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Loop Length Outside Diameter

This document provides theoretical background on helical springs. It discusses key properties and design considerations for extension and compression springs including spring rate, deflection, stress, mean coil diameter, spring index, and configurations for springs arranged in series or parallel. Equations are presented for calculating values like stress, deflection, spring rate, and the combined rate of multiple springs.

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Shiki Masachika
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28 views7 pages

Loop Length Outside Diameter

This document provides theoretical background on helical springs. It discusses key properties and design considerations for extension and compression springs including spring rate, deflection, stress, mean coil diameter, spring index, and configurations for springs arranged in series or parallel. Equations are presented for calculating values like stress, deflection, spring rate, and the combined rate of multiple springs.

Uploaded by

Shiki Masachika
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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CHAPTER 2

THEORETICAL BACKGROUND

2.1 Helical Spring

Helical springs are composed of wires with round cross-section wound into a helix. They
are common and important machine elements used to absorb energy, act as a source of
energy, produce pressure force, and absorb vibrations (Faires, 1969). They are assumed to be
perfectly elastic within its working range (Tordillo, 2012).

2.1.1 Extension spring


Extension spring maintains the torsional stress in the wire by exerting a
resistive force to pulling force (Marghitu, 2001). It is designed with an initial tension
determined by how tightly coiled the spring is. Extension springs are most commonly
used in return mechanisms where both ends of the spring are attached to moving
components (Wright, 1997). Figure 2.1 shows the nomenclature of the extension
spring.

Outside Loop
diameter length

Free Body length


length Gap

Inside
Hook length
diameter

Figure 2.1 Helical extension spring with hook and loop end configuration nom

2.1.2 Compression spring


Compression springs are designed to work with linear compressive loads
(Wright, 1997). The applied load on the spring compresses it to a certain length until
the spring reaches its solid length. Figure 2.2 shows the nomenclature of the
compression spring.

Figure 2.2 Compression spring nomenclature

2.1.2.1 Torsional shear stress in wire


Torsional shear stress is produced as the wire is subjected to a torque or
twisting when load is applied to the spring (Pytel & Kiusalaas, 2013).
Equation 2-1 shows the torsional shear stress of compression springs having
wires of circular cross-section.

8 F Dm
S s =K (2-1)
d3

S s =torsional shear stress wire , kPa


where:

K=spring factor

F=axial force , kN

D m=meancoil diameter , m
d=diameter of wire , mm

2.1.2.2 Deflection
Deflection is the displacement or movement of the spring, either by
application of external force or removal of an external load (Wright, 1997).

2.1.2.2.1 Axial deflection


Angular deflection is the change in spring length as load is
applied or removed. The linear deflection of coil springs can be
determined as shown in Equation 2-2.

3
8 FC n
y= (2-2)
Ed

where: y=axial deflection , mm

F=axial force , N

n=effective number of coils

E=modulus of elasticity MPa

d=diameter of wire , mm

2.1.2.2.2 Angular deflection


Angular deflection is the measure of the wires rotation as
the spring is subjected to twist. The linear deflection of coil springs
can be determined as shown in Equation 2-3.

64 T D m n
= (2-3)
Ed

where: =angular deflection , rad

T =twisting moment , Nm
D m=meancoil diameter , m

n=active number of coils

E=modulus of elasticity , MPa

d=wire diameter , mm

2.1.2.3 Spring factor


Spring factor or Wahls factor corrects both curvature and direct shear
effects. The curvature of the wire increases the stress on the inside of the
spring and decreases it on the outside (Marghitu, 2001). Spring factor can be
obtained equation 2-4.

4 C1 0.615
K= + (2-4)
4 C4 C

where: K=spring factor

C=spring index

2.1.2.4 Spring index


Spring index is the ratio of the mean coil diameter and the wire diameter.
It is an important parameter in designing springs. The spring index determines
the ease of fabricating a spring (Marghitu, 2001). Spring index ranges from 4
to 12 with the optimum value of 9 (Tordillo, 2012). Spring index can be
determined as shown in Equation 2-5.

Dm
C= (2-5)
d

where: C=spring factor


D m=meancoil diameter , m

d=diamter of wire , m

2.1.2.5 Mean coil diameter


Mean coil diameter is an important measure that determines the diameter
between the springs outer and inner diameter. It is used to determine several
other important significant properties of the springs like the spring index and
the torsional shearing stress. Mean coil diameter can be determined as shown
in Equation 2-6.

1
D m= (D o + Di) (2-6)
2

Dm=meancoil diameter , m
where:

D o=outside diameter ,m

D i=insidde diameter , m

2.1.2.6 Spring rate


Spring rate is defined as the load required per unit deflection of the spring.
It describes the stiffness of the spring (Khurmi & Gupta, 2005). The spring
rate can be determined as shown in equation 2-7.

F
k= (2-7)
y

N
k =spring rate ,
where: mm

F=axial load , N
y=axial deflection , mm

2.1.2.6.1 Springs in series


Springs are arranged in series when the end of each spring
is connected to another spring. Figure 2.3 shows springs of certain
spring rate arranged in series.

Figure 2.3 Springs arranged in series

The total spring rate of the three springs in figure 2.3 can
be obtained from equation 2-8.

1
k=
1 1 1 (2-8)
+ +
k1 k2 k3

where: k =spring rate

2.1.2.6.2 Springs in parallel


Springs are arranged in parallel when the end of each spring is
connected to each other. Figure 2.4 shows springs of certain spring rate
arranged in series.
Figure 2.4 Springs arranged in parallel

The total spring rate of the three springs in figure 2.4 can
be obtained from equation 2-9.

k =k 1 +k 2 + k 3 (2-9)

where: k =spring rate

2.1.2.7 Impact load on spring

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