A Project Report

On
DESIGN AND ANALYSIS OF A COIL SPRING FOR DIFFERENT
MATERIALS USING ANSYS.
Submitted to
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY
ANANTAPUR
In partial fulfillment of the requirements for the award of the degree of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted by
G.JEENESH REDDY (17691A0370)
S.PRASHANTH KUMAR (17691A03D0)
K.PAVAN KUMAR (17691A03C2)
SHAIK MUJAHID MOHAMMED(17691A03A4)
SHAIK JAMEEL (17691A0369)

Under the Guidance of

Dr.T.Arun Nellaiappan
Sr.Assistant Professor
Department of Mechanical Engineering

DEPARTMENT OF MECHANICAL ENGINEERING

MADANAPALLE INSTITUTE OF TECHNOLOGY & SCIENCE
(UGC - AUTONOMOUS)
(Affiliated to JNTUA, Ananthapuramu)
An ISO 9001:2008 Certified Institution, Accredited by NBA
ANGALLU, MADANAPALLE
2020 - 2021
 DECLARATION
by the B.Tech. Student

I/We hereby declare that the Project Work Report entitled Design and Analysis of
a Coil Spring for different Materials Using Ansys which is being submitted to the
Madanapalle Institute of Technology and Science, Madanapalle for the award of
the Degree of Bachelor of Technology in MECHANICAL ENGINEERING is a
bonafide report of the work carried out by us. The material contained in this Project
Work Report has not been submitted to any University or Institution for the award
of any degree.
Name Register number Signature of the Student(s):
(1) G.Jeenesh Reddy - (17691A0370)
(2) S.Prashanth Kumar - (17691A03D0)
(3) K.Pavan Kuamar - (17691A03C2)
(4)Shaik Mujahid Mohammed - (17691A03A4)
(5) Shaik Jameel - (17691A0369)

Department of Mechanical Engineering.

Place: MITS, Madanapalle

Date:27-07-2021
 Ph.08571-280255,280590 Fax: 08571-280433
MADANAPALLE INSTITUTE OF TECHNOLOGY & SCIENCE
(UGC – AUTONOMOUS)
An Engineering College Sponsored by
RATAKONDA RANGA REDDY EDUCATIONAL ACADEMY
Approved by AICTE, New Delhi and Affiliated to JNTUA, Anantapur
An ISO 9001:2008 Certified Institution
P.B.No-14, Angallu, Madanapalle -517325, Chittoor District, A.P.
www.mits.ac.in

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

Certified that this project report titled “Design and Analysis of a Coil Spring for

different Materials Using Ansys” is the bonafide work of G.Jeenesh Reddy, S.Prashanth
Kumar, K.Pavan Kumar,Shaik Mujahid Mohammed, Shaik Jameel bearing Hall Ticket
Numbers 17691A0370,17691A03D0,17691A03C2,17691A03A4,17691A0369 who carried out
the project under our supervision. Certified further, that to the best of our knowledge the work
reported herein does not form part of any other project report or dissertation on the basis of which
a degree or award was conferred on an earlier occasion on this or any other candidate.

PROJECT GUIDE HEAD OF THE DEPARTMENT

Dr.T.Arun Nellaiappan Dr. T V V L N Rao,Ph.D
Sr.Assistant Professor Professor & Head
Dept. of Mechanical Engineering, Dept. of Mechanical Engineering,
MITS, MITS,
Madanapalle. Madanapalle.

Date: 27/07/21 Examiner 1.

Place:MADANAPALLE Examiner 2.
 Department of Mechanical Engineering
PLAGIARISM VERIFICATION CERTIFICATE
This is to certify that the B. Tech Project report titled, “A PROJECT ON STUDY OF
CEMENT PLANT PRODUCTION AND IMPORTANCE OF ALTERNATIVE
FUELS IN CEMENT INDUSTRY” submitted by G.Jeenesh Reddy(17691A0370),
S.Prashanth Kumar(17691A03D0), K.Pavan Kumar(17691A03C2),Shaik Mujahid
Mohammed(17691A03A4),Shaik Jameel(17691A0369) has been evaluated using online
plagiarism checker and based on the analysis report generated by the faculty, the reports
similarity index is found to be 13 % for the dissertation consisting of 54 pages.

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Signature of Guide
 ACKNOWLEDGEMENT

We sincerely thank the MANAGEMENT of Madanapalle Institute of

Technology and Science for providing excellent infrastructure and lab facilities that
helped me to complete this project.
We sincerely thank Dr. C. Yuvaraj, Principal for guiding and providing facilities for the
successful completion of our project at Madanapalle Institute of Technology and
Science, Madanapalle.
We express our deep sense of gratitude to Dr. T V V L N Rao, HOD of Mechanical
Engineering for his valuable guidance and constant encouragement given to us during this
work.
We express our deep gratitude to my guide Dr. T.Arun Nellaiappan, Sr.Assistant
Professor, Department of ME for his guidance and encouragement that helped us to
complete this project.
We express my deep sense gratitude to Dr. R. Prithivirajan, Project Coordinator for
their guidance and encouragement that helped us to complete this project.
We also wish to place on record my gratefulness to other Faculty of ME Department and
also to our friends and our parents for their help and cooperation during our project work.
 Abstract
A coil spring is a mechanical device which is typically used to store energy and
subsequently release it, to absorb shock, or to maintain a force between contracting surface. They
are made of an elastic material formed into the shape of a helix which returns to its natural length
when unloaded. The purpose of this project is comparative study and analysis of a coil spring with
three different materials ( Stain less steel, Phosphor bronze, Chrome vanadium). Static analysis is
done using ANSYS 18.1 to determine the optimum material to reduce the stress and deflection.
The modelling of spring is developed on CATIA V5R21 and analysis is carried out on
ANSYS 18.1 and further is to check the feasibility of coil spring by changing the dimensions for
wire diameter, pitch, number of coils.The comparative study has been made with optimum material
by varying pitch , number of coils and wire diameter.
The results and comparative study shows the optimum material that can be selected as
spring material for efficient function and long life. A 3D printed spring is also developed with PLA
( poly Lactic Acid) material. A reduced such size model of coil spring is being printed using 3D
printing technology.
CONTENTS
S. No Name Page No.

LIST OF FIGURES i

LIST OF TABLES ii

ABSTRACT

1. INTRODUCTION 01-06

1.1 Introduction to springs

1.2 Types of springs

1.2.1 Helical springs

1.2.2 Conical and Volute springs

1.2.3 Torsion springs

1.2.4 Disc springs

1.2.5 Special purpose springs

1.2.6 Leaf springs

1.3 Applications of coil spring

1.4 Materials for Coil spring

2. LITERATURE REVIEW 07-08

3. DATA COLLECTION 09

3.1 Design calculation of coil spring

4. DESIGN OF COIL SPRING USING CATIA V5 10-15

4.1 Introduction to CATIA

4.2 Design of Coil Spring in CATIA V5 Software

4.2.1 Design Steps

5.ANALSYS OF COIL SPRING BY USING ANSYS 16-29

5.1 Introduction To FEM

5.2 Finite Element Analysis Procedure

 5.3 FEA Processor

5.4 Applications of Finite Element Analysis

5.5 Advantage of Finite Element Analysis

5.6 Limitations of finite elements analysis

5.7 Introduction to Ansys

5.8 Introduction to Static Analysis

5.9 Overview of Sequential Operations in Static Analysis

5.9.1 Building the mode

5.10 Stastic Analysis Of a Coil Spring

5.11 Analysis Procedure

5.11.1 Engineering Data

5.11.2 Geometry

5.11.3 Modeling

5.11.4 Meshing and setup

5.11.5 Solution

5.11.5.1 Equivalent Stress

5.11.5.2 Equivalent Strain

5.11.5.3 Total Deformation.

6. RESULTS AND DISCUSSIONS 31-52

6.1 Stainless Steel

6.2 Inconel 600(Nickel chromium Alloy)

6.3 Chrome Vanadium

6.4 Analysis of the coil Spring by Comparing .

7. VALIDATION OF RESULTS 52-53

8. CONCLUSION AND SCOPE FOR FUTURE WORK 54

BIBLIOGRAPHY
 LIST OF FIGURES
Figure. No. DESCRIPTION Page No.

1.1 Helical Spring 02

1.2 Conical and Volute Spring 03

1.3 Torsion Spring 03

1.4 Disc Spring 04

1.5 Special Purpose Spring 04

1.6 Semi Elliptical Leaf Spring 05

4.1 Flow chart of design of Coil spring 13

4.2 Design of coil spring in 2D format 14

4.3 Converting of 2D model to 3D model 14

4.4 3D model of coil spring 15

4.5 Shelling (material removal) 15

5.1 FEA(Finite element analysis) process 18

5.2 Flow diagram of static analysis 22

5.3 Analysis procedure 24

5.4 CATIA model imported to ansys 26

5.5 Meshing of the coil spring 27

6.1 Total deformation for structural steel 30

6.2 Equivalent (von mises) stress for stainless steel 30

6.3 Equivqlent elastic strain for stainless steel 31

6.4 Total deformation for Inconel 600 31

6.5 Equivalent (von mises) stress for Inconel 600 32

6.6 Equivqlent elastic strain for Inconel 600 32

Figure. No. DESCRIPTION Page No.

6.7 Total deformation for chrome vanadium 33

6.8 Equivqlent (von mises) stress for chrome vanadium 33

6.9 Equivqlent elastic strain for chrome vanadium 34

6.10 Simulated Model result figures for different models 36-51

8.1 Stereo lithography (SLA) 55

8 .2 Selective laser sintering (SLS) 56

8.3 Fused Deposition Modeling 57

8.4 ABS Filament (Acrylonitrile Butadiene Styrene) 59

8.5 PLA Filament (Poly Lactic Acid) 59

8.6 PET Filament 61

8.7 Nylon Filament 62

8.8 PVA Filament 63

8.9 The structure of a typical 3D printer 64

8.10 Global Pramaan 200 3D printer 67

8.11 PLA (Polylactic Acid) coil spring 3D printing 71

i
 LIST OF TABLES
Table No. DESCRIPTION Page No.

5.1 Properties of Stainless steel , Inconel 600 and Chrome vanadium 25

6.1 Comparison with stainless steel with Inconel 600 with chrome vanadium 34

6.2 Combinations of different models created in CATIA by varying wire 35

diameter
6.3 Comparison of results 40

6.4 Combinations of different models created in CATIA by varying No. of coils 41

6.5 Comparison ofresults 46

6.7 Comparison of results 51

6.8 Validation of results 52

 Chapter 1
INTRODUCTION
1.1 INTRODUCTION TO SPRINGS
Suspension is the system of tires, tire air, springs, shock absorbers and
linkages that connects a vehicle to its wheels and allows relative motion between the two.
Suspension systems serve a dual purpose, contributing to the vehicle's road holding, handling
and braking for good active safety and driving pleasure, and keeping vehicle occupants
comfortable and a ride quality reasonably well isolated from road noise, bumps, vibrations, etc.

The helical springs are made up of a wire coiled in the form of a helix and are primarily
intended for compressive or tensile loads. The cross-section of the wire from which the spring
is made be circular. The helical springs are said to be closely coiled when the spring wire is
coiled so close that the plane containing each turn is nearly at right angles to the axis of the helix
and the wire is subjected to torsion.In other words, in a closely coiled helical spring, the helix
angle is very small, it is usually less than 10 degrees. The major stresses produced in helical
springs are shear stresses due to twisting. The load applied is parallel to or along the axis of the
spring. In open coiled helical springs, the spring wire is coiled in such a way that there is a gap
between the two consecutive turns, as a result of which the helix angle is large.

When a vehicle is traveling on a level road and the wheels strike a bump, the
spring is compressed quickly. The compressed spring will attempt to return to its
normal loaded length and, in so doing, will rebound past its normal height, causing the body
to be lifted. The weight of the vehicle will then push the spring down below its normal loaded
height. This, in turn, causes the spring to rebound again. This bouncing process is repeated
over and over, a little less each time, until the up-and-down movement finally stops. If
bouncing is allowed to go uncontrolled, it will not only cause an uncomfortable ride but will
make handling of the vehicle very difficult.

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 Helical springs are generally used in two different applications. The first is the role of
compression spring which offers resistance to forces moving two components towards each
other. Typical applications are car suspension and matters spring. Compression springs typically
have their ends end and allowing for easy mounting. The second common use for helical spring
is as a tensioning element. Springs used in this role resists forces moving in two objects away
from each other. A couple of common tension spring applications include spring scales and
automatic door closers.
1.2 TYPES OF SPRINGS
1. Helical Springs
2. Conical and Volute Springs
3. Torsion Springs
4. Disc Springs
5. Special Purpose Springs
6. Leaf Springs
1.2.1 Helical Springs
The helical springs are made up of a wire coiled in the form of a helix and is primarily
intended for compressive or tensile loads. The cross-section of the wire from which the spring
is made may be circular, square rectangular.

Fig.1.1 Helical Spring

1.2.2 Conical and Volute Springs
The conical and volute springs are used in special applications where a telescoping

Page3
spring or a spring with a spring rate that increases with the load is desired.

Fig.1.2 Conical or Volute spring

1.2.3 Torsion Springs
These springs may be of helical or spiral type. The helical type may be used only in
applications where the load tends to wind up the spring and are used in various electrical
mechanisms. The spiral type is also used where the load tends to increase the number of coils
and when made of flat strip are in watches and clocks.

Fig.1.3 Torsion Springs

1.2.4 Disc Springs
These springs consist of a number of conical discs held together against slipping by a
central bolt or tube. These springs are used in applications where high spring rates and compact
spring units are required. The major stresses produced in disc springs are tensile and

Page4
compressive stresses.

Fig.1.4 Disc Spring

1.2.5 Special Purpose Springs
These springs are air or liquid springs, rubber springs, ring springs etc. The fluids (air
or liquid) can behave as a compression spring. These springs are used for special types of
applications only.

Fig.1.5 Special Purpose Springs

1.2.6 Leaf Springs
Aspringisdefinedasanelasticbody,whosefunctionistodistortwhenloadedandto recover
its original shape when the load is removed. Springs are elastic bodies that can be twisted,
pulled or stretched by some force. They can return to their original shape when the force is
released. Leaf spring (also known as flats springs)is made out off latplate.

Page5
 Fig.1.6 Semi elliptical leaf spring
.3 PPLICATIONS OF COIL SPRING

⚫ To absorb and modify the energy caused due to vibrations and shocks in automobile
suspension system , vibration dampers , flexible coupling, etc.

⚫ To store energy in kick starters , clocks, toy motors, etc.

⚫ To exert or apply force in spring loaded valves, brakes, clutches, etc.

⚫ To calculate or measure forces in measuring, instruments spring balance, engine

indicators, etc.

⚫ To control relative motion between two connected members in valve springs , cams and
followers.

1.4 MATERIALS FOR COIL SPRING

1.4.1 STAINLESS STEEL

The use of stainless steel has increased considerably in recent years. Several new
compositions are now available to withstand corrosion. All of these materials can be used for
high temperature up to 650 F.

CHEMICAL COMPOSITION OF STAINLESS STEEL

⚫ 16.0 - 18.0 % Cr,

⚫ 10.0 - 14.0 % Ni,

⚫ 2.0 - 3.0 % Mo.

Page6
1.4.2 INCONEL 600 ( NICKEL CHROMIUM ALLOY)

This material belongs to the family of nickel-chromium based super alloys .

Inconel alloys are oxidation - corrosion- resistant materials well suited for service in
extreme environments subjected to pressure and heat and have good stress corrosion
cracking resistance property in both room temperature and high temperature.

CHEMICAL COMPOSITION OF INCONEL 600

⚫ 70.0 - 72.0 % Ni,

⚫ 14.0 - 17.0 % Cr,

⚫ 6.0 - 10.0 % Fe.

1.4.3 CHROME VANADIUM

The alloy spring steels have a definite place in the field of spring materials, particularly for
conditions involving high stress and for applications where shock or impact loading occurs.

CHEMICAL COMPOSITION OF CHROME VANADIUM

⚫ 0.48 - 0.53 % C,

⚫ 0.80 - 1.10 % Cr,

⚫ 0.15 - min % V.

Page7
 Chapter2
LITERATUREREVIEW

Before starting any dissertation work, the literature review of the topic is must,
because it helps us in knowing the amount of work that has been done int hat topic by the
different researchers. It also helps us in doing the further work by taking the reference of the
previous work done in the best possible way.
[1] K.Vinay Kumar et.al. used three different materials like alloy steel, chromium
vanadium steel; stainless steel was used with a constant load of 850N. Among the above
materials alloy steel material gave the better stress and deformation values. Mostly prefer
alloy steel material for bike suspension spring due it its material stability and ductility by
observing those analysis stress and deformation values. Alloy steel material is staying stable
up to load 2550N. Later, by increasing loads the stress was crossing the yield strength of the
material due to that the breaking of spring will be takes place. Therefore, from the above
practical result alloy steel material is more stable and gives good efficiency compared to other
two materials.
[2] Prince Jerome Christopher et.al. designed a Shock Absorber used for 160 cc bike
and they have modeled it by using 3D parametric software, Pro/Engineer. The shock absorber
design is modified by reducing the diameter and stress analysis is performed. The stress value
is lesser in the designed spring then in original which adds an advantage to the design. By
comparing the results in the table they could analyze that the modified spring has reduced in
weight and is safe.
[3] N.Lavanyaet.al.Discussed about the vonmises stress and strain induced in
chromium vanadium steel and low carbon structural steel in various condition. The total
mechanical stress and strain values obtained for chromium vanadium is best suitable for the
production of helical spring when compared with the low carbon structural steel.
[4] Logavigneshwaran et.al. Redesigned that the stress acting on the shock absorber is
reduced. The proposed redesign will reduce the deformation an induced stress magnitude for
the same applied loading conditions when compared with the existing design. This in turns
increases the life of shock absorber by reducing its failures. The analytical result conforms to
the simulation result from the ANSYS.
[5] Chang-Hsuan Chiu, Chung-Li Hwan, Han-Shuin Tsai and Wei-Ping Lee have
conducted the experiment on mechanical behavior of helical composite springs.They have
made the springs with different material like, unidirectional laminates, rubber core

Page8
unidirectional laminates, unidirectional laminates with a braided outer layer, and rubber core
unidirectional laminate with a braided outer layer.

[6] P.K. Mallick has fabricated and conducted the performance test for the composite
elliptic spring. The composite leaf springs are successfully used in the suspension of the light
vehicles. The fibers used in these are unidirectional E-glass due to their high extensibility,
toughness and low cost. The composite leaf spring is designed and analyzed using ansys. The
results showed that an optimum spring width decreases hyperbolically and the thickness
increases linearly from the spring eye towards the axle seat. Compared to steel springs the
optimized composite spring has strength that are much lower, the natural frequency is high
and the spring weight is nearly 80% lower.
[7] D. Abdul Budan and T.S. Manjunatha has investigated the use of different
composite material in helical coil spring of suspension system and other automotive
applications. In all of the above research papers it has been observed that the application of
composite materials has been limited to light weight vehicles. An effort has been made by
the author to prepare a solution for application of composite materials in regular vehicle.
[8] Vijayeshwar BV. et al. [1] In this research paper they evaluated the manufacturing
of helical coil suspension springs as per requirement. The objective of this work is a
comparative study and analysis of suspension helical coil spring with two different materials
like Chrome Silicon and Hard drawn carbon steel. They designed the shock absorber model
using Pro/E Creo 2.0 and analysis of stress and deflection they used ANSYS 15.0. After the
theoretical and ANSYS results shows that Chrome silicon spring steel is the optimum suitable
material with low weight and high stiffness for helical spring applications like mono shock
suspensions in bikes and many more.

Page9
 Chapter-3
DATA COLLECTION

3.1 DESIGN CALCULATION OF COIL SPRING

The functions of springs are absorbing energy and release this energy according to the
desired functions to be performed. Socoil springs design depends on load carrying capacity
and deflection.
Hence the100 CC bike is considered for design of Coil spring.

For the given coil spring

Wire diameter of the spring d = 7 mm.
Total No. of coils N = 16
Free length L = 200 mm
Mean coil diameter of the spring D = 43 mm
Outer diameter of the spring Do = 50 mm
Inner diameter of the spring Di = 36 mm
Pitch p = 12 mm

Weight of the bike = 125 kgs

Let weight of 1 person = 75 Kgs
Weight of 2 persons = 75 x 2 =150 Kgs
Weight of bike + 2 persons = 275 kgs
Load applied on the spring P = mg
= 275 * 9.81
= 2700 N

Spring index C = D/d

= 43/7
= 6.14

Wahl factor K = (4C-1/4C-4)+(0.615/C)

= 1.145 + 0.100
= 1.245

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 Chapter-4

DESIGN OF COIL SPRING USING CATIA V5

4.1 INTRODUCTION TO CATIA

• Work bench

The Sketcher workbench is a set of tools that helps you create and constrain 2Dgeometries.
Features (pads, pockets, shafts…etc) may then be created solids or modifications to solids using
these 2D profiles. You can the Sketcher workbench in various ways.

Two simple ways a e by using the top pull down menu (Start – Mechanical Design – Sketcher),
or by selecting the Sketcher icon. When you enter the sketcher.

CATIA requires that you choose a plane to sketch on. You can choose this plane either before
or after you select the

Sketcher icon

To exit the sketcher, select the Exit Work bench icon. The Sketcher workbench contains the
following standard workbench specific toolbars.

• Profile toolbar

The command in this toolbar allow you to create simple geometries (rectangle,
circle, line, etc...) and more complex geometries (profile, spline, etc...).

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⚫ Operation toolbar

Once a profile has been created, it can be modified using commands such as trim,
mirror, chamfer, and Operation toolbar.

Constraint toolbar

Profiles may be constrained with dimensional (distances or geometrical,

tangent, parallel, etc...) constraints using the commands located in he Constraint
toolbar.

• Sketch tools toolbar

The commands in this toolbar allow you to work in different modes which make
sketching easier.

• User Selection Filter toolbar

Always out activate different selection filters.

• Visualization toolbar

allows out among other things to cut the pat by the sketch plane and choose
lighting effects and other factors that influence how the part is visualized

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The Sketch tools Toolbar

The Sketch tools toolbar contains icons that activate and deactivate different work
modes. These work modes drawing2Dprofiles.Reading from left to right, the toolbar
contains the following work modes.(each work mode is active each work mode is active
if the is orange and inactive if it is blue)

(Active if the icon is orange and inactive if it is blue.)

• Snap to Point

If active, your cursor will snap to the intersections of the grid lines.

• Construction / Standard Elements

You can draw two different types of elements in CATIA a standard element and a
construction element. A standard element (solid line type) will be created when
the icon is inactive (blue).

It will be used to create a feature in the Part Design workbench. A construction

element (dash edit line type) will be created when the icon is active (orange).

They are used to help construct your sketch, but will not be used to create features.

• Geometric Constraints

When active, geometric constraints will automatically

• Dimensional constraints

when active dimension constraints will automatically be applied when corn(fillets)

or chamfer are created or when quantities are entered inhe value field is a place
where dimensions such as line length and angle are manually entered

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 4.2 DESIGN OF COIL SPRING IN CATIA V5 SOFTWARE

Design of Coil Spring in CATIA V5 software by using the profile tool bar. Design
of the spring is in the 1 : 1 dimensions.

Convert into 2D to 3D by using the CATIA V5 software

4.2.1 Design steps

Open CATIA v5 software

Start

Mechanical design

Part design

Draw the coil spring according to the dimensions

Rib

Pocket

Shelling with thickness 1mm at the end

Save the file into STL form

Page14
 Fig.4.1 flow chart of design of coil spring

Fig.4.2 Design of coil spring in 2d format

Fig.4.3 Converting of 2D model to 3D model

Page15
 Fig.4.4 3D model of coil spring

Fig.4.5 Shelling (material removal of coil spring at the end )

Final completing part will be save into the stl( standard triangle language), and also
Save in the form of the CATIA format.

This CATIA file will be imported to ansys for analysis purpose .

Page16
 CHAPTER-5

ANALYSIS OF SPRING BY USING ANSYS 18.1

5.1 INTRODUCTION TO FEM

Finite element method (FEM) has become one of the most widely used techniques, for
analyzing mechanical loading characteristics in modern engineering components. Traditional
analysis techniques can only be satisfactorily applied to a range of conventional component
shapes and specific loading conditions.

Unfortunately, the majority of engineering loading situations are not simple and straight
forward therefore the traditional techniques often need to be modified compromised to suit
situations for which they were not intended.

The uncertainty thus created, commonly leads to the designer applying excessively high
factor of safety to the mechanical loads and so to over design components by specifying either
unnecessarily bulky cross sections or high quality materials, inevitably the cost of the product
is adversely affected.

Finite element method is one of the numerical methods that process certain
characteristics that take advantage of special facilities, offered by the high speed computers.

In particular the finite element method can be systematically programmed to

accommodate such complex and difficult problems as non homogeneous materials, nonlinear
stress strain behavior and complicated boundary conditions.

Ansys Inc. is an American public company based in Canonsburg, Pennsylvania. It

develops and markets engineering simulation software. Ansys software is used to design
products and semiconductors, as well as to create simulations that test a product's durability,
temperature distribution, fluid movements, and electromagnetic properties.

Ansys was founded in 1970 by John Swanson. Swanson sold his interest in the company
to venture capitalists in 1993. Ansys went public on NASDAQ in 1996. In the 2000s, Ansys
made numerous acquisitions of other engineering design companies, acquiring additional
technology for fluid dynamics, electronics design, and other physics analysis.

Page17
5.2 FINITE ELEMENT ANALYSIS PROCEDURE

The Basic steps involved in the Finite Element Analysis are

Step 1

The finite element method is based on the concept of discretization.

The first step is modeling, descretization of the given domain using finite elements of
different types, shapes and orders.

Step 2

The second is approximation of field variables over each element domain.

Step 3

After approximating the field variables the element matrix is generated.

Step 4

The fourth step involves the assembly of element matrices.

Step 5

After assembling the element matrices the boundary conditions are defined. The fifth
step involves imposition of boundary and constraint conditions.

Step 6

The sixth step is solution of global matrix equations.

Step 7

Post processing of the results is performed in step seven.

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5.3 FEA PROCESSOR

Physical problem
(Modeling)

FEM
(Generates nodes, elements, Pre
B.C’s, material properties, processe
loads, data files r

FEA Solver
(Generates element matrices,
compute nodal values and
derivatives and store results)

Analyze results
=
(Display curves, contours,
Post
deformed shapes ) processor

Fig .5.1 FEA processor

5.4 APPLICATIONS OF FINITE ELEMENT ANALYSIS

Finite element analysis is used in various applications in various disciplines.

Some of the applications are:

➢ Structural strength design

➢ Structural interaction with fluid flow

Page19
 ➢ Analysis of shock

➢ Acoustics

➢ Thermal analysis

➢ Vibrations

➢ Crash simulations

➢ Fluid flows

➢ Electrical analysis

➢ Mass diffusion etc.

5.5 ADVANTAGES OF FINITE ELEMENT ANALYSIS

➢ Avoid the creation of expensive prototype modeling.

➢ Economy in terms of time and money.

➢ Very complex model can be solved with greatest ease.

➢ Any change in the model can be easily incorporated.

➢ Helps in optimization of the product.

➢ Any type of optimization can be performed.

➢ Extension graphic capabilities.

5.6 LIMITATIONS OF FINITE ELEMENT ANALYSIS

• This method is an approximate one and does not give exact solution.

• Storing of large data.

• User judgment is very essential.

Page20
 • Aspect ratio should be carefully maintained to give higher accuracy.

• The user should have good interpreting capabilities.

5.7 INTRODUCTION TO ANSYS

ANSYS is general purpose software, which can be used for almost any type of finite
element analysis virtually in any industry-automobiles, aerospace, railways, machinery,
electronics, sporting goods, power generation, power transmission and bio-mechanics.”
General purpose” also refers to the fact that the software can be used in all disciplines of
engineering-structural, mechanical, electrical, electromagnetic, electronic, thermal, fluid and
bio-medical.

1. Build computer models or transfer CAD models of structures, products, and components
systems.

2. Applying operating loads or other design performance conditions.

3. Study physical responses such as, stress levels, temperature distributions or the impact of
electromagnetic fields.

4. Optimize a design early in the development process to reduce production costs.

5. Do prototype testing in environments where it otherwise would be undesirable or impossible.

The ANSYS program has a comprehensive graphical user interface (GUI) that gives
users easy interactive access to program functions, commands, documentation and reference
material.

5.8 INTRODUCTION TO STATIC ANALYSIS

The term ‘static” means that the forces do not vary with time or, that the time variation
is insignificant and can therefore be safely ignored. A static analysis calculates the effects of
steady loading conditions on a structure, while ignoring inertia and damping effects, such as
those caused by time-varying loads. A static analysis can, however, include steady inertia loads
(such as gravity and rotational velocity), and time-varying loads that can be approximated as
static equivalent loads.

➢ Externally applied forces and pressures.

Page21
 ➢ Steady-state inertia forces (such as gravity or rotational velocity).

➢ Imposed (non zero) displacements.

➢ Temperatures (for thermal strains).

5.9 OVERVIEW OF SEQUENTIAL OPERATIONS IN STATIC ANALYSIS

The procedure for a static analysis consists of three main steps.

5.9.1 Building the mode

Define the element type, element cross-sectional properties, and material properties &
build the model using the model geometry.

Solve for the results using the ANSYS solver.

Obtain the final solution

Begin

Geometric modeling of the asperity

Specifying material & its properties

Discretize all the elements

Applying Loads and Constraints

Transformation of the Model into its equivalent

matrices.

Determining the Displacements & stresses

Fig .4.2 Flow diagram of static analysis

Determining FOS for strength

END Page22
5.10 STASTIC ANALYSIS OF COIL SPRING

Static structural analysis is a finite element analysis used to simulate and ascertain the various
loads, stresses, strains, deformations, etc. acting on a system. In this analysis the inertia and the
effects of inertia is neglected. The main aim of the paper is to analyse the forces acting on a
coil spring and the various stresses and strains developed so as to ascertain the cause of the
frequent failure of the joint.

To find out the various stresses and strains we perform static structural analysis on the
coil spring in ANSYS Workbench. The material of the spring is stainless steel (AISI 316), the
properties of which are given in table 2. One end of the spring is fixed while other end is
subjected to a load of 2700 N. On solving the meshed model with the given boundary
conditions give the following results.

5.11 ANALYSIS PROCEDURE

Open the ansys software

Work bench 18.1

Static structural

Engineering data

Geometry

Mesh

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 Setup

Solutions

Results

Fig.4.3 Analysis procedure

5.11.1 ENGINEERING DATA

In this engineering data assign the material type and their properties

These material properties are given in the material data. By giving these and selecting
the required, the material will be applied to the geometry

Table 5.1 Properties of Stainless steel , Inconel 600 and Chrome vanadium

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 Fig.5.4 CATIA Model imported to Ansys
5.11.2 Geometry

Design the conical nozzle by using the catia software

5.11.3 Modeling

After that of the adding materials and design next step is import of design into the ansys
in the form of Initial Graphics Exchange Specification

5.11.4 Meshing

ANSYS Meshing is a general-purpose, intelligent, automated high-performance

product. It produces the most appropriate mesh for accurate, efficient multiphysics solutions.

A mesh well suited for a specific analysis can be generated with a single mouse click
for all parts in a model. Full controls over the options used to generate the mesh are available
for the expert user who wants to fine-tune it.

The power of parallel processing is automatically used to reduce the time you have to
wait for mesh generation

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 Fig.5.5 Meshing of the coil spring

5.11.4 Setup

In this setup apply the loads and pressure to the conical nozzle .Apply the all degrees
of freedom at the inlet of the conical nozzle.

Apply the pressure of the conical nozzle varying from the 50 bar to the 60 bar pressure.

At each and every stage identify the stress, strain, deformation, and strain energy of the
conical nozzle.

Compare with the standard material stress of the conical nozzle, if any value of those
are increasing change the material type. In our project we are introduce the tungsten carbide in
the place of the titanium alloys

5.11.5 Solution

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 Analysis of conical nozzle is in the way of

• Equivalent (von- Misses) stress

• Equivalent ( von-Misses) strain

• Total deformation

5.11.5.1 Equivalent (von-misses) stress

Equivalent (von-Misses) Equivalent stress is related to the principal stresses by the

equation. Equivalent stress is part of the maximum equivalent stress failure theory used to
predict yielding in a ductile material

5.11.5.2 Equivalent (von- misses) strain

The von Misses yield criterion (also known as the maximum distortion energy criterion
suggests that yielding of a ductile material begins when the second deviatoric stress
invariant reaches a critical value.

It is part of plasticity theory that applies best to ductile materials, such as some metals.
Prior to yield, material response can be assumed to be of a nonlinear elastic, or linear elastic
behavior.

In materials science and engineering the von Misses yield criterion can also be
formulated in terms of the von Misses stress or equivalent tensile stress, . This is a scalar value
of stress that can be computed from the Cauchy stress tensor.

In this case, a material is said to start yielding when the von Misses stress reaches a
value known as yield strength.

The von Misses stress is used to predict yielding of materials under complex loading
from the results of uni axial tensile tests.

The von Misses stress satisfies the property where two stress states with equal
distortion energy have an equal von Misses stress.

5.11.5.3 Total deformation

Page27
 Deformation results generally can be in ANSYS Work Bench as total deformation or
directional deformation. Both of them are used to obtain displacements from stresses. The main
difference is the directional deformation calculates for the deformations in X, Y, and Z planes
for a given system

Page28
 CHAPTER-6

RESULTS AND DISCUSSIONS

6.1 STAINLESS STEEL

⚫ Total deformation

Fig.6.1 Total deformation for stainless steel

⚫ Equivalent (von- Misses) stress

Fig.6.2 Equivalent (von- misses) stress for stainless steel

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⚫ Equivalent strain

Fig.6.3 Equivalent elastic strain for stainless steel

6.2 INCONEL 600 (NICKEL CHROMIUM ALLOY)

⚫ Total deformation

Fig.6.4 Total deformation for Inconel 600

Page30
⚫ Equivalent (von- Misses) stress

Fig.6.5 Equivalent (von- misses) stress for Inconel 600

⚫ Equivalent strain

Fig.6.6 Equivalent Elastic strain for Inconel 600

Page31
6.3 CHROME VANADIUM
⚫ Total deformation

Fig.6.7 Total deformation for chrome vanadium

⚫ Equivalent (Von- Misses) Stress

Fig.6.8 Equivalent (von- misses) stress for chrome vanadium

Page32
⚫ Equivalent strain

Fig.6.9 Equivalent elastic strain for chrome vanadium

6.4 ANALYSIS OF THE COIL SPRING BY COMPARING THE

STAINLESS STEEL WITH INCONEL 600 AND CHROME VANADIUM

Table 6.1 Comparison with stainless steel with Inconel 600 with chrome vanadium

TOTAL
DEFORMATION EQUIVALENT EQUIVALENT
S.No. MATERIAL
STRESS(Mpa) STRAIN
(mm)

1 Stainless Steel 71.762 1193 0.00652

2
Inconel 600 68.828 1193.9 0.0060916

3 Chrome vanadium 66.424 1192.8 0.00608

Here, from comparison of Coil spring with different materials as shown in table 5.1, it
can be seen that the minimum deformation 66.424mm. Also the equivalent stress is 1192.8

Page33
MPa and equivalent strain is 0.00608 in the chrome vanadium material. Therefore, Study has
been made Coil spring with respect to chrome vanadium.

6.10 Combinations of different models created in CATIA

Table 6.2 Combinations of different models created in CATIA by varying wire diameter of
the spring and maintaining pitch and No. of coils as constant

PARAMETER

WIRE
S. No. Model No. PITCH (p) NO. OF COILS(N) DIAMETER(d)

1 Model- 1 12 16 7.5

2 Model- 2 12 16 8

3 Model- 3 12 16 8.5

RESULTS AND DISCUSSIONS

Model (1)

Fig.6.1.1 (i) Total Deformation of Model- 1

Page34
Fig.6.1.2 (ii) Equivalent Elastic strain of Model- 1

Fig.6.1.3 (iii) Equivalent Stress of Model- 1

Page35
Model (2)

Fig.6.2.1 (i) Total Deformation of Model- 2

Fig.6.2.2 (ii) Equivalent Elastic strain of Model- 2

Page36
 Fig.6.2.3 (iii) Equivalent Stress of Model- 2

Model (3)

Fig.6.3.1 (i) Total Deformation of Model- 3

Page37
Fig.6.3.2 (ii) Equivalent Elastic Strain of Model- 3

Fig.6.3.3 (iii) Equivalent Stress of Model- 3

Page38
 6.2 COMPARISON OF RESULTS FOR DIFFERENT COMBINATIONS

Table6.3 Comparison ofresults

Pitch(p) No. Of Wire Total Equivalent Equivalent
Models mm coils(N) diameter(d) Deformation Elastic Stress
mm (mm) Strain (MPa)
1 12 16 7.5 50.567 0.00480 973.88
2 12 16 8 38.946 0.004080 822.85
3 12 16 8.5 30.424 0.003314 678.13

Here,from comparison of Coil spring with different models by varying wire diameter as
shown in table 5.2, it can be see that the minimum deformation 30.424mm. Also the
equivalent stress is 678.13 MPa and equivalent strain is 0.003314 in the model-3 at wire
diameter d= 8.5 mm. There fore ,Study has been made Coil spring by selecting optimum wire
diameter as 8.5mm.

Table 6.4 Combinations of different models created in CATIA by varying No. of coils of
the spring and maintaining pitch and wire diameter as constant
PARAMETER

WIRE
PITCH (p)(mm) DIAMETER(d)(mm NO. OF
S. No. Model No. ) COILS(N)

1 Model- 4 12 8.5 14

2 Model- 5 12 8.5 12

3 Model- 6 12 8.5 10

Page39
 RESULTS AND DISCUSSIONS contd
Model (4)

Fig.6.4.1 (i) Total Deformation of Model- 4

Fig.6.4.2 (ii) Equivalent Elastic Strain of Model- 4

Page40
 Fig.6.4.3 (iii) Equivalent Stress of Model- 4

Model (5)

Fig.6.5.1 (i) Total Deformation of Model- 5

Page41
Fig.6.5.2 (ii) Equivalent Elastic Strain of Model- 5

Fig6.5.3 (iii) Equivalent Stress of Model- 5

Page42
Model (6)

Fig.6.6.1 (i) Total Deformation of Model- 6

Fig.6.6.2 (ii) Equivalent Elastic Strain of Model- 6

Page43
 Fig.6.6.3 (iii) Equivalent Stress of Model- 6

6.3 COMPARISON OF RESULTS FOR DIFFERENT COMBINATIONS

Table 6.5 Comparison of results

Pitch( Wire No. Of Total Equivalent Equivalent
Models p) diameter(d) coils(N) Deformat Elastic Stress
mm mm ion (mm) Strain (MPa)
4 12 8.5 14 25.87 0.00324 668.69
5 12 8.5 12 21.334 0.00320 656.58
6 12 8.5 10 16.767 0.00319 644.52

Here,from comparison of Coil spring with different models by varying wire diameter as
shown in table 5.3, it can be see that the minimum deformation16.767mm. Also the
equivalent stress is 644.52 MPa and equivalent strain is 0.00319 in the model-6 at No. of
coils N=10 .There fore , Study has been made Coil spring by selecting optimum No. Of coils
as 10.

Page44
Table 6.6 Combinations of different models created in CATIA by varying pitch of the
spring and maintaining No. Of coils and wire diameter as constant

PARAMETER

NO. OF WIRE
S. No. Model No. COILS(N) DIAMETER(d)(mm) PITCH (p)(mm)

1 Model- 7 10 8.5 11

2 Model- 8 10 8.5 10

3 Model- 9 10 8.5 9

RESULTS AND DISCUSSIONS

Model (7)

Fig.5.7.1 (i)Total Deformation of Model- 7

Page45
Fig.5.7.2 (ii) Equivalent Elastic Strain of Model- 7

Fig.5.7.3 (iii) Equivalent Stress of Model- 7

Page46
Model (8)

Fig.5.8.1 (i)Total Deformation of Model- 8

Fig.5.8.2 (ii) Equivalent Elastic Strain of Model- 8

Page47
 Fig.5.8.3 (iii) Equivalent Stress of Model- 8

Model (9)

Fig.5.9.1 (i) Total Deformation of Model- 9

Page48
Fig.5.9.2 (ii) Equivalent Elastic Strain of Model- 9

Fig.5.9.3 (iii) Equivalent Stress of Model- 9

Page49
 6.4 COMPARISON OF RESULTS FOR DIFFERENT COMBINATIONS

Table 6.7 Comparison of results

Models No. of Wire Pitch(p) Total Equivalent Equivalent
coils(N) diameter(d) mm Deformation Elastic Stress
mm (mm) Strain (MPa)
7 10 8.5 11 16.7 0.003105 641.96
8 10 8.5 10 16.081 0.0030372 625.62
9 10 8.5 9 15.469 0.0030011 616.33

Here, from comparison of Coil spring with different models by varying pitchas
shown in table 5.4, it can be seen that the minimum deformation15.469mm. Also the
equivalent stress is 616.33 MPa and equivalent strain is 0.0030011 in the model-9 at pitch p=
9mm .There fore , Study has been made Coil spring by selecting optimum pitch as 9 mm.

CHAPTER-7

VALIDATION OF RESULTS

6.8 COMPARISON OF RESULTS FOR DIFFERENT COMBINATIONS

Pitch(p) No. Of Wire Total Equivalent Equivalent

Models mm coils(N) diameter(d) Deformation Elastic Stress
mm (mm) Strain (MPa)

1 12 16 7.5 50.567 0.00480 973.88

2 12 16 8 38.946 0.004080 822.85
3 12 16 8.5 30.424 0.003314 678.13
4 12 14 8.5 25.87 0.00324 668.69
5 12 12 8.5 21.334 0.00320 656.58
6 12 10 8.5 16.767 0.00319 644.52
7 11 10 8.5 16.7 0.003105 641.96
8 10 10 8.5 16.081 0.0030372 625.62
9 9 10 8.5 15.469 0.0030011 616.33

Page50
 Chapter -8

CONCLUSION
The objective of the work is to study the behavior of coil springs adopted for automobile
suspension system under static loading conditions and design modifications. For this analysis
three different materials are carried out which includes stainless steel, phosphor bronze and
chrome vanadium and the following conclusions are drawn from this work.
1. The modelling was done in CATIA V5R21 and analysis in ANSYS 18.1
2. comparison has been made among the three different materials and it is observed that
chrome vanadium(Cr-V) is the best material of construction for coil spring from static
analysis.
3. The values of total deformation, equivalent stress and equivalent elastic strain of various
spring materials are compared and it is observed that minimum deformation (66.424
mm), equivalent stress(1192.8 Mpa) and equivalent elastic strain(0.00608) in the chrome
vanadium material.
4. And also comparison has been made for a coil spring with optimum material i.e, chrome
vanadium by varying the pitch, no. of coils and wire diameter.
5. From the static analysis results, it is observed that total deformation is (15.469 mm),
equivalent stress(616.33 Mpa) and equivalent elastic strain(0.0030011) at the optimum
parameters p=9 mm , N=10 and d=8.5 mm.

Taking, the results of analysis into consideration it can be finally concluded that
Chrome vanadium spring steel with model having p=9 mm , N=10 and d=8.5 mm is the
optimum suitable material which has low deflection , equivalent stress and equivalent elastic
strain for the helical spring applications.

A 3D printed coil spring was developed using PLA(PolyLactic acid)

material.Itdoesthisbyeliminatingtraditionalmanufacturingmethods, replacing
them with faster, less costly 3D printing technology, suitable for customization.
It enables the creation of complex shapes, in multiple colors and textures ,that
can’t be practically modeled or machined.

Page51
Futurescope

⚫ Design modification can be done to minimize the weight of helical spring and the inertia
force.
⚫ Dynamic analysis of spring can also be performed on Ansys software to get better
analysis
⚫ Vibrational analysis can be done in Ansys software for minimize the fatigue failure
⚫ Torsional analysis can be done due to presence of small amount of torsional moment in
spring wire.
⚫ Analysis of different spring either for heavy duty vehicle or light duty vehicle can also
be analyzed.

BIBLIOGRAPHY

1.N. Lavanya, P. Sampath Rao and M. Pramod Reddy , “Design and Analysis of A
Suspension Coil Spring For Automotive Vehicle” Int. Journal of Engineering Research and
Applications, Vol. 4, Issue 9( Version 5), September 2014, pp.151-157.
2.K. Vinay Kumar, R.Rudrabhiramu, “Design And Analysis of Helical Springs in Two
Wheeler Suspension System” International Journal of Research in Advanced Engineering
Technologies , Volume 5, Issue 2 DEC 2015
3. “STATIC ANALYSIS OF HELICALCOMPRESSIONSPRING USED IN
TWOWHEELER HORN” by S.S. Gaikwad, P.S. Kachare, International Journal of
Engineering and Advanced Technology (IJEAT) ISSN: 2249 – 8958, Volume-2, Issue-3
February 2013.
4.Logavigneshwaran S., Sriram G and Arunprakash R. “Design and Analysis of Helical Coil
Spring in Suspension System” International Journal for Trends in Engineering
&Technology , Volume 9 Issue 1 – September 2015 - ISSN: 2349 - 9303
5.Aakash Bhatt, Anil Devani and ParthZalavadiya, “Design analysis of helical spring of
suspension System” IJEDR | Volume 4, Issue 3. 2016
6.HarshalRajurakar, M. C. Swami “Analysis Of Helical Compression Spring For Two
Wheeler Automotive Rear Suspension” Journal of Mechanical and Civil Engineering
(IOSR-JMCE) Volume 13, Issue 2 Ver. II (Mar. - Apr. 2016)

Page52
7. DESIGN OF HELICAL COIL COMPRESSION SPRING” A REVIEW” by P.S.Valsange
/ International Journal of Engineering Research and Applications, ISSN:2248-9622.
8.Vijayeshwar BV, Preetham B M, Bhaskar U “ Design and Static Analysis of Helical
Suspension Spring with Different Materials” International Advanced Research Journal in
Science, Engineering and Technology , Vol. 4, Special Issue 7, May 2017

9. Zeeshan Khutbuddin Shaikh and Sayyad Asma Naser “Experimental Study of Helical
Compression Spring” International Journal of Engineering Technology Science and
Research, Volume 4, Issue 12, December 2017.
10. Harale, S. G. and Elango, M. 2014, Design of Helical Coil Suspension System by
Combination of Conventional Steel and Composite Material, International Journal of
Innovative Research in Science, Engineering and Technology 3, (8) 15144-15150.

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