Effects of Viscoelasticity on the Stress Evolution over the Lifetime of Filament-Wound Composite Flywheel Rotors for Energy Storage

High-velocity and long-lifetime operating conditions of modern high-speed energy storage flywheel rotors may create the necessary conditions for failure modes not included in current quasi-static failure analyses. In the present study, a computational algorithm based on an accepted analytical model was developed to investigate the viscoelastic behavior of carbon fiber reinforced polymer composite flywheel rotors with an aluminum hub assembled via a press-fit. The Tsai‑Wu failure criterion was applied to assess failure. Two simulation cases were developed to explore the effects of viscoelasticity on composite flywheel rotors, i.e., a worst-case operating condition and a case akin to realistic flywheel operations. The simulations indicate that viscoelastic effects are likely to reduce peak stresses in the composite rim over time. However, viscoelasticity also affects stresses in the hub and the hub-rim interface in ways that may cause rotor failure. It was further found that charge-discharge cycles of the flywheel energy storage device may create significant fatigue loading conditions. It was therefore concluded that the design of composite flywheel rotors should include viscoelastic and fatigue analyses to ensure safe operation.

Stochastic Modeling of a High Speed Composite Flywheel for Energy Storage

This work will demonstrate the development and experimental validation of the stochastic models to predict the composite material’s mechanical and electromagnetic response as a function of the constituent reinforcing materials. First, stochastic micromechanics models will be developed for the case of multiple disparate supporting materials. These micromechanics models will then be validated against traditional finite element models and experimental results over the feasible parameter space. The developed models will then be utilized to define the optimal geometry of the composite flywheel including constraints such as displacement, stress, flux, magnetic field density, and manufacturability.