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Analytical and Experimental Study of Conical Telescoping Springs With Nonconstant Pitch
Analytical and Experimental Study of Conical Telescoping Springs With Nonconstant Pitch
ðR
geometry of the end coils. Second, it is assumed that, upon deflec- 2La dr 2La 2R
tion, the generic point of the helix moves vertically (angle h is hðRÞ ¼ ¼ Ln (6)
ðD2 D1 Þ tan a D1 r ðD2 D1 Þ tan a D1
maintained). This implies that the length of the wire shortens 2
where si represents the constant stress at solid. DL is calculated using Eq. (21).
But we still know that hðD2 =2Þ ¼ 2pNa . Thus, the constant value
of PM can be calculated
Gd4 La 1 1
PM ¼ (24)
16Na ðD2 D1 Þ D21 D22
Being fully linear, this kind of spring is the only one to offer a
conical shape at any compression state. The other kinds of springs
have a conical shape only when uncompressed and their shape is
nonconical when they are compressed, even for conical springs
with constant pitch.
6 Case study
6.1 Initial Geometry. The following case study illustrates
the work presented above. Various conical springs, all having the
Fig. 4 Load-length relations obtained same design parameters are considered (see details in Table 1).
able to predict the Load/Length curve of telescoping springs more pected to be the main cause of the gap. To reach the required ac-
precisely near their solid length. curacy, the studies would have to manage large displacements,
contact between coils and contact between coils and the ground.
Such finite element studies would be able to test several options
7 Conclusions for the end coil geometry and may help to find the most suitable
Most research papers that exploit conical springs focus only on ones.
conical springs with a constant pitch. In order to increase the Another source of improvement could be to precisely identify
range of possibilities, this paper has studied conical springs with the loads (forces and moments) induced by the end coils as they
other types of spirals projected on the conical shape. are, and toperform another analytical study to determine the asso-
The analytical study enabled us to define the theoretical geome- ciated load-length relations.
try of the spiral in order to obtain a conical spring with a constant
angle, with a constant maximum stress and with a fully linear
load-length relation for fully telescoping springs. Nomenclature
Based on the spirals proposed, the corresponding initial flexibil- a¼ current helix angle
ities have been calculated using the common assumptions for h¼ angle that defines the position on the conical helix
springs. The formulae can be used for any kind of conical shape d¼ deflection
(whether the spring is able to telescope or not). The load-length d1 ¼ deflection of the part of the spring that is free to deflect
relations have also been described in their nonlinear range but (from D1 to DL)
only for fully telescoping springs. d2 ¼ deflection of the part that is at solid (from DL to D2)
Note that all the initial flexibility formulae (9), (19), (27) for s¼ uncorrected stress
conical springs lead to the standard equation for a cylindrical si ¼ constant uncorrected stress at solid.
compression spring [4,14] when D1 tends to D2. d¼ wire diameter
Tests on conical springs made using Fused Deposition Model- dn ¼ elementary coil
ing showed that all the analytical formulae proposed enable the dr ¼ elementary radial displacement on the conical shape
initial rates to be determined with accuracy. dl ¼ elementary orthoradial displacement on the conical shape
On the other hand, the theoretical formulae related to the non- dz ¼ elementary axial displacement on the conical shape
linear behaviors tend to under- estimate the load required to reach D1 ¼ minimum mean diameter
a given length. It would be of great interest to increase the accu- D2 ¼ maximum mean diameter
racy of the predictions. Thus, advanced finite element studies DL ¼ diameter that defines the limit between coils that are free to
could be used to evaluate the effect of end coils, which is sus- deflect and coils at solid for a given load P