Finite element optimization of flywheel employed in internal combustion engines

Department of Mechanical Engineering Techniques of Power, Technical Engineering College of Najaf, Al-Furat Al-Awsat Technical University, Iraq

^* Corresponding author: Ahmed.Al-murshedi@atu.edu.iq

Published online: 7 January 2026

Abstract

The paper researched a flywheel design based on the replacement of typical circular cutouts with longitudinal radial slots which optimizes weight with simultaneous enhancement of the dynamic stress capabilities. A grey cast iron flywheel (FG 200), under conditions representative of its operating conditions, has been modelled using finite element analysis (FEA) in ANSYS and analysed using harmonic, stress analysis and static- equivalent stress analyses. Comparisons of traditional circular cutouts with longitudinal radial slits at the same mass reductions achieved had been done. Slot-based design had less maximum von Mises stress and more evenly spread stress along with smaller resonant amplitudes on the operating band. They will give detailed material properties, boundary condition, meshing and convergence and run sensitivity analysis of slot length, width and end radius to quantify the trade-off between weight reduction and stress. The findings encourage longitudinal radial slot as a viable alternative of reducing inertia and enhancing robustness, so far as slot geometry is optimized and operating speeds would not be resonating.