Mechanical Spring ME

MECHANICAL SPRINGS
ME 201: Elements of Theory of Machine and Machine

Design
Md. Arif Mahmud Shuklo Shoshe

Fall 2020
Ahsanullah University of Science and Technology
Table of contents
1. Introduction
2. Spring Geometry
3. Stress in Helical Spring
4. Spring Materials
5. Conclusion
1
Introduction
Mechanical Springs
• Mechanical Springs allow controlled application of force or

torque; the storing and release of energy can be another
purpose.
2
Mechanical Springs
• Mechanical Springs allow controlled application of force or

torque; the storing and release of energy can be another
purpose.
• With cleverly controlled geometry, the flexibility allows
temporary distortion for access and the immediate restoration
of function.
2
Classification of Mechanical Springs

• Wire Spring
3

• Wire Spring
• Flat Spring
3

• Wire Spring
• Flat Spring
• Special shaped Spring
3
Wire Spring
Wire Spring
Wire springs include helical springs of round or square wire, made to
resist and deflect under tensile, compressive, or torsional loads.
4
Round and Square Wire Springs
Round Wire Springs

Square Wire Springs
5
Helical Compression Spring
Helical Compression Springs
6

7
Helical Tension Spring
Helical Tension Spring
8
Torsion Spring
Torsion Spring
9
Torsion Spring
k
Chapter 17 Springs
P P
d
a
12.65D Design a handgrip strengthener of the type shown in Figure P12.65D. The force requ
the handle from the initial unstressed spring position to the retained position is Fi an
position is Fmax . The initial handle rotation is 𝜃, and the handle rotates 45∘ from
position to the final position. The steel spring wire diameter is d, and the spring mea
Figure 17.12: Helical torsion spring.
eter D = 25 mm. Consider using four turns in the spring coil. The grip handle is m
an engineering thermoplastic. Calculate the nominal bending stress for the maximum
Torsion Spring
figuration, select a specific material, and calculate the safety factor for a torsion s
providing infinite fatigue life.
Initial
Helical position
R
spring Fi
po
Retainer θ
clip
Fmax
45
Handles
35 mm
80 mm
10
F
Flat Spring
Flat springs include cantilever and elliptical types, wound motor- or

clock-type power springs, and flat spring washers, usually called
Belleville springs.
11
Flat Spring
Leaf springs
12
Special shaped Spring
Volute springs
13
Special shaped Spring
Belleville springs
14
Special Shaped Spring
Belleville Wave Slotted Finger Curve Internally slotted

(as used in automotive clutches)
FIGURE 12.31 Types of spring washers [1].
15
(a)
High pressure
nitrogen gas
chamber Metering orifice
Integral grease
chamber
Seals
Oil zone for end position Polished steel rod

damping and lubrication
(b)
Figure 17.15: Gas springs. (a) A collection of gas springs.
Note that the springs are available with a wide variety of end
attachments and strut lengths. Source: Courtesy of Newport
Engineering Associates, Inc. (b) Schematic illustration of a
typical gas spring.
16
510
(a) (b) (c)
Figure 17.19: Examples of common wave spring configura-

tions. (a) Common crest-to-crest orientation; (b) crest-to-crest
orientation with shim ends; (c) nested wave springs. Source:
Courtesy of Smalley Co.
17
Spring Geometry
Helical spring geometry
18
The primary spring parameters are as follows.
• Free Length, Lo is the length of the unloaded spring.
19

• Wire Diameter d is the diameter of the wire that is wound into a
helix.
19

helix.
• Coil Diameter D is the mean diameter of the helix, i.e.,
(OD + ID)/2.
19

helix.
• Coil Diameter D is the mean diameter of the helix, i.e.,
(OD + ID)/2.
• Total Coils Nt is the number of coils or turns in the spring.
19
End Treatment of Helical Compression Spring
The four types of ends generally used for compression springs.
• Plain: Ends are non-interrupted.
20

• Squared: Ends are deformed to zero helix angle.
20

• Plain and ground: Plain ends that grinded flat.
20

• Plain and ground: Plain ends that grinded flat.
• Squared and ground: Ends grinded after squaring.
20
End Treatment of Helical Compression Spring Mechanica
sion + +
n;
both
(a) Plain end, right hand (c) Squared and ground end,
left hand
und.
+ +
(b) Squared or closed end, (d ) Plain end, ground,

right hand left hand
Helical spring end treatment
Type of Spring Ends

21
Helical spring end treatment
22
Plain End Helical Compression Spring
Plain End Helical Compression Spring

23
Squared or Closed End Helical Compression Spring
Squared or Closed End Helical Compression Spring
24
Ground End Helical Compression Spring
25
Ground End Helical Compression Spring
Squared and Ground End Helical Compression Spring
26
Squared and Ground End Helical Compression Spring
Effect of End Treatment
+ +
(b) Squared or closed end, (d ) Plain end, ground,

right hand left hand
Type of Spring Ends

Plain and Squared or Squared and
Term Plain Ground Closed Ground
End coils, Ne 0 1 2 2
gs. Total coils, Nt Na Na 1 1 Na 1 2 Na 1 2
Free length, L0 pNa 1 d p(Na 1 1) pNa 1 3d pNa 1 2d
Solid length, Ls d(Nt 1 1) dNt d(Nt 1 1) dNt
Pitch, p (L0 2 d)yNa L0y(Na 1 1) (L0 2 3d)yNa (L0 2 2d)yNa
Spring.
Dimensional Characteristics of Compression Springs

used without question. Some of these need closer scrutiny as they may not be integers.
This depends on how a springmaker forms the ends. Forys4 pointed out that squared
and ground ends give a solid length Ls of
Ls 5 (Nt 2 a)d
where a varies, with an average of 0.75, so the entry dNt in Table 10–1 may be over- 27
stated. The way to check these variations is to take springs from a particular spring-
Dimensional Characteristics of Compression Springs on End
Treatment
The following geometric parameters depends on the specified end

type.
• Active Coils Na is the number of coils which actually deform

when the spring is loaded. The inactive turns at each end, are in
contact with the spring seat or base.
28
Treatment

type.

• Solid Length Ls is the minimum length of the spring, when the
load is sufficiently large to close all the gaps between the coils.
28
Treatment

type.

• Pitch P is the distance from center to center of the wire in
adjacent active coils.
28
Treatment

type.

• Pitch P is the distance from center to center of the wire in
adjacent active coils.
• Pitch Angle α is the angle between the coils and the base of the
spring.
28
Solid Length
(P = 0)
Pr
Po
Ps
lf
li
lo
ga ls
(a) (b) (c) (d)
Figure 17.6: Various lengths and forces applicable to helical compression springs. (a) Unloaded; (b) under initial load; (c) under
operating load; (d) under solid load.
29
Stress in Helical Spring
8FD 4F
Stress in Helical Spring t5 3 1
pd pd 2
F F
helical
y diagram
ire is
ct shear
ar.
T = FD兾2
F
For equilibrium, (a)

the isolated section contains a direct shear force F
and a torsional moment T = FD/2.
30
F FF
λ F F
d
FD
T=
2 d
D
F FD
T=
2
F (b) D
Top portion of
compression spring F
D shown as a free body
in equilibrium
F (d)
d Top portion of tension
spring shown as a free
body in equilibrium
End surface
ground flat (c)
Tension spring
(a)
Compression spring
(ends squared and ground)
FIGURE 12.2 Helical (coil) compression and tension springs.
31
The maximum shear stress in the wire may be computed by

superposition of the direct shear stress and the torsional shear
stress as, (at the inside fiber of the spring)
Tr F
τmax = +
J A
32
495
d d
(a) (b)
Spring
axis Spring
T = PR axis
R d d
P
(b)
D/2 D/2
wire showing applied (c) (d)
wing torsional and di-
Figure 17.3: Shear stresses acting on wire and coil. (a) Pure
Shear stressestorsional
acting on wire (b)
loading; andtransverse
coil. (a)loading;
Pure torsional loading;
(c) torsional and (b)
transverse loading; (c) torsional and transverse loading with no curvature
transverse loading with no curvature effects; (d) torsional
and transverse loading with curvature effects.
sion effects; (d) torsional and transverse loading with curvature effects.
Springs
wound with constant 17.3.3 Combined Torsional and Transverse
h is the distance, mea- Shear Stress 33
enter of one coil to the
Substitution of τmax = τ , T = FD/2, r = d/2, J = πd4 /32, and A = πd2 /4

gives
8FD 4F
τ= 3
+
πd πd2
34
• Using spring index C = D/d, a measure of coil curvature. The

preferred value of C ranges from 4 to 12. The equation of τ can
be rearranged to give,
8FD
τ = Ks
πd3
35
• Using spring index C = D/d, a measure of coil curvature. The

preferred value of C ranges from 4 to 12. The equation of τ can
be rearranged to give,
8FD
τ = Ks
πd3
• where Ks is a shear stress-correction factor and is defined as,
2C + 1
Ks =
2C
35
The Curvature Effect
• The equation of shear stress is based on the wire being straight

up to this point.
36

up to this point.
• The curvature of the wire causes a localized increase in stress
on the inner surface of the coil.
36

up to this point.
• The curvature of the wire causes a localized increase in stress
on the inner surface of the coil.
Plane m
n
Plane
τ = Tr T
τ>
Tr
0 J c d J
T
Tr 0
T τ= a b
J
T Tr
(a) τ>
J
Straight torsion bar
(b)
Curved torsion bar
FIGURE 12.3 Torsional stress distribution in straight versus curved torsion bars. (Note the
36
• increased stress on the inside surface of the curved bar.)
• For static loading, the curvature effect is normally neglected

because any localized yielding leads to localized strain
strengthening.
37
• For static loading, the curvature effect is normally neglected

because any localized yielding leads to localized strain
strengthening.
• For fatigue applications, a curvature factor should be included.
37
• To account the curvature effect the Ks factor is replaced by

another K factor, which corrects for both curvature and direct
shear.
38

shear.
• Wahl factor
4C − 1 0.615
KW = +
4C − 4 C
38

shear.
• Wahl factor
4C − 1 0.615
KW = +
4C − 4 C
• Bergsträsser factor
4C + 1
KB =
4C − 3
38

shear.
• Wahl factor
4C − 1 0.615
KW = +
4C − 4 C
• Bergsträsser factor
4C + 1
KB =
4C − 3
• The results of these two equations differ by the order of 1

percent, so Bergsträsser factor is preferred.
38
Deflection of Helical Springs
• The deflection-force relations are obtained by using

Castigliano’s theorem.
39

• The total strain energy for a helical spring is composed of a
torsional component and a shear component.
39

• The total strain energy for a helical spring is composed of a
torsional component and a shear component.
• From Strain energy,
T2 l F2 l
U= +
2GJ 2AG
39
• Substitution of T = FD/2, l = πDN, J = πd4 /32, and A = πd2 /4

gives,
4F2 D3 N 2F2 DN
U= + 2
d4 G dG
40
• Substitution of T = FD/2, l = πDN, J = πd4 /32, and A = πd2 /4

gives,
4F2 D3 N 2F2 DN
U= + 2
d4 G dG
• Using Castigliano’s theorem,
∂U 8FD3 N 4FDN
y= = + 2
∂F d4 G dG
40
• Since C = D/d, the deflection equation can be rearranged as,
8FD3 N ( 1 ) 8FD3 N
y= 1 + =
d4 G 2C2 d4 G
41
8FD3 N ( 1 ) 8FD3 N
y= 1 + =
d4 G 2C2 d4 G
• As,
1
≈0
2c2
41
8FD3 N ( 1 ) 8FD3 N
y= 1 + =
d4 G 2C2 d4 G
• As,
1
≈0
2c2
• Spring rate or the scale of the spring is,
F d4 G
k= =
y 8D3 N
41
Stability of compression coil springs
• Compression coil springs may buckle

like a column when the deflection P
becomes too large. y
Figure 9.4: Buckling of rectangular section.
42

• For steels, the condition for absolute x
stability is,
D
Lo < 2.63
α
42

• For steels, the condition for absolute x
stability is,
D
Lo < 2.63
α
• For squared and ground ends

supported between flat parallel
surfaces, α = 0.5. Thus, P
Lo < 5.26D
42
Spring Materials
Stress–strain curve
Stress-strain curve of low carbon steel

43
Spring Materials
• Tensile strength of spring materials vary with wire diameter, and

simply can not specified without wire diameter.
44
Spring Materials

•
A
Sut =
dm
44
Spring Materials

•
A
Sut =
dm
• The Sut here is the ultimate tensile strength of the material.
44
Spring Materials
• The torsional yield strength, Ssy is needed to design the spring

and to analyze the performance.
45
Spring Materials
• The torsional yield strength, Ssy is needed to design the spring

and to analyze the performance.
• Some correlations with carbon steel springs show that, the
tensile yield strength, Sy of spring wire in torsion can be
estimated as,
Sy = 0.75Sut
45
Spring Materials
• The corresponding estimate of the torsional yield strength, Ssy

based on distortion energy theory will be,
46
Spring Materials
• The corresponding estimate of the torsional yield strength, Ssy

based on distortion energy theory will be,
•
Ssy = 0.577Sy = 0.577 × 0.75Sut ≈ 0.45Sut
46
Problems
Problem 1
A helical compression spring is made of no. 16 music wire. The wire
diameter for gauge 16 is, d= 0.94 mm. The outside coil diameter of
the spring is 11 mm. The ends are squared and grounded, and there
are 12.5 total turns.
i Estimate the torsional yield strength of the wire.

ii Estimate the static load corresponding to the yield strength.
iii Estimate the scale of the spring.
iv Estimate the deflection that would be caused by the load in part
(ii).
v Estimate the solid length of the spring.
vi Estimate the free length.
vii Given the length found in part (vi), is buckling a possibility?
47
Problems
Problem 2
A compression coil spring is made of music wire with squared and
ground ends. The spring is to have a spring rate of 1250 N/m. The
force corresponding to the solid length is 60 N. The spring index is
fixed at 10. Static loading conditions are assumed with few loading
cycles, so that the transverse shear factor can be used. Find the wire
diameter, mean coil diameter, free and solid lengths, and indicate
whether buckling is a problem. Analyze the nominal case (ns = 1)
and give a design recommendation.
48
Problems
Problem 3
A helical compression spring has 14 active coils, a free length of 32
mm, and an outside diameter of 11 mm. The ends of the spring are
squared and ground and the end plates are constrained to be
parallel. The material is music wire with a diameter of 1 mm. For
static conditions, compute the spring rate, the solid length, and the
stress when the spring is compressed to the solid length. Will static
yielding occur before the spring is compressed to its solid length?
49
Problems
Problem 4
A spring is known to be made from music wire, ASTM A228 steel, but
no other data are known. You are able to measure the following
features using simple measurement tools:
Free length, Lf is 45 mm, Outside diameter, OD is 17.6 mm, Wire
diameter, d is 1.6 mm The ends are squared and ground. The total
number of coils is 10.0. This spring will be used in an application
where the normal operating load is to be 65 N.
For this spring, compute and/or do the following: The music wire
gage number, mean diameter, inside diameter, spring index,
Bergsträsser factor, solid length, and spring rate. The expected stress
and deflection of the spring at the operating load of 65 N. The force
on the spring when it is at its solid length and the corresponding
stress at solid length. The maximum permissible stress; then
compare it with the actual operating stress and the stress at solid
length. Finally check the spring for buckling.
50
Problems
Use the following table for finding the music wire gage number of
Problem 4.
Gauge Number Diameter in mm

23 1.295
24 1.397
25 1.499
26 1.600
27 1.702
28 1.803
29 1.905
30 2.032
31 2.159
32 2.286
33 2.413
51
Conclusion
Summary
Mechanical Spring
Design of Helical Compression Spring was covered in detail in this
lecture. Also, different types of mechanical springs were discussed.
Students are expected to understand the reason behind the different
shaped springs and design helical compression spring for different
practical application from this lecture.
Reading
Shigley 10.1-10.7.
52
Questions?
52

Mechanical Spring ME

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Mechanical Spring ME

Uploaded by

Copyright:

Available Formats

MECHANICAL SPRINGS

ME 201: Elements of Theory of Machine and Machine

Md. Arif Mahmud Shuklo Shoshe

3. Stress in Helical Spring

• Mechanical Springs allow controlled application of force or

• Mechanical Springs allow controlled application of force or

Classification of Mechanical Springs

Classification of Mechanical Springs

Classification of Mechanical Springs

Round Wire Springs

Helical Compression Springs

Helical Compression Spring

Helical Tension Spring

Flat springs include cantilever and elliptical types, wound motor- or

Belleville Wave Slotted Finger Curve Internally slotted

FIGURE 12.31 Types of spring washers [1].

Oil zone for end position Polished steel rod

(a) (b) (c)

Figure 17.19: Examples of common wave spring configura-

Helical spring geometry

The primary spring parameters are as follows.

• Free Length, Lo is the length of the unloaded spring.

The primary spring parameters are as follows.

• Free Length, Lo is the length of the unloaded spring.

The primary spring parameters are as follows.

• Free Length, Lo is the length of the unloaded spring.

The primary spring parameters are as follows.

• Free Length, Lo is the length of the unloaded spring.

The four types of ends generally used for compression springs.

• Plain: Ends are non-interrupted.

The four types of ends generally used for compression springs.

• Plain: Ends are non-interrupted.

The four types of ends generally used for compression springs.

• Plain: Ends are non-interrupted.

The four types of ends generally used for compression springs.

• Plain: Ends are non-interrupted.

(b) Squared or closed end, (d ) Plain end, ground,

Helical spring end treatment

Type of Spring Ends

Helical spring end treatment

Plain End Helical Compression Spring

Squared or Closed End Helical Compression Spring

(b) Squared or closed end, (d ) Plain end, ground,

Type of Spring Ends

Dimensional Characteristics of Compression Springs

The following geometric parameters depends on the specified end

• Active Coils Na is the number of coils which actually deform

The following geometric parameters depends on the specified end

• Active Coils Na is the number of coils which actually deform

The following geometric parameters depends on the specified end

• Active Coils Na is the number of coils which actually deform

The following geometric parameters depends on the specified end

• Active Coils Na is the number of coils which actually deform

(a) (b) (c) (d)

For equilibrium, (a)

FIGURE 12.2 Helical (coil) compression and tension springs.

The maximum shear stress in the wire may be computed by

Substitution of τmax = τ , T = FD/2, r = d/2, J = πd4 /32, and A = πd2 /4

• Using spring index C = D/d, a measure of coil curvature. The

• Using spring index C = D/d, a measure of coil curvature. The

• where Ks is a shear stress-correction factor and is defined as,

• The equation of shear stress is based on the wire being straight