Flywheel Design Homework Problem

High Power Energy Storage

Spring 2016
Prof. C. E. Bakis
Assigned: Fri. Jan. 29
Submitted by: Anjali Dhobale (Worked with Gunwoo Jo)
Due: Mon. 8 Feb., 11 pm.
Part I
Available space allows you to use a flywheel rim of 0.200 m outside radius and 0.05 m axial
length in an HEV. Evaluate and compare the maximum energy storage capability of the
following materials in single-ring flywheel concepts. Assume 100% of the stored kinetic energy
of the ring is available for use. Specifically, calculate and tabulate the inside radius (m), the tip
speed (m/s), the rotational speed (in revolutions per minute), the mass (kg), the energy storage
(Watt-hr), specific energy (Watt-hr/kg), and energy density (energy per unit volume, kiloWatthr/m3) for the optimal configuration of each material type.
Base your optimal design on the attainment of simultaneous failure by maximum radial stress
and maximum hoop stress according to the maximum stress failure criterion. Homing in on the
solution to the nearest 0.1 millimeter of inside radius will suffice. Reminder: these failures most
likely will not occur at the same locations through the radius of the optimally designed flywheel
rim, but they will occur at the same tip speed. Use just the mass of the rim in these calculations
(ignore the mass of the other components like motor/generator, hub, bearings, and containment).
The volume to use in the denominator of the en/vol. calc is defined here as the volume of the
material in a rim of given inside and outside radii and length as determined in solving this
problem.
Material
Mass Density, (kg/m3)
Hoop Modulus, Eh (GPa)
Radial Modulus, Er (GPa)
Poissons Ratio, hr
Hoop Tensile Fatigue Strength, Xt (MPa)
Radial Tensile Fatigue Strength, Yt (MPa)
Cost ($/kg)

Carbon/epoxy
1,600
200
8
0.30
2,200
25
100

E-glass/epoxy
1,900
50
20
0.35
800
30
4.20

Please use the following tabular format (and units) for the calculated results:
Matl

Inside
radius
(m)

c/ep

0.1675

gl/ep

0.1220

Tip speed
(m/s)

Rotational
speed
(RPM)

Mass
(kg)

1.2477e+03 5.9577e+04 3.0018

719.6673

3.4364e+04 7.4959

Energy
storage
(Wh)

Specific
energy
(Wh/kg)

Energy
density
(kWh/m3)

552.1215

183.9307

294.2891

369.9228

49.3500

93.7650

Notes: a nonoptimal beta results in less rotational speed, tip speed, energy, and energy per
encased vol vs. optimal beta. The energy per mass and energy per material vol. are max as
beta 1.
Part II
Plot radial and hoop stress (MPa) vs. radius (on separate graphs due to large differences in
values) for both of the rims designed in Part I.

Plot of Radial Stress vs Flywheel Radius

#10 7

Glass Epoxy

Radial Stress (Pascals)

0
0.12

0.13

0.14

0.15

0.16

0.17

0.18

0.19

0.2

Flywheel Radius(m)

Part III
For the rims designed in Part I, compute the material cost and the energy storage per unit cost.
Compute valuate the well-known metric of energy storage per unit mass using the industry rule
of thumb: divide the hoop-direction fatigue strength by the rims mass density and convert the
units to Wh/kg. Compute the so-called form factor defined in class (C) by dividing the
calculated energy per unit mass from Part I by Xt/. Note that higher form factors imply higher
material utilization in a rim design.
Matl

Cost ($)

Energy per unit

Cost (Wh/$)

Xt/ (Wh/kg)

Form Factor, C

c/ep

361.9115

1.7729

1375000

1.2894e-04

gl/ep

31.4828

11.7500

4.2105e+05

1.1721e-04

Matlab Codes
%Anjali Dhobale
%ESC551 Flywheel Hw1 - Carbon Epoxy
%Given
%ri=0.00; %Selecting inner radius
clear all
close all
clc
ro=0.2; %outside radius m
l=0.05; %axial length m
d=1600; %mass density (kg/m^3)
Eh=200E9; %Hoop Modulus Pa
Er=8E9; %Radial Modulus Pa
Pr=0.30; %PoissonRatio
Xht=2200E6; %Hoop Tensile Fatigue Strength MPa
Yrt=25E6; %Radial Tensile Fatigue Strength MPA
%Defining Constants
mu=sqrt(Eh/Er) %Mu

B = 0:0.1:1;
ri=B.*ro; %inner radius
L = ((B.^(-mu-1)-(B.^2))./((B.^(-mu-1))-(B.^(mu-1))));
%r=ri+((ro-ri)./100);
%K = r./ro;
n=10; %number of finite elements in the middle portion

i=0;
while (1)
i=i+1;
w(i)=ro-ri(1,i);
r(i)=ri(1,i)+(w(i)/n);
K(i)=r(i)/ro;

j=1;
while j<12
L(j)=L(1,j);
omegaH(i,j)=sqrt(Xht/(d*ro^2*((3+Pr)/(9-mu^2))*((mu*L(j)*K(i)^(mu1))+(mu*(L(j)-1)*K(i)^(-mu-1))- K(i)^2*((mu^2+3*Pr)/(3+Pr)))))
Sradial(i,j)=d*omegaH(i,j)^2*ro^2*((3+Pr)/(9-mu^2))*((L(j)*K(i)^(mu1))-((L(j)-1)*K(i)^(-mu-1))- K(i)^2);
%collection of valid points that give acceptable radial stress
if Sradial(i,j)<=25E6
SpecialRadial(i,j)=Sradial(i,j)
else
SpecialRadial(i,j)=0;
end
%Selected the highest stress from the Special matrix Yrt=14.53E6 Pa
%and used this value to calculate OmegaR
maxYrt=1.453742765523877e+07;
omegaR(i,j)=sqrt(maxYrt/(d*ro^2*((3+Pr)/(9-mu^2))*((L(j)*K(i)^(mu1))-((L(j)-1)*K(i)^(-mu-1))- K(i)^2)));
%Used omegaR to calculate hoop stresses
Shoop(i,j)=d*omegaR(i,j)^2*ro^2*((3+Pr)/(9-mu^2))*((mu*L(j)*K(i)^(mu1))+(mu*(L(j)-1)*K(i)^(-mu-1))- K(i)^2*((mu^2+3*Pr)/(3+Pr)));
%Collect valid hoop stress points in a special Hoop matrix.
Condition: Should
%be positive
if Shoop(i,j)>=0
SpecialHoop(i,j)=Shoop(i,j)
else
SpecialHoop(i,j)=0;
end
j=j+1;
end
%For the next iteration, add another piece of element to radius
r(i)=r(i)+(w(i)/n);
%End the loop when the assigned iterations number is complete
if i>=n,break,end

end
%Part1
MaxHoopStress=SpecialHoop(9,9)
MaxRadialStess=SpecialRadial(9,9)
omega=omegaH(9,9) %same value as omegaRadial in rad/s
omegaRPM=omega*9.55
innerRadius=ri(1,9)
tipSpeed=omega*ro
volume=pi*l*((ro^2)-(innerRadius^2))
mass=d*volume
I=0.5*mass*((ro^2)+(innerRadius^2))
energyStorage=0.5*I*(omega^2)*0.000277778 %conversion joules to Whr
specificEnergy=energyStorage/mass
energyDensity=(energyStorage*10^-3)/volume
%Part3
cost=mass*100
energyPerUnitCost=energyStorage/cost
XtD=Xht/d
C=specificEnergy/XtD

%CarbonEpoxyPlots
%ri=0.00; %Selecting inner radius
clear all
close all
clc
ro=0.2; %outside radius m
ri = 0.16
l=0.05; %axial length m
d=1600; %mass density (kg/m^3)
Eh=200E9; %Hoop Modulus Pa
Er=8E9; %Radial Modulus Pa
Pr=0.30; %PoissonRatio
Xht=2200E6; %Hoop Tensile Fatigue Strength MPa
Yrt=25E6; %Radial Tensile Fatigue Strength MPA
%Defining Constants
mu=sqrt(Eh/Er) %Mu

B = 0.8;
ri=B.*ro; %inner radius
omega=6238.41
L = ((B.^(-mu-1)-(B.^2))./((B.^(-mu-1))-(B.^(mu-1))));
%r=ri+((ro-ri)./100);
%K = r./ro;
n=500; %number of finite elements in the middle portion

w=(ro-ri)/n;
r1=ri+w;
r(1)=r1;
k(1)=r1/ro
i=0;
while (1)
i=i+1;
r(i+1)=r(i)+w;
K(i+1)=r(i)/ro;
Sradial(i+1)=d*omega^2*ro^2*((3+Pr)/(9-mu^2))*((L*K(i+1)^(mu-1))-((L1)*K(i+1)^(-mu-1))- K(i+1)^2);
Shoop(i+1)=d*omega^2*ro^2*((3+Pr)/(9-mu^2))*((mu*L*K(i+1)^(mu-1))+(mu*(L1)*K(i+1)^(-mu-1))- K(i+1)^2*((mu^2+3*Pr)/(3+Pr)));
if i>=n,break,end
end
figure(1)
plot(r,Sradial)
xlabel('Flywheel Radius(m)')
ylabel('Radial Stress (Pascals)')
title('Plot of Radial Stress vs Flywheel Radius')
axis([0.16 0.2 0 4E7 ])
figure(2)
plot(r,Shoop)
xlabel('Flywheel Radius(m)')
ylabel('Hoop Stress (Pascals)')
title('Plot of Hoop Stress vs Flywheel Radius')
axis([0.16 0.2 0 2.5E9 ])
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