2013)
For hundreds of years, flywheels have been employed
as energy storage devices, as a flywheel is a rotor that Flywheel systems have a better energy density than
stores kinetic energy by revolving around an axis. An lead acid batteries, although being more expensive.
electric motor accelerates the flywheel's spin by The value is further increased by adding elliptical
converting electrical power into kinetic energy. The holes to the rotor. The primary issue for flywheel
flywheel's moment of inertia and angular velocity technology is lowering the self-discharge rate, or
determine how much energy it can hold. The flywheel energy loss over time. Development in low-EMD
keeps more energy the easier it turns. Conversely, by generators and bearing technologies are both
supplying a decelerating force to the flywheel, the contributing to this effort (Pullen et al, 2017).
electric motor recovers the kinetic energy to electric B) Overview of flywheel energy systems
power as a generator. Flywheel energy storage has
recently advanced, showing its potential for An energy-storing spinning mass is used in a
integration with sustainable energy sources and flywheel, an inertial energy storage device. A
electrical grids. Nonetheless, most systems in use revolving cylindrical body that stores kinetic energy is
today were created for UPS (Uninterruptible Power what a flywheel rotor is often made of. Flywheels are
Supply) and frequency control purposes. Usually, they well recognized for their ability to be employed as
have rotors made of fibre-reinforced composite that energy storage devices, even though their most
are magnetically bearing-built. It is still not possible
common usage is to moderate speed variations in
to create a large-scale, reasonably priced flywheel
machinery (like engines). Flywheel energy may be
energy storage device for a wider variety of uses, such
as load shifting. The difficulties brought on by the transformed into mechanical energy and then stored
need for energy storage that is secure, effective, and by joining the rotor to a motor/generator unit.
ecologically friendly could be greatly impacted by Operating as both a generator and a motor, the
flywheel technology. It is still relatively new to motor/generator unit may recover energy from the
construct flywheel rotors using steel laminated; most flywheel by accelerating it. Diagrams showing a
recent designs have concentrated on high-speed flywheel energy storage system’s main parts and
rotors, which are costly and significantly have energy operation are displayed. There are three main parts of
losses. Concerns about safety with exceptionally a flywheel energy storage system. According to

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 Optimizing Energy Storage Capacity Metallic Flywheel Rotor Stress Concentration Reduction
Technique

(Pentadiene et al 2007) these elements and their roles In comparison to conventional chemical batteries,
are as follows: flywheel energy storage systems, also referred to as
flywheel batteries, could store a large amount more
energy per unit of mass. This is crucial when storing
the most amount of energy possible in the lowest
amount of bulk possible (such as in spacecraft).
Flywheel batteries also have a higher specific power.
More than 90% of the energy stored in flywheel can
be recovered if they are combined with magnetic
bearing and sophisticated motor/generator systems,
which is a significantly higher efficiency than
conventional chemical batteries, which can only
recover less than 80% of the energy input (Hebner et
Figure 1 Flywheel Energy storage system (Pentadiene et al, 2006) al, 2002). Flywheel batteries’ high energy storage
efficiency results in weight and dimension reductions,
 Rotor which are essential qualities for vehicle applications.
Satellites use Flywheel Energy Storage System,
A hub and rim make up a full rotor assembly. because of its high efficiency and rapid recharging
Kinetic energy is the form that the rotating rotor stores times, even though can also take advantage of the
the energy in. Most of the energy is stored in the additional benefits of the gyroscopic effect to regulate
rotor’s main rotational mass, or the rim. The rim and the satellite’s motion in orbit. Attraction in Flywheel
shaft are joined by the hub. Energy Storage System has increased because to the
recent advancements in power electronics technology,
 Motor/generator
new lightweight, robust materials, magnetic bearings.
Energy can be converted in an electromechanical
interface due to a Motor/Generator, when the machine
functions as a motor, the charging procedure entails
storing energy in the flywheel energy storage system.
However, when applied as a generator, the flywheel
energy storage system is discharged. The generator is
a device that gets back electricity by reducing the
rotor after supplying the motor with electrical energy.
Typically, hub and shaft are used to transfer torque
from the rotor rim to motor/generator unit during rotor
acceleration and deceleration. The motor and
generator are often merged into a single unit to save
weight and expense of the flywheel system because
power input and output processes usually vary in time
(Hebner et al, 2002).

 Rotor bearing Figure 3 Mounting bracket and flywheel for NASA (NASA G2
flywheel, 2024)
Low resistance from rotor rotation is made
possible by the mechanical or magnetic bearings that The flywheel energy storage systems have a wide
support the revolving flywheel shaft. Magnetic range of uses:
bearings are chosen over mechanical ones because  UPS (Uninterruptible Power Supply)
bearing friction results in energy loss.
A UPS is a type of electronic control equipment
with a right of way energy storage capability. For
high-power flywheels, a UPS is regarded as one of
most helpful forms of power supply for situations
running no longer than 15 seconds. 97% of power
outages occur for less than one second, which causes
problems with voltage and frequency, and 80% of
power outages last for less than three seconds. When
used in conjunction with a UPS, these applications
serve as file backups during a failure and supply
electricity when the grid is down. This happens until
Figure 2 Dynamic model with a rotor. The j-to ball in the bearing another power source is restored. Batteries are often
has a contact deformation of II (Henber et al, 2002) employed as storage in UPS systems. One of the most
developed items in the world is the UPS system
C) Benefits and applications of flywheel energy created with this FESS. Among the vendors are Active
storage system Power, Piller, VYCON, and Power thru. Reluctant in

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 Optimizing Energy Storage Capacity Metallic Flywheel Rotor Stress Concentration Reduction
Technique

nature, the Active Power motor’s flywheel rotates at a similarly performing turbo six-cylinder. Plans to use
rate of 7700 revolution per minute. The the technology on its product line were not made
electromagnetic suspension technology of the public by the corporation.
VYCON product allows it to run at a speed of 36000
revolutions per minute. The Powershred’s FESS can
rotate at 53000 rpm and is powered by molecular
pump and synchronous reluctance motors.

Figure 6 S60 Sedan Volvo flywheel (Volvo, 2013)

 Integration of renewable energy sources

The usage of a hybrid system, which combines
Figure 4 UPS in flywheel (Juila et al,2018)
solar energy panels and wind turbines, who also
specify a 40% fuel consumption owing to diesel-
 Transportation powered engines, which cannot result in fuel
preservation. Generators powered by diesel should be
Flywheel systems are a viable substitute for generally off and only activated when necessary. As a
traditional chemical batteries in mobile applications, result, flywheel energy storage system can reduce the
including electric automobiles. In comparison to frequency of periodic cycles for starting and stopping
chemical battery power systems, flywheel power the generators, which aids in fuel conservation and
systems have certain advantages for these lowers the variability in power. To integrate with
applications, including deep discharge capability, high renewable energy systems like Urenco Power,
power pulse capability and fast charging, wide VYCON technology, ABB’s Power Store, and Beacon
temperature operating range tolerance, longer Power, a vast scale of flywheel systems has been
operational life, and reduced weight (Hebner et al., developed.
2002).

Figure 5 Applications of flywheels in vehicles (Henber et al., 2002).

Figure 7 The Beacon Power Flywheel (Beacon Power, 2019)
A flywheel system installed on the S60 sedan’s rear
axle was introduced by Volvo in 2013. To halt the D) Aims and Objectives
front-mounted engine, brake action rotates its
flywheel at up to 60000 rpm. The car can be powered There is a direct correlation between the overall
entirely or in part by using flywheel energy through a energy storage capacity of a flywheel and the stress
unique gearbox. A 6 Kg, 20-centimeter, carbon fiber concentrations that are present in the kinetic energy
flywheel reduces friction by spinning in a vacuum. It flywheel rotor during operation. For the purpose of
can save up to 25% on fuel when used in conjunction maximizing the system’s energy storage capability,
with a four-cylinder engine, giving it an 80 the study will investigate the interaction with the
horsepower (60 kW) boost and enabling it to reach objective of lowering levels of stress within the rotor.
100 km per hour (62 mph) in 5.5 seconds instead of a This will be accomplished by taking considering the

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 Optimizing Energy Storage Capacity Metallic Flywheel Rotor Stress Concentration Reduction
Technique

following goals, which offer appropriate results to 2-D model extends the shaft by 251.25 mm on both
meet the project’s aims. ends.
 Apply the FEA Ansys approach to investigate
stress concentrations on a hollow-sectioned rotor
disc in comparison to a solid disc.
 How does this affect the metallic flywheel’s
ability to store energy?
 Are non-central hole designs able to decrease the
concentration of load on the solid rotor?
 How do the hole’s diameter and radially
positioning on the rotor disc affect the
concentration of stress surrounding a non-central
hole?
 Regarding minimizing stress concentration, how
may the non-central hole layout be further Figure 8 two-dimensional rotor geometry
optimized?
 Optimization of Rotor Geometry
E) Purpose and Importance of Current Research
Flywheel shape optimization has been researched,
This dissertation studies the design, analysis, and as was already demonstrated, the rotor’s energy
testing of a large-scale, inexpensive flywheel energy density depends on both its material composition.
storage device. A sizable steel rotor will be present in Shape factor K is a constant that was created to
the flywheel energy storage. To provide a parametric describe the rotor’s geometrical arrangement. It
representation of the essential components of the connects the flywheel energy storage system’s energy
design, theoretical analysis of the stress distribution of density to the following material properties:
the rotor is described. To estimate the rotational speed
and optimize the rotor’s shape, the stress-strain σu
e=α ' α ' ' α ' ' ' K
distribution of the rotor is analysed using the finite ρ
element method. Additionally, dynamic response (1)
(resonant modes and frequencies) of the rotor is
revealed by frequency analysis using the finite α ' is the burst-resistant safety factor, the depth of
element approach (FEA). Efficiency in energy storage charge and discharge, or α ' ' is the ratio of the
is essential for the viability of this flywheel system. energy’s usable fraction to its entire capacity.
Furthermore, α ' ' ' represents the proportion of the
II. Methodology flywheel energy storage’s total weight to the rotor’s
weight. Additionally, the ratio of the rotor’s angular
 SolidWorks Flywheel Rotors speed to the angular speed of a thin rim with same
This created flywheel concept is based on an exterior diameter and density under the same load is
improved commercial flywheel design from Temporal known as the speed factor K. In various rotor shapes
Power. The rotor’s material characteristics are shown are displayed along with the matching shape factors
in this section. During optimization, the rotational and speed factors. (Genta et al, 1985) it defines
topology was parameterized using eight control points K=0.606 as the shape factor for a solid disc.
that were similarly spaced throughout the flywheel’s
radius and had different heights along the y-axis. The
rotor topology was developed by tracing the points
using a cubic B-spline. While modelling a flywheel
rotor, revolved profile can be utilized to simulate its
usual round disc shape. Due to having the capacity to
produce curves that are smooth with local control over
shape, cubic b-spline is an excellent choice for
generating the revolved profile. Because b-spline has
the advantage of offering opportunities for intuitive
shaping because changes with the fit points only
impact the immediate region. SolidWorks was used to
rebuild the geometry, this two-dimensional in nature
surface was mirrored along the direction of the x-axis
and then rotated around the y-axis to create a two- Figure 9 Potential rotor forms along with their matching speed
dimensional representation. The dimensions of the parameters A and shape factors K (Genta et al, 1985).
shaft were determined by the 2D model to be r = 0.05
times the overall radius and h =1.25 times the ordinate  Kinetic Energy
of the spline’s initial point. For improved support, the

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 Optimizing Energy Storage Capacity Metallic Flywheel Rotor Stress Concentration Reduction
Technique

A flywheel’s capacity to store energy is the FEA program with the theoretical results. Hooke’s
determined by the square of its rotational velocity and law produces the differential equation and combining
moment of inertia. Because of this relationship, the strain-displacement relations and the plane stress
variations in the flywheel’s rotational velocity have a (Kelly et al, 2008).
bigger impact on its capacity to store energy than
variations in its moment of inertia. 2 2
d u 1 du 1 −1−v 2
2
+ − 2 u= ρr ω
1 2 d r r dr r E
KE= I ω (6)
2
(2) It may be used to find the radial displacement at
It defines the moment of inertia for a solid disc or radius (r) for a solid disc when the appropriate
cylinder. boundary conditions are met (Kelly et al, 2008).

1
I ( solid cylinder )= m r
2
2
u ( r )=
3+ v
8
ρ ω2
1−v
E ( )[ (
r r 2o −
1+v 2
3+ v
r )]
(3) (7)

It defines the moment of inertia for a disc with a The 2-D Lame equation of radial and tangential stress
central hole or a thick-walled cylinder. in a hollow disc may determine the theoretical value
of displacement (∆) within the disc (Lamare et al,
1 2 2 2013).
I ( thick walled cylinder ) = m(r i + r o )
2
(4)
∆ r i=( d ω2 ) r i
It indicates that the flywheel’s mass and radius have (8)
an impact on the storage capacity as well. While these
formulas are combined with growing mass, the total γ ρ 1+ 3 v
d= ¿ , γ = ( 3+ v ) , φ= (9)
kinetic energy storage capacity is obtained. 2E 4 3+ v
1 1) Hollow disc Stress
KE= ρπt ( r o −r i ) ω
4 4 2
4
(5) A circular mass with a central hole that is either
linked immediately to a central axis or via the use of
 Stress spokes is used in several historical flywheel designs.
This investigation will include a look at a flywheel
The amount of stress that flywheel material that uses a rotor composed of many hollow discs. This
experiences when operating determines the maximum rotor may be categorized as a thick-walled cylinder
rotational velocity of a flywheel. There will be a since its thickness is more than tenth of its whole
larger force applied the faster the wheel moves. More
diameter.
energy can be stored by a stronger material since it
can spin faster and sustain higher stress levels. An
axisymmetric issue is one in which the geometry and
loading are both axisymmetric, for as when
calculating stress in a spinning disc with constant
angular velocity. There will be strains when the disc
rotates.

Figure 10 Stress in a cylinder with thick walls

A thick-walled cylinder with stress occurring in three

directions is seen in figure 9. Radial stress is denoted
by σ r, hoop stress by σ h, and axial stress by σ a. Note
that in a rotating system, axial tension might be
regarded as insignificant. The inner radius is
represented by r i , and the outer radius by r 0 . (Pope et
Figure 9 Stress within rotating Disc (Kelly et al, 2008)
al, 1997) it illustrates that for a revolving circular disc
with a central hole of radius r i and an outer radius r 0 ,
As a result, there will be matching strains and
the greatest stress on the radial plane occurs at r and
displacements associated with each of these stressors.
the highest hoop stress occurs at r i .
The radial displacement will be taken into
consideration to compare the findings obtained from

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 Optimizing Energy Storage Capacity Metallic Flywheel Rotor Stress Concentration Reduction
Technique

0.5
r =( r i r 0 ) (10)
The material yield strength and the size
restrictions listed will then be used to create a baseline
According to (Kelly et al, 2008), the largest radial rotor design. There will be research done on ways to
decrease the stress concentrations in the rotor, and the
stress may be defined.
rotor design will be adjusted accordingly. To evaluate
2 2 these approaches’ efficiency, more modelling will be
ρ ω ( r 0−r i ) (3+v ) done, and the outcomes will be contrasted with the
σ rmax=
8 original rotor design. As a unitless numerical
(11) comparing tool, the stress ratio will be utilized to
compare the outcomes of the model runs with
It provides a definition for the maximum hoop stress different rotor designs and hole configurations.
(Kelly et al, 2008).
σ max ( modified disc )
ρ ω2 ( ( 3+ v ) r 2o + ( 1−v ) r 2i ) σ ratio=
σ h max= σ max ( plain disc )
4 (15)
(12)
By dividing the maximum Von Mises stress in the
modified disc by the maximum Von Mises stress in
the ideal plain disc, one way determines the stress
2) Solid Disc Stress
ratio.
As seen in figure 11, a revolving solid disc with a  Validation
consistent thickness will also be investigated in this
study. The direction of the centripetal acceleration, Since Ansys FEA is a well-known modelling
that is how fast the particles are accelerating toward software that is regarded as industry standard, it is
the disc’s center is shown by the dashed line’s arrow. crucial to make sure the outcomes it generates are
legitimate and reasonable. This was accomplished by
modelling a solid disc using the characteristics. The
outcomes generated by theoretical calculations will be
contrasted with those generated by the model. A
model is considered valid if the outcomes produced
by the model agree with those predicted by the theory.
Subsequent results can be regarded with confidence
and are deemed accurate.
Inner Outer Thickness Rotational Rotationa
Radius radius (mm) Velocity l Velocity
(mm) (mm) (RPM) (rad/s)
Figure 11 Rotating Solid Disc 40 160 10 10000 1570.8
Table 2 Initial Hollow Disc Parameters
It illustrates that for a spinning solid circular disc Outer Radius Thickness Rotational Rotational
with uniform thickness, the greatest radial and hoop (mm) (mm) velocity Velocity
stresses occur at the disc’s center and are equal. (RPM) (rad/s)
200 10 10000 1047.2
2 2
ρ ω r o (3+v )
σ rmax=σ h max= Table 3 Initial Solid Disc Parameters
8
(12)  Model

It can be used to find the radial tension at radius r Table 3 parameters were used to draw a solid disc
(Pope et al, 1997). geometry in the ANSYS tool ‘design modeler’. Next,
a mesh was added to the disc after importing the

( )
2 2 geometry into ANSYS ‘Mechanical’. With a 2 mm
ρ ω2 ( 3+ v ) 2 2 r o r i 2
σ r= (r o+ r i − 2 −r ) element size, a body sizing control was configured.
8 r The mesh used for initial modeling’s quality
(13) parameter are displayed in Table 3.

It can be used to find the hoop stress at radius r (Pope MESH NODES ELEMENTS ELEMENT
METHOD SIZE (MM)
et al, 1997). AUTOMATIC 188363 40340 2
2 Table 4 Solid Disc Mesh Parameters
ρ ω (3+ v )
σ h= ¿ (14)
After that, the model’s parameters were established,
8
the disc’s rotating velocity was adjusted along its
 Stress Ratio centre axis, and it was held together by a single
frictionless support on its lower face. The purpose of

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 Optimizing Energy Storage Capacity Metallic Flywheel Rotor Stress Concentration Reduction
Technique

running the software was to produce data values. A

probing tool was used to create a value at spots along
the solid disc’s radius to extract a displacement figure
from the model. At a position in the disc’s centre
(t=10 mm), the probing instrument was configured to
measure displacement values at intervals of 10 mm
along the radius. After taking all the displacement
values produced by the model in addition to the
theoretical values, a percentage error has been
generated.

Figure 13 Theoretical and Modelled radial displacements in hollow

disc. (Ansys R2, 2023)

As r/r_Outer gets closer to 0.001 (the disc’s edge),

Figure 13 illustrates a divergence of displacement
values between theory and simulated values. This
suggests that the model setup has a mistake. It ran
several models runs with different values of r_inner to
make sense of these results. This demonstrated that
the extent of inaccuracy between the theoretical and
modelled values dropped as r_inner decreased, but
Figure 12 Mesh Quality and drawing the solid disc. this did not increase confidence in the model’s output.
Figure 12 demonstrates how displacement values are  Solid Disc – Analytical Model
taken out of the FEA model and the mesh that is
applied to the geometry. To shorten the computational When the equation 7 is plotted, it displays the
processing time required to run the model, symmetry theoretical radial displacements that resulted from the
areas have been used instead of meshing the entire rotor settings listed in Table 3.
disc. Throughout the investigation, this methodology
is employed.
III. Result & Discussion
A) Analytical Model
1) Hollow Disc – Analytical Model
For the reason of trying to verify the hollow disc
model, a geometry was created using the values
shown in table 2. Then, in ANSYS Mechanical, a
mesh was applied to the disc geometry with a body Figure 14 Baseline Solid Disc Displacement result
sizing control and an element size of 2 mm. When the
center hole was added, the model’s constraints were
altered during model setup, a pressure was added to
the bore’s inner face, and the frictionless support was
taken out of the disc’s bottom face. After running the
model, the results were extracted. Equation 7 is
displayed for different values of r/r_Outer, and figure
13 displays the displacement values that the model
produced for a hollow disc with r_inner = 40 mm and
r_outer = 160 mm.

Figure 15 Baseline Solid Disc - Stress Vs Strain

When the equation 12 is plotted, it displays the

theoretical radial and Hoop stress that resulted by
142.04 MPa from the rotor settings listed in Table 3.
 Solid Disc & Hollow Disc
In phase one of the modelling process, the impact
of adding a central hole to a solid disc on the amount

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 Optimizing Energy Storage Capacity Metallic Flywheel Rotor Stress Concentration Reduction
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of stress concentrations within the disc material was close to the disc center is because the stress flow
taken into consideration. Figure 16 illustrates how concentration surrounding the holes is interacting with
adding a central hole to a disc with the characteristics one another, raising the concentration there. Figure 18
listed in table 2 and then increasing its radius has an demonstrates the stress ratio as the holes get into the
impact on stress concentration. disc’s edge. The lowest stress ratio, 0.57441, is found
in the hole with a diameter of 5 mm at strain equals
0.00072138. In comparison to the two smaller holes,
the 15 mm diameter holes have not much bigger stress
ratio at their lowest that is 0.61427. To secure the disc
stack, the hole this size is also probably going to be
excessively huge. According to the data, the 10 mm
diameter hole has peak stress ratio of 0.97874 at strain
is 0.00122563. The size of hole should be able to
handle a fastener that is appropriate in size to retain
the disc stack. The 10 mm hole’s stress ration is about
not the same as the 5 mm holes at 0.00072138. These
Figure 16 Strain Vs Stress - Solid & Hollow Disc parameters would suggest that the ideal hole diameter
is 10 mm. The effect of moving the hole to a spot
 Solid Disc Non-Concentric Holes where 0.00122563 is greater must be considered.
Four non-concentric circular holes weren’t  Solid Disc Multiple Non-Concentric
positioned symmetrically along the x and y central
axes that were added to the baseline solid disc As can be seen from the data in figure 19, when
specified for consideration in the following stage of Length supporting Is = 17 mm and ds/dh = 0.82, the
the study. The distance between the disc centre and most advantageous stress ratio 1.319 was attained, in
the hole centre (rh) was varied during model runs. To contrast to the lowest figure in the disc with single NC
determine the ideal hole diameter to generate a stress Holes, this number indicates a 25.2% drop in the
ratio with a value as close to one as feasible, this run stress ratio. The values attained by (Ricky et al, 1978)
was repeated for three holes of different dimension are consistent with these results. At a rh/rO value of
(dh). In this section, non-concentric holes introduced 0.88, which was chosen with a margin of safety to
into the solid disc geometry shall be referred to as
move the hole center inward and away from the disc
‘NC Holes’ for the sake of this study.
edge, these findings were obtained. It was determined
to take the settings that were used to produce 1.4656
and again modify the value of rh/rO to extract the
absolute optimal stress ratio from the disc.

Figure 17 Stress Vs Hole Position between 3-hole Diameters.

Figure 19 Multi NC Holes, Stress Ratio vs Strain

Figure 20 illustrates how changing the rh/rO value for

the many NC Holes led to the lowest stress ratio of
1.315 at rh/rO = 0.92. The modelling strategy that
produced these and earlier findings involved starting
with a large sample size in the first study. Following
review of the first study’s results, further points could
be refined to look more closely at the values of rh/rO
Figure 28 Stress Ratio Vs Hole Position that provide the desired effects.
Figure 17 demonstrates how the disc’s middle around
strain = 0.00122563, is where the maximal equivalent
stress for all hole sizes peaks. The reason for this peak

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Figure 20 Multi NC Holes Stress ratio Vs Strain

Figure 22 Hollow Disc Displacement (single friction support)
B) FEA Result
 Solid Disc & Hollow Disc
 Results: Setting the Baseline
The tension within the disc is focused on the
Baseline characteristics for the solid disc that
margins of the central hole as soon as a hole of any
would satisfy the necessary design criteria had to be
radius is inserted, as seen in figure 23. These findings
determined while designing a rotating disc with NC
demonstrate that, under the same set of circumstances,
holes. The stress levels encountered in the disc
a hollow disc with the different dimensions will have
surpassed the material’s yield strength. which shows
stress concentrations that are far higher than those
the square connection between rotational velocity and
seen in a simple solid disc. Stress levels rise by
maximum stress, the rotational velocity of 10000 rpm
58.15%. At r_i = 5mm, this rises to 94.5%, these
for a steel rotor is probably excessively optimistic.
results demonstrate that the ideal rotor design is a
This is probably the main cause of the yield strength
solid disc since it minimizes stress concentrations
deviation. It details the modifications made to the
within the rotor and increases the rotor’s spinning
rotational velocity and outer diameter after taking
velocity. This presents a dilemma, though, since the
advantage of the variables used for the first modelling
steel laminate discs that will comprise the rotor mass
and validation. The highest equivalent stress that may
need a way to be secured to one another. When using
exist within a rotor with the modified rotor size is
hollow discs in a rotor, the discs can be stacked and
141.84 MPa. This number will serve as the baseline
secured to the spindle using a press fit or keyway after
maximum stress value to determine the stress ratio
the central axle has been threaded through it.
later in the study. This provides a wide safety margin
below the 250 MPa material yield strength.

Figure 21 Equivalent Stress in Baseline Solid Disc

Figure 23 Equivalent Stress in hollow Disc r_i = 5mm r0 = 160
The storage of energy capacity for a single solid disc mm by Hoop stress = 409.2 MPa
may be calculated.

1  Solid Disc Non-Concentric Holes

4 2 3
KE ( single solid disc )= ρπt r 0 ω =108.2× 10 J
4 Figure 24 illustrates this phenomenon, the more the
hole gets to the disc’s edge, the lower the stress level
It shows that one hollow disc has a capacity of 108.2 becomes. Stress starts to build up again when the hole
KJ for energy storage. gets to the disc’s edge. This is seen in figure 25 where
an decrease in stress concentration is surrounding the
 Hollow Disc hole because of the stress flow around the hole
The displacement results are displayed following interfering with the disc’s edge. No matter where the
setup modifications. Remember the displacement hole is located, the maximum tension within the disc
always occurs along its edge, according to the results.
value’s first decline from bore to edge, its subsequent
There is theoretical evidence to support this.
climb to a peak ¾ of the way down the disc. And its
Maximum stress will be around the hole bore for a
subsequent fall away. The displacement form in figure plate of infinite size subjected to uniaxial strain,
22 is consistent with this profile.

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 Optimizing Energy Storage Capacity Metallic Flywheel Rotor Stress Concentration Reduction
Technique

according to kirsch’s linear elastic solution for D15) and the distance between the original hole center
stresses surrounding a hole. (kirch et al, 1898). and the supporting holes (L11, L15). As discussed in
the preceding section, the distance of 175 mm will
remain the same between the disc center and the hole
center (L18). The parameters that are mentioned
above in brackets are shown in figure 26. Diameter
supporting (ds) refers to the diameter of the
supporting holes (D2, D3) to maintain uniform
nomenclature throughout the investigation. The
diameter of the initial hole is denoted by dh, length
supporting, or length supporting refers to the distance
between the original hole center and the supporting
hole center (L1, L7). In the first modelling, Length
supporting was fixed at a fixed, arbitrary value of 17
mm. To get the ideal stress ratio, ds was then adjusted.
For two further values of Is on either side of 16.5 mm,
same procedure was repeated. After one run at Is
=16.5 mm, which revealed a significant rise in the
stress ratio for ds = 15 mm, a second run at Is = 17
Figure 24 NC Holes, dh =10 mm, rh =10 mm mm was carried out.
IV. Conclusion
Due to the extended lifespan and high-power
density, metallic flywheels provide a potential energy
storage technology. However, the rotor’s stress
concentrations restrict how much energy they can
store. To maximize energy capacity and minimize
stress concentrations, this work has investigated
methods for optimizing the rotor geometry. It is
demonstrated that, in comparison to change the
thickness design, the implementation of a progressive
F thickness taper at the rotor’s inner bore greatly
igure 25 rh =10 mm, rh = 188 mm reduces peak stresses. To further lessen the
consequences of stress concentration, fillets are added
 Solid Disc Multiple Non-Concentric at the rotor hub-web interface. According to FEA
result, an ideal rotor including a filleted hub and
Stress spreading holes applied to the initial NC holes
tapered bore might boost energy storage capacity by
examined in this section shall be referred to as ‘Multi
up to 40% when compared to an unaltered baseline
NC Holes’ for the sake of this study. This serves to set
design. Higher tip speeds and stored energy are made
this effort apart from rotor geometries that came
possible by the decreased peak pressures, which also
before and after.
contribute to the increased capacity.
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