Engineering

Design II

Springs I
- Introduction

www.eng.monash.edu
Mechanical Springs

• Exert Force
• Provide flexibility
• Store or absorb energy

2
 Torsion Springs Torsional Stress : τ =
Tr
J

α
0 0 Torque TL
Torque θ Angular deflection : θ =
L GJ

r
T JG
σs
Spring rate : K = =
θ L

E
Modulus of Rigidity G =
2(1 +ν )

Torsional
Displacement
T θ
= =α
GJ L
3
Torsion Springs

π
For solid round bar : J = I xx + I yy = D4
32

16T
Stress :τ = 3
πd
32TL
Angular deflection : θ = 4
πd G
JG πd 4G
Spring stiffness : k = =
L 32 L

4
Torsion Springs

Spring

Force P

• Only allows for relatively small displacement before

material yields.
• Usually require relatively large loads.
• Generally spring stiffness k is large.
5
Coil springs

• Take torsion spring and coil it into a helix.

• That becomes a coil spring.

Compressive Spring Tensile springs

6
Table 12.1 (p. 476)
Relative Costa of Common Spring Wire of 2-mm (0.079-in.) Diameter
7
Engineering
Design II

Springs II
- Stresses in Springs

www.eng.monash.edu
Stresses in a spring

Spring Index, C=D/d

d

T = FD / 2
T

Tr 16T 8FD
τ= = 3 =
F
J πd πd 3
D

9
Actual stress in a spring

• Add shear force component.

• Increase in stress on the inner side of the coil
because it “twist” more than the outer side. See
next slide
4C − 1 0.615
• Dynamic Loading, Whal Factor K w = +
4C − 4 C
Twist Shear Force
• Static Loading
– can neglect “twist” as it is similar to stress concentration.
– Shear force component also reduced because some yielding
occurs and the load is distributed better.
0.5
KS = 1 +
C
10
Torsional stress distribution in straight versus curved torsion bars. (Note the
increased stress on the inside surface of the curved bar.)
11
Shear stress in springs

Dynamic Loading

8FD 8F
τ= 3
K w = 2 CK w
πd πd

Static Loading

8FD 8F
τs = 3
K S = 2 CK S
πd πd
12
• Assumptions in:
– Bending
– Load eccentricity
– Axial loading

13
Example

• For a spring D=20 mm, d= 2 mm, Find the

shear stress with F=50 N

C = D / d = 10, K w = 1.15
8 FD 8(50)(0.02)
τ= 3
Kw = 3
1.15 = 366 MPa
πd π (0.002)

• If static case, use Ks=1.05

• In some cases, easier to use the alternative
equation: 8F
τ = 2 CK w
πd
14
Engineering
Design II

Springs III
- Spring Stiffness

www.eng.monash.edu
 Spring stiffness d

πD

d
TL
T Angular deflection : θ =
GJ
F πd 4 Fd
J= , T= , L = πD
32 2
D 16 FD 2
∴θ =
Gd 4
Tθ Fδ
T F
Energy = =
2 2
4 F 2 D 3 Fδ
∴ 4
=
Gd 2
Energy θ Energy δ
8FD 3
∴δ =
Gd 4 16
Spring stiffness
• Integrate the deflection for the entire
spring, we get
8FD 3 N E
δ= 4
G=
2(1 + ν )
d G
• Spring stiffness is defined as …
Material properties
F d 4G dG
k= = = E – Young’s modulus
δ 8D N 8 NC 3
3
v – Poisson’s Ratio

17
Example

• For a spring D=20 mm, d= 2 mm, G=79

GPa, find the spring constant

dG (0.002)(79 ×109 )
k= 3
=
8 NC 8(10)(10)3
= 1975 N/m = 1.975 N/mm

18
Engineering
Design II

Springs IV
- Design Considerations

www.eng.monash.edu
20
Allowable static shear stress
Stress level limits are chosen to limit creep to less
than 2%. (creep - the gradual, permanent
deformation of a body produced by a continued
application of heat or stress. )
Presetting - initially coiling the spring longer than
desired and then yielding it to the desired length by
closing it solid.
Solid height is when all coils touch under load.
Max shear stresses associated with force F
corresponding to spring solid:
– τs ≤ 0.45 Su (ferrous - without presetting)
– τ s ≤ 0.35 Su (nonferrous and austenitic stainless - without
presetting)
– τ s ≤ 0.65 Su (ferrous - with presetting
– τ s ≤ 0.55 Su (nonferrous and austenitic stainless - with
presetting)) 21
 Solid

• If sufficient load, spring becomes solid.

Free

δ
Free
Solid
Length
Lf

Ls

22
 Bottoming
Coils more closely spaced

Compressive springs are

sometimes designed this way
so that the coil near the end bottom
out first.
This makes the spring progressively
stiffer
before completely bottoming out.

Coils more sparse

Coils more closely spaced

23
Tension spring design

24
Compression spring design

25
End design
• The four standard end designs
• Solid height Ls, Total No. of turns Nt, and No of
active turns N
• Nt ≈ N+2

26
 Buckling
• Particularly for large
ratios of length to mean
diameter
• Install a cylinder
inside/outside with small
clearance

27
Design of coil springs
• The two basic requirements: stress and spring
rate
• Typically D and d are determined based on
maximum stress level, then N is considered
based on spring rate expected.
• Additional considerations: buckling, length, etc.

28
Design example (J&M 12.1)
• A helical spring is required to exert a force of 60
lb at a length that cannot exceed 2.5 in., and 105
lb at a length that is 0.5 in. shorter. Must fit
inside a 1.5 in diameter hole. Loading is static.
Find a design with ASTM 229 wire.

29
Design example (J&M 12.1)
• Spring rate: k=F/δ=45 lb / 0.5 in =90 lb/in
• 10% clash allowance : 0.1(105 lb/90 lb/in)=0.12 in
• Fsolid = 105 + 90(0.12) =116 lb

30
 Design example (J&M 12.1)
• τs ≤ 0.45 Su (ferrous – w.o. presetting), 225 ksi
assuming 0.1 in diameter ASTM 229 wire
• so τs ≤ 101 ksi Constraints:
8FD 8F
τs = 3
K S = 2 CK S ≤ 101 ksi D + d < 1.5 in
πd πd

• Iterative process for D and d

31
32
 Design example (J&M 12.1)
• Suppose d=0.157 in
8F
τ s = 2 CK S
πd
8(116)
110 ksi = 2
CK S
π 0.157
CK S = 7.89

From diagram (12.4)

Spring index C = 7.3
So D = Cd = 1.15
• D and d determined
33
 Design example (J&M 12.1)
• Spring stiffness

d 4G (0.157) 4 (11.5 ×10 6 )

k= 90 =
8D 3 N 8(1.15) 3 N
• N=6.38 (active turns), Nt=6.38+2=8.38 (total turns)
• Ls=Ntd=1.32 in (solid height)

• Buckling check:
• Lf Free length of the spring: Ls+∆F/k =
Ls+116/90=2.61
• δs /Lf and Lf /D to check buckling (0.49, 2.27)

34
Buckling
• Particularly for large
ratios of length to
mean diameter
• Install a cylinder
inside/outside with
small clearance

35
Engineering
Design II

Springs IV
- Fatigue in Springs

www.eng.monash.edu
Design of Springs for Fatigue Loading
• Compression springs often subject to dynamic
loading
• Recall the fatigue section (reversed torsional)

37
Design of Springs for Fatigue Loading
• Reversal may be incomplete, load to zero then repeated
• Region of interest as shown below

38
Example:
Allowable
Fluctuating
Loads
On
Spring
Wire

Figure 12.16 (p. 487)

Infinite-life fatigue diagram. Pretempered carbon or alloy steel high-duty spring
39
wire, d ≤ 5 mm (0.2 in.).
Shot Peening

• Cold-working treatment with high, velocity

metal beads (shots) to bombard the surface
• Form a compressive layer to resist fatigue
failure

40
Spring Surge

• Occurs when applied 353,000d

frequency is close to or fn =
ND 2
above fundamental
frequency of spring. f n in Hz
• Avoid springs surge by D, d in mm
ensuring the applied N in cycles
frequency is <<
fundamental frequency
of spring.
• For steel springs see
equation 12.11a in J&M.

41
Design example (J&M 12.2D)
• Camshaft rotates 650
rpm, and the follower
results in force on the
spring with a force
between 300 and 600
N
• Spring length range of
25 mm.
• Material ASTM A232
with fatigue strength
shown in Fig 12.16.
• Presetting is to be
used.
42
 Design example (J&M 12.2D)
• With 650 rpm rotation, 1 millions cycles in 26 hours!
• τmin / τmax = 600/300, intersection τmax = 800 Mpa
• Safety factor needed, say 1.1, then τmax = 661 Mpa
• Assume C=10 (possible iterative process)

8F
τ = 2 CK w
πd
8 FCK w
∴d =
πτ
8( 600 )(10 )(1.14 )
=
π ( 661)
= 5 .13 mm (round to 5 mm)
43
Design example (J&M 12.2D)
• With d= 5mm, corresponding CKw=10.82, C can be
found in diagram, Then D=Cd=47 mm

• Spring rate: k=300 N / 25 mm=12 N/mm

d 4G
F dG
k= = =
δ 8D N 8 NC 3
3

dG 5(79,000)
N= 3
= 3
= 4.95
8kC 8(9.4) (12)
L f = Ls + Fsolid / k
353,000d 353,000(5)
• Natural frequency: f n = 2
= 2
= 161.4 Hz
ND (4.95)(47)
44
Other springs

45
Summary
• Based on stress and spring rate, find the proper D and
d and other geometric parameters.
• Without restriction, it results in infinite range of D and
d, but not economical. D/d is suggested to be in the
range of 6-12.
• Buckling check required.
• For fatigue design, the ratio of the min/max loads can
be used to find τmax followed by finding the D/d

46