Flywheel Design Calculator
Calculate flywheel diameter, mass, moment of inertia, torque, and energy storage. Step-by-step formulas included for safe and efficient flywheel design.

flywheel design calculator
Calculate Flywheel Design with this Flywheel Design Calculator. Input needed: torque, energy, and rotating speed to determine ideal flywheel dimensions. Gradual calculations provide a good design of flywheels in safety and efficiency.
flywheel design Tool Formula:
Energy Stored (E):
\[ E = 0.5 \times I \times \omega^{2} \]
(where E = energy stored, I = moment of inertia, ω = angular velocity)
Moment of Inertia for a Solid Disk (I):
\[ I = 0.5 \times m \times r^{2} \]
(where m = mass, r = radius)
Angular Velocity (ω):
\[ \omega = \frac{2 \times \pi \times N}{60} \]
(where N = rotational speed in RPM)
The Flywheel Design Calculator assists engineers, students, and other technicians in designing and analyzing flywheels in mechanical systems to provide energy storage, torque smoothing, and load balancing. Flywheels are kinetically stored masses rotating with some angular velocity and are utilized in engines, presses, and industrial machinery.
The required energy storage, shaft speed, material density, and safety factor can be entered by users. The calculator is used to compute flywheel mass, flywheel diameter, moment of inertia, the rotational speed, and the maximum torque. Step-by-step solutions demonstrate formulas on moment of inertia, kinetic energy, angular velocity, and transmission of torque; hence, it is easy to optimize flywheel design for energy storage and smooth running.
SI units are accepted:· N · m, kg, mm, rad/s, J. This is a perfect tool to use by mechanical engineers, design engineers, students, and educators engaged in rotating machinery, engine flywheels, presses, and energy recovery systems to make sure that flywheels are sized correctly and safely.
⚡ Work & Installation Input to Output:
Input:
- Required energy storage (E, J)
- Shaft rotational speed (N, RPM)
- Material density (ρ, kg/m³)
- Safety factor (SF)
- Flywheel type (solid, rim, disc)
- Units: mm, kg, N·m, rad/s, J
Processing:
- Compute angular velocity: ω = 2π N / 60
- Compute moment of inertia: I = E / (0.5 × ω²)
- Determine flywheel dimensions (diameter, thickness, mass) based on material density and geometry
- Compute maximum torque: T = I × α (if angular acceleration known)
- Apply safety factor to ensure material stress limits
Output:
- Flywheel mass (m)
- Diameter (D) and thickness (t)
- Moment of inertia (I)
- Angular velocity (ω)
- Stored kinetic energy (E)
- Maximum torque (T)
- Step-by-step formulas and calculations
Testing and Final Adjustments
Test common scenarios:
- Energy E = 1000 J, N = 1200 RPM, material ρ = 7800 kg/m³ → compute mass, diameter, moment of inertia, angular velocity, torque
- Edge cases: very high-speed flywheels, large energy storage, rim vs solid design
- Units validation: N·m ↔ J, mm for dimensions, kg for mass
- Step-by-step clarity for students and engineers
- Mobile/desktop UX: numeric keypad, labels, error messages
- Include standard material densities (steel, cast iron, aluminum)
- SEO metadata: "Flywheel Design Calculator," "Rotational Inertia," "Torque Calculation," "Energy Storage," schema markup
Frequently Asked Questions - Flywheel Design Calculator:
What is a flywheel?
A flywheel is a rotating mechanical device that stores kinetic energy to smooth out torque fluctuations.
How do I calculate flywheel mass?
Mass m = Volume × Material density, where volume is determined from required inertia and diameter.
How do I calculate moment of inertia?
I = E / (0.5 × ω²), where E is kinetic energy and ω is angular velocity.
What types of flywheels are supported?
Solid, rim, and disc-type flywheels.
How do I calculate stored energy?
Kinetic energy E = 0.5 × I × ω².
Which units are supported?
Energy in J, mass in kg, torque in N·m, dimensions in mm, angular velocity in rad/s.
Who should use this calculator?
Mechanical engineers, design engineers, students, and educators designing rotating machinery.
Why is flywheel design important?
Proper flywheel design ensures energy storage, torque smoothing, and safe operation of rotating machinery.
Can it compute torque capacity?
Yes, torque T = I × α if angular acceleration is known.
Does it show step-by-step calculations?
Yes, all formulas and intermediate steps are displayed for clarity and verification.
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