Abstract

Flywheel energy storage systems impose high demands on the mechanical properties and structural integrity of rotors, particularly in high-speed applications. This study focuses on the numerical analysis of gravity casting of a steel rotor manufactured from low alloy 34CrMo4 steel, with the aim of identifying critical regions related to molten metal flow, solidification behaviour and shrinkage defect formation. Numerical simulations were calculated using a MAGMASOFT® 5.5 software environment based on the finite volume method and included both mold filling and subsequent solidification and cooling stages. Flow stability, temperature field distribution and solidification characteristics were researched thoroughly. The results showed that optimization of the gating and feeding system lowered porosity under 2% within the casting and relocated shrinkage defects to the risers. At the same time, solidification directionality was improved and the Hot Spot value was reduced. From the perspective of casting quality, the proposed design represents the most suitable solution, despite a lower metal utilization rate. The analysed casting forms the structural body of a hybrid flywheel rotor intended for the subsequent integration of high-density tungsten segments.

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