SUMMARY
Novel fiber-reinforced composite materials enable the potential for high performance flywheel energy storage systems. Designing flywheel components capable of realizing this potential is a challenge that heavily relies on simulation driven design. The work presents the Abaqus finite element analysis (FEA) techniques used to successfully design a flywheel assembly capable of operating at more than 35,000 rpm. Strength and compliance behaviors had to be balanced under the rotational inertial loads. This was accomplished by applying a multi-level design optimization approach using the Tosca framework. Rotordynamic analyses of the optimized system were then conducted to determine critical speeds of the system so performance problems associated with these resonances could be avoided when subsequent spin testing is performed.