Stresses in spring

Consider spring subjected to load ‘W’, as shown below

The axial force ‘W’ induce stress on the spring wire can be find by considering
direct load and torque created due to eccentric distance from axis.

The total shear stress induced on the wire can be

Total shear stress = Direct shear stress due to ‘W’ + Torsional shear stress due to ‘T’
Stresses in spring

Total shear stress = Direct shear stress due to ‘W’ + Torsional shear stress due to ‘T’

total= direct+torsional
Force W 4W
 direct   
area  d 2  d 2
4

T W X D/2 8 W D
 torsional   
 3  3 d 3
d d
16 16

T= Torque
Stresses in spring

Total shear stress = Direct shear stress due to ‘W’ + Torsional shear stress due to ‘T’
total= direct+torsional
8W D 4W
 total  
d 3
d 2

8 W D 4 W 2 d D
 total    X X X 
d 3
 d
2
2 d D

8 W D 8 W D 1 d 1
 total   
 X X X 
d 3
 d
3
2 1 D

8 W D 8 W D d 
 total   
 X 
d 3
 d
3
2D 
Stresses in spring

Total shear stress = Direct shear stress due to ‘W’ + Torsional shear stress due to ‘T’
total= direct+torsional

8W D 8W D d
 total   X
d 3
d 3
2D

8 W D d 
 total   1  
d 3  2 D 

8W D
 total  Ks
d 3

 d 
K s  1  
 2 D 
WAHL’s Correction factor

The curvature of wire and its effect on the shear stress is considered by
A.H.Wahl. The present equation of shear stress is modified to determine
corrected shear stress factor Kw. The equation is stated with stress factor as
below,
8W D
 total  Kw
d 3

Where Kw is Wahl correction factor

 4C  1 0.615 
Kw    
 4C  4 C 


K w  Correction for curvature effect  Correction for direct shear effect 

C= Spring index = D/d

End connections of compression helical springs
Ex.01) A closed coil helical spring is used for front suspension of an
automobile. The spring has stiffness 90N/mm with square and ground ends.
The load on the spring causes a total deflection of 8.5 mm. By taking
permissible shear stress of material as 450MPa. Find spring wire diameter.
Assume spring index 6.

Given : K=90N/mm, =8.5 mm, =450Mpa, C=6

W
K 

W  K  90 X 8.5  765N

 4C  1 0.615   4 X 6  1 0.615 
Kw        1.2525
 4C  4 C   4X 6  4 6 

8W D 8 X 765 X 6 Xd
 total  Kw  X 1.2525
d 3
d 3

d=5.70mm = 6mm