How Can A Flywheel Be Lightened

· Lightweight Flywheel

We ZNDmotor focus on removal of weight from flywheel’s outer area even though we maintain a good ring of material at the extreme circumference nearest the ring gear, which is useful and helpful for maintaining inertia. Weight removed from this area has a more significant impact than those removed near center. It is unnecessary to remove material from center, and this does not have too much impact. However, it is more likely to cause failure if material is removed here, since this area is under the maximum stress. As a result, it is the shape and section of material that is vital, instead of the total weight. When machining, we ZNDmotor use tapers and radii to make sure there do not exist any stress points in the material, which can lead to cracking and even failure.

During the procedure of lightening, material is removed from the back of flywheel to make sure the surfaces of clutch remain undisturbed, which can make clutch operation maintained. However, in some particular cases, clutch cover does not fully occupy available surface area. Hence it is likely to remove extra material from outside the diameter of clutch cover without any negative impact.

In fact, the materials for flywheel vary among manufacturers and can even be various among engines produced by same entity. Thus, it proves to be vitally important to conduct each job depending upon different merits, instead of simply complying with rule of minimum thickness across the board.

Taking all of these into consideration, unluckily, it is unlikely to work to a weight when lightening flywheel. Our goal is making the piece as light as possible without damaging integrity or losing strength.

Removal of weight turns out to be some kinds of promotions and would be benefited for the performance of engine. There only exist advantages when flywheel is lightened correctly.

When flywheel is lightened, it is likely to distort the entire component because of machining stress. We ZNDmotor highly recommend re-facing lightened flywheel to make sure total flatness and perfect clutch operation.

We ZNDmotor also suggest balancing the lightened flywheel. Despite we can make sure all dimensions are symmetrical, cast materials may vary in terms of density and may contain voids in material, which can impact balance. Although flywheel can be balanced as individual part, it would be much better to balance all of parts that are rotating as a whole, namely crankshaft, pulley, flywheel and clutch.

Still confused about lightweight flywheel? Do not hesitate and feel free to talk with us about what you would like to know. We ZNDmotor are all here to help.

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