Professional Documents
Culture Documents
4.0 Springs
4.0 Springs
4.0 Springs
Springs
Definition
An elastic machine element, which deflects under the
action of load and returns to its original shape when
the load is removed.
TOPIC: SPRINGS
3/19/2015
Functions
Absorbs shocks and vibrations, e.g. suspensions
Store energy, e.g. Clocks
Measure forces, Weighing balance
Apply forces and control motion, e.g. Springs used in
clutch
Springs Types
3/19/2015
Helical springs
Compression (Open coiled)
Tension/extension (Close coiled)
Torsion
Multi-leaf or Laminated spring
Di
Do =
D
D=
3/19/2015
3/19/2015
Do Di
2
4
3/19/2015
C=
D
d
Compressed
4 12
69
3/19/2015
Preferred values
Solid length
Solid length = N t d
Nt = total number of coils
3/19/2015
3/19/2015
3/19/2015
Recommended clearance
Total clearance 15% of
Gap between adjacent coils as
1 2 mm
Gap between
Total gap = (N t 1) x
adjacent coils
3/19/2015
p=
Free length
N t -1
3/19/2015
10
Number of Coils
Active Coils (N)
The coils in the spring which contribute to spring
action, support the external force and deflect under
the action force
Square
(Nt - 2)
(Nt - 2)
11
3/19/2015
12
3/19/2015
Stress
Helical spring and
equivalent bar
Stress concentration
at bend should be
minimum
3/19/2015
13
14
Stress
Helical spring is made from a bar of equivalent length
When the equivalent bar is bent in the form of helical
coil, addition stresses generated due to two factors
Direct / transverse shear stress in the spring wire
When bar is bent in the form of coil, the length of
inside fibre is less than length of outside fibre,
which results in stess concentration at the inside
fibre of coil.
Resultant stress consist of superposition of torsional
shear stresses, direct shear stress and additional
stress due to the curvature of the coil
3/19/2015
3/19/2015
15
Stress
Based on Torsion theory
1 =
8PD
d3
8 P D 0.5d
8P D
1+
= Ks
3
3
d
D
d
0.5d 0.5
K s = 1 +
= 1 +
D
C
16
3/19/2015
Stress
A M Wahls equation for resultant stress
Deflection
Load deflection relation
8P D
=K
3
d
8 P D3 N
G d4
G Modulus of rigidity
4 C - 1 0.615
K=
+
4C-4 C
k=
17
3/19/2015
18
E=
spring rate
C Spring index
1
P
2
Series combination
Parallel combination
3/19/2015
19
3/19/2015
20
3/19/2015
Sum of forces on
individual springs
Total Deflection of
combination
Sum of deflections
Same and equal
of individual springs
Combined
stiffness, k
1 1 1
= + + ....
k k1 k 2
3/19/2015
k = k1 + k 2 + ....
21
3/19/2015
22
Steel
Patented and cold drawn steel wires (unalloyed)
Oil-hardened and tempered spring steel wires and
valve spring wires (unalloyed)
Oil-hardened and tempered steel wires (alloyed)
Stainless steel spring wires
Non-ferrous materials
Brass
Phosphor bronze
Silicon bronze
Monel
Beryllium-copper
Steel
3/19/2015
3/19/2015
23
Patented &
Cold-drawn
0.85 0.95% C
Grades
High tensile
1. Static / low load
strength
cycle
High elastic limit
2. Mod. load cycles
Ability to withstand
3. High stressed &
high stresses under
dynamic load
repeated loading
4. Severe stress
Unalloyed
oilhardened &
tempered
0.22 - 0.75% C
Excellent surface
finish
Reliable
Temperature limit
Grades
SW Mod. fluctuating
forces and
<100 0C
VW - high fluctuating
and < 80 0C
24
3/19/2015
Steel
Steel
Patented and cold drawn
steel wires
(0.48-0.53% C; 0.80-1.10%
Cr; 0.15%Si)
Steel
wires
Excellent corrosion
resistance
3/19/2015
25
26
Steel
Oil-hardened and
tempered spring steel
wire
Steel
Cost comparison
Spring material
Modulus of rigidity
= 81370 N/mm2
3/19/2015
3/19/2015
27
Cost index
1.0
3.5
1.5
8.5
3/19/2015
4.0
28
3/19/2015
Requirement
Sufficient strength to withstand the external load
Required load deflection characteristics
No buckle under external load
Basic Design Parameters
Wire diameter
Mean coil diameter
Number of active coils
Factor of Safety
Usually
1.5 or low
Reasons for low FoS
As forces are calculated precisely, no need to consider
high FoS for uncertainty in external forces
For compression springs, maximum deflection is limited
by the gap between two coils, which prevents
excessive deflection and stresses
For extension springs, overload stops are provided
Uniform and controlled manufacturing processes at all
stages
29
IS 4454-1981
Procedure - I
1. Estimate maximum spring force (P), corresponding
deflection () and stiffness (k)
2. Select material and calculate permissible stress
0.3Sut
0.5Sut
0.5Sut
3/19/2015
30
0.3Sut
3/19/2015
(8 is good)
4C-4 C
31
3/19/2015
32
3/19/2015
Procedure - I
5. Determine wire diameter
8P D
=K
3
d
6. Determine mean coil diameter
Procedure - I
9. Determine solid length of spring
Solid length = N t d
10. Determine actual deflection
8 P D3 N
=
G d4
11. For spring under maximum load, assume gap
between adjacent coils as 0.5 2 mm, and calculate
total axial gap
D=Cd
3/19/2015
33
3/19/2015
Procedure - I
12. Determine free length of spring
Procedure - I
16. Safety against buckle failure
34
35
3/19/2015
free length
2.6
mean coil diameter
free length
> 2.6
mean coil diameter
[Guide required]
36
3/19/2015
Procedure - II
1. Assume some wire diameter (d)
2. Find out ultimate tensile strength and calculate
permissible stress
3. Find out induced stress
4. Check whether permissible stress is more than
induced stress.
5. If not, increase wire diameter and repeat above
procedure
6. Repeat above procedure till the value of induced
stress comes less than permissible stress
3/19/2015
3/19/2015
37
38
Leaf Springs
Solution
3/19/2015
39
3/19/2015
40
10
3/19/2015
Leaf Springs
n = nf + ng
b
t
41
Graduated leaves
( b )g =
6PL
=
(n g b) t 2
(3n
12 P L
+ 2n g ) bt 2
Full-length leaves
( b )f =
Deflection
42
( b )permissible
3/19/2015
6PL
E (n g b ) t 3
(3n
18 P L
2
f + 2n g ) bt
Deflection (Same)
( b )f = 3 ( b )g
12 P L3
(3n f + 2n g ) Ebt 3
3/19/2015
43
3/19/2015
44
11
3/19/2015
Based on
Load-stress equations
Load-deflection equations
Nominal values
Let,
2L = Span / length of spring
l
Thickness, mm
Width, mm
= 32, 40, 45, 50, 55, 60, 65, 70, 75, 80, 90,
100 and 125
2
Effective length of spring = 2 L l
3
bore diameters, = 19, 20, 22, 23, 25, 27, 28, 30, 32, 35, 38,
mm
50 and 55
3/19/2015
45
3/19/2015
46
No of full
= Ineffective length,
For bands width of band
For U bolts - distance between center of U bolts
No of graduated
nf = 1
Leaves to be cut is n
nf = 2
Leaves to be cut is (n 1)
nf = 2
Effective length
Length of smallest leaf = 1
Ineffective length
(z 1)
Effective length
Leangth of next leaf = 2
Ineffective length
(z 1)
Effective length
Length of (z - 1)th leaf = ( z 1)
Ineffective length
(z 1)
Leaves to be cut is (n 2)
= 2 L + (d + t )2
3/19/2015
47
3/19/2015
48
12
3/19/2015
R=
0 (2R - 0 ) =
l12
8 0
l12
4
0 - camber
R - radius of curvature
l1 - Span of spring = 2L
3/19/2015
49
Usual materials
Steel
55Si2Mn60
50Cr1 or 50Cr1V23
Automobiles
50 Cr 1, 50 Cr 1 V 23, and 55 Si 2 Mn 90
all used in hardened and tempered state
Rail road springs
C 55 (water-hardened),
C 75 (oil-hardened),
40 Si 2 Mn 90 (waterhardened)
55 Si 2 Mn 90 (oil-hardened)
3/19/2015
50
Physical properties
All values are for oil quenched condition and for
single heat only.
- 1.5 is sufficient
Rail roads
- 2 to 2.5
Automobile suspension
Rear springs
2.25 to 2.5
Front springs
3.25 to 3.5
If design considers shock loads
1.25 or 1.5 is sufficient
3/19/2015
51
3/19/2015
52
13
3/19/2015
Importance
Defines limit for working stress for leaf springs and
should not exceed yield stress
Criteria
40 to 50 % of ultimate strength in tension
e.g.
For normal spring steels, working bending stress is
1000 to 1300 MPa, but normal design does not
account for sudden loads, so safe stress used is 600
to 650 MPa
3/19/2015
53
2 ng nf P
n (3n f + 2n g )
3/19/2015
Method
Stresses can be equalized by preloading full length
leaves
Is done by bending leaves to different radii of
curvature
The gap C is called as nip & process is called as
nipping
3/19/2015
54
1. Initial considerations
a. Load on spring and shocks it has to absorb, 2P
b. Span length (based on space available), 2L
c. Deflection,
d. Type of laminated spring, nipping, variable leaf thickness
2. Decide material and select it Endurance Limit, Factor of
safety and find Permissible Bending Stress
3. If both Permissible (b) and is available then using
equations for both calculate b and t.
4. If only permissible (b) then assume nominal thickness (t) for
calculation of b.
5. Decide clamping option (U-bolt / band) and finalize its length
depending on diameter of axle / place where it is mounted.
b =
2 P L3
C=
Enbt 3
Pi =
Why
6PL
n b t2
55
3/19/2015
56
14
3/19/2015
( b )permissible =
6PL
(n g b) t 2
57
11. U-bolt of band will be designed for an initial load (Pi) applied
reduce gap between plates to zero. Both will be under
tension
2 ng nf P
Pi =
n (3n f + 2n g )
Calculate dimension for U bolt or size of the band safe
against initial tensile load Pi
3/19/2015
P
= inclination of plates,
cos usually 45o or can be 0
P
d p b pb =
cos
3/19/2015
58
Pin load =
(2 L) 2
4
59
3/19/2015
60
15
3/19/2015
Components
Consists of a coned disc, resembles like a dinner
plate without a bottom
Also called as
coned disc spring
Applications
Plate clutches & Brakes
Gun recoil mech.
Relief valves
Bolted connections
3/19/2015
61
linear
non-linear
3/19/2015
62
load-deflection
Provides S curve
Useful in application e.g. snap acting mechanism
h/t = 2.1
Series
3/19/2015
63
3/19/2015
Parallel
Series-Parallel
64
16
3/19/2015
do
di
M, C1, C2
E
h (h )t + t 3
P=
2
2
2 do
M (1 ) 2
Axial load, N
Deflection of spring, m
Thickness of washer, m
Free height minus thickness, m
Modulus of elasticity, N/m2
Stress at inside circumference, N/m2
Outer diameter of washer, m
Inner diameter of washer, m
Poissons ratio (0.3 for steel)
Constants
3/19/2015
C1 h + C1t
=
2
2
2 do
M (1 ) 2
65
3/19/2015
66
do
d i 1
6
M =
log e d o d o
d i d i
Constants
do
d i 1
6
C1 =
1
log e d o log e d o
d i
d i
do
d i 1
6
C2 =
2
log e d o
d
i
3/19/2015
67
17