4 February 2022 Machine Design 1
Spring
- is an elastic machine component which deflects under the action
of the load & returns to its original shape when the load is
removed.
Functions & Typical Applications
Functions Typical applications
Used to absorb shocks & vibration Vehicle suspension springs
(Cushioning , absorbing , or controlling of Railway buffer springs
energy due to shock and vibration)
Vibration mounts for machine
Used to apply force & control Cam & follower mechanism
motion Engine valve mechanism
Force required to engage the clutch &
brakes
Used to store energy Circuit breakers & starters, clocks,
toys etc.
Used to measure the force
4 February 2022 Weighing
Machine Design balances 2
1
Functions & Typical Applications
Functions Typical applications
Used to absorb shocks & vibration Vehicle suspension springs
(Cushioning , absorbing , or controlling of Railway buffer springs
energy due to shock and vibration)
Vibration mounts for machine
4 February 2022 Machine Design 3
Functions Typical applications
Used to apply force & control Cam & follower mechanism
motion Engine valve mechanism
Force required to engage the clutch &
brakes
4 February 2022 Machine Design 4
2
Functions Typical applications
Used to apply force & control Cam & follower mechanism
motion Engine valve mechanism
Force required to engage the clutch &
brakes
4 February 2022 Machine Design 5
Types of Springs or Spring Configuration
According to their shape or physical configuration
4 February 2022 Machine Design 6
3
Types of Springs or Spring Configuration
4 February 2022 Machine Design 7
Types of Springs or Spring Configuration
Compression
Closely-coiled
Coil or helical Extension
Open coiled
Torsion
Types of Springs Flat or Beam spring & Leaf Spring
Spring washer, Belleville Spring
4 February 2022 Machine Design 8
4
Helical Springs
Compression Torsion Extension
4 February 2022 Machine Design 9
Closely-coiled helical spring vs. Open-coiled helical spring
Closely-coiled helical spring Open-coiled helical spring
When the spring wire is coiled so When the spring wire is coiled in
close that the plane containing such a way, that there is large gap
each coil is almost at right angles between adjacent coils. Helix
to the axis of the helix. Helix angle is large
angle is very small.
Helix angle < 10 Helix angle > 10
More popular & extensively used
4 February 2022 Machine Design 10
5
Spring Materials
Factors are considered for selecting of the materials of the spring wire
The load acting on the spring
The range of stress through which the spring operates
The expected fatigue life
The environmental conditions in which the spring will operate such as temperature
& corrosive atmosphere
The severity of deformation encountered while making the spring
The limitation on mass & volume of spring.
Steel wire for spring %C Remarks CI
Cold drawn (or hard drawn) spring steel 0.85-0.95% 1
Oil-tempered & hardened spring steel 0.55-0.75% 1.5
Music wire (hard drawn spring steel) 0.80-0.95% 3.5
Oil-tempered & hardened spring steel (alloyed) 0.55-0.75%
Alloy steel: Chromium-vanadium 4.0
Chromium-silicon
Stainless steel
4 February 2022 Machine Design
8.5 11
Spring Materials
4 February 2022 Machine Design 12
6
Spring Materials
4 February 2022 Machine Design 13
Terminology of Helical Springs
Spring Index (C)
- Ratio of mean coil diameter to wire diameter
3 ≤ C ≤ 12
Preferred Range:
6 ≤ C ≤ 10
In the design of helical springs, the designer should use good judgement in selecting the
value of the spring index (C).
4 February 2022 Machine Design 14
7
Terminology of Helical Springs
The spring index indicates the relative sharpness of the curvature of the coil
When C < 3
- 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 & special care in coiling is required
to avoid cracking in wires.
When C > 12
- When the spring index is high (C > 12), it results in large variation in the coil
diameter. Such spring is prone to buckling.
4 February 2022 Machine Design 15
Terminology of Helical Springs
Terms related to helical compression spring
Solid length Axial length of the helical compression
spring when it is so compressed that
adjacent coils touch each other.
Compressed Length
Axial length of the spring when it is subjected to max. compressive force/max. deflection ().
In this situation, there should be some gap or clearance between the adjacent coils to
prevent clashing of the coils.
-is an important dimension in spring design & manufacturing
Free length
Axial length of the unloaded helical
compression spring (i.e., in free condition prior
to assembly.
4 February 2022 Machine Design 16
8
Terminology of Helical Springs
Terms related to helical compression spring
Pitch of the Axial distance between adjacent coils in uncompressed state
coil of spring.
Stiffness of the spring or Spring constant or Rate of spring or Gradient of spring
Is defined as force required to produce unit deflection.
4 February 2022 Machine Design 17
Springs in Series & in parallel
Fi=ki.xi 1 1 1 1
k series k1 k 2 k3
F=k3.x3 k parallel k1 k 2 k3
F=k2.x2
x=x1+x2+x3
F=k1.x1
F/ks=F/k1+F/k2+F/k3
1/ks=1/k1+1/k2+1/k3
2/4/2022 18
9
Springs in Series & in parallel
F ky
kF/y
1 1 1 1
k series k1 k 2 k3
k parallel k1 k 2 k3
2/4/2022 19
End Style or End Design of Helical Springs
End Style or End Design of End Style or End Design of
Helical Compression Springs Helical Extension Springs
End Style or End Design of
Helical torsion Springs
4 February 2022
Machine Design 20
10
Spring design – end treatment
End details affect active coils
• Plain ends
• Squared ends
• Squared
• Ground
2/4/2022 21
Design Analysis of Closely coiled Helical Springs
Load-Stress Equation
Load-Deflection Equation
4 February 2022 Machine Design 22
11
F F F F F F
M=Fd
B
d A d d d
F
F
Design Analysis of Closely coiled Helical Springs
Load-Stress Equation
P P
D
The axial force P can be considered as a direct
force P acting on the spring at the mean coil radius
together with a couple M=P.D/2 whose moment
vector is perpendicular to the axis of the spring.
The moment M=P.D/2 is resolved into twisting
moment T & Bending Moment Mb.
FBD 24
12
P
Front view Side view
4 February 2022 Machine Design 25
Design Analysis of Closely coiled Helical Springs
When (angle of helix) is
Load-Stress Equation very small, cos1, sin0
+ =
+ =
Machine Design 26
13
Design Analysis of Closely coiled Helical Springs
Load-Stress Equation
The free-body diagram (FBD) shows that there will
be two components of stress on any cross-section of
spring wire.
(i) Torsional shear stress (s) due to T
(ii) Direct shear stress (d) due to P
These two stresses add directly & maximum shear stress ()
occurs at the inner fiber of the wire cross-section
3 ≤ C ≤ 12
Where Ks=shear stress correction factor
It is evident that for spring of small C, the effect of direct shear is appreciable. 27
Design Analysis of Closely coiled Helical Springs
Load-Stress Equation
The effect of curvature of the wire as it forms the coil
should be considered also.
There is an increase in the intensity of torsional
shear stress in inner fiber because of the curvature
of the coil.
In order to include both the effect of direct shear and
effect of wire curvature on torsional shear stress, a
stress factor has been determined by A.M. Wahl
(1929) which may be used to determine the maximum
shear stress in the inner fiber of the wire cross-section.
This stress factor is also known as Wahl Factor (Kw).
Where Kw=Wahl factor
3 ≤ C ≤ 12
28
14
Design Analysis of Closely coiled Helical Springs
Load-Deflection Equation
Deflection equation in closely coiled helical springs
Assumption Assuming that direct shear contributes negligibly to the deflection
Torsion formula
where
Strain energy due to torsional load
The deflection due to torsional loading
Castigliano’s Theorem
Stiffness of the spring
29
Design of Closely coiled Helical Springs
Objectives Spring should possess sufficient strength to withstand the external load
Spring should have the required load-deflection characteristics
Spring should not buckle under the external load
Design parameters Wire diameter (d)
Mean coil diameter (D) or Spring Index (C)
Number of active coils (N)
Angle of Helix
Pitch of the coil
Stiffness of the spring
Practical Limitation Space limitations for outside & inside diameter of the coil
Load-Stress Eq.
Basic Design parameters Wire diameter (d)
Mean coil diameter (D) or Spring Index (C)
Number of active coils (N) Load-Deflection Eq.
4 February 2022 Machine Design 30
15
Design of Closely coiled Helical Springs
Step 1 Specify functions of the spring
Functions Typical applications
Used to absorb shocks & vibration Vehicle suspension springs
Railway buffer springs
Vibration mounts for machine
Used to apply force & control motion Cam & follower mechanism
Engine valve mechanism
Force required to engage the clutch & brakes
Step 2 Load Analysis
Estimate the maximum spring force (P) &
The required deflection () or required stiffness (k).
Free Body Diagram of forces
4 February 2022 Machine Design 31
Design under Static Load
4 February 2022 Machine Design 32
16
Step 3 Material Selection Steel wire for spring
Cold drawn (or hard drawn) spring steel
From Data Book: Oil-tempered & hardened spring steel
Mechanical properties
Music wire (hard drawn spring steel)
Syt, Sut
Oil-tempered & hardened spring steel (alloyed)
Alloy steel, Stainless steel
Step 4 Design Analysis
Choose suitable Factor of Safety
The factor of safety in the design of springs is usually 1.5 or less.
Reasons for assuming relatively low FOS
In most of the applications, springs operate will well defined deflections. Therefore,
the forces acting on the spring & corresponding stresses can be precisely
calculated. It is not necessary to take higher FOS to account for uncertainty in
external forces acting on springs.
In case of helical compression springs, an overload will simply close up the gaps
between coils without a dangerous increase in deflection & stresses.
In case of helical extension springs, usually overload stops are provided to prevent
excessive deflection & stresses.
Allowable Tensile stress & Allowable Shear Stress of the spring material
Step 4 Design Analysis
Choose suitable value for spring Index (C) Preferred Range:
6 ≤ C ≤ 10
Calculate Wahl factor
Calculate wire diameter
Load-Stress Eq.
Calculate mean coil diameter
Calculate the No. of active coils Load-Deflection Eq.
Calculate the No. of coils
Decide the end style or design of the spring
Calculate the actual deflection
Calculate the solid, free length of the spring
Calculate the pitch of the coils
Calculate the stiffness of the spring
17
Step 4 Design Analysis
Problem based on Design Analysis
Ex # 1 Solution
Given data
Material: Cold drawn steel
Step 1: Calculation of wire diameter
18
Step 2: Calculation of mean coil diameter
Step 3: Calculation of no. of coils
Step 5: Calculation of spring rate
Step 4: Calculation of solid length & Required spring rate or stiffness
Free length of the spring
Actual spring rate or stiffness
4 February 2022 Machine Design 37
19
