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Prepared By: Suraj Kumar Chand Assistant Professor: 02-12-2017 Department of ME, GEC Raipur 1
Prepared By: Suraj Kumar Chand Assistant Professor: 02-12-2017 Department of ME, GEC Raipur 1
Prepared By: Suraj Kumar Chand Assistant Professor: 02-12-2017 Department of ME, GEC Raipur 1
• They are designed to store energy, measure a force, or absorb shocks and vibrations.
• There are three criterions in design of springs which is sufficient strength to withstand
external load, desired load deflection characteristic and sufficient buckling strength.
• Springs are used to store energy, e.g., springs used in clocks, toys, movie-cameras,
circuit breakers, and starters.
• Springs are used to measure the force, e.g., springs used in weighing balance and
scales.
• Springs are used to apply force and control motion, e.g., in cam follower
mechanism to maintain the contact between them, in clutch it provides the
required force to engage the clutch.
1. Helical spring : the helical spring is made from wire, usually of circular cross-section,
which is bent in the form of a helix. There are two types of helical spring-
I. Helical compression spring II. Helical extension spring
ADVANTAGES
• They are easy to manufacture.
• They are cheaper than other types of springs.
• Their reliability is high.
• The deflection of spring is linearly proportional to the force acting on the spring.
• The spring index indicates the relative sharpness of the curvature of the coil-
A low spring index means high sharpness of curvature. When the spring index is low (C < 3),
the actual stresses in the wire are excessive due to curvature effect. Such a spring is difficult to
manufacture and special care in coiling is required to avoid cracking in some wires.
when the spring index is high (C > 15), it results in large variation in coil diameter.
Such a spring is prone to buckling and also tangles easily during handling.
Therefore spring index from 4 to12 is considered better for manufacturing consideration.
• For helical extension springs, all coils are active coils. The number of active coils (N) is the same as
the total number of coils (𝑁𝑡).
Load-stress Equation
Torsional moment, 𝑀𝑡 = 𝑃𝐷
2
8𝑃𝐷
Torsional shear stress, τ 1 = 16𝑀3𝑡 or …..(a)
π𝑑 π𝑑 3
When the equivalent bar is bent in the form of helical coil, there is additional stresses on
account of following two factors:
i. There is a direct or transverse shear stress in the spring wire.
ii. When the bar is bent in the form of coil, the length of inner fibre is less than the length of outside fibre.
This results in stress concentration at the inside fibre of the coil.
1= 1 + 1
k = 𝑘1+ 𝑘2
𝑘 𝑘2 𝑘2
• They are made of high carbon steel and contain 0.85-0.95% carbon.
• Least expensive.
• Patented and cold-drawn steel wires are mainly used in springs subjected to static forces
and moderate fluctuating forces.
• If springs are of very small diameter and the wire diameter is also small then the springs
are normally manufactured by a cold drawn process through a mangle.
• However, for very large springs having also large coil diameter and wire diameter (greater
than 6 mm) one has to go for manufacture by hot processes. First one has to heat the wire
and then use a proper mangle to wind the coils.
The main dimensions to be calculated in the spring design are- wire diameter, mean coil
diameter and the number of active coils. The first two are calculated by load-stress equation,
while the third is calculated by load-deflection equation.
The factor of safety in design of spring is usually 1.5 or less.
𝑆 𝑠𝑦
τ=
1.5
Assuming, 𝑆 𝑦𝑡 = 0.75 𝑆𝑢𝑡
and 𝑆𝑠𝑦 = 0.577 𝑆𝑦𝑡
τ ≈ 0.3 𝑆𝑠𝑦
Generally in design of helical springs, the permissible shear stress (τ) is taken from 30% to
50% of ultimate tensile strength (𝑆 𝑢 𝑡 )
02-12-2017 Department of ME, GEC Raipur 27
τ = 0.3 𝑆 or 0.5 𝑆
Procedure…
1. For the given application, estimate the maximum spring force (P) and the corresponding required
deflection (δ) of the spring. In some cases, maximum spring force (P) and stiffness k, which is
(P/δ), are specified.
2. Select suitable spring material and find out ultimate tensile strength (𝑆 𝑢𝑡 ) from the data.
Calculate the permissible shear stress for the spring wire by following relationship:
τ = 0.3 𝑆 𝑢𝑡 or 0.5 𝑆 𝑢𝑡
3. Assume a suitable value for spring index (C). For industrial applications, the spring index varies
from 8 to 10. A spring index of 8 is considered as a good value. The spring index for springs in
valves and clutches is 5. the spring index should never be less than 3.
4. Calculate the Wahl factor by following equation:
4𝐶−1 0.615
K= +
8𝑃𝐷
4𝐶−4 𝐶
5. Determine wire diameter (d) by, τ = K ( 3)
π𝑑
6. Determine mean coil diameter (D) by following relationship
D = Cd
let us consider a spring subjected to an external fluctuating force, which changes its magnitude from
𝑃𝑚𝑎𝑥 𝑡𝑜 𝑃 𝑚𝑖𝑛 in the load cycle.
𝑃𝑚= ½ (𝑃𝑚𝑎𝑥 + 𝑃 𝑚 𝑖 𝑛 )
𝑃𝑎= ½ (𝑃𝑚𝑎𝑥 - 𝑃 𝑚 𝑖 𝑛 )
Mean stress is given by,
8𝑃𝑚
τ 𝑚 = 𝐾𝑠( 𝐷 3 )
𝜋𝑑
where, 𝐾𝑠 = (1 + 0.5 𝐶
)
𝐾𝑠 is the correction factor for direct shear stress and it is applicable to mean stress only. For torsional
stress amplitude (τ𝑎 ), it is necessary to also consider the effect of stress concentration due to curvature in
addition to direct shear stress. Therefore,
τ𝑎 = 𝐾𝑠𝐾𝑐 8𝑃 𝑎 𝐷 ; τ𝑎 = 𝐾
𝜋 𝑑𝑎 3𝐷
8𝑃
where K is the Wahl factor,
𝜋 𝑑 3which takes into consideration the effect of direct shear stress as well as
of stress concentration due to curvature.
• 𝑆𝑠𝑒
′ is the endurance limit in shear for the stress variation from zero to some maximum value.
• The data regarding the experimental values of endurance strength of spring wire is not readily
available. In absence of such values, the following relationships suggested by H.J. Elmendorf can
be used,
For patented and cold-drawn steel wires (Grade -1 to 4),
𝑆𝑠′ 𝑒 = 0.21 𝑆𝑢 𝑡 ; 𝑆𝑠′𝑦 = 0.42 𝑆 ……………………………..
𝑢 𝑡 (a)
The line GH is constructed in such a way that its slope θ is given by, tan θ =
𝜏𝑎 𝜏𝑚
Consider similar triangles XFD and
AEB, 1 𝑠′
� 2𝑆
𝑋𝐹
=
𝐴𝐸
; or = 𝑒1 ′
𝑆 𝑠𝑦 �
𝜏 −𝜏 𝑚 𝑆 𝑠 𝑦 − 2 𝑆 𝑠𝑒
(𝑓𝑠)
𝐹𝐷 𝐸𝐵
02-12-2017 Department of ME, GEC Raipur 34
SURGE IN SPRING
• When the natural frequency of vibrations of spring coincides with the frequency of external
periodic force, which acts on it, resonance occurs. In this state, the spring is subjected to a wave of
successive compressions of coils that travels from one end to the other and back. This type of
vibratory motion is called ‘surge’ of spring. Surge is found in valve springs, which are subjected to
periodic force.
Methods to avoid surge in springs:
• The spring is designed in such a way that the natural frequency of the spring is 15 to 20 times the frequency
of excitation of the external force. This prevents the resonant condition to occur.
• The spring is provided with friction dampers on central coils. This prevents propagation of surge valve.
• A spring made of stranded wire reduces the surge. In this case, the wire of spring is made of three strands. The
direction of winding of strands is opposite to the direction of winding of the coils while forming the spring. In
case of compression of coils, the spring tends to wind the individual wires closure together, which introduces
friction. This frictional damping reduces the possibility of surge.
U = ∫ 𝑀𝑏
2𝐸𝐼
𝑃 2𝑟 2
U=∫
or (𝜋𝐷𝑁) 2𝐸𝐼
We have, θ = 64 𝑃𝑟𝐷𝑁
𝐸 𝑑4
(𝑃 𝐿)(𝑡/2)
(σ𝑏 ) = 𝑀𝐼𝑏 𝑦 1
𝑔
3
𝑔 [12 (𝑛 𝑔 𝑏)(𝑡 )]
=
Or, (σ ) = 6𝑃𝑔 𝐿
𝑏 𝑔 𝑛𝑔 𝑏𝑡2
𝑃𝑔 𝐿3
And deflection, δ
𝑔 = 2𝐸𝐼 𝑚 𝑎
3 𝑥.
6𝑃 𝑔 𝐿
δ
𝑔 = 𝐸𝑛 𝑏𝑔 𝑡 3
It is seen from the above equations that bending stresses in full length leaves are 50% more than
in
graduated length leaves. The deflection at the end of spring (δ) is given by,
12 𝑃𝐿3
δ=
𝐸 𝑏 𝑡 3 (3𝑛 𝑓 +2𝑛 𝑔 )
And finally the stresses are equal in all leaves is given by, 𝜎𝑏 = 6 𝑃𝐿 2
𝑛𝑏𝑡