GTU Paper Analysis

Chapter 3 – Design of Springs

May – 16

May – 17

May – 18

May – 19
Nov – 16

Nov – 17

Nov – 18
Dec – 15
Sr.
Questions
No.

Theory
1. Explain buckling of spring in detail. 04
2. What is nipping in a leaf spring? Discuss its role. 04 04 04 04
3. Explain surge phenomenon in spring. 04 03 01 03
4. When a helical compression spring is subjected to an axial compressive load, 01 01
the stress induced in the wire is
(a) tensile stress (b) compressive stress (c) torsional shear stress (d) bending
stress
5. In leaf springs, the longest leaf is known as 01
(a) lower leaf (b) master leaf (c) upper leaf (d) none of these
6. What is shot peening? 03
7. Define Spring Rate. 01
8. Which type of spring is mostly used in Gramophone? 01
9. What is the function of a spring? In which type of springs the behavior is non- 03
linear?
10. Explain the following terms of the spring: 04
(1) Free Length (2) Spring Rate (3) Spring Index (4) Solid Height.
11. The extension springs are in considerably less use than the compression springs, 03
why?
12. What is helical torsion spring? How does it differ from helical compression 07
spring?

Design of Machine Elements (2151907)

Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
 GTU Paper Analysis
13. Classify and explain springs according to their shapes with neat sketches. 03
14. Prove that equal strength nested springs having the same solid length and 04
deflection would have the same spring index.
15. Why is factor of safety in spring preferred near to unity? 03
16. Explain the stresses induced in compression and tension spring. 04
17. Explain the Belleville spring and its applications. 03
18. Explain the design steps of semi elliptical laminated multi leaf spring. 04
19. Explain leaf spring with neat sketch. 03
20. Explain springs in series and parallel connections with sketch. 04
21. Explain the merits and demerits of Non-circular cross section wire used in spring 04
22. Explain concentric spring and its applications. 03
Examples
1. Design a helical compression spring from the following data: 07
Minimum load = 100 N, Maximum load = 225.6 N,
Compression of spring = 10 mm, Permissible shear stress for spring material =
440 MPa,
Spring end – square and ground ends,
Modulus of rigidity for spring material = 0.80 x 105 MPa.
2. A semi-elliptic leaf spring consists of two extra full length leaves and eight 07
graduated length leaves, including the master leaf. The center to center distance
between the two eyes of the spring is 1 m. The maximum force acting on the
spring is 10 kN and the width of the leaf is 50 mm. The spring is initially
preloaded in such a way that when the load is maximum, the stresses induced in
all the leaves are equal to 350 N/mm2. The modulus of elasticity of the leaf
material is 2.07 x 105 N/mm2.
Determine: (i) The thickness of leaves. (ii) The deflection of the spring at
maximum load.
3. A helical compression spring made of oil tempered carbon steel is subjected to 07

Design of Machine Elements (2151907)

Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
 GTU Paper Analysis
a fluctuating load from 400 N to 1000 N. The spring index is 6 and the design
factor of safety is 1.25. If the yield stress in shear is 770 MPa and endurance
stress in shear is 350 MPa, Find: 1. Size of the spring wire, 2. Diameters of the
spring, 3. Number of turns of the spring, and 4. Free length of the spring. The
compression of the spring at the maximum load is 30 mm. For spring material,
the modulus of rigidity is 80 KN/mm2. Spring ends are square and ground.
4. A semi-elliptical laminated vehicle spring to carry a load of 6000 N is to consist 07
of seven leaves 65 mm wide, two of the leaves extending the full length of the
spring. The spring is to be 1.1 m in length and attached to the axle by two U-bolts
80 mm apart. The bolts hold the central portion of the spring so rigidly that they
may be considered equivalent to a band having a width equal to the distance
between the bolts. Assume a design stress for spring material as 350 N/mm2.
Determine: 1. Thickness of leaves 2. Deflection of spring 3. Diameter of eye 4.
Length of leaves. Take E = 210 KN/mm2, Bearing pressure = 8 N/mm2.
5. The valve of an aircraft engine is operated by a cluster of two concentric 07
springs made of same material. The maximum load on the spring is 6500 N. The
permissible shear stress for the spring material is 625 N/mm2. Assuming spring
index for both springs as 6 and the deflection under the load should not exceed
30 mm. Calculate the main dimensions of the springs. G = 8 ×104 N/mm2. Use
standard coil clearance.
6. A semi-elliptical spring has ten leaves in all, with the two full length leaves 07 07
extending 625 mm. It is 62.5 mm wide and is made of strips 6 mm thick. The
leaves are pre-stressed so as to equalize stresses in all leaves.
7. Design a helical compression spring for a maximum load of 1000 N for a 07
deflection of 25 mm using the value of spring index as 5. The maximum
permissible stress for spring wire is 420 N/mm2, and modulus of rigidity is 84
KN/ mm2.
8. Design a leaf spring for following specification: Total load = 14 tonnes, Numbers 07
of springs supporting the load = 4, Maximum number of leaves = 10, Span of the
spring = 1000 mm, Permissible deflection = 80 mm, Take Young Modulus = 0.2 x
106 N/mm2, Allowable stress in spring material = 600 N/mm2

Design of Machine Elements (2151907)

Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
 GTU Paper Analysis
9. Design a close coiled helical compression spring for a service load ranging 07
from 2250 N to 2750 N. The axial deflection of the spring for the load range is 6
mm. Assume a spring index of 5. The permissible shear stress intensity is 420
N/mm2 and modulus of rigidity, G = 84 kN/mm2.
10. A semi-elliptic leaf spring used for automobile suspension consists of three 07
extra full-length leaves and 15 graduated-length leaves, including the master leaf.
The centre-to-centre distance between two eyes of the spring is 1 m. The
maximum force that can act on the spring is 75 kN. For each leaf, the ratio of
width to thickness is 9:1. The modulus of elasticity of the leaf material is 207000
N/mm2. The leaves are pre-stressed in such a way that when the force is
maximum, the stresses induced in all leaves are same and equal to 450 N/mm2.
Determine (i) the width and thickness of the leaves; (ii) the initial nip.
11. A wagon weighing 1530 Kg mass and moving with a speed of 3 km/hr is to be 07
brought to rest by means of a buffer made of two closed helical springs of
circular section, on each end of wagon. The spring stiffness is 30 kN/mm and
spring index is 6. Maximum permissible shear stress is not to exceed 600
N/mm2. Find the diameter of wire and number of coils in each spring. Take for
spring material G = 8.4 x 104 N/mm2. Check the design for buckling.
12. A laminated spring of an automobile is to carry a load of 5 kN. The spring is 07
made 1000 mm between the supports. Design the spring. Number of leaves to be
taken as 8 with two of them of full length. Distance between U-bolts may be
taken as 60 mm.
13. A spring having outer diameter of coil as 72 mm, deflects for 50 mm at the 07
maximum load of 700 N. Calculate the wire diameter and number of turns for the
spring if the shear stress is 300 MPa and modulus of rigidity 84 KN/mm2. Take
spring index of 8.
14. Design a helical compression spring with plain ends made out of bronze for 07
operating load range of 100 N to 150 N. The deflection of the spring is 6 mm and
spring index = 9. The allowable shear stress for spring is 300 MPa and modulus
of rigidity is 80 KN/mm2. Determine (1) Diameter of spring wire (2) Mean coil
diameter (3) Total number of turns (4) Stiffness of spring
15. Calculate the dimensions of a helical spring for a spring loaded Ramsbottom 07
safety valve from the following data: Valve diameter = 65 mm, Maximum

Design of Machine Elements (2151907)

Department of Mechanical Engineering
Darshan Institute of Engineering & Technology
 GTU Paper Analysis
pressure when the valve blows off freely = 0.73
N/mm2 Valve lift when pressure
rise from 0.7 to 0.73 N/mm2 = 3.2 mm Maximum permissible stress = 500
N/mm2 Spring Index = 6 Modulus of rigidity = 0.85x105 N/mm2.

Design of Machine Elements (2151907)

Department of Mechanical Engineering
Darshan Institute of Engineering & Technology