Step 2: Determine the active number

of coils using deflection equation

 = 8 FC3 n
Gd

n =  Gd .

8 FC3 n

= 30 x 84 x 103 x 8.23
8 x 1500 x 53

= 13.82  14

 Active no. of coils, n = 14.

Step 3: Decide the total number of coils,
assuming the end condition of
the spring
The four types of ends are:
 Plain
Plain and ground
Square
Squared and ground

Assuming squared and ground end

Total No. of coils, n1 = n + 2
= 14 + 2
= 16
Step 4: Determine the free length of the coil, Lf

Lf = n1d + (n1-1) x 0.1

+  max. mm
= 16 x 8.23 + (16-1) x 0.1 + 30

= 131.68 x 1.50 + 30

= 163.18 mm.
Step 5: Determine the pitch of coil

P = Free length
n1-1
Step 6: Check for buckling

Free length, Lf < 3

Mean coil, Dia, D

163.18 = 3.9 > 3

41.15

To avoid buckling the spring should be suitably

guided.
 PROBLEM 2

Design a helical compression spring for a

service load ranging from 2250 N. The axial
deflection for the load range is 15 mm.
Assume a spring index of 5. The permissible
shear stress intensity is 420 N / mm2 and the
modules of rigidity, G = 84 kN/ mm2.
SOLUTION OF PROBLEM 2
Data Given:
Maximum Load, Fmax. = 2750 N
Maximum Load, Fmin. = 2250 N

Deflection for the

range of load, r = 15 mm.
Spring index, C = 5

Allowable shear stress, [C] = 420 N / mm2

Modules of Rigidity, G = 84 x 103 N / mm2
Step 1: Determine the wire diameter of the
spring, using maximum load

2
d = 8 Fmax C Kw
 [C]

= 8 x 2750 x 5 x 1.31
 [420]

d = 10.45 mm.
Standard SWG-5, d = 10.97 mm
D = 5 x 10.97 = 54.85 mm
Do= 54.85 + 10.97 = 65.82 mm
Step 2: Determine the active number of coils,
using range of load which causes
deflection

Range of load, Fr = Fmax – Fmin

= 2750 – 2250
= 500 N

r = 8 Fr C 3
n
Gd

n = r Gd = 15 x 84 x 103 x 10.97
8 Fr C3 8 x 500 x 53

= 27.644  28 coils.
Assuming squared and ground end Total no.
of coils, n1 =n+2
= 28 + 2
= 30
Free length of the coil,Lf
= (30 x 10.97) + (30-1) x 0.1
+  max.

 max.= r x Fmax
Fr

= 15 x 2750 = 82.5 mm
500
Pitch of the coil, P = Lf = 414.5
n1-1 30-1

= 14.293 mm

Checking for Buckling Failure:

Lf < 3
D

414.5 = 7.557 > 3

54.85