HELICAL SPRINGS aay armel he Spring Research Association ublished for the Design Council, e British Standards Institution and e Council of Engineering Institutions by Oxford University oe |ENGINEERING DESIGN GUIDES 08 HELICAL SPRINGS prepared by The Spring Research Association on behalf of the United Kingdom Atomic Energy Authority Published for the Design Council, the British Standards Institution, and the Council of Engineering Institutions, in conjunction with the United kingdom ‘Atomic Energy Authority by Oxford University Press {dtorial Advisory Board Des Moule Chaimnan CBE.CEng FANE FRACS. HG, Conway CBEMA HonD Sc Ging FIMeChE FRACS. De. Castod Cg FICE F1Stact CGS, MGons MajorGeneral MUL Gavin CB CBE Copyright (the United Kingdom Atomic Energy Authority 1974 A ighs reserved No part of this publication may be erode ‘Sore aretivalsjtem or transl ev any frm by ary ena ‘dectrnic. mechanical photocopying recorder yor otherwise wit the per permiscea the Lente King Ate nergy Aut The Dessn Counct the Beth Stand Engineer tutions as pansons ingcom Atomic Energy Authonty hav accuracy inal responsi 1048 msttution and the Co Fimset and printed n teat Brita by BAS Panters Lined, Wallop, Hams Contents Introduction Initial design considerations Functional classification Category 1: springs requiring no load measurements Category 2: springs requiring one loadilength measurement Category 3: springs requiring two or more load length measurements, Category 4: springs requiring measurement of rate Selection of materials Carbon steels and alloy steels Stainless steels (nickel-chromium steels) Copper and copper alloys Nickel alloys Other materials for special applications ubleation. and the United tents eae nh the aan Materials to be used in some common environments Corrosive environments Flevated temperatures Low temperatures, Nuclear irradiation Fatigue conditions Working stresses Shot-peening Vapour-blasting and dry honing Static conditions Limiting factors Dynamic loading of springs Spring index Compression springs Tension springs Spring ends Compression springs Tension spring ends Appendix 1: Calculations Notation Basic formulae General relationships for use with compression springs. Relationships for use with tables (see ‘Appendix 3) when desired spring rate is known (compression springs) Natural frequency of vibration Buckling Telescopic and nested springs Example of a design calculation for a compression spring General relationships for use with tension springs Relationships for use with tables (see Appendix 3) when desired spring rate is known (tension springs) Stresses in end hooks (tension springs) Example of a design calculation for a tension spring ‘Appendix 2: Specification Tolerances Heat-treatment Protective finishes Presentation of data Appendix 3: Tables British Standards Ministry of Defence Specifications Bibliography 10 10 10 10 n n " " u n R B B B B uw 4 5 5 15 B 30 30Introduction In order to specify a spring for a particular applica- tion, the designer will normally be aware of the approximate forces and the degree of accuracy required, together with the environmental con- ditions in which the spring must operate. From this basic information itis logical to select a material from which the cheapest spring can be made to provide a satisfactory performance in the given environmental conditions. A maximum, permissible stress can then be determined, which together with the load requirements will enable suitable dimensions to be selected. Details of practical spring calculations and. specifications are given in Appendixes 1 and 2 and extensive tables of spring properties in Appendix 3. Before starting to design a new spring, con- sideration should be given to standard stock commercial springs. However, these should not bbe used where the function is of vital importance or where a full specification for replacement purposes is required, since the material specifica- tions and precise characteristics of commercial springs may be difficult to establish, Most large design organizations set up a ‘bank’ of spring, designs already in production to encourage, wherever possible, the use of existing items. Initial design considerations Where design considerations permit the choice of using a spring either in compression or in tension. the former is to be preferred, because the con: centration of stress which occurs at the ends of tension springs will result in loss of performance. It is strongly recommended that, wherever possible, springs should be designed before the details of housings or other adjacent parts have been finally established. This procedure will mini- mize restrictions on the design of the spring by ensuring that adequate space is allowed for its accommodation Wireshouldbe of circular ratherthan rectangular section, since the only advantages of rectangular section springs are that they can be designed to, give greater volumetric efficiency and that they have superior resistance to buckling Wire of Circular section is cheaper, has a superior surface condition, and is much easier to obtain than that of rectangular section, For maximum volumetric efficiency, nested springs in parallel should be considered. In such cases the solid length, including end coils of the outer spring in a nest, should be slightly greater than that of the inner spring or springs. Adjacent springs should be wound in opposite directions to prevent interference In cases where the deflection is large in relation to the length of housing available, nested springs in series (that is, telescopic springs) may be an. advantage. Functional classification The designer should classify every spring according to its functional requirements into one of the following four categories, putting as many as possible into category 1 since these are the easiest to make, while categories 2, 3, and 4 become progressively more difficult. Category 1: springs requiring no load measurements These are sufficient where the load exerted by the spring is not of great importance and is fixed arbitrarily for design purposes, such as when operating a simple locking plunger. Category 2: springs requiring one loadilength measurement These are adequate where theload at one operating length must fall within definite limits, but where the loads at other deflections are not particularly important. Category 3: springs requiring two or more loadilength measurements These should be used only when accurate control of the load at two or more specific points through: ‘out the operating range is necessary. Category 4: springs requiring measurement ol rate These should be used only when a definite rate is