Flywheel material

Flywheel material

Home Forums Materials Flywheel material

Viewing 7 posts - 1 through 7 (of 7 total)
  • Author
    Posts
  • #854955
    Speedy Builder5
    Participant
      @speedybuilder5

      Farm Boy project.  Looking for material to make the cast iron flywheels.  They are 6″ dia by 0.80″ wide with straight radial spokes.

      I have several exercise weights which could be be machined to suit, but would the material be a non starter.

      Alternatively, I can buy relatively cheaply, 1″ thick aluminium alloy plate and thick walled tube to make a composite wheel.

      I believe max revs are about 800rpm.

      What are the views on the subject?

      Bob

      #854962
      JasonB
      Moderator
        @jasonb

        Weights can be a bit variable and I’ve yet to find one anywhere near as nice as GR17 iron bar. Probably OK if you go with fairly chunky spokes, don’t mind plugging the oversize hole in the middle and don’t want to polish up the rim too much.

        Have you considered a couple of discs of CI round bar which is what I mostly carve flywheels out of. M-machine would cut a couple of say 0.9″ thick slices.

        If you go aluminium spokes and thick wall steel tube rim then make the rim a bit thicker than shown so you regain the weight lost from the spokes

        #854984
        alecs
        Participant
          @alecs

          Or just make it out of mild steel?

          Weights can have widely variable quality of material and can have some very hard material if they were chilled quickly during manufacture. You could try heating them up to a dull red and letting them cool slowly to anneal them before machining. Weather is a bit warm for the traditional burying in the fireplace and leaving overnight in the embers.

          #854985
          JasonB
          Moderator
            @jasonb

            I’ve not had weights that are chilled, it is just the quality of the iron is a lot less being coarse and more granular. They are not the nicest stuff to machine unlike GR17 bar which is a joy to machine and a lot easier to cut than even a free cutting steel.

            This is why I said go for a thicker spoke as the weights are not as robust as good iron, here is a bit I broke earlier you can see the very coarse grain and all the little voids on the machined surfaces.

            DSC02568

             

            #854986
            John Haine
            Participant
              @johnhaine32865

              I see that Model Engineer’s Laser can work in 20mm mild steel.  Getting a laser cut blank with the spokes and bore already roughed out could save you a lot of time and effort.  Might still be worth thoroughly annealing before further machining – in my limited experience laser cutting can leave a hard region by the cut.

              #855041
              Howard Lewis
              Participant
                @howardlewis46836

                The object of a flywheel is that it will have a latge momentof inertia to carry the engine round on non power strokes

                The limit of how heavy it can be is set  the main bearings (I’ve seen a crankshaft broken by fitt ing a flywheel so heavy that it exceeded the maximum overhung load, and failed the crankshaft on fatigue.

                To maximise moment of inertia it would be advisable to concentrate as much weight in the rim, being aware of the strength of the spokes, and the centrifugal forces to which they are subjected when the engine runs at above its nornal speed. (A flywheel, even small, failed by overspeed is dangerous!)

                So a very dense, but strong, material is indicated. (lead is too weak, and Tungsten tends to be hard to come by), so cast iron tends to be a cost competetive compromise.

                Howard

                #855046
                Dalboy
                Participant
                  @dalboy

                  It is a shame that the man on e bay that use to sell the correct sized flywheels no longer shows them. I must have been lucky when I got mine for my Farm Boy.

                  I would go for a good cast iron blank and make your own.

                  A picture of mine for reference

                  During machining

                  DSCF3917

                  And final fitting

                  in case 10

                Viewing 7 posts - 1 through 7 (of 7 total)
                • Please log in to reply to this topic. Registering is free and easy using the links on the menu at the top of this page.

                Latest Replies

                Home Forums Materials Topics

                Viewing 25 topics - 1 through 25 (of 25 total)
                Viewing 25 topics - 1 through 25 (of 25 total)

                View full reply list.