CH 12

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SOLUTION (12.1)
Known: A steel torsion bar spring is shown in Figure 12.1a. One end of the bar
angularly rotates 65o relative to the other end. The length of the torsion bar portion is
50 in. and the diameter is 0.312 in.
Find: Calculate the energy stored in a steel torsion bar. Also, calculate the maximum
shear stress.
Schematic and Given Data:
50 in.
Fixed
o
end
! = 65
d = 0.312 in.
Assumptions:
1. The bar remains straight and the torque is applied about the longitudinal axis.
2. The material is homogeneous and perfectly elastic within the stress range
involved.
Analysis:
1. From Table 5.1, for a torsional case (Case 2):
! = TL , therefore , T = !JG
JG L
2. θ = (65/180)π = 1.1345 rad; and J = πd4/32 = π(0.312)4/32 = 0.00093 in.4
From (Appendix C-1), G = 11. 5 ! 106 psi
6
! ! !
3. Therefore, T = 1.1345 0.00093 11.5 10 = 242.66 lb in.
50
4. The internal energy stored in the spring is equal to the work done to angularly
rotate the spring, i. e., U = (1/2)Tθ = 0.5(242.66 lb in.)(1.1345 rad) = 137.65 in.-lb.
■
5. From Eq. (4.4), for a solid round rod,
! = 16T/"d 3 = (16)(242.66) = 40.69 ksi

"(0.312) 3
12-1
SOLUTION (12.2D)
Known: A steel torsion bar spring is shown in Figure 12.1a. The bar is 45 in. long, the
diameter is 0.250 in., and the bar rotates 45o relative to the other end.
Find: Calculate the energy stored in a steel torsion bar spring. Also, calculate the
maximum shear stress.
45 in.
Fixed
o
end
! = 45
d = 0.250 in.
Assumptions:
involved.
Analysis:
JG L
2. θ = (45/180)π = 0.785 rad
J = πd4/32 = π(0.250)4/32 = 0.000384 in.4
6
! ! !
3. Therefore, T = 0.785 0.000384 11.5 10 = 77.035 lb in. ■
45
4. The internal energy stored in the spring is equal to the work done to angularly
rotate the spring, i. e., U = (1/2)Tθ = 0.5(77.035 lb in.)(0.785 rad) = 30.236 in.-lb.
■
! = 16T/"d 3 = (16)(77.035) = 25.11 ksi

"(0.250) 3 ■
12-2
SOLUTION (12.3)
Known: A torsion bar has a known length and diameter.
Find:
(a) Estimate the change in shear stress when one end of the rod rotates through 75°
relative to the other end.
(b) Estimate the change in torque.
42.5 in.
Fixed
o end
! = 75
d = 0.312 in.
Assumptions:
involved.
Analysis:
JG L
2. θ = (75/180)π = 1.31 rad
J = πd4/32 = π(0.312)4/32 = 0.00093 in.4
6
1. 31 × 0. 00093 × 11. 5 × 10 = 329. 66 lb in.
3. Therefore, T = ■
42. 5
τ = 16T/πd = (16)(329. 66)

3
3
= 55. 3 ksi
π(0. 312) ■
12-3
SOLUTION (12.4)
Find:
50 in.
Fixed
o end
! = 80
d = 0.312 in.
Assumptions:
involved.
Analysis:
JG L
2. θ = (80/180)π = 1.39 rad
J = πd4/32 = π(0.312)4/32 = 0.00093 in.4
6
3. Therefore, T = 1. 39 × 0. 00093 × 11. 5 × 10 = 297. 32 lb in. ■
50
τ = 16T/πd = (16)(297. 32)

3
3
= 49. 9 ksi
π(0. 312) ■
12-4
SOLUTION (12.5)
Known: A torsion bar spring serves as a counterbalance for a trap door with a given
weight. The maximum allowable torsional stress for the spring is 50 ksi.
Find:
(a) Determine the length and diameter of a solid steel torsion bar that would
counterbalance 80% of the door weight when closed, and provide a 6 lb-ft torque
holding the door against the stop.
(b) Make a graph showing gravity torque, spring torque, and net torque all plotted
against door opening angle.
Door stop
RD 24 in.
60 lb Tc
! = 110°
T o = 6 lb ft R
60 lb
Opened Closed
Assumptions:
1. The bar is straight and the torque is applied about the longitudinal axis.
2. The material is homogeneous and perfectly elastic within the stress range involved.
3. The cross section considered is sufficiently remote from points of load application
and from stress raisers.
Analysis:
3
1. From Eq. (4.4), for a solid round rod τ = 16T3 or d = 16T/πτ
πd
When the door is closed, the bar will counterbalance 80% of the door weight.
Thus, Tc = (0.80)(60 lb)(24 in.) = 1152 lb in.
Since a maximum allowable torsional stress is 50 ksi,
3
d= 16(1152)/π(50, 000) = 0. 49 in. ■
2. From Table 5.1, for a torsional case (Case 2) θ = TL and K = T = JG
JG θ L
12-5
4
where J = !d = 0. 005660 in. 4
32
G = 11.5 ✕ 106 psi (Appendix C-1)
T -T (1152 - 72) lb in.
K = !T = c o = = 562. 5 lb in. /rad
!" !" 1. 92 rad
(0. 005660)(11. 5 ! 106)
Thus, L = JG = = 115. 7 in. ■
K 562. 5
3. Let clockwise torque be positive.
1600
Gravity torque = 1440 cos !

1200
Door closing torque (lb in.)
800
Gravity + Spring torque
400
90° 110°
0
30° 60° 120°
-400 Door opening angle, !
-800 -72
Spring torque
-1200
-1152
SOLUTION (12.6)
weight. The trap door must be designed to open only 60o. The maximum allowable
torsional stress for the spring is 50 ksi.
Find:
(a) Determine the length and diameter of torsion bar that would counterbalance 80%
of the door weight when closed, and provide a net torque of 12 lb-ft when open
60o.
12-6
RD Door stop
24 in.
60 lb Tc
To
! = 60°
60 lb R
Opened Closed
Assumptions:
Analysis:
3
1. From Eq. (4.4), for a solid round rod τ = 16T3 or d = 16T/πτ
πd
when the door is closed, the bar will counter-balance 80% of the door weight.
Thus, Tc = (0.80)(60 lb)(24 in.) = 1152 lb in. Since a maximum allowable
3
torsional stress is 50 ksi, d = 16(1152)/π(50, 000) = 0. 49 in. ■
2. From Table 5.1, for a torsional case (case 2), θ = TL and K = T = JG

JG θ L
4
where J = !d = 0. 005660 in. 4
32
G = 11.5 ✕ 106 psi (Appendix C-1)
For 60o opening, gravity torque = 60(24) cos 60o
= 720 lb in.
Thus, spring torque required, To = 720 + 144
= 864 lb in.
(1152 - 864) lb in.

K = !T = = 274. 3 lb in. /rad
!" 1. 05 rad
JG (0. 005660)(11. 5 ! 106)

Therefore, L = = = 237 in. ■
K 274. 3
12-7
1600 Gravity torque = 1440 cos !
1200
720
Door closing torque (lb in.)
800
Gravity + Spring torque
400
60°
0
20° 40° 80°
-800
-1200 -864
-1152 Spring torque
SOLUTION (12.7)
Modified Problem 12.5
weight. The maximum allowable torsional stress for the spring is 350 MPa.
Find:
(a) Determine the length and diameter of a solid steel torsion bar that would
counterbalance 80% of the door weight when closed, and provide a 8 N•m torque
holding the door against the stop.
Door stop
RD 600 mm
250 N Tc
! = 110°
T o = 8 N•m R
250 N
Opened Closed
12-8
Assumptions:
Analysis:
3
1. From Eq. (4.4), for a solid round rod ! = 16T or d = 16T/"!
"d3
When the door is closed, the bar will counterbalance 80% of the door weight.
Thus, Tc = (0.80)(250 N)(0.60 m) = 120 N•m.
Since a maximum allowable torsional stress is 350 MPa,
d = 3 16(120)/!(350 " 106) = 0. 01204 m or d = 12.04 mm ■
2. From Table 5.1, for a torsional case (Case 2) θ = TL and K = T = JG

JG θ L
4
where J = !d = 2. 063 " 10-9 m4
32
G = 79 ✕ 109 Pa (Appendix C-1)
T -T
K = !T = c o = 120 - 8 = 58. 3 N•m/rad
!" !" 1. 92
(2. 063 ! 10-9)(79 ! 109)
Thus, L = JG = = 2. 79 m ■
K 58. 3
200
150 Gravity torque = 150 cos !

Door closing torque (N •m)
Gravity +
100
Spring torque
50
90° 110°
0
30° 60° 120°
-100 -8
Spring torque
-150 -120
Modified Problem 12.6

weight. The trap door must be designed to open only 60o. The maximum allowable
torsional stress for the spring is 350 MPa.
12-9
Find:
(a) Determine the length and diameter of torsion bar that would counterbalance 80%
of the door weight when closed, and provide a net torque of 16 N•m when open
60o.
RD Door stop
600 mm
250 N Tc
To
! = 60°
250 N R
Opened Closed
Assumptions:
Analysis:
1. From Modified Problem 12.6, d = 12.04 mm ■
2. From Table 5.1, for a torsional case (case 2), θ = TL and K = T = JG

JG θ L
4
where J = !d = 2. 063 " 10-9 m4
32
G = 79 ✕ 109 Pa
For 60o opening, gravity torque = 250(0.6) cos 60o = 75 N•m
Thus, spring torque required, To = 75 + 16 = 91 N•m
K = ΔT = 120 - 91 = 27. 62 N•m/rad

Δθ 1. 05
(2. 063 ! 10-9)(79 ! 109)
Therefore, L = JG = = 5. 90 m ■
K 27. 62
12-10
200
Gravity torque = 150 cos !
150
Door closing torque (N •m)
Gravity +
100 Spring torque
50
60°
0
20° 40° 80°
-100
-91
-150 -120
Spring torque
SOLUTION (12.8)
Find:
45 in.
Fixed
o
end
! = 70
d = 0.312 in.
Assumptions:
12-11
Analysis:
JG L
2. θ = (70/180)π = 1.22 rad
J = πd4/32 = π(0.312)4/32 = 0.00093 in.4
1. 22 ! 0. 00093 ! 11. 5 ! 106
3. Therefore, T = = 290. 43 lb in. ■
45
(16)(290. 43)
! = 16T/"d3 = = 48. 7 ksi ■
"(0. 312)3
12-12
SOLUTION (12.10D)
Known: A plastic composite compression spring is to have an outside diameter of
approximately 1.0 in., a free length of 1.00 in., and a wire diameter of 0.085 in.
Find: Select a plastic composite compression spring and determine the (a) “to work in
hole diameter,” (b) load at solid height, (c) spring rate, (d) solid height, and (e) total
number of coils.
Analysis: This web site http://www.leespring.com provides the following information:
a. Hole Diameter To Work In: 1.000 (in)
b. Load At Solid Height: 15.93 (lb)
c. Spring Rate: 22.81 (lb/in)
d. Solid Height: 0.303 (in)
e. Total Number of Coils: 3.5
Comment: As an aside, other information of importance for compression springs
would include:
(a) Mandatory specifications generally required while ordering a compression spring.
1. OUTSIDE DIAMETER
2. INSIDE DIAMETER
3. Load and Rate
4. Maximum solid height
5. Direction of helix
6. Type of ends
(b) Other information or data important in ordering a compression spring.
Advisory data
1. FREE LENGTH
2. Wire diameter in. (mm)
3. Mean coil diameter in. (mm)
4. No. of active coils
5. Total no. of coils
Special Information
1. Type of Material
2. Finish
3. Squareness (free): within degrees
4. Frequency of compression, cycles/sec., and working range, in. (mm) to in.
(mm) of length
5. Operating temp. degrees F (degrees C)
6. End use or application
7. Other
12-13
SOLUTION (12.11D)
Known: A compression spring is to have an outside diameter of 0.102 in., a free length
of 1.000 in., and a wire diameter of 0.010 in.
Find: Select a compression spring and determine the (a) "hole diameter to work in," (b)
load at solid height, (c) spring rate for music wire, (d) spring rate for stainless steel, (e)
solid height, (f) total number of coils.
Analysis: This web site http://www.leespring.com provides the following
information:
a. Hole Diameter To Work In: 0.109 (in)
b. Load At Solid Height: 0.70 (lb)
c. Music Wire Spring Rate: 0.90 (lb/in)
d. Stainless Steel Spring Rate: 0.70 (lb/in)
e. Solid Height: 0.246 (in)
f. Total Number Coils: 24.60
SOLUTION (12.12)
Known: A helical coil spring with given D and d is wound with a known pitch value.
The material is ASTM A227 cold drawn carbon steel.
Find: If the spring is compressed solid, would you expect it to return to its original
free-length when the force is removed?
ASTM A227
Cold drawn carbon steel
p = 14 mm
d = 10 mm
D = 50 mm
Assumptions:
1. There are no unfavorable residual stresses.
2. Both end plates are in contact with nearly a full turn of wire.
3. The end plate loads coincide with the spring axis.
Analysis:
1. Force to compress spring solid can be calculated by using Eq. (12.7).
4
F = d G!
8D3N
where δ/N = p - d = 14 - 10 = 4 mm
12-14
(10 ! 10-3)4(79 ! 109)(4 ! 10-3)
F= = 3160 N
8(50 ! 10-3)3 ■
2. The corresponding stress can be calculated by using Eq. (12.6).
τ = 8FD Ks
πd 3
for C = D/d = 50/10 = 5
Ks = 1.1 (Fig. 12.4)
8(3160)(50 " 10-3)
!= (1. 1) = 442. 6 MPa
#(10 " 10-3)3
3. From Eq. (12.9), τs ≤ 0.45 Su
From Fig. 12.7, Su ≈ 1300 MPa
Thus, 0.45 Su = 585 MPa
4. Since 442.6 MPa < 585 MPa, no set should occur; therefore, spring should return
to original length. ■
Comment: Even considering the curvature (stress concentration) factor of the inner
surface by using Kw = 1.3, the inner surface stress is only (1.3)(442.6) = 575.4 MPa
which is still less than 585 MPa.
SOLUTION (12.13)
ASTM A227
p = 7 mm
d = 5 mm
D = 25 mm
Assumptions:
12-15
Analysis:
4
F = d G!
8D3N
where δ/N = p - d = 7 - 5 = 2 mm

-3 4 9 -3
(5 ! 10 ) (79 ! 10 )(2 ! 10 )
F= -3 3
= 790 N
8(25 ! 10 ) ■
τ = 8FD Ks
πd 3
for C = D/d = 25/5 = 5
Ks = 1.1 (Fig. 12.4)
" -3
! = 8(790)(25 10 ) (1.1) = 442.6 MPa
#(5 " 10 -3)3
3. From Eq. (12.9), τs ≤ 0.45 Su
Thus, 0.45 Su = 585 MPa
4. Since 442.6 MPa < 585 MPa, no set should occur; therefore, spring should return
to original length. ■
surface by using Kw = 1.3, the inner surface stress is only (1.3)(442.6) = 575.4 MPa
which is still less than 585 MPa.
SOLUTION (12.14)
12-16
ASTM A227
p = 10 mm
d = 5.5 mm
D = 50 mm
Assumptions:
Analysis:
4
F = d G!
8D3N
where δ/N = p - d = 10 - 5.5 = 4.5 mm
G = 79 ✕ 109 PA (Appendix C-1)
(5. 5 ! 10-3)4(79 ! 109)(4. 5 ! 10-3)
F= = 325 N ■
8(50 ! 10-3)3
τ = 8FD Ks
πd 3
for C = D/d = 50/5.5 = 9.09
Ks = 1.05 (Fig. 12.4)
8(325)(50 " 10-3)
!= (1. 05) = 261 MPa
#(5. 5 " 10-3)3
3. From Eq. (12.9), τs ≤ 0.45 Su
Thus, 0.45 Su = 585 MPa
4. Since 261 MPa < 585 MPa, no set should occur; therefore, spring should return to
original length. ■
surface by using Kw = 1.17, the inner surface stress is only 290 MPa which is still less
than 585 MPa.
SOLUTION (12.15)
12-17
ASTM A227
p = 5 mm
d = 2.75 mm
D = 25 mm
Assumptions:
Analysis:
4
F = d G!
8D3N
where δ/N = p - d = 5 - 2.75 = 2.25 mm
G = 79 ✕ 109 PA (Appendix C-1)

-3 4 9 -3
(2.75 ! 10 ) (79 ! 10 )(2.25 ! 10 )
F= -3 3
= 81.33 N ■
!
8(25 10 )
τ = 8FD3
Ks
πd
for C = D/d = 25/2.75 = 9.09
Ks = 1.05 (Fig. 12.4)

-3
"
! = 8(81.33)(25 10 ) (1.05) = 261 MPa
#(2.75 " 10 -3)3
3. From Eq. (12.9), τs ≤ 0.45 Su

12-18
Thus, 0.45 Su = 585 MPa
4. Since 261 MPa < 585 MPa, no set should occur; therefore, spring should return to
original length. ■
surface by using Kw = 1.17, the inner surface stress is only 290 MPa which is still less
than 585 MPa.
SOLUTION (12.16)
Known: A coiled compression spring is loaded against a support. A plot of the
resulting force-deflection curve is shown.
Find: Briefly state the reasons the curve changes at points A, B, and C.
B
Deflection
A
! C
Force
Force Deflection
Assumptions:
Analysis:
1. At A, the force overcomes the spring preload, causing deflection to begin.
2. At B, significant yielding of the spring begins. (In most instances, this would
indicate an improperly designed spring.
3. At C, the spring closes solid.
SOLUTION (12.18D)
Known: Experimental load-deflection characteristics of a spring are sometimes needed
to validate performance predicted using empirical-theoretical equations.
Find:
(a) Illustrate methods for experimentally evaluating load-deflection characteristics.
(b) Search the internet for accurate or fully automatic commercial testers. Describe
several types.
12-19
Analysis: This exercise is left to the student.
A helpful reference is the article "17 Ways of Testing Springs," C.J. McClintock,
Product Engineering Design Manual, Douglas Greenwood, editor, McGraw-Hill, 1959.
The article illustrates:
1. Dead weight testing
2. Ordnance gage incorporates "go-no-go" principle
3. Pilot-beam testing
4. Zero-gradient beam
5. Spring against spring
6. Fully-automatic testing
7. Commercial testers
12-20
SOLUTION (12.19)
Known: A conical compression coil spring in Fig. 12.6 is made of steel wire. There are
four active coils. A force is applied to compress the spring, and the stresses always
remain in the elastic range.
Find:
(a) Which coil deflects to zero pitch first?
(b) Calculate the force required to cause the deflection in (a).
(c) Sketch a force vs. deflection for the spring.
Dmin = 20 mm
d = 3 mm
p = 7 mm
Dmax = 45 mm
Assumptions:
Analysis:
4
1. From Eq. 12.8, k = F = d G
δ 8D 3N
d4
Since k ∝ and d is constant throughout, the largest active coil will have the
D3
smallest value of k. Thus, the largest (bottom) coil will deflect to zero pitch first.
12-21
4
2. From Eq. (12.7), F = d G!
8D3N
where G = 79 GPa (Appendix C-1)
(3 ! 10-3)4(79 ! 109)(7 ! 10-3)
F= = 61. 4 N
8(45 ! 10-3)3(1) ■
3. Flattening the smallest active coil requires
(3 ! 10-3)4(79 ! 109)(7 ! 10-3)
F= = 700 N
8(20 ! 10-3)3(1)
Total deflection = p(N) = 7(4) = 28 mm
d 4G (3 ! 10-3)4(79 ! 109)
Initial k ≈ = = 5800 N/m
8Davg3N 8(32. 5 ! 10-3)3(4)
or k = 5.8 N/mm
d 4G (3 ! 10-3)4(79 ! 109)
Final k ≈ = = 100,000 N/m
8Dmin3N 8(20 ! 10-3)3(1)
or k = 100 N/mm
4.
800
700 N
600
Force (N)
400
200 100 N/mm
5.8 N/mm
0
0 10 20 28 30
Deflection (mm)
12-22
SOLUTION (12.20)
Known: A conical compression coil spring in Fig. 12.6 is made of steel wire. There are
four active coils. A force is applied to compress the spring, and the stresses always
remain in the elastic range.
Find:
(a) Which coil deflects to zero pitch first?
(b) Calculate the force required to cause the deflection in (a).
(c) Sketch a force vs. deflection for the spring.
Dmin = 25 mm
d = 5 mm
p = 7 mm
Dmax = 55 mm
Assumptions:
Analysis:
4
1. F
From Eq. 12.8, k = = d G
δ 8D 3N
d4
Since k ∝ 3 and d is constant throughout, the largest active coil will have the
D
smallest value of k. Thus, the largest (bottom) coil will deflect to zero pitch first.
12-23
4
2. From Eq. (12.7), F = d G!
8D3N
(5 ! 10-3)4(79 ! 109)(7 ! 10-3)
F= = 259. 67 N
8(55 ! 10-3)3(1) ■
3. Flattening the smallest active coil requires
(5 ! 10-3)4(79 ! 109)(7 ! 10-3)
F= = 2765. 43 N
8(25 ! 10-3)3(1)
Total deflection = p(N) = 7(5) = 35 mm
d 4G (5 ! 10-3)4(79 ! 109)
Initial k ≈ = = 19,287 N/m
8Davg3N 8(40 ! 10-3)3(5)
or k = 19.3 N/mm
d 4G (5 ! 10-3)4(79 ! 109)
Final k ≈ = = 395,000 N/m
8Dmin3N 8(25 ! 10-3)3(1)
or k = 395 N/mm
4.
3000 2765 N
Force (N)
2000
395 N/mm
1000
19.3 N/mm
0
0 10 20 30 35 40
Deflection (mm)
12-24
SOLUTION (12.21)
Known: A machine uses a pair of concentric helical compression springs to support a
known static load. Both springs are made of steel and have the same length when
loaded and when unloaded.
Find: Calculate the deflection and the maximum stress in each spring.
F = 3.0 kN
do di
Di
Do
Do = 45 mm Di = 25 mm
do = 8 mm di = 5 mm
No = 5 Ni = 10
Assumptions:
Analysis:
k = d 4G
1. From Eq. (12.8),
8D 3N
where G = 79 ✕ 109 Pa for steel. (Appendix C-1)
(8 mm)4(79, 000 N/mm2)
ko = = 88. 77 N/mm
8(45 mm)3(5)
(5 mm)4(79, 000 N/mm2)
ki = = 39. 50 N/mm
8(25 mm)3(10)
12-25
F or δ = F
2. From Eq. (12.8), k =
δ k
3, 000
δ= = 23. 39 mm
(39. 5 + 88. 77) ■
3. Using F = kδ, we can calculate the force on each spring.
Fo = koδ = (88.77 N/mm)(23.39 mm) = 2076 N
Fi = kiδ = (39.50 N/mm)(23.39 mm) = 924 N
4. Using Fig. 12.4, we can find Ks values for each spring.
For outer spring, C = 45/8 = 5.63, Ks = 1.09
For inner spring, C = 25/5 = 5.00, Ks = 1.10
5. From Eq. (12.6), ! = 8FD Ks
"d3
8(2076)(45)
τo = 3
(1. 09) = 506 MPa ■
π(8)
8(924)(25)
τi = 3
(1. 10) = 518 MPa ■
π(5)
SOLUTION (12.22)
Known: A machine uses a pair of concentric helical compression springs to support a
known static load. Both springs are made of steel and have the same length when
loaded and when unloaded.
Find: Calculate the deflection and the maximum stress in each spring.
F = 3.0 kN
do di
Di
Do
Do = 50 mm Di = 30 mm
do = 9 mm di = 5 mm
No = 5 Ni = 10
12-26
Assumptions:
Analysis:
4
d G
1. From Eq. (12.8), k =
8D 3N
where G = 79 ✕ 109 Pa for steel. (Appendix C-1)
(9 mm)4(79, 000 N/mm2)
ko = = 103. 66 N/mm
8(50 mm)3(5)
(5 mm)4(79, 000 N/mm2)
ki = = 22. 86 N/mm
8(30 mm)3(10)
F or δ = F
2. From Eq. (12.8), k =
δ k
3, 000
!= = 23. 71 mm
(22. 86 + 103. 66) ■
3. Using F = kδ, we can calculate the force on each spring.
Fo = koδ = (103.66 N/mm)(23.71 mm) = 2458.0 N
Fi = kiδ = (22.86 N/mm)(23.71 mm) = 542 N
4. Using Fig. 12.4, we can find Ks values for each spring.

For outer spring, C = 50/9 = 5.56
Ks = 1.09
For inner spring, C = 30/5 = 6
Ks = 1.08
5. From Eq. (12.6), ! = 8FD Ks

"d3
8(2458)(50)
!o = (1. 09) = 467. 94 MPa ■
"(9)3
8(542)(30)
!i = (1. 08) = 357. 75 MPa ■
"(5)3
SOLUTION (12.23)
The material is ASTM B197 beryllium copper spring wire.
12-27
ASTM B197
!!!!!!Beryllium copper
!!!!!!spring wire!!
p = 14 mm
d = 10 mm
D = 50 mm
Assumptions:
Analysis:
4
F = d G!
8D3N
where δ/N = p - d = 14 - 10 = 4 mm
(10 × 10 -3)4(50 × 10 9)(4 × 10 -3)
F= = 2000 N
8(50 × 10 -3)3 ■
τ = 8FD Ks
πd 3
for C = D/d = 50/10 = 5
Ks = 1.1 (Fig. 12.4)
-3
×
τ = 8(2000)(50 10 ) (1.1) = 280. 1 MPa
π(10 × 10 -3)3
3. For beryllium copper spring wire without presetting, τs ≤ 0.35 Su.
Also, for beryllium copper spring wire without presetting, Su = 750 MPa
and 0.35 Su = 262.5 MPa
4. Since 280.1 MPa > 262.5 MPa, set should occur; therefore, spring would not
return to original length. ■
Comment: By considering the curvature (stress concentration) factor of the inner

surface by using Kw = 1.3, the inner surface stress is (1.3)(280.1) = 364.1 MPa which
is clearly even larger than 262.5 MPa.
12-28
SOLUTION (12.24)
Known: A helical coil spring with D =25 mm and d = 5 mm is wound with a pitch of 7
mm. The material is ASTM B197 beryllium copper spring wire.
ASTM B197
! ! ! !
! ! Beryllium
copper
p = 7 mm
d = 5 mm
D = 25 mm
Assumptions:
Analysis:
4
F = d G!
8D3N
where δ/N = p - d = 7 - 5 = 2 mm

-3 4 9 -3
(5 ! 10 ) (50 ! 10 )(2 ! 10 )
F= -3 3
= 500 N
8(25 ! 10 ) ■
τ = 8FD Ks
3
πd
for C = D/d = 25/5 = 5
Ks = 1.1 (Fig. 12.4)

12-29
-3
"
! = 8(500)(25 10 ) (1.1) = 280.1 MPa
#(5 " 10 -3) 3
3. For beryllium copper spring wire without presetting, τs ≤ 0.35 Su.

Also, for beryllium copper spring wire without presetting, Su = 750 MPa
and 0.35 Su = 262.5 MPa
4. Since 280.1 MPa > 262.5 MPa, set should occur; therefore, spring would not
return to original length. ■
Comment: By considering the curvature (stress concentration) factor of the inner

surface by using Kw = 1.3, the inner surface stress is (1.3)(280.1) = 364.1 MPa which
is clearly even larger than 262.5 MPa.
12-30
SOLUTION (12.25)
Known: A helical compression spring is to be made with given wire diameter, outside
diameter, and number of active coils. The least expensive steel spring wire is to be
used, and presetting will not be used.
Find:
(a) Estimate the maximum static load that can be applied without encountering more
than 2% long-term set.
(b) What is the spring rate?
(c) What should be the free-length in order that the spring becomes solid when load
determined in (a) is applied?
(d) Would buckling problems be encountered if one end plate is free to tilt?
d = 2 mm
N = 10
19 mm
Assumptions:
Analysis:
1. For d = 2 mm and outside diameter = 19 mm, D = 17 mm, and C = D/d = 8.5.
2. From Table 12.1, the least costly steel spring wire is cold drawn ASTM A227.
3. From Eq. (12.9), τmax = 0.45 Su where Su = 1550 MPa (Fig. 12.7)
τmax = 0.45(1550) = 697.5 MPa
πd 2τmax
4. From Eq. (12.6), F max = where Ks = 1.06 (Fig. 12.4)
8 CK s
!(2)2(697.5)
Fmax = = 122 " ■
8(8. 5)(1. 06)
k = d 4G
5. From Eq. (12.8), where G = 79 GPa (Appendix C-1)
8D 3N
12-31
24(79, 000)
k= = 3. 22 N/mm
8(17)3(10) ■
6. The amount of deflection when Fmax = 122 N is applied to the spring is
!s = Fmax/k = 122 = 37. 89 mm
3. 22
From Fig. 12.8(d), Ls = Ntd
Ls = (N + 2)d = (10 + 2)2 = 24 mm
Therefore, Lf = Ls + δs
Lf = 24 + 37.89 = 61.89 mm ■
7. Lf/D = 61.89/17 = 3.64
δs/Lf = 37.89/61.89 = 0.612
From Fig. 12.10, for the case B, no buckling should occur. ■
12-32
SOLUTION (12.26)
Known: A helical compression spring is to be made with given wire diameter, outside
diameter, and number of active coils. The least expensive steel spring wire is to be
used, and presetting will not be used.
Find:
(a) Estimate the maximum static load that can be applied without encountering more
than 2% long-term set.
(b) What is the spring rate?
(c) What should be the free-length in order that the spring becomes solid when load
determined in (a) is applied?
(d) Would buckling problems be encountered if one end plate is free to tilt?
d = 4 mm
N=8
19 mm
Assumptions:
Analysis:
1. For d = 4 mm and outside diameter = 19 mm, D = 15 mm, and C = D/d = 3.75
2. From Table 12.1, the least costly steel spring wire is cold drawn ASTM A227.
3. From Eq. (12.9), τmax = 0.45 Su where Su = 1550 MPa (Fig. 12.7)
τmax = 0.45(1550) = 697.5 MPa
πd 2τmax
4. From Eq. (12.6), F max = where Ks = 1.13 (Fig. 12.4)
8 CK s
12-33
!(4)2(697.5)
Fmax = = 1034. 22 "
8(3. 75)(1. 13) ■
d 4G
5. From Eq. (12.8), k = where G = 79 GPa (Appendix C-1)
8D 3N
44(79, 000)
k= = 93. 63 N/mm
8(15)3(8) ■
6. The amount of deflection when Fmax = 1034.22 N is applied to spring is
!s = Fmax/k = 1034. 22 = 11. 05 mm
93. 63
From Fig. 12.8(d), Ls = Ntd
Ls = (N + 2)d = (8 + 2)4 = 40 mm
Therefore, Lf = Ls + δs
Lf = 40 + 11.05 = 51.05 mm ■
7. Lf/D = 51.05/15 = 3.4
δs/Lf = 11.05/51.05 = 0.216
From Fig. 12.10, for the case B, no buckling should occur. ■
12-34
SOLUTION (12.27)
Known: A helical compression spring with squared and ground ends is to be designed
with given force and deflection requirement. Presetting is to be used. The loading is
static.
Find: Determine appropriate values for D, N, and Lf. Check for possible buckling.

500 N
1000 N
Fs
60 mm
Lf
Music wire Clash allowance

with d = 5 mm
Assumptions:
3. The clash allowance is 10% of the maximum deflection.
Analysis:
F
1. From Eq. (12.8), k =
!
k = ΔF = 1000 - 500 = 8. 33 N/mm

Δδ 60
2. Since class allowance is 10% of maximum deflection,
Fs = 110% of 1000 N = 1100 N
3. From Eq.(12.9), τs = 0.65 Su
4. From Fig. 12.7, Su ≈ 1650 MPa for music wire with d = 5 mm.
5. Thus, τs = 0.65(1650) = 1073 MPa.
2
6. From Eq. (12.6), ! = 8F2 CKs or CKs = !"d
"d 8F
(1073)(!)(5)2
CKs = = 9. 58
8(1100)
Therefore, C = 9.0 (Fig. 12.4) and D = Cd = 9.0(5) = 45.0 mm ■
dG
7. From Eq. (12.8), N = where G = 79 GPa (Appendix C-1)
8kC 3
12-35
(5)(79, 000)
N= = 8. 13
3
8(8. 33)(9. 0) ■
8. For ends squared and ground,
Ls = Ntd = (N + 2)d [Fig. 12.8(d)]
Ls = (8.13 + 2)5 = 50.65 mm
Lf = Ls + Fs/k = 50.65 + 1100/8.33 = 182.7 mm ■
9. Lf/D = 182.7/45 = 4.1

!s/Lf = 1100 /182. 7 = 0. 72
8. 33
From Fig. 12.10, we see that the end plates must be constrained parallel (case A)
to avoid buckling. ■
12-36
SOLUTION (12.28)
Known: A helical compression spring with squared and ground ends is to be made of
steel, and presetting is to be used. The loading is static.
Find: Determine D, d, N, and Lf.

40 lb
90 lb
Fs
1.5 in.
Lf
Su = 200 ksi Clash allowance

C=8
Assumptions:
Analysis:
1. From Eq. (12.9), τs = 0.65 Su = 0.65(200) = 130 ksi.
2. With 10% clash allowance, Fs = 1.10(90) = 99 lb.
3. k = ΔF = 50 = 33. 3 lb/in.
Δδ 1. 5
4. From Eq. (12.6), !s = 8F2 CKs where Ks = 1.06 (Fig. 12.4)
"d
1/2
d = 8Fs CKs
!"s
8(99) 1/2
d= (8)(1. 06) = 0. 128 in. ■
!(130,000)
5. D = Cd = 8(0.128) = 1.02 in. ■

4
6. From Eq. (12.8), N = d G where G = 11.5 ✕ 106 psi (Appendix C-1)
8D3k
(0. 128)4(11. 5 ! 106)
N= = 10. 92 ■
8(1. 02)3(33. 3)
12-37
7. From Fig. 12.8, for squared and ground ends,
L s = N td or Ls = (N + 2)d
Ls = (10.92 + 2)(0.128) = 1.65 in.
Fs
Lf = Ls + ! s = Ls +
k
99
Lf = 1.65 + = 4.62 in. ■
33. 3
Comment:
4. 62
Lf/D = = 4.53
1. 02
δs/Lf = ( 33.993)/4.62 = 0.644

From Fig. 12.10, we can see that the end plates should be constrained parallel to avoid
buckling.
12-38
SOLUTION (12.29)
Known: A helical compression spring used for essentially static loading has known d,
D, and N and squared and ground ends. It is made of ASTM A227 cold drawn steel
wire.
Find:
(a) Compute the spring rate and the solid height.
(b) Estimate the greatest load that can be applied without causing long-term
permanent set in excess of 2%.
(c) What spring free-length will result in the load determined in (b) just causing the
spring to become solid?
d = 0.100 in.
N=8
D = 0.625 in.
Assumptions:
Analysis:
k = d 4G
1. From Eq. (12.8), 3
where G = 11.5 ✕ 106 psi (Appendix C-1)
8D N
(0. 1)4(11. 5 ! 106)

k= = 73. 6 lb in. ■
8(0. 625)3(8)
2. To avoid set, use Eq. (12.9) τ = 0.45 Su where Su = 215 ksi (Fig. 12.7)
τ = 0.45(215) = 97 ksi
3
3. For static loads, ! = 8FD Ks [Eq. (12.6)] or F = !"d
"d3 8DKs
At C = 6.25, Ks = 1.08 (Fig. 12.4)
12-39
(97,000)!(0. 1)3
Thus, F = = 56. 4 lb ■
8(0. 625)(1. 08)
4. Ls = (N + 2)d = (10)(0.1) = 1.0 in. ■
Lf = Ls + Fs/k = 1.0 + 56.4/73.6 = 1.77 in. ■
SOLUTION (12.30)
Known: A particular machine requires a helical compression spring, having ends
squared and ground, to support a known essentially static load. The spring constant, the
stress at the design load, and D are known. The clash allowance is to be 0.10 in.
Find: Determine N, d, and Lf.
D = 3 in.
F = 500 lb
! = 80 ksi
k = 200 lb/in.
Assumptions:
Analysis:
1. From Eq. (12.6), ! = 8FD Ks assume Ks = 1.06, check later
"d3
8(500)(3)
80, 000 = (1. 06)
!d3
d3 = 0.0506
d = 0.370 in.
2. C = D/d = 3/0.370 = 8.1
12-40
From Fig. 12.4, Ks = 1.06
Therefore, d = 0.370 in. ■
4 4
3. From Eq. (12.8), k = d G or N = d G3
8D3N 8kD
6
(0. 370)4(11. 5 ! 10 )
N= = 5. 0 ■
8(200)(3)3
4. Ls = (N + 2)d = (5.0 + 2)(0.370) = 2.59 in.
Expansion from solid = 0.1 + 500/200 = 2.6 in.
Lf = 2.59 + 2.6 = 5.19 in. ■
12-41
SOLUTION (12.31D)
Known: A web site http://www.acxesspring.com lists spring materials.
Find: List (a) common spring materials, (b) spring materials highly susceptible to
hydrogen embrittlement, and (c) processes that cause hydrogen embrittlement.
Analysis:
(a) High-Carbon Spring Wire:
Music Wire ASTM A 228
Hard Drawn ASTM A 277
High Tensile Hard Drawn ASTM A 679
Oil Tempered ASTM A 229
Carbon Valve ASTM A 230
Alloy Steel Wire:
Chrome Vanadium ASTM A 231
Chrome Silicon ASTM A 401
Stainless Steel Wire:
AISI 302/304 ASTM A 313
AISI 316 ASTM A 313
17-7 PH ASTM A 313 (631)
Non-Ferrous Alloy Wire:
Phosphor Bronze Grade A ASTM B 159
Beryllium Copper ASTM B 197
Monel 400 AMS 7233
Monel K 500 QQ-N-286
(b) Flat High-Carbon Spring Steels: Sections under 0.015" having carbon content
over 0.85 with hardness over Rockwell C47 are highly susceptible to hydrogen-
embrittlement even though special plating and beating operations are employed.
(c) Hydrogen Embrittlement: Hydrogen absorbed in electroplating or pickling of
carbon steels, tending to make the spring material brittle and susceptible to
cracking and failure, particularly under sustained loads.
SOLUTION (12.35)
Known: A coil spring with squared and ground ends is to operate with a load that
fluctuates between 90 and 180 lb, during which the deflection is to vary by 1 in. Use a
steel spring wire having d = 0.200 in. and fatigue strength properties as shown on Fig.
12.16 for shot-peened wire. Presetting, and a clash allowance of 1/4 in. are to be used.
Residual stresses due to presetting are not to be taken into account.
Find: Determine appropriate values for N, D, and Lf.
12-42
F = 90 to 180 lb
Deflection = 1 in.
d = 0.200 in.
Clash allowance = 1/4 in.
Squared and
F ground end
Assumptions:
Analysis--Case A--with shotpeening:
1. From Fig. 12.16, for τmax/τmin = 2, τmax = 800 MPa = 116 ksi
2
2. From Eq. (12.5), ! = 8F2 CKw or CKw = !d "max
"d 8Fmax
2
!(0. 2) (116, 000)
CKw = = 10. 12
8(180)
3. From Fig.12.4, C = 8.5
D = Cd =8.5(0.2) = 1.70 in. ■
4. k = F/δ = 90/1 = 90 lb/in.
dG dG
5. From Eq. (12.8), k = 3 or N = 3
8NC 8kC
where G = 11.5 ✕ 106 ksi (Appendix C-1)
(0. 2)(11. 5 ! 106)
N= = 5. 2
8(90)(8. 5)3 ■
6. Ls = (N + 2)d = (5.2 + 2)(0.2) = 1.44
Clash allowance = 0.25 in.
Working deflection = F/k = 180/90 = 2.00 in.
Lf = 1.44 + 0.25 + 2.00 = 3.69 in. ■
Analysis--Case B--without shotpeening:

1. From Fig. 12.16, for τmax/τmin = 2, τmax = 640 MPa = 93 ksi
2
2. From Eq. (12.5), ! = 8F2 CKw or CKw = !d "max
"d 8Fmax
12-43
!(0. 2)2(93, 000)
CKw = = 8.1
8(180)
3. From Fig. 12.4, C = 6.5
D = Cd = 6.5(0.2) = 1.30 in. ■
4. k = F/δ = 90/1 = 90 lb/in.
dG N = dG 3
5. From Eq. (12.8), k = 3 or
8NC 8kC
6
(0. 2)(11. 5 ! 106)
N= = 11. 6 ■
8(90)(6. 5)3
6. Ls = (N + 2)d = (11.6 + 2)(0.2) = 2.72
Working deflection = F/k = 180/90 = 2.00 in.
Lf = 2.72 + 0.25 + 2.00 = 4.97 in.
Comment: The answers given in the textbook are correct for non shot peened wire but
are incorrect for shot peened wire.
SOLUTION (12.36)
Known: An automatic production machine requires a compression coil spring to keep a
follower in contact with a cam with a known angular speed. When installed, the spring
force is to vary between 150 and 600 N while the spring height varies over a range of
10 mm. An available supply of 4.5-mm-dia shot-peened wire is to be used, for which
Fig. 12.16 applies. Clash allowance is to be 2.5 mm. The limiting stress is 800 MPa
when the spring is closed solid. Ends are to be squared and ground, and presetting is
not to be used.
Find:
(a) Determine appropriate values for D, N, Ls, and Lf.
(b) Determine the likelihood of buckling, the likelihood of encountering spring surge
problems, and the approximate safety factor during normal operation.
(c) Determine the safety factor if presetting is used resulting in a residual torsion
stress of 100 MPa.
12-44
F = 150 to 600 N
!x = 10 mm
Limiting stress = 800 MPa
n = 1800 rpm
Assumptions:
Analysis: Part (a) and (b)
600 - 150 = 45 N/mm
1. k =
10
2. Fs = 600 + 45(2.5) = 712.5 N
8Fs CK
3. From Eq. (12.5), !s = w
"d2
8(712. 5)
800 = CKw Therefore, CKw = 8.93
!(4. 5)2
From Fig. 12.4, C = 7.4
Thus, D = 7.4(4.5) = 33.30 mm ■
dG dG
4. From Eq. 12.8, k = 3 or N = 3
8NC 8C k
where G = 79 GPa. (Appendix C-1)
4. 5(79, 000)
N= 3
= 2. 44 ■
8(7. 4) (45)
5. Ls = (N + 2)d = (2.44 + 2)(4.5) = 19.98 mm ■
6. Lf = 19. 98 + 712. 5 = 35. 81 mm ■

45
7. Since, Lf/D = 35.81/33.30 = 1.08, from Fig. 12.10,
the spring is well out of the buckling range. ■
12-45
8. From Eq. (12.11a),
353, 000d 353, 000(4. 5)
fn = 2
Hz = = 587 Hz = 35, 226 rpm ■
ND 2. 44(33. 30)2
Since resonance at 1800 rpm would involve the 35,226/1800 ≈ 20th harmonic, no
harmonics this high are likely to be significant. Thus, no surge problems are
expected. ■
9. For normal operation, using Eq. 12.5
! = 8F2 CKw
"d
8(600)
!max = (8. 93) = 674 MPa
"(4. 5)2
!min = 674 150 = 169 MPa
600 ( )
10.
1000
Design overload (965, 965)
point
750 740
Normal load
(169, 674)
! max (MPa)
689
500
250
0 250 500 750 1000

!min MPa
11. From the graph above,

SF = 740 = 1. 1
674 ■
Analysis: Part (c)
1. From Part (a) and (b) we have k = 45 N/mm, Fs = 712.5 N, and CKw = 8.93.
2. For a residual stress (with zero external load) of τmax = τmin = -100 MPa, the
normal load stresses are: [using Eq. (12.5)]
! = 8F2 CKw
"d
12-46
8(600)
!max = (8. 93) # 100 = 574 MPa
"(4. 5)2
( )
!min = 674 150 " 100 = 69 MPa
600
3.
1000
Design overload (965, 965)

point
750 720
689
(69, 574)
! max (MPa)
500
250
0 250 500 750 1000

!resid -100, -100 !min MPa
4. As shown on the plot above, the load could give a maximum stress of
720 + 100 = 820 MPa. It actually gives τmax = 674 MPa. Hence,
SF = 820 = 1. 22
674 ■
SOLUTION (12.37)
Known: A coil spring with squared and ground ends is to operate with a load which
fluctuates between 3 and 9 lb, during which the deflection is to vary by 2.5 in. Mean
coil diameter is 0.625 in. Steel wire corresponding to shot-peened wire in Fig. 12.16 is
to be used. The effect of presetting is not to be taken into account.
Find: Choose an appropriate clash allowance, and determine appropriate values for N,
d, and Lf.
12-47
F
F = 3 to 9 lb
Deflection = 2.5 in.
D = 0.625 in.
Squared ends
F
Assumptions:
Analysis--Case A--with shot peening:
1. See Fig. 12.16:
For τmax/τmin = 3, τmax = 761.6 MPa = 110.5 ksi
2. k = F/δ = 6/2.5 = 2.4 lb/in.
8F D
3. From Eq. (12.5), !max = max3 Kw
"d
Assume Kw = 1.2
8(9)(0. 625)
110, 500 = 3
(1. 2)
!d
d = 0.054 in.
4. C = D/d = 0.625/0.054 = 11.6
Kw = 1.13 (Fig. 12.4)
5. Assume Kw = 1.13
8(9)(0. 625)
110, 500 = 3 (1. 13)
!d
d = 0.053 in.
6. C = D/d = 11.8, Kw ≈ 1.125
From Eq. (12.5), d = 0.053 in. ■
4 4
dG dG
7. From Eq. (12.8), k = 3 or N = 3
8D N 8D k
12-48
4 6
(0. 053) (11. 5 ! 10 )
N= 3 = 19. 36
8(0. 625) (2. 4) ■
8. Clash allowance = 10%
! solid = (1.1) 9 lb = 4.125 in.
2.4 lb/in.
Solid height = (N + 2)d = (19.36 + 2)(0.053) = 1.132 in.
Lf = 1.132+ 4.125 = 5.257 in. ■
Analysis--Case B--without shot peening:

1. See Fig. 12.16:
For τmax/τmin = 3, τmax = 590 MPa = 85.6 ksi
2. k = F/δ = 6/2.5 = 2.4 lb/in.
8FmaxD K
3. From Eq. (12.5), !max = w
"d3
Assume Kw = 1.2
8(9)(0. 625)
85, 600 = 3
(1. 2)
!d
d = 0.0586 in.
4. D/d = 0.625/0.0586 = 10.67
Kw = 1.14 (Fig. 12.4)
5. Assume Kw = 1.14
8(9)(0. 625)
85, 600 = 3
(1. 14)
!d
d = 0.0576 in.
6. D/d = 10.85, Kw ≈ 1.14
Thus, d = 0.0576 in. ■
4 4
dG dG
7. From Eq. (12.8), k = 3 or N = 3
8D N 8D k
4 6
(0. 0576) (11. 5 ! 10 )
N= 3 = 27. 0
8(0. 625) (2. 4) ■
8. Clash allowance = 10 %
! solid = (1.1) 9 lb = 4.125 in.
2.4 lb/in.
Lf = 1.670 + 4.125 = 5.795 in.
12-49
SOLUTION (12.38new)
fluctuates between 30 and 90 lb, during which the deflection is to vary by 2.5 in. Mean
coil diameter is 0.625 in. Steel wire corresponding to shot-peened wire in Fig. 12.16 is
to be used. The effect of presetting is not to be taken into account.
d, and Lf.

F
F = 30 to 90 lb
Deflection = 2.5 in.
D = 0.625 in.
Squared ends
F
Assumptions:
1. See Fig. 12.16:
For τmax/τmin = 3, τmax = 761.6 MPa = 110.5 ksi
2. k = F/δ = 60/2.5 = 24 lb/in.
8FmaxD K
3. From Eq. (12.5), !max = w
"d3
Assume Kw = 1.2
8(9)(0. 625)
110, 500 = 3 (1. 2)
!d
d = 0.1159 in.
4. C = D/d = 0.625/0.1159 = 5.39
12-50
Kw = 1.28 (Fig. 12.4)
5. Assume Kw = 1.28
8(90)(0.625)
110,500 = (1.28)
!d 3
d = 0.1183 in.
6. C = D/d = 5.283, Kw ≈ 1.28
From Eq. (12.5), d = 0.1183 in. ■

4 4
7. From Eq. (12.8), k =
dG
3 or
N= d G
3
8D N 8D k
4 6
(0.1183) (11.5 ! 10 )
N= 3
= 48.05
8(0.625) (24) ■
! solid = (1.1) 90 lb = 4.125 in.

24 lb/in.
Lf = 5.92 + 4.125 = 10.05 in. ■

1. See Fig. 12.16:
For τmax/τmin = 3, τmax = 590 MPa = 85.6 ksi
2. k = F/δ = 60/2.5 = 24 lb/in.
8FmaxD K
3. From Eq. (12.5), !max = w
"d3
Assume Kw = 1.2
8(90)(0.625)
85,600 = (1.2)
!d 3
d = 0.126 in.
4. D/d = 0.625/0.126 = 4.96
12-51
Kw = 1.3 (Fig. 12.4)
5. Assume Kw = 1.3
8(90)(0.625)
85,600 = (1.3)
!d 3
d = 0.129 in.
6. D/d = 4.82, Kw ≈ 1.32
Thus, d = 0.129 in. ■

4 4
dG dG
7. From Eq. (12.8), k = 3 or N = 3
8D N 8D k
4 6
(0.129) (11.5 ! 10 )
N= 3
= 67.9
8(0.625) (24) ■
! solid = (1.1) 90 lb = 4.125 in.

24 lb/in.
Lf = 9.017 + 4.125 = 13.142 in.
12-52
SOLUTION (12.39)
fluctuates between 45 and 90 lb, during which the deflection is to vary by 1/2 in. Mean
coil diameter is 2 in. Steel wire corresponding to shot-peened wire in Fig. 12.16 is to be
used. The effect of presetting is not to be taken into account.
d, and Lf.
F = 45 to 90 lb
Deflection = 1/2 in.
D = 2 in.
Squared and
F ground end
Assumptions:
1. See Fig. 12.16:
For τmax/τmin = 2, τmax = 800 MPa = 116 ksi
2. k = F/δ = 45/0.5 = 90 lb/in.
8F D
3. From Eq. (12.5), !max = max3 Kw
"d
Assume Kw = 1.2
8(90)(2)
116, 000 = (1. 2)
!d3
d = 0.168 in.
4. C = D/d = 2/0.168 = 11.9
Kw = 1.125 (Fig. 12.4)
5. Assume Kw = 1.125
8(90)(2)
116, 000 = (1. 125)
!d3
12-53
d = 0.164 in.
6. C = D/d = 12.19, Kw ≈ 1.12
From Eq. (12.5), d = 0.164 in. ■
4 4
dG dG
7. From Eq. (12.8), k = 3 or N = 3
8D N 8D k
(0. 164)4(11. 5 ! 106)
N= = 1. 44
8(2)3(90) ■
δ solid = (1. 1) 90 lb = 1. 1 in.

90 lb/in.
Lf = 0.565+ 1.1 = 1.665 in. ■

1. See Fig. 12.16:
For τmax/τmin = 2, τmax = 640 MPa = 93 ksi
2. k = F/δ = 45/0.5 = 90 lb/in.
8FmaxD K
3. From Eq. (12.5), !max = w
"d3
Assume Kw = 1.2
8(90)(2)
93, 000 = (1. 2)
!d3
d = 0.181 in.
4. D/d = 2/0.181 = 11.1
Kw = 1.13 (Fig. 12.4)
5. Assume Kw = 1.13
8(90)(2)
93, 000 = (1. 13)
!d3
d = 0.177 in.
6. D/d = 11.3, Kw ≈ 1.13
Thus, d = 0.177 in. ■
4 4
dG dG
7. From Eq. (12.8), k = 3 or N = 3
8D N 8D k
(0. 177)4(11. 5 ! 106)
N= = 1. 96
8(2)3(90) ■
12-54
δ solid = (1. 1) 90 lb = 1. 1 in.
90 lb/in.
Lf = 0.737 + 1.1 = 1.837 in.
SOLUTION (12.40)
Known: A helical compression spring is subjected to a load fluctuating between 100
and 250. Fatigue properties of the spring wire correspond to the curve for shot-peened
wire given in Fig. 12.16. The spring failed in service after about 105 cycles. A
replacement spring was found which was identical in all respect except that its free-
length was slightly shorter. To correct for this, the spring was stretched slightly to
increase its free-length to exactly that of the original spring.
Find: Show by means of a τmax - τmin plot, whether you would expect the life of the
replacement spring to be the same as, less than, or greater than that of the original.
F = 100 to 250 N F = 100 to 250 N
F F
Original spring Replacement
failed in service spring stretched to
after about 10 5 the same length as
cycles the original spring
Analysis:
Design overload
! max
points
Without residual
stress
Residual stress
0 ! min
12-55
In this problem, the residual stress causes the load stresses to begin closer to the
fatigue limit line. Thus, the life of the replacement spring will be shorter than the
original. ■
Comment: Stretching the spring in tension gives residual stresses beneficial for future
tensile load but harmful for future compressive load.
SOLUTION (12.41)
Known: When the clutch is engaged, the springs must provide a clamping force of
1020 lb (170 lb per spring). When the clutch is disengaged the springs are all 0.10 in.
shorter where a 25 lb increase of the force of each spring is considered satisfactory.
The clash allowance is to be 0.050 in. The wire size is 0.192 in. The material is to be
shot-peened wire having fatigue properties as indicated in Fig. 12.16. Use a safety
factor for eventual fatigue failure of 1.3. Presetting is to be used but not taken into
account in the calculations.
Find: Determine a suitable combination of D, N, Ls, and Lf.

Clamping
force Clamping force
+ "F
Clamping force = 170 lb/spring
! = 0.10 in.
! "F = 25 lb/spring
d = 0.192 in.
SF = 1.3
Engaged Disengaged
Assumptions:
3. The springs have squared and ground ends.
Analysis:
τmax F max 170 + 25
1. For = = = 1. 15
τmin F min 170
12-56
2. See Fig. 12.16
150
!max = 133
" life, shot peened
100
!max = 1.15
!max (ksi)
!min
50
0
0 50 100 150
! min (ksi)
3. From above graph, τmax = 133 ksi

133 = 102 ksi
For SF = 1.3, use !max =
1. 3
8F
4. From Eq. (12.5), !max = max CKw
"d2
8(195)
102, 000 = CKw
!(0. 192)2
CKw = 7.57
5. From Fig. 12.4, C = 6.0
D = Cd = (6.0)(0.192) = 1.15 in. ■
6. k = F = 25 lb = 250 lb/in.
δ 0. 1 in.
dG dG
7. From Eq. (12.8), k = 3 or N = 3
8C N 8C k
(0. 192)(11. 5 ! 106)
N= = 5. 1 ■
8(6. 0)3(250)
8. Assuming squared and ground ends,
Ls = (N + 2)d = (7.1)(0.192) = 1.36 in. ■
F max
Lf = Ls + clash allowance + = 1. 36 + 0. 05 + 195 = 2. 19 in. ■
k 250
12-57
SOLUTION (12.42D)
Known: A force of 4.45 kN is required to engage a clutch similar to the one shown in
Fig. 18.2. This force is to be provided by nine identical springs equally spaced around
the pressure plate of the clutch. The outside diameter of the coils can be no more than
40 mm, and the length of the springs when the clutch is engaged cannot exceed 52 mm.
The pressure plate must move 3 mm to disengage the friction surfaces, and the lowest
spring rate reasonably possible is desired.
Find: Design the springs, determining a satisfactory combination of D, d, N, wire
material, type of ends, Ls, and Lf.
52 mm
4.45 kN D0 ! 40 mm Engaged
9 Position
4.45 kN + (3)(k) mm Disengaged

9 9 Position
3 mm
See Fig. 18.2 where total clamping force = 4.45 kN
Decisions/Assumptions:
1. The clash allowance is 2 mm.
2. The safety factor is 1.3.
3. The ends are squared and ground.
4. Presetting is to be used but not taken into account in the calculations.
5. The spring is made of shot-peened steel wire having fatigue properties as indicated
in Fig. 12.16.
Analysis:
1. Design constraints are:
(a) Since the lowest spring rate reasonably possible is desired, from Eq. 12.8
4
k = d G the largest D, largest N, and smallest d is desired.
8D3N
(b) D + d ≤ 40 mm
(c) Ls ≥ Engaged length − Working deflection − Clash allowance
Assuming the clash allowance to be 2 mm,
Ls ≤ (52 − 3 − 2) = 47 mm
12-58
2. First, choose C = 8.0, N = 9, and D = 35 mm. Then, d = 4.375 mm and D + d < 40
mm.
Ls = (N + 2)d = 48.1 mm which is too long. Thus, choose a smaller N.
3. Choose N = 7.5. Then, Ls = (7.5 + 2)4.375 = 41.6 mm which is satisfactory.
4. From Eq. 12.8, where G = 79 MPa for a steel wire.
(4. 375)4(79, 000)

k= = 11. 25 N/mm
8(35)3(7. 5)
Fengaged (4450/9)
5. Lf = + Lengaged = + 52 = 95. 95 mm
k 11. 25
6. Fengaged = 4450/9 = 494 N, Fdisengaged = (95.95 − 49)11.25 = 528 N
Thus, Fmax = !max = 528 = 1. 07 " 1
Fmin !min 494
7. From Fig. 12.16, for infinite-life with shot-peening, τmax = 965 MPa.
With a safety factor of 1.3,
τmax = 965/1.3 = 742 MPa.
8. Using Eq. 12.5,
8Fdisengaged
!disengaged = CKw where Kw = 1.18 (Fig. 12.4)
"d2
8(528)
!diseng. = (8)(1. 18) = 663 MPa
" 4. 375 # 10-3 2
Therefore, τdiseng. < τmax
9. Checking for buckling using Fig. 12.10, Lf/D = 95.95/35 = 2.74. Thus, the spring
will not buckle.
10. In summarizing the answers, the spring is made of shot-peened steel wire having
properties as indicated in Fig. 12.16, has squared and ground ends, and
d = 4.375 mm
D = 35 mm
N = 7.5
Ls = 41.6 mm
Lf = 95.95 mm ■
Comment: If a lower spring rate is desired, the above steps can be repeated with
different combinations of C, N, and D.
SOLUTION (12.43)
Known: A helical compression spring is to be designed for infinite life when subjected
to a known fluctuating load. Su, Sus, Sy, Sys, and a zero-to-maximum torsional
endurance limit are known for the steel spring wire. The value of C = 7 and safety
factor = 1.
Find: Determine the wire diameter theoretically required:
(a) if presetting is not used
(b) if presetting is used to maximum advantage.
12-59
F
F = 55 ~ 100 lb
Su = 180 ksi
Sus = 144 ksi
Sy = 170 ksi
Sys = 99 ksi
Zero-to-maximum torsional
endurance limit = 80 ksi
C=7
SF = 1
Assumptions:
Analysis:
1. For C = D/d = 7, from Fig. 12.4 Kw = 1.21
8Fmax CK
2. From Eq. (12.5), !max = w
"d2
8(110)
!max = 2
(7)(1. 21) = 2373
"d d2
3.
150 (144, 144)
b a' !max = 99
100
a
80
!max (ksi)
!max = Fmax = 2
!max due 50 !min Fmin
to load in
!part (b)
= 120 ksi
0 50 100 150
! min (ksi)
(-25, -25)
4. From the above graph, τmax = 99,000 psi; therefore,
99, 000 = 2373

2 or d = 0.155 in. ■
d
12-60
(Note: This assumes no yielding is permitted. If slight yielding is okay, the
operating point moves from a to aʹ′ on the graph, giving slightly higher τa, which is
permitted; therefore, slightly smaller d.)
5. The theoretical maximum τresidual = Sys/3. Assume practical limit is about

Sys/4 ≈ 25 ksi. Then from graph, τmax due to load = 120 ksi.
2373
Therefore, 120, 000 = 2 or d = 0.141 in. ■
d
SOLUTION (12.44)
Known: The specifications for a coil spring are known. Infinite fatigue life is required,
using a safety factor of 1.3 applied to the maximum load only. The fatigue strength can
be represented by a line between τmax = 600, τmin = 0 and τmax = τmin = 900 MPa.
Find: Determine a suitable combination of d, D, and N.

F
Static load per spring = 3500 N

Rate per spring = 40 N/mm
Jounce = 150 mm
Rebound = 58 mm
Assumptions:
Analysis:
1. First, choose a reasonable value of C, say C = 8. Thus, from Fig. 12.4
Kw = 1.18.
2. At the "design overload":
Using Eq. (12.5),
8F 8[(3500 + (40)(150))1. 3]
! max = max2 CK w = 2 (8)(1. 18) = 296,879/d2
"d "d
8F min 8[(3500 # (40)(58)]
! min = 2 CK w = 2 (8)(1. 18) = 28,366/d2
"d "d
τmax/τmin = 296,879/28,366 = 10.47
12-61
3.
1000
(900, 900)
!max = 10.47
!min
800
!max (MPa)
600
!max = 620
400
200
0 200 400 600 800 1000

!min (MPa)
4. From graph, τmax = 620 MPa.

296, 879
620 = 2 or d = 21.88 mm* ■
d
5. D = Cd = 8(21.88) = 175.0 mm ■
dG
6. From Eq. (12.8), k = 3 where G = 79 GPa (Appendix C-1)
8NC
(21. 88)(79, 000)
N= 3 = 10. 55 ■
8(8) (40)
Comment: *A slightly modified solution with d = 22 mm would probably be preferred.
SOLUTION (12.45)
Known: A valve spring is subjected to the accelerations shown. The critical point for
the spring is the valve lift of 0.201 in. A larger spring force is required at maximum
valve lift (0.384 in.) but this is easily satisfied because the spring is further compressed.
The specifications of the valve spring are known. High quality valve spring wire is to
be used, and full advantage taken of both shot-peening and presetting. The fatigue
failure will not occur if the calculated stress with spring solid is limited to 800 MPa.
Ends are to be closed and ground.
Find: Determine a suitable combination of d, D, N, and Lf.
12-62
3600 engine rpm
1800 camshaft rpm
Valve acceleration
+
-
Cam angle
"Reversal point" "Reversal point"
Valve lift is 0.201 in.
Valve lift is 0.384 in.
(maximum--on "nose of cam)
Ends closed and ground

Maximum stress with spring
solid = 800 MPa
Valve spring specifications:

1. Spring length when valve is closed: not over 1.50 in.
2. Spring force when valve is closed: at least 45 lb.
3. Spring force when valve lift is 0.201 in.: at least 70 lb.
4. Spring force at maximum valve lift of 0.384 in.: at least 86 lb
but not over 90 lb.
5. Spring outside diameter: not over 1.65 in.
6. Clash allowance: 0.094 in.
7. Natural frequency: at least as high as the 13th harmonic at 1800
camshaft rpm (i.e., at least 390 Hz).
Assumptions:
Analysis:
1. For maximum fn, select highest allowable stiffness:
F 90 − 70
k=Δ = = 109. 29 lb/in.
δ 0. 384 − 0. 201
This gives a valve closed force of 70 − (109.29)(0.201) = 48.03 lb which is
satisfactory.
2. Spring rate requirement:
4
dG
From Eq. (12.8), k = 3
8D N
12-63
d 4G d4(11. 5 ! 106)
Thus, N = =
8D3k 8(109. 29)D3
13, 153d
Since C = D/d, N = 3 (1)
C
3. Spring length requirement:
Valve open length = Ls + 0.384 + clash allowance < 1.50
(N + 2)d + 0.384 + 0.094 < 1.50
(N + 2)d < 1.022 (2)
4. Spring diameter requirement:
D + d ≤ 1.65 (3)
5. Spring stress requirement:
Fs = 90 + (0.094)(109.29) = 100.27 lb
8F
From Eq. (12.5), !s = s2 CKw
"d
800 MPa = 800(0.145) = 116 ksi
8(100. 27)
116, 000 = CKw
!d2
CK w
d= (4)
454. 74
6. Spring natural frequency requirement:
13, 900d
From Eq. (12.11), f n = 2 Hz where d and D are in inches.
ND
13, 900d 13, 900
fn = 2 = ≥ 390 Hz (5)
ND NDC
7. For maximum nominal wire stress (for minimum wire mass and high fn), try to
satisfy Eq. (4) with smallest Kw.
8. From Fig. 12.4, choose C = 9 for first trial.
From (4), d = 10. 46 = 0. 152 in. ■

454. 74
D = Cd = (9)(0.152) = 1.365 in. ■
From (3), D + d = 1.52 in. < 1.65 in.; therefore, OK.
13, 153(0. 152)
From (1), N = = 2. 74 ■
93
From (2), (2.74 + 2)(0.152) = 0.72 in. < 1.022 in.; therefore OK.
13, 900(0. 152)

From (5), f n = 2
= 414 > 390 Hz; therefore OK.
(2. 74)(1. 365)
12-64
Lf = Ls + clash allowance + 90 lb/k
= (N + 2)d + 0.094 + 90/109.23
= (4.74)(0.152) + 0.094 + 0.824
= 1.638 in. ■
Lf/D = 1.20, Fig. 12.10 shows no buckling concern.
9. For comparison, try solution with C = 7.
From (4), d = 8. 49 = 0. 137 in. ■

454. 74
D = Cd = (7)(0.137) = 0.956 in. ■
From (3), D + d = 1.093 in. < 1.65 in.; therefore, OK.
13, 153(0. 137)
From (1), N = 3 = 5. 25 ■
7
From (2), (5.25 + 2)(0.137) = 0.993 in. < 1.022 in.; therefore OK.
13, 900
From (5), f n = (5. 25)(0. 956)(7) = 396 > 380 Hz; therefore OK. (But not as good
as C = 9)
Lf = (7.25)(0.137) + 0.094 + 0.824
= 1.911 in. ■
Lf/D = 2.0, Fig. 12.10 shows no buckling concern.
SOLUTION (12.46)
Known: A cam and follower is to rotate at 10 Hz and impart a harmonic or sinusoidal
oscillation to the follower. Total follower lift and weight of the oscillating parts are
known. The spring diameter is limited by the available space.
Find: Determine a satisfactory combination of D, d, N, material, Ls, Lf. Determine the

natural frequency of the spring proposed.
Total follower lift = 20 mm

Weight of the oscillating parts = 90 N
Spring minimum inside diameter = 25 mm
20 mm Spring maximum outside diameter = 50 mm
Frequency of rotation = 10 Hz
Assumptions:
12-65
Analysis: [The following is only one of many possible solutions.]
1.
Spring force = 220 + 180 sin ! t
F1 = m x = -362 sin ! t
Displacement, x (mm)
400 when ! = 10 Hz
Force (N)
300
200 20
100 10
0 0
0 !t
" x = 10 + 10 sin ! t
Spring force required
(for ! = 10 Hz)
2. The above graph shows follower displacement, x, vs. cam angle, wt. The
equation with x in meters is: x = 0.01 + 0.01 sin ωt
3. At a rotating speed of ω = 10 Hz = 20π rad/s, the inertial force, Fi is:
Fi = mx = 90 N 2 !0. 01(20")2sin #t
9. 81 m/s
= −362 sin ωt (in newtons)
4. The spring is needed only to oppose the negative acceleration. Both Fi and spring
force are plotted above.
5. To compensate for small friction and gravity forces plus provide a small safety
factor, select minimum and maximum spring forces of 40 N and 400 N
Δ F = 400 − 40 = 18 N/mm
respectively (as shown on graph). Thus, k =
δ 20
And the expression for the spring force plotted is:
F = 40 + kx = 40 + 18(10 + 10sin ωt) = 220 + 180 sin ωt
6. Select spring wire having fatigue properties shown in Fig. 12.16, and specify
shot-peening.
τmax F max 400
= = = 10
τmin F min 40
7. From Fig. 12.16, τmax = 710 MPa
8. Based on information on Fig. 12.4, tentatively select C = 8. Since a high fn is not
required and since space is ample, select a generous safety factor of 1.4. Hence,
design for τmax = 710/1.4 = 507 MPa.
12-66
9. From Eq. (12.5), !max = 8Fmax CKw
"d2
8(400)
507 = (9. 47)
!d2
Therefore, d = 4.36 mm ■
D = Cd = 8(4.36) = 34.9 mm ■
10. From Eq. (12.8), k = dG 3 where G = 79 GPa (Appendix C-1)

8NC
(4. 36)(79, 000)
N= 3 = 4. 67 ■
8(18)(8)
11. Choose a dash allowance of 10 % of deflection at 400 N load; therefore,
Fs = 400(1.1) = 440 N.
12. Ls = (N + 2)d = 6.67(4.36) = 29.08 mm ■
Lf = Ls + Fs/k = 29.08 + 440/18 = 53.52 mm ■
353, 000d
13. From Eq. (12.11a), fn = Hz where d and D are in mm
ND2
353, 000d
fn = 2 = 271 Hz
4. 67(34. 9)
Lf/D = 53.52/34.9 = 1.53; therefore, no buckling problem.
14. For rotation at 10 Hz, only harmonics would be in resonance during starting and
stopping. Since this cam should give no harmonics, dynamics should be of no
concern.
Comment: Since fn and size limitations were easily met, one should consult the spring
supplier in search of a lowest cost solution, retaining high reliability.
SOLUTION (12.47D)
Known: The internet has various sites that contain calculators useful for designing
compression springs.
Find: Select a calculator that is (a) potentially useful, (b) easy to use, and (c) accurate.
Write a short description of the spring calculator.
Analysis: This exercise is left for the student.
12-67
SOLUTION (12.48D)
Known: Helical tension springs used as a component of a mass-produced machine
have improperly formed hooks, causing the load to be applied closer to the outside of
the outside of the spring than to its geometric axis. Upon attempting to use these
springs, it is noted that they deform permanently as soon as the maximum normal load
is applied.
Find: Explain why, briefly.
Assumption: No residual stresses are present.

Analysis: With proper (concentric) load positioning, the maximum torque on any wire
segment is F(D/2) and the maximum bending moment is zero. If the load is eccentric
by an amount e, these values are increased to
Tmax = F(D/2 + e) and Mmax = Fe
SOLUTION (12.49D)
Known: A tension spring must exert an essentially static force of 135 N. The initial
tension and the spring rate are known.
Find:
(1) Determine a satisfactory combination of D, d, N, and wire material.
(2) Determine the length of the coiled section when unloaded and when the 135 N
force is applied.
12-68
Initial tension = 45 N
Spring rate = 11.0 kN/m
Assumption: The applied load coincides with the geometrical axis of the spring.
Analysis:
1. Because of cost (see Table 12.1), try a solution using ASTM A227
steel wire. ■
Su varies with d, but start with a valve in mid-range, say Su = 1500 MPa.
(Fig. 12.7)
2. From Eq. (12.9), τs < 0.45Su would be appropriate for a compression spring.
Use this value for load stress here, but because tension springs can easily be
overloaded, use safety factor = 2 applied to load.
3. From Fig. 12.4, try a solution with C = 9
4. From Eq. (12.6), ! = 8F2 CKs
"d
where CKs = 9.5 (Fig. 12.4)
8(2)(135)
(0. 45)(1500) = (9. 5)
!d2
Therefore, d = 3.11 mm ■
D = Cd = (9)(3.11) = 28.0 mm ■
5. For d = 3.11, Su ≈ 1400 MPa; therefore, SF = 1.9 not 2.
6. From Eq. (12.8), k = dG 3
8NC
(3. 11)(79, 000)
N= 3 = 3. 83 ■
8(11. 0)(9)
7. Unloaded length of coiled section = (N + 1)d =
4.83(3.11) = 15.0 mm ■
8. When loaded, the first 45 N overcomes preload. The remaining 90 N elongates
the spring; therefore, the loaded length of the coiled section = 15.0 + 90/11.0 =
23.2 mm ■
Comment: This is only one of several possible solutions.
12-69
SOLUTION (12.50D)
Known: A wheel chair brake in its retracted position has a tension spring exerting a
force of 4 N, which holds the handle against the stop-pin. When the handle is moved
clockwise, pivot A drops below the axis of the spring and the spring acts to hold the
brake shoe against the tire. The outside diameter is limited to 10 mm.
Find: Estimate dimensions needed by scaling the drawing. Determine a satisfactory
combination of D, d, N, wire material, and free-length of coiled section.
F F
35 mm
Decision: A minimum value of k is desired for ease of operation.

Assumption: The applied load coincides with the geometrical axis of the spring.
Design Analysis:
1. From the drawing, maximum distance between spring ends ≈ 35(0.707)2
≈ 50 mm, giving δ = 15 mm
2. A minimum value of k is desired for ease of operation. As a rough preliminary
estimate, assume Fmax (at δ = 15 mm) = 12 N.
12 − 4
Then, k = = 0. 533 N/mm
15
3. For high reliability in a safety-critical application, choose a high quality material.
Assume Figure 12.16 "shot-peened" fatigue properties. Load line slope is not yet
known, but estimate τmax = 800 MPa, and apply safety factor of 2.5 to the load.
4. From Fig. 12.4, choose C = 9 for the first trial.
8Fmax CK
From Eq. 12.5, !max = w
"d2
where CKw = 10.46 (Fig. 12.4)
!max = 8Fmax CKw

"d2
8(12)(2. 5)
800 = (10. 46)
!d2
Thus, d = 0.994 or d = 1.00 mm ■
and D = Cd = 9(1.00) = 9.00 mm ■
5. This just satisfies the outside diameter requirement that D + d ≤ 10 mm.
12-70
Su
6. From Eq. (12.12), assume !initial = 0. 4
C
From Fig. 12.16 and 12.7, estimate Su ≈ 1800 MPa,
then !i = 0. 4(1800)/9 = 80 MPa.
7. For τmax = 800 MPa at F = (12)(2.5) = 30 N, by proportion, τi = 80 MPa
corresponds to Fi = 3N. This means that the specified Fmin = 4N requires
δ= 4N - 3N or an initial δ of 1.9 mm. Assume that, due to tolerances and

0. 533 N/mm
wear, an initial deflection of (at least) 2 mm is desired (with slightly less initial
tension in the spring).
8. By scaling the drawing, assume solid height of coiled section can be 23 mm minus
the 2 mm initial deflection. Then (N + 1)d = 23 mm with d = 1.00,
N = 22. ■
dG
9. From Eq. 12.8, k = where G = 79 GPa (Appendix C-1)
8NC 3
(1)(79, 000)
k= = 0. 616 N/mm; hence
8(22)(9)3 ,
Fmax = 4 + kδ = 4 + (0.616)15 = 13.24 N.
Since this exceeds the initially assumed Fmax of 12N, the safety factor is reduced
to 2.5 (12/13.24) = 2.3.
τmax F max 13. 24
Also, = = = 3. 31, Fig. 12.16 shows a fatigue limited τmax of 740
τmin F min 4
MPa instead of the initially assumed 800 MPa. Thus, safety factor is further
lowered to 2.3(740/800) = 2.1, but this should be satisfactory.
SOLUTION (12.51)
Known: A semi-elliptic leaf spring has four leaves, each made from 0.1 in. ✕ 2 in. steel
having known properties.
Find: Use the simplified "triangular plate" model.
(a) Determine the total spring length needed to give a spring rate of 75 lb/in.
(b) In service, the spring will carry a static load (applied to the center) of P, plus a
superimposed dynamic load which varies from +P/2 to -P/2. Determine the
highest value of P that will give infinite life, with a safety factor of 1.3.
Su = 180 ksi
Sy = 160 ksi
Sn = 80 ksi
Kf = 1.3
12-71
Assumptions:
1. The end points apply to a uniform load over the width of the spring ends.
2. Failure does not occur at the spring end.
3. The central force is aligned so as not to induce twisting in the spring.
4. The deflections do not significantly change the geometry.
Analysis:
3
1. With reference to Fig. 12.22b, k = 2F = Ebh3
δ 3L
6
where E = 30 ✕ 10 psi (Appendix C-1)
(30 ! 106)(2)(4)(0. 1)3
75 =
3L3
L = 10.2 in.
Hence, spring length = 20.4 in. ■
2. From Fig. 12.22b, ! = 6FL Kf
bh2
6(P/2)(10. 2)
!m = (1. 3) = 497 P
8(0. 1)2
6(P/4)(10. 2)
!a = (1. 3) = 284. 5 P
8(0. 1)2
3.
80 "a
! "m = 0.5
life
" a (ksi)
42 ksi
0 100 Sy Su 200
"m (ksi)
4. From graph, σa = 42 ksi = 248.5P; therefore, P = 169 psi. But with safety factor of
1.3, P = 169/1.3 or P = 130 lb. ■
SOLUTION (12.52)
Revised Sample Problem 12.4
Known: A semi-elliptic leaf with known spring rate is subjected to a known fluctuating
force.
Find: Estimate the overall spring length and width of the leaf.
12-72
F F = 1000 to 5000 N
2F
h = 7 mm k = 20 N/mm
Kf = 1.3
Assumptions: Same as those in sample problem 12.4.

Analysis:
1. Steps 1-3 are the same as in sample problem 12.4.
4. The spring rate k = 20 N/mm. Substituting the given values of F and k, we have
(200, 000)(0. 61 L)(7)3
20 = , or L = 835 mm
3L3
b = 0.61L = 0.61(835) = 509 mm
5. Overall length is 2L, or 1670 mm. The width of each of the five leaves is one-fifth
of 509 mm, or 101.8 mm. ■■
Comment: If the conservative Goodman line for infinite bending life is used rather
than the infinite-life bending curve given in Fig. 12.26b, we find that σa = 425 MPa;
and hence, b = 692 mm and L = 925 mm, or 2L = 1850 mm and b/5 = 138.4 mm. That
is, a larger spring would be required.
Revised Sample Problem 12.5
Known: An actual leaf spring is equivalent to a trapezoidal plate rather than a
triangular plate.
Find: Determine the change in the stiffness and energy capacity of the trapezoidal plate
versus the triangular plate.
Triangular Plate
b = 509 Triangular-plate solution to revised Sample Problem 12.4

L = 835
Trapezoidal Plate
L = 835
L = 835
b = 509 102 = b = 407 + 102
L = 835
12-73
Assumption: The effect of interleaf friction is insignificant.
Analysis:
3 3 3
1. Triangular plate: ! = 6FL = 0. 01179 FL , k = F = 84. 83 Eh ■
Ebh 3 Eh 3 ! L3
3
2. Trapezoidal plate: !1 = 6FL3 = 0. 0147 FL3 , k1 = F = 67. 83 Eh
3 3
Ebh Eh !1 L3
3 3 3
!2 = 4FL3 = 0. 0392 FL3 , k2 = F = 25. 5 Eh
Ebh Eh !2 L3
3
k = k1 + k2 , k = 93. 33 Eh3 ■
L
3. The three points under analysis in SAMPLE PROBLEM 12.4 apply to the revised
design as well.
SOLUTION (12.53)
Known: A semi-elliptic leaf spring has four leaves, each made from 0.1 in. ✕ 1.8 in.
steel having known properties.
Find: Use the simplified "triangular plate" model.
(a) Determine the total spring length needed to give a spring rate of 80 lb/in.
(b) In service, the spring will carry a static load (applied to the center) of P, plus a
superimposed dynamic load which varies from +P to -P. Determine the highest
value of P that will give infinite life, with a safety factor of 1.5.
Su = 150 ksi
Sy = 100 ksi
Sn = 70 ksi
Kf = 1.2
Assumptions:
1. The end points apply to a uniform load over the width of the spring ends.
12-74
Analysis:
3
1. With reference to Fig. 12.22b, k = 2F = Ebh3
δ 3L
(30 ! 106)(1. 8)(5)(0. 1)3
80 =
3L3
L = 10.6 in.
Hence, spring length = 21.2 in. ■
2. From Fig. 12.22b, ! = 6FL Kf
bh2
6(P/2)(10. 6)
!m = (1. 2) = 424 P
9(0. 1)2
6(P/2)(10. 6)
!a = (1. 2) = 424 P
9(0. 1)2
3.
"a
"m = 1
80
70
yielding line
" a (ksi)
47.7 ksi
! li
fe
0 180
Sy = 100 ksi Su = 150 ksi
"m (ksi)
4. From graph, σa = 47.7 ksi = 424P; therefore, P = 112.5 psi. But with safety factor
of 1.5, P = 112.5/1.5 or P = 75 lb. ■
SOLUTION (12.54)
Known: A semi-elliptic leaf spring is to be designed so that it will just have infinite
fatigue life at an overload that varies between 400 and 1200 N. The total length of the
spring is to be 1 m. The steel to be used has known properties.
Find:
(a) Estimate the appropriate values of h and b for a spring of proportion b = 50h.
(b) Based on a trapezoidal approximation similar to the one in Fig. 12.27b, determine
the deflection at the center of the spring when a 1200 N load is applied.
12-75
F F
1000 mm
Su = 1200 MPa
Sy = 1030 MPa
Sn = 500 MPa
K f = 1.3
2F
400 to 1200 N
Assumptions:
1. The end pivots apply a uniform load over the width of the spring ends.
Analysis:
1. Using "triangular plate" approximation:
500
!a !a
!m = 0.5
(MPa)
550
0 500 1000 1200

!m (MPa)
2. Fm = 400 N, Fa = 200 N, σa/σm = 0.5
6F mL
3. From Fig. 12.22b, σm = 2 Kf
bh
6(400)(500)
550 = (1. 3)
50h h2
Therefore, h = 3.84 mm ■
and b = 50 h = 192.1 mm ■
4. Assume 5 leaves* of 192.1/5 = 38.4 mm width. The equivalent trapezoidal

cantilever has F = 1200/2 = 600 N.
12-76
5. From Fig. 12.27b,
L = 500 mm
L = 500 mm
1 + 2
b = 38.4 mm
b = 153.7 mm
3 3
k1 = F = Ebh3 = 25. 62 Eh3
! 6L L
3 3
k2 = F = Ebh3 = 9. 60 Eh3
! 4L L
3
k = k 1 + k 2 = 35. 22 Eh3
L
3
δ = F=
6. FL
k 35. 22Eh 3
where E = 207 GPa (Appendix C-1)
3
600(500)
δ= 3 = 0. 182 m
35. 22(207, 000)(38. 4)
or δ = 182 mm ■
* Other numbers might also be used.
12-77
SOLUTION (12.55)
Known: A full-elliptic leaf spring operates normally with a load which fluctuates
between 100 and 200 lb, but is to be designed for an overload that fluctuates between
100 and 300 lb. The total spring length, h, Kf, and the properties of the spring are
known.
Find:
(a) Determine the total width, b, required.
(b) Show, on a σm-σa diagram the "operating points" for (1) machine turned off and
spring supporting a static load of 100 lb only, (2) normal loads applied, and (3)
design overloads applied.
(c) Determine the spring rate.
24 in.
2F
Su = 180 ksi
Sy = 160 ksi
Sn = 80 ksi
K f = 1.3
h = 0.1 in.
2F
100 to 300 lb
Assumptions:
Analysis:
1. During overload, 2Fm = 200 lb, 2Fa = 100 lb, σa/σm = 0.5
2.
80
!a (ksi)
3
40
2 85
1 45°
0 40 80 120 160 180
!m (ksi)
12-78
3. From Fig. 12.22c,
6F mL
σm = 2 Kf
bh
6(100)(12)
85, 000 = 2 (1. 3)
b(0. 1)
therefore, b = 11.01 in. ■
4. Point 1: machine turned off and spring supporting a static load of 100 lb only
σa = 0 ■
6(50)(12)
σm = 2 (1. 3) = 42. 5 ksi ■
(11. 01)(0. 1)
Point 2: normal loads applied
Fm = 75 lb
Fa = 25 lb
6(75)(12)
Thus, σm = 2 (1. 3) = 63. 7 ksi ■
(11. 01)(0. 1)
6(25)(12)
σa = 2 (1. 3) = 21. 2 ksi ■
(11. 01)(0. 1)
Point 3: design overloads applied.
Fm = 100 lb
Fa = 50 lb
From graph above, σm = 85 ksi ■
6(50)(12)
σa = 2 (1. 3) = 42. 5 ksi ■
(11. 01)(0. 1)
(Note: Points 1 and 2 can be located by merely dropping down at 45o from point
3.)
3
2F = Ebh
5. From Fig. 12.21(c), k = 3
2δ 6L
(30 ! 106)(11. 01)(0. 1)3
k= = 31. 9 lb/in. ■
6(12)3
12-79
SOLUTION (12.56)
Known: A semi-elliptic leaf spring is to be made of steel having known properties.
The spring is 1.2 m long, and has five leaves of 5 mm thickness and 100 mm width.
When the trailer is fully loaded, the static load applied to the center of the spring is
3500 N.
Find:
(a) Estimate the alternating load that, when superimposed onto the fully loaded spring,
would be just on the verge of causing eventual fatigue failure.
(b) Calculate the maximum deflection of the spring when loaded as determined in (a).
(c) Determine the energy absorbed by the spring in going from minimum load to
maximum load when loaded as determined in (a).
(d) Determine the value the alternating load could be increased if only 104 cycles of
life are required.
2L = 1200 mm
Su = 1200 MPa
Sy = 1080 MPa
Fully corrected endurance
limit = 550 MPa
Kf = 1.4
2F
Assumptions:
Analysis:
1. From Fig. 12.22b,
6F mL 6(1750)(600)
σm = 2 Kf = 2 (1. 4) = 705. 6 MPa
bh (5)(100)(5)
12-80
2.
0.9 Su = 1080
1080
860
Log S, MPa
S-N curve
550
103 104 105 106

Log N
860
104 life
550
500 ! life
"a 350
(MPa)
230
705.6
0 500 1000 Sy 1200

"m (MPa)
3. For ∞ life, σa can be 230 MPa (from graph).

6F aL
σa = 2 Kf
bh
6F a(600)
230 = 2 (1. 4)
(500)(5)
Fa = 570 N
Therefore, the alternating force = 2Fa = 1140 N ■
12-81
3
4. From Fig. 12.22b, δ = 6FL3
Ebh
3
6(1750 + 570)(600)
δ= 3
= 232. 4 mm ■
(207, 000)(500)(5)
5. Energy = (Average force)(Distance)
Average force = 2Fm = 3500 N
Distance = Cantilever deflection due to F (2Fa = 1140 N)
3
6(1140)(600)
= 3
= 114. 2 mm
(207, 000)(500)(5)
Energy = (3500 N)(0.1142 m) = 400 N•m ■
6. From S-N curve, S at 104 N = 860 MPa
From σm-σa curve, σa can be 350 MPa for 104 N
6F aL
σa = 2 Kf
bh
6Fa(600)
350 = (1. 4)
(500)(5)2
Fa = 868 N
Therefore, the alternating spring force = 2Fa = 1736 N ■
SOLUTION (12.59)
Known: A symmetrically matched pair of steel torsion springs in a conventional
arrangement are supporting the weight of a domestic overhead garage door. The 25
mm shaft is supported to the fixed structure by bearings at each end and in the center.
A cable wrapped around each of the pulleys supports the weight of the door. Each
spring has known dimensions. The total extension of the cables from spring-loaded to
door-closed position is 2.1 m.
Find:
(a) Calculate the nominal bending stress in the springs in the door-closed position.
(b) List important factors that would tend to make the actual maximum stress different
than the nominal value.
(c) Determine the supporting force provided by each cable in the door-closed position.
12-82
110 mm dia.
25 mm shaft
110 mm dia. Cable
D = 45 mm
Torsional springs d = 6 mm
120 turns
Cable
Assumption: The friction between adjacent spring coils is negligible.

Analysis:
1. Total shaft revolutions = 2100 mm = 6. 08
110π mm
2. Deflection per spring turn = 6.08/120 = 0.0507 revolution
= 0.318 rad
3. Length, L, per spring turn = 45π mm
4
π(6) 4
4. I = πd = = 63. 62 mm 4
64 64
c = D/d = 45/6 = 7.5
From Fig. 12.30, Ki = 1.13
5. From Table 5.1 case 3,
! = ML or M = EI!
EI L
(207, 000)(63. 62)(0. 318)
M= = 29, 623 N•mm
45π
6. From Eq. (12.16),
32(29, 623)
! = 32M Ki = (1. 13)
"d3 "(6)3
σ = 1579 MPa ■
7. The important factors that would tend to make the actual maximum stress different
than the nominal value are:
(a) Residual stress due to manufacture
(b) Friction with rod and with adjacent turns
12-83
Spring moment 29. 6 N•m
8. Cable force = = = 538 N ■
Pulley radius 0. 055 m
SOLUTION (12.60)
Known: Your own measurements of an overhead garage door support will be used.
Find:
(a) Calculate the nominal bending stress in the springs in the door-closed position.
(b) List important factors that would tend to make the actual maximum stress different
than the nominal value.
(c) Determine the supporting force provided by each cable in the door-closed position.
Analysis: Compare your solution with Problem 12.51 solution.
SOLUTION (12.61)
Known: Ordinary window shade rollers have long torsion springs that work on the
same principle as the overhead garage door support. A roller has 33 mm diameter and
the spring made of 1.2 mm square steel wire has D = 19 mm. A shade pull force of 14
N with the spring wound up 14 turns is needed.
Find:
(a) Determine N.
(b) Determine the value of maximum bending stresses in the spring.
33 mm dia.
33 mm dia. Cable
Torsional springs
Cable 1.2 mm square steel wire

D = 19 mm
12-84
Analysis:
1. ( )
M = 14 N 33 mm = 231 N•mm
2
3
2. From Appendix B-1, I = bh for square
12
(1. 2) 4
I= = 0. 1728 mm 4
12
3. From Table 5.1 case 3, ! = ML

EI
(207, 000)(0. 1728)(28")

L = EI! =
M 231
L = 13,621 mm
13, 621
4. N= L = = 228 turns ■
!D 19!
5. From Eq. (12.17), for a square wire (b=h)
! i = 6Fa Ki,rect = 6M Ki,rect

2 3
bh h
6. With D/h = 19/1.2 = 15.8 and from Fig. 12.30, Ki,rect = 1.05 by extrapolation.
6(231)
Therefore, σi = 3
(1. 05)
(1. 2)
σi = 842 MPa ■
SOLUTION (12.62)
Known: The torsion bar in Problem 12.5 is to be replaced with a torsion spring made of
steel having same physical properties. Space is available for a spring of outside
diameter up to 5 in.
Find:
(a) Determine one appropriate combination of values of d, D, and N.
(b) Determine the overall length of the coiled section of the spring proposed.
(c) Compare the weight of the torsion spring with that of the torsion bar.
12-85
Door stop
RD 24 in.
60 lb Tc
! = 110°
T o = 6 lb ft R
60 lb
Opened Closed
Maximum allowable torsional stress = 50 ksi

Analysis:
1. The torsion spring needs to counterbalance 80% of the door weight when closed.
Thus,
M = (60)(0.8)(24) = 1152 in.lb
2. Assume τallow = 50 ksi is equivalent to σallow = 50/0.58 = 86 ksi
3. From Eq. (12.16), ! = 32M Ki

"d3
where Ki is assumed to be 1.1
32(1152)
86, 000 = (1. 1)
!d3
or, d = 0.531 in.
4. For outside diameter of 5 in, D = 4.47 in, ■
C = 8.4, and Ki = 1.09; therefore, assumed value of Ki is acceptable.
5. M is to change from 72 to 1152 in.lb during θ = 110o = 1.92 rad; therefore,
!M = 1152 - 72 = 563 in. lb/rad
!" 1. 92
ΔM = EI
6. From Table 5.1, ! = ML or
EI Δθ L
4 !(0. 531) 4
where I = !d = = 0. 00390 in. 4
64 64
6
E = 30 ✕ 10 psi (Appendix C-1)
(30 ! 106)(0. 00390)
Thus, 563 =
L
L = 207.8 in.
12-86
7. N = L = 207. 8
!D !(4. 47)
N = 14.80 active turns ■
8. Length of coiled section ≈ (N + 1)d = 15.8(0.531) = 8.4 in. ■
2
9. Torsion bar active volume (Prob. 12.5) = !d L
4
!(0. 49)2
= (115. 7) = 21. 82 in. 3
4
2
Torsion spring active volume (Prob. 12.54) = !d L
4
!(0. 531)2
= (207. 8) = 46. 01 in. 3
4
Thus, the torsion spring is about 2.1 times as heavy as the torsion bar. ■
SOLUTION (12.63)
Known: The torsion bar in Problem 12.6 is to be replaced with a torsional spring made
of steel having physical properties. Space is available for a spring of outside diameter
up to 5 in.
Find:
(a) Determine one appropriate combination of values of d, D, and N.
(b) Determine the overall length of the coiled section of the spring proposed.
(c) Compare the weight of the torsion spring with that of the torsion bar.
RD Door stop
24 in.
60 lb Tc
To
! = 60°
60 lb R
Opened Closed
Maximum allowable torsional stress = 50 ksi
12-87
Analysis:
1. The torsion spring needs to counterbalance 80% of the door weight when closed.
Thus,
M = (60)(0.8)(24) = 1152 in.lb
2. Assume τallow = 50 ksi is equivalent to σallow = 50/0.58 = 86 ksi
3. From Eq. (12.16), ! = 32M Ki

"d3
where Ki is assumed to be 1.1
32(1152)
86, 000 = (1. 1)
!d 3
or, d = 0.531 in. ■
4. For outside diameter of 5 in., D = 4.47 in., ■
C = 8.4, and Ki = 1.09; therefore, the assumed value of Ki is acceptable.
5. M is to change from 864 to 1152 in.lb during θ = 60o = 1.047 rad; therefore,
!M = 288 = 275 in. lb/rad
!" 1. 047
ΔM = EI
6. From Table 5.1, ! = ML or
EI Δθ L
4 !(0. 531) 4
where I = !d = = 0. 00390 in. 4
64 64
E = 30 ✕ 106 psi (Appendix C-1)
(30 ! 106)(0. 00390)
Thus, 275 =
L
L = 425.5 in.
7. N = L = 425. 5 = 30. 30 active turns ■

!D !(4. 47)
8. Length of coiled section ≈ (N + 1)d
= (31.30)(0.531) = 16.6 in. ■
9. Torsion bar active volume (Prob. 12.6)
2 !(0. 49)2
= !d L = (237. 3) = 44. 75 in. 3
4 4
Torsion spring active volume (Prob. 12.55)
2 !(0. 531) 2
= !d L = (425. 5) = 94. 2 in. 3
4 4
Thus, the torsion spring is about 2.1 times as heavy as the torsion bar.
12-88
SOLUTION (12.66D)
Known: The internet contains information on nitrogen cylinder springs and coil
springs.
Find: List advantages of nitrogen cylinder springs compared to coil springs.
Analysis: The following are potential answers:
• Gas springs are available in many diameters, stroke lengths, and pressures.
• One nitrogen cylinder can do the work of as many as 20 die springs.
• Gas spring pressure can be monitored during production. As pressure falls, the
cylinder can be replaced immediately to reduce the risk of producing defective
parts.
• Gas spring force can be regulated and controlled by changing nitrogen gas
pressures.
• Space requirements are minimal and cylinders can be easily installed on die
stamping machines.
SOLUTION (12.67D)
Known: A web site address is given as http://www.mwspring.com.
Find: List the information needed to manufacture a torsion spring.
Analysis: The following information is needed:
Quantity
Wire Size
Material
Free Length: Maximum, Minimum
Controlling Diameter: Outside Maximum, Inside Minimum
Torque: IN-LB at Deflection of °
Winding Direction
Leg Length
Finish
Maximum Wound Position in: Turns or °
From Free Position
Frequency of Rotation
Range of Operating Temperature
SOLUTION (12.68)
Known: Steel springs made in the form of torsion bars, helical compression springs,
helical tension springs, rectangular plate cantilever springs, triangular plate cantilever
springs, and torsion springs are given.
Find: Compare the energy absorbing capacity per unit weight or volume for above
springs.
12-89
Helical compression Helical tension spring

spring
Torsion bar
Torsion spring
Triangular plate Rectangular plate

cantilever spring cantilever spring
Assumption: The material is homogeneous and perfectly elastic.

Analysis:
1. Basic equations:
(a) Torsion bar
Energy = U = 1 T max! max

2
!d3"max [Eq. (4. 4)]
where T =
16
! = 32TL (Table 5. 1)
"d4G
2 2 2
Therefore, U = !L" d and with V = !d L
16G 4
2
U=!V
4G
(b) Torsion spring (helical)
U = 1 M!
2
3
where M = !d " [Eq. (4.8)]
32
! = ML = 64ML (Table 5. 1)
EI "d4E
12-90
2 2 2
Therefore, U = !L" d and with V = !d L
32E 4
2
U=σV
8E
(c) Rectangular plate cantilever
U = 1 F!
2
2
where F = σbh [Eq. (4.7)]
6L
3 3
! = FL = 4FL (Table 5.1)
3EI Ebh3
2
Therefore, U = ! bhL and with V = bhL
18E
2
U=! V
18E
(d) Triangular plate cantilever
U = 1 F!
2
2
where F = σbh [Eq. (4.7)]
6L
3
δ = 6FL 3 [Eq. (12.14)]
Ebh
2
Therefore, U = σ bhL and with V = 1 bhL
12E 2
2
U=σV
6E
(e) Helical tension and compression spring
U = 1 F!
2
3
where F = !d " [Eq. (12.5)]
8D
3
δ = 8FD N
[Eq. (12.7)]
d 4G
12-91
2 2 2 2 2
Therefore, U = ! " d DN and with V = ! d DN
16G 4
2
U=!V
4G
2. Relative energy values:
For steel, G = 0.383E; therefore, E ∝ 1 and G ∝ 0.383.
For steel, τallow ≈ 0.58σallow; therefore, σ ∝ 1 and τ ∝ 0.58.
For helical tension springs, consider Kw of average value ≈ 1.2. Thus use
! " 0. 58 = 0. 48
1. 2
Similarly, for torsion springs, consider Ki ≈ 1.1, so use σ ∝ 1/1.1 = 0.91
(a) Torsion bar:
(0. 58)2V
U! = 0. 220V
4(0. 383)
(b) Torsion spring (helical):
(0. 91)2V
U! = 0. 104V
8(1)
(c) Rectangular plate cantilever:
(1)2V
U! = 0. 056V
18(1)
(d) Triangular plate cantilever:
(1)2V
U! = 0. 166V
6(1)
(e) Helical tension and compression spring:
(0. 48) 2V
U= = 0. 150V
4(0. 383)
3. The relative energy absorbing capacities per unit volume or weight are:
(a) Torsion bar 100%
(b) Torsion spring (helical) 47%
(c) Rectangular plate cantilever 25.3%
(d) Triangular plate cantilever 76%
(e) Helical tension and compression spring 68%
Comment: This analysis considered only active material. The percentage of inactive
material (which does not contribute to deflection or energy absorption) would be
somewhat different in the various spring types.
12-92

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! = 16T/"d 3 = (16)(242.66) = 40.69 ksi

! = 16T/"d 3 = (16)(77.035) = 25.11 ksi

τ = 16T/πd = (16)(329. 66)

τ = 16T/πd = (16)(297. 32)

Gravity torque = 1440 cos !

2. From Table 5.1, for a torsional case (case 2), θ = TL and K = T = JG

(1152 - 864) lb in.

JG (0. 005660)(11. 5 ! 106)

1600 Gravity torque = 1440 cos !

2. From Table 5.1, for a torsional case (Case 2) θ = TL and K = T = JG

150 Gravity torque = 150 cos !

Modified Problem 12.6

2. From Table 5.1, for a torsional case (case 2), θ = TL and K = T = JG

K = ΔT = 120 - 91 = 27. 62 N•m/rad

G = 79 ✕ 109 Pa (Appendix C-1)

G = 79 ✕ 109 PA (Appendix C-1)

Ks = 1.05 (Fig. 12.4)

3. From Eq. (12.9), τs ≤ 0.45 Su

Schematic and Given Data:

200 100 N/mm

4. Using Fig. 12.4, we can find Ks values for each spring.

5. From Eq. (12.6), ! = 8FD Ks

Comment: By considering the curvature (stress concentration) factor of the inner

Schematic and Given Data:

G = 50 ✕ 109 Pa (Appendix C-1)

Ks = 1.1 (Fig. 12.4)

3. For beryllium copper spring wire without presetting, τs ≤ 0.35 Su.

Comment: By considering the curvature (stress concentration) factor of the inner

Schematic and Given Data:

Music wire Clash allowance

k = ΔF = 1000 - 500 = 8. 33 N/mm

9. Lf/D = 182.7/45 = 4.1

Find: Determine D, d, N, and Lf.

Schematic and Given Data:

Su = 200 ksi Clash allowance

5. D = Cd = 8(0.128) = 1.02 in. ■

Ls = (10.92 + 2)(0.128) = 1.65 in.

δs/Lf = ( 33.993)/4.62 = 0.644

(0. 1)4(11. 5 ! 106)

Find: Determine N, d, and Lf.

Schematic and Given Data:

Therefore, d = 0.370 in. ■

Expansion from solid = 0.1 + 500/200 = 2.6 in.

Lf = 2.59 + 2.6 = 5.19 in. ■

Find: Determine appropriate values for N, D, and Lf.

Analysis--Case B--without shotpeening:

6. Lf = 19. 98 + 712. 5 = 35. 81 mm ■

0 250 500 750 1000

11. From the graph above,

Design overload (965, 965)

0 250 500 750 1000

Analysis--Case B--without shot peening:

Schematic and Given Data:

For τmax/τmin = 3, τmax = 761.6 MPa = 110.5 ksi

2. k = F/δ = 60/2.5 = 24 lb/in.

6. C = D/d = 5.283, Kw ≈ 1.28

From Eq. (12.5), d = 0.1183 in. ■

! solid = (1.1) 90 lb = 4.125 in.

Lf = 5.92 + 4.125 = 10.05 in. ■

Analysis--Case B--without shot peening:

For τmax/τmin = 3, τmax = 590 MPa = 85.6 ksi

2. k = F/δ = 60/2.5 = 24 lb/in.