Suryawanshi et al.

, International Journal of Advanced Engineering Research and Studies E-ISSN22498974

Review Article

CAE ANALYSIS FOR FATIGUE FAILURE FOR COILED

SPRING LIFE ENHANCEMENT IN PRESS MACHINE
STAMPING OPERATION
1

Purushottam Sarjerao Suryawanshi, 2Prof. T. S. Shikalgar, 3Swapnil S. Kulkarni

Address for Correspondence

1

ME-Mechanical Design-2nd yr, 2Professor, D.Y. Patil College of Engineering, Akurdi, Pune
3
Director-Able Technologies India Pvt. Ltd., Pune
ABSTRACT:
Compression springs are coil springs that resist a compressive force applied axially. Compression springs or coil springs
have a spring constant and may be cylindrical springs, conical springs, tapered, concave or convex in shape. The
changing of compression spring ends, direction of the helix, material, and finish all allow a compression spring to meet a
wide variety of special industrial needs. Coil springs can be manufactured to very tight tolerances; this allows the coil
spring to precisely fit in a hole or around a shaft. A digital load tester, or coil spring compression tester can be
used to accurately measure the specific load points in your metal spring. Compression springs are able to have two
entirely different spring rates or a different spring constant associated with its design. Compression springs can be
made from nonmagnetic spring wire like Phosphor Bronze or Beryllium Copper.

INTRODUCTION:
Springs are mainly used in the industry as members
absorbing shock energy as well as for restoring the
initial position of a part upon displacement for
initiating
a
given
function.
Compression
springs are coil springs that resist a compressive
force applied axially. Compression springs may be
cylindrical, conical, tapered, concave or convex in
shape. Coil compression springs are wound in a helix
usually out of round wire.
Every two-wheeler has a provision for a sounding a
horn to be used while communicating so as to warn
the passer-by of the approaching vehicle as well as a
signal for maintaining a safe distance or to
communicate for any other reasons for safety. The
horn is crucial as it is directly related to safety and
the malfunction may evoke secondary claims and
may affect the good-will of the customer.
The horn switch has a helical compression spring at
the base within the assembly to restore the position of
the horn switch once used. Typically, the spring is
subjected to cyclic loading with a maximum expected
frequency of usage at about 10~50 cycles a day.
Considering the design life of a two-wheeler at about
15 years, the spring should withstand a cyclic
compression loading for about a million times. It has
been reported by the warranty/ maintenance
department that frequent complaints are being
received over the failures of these springs well within
their intended life span. The springs must be designed
for reliability. The springs must be designed to
withstand the cyclic loading during operation.
Therefore in this dissertation work it is proposed to
carry out the design and fatigue analysis of
compression spring used for Horn in a two-wheeler
so as to have better performance in terms of longer
life.

Fig-Typical Image of Spring

LITERATURE REVIEW:
1. Reza Mirzaeifar, Reginald DesRoches, Arash
Yavari. In this paper, the pseudoelastic response of
shape memory alloy (SMA) helical springs under
axial force is studied both analytically and
numerically. In the analytical solution two different
Int. J. Adv. Engg. Res. Studies/III/III/April-June,2014/61-63

approximations are considered. In the first

approximation, both the curvature and pitch effects
are assumed to be negligible. This is the case for
helical springs with large ratios of mean coil radius to
the cross sectional radius (spring index) and small
pitch angles. Using this assumption, analysis of the
helical spring is reduced to that of the pure torsion of
a straight bar with circular cross section. A threedimensional
phenomenological
macroscopic
constitutive model for polycrystalline SMAs is
reduced to the one-dimensional pure shear case and a
closed-form solution for torsional response of SMA
bars in loading and unloading is obtained. In the next
step, the curvature effect is included and the SMA
helical spring is analyzed using the exact solution
presented for torsion of curved SMA bars. In this
refined solution, the effect of the direct shear force is
also considered. In the numerical analyses, the threedimensional constitutive equations are implemented
in a finite element method and using solid elements
the loadingunloading of an SMA helical spring is
simulated. Analytical and numerical results are
compared and it is shown that the solution based on
the SMA curved bar torsion gives an accurate stress
analysis in the cross section of the helical SMA
spring in addition to the global loaddeflection
response. All the results are compared with
experimental data for a Nitinol helical spring. Several
case studies are presented using the proposed
analytical and numerical solutions and the effect of
changing different parameters such as the material
properties and temperature on the loadingunloading
hysteretic response of SMA helical springs is studied.
Finally, some practical recommendations are given
for improving the performance of SMA helical
springs used as energy dissipating devices, for
example for seismic applications.
2. Y.Prawoto, M. Ikeda, S.K. Manville, A. Nishikawa.
This paper is a discussion about automotive
suspension coil springs, their fundamental stress
distribution, materials characteristic, manufacturing
and common failures. An in depth discussion on the
parameters influencing the quality of coil springs is
also presented. Following the trend of the auto
industry to continuously achieve weight reduction,
coil springs are not exempt. A consequence of the
weight reduction effort is the need to employ spring
materials with significantly larger stresses compared
to similar designs decades ago. Utilizing a higher
strength of steel possesses both advantages and

Suryawanshi et al., International Journal of Advanced Engineering Research and Studies E-ISSN22498974

disadvantages. The advantages include the freedom

to design coil springs at higher levels of stress and
more complex stresses. Disadvantages of employing
materials with higher levels of stress come from the
stresses themselves. A coils failure to perform its
function properly can be more catastrophic than if the
coil springs are used in lower stress. As the stress
level is increased, material and manufacturing quality
becomes more critical. Material cleanliness that was
not a major issue decades ago now becomes
significant. Decarburization that was not a major
issue in the past now becomes essential. To assure
that a coil spring serves its design, failure analysis of
broken coil springs is valuable both for the short and
long term agenda of car manufacturer and parts
suppliers. This paper discusses several case studies of
suspension spring failures. The failures presented
range from the very basic including insufficient load
carrying capacity, raw material defects such as
excessive inclusion levels, and manufacturing defects
such as delayed quench cracking, to failures due to
complex stress usage and chemically induced failure.
FEA of stress distributions around typical failure
initiation sites are also presented.
3. Abdul Rahim Abu Talib, Aidy Ali, G. Goudah, Nur
Azida Che Lah, A.F. Golestaneh. An automotive
suspension system is designed to provide both safety
and comfort for the vehicle occupants. In this study,
finite element models were developed to optimize the
material and geometry of the composite elliptical
spring based on the spring rate, log life and shear
stress parameters. The influence of the ellipticity
ratio on the performance of woven rovingwrapped
composite elliptical springs was investigated both
experimentally and numerically. The study
demonstrated that composite elliptical springs can be
used for light and heavy trucks with substantial
weight reduction. The results showed that the
ellipticity ratio significantly influenced the design
parameters. Composite elliptic springs with ellipticity
ratios of a/b = 2 had the optimum spring parameters.
4. B. Pyttel, I. Brunner a, B. Kaiser, C. Berger, M.
Mahendran. Long-term fatigue tests on shot peened
helical compression springs were conducted by
means of a special spring fatigue testing machine at
40 Hz. Test springs were made of three different
spring materials oil hardened and tempered SiCrand SiCrV-alloyed valve spring steel and stainless
steel. With a special test strategy in a test run, up to
500 springs with a wire diameter of d = 3.0 mm or
900 springs with d = 1.6 mm were tested
simultaneously at different stress levels. Based on
fatigue investigations of springs with d = 3.0 mm up
to a number of cycles N = 109 an analysis was done
after the test was continued to N = 1.5,109 and their
results were compared. The influence of different
shot peening conditions were investigated in springs
with d = 1.6 mm. Fractured test springs were
examined under optical microscope, scanning
electron microscope (SEM) and by means of
metallographic microsections in order to analyse the
fracture behaviour and the failure mechanisms. The
paper includes a comparison of the results of the
different spring sizes, materials, number of cycles
and shot peening conditions and outlines further
investigations in the VHCF-region.
5. Niels stergaarda, Anders Lyckegaard, Jens H.
Andreasen. The work presented in this paper is
Int. J. Adv. Engg. Res. Studies/III/III/April-June,2014/61-63

motivated by a specific failure mode known as lateral

wire buckling occurring in the tensile armor layers of
flexible pipes. The tensile armor is usually
constituted by two layers of initially helically wound
steel wires with opposite lay directions. During pipe
laying in ultra deep waters, a flexible pipe
experiences repeated bending cycles and longitudinal
compression. These loading conditions are known to
impose a danger to the structural integrity of the
armoring layers, if the compressive load on the pipe
exceeds the total maximum compressive load
carrying ability of the wires. This may cause the
wires
to buckle in the circumferential pipe direction, when
these are restrained against radial deformations by
adjacent layers. In the present paper, a single
armoring wire modeled as a long and slender curved
beam embedded in a frictionless cylinder bent into a
toroid will be studied in order to gain further
understanding of this failure mode. In order to study
the compressive behavior, both perfect beams as well
as beams with small geometrical imperfections are
studied. The mathematical formulation of the
problem is based on curved beam equilibrium and
allows large deflections to be taken into calculation.
PROPOSED WORK:
In this dissertation work it is proposed to Conduct
Analysis for the compression spring using CAE
(Nastran/ Ansys/ MSC Fatigue or equivalent),
Propose new Design and Validate the Design through
trials and testing of the Compression Spring for
fatigue failure. The above said work is planned in
following phases.
Phase I - Review the Design for the existing
compression spring.
To understand the previous work done, various
results obtained by researchers and scientists.
Phase II - Conduct Analysis for the compression
spring using CAE.
Analysis of the spring model using FEA (Fatigue)
will be carried out using suitable softwares like
Nastran/ Ansys/ MSC Fatigue or equivalent.
Phase III - Propose new Design by considering the
factors affecting fatigue life.
New design of the compression spring will be
proposed by taking into account the results for
analysis. The change could be proposed in any of the
forms as Change in Material, Change in
Manufacturing process for the spring, Change in
boundary conditions of the spring, Change in the
geometry (specs) or Use of a co-axial spring etc.
Phase IV - Validation of the Design through trials
and testing of the Compression Spring for fatigue
failure:
Fatigue testing SPM (Special Purpose Machine)
would be deployed for testing the revised design of
the spring. This setup would offer cyclic loading with
a preset load of 0.2 to 0.5kg (simulating the normal
higher load offered by the thumb of a human being).
The frequency for compression and decompression
would be set at 1sec. If any, the dwell time could be 0
to 1 sec for activating the next cycle. This would be
repeated for one million cycles. The trials are
conducted in a very controlled environment with
focus on the variables influencing the fatigue life.
The trial runs are conducted to ensure consistency/
repeatability of the spring behavior. The virtual
validation of the spring (simulation using software)

Suryawanshi et al., International Journal of Advanced Engineering Research and Studies E-ISSN22498974

should address the given problem during the design

selection stage. While the spring is made available in
the physical form, the trials and testing would address
the phase of validation.

Fig-Experimental Setup
Since the cycle time is 1 sec with a maximum dwell
of 1 sec, the total testing time using the physical
setup should not take more than three weeks after
complete test setup is ready.
REFERENCES:
1.

2.

3.

4.

5.

Reza Mirzaeifar, Reginald DesRoches, Arash Yavari.

George W. Woodruff School of Mechanical Engineering,
Georgia Institute of Technology, Atlanta, GA 30332, USA,
School of Civil and Environmental Engineering, Georgia
Institute of Technology, Atlanta, GA 30332, USA. A
combined analytical, numerical, and experimental study of
shape-memory-alloy helical springs. International Journal
of Solids and Structures 48 (2011) 611624.
Y. Prawoto, M. Ikeda, S.K. Manville, A. Nishikawa. NHK
International Corporation, 50706 Varsity Court, Wixom, MI
48393, United States. NHK Spring Corporation, 3-10
Fukuura Kanazawa-ku, Yokohama 236-0004, Japan.
Received 23 July 2007; accepted 19 November 2007,
Available online 21 February 2008. Design and failure
modes of automotive suspension springs. Engineering
Failure Analysis 15 (2008) 11551174.
Abdul Rahim Abu Talib, Aidy Ali, G. Goudah, Nur Azida
Che Lah, A.F. Golestaneh. Department of Aerospace
Engineering, University Putra Malaysia, 43400 UPM,
Serdang, Selangor, Malaysia. Department of Mechanical
and Manufacturing Engineering, University Putra Malaysia,
43400 UPM, Serdang, Selangor, Malaysia. Developing a
composite based elliptic spring for automotive
applications. Materials and Design 31 (2010) 475484.
B. Pyttel, I. Brunner a, B. Kaiser, C. Berger, M. Mahendran.
State Materials Testing Institute and Institute for Materials
Technology, Technische Universitt Darmstadt, Grafenstr.
2, 64283 Darmstadt, Germany. Department of Metallurgical
and Materials Engineering, Indian Institute of Technology,
Kharagpur 721 302, India. Fatigue behaviour of helical
compression springs at a very high number of cycles
Investigation of various influences. International Journal of
Fatigue xxx (2013) xxxxxx.
Niels stergaarda, Anders Lyckegaard, Jens H. Andreasen.
NKT-Flexibles/Aalborg University,
Department
of
Mechanical and Production Engineering, Denmark. NKTFlexibles, Priorparken 480, Brndby, Denmark. Department
of Mechanical and Production Engineering, Aalborg
University, Denmark. Imperfection analysis of flexible
pipe armor wires in compression and bending. Applied
Ocean Research 38 (2012) 4047.

Int. J. Adv. Engg. Res. Studies/III/III/April-June,2014/61-63