Authors : H.M. Sheidi and C.I. Ajuwa
Abstract: Flywheel energy storage systems employing light weight-high speed composite flywheel can be evaluated to replace the traditional heavy wheels in vehicles. The composite flywheel can provide extended operating life and significant reduction in weight and volume comparatively. This study describes the testing of a composite vehicle composite flywheel with emphasis on materials allowable test methods, design criteria and analysis techniques. The flywheel is a composite of an aluminium alloy hub, cast iron friction surface and a steel alloy gear rim resulting in compact, lightweight, high energy density structure. The study also describes the heat treatment processes to upgrade metallurgical and mechanical properties; including hardness test, tensile test, vibration analysis and dynamic balancing. The aluminium hub was solution treated and artificially aged, cast iron friction surface was annealed and the steel rim quenched and tempered. The components were assembled using high strength fasteners. A description of the experimental setup and a discussion of spin testing of the wheel up to 455 rpm (7.58 Hz) and 2,995 rpm (49.25 Hz) are also presented. A CSI 2120 portable dual channel vibration analyzer was used to conduct vibration analysis on the wheel and also a CSI ultraspec 8117 balancing kit was used to carry out dynamic balancing of the wheel.
H.M. Sheidi and C.I. Ajuwa , 2008. Mechanical Testing of High Performance Vehicle Composite Flywheel for Optimal Performance. Journal of Engineering and Applied Sciences, 3: 178-183.