CHAPTER 1

1.1 INTRODUCTION OF SPRING

FIGURE 1 SPRING

A spring is an elastic object used to store mechanical energy. Springs are usually made out of
steel. Small springs can be wound from pre-hardened stock, while larger ones are made
from annealed steel and hardened after fabrication. Some non-ferrous metals are also used
including phosphor bronze and titanium for parts requiring corrosion resistance and beryllium
copper for springs carrying electrical current(because of its low electrical resistance).

When a spring is compressed or stretched, the force it exerts is proportional to its change in
length. The rate or spring constant of a spring is the change in the force it exerts, divided by the
change in deflection of the spring. That is, it is the gradient of the force versus deflection curve.
An extension or compression spring has units of force divided by distance, for example lbf/in or
N/m. Torsion springs have units of force multiplied by distance divided by angle, such
as N·m/rad or ft-lb/degree. The inverse of spring rate is compliance, that is: if a spring has a rate
of 10 N/mm, it has a compliance of 0.1 mm/N. The stiffness (or rate) of springs in parallel
is additive, as is the compliance of springs in series.
 Depending on the design and required operating environment, any material can be used to
construct a spring, so long as the material has the required combination of rigidity and elasticity:
technically, a wooden bow is a form of spring.

Simple non-coiled springs were used throughout human history e.g., the bow (and arrow). In
the Bronze Age more sophisticated spring devices were used, as shown by the spread
of tweezers in many cultures. Ctesibius of Alexandria developed a method for making bronze with
spring-like characteristics by producing an alloy of bronze with an increased proportion of tin, and
then hardening it by hammering after it is cast.

Coiled springs appeared early in the 15th century in door locks. The first spring powered-clocks
appeared in that century and evolved into the first large watches by the 16th century.

In 1676 British physicist Robert Hooke discovered the principle behind springs' action, that the
force it exerts is proportional to its extension, now called Hooke's law.

1.2 TYPES OF SPRING

Springs can be classified depending on different factor as describe below.

(1) How the load force is applied on spring.

 Tension/Extension spring – the spring is designed to operate with a tension load, so the
spring stretches as the load is applied to it.
 Compression spring – is designed to operate with a compression load, so the spring gets
shorter as the load is applied to it.
 Torsion spring – unlike the above types in which the load is an axial force, the load applied
to a torsion spring is a torque or twisting force, and the end of the spring rotates through an
angle as the load is applied.
 Constant spring - supported load will remain the same throughout deflection cycle.
 Variable spring - resistance of the coil to load varies during compression.

(2) They can also be classified based on their shape:

 Coil spring – this type is made of a coil or helix of wire

 Flat spring – this type is made of a flat or conical shaped piece of metal.
  Machined spring - this type of spring is manufactured by machining bar stock with a lathe
and/or milling operation rather than coiling wire. Since it is machined, the spring may
incorporate features in addition to the elastic element. Machined springs can be made in
the typical load cases of compression/extension, torsion, etc.

(3) the most common types of spring are:

 Cantilever spring – a spring this is fixed only at one end.

 Coil spring or helical spring – a spring (made by winding a wire around a cylinder) and
the conical spring – these are types of torsion spring, because the wire itself is twisted when
the spring is compressed or stretched. These are in turn of two types:
 Compression springs are designed to become shorter when loaded. Their turns (loops) are
not touching in the unloaded position, and they need no attachment points.
 A volute spring is a compression spring in the form of a cone, designed so that under
compression the coils are not forced against each other, thus permitting longer travel.
 Tension or extension springs are designed to become longer under load. Their turns
(loops) are normally touching in the unloaded position, and they have a hook, eye or some
other means of attachment at each end.
 Hairspring or balance spring – a delicate spiral torsion spring used in watches, galvanometers,
and places where electricity must be carried to partially rotating devices such as steering
wheels without hindering the rotation.
 Leaf spring – a flat spring used in vehicle suspensions, electrical switches, and bows.
 V-spring – used in antique firearm mechanisms such as the wheel
lock, flintlock and percussion cap locks.

(4) Other types include:

 Belleville washer or Belleville spring – a disc shaped spring commonly used to apply tension
to a bolt (and also in the initiation mechanism of pressure-activated landmines).
 Constant-force spring — a tightly rolled ribbon that exerts a nearly constant force as it is
unrolled.
 Gas spring – a volume of gas which is compressed.
 Ideal Spring – the notional spring used in physics: it has no weight, mass, or damping losses.
 Mainspring – a spiral ribbon shaped spring used as a power source in watches, clocks, music
boxes, windup toys, and mechanically powered flashlights
 Neglector spring – a thin metal band slightly concave in cross-section. When coiled it adopts
a flat cross-section but when unrolled it returns to its former curve, thus producing a constant
force throughout the displacement and negating any tendency to re-wind. The commonest
application is the retracting steel tape rule.
 Progressive rate coil springs – A coil spring with a variable rate, usually achieved by having
unequal pitch so that as the spring is compressed one or more coils rests against its neighbor.
 Rubber band – a tension spring where energy is stored by stretching the material.
 Spring washer – used to apply a constant tensile force along the axis of a fastener.
 Torsion spring – any spring designed to be twisted rather than compressed or extended. Used
in torsion bar vehicle suspension systems.
 Wave spring – a thin spring-washer into which waves have been pressed.

1.3 BASIC WORKING PRINCIPLE OF SPRING

HOOKE'S LAW

As long as they are not stretched or compressed beyond their elastic limit, most springs obey
Hooke's law, which states that the force with which the spring pushes back is linearly proportional
to the distance from its equilibrium length:

Where

X is the displacement vector – the distance and direction the spring is deformed from its
equilibrium length.
F is the resulting force vector – the magnitude and direction of the restoring force the spring
exerts
K is the rate, spring constant or force constant of the spring, a constant that depends on the
spring's material and construction.

Coil springs and other common springs typically obey Hooke's law. There are useful springs
that don't: springs based on beam bending can for example produce forces that
vary nonlinearly with displacement.
Simple harmonic motion

Since force is equal to mass, m, times acceleration, a, the force equation for a spring
obeying Hooke's law looks like:

Figure 2:- displacement and time diagram

The displacement, x as a function of time is called amplitude. The amount of time that passes
between peaks is called the period.

The mass of the spring is assumed small in comparison to the mass of the attached mass and is
ignored. Since acceleration is simply the second derivative of x with respect to time,

This is a second order linear differential equation for the displacement as a function of time.
Rearranging:

The solution of which is the sum of a sine and cosine:

 And are arbitrary constants that may be found by considering the initial displacement and
velocity of the mass. The graph of this function with (zero initial position with some
positive initial velocity) is displayed in the image on the right.

In classical physics, a spring can be seen as a device that stores potential energy,
specifically elastic potential energy, by straining the bonds between the atoms of
an elastic material.

Hooke's law of elasticity states that the extension of an elastic rod (its distended length minus
its relaxed length) is linearly proportional to its tension, the force used to stretch it. Similarly, the
contraction (negative extension) is proportional to the compression (negative tension).

This law actually holds only approximately, and only when the deformation (extension or
contraction) is small compared to the rod's overall length. For deformations beyond the elastic
limit, atomic bonds get broken or rearranged, and a spring may snap, buckle, or permanently
deform. Many materials have no clearly defined elastic limit, and Hooke's law cannot be
meaningfully applied to these materials. Moreover, for the super elastic materials, the linear
relationship between force and displacement is appropriate only in the low-strain region.

Hooke's law is a mathematical consequence of the fact that the potential energy of the rod is a
minimum when it has its relaxed length. Any smooth function of one variable approximates
a quadratic function when examined near enough to its minimum point as a result of the Taylor
series. Therefore, the force—which is the derivative of energy with respect to displacement—will
approximate a linear function.

Force of fully compressed spring

Where
E – Young's modulus
d – Spring wire diameter
L – Free length of spring
n – Number of active windings
– Poisson ratio
D – Spring outer diameter
MATHEMATICS OF SPRING MAKING

Naturally, spring design software is available — you can find out where to get it in
the Addendum. For the purists (or those who don't want to pay for a program), here's a very short
summary of the mathematics of spring design. These equations, by the way, are taken from The
New American Machinist's Handbook, published by McGraw-Hill Book Company, Inc. in 1955.
I don't pretend to understand them.

There's a lot more in the way of engineering that goes into spring design: these are only the
basic equations. If you're interested, you can contact someone who makes spring design
software or (gasp!) find it in the library under Dewey classification number 621.824.

You can also contact the Spring Manufacturers' Institute: they make a handy-dandy spring
calculator, suitable for simple design work, that anyone can learn to use. They also have spring
design software, training classes, and a bunch more stuff. Dave sez, “Check it out.”
1.4 MATERIAL USED IN SPRING PRODUCTION

Steel alloys are the most commonly used spring materials. The most popular alloys include high-
carbon (such as the music wire used for guitar strings), oil-tempered low-carbon,
chrome silicon, chrome vanadium, and stainless steel.

Other metals that are sometimes used to make springs are beryllium copper alloy, phosphor
bronze, and titanium. Rubber or urethane may be used for cylindrical, non-coil springs. Ceramic
material has been developed for coiled springs in very high-temperature environments. One-
directional glass fiber composite materials are being tested for possible use in springs.

Springs are usually made from alloys of steel. The most common spring steels are music wire,
oil tempered wire, chrome silicon, chrome vanadium, and 302 and 17-7 stainless. Other materials
can also be formed into springs, depending on the characteristics needed. Some of the more
common of these exotic metals include beryllium copper, phosphor bronze, Inconel, Monel, and
titanium. The following table summarizes the more important properties of each material:

Common
Material Properties and Uses
Sizes

Music Wire .003-.250 A high-carbon steel wire used primarily for applications
demanding high strength, medium price, and uniformly high
quality. Guitar and piano strings are made from this material,
as are most small springs. Music wire will contract under
heat, and can be plated.

Oil Tempered .010-.625 This is the workhorse steel spring wire, being used for many
Wire (OT) applications in which superior strength or uniformity is not
crucial. Will not generally change dimensions under heat. Can
be plated. Also available in square and rectangular sections.

Chrome .010-.500 These are higher quality, higher strength versions of Oil
Silicon, Tempered wire, used in high-temperature applications such as
Chrome automotive valve springs. Will not generally change
Vanadium dimensions under heat. Can be plated.

Stainless Steel .005-.500 Stainless steels will not rust, making them ideal for the food
industry and other environments containing water or steam.
 302 series stainless will expand slightly under heat: 17-7 will
usually not change. Cannot be plated.

Inconel, .010-.125 These specialty alloys are sometimes made into springs which
Monel, are designed to work in extremely high-temperature
Beryllium environments, where magnetic fields present a problem, or
Copper, where corrosion resistance is needed in a high-temperature
Phosphor working environment. They are much more costly than the
Bronze more common stocks and cannot be plated. Generally will not
change dimensions under heat.

Titanium .032-.500 Used primarily in air- and spacecraft because of its extremely
light weight and high strength, titanium is also extremely
expensive and dangerous to work with as well: titanium wire
will shatter explosively under stress if its surface is scored.
Generally will not change dimensions under heat. Cannot be
plated.

Titanium is the strongest material, but it is very expensive. Next come chrome vanadium and
chrome silicon, then music wire, and then oil tempered wire. The stainless and exotic materials are
all weaker than the rest.

1.5 THE MANUFACTURING PROCESS

The following description focuses on the manufacture of steel-alloy, coiled springs.

1.5.1 COILING

(1) Cold winding Wire up to 0.75 in (18 mm) in diameter can be coiled at room temperature using
one of two basic techniques. One consists of winding the wire around a shaft called an arbor or
mandrel. This may be done on a dedicated spring-winding machine, a lathe, an electric hand drill
with the mandrel secured in the chuck, or a winding machine operated by hand cranking. A guiding
mechanism, such as the lead screw on a lathe, must be used to align the wire into the desired pitch
(distance between successive coils) as it wraps around the mandrel.

Alternatively, the wire may be coiled without a mandrel. This is generally done with a central
navigation computer (CNC) machine.
 The wire is pushed forward over a support block toward a grooved head that deflects the wire,
forcing it to bend. The head and support block can be moved relative to each other in as many as
five directions to control the diameter and pitch of the spring that is being formed.

For extension or torsion springs, the ends are bent into the desired loops, hooks, or straight
sections after the coiling operation is completed.

Figure 3: - Examples of different types of springs.

(2) Hot winding thicker wire or bar stock can be coiled into springs if the metal is heated to make
it flexible. Standard industrial coiling machines can handle steel bar up to 3 in (75 mm) in diameter,
and custom springs have reportedly been made from bars as much as 6 in (150 mm) thick. The
steel is coiled around a mandrel while red hot. Then it is immediately removed from the coiling
machine and plunged into oil to cool it quickly and harden it. At this stage, the steel is too brittle
to function as a spring, and it must subsequently be tempered.
1.5.2 HARDENING

(3) Heat treating. Whether the steel has been coiled hot or cold, the process has created stress
within the material. To relieve this stress and allow the steel to maintain its characteristic resilience,
the spring must be tempered by heat treating it. The spring is heated in an oven, held at the
appropriate temperature for a predetermined time, and then allowed to cool slowly. For example,
a spring made of music wire is heated to 500°F (260°C) for one hour.

1.5.3 FINISHING

(4) Grinding. If the design calls for flat ends on the spring, the ends are ground at this stage of the
manufacturing process. The spring is mounted in a jig to ensure the correct orientation during
grinding, and it is held against a rotating abrasive wheel until the desired degree of flatness is
obtained. When highly automated equipment is used, the spring is held in a sleeve while both ends
are ground simultaneously, first by coarse wheels and then by finer wheels. An appropriate fluid
(water or an oil-based substance) may be used to cool the spring, lubricate the grinding wheel, and
carry away particles during the grinding.

(5) Shot peening. This process strengthens the steel to resist metal fatigue and cracking during its
lifetime of repeated flexing. The entire surface of the spring is exposed to a barrage of tiny steel
balls that hammer it smooth and compress the steel that lies just below the surface.

(6) Setting. To permanently fix the desired length and pitch of the spring, it is fully compressed so
that all the coils touch each other. Some manufacturers repeat this process several times.

(7) Coating. To prevent corrosion, the entire surface of the spring is protected by painting it,
dipping it in liquid rubber, or plating it with another metal such as zinc or chromium. One process,
called mechanical plating, involves tumbling the spring in a container with metallic powder, water,
accelerant chemicals, and tiny glass beads that pound the metallic powder onto the spring surface.

Alternatively, in electroplating, the spring is immersed in an electrically conductive liquid that

will corrode the plating metal but not the spring. A negative electrical charge is applied to the
spring. Also immersed in the liquid is a supply of the plating metal, and it is given a positive
electrical charge. As the plating metal dissolves in the liquid, it releases positively charged
molecules that are attracted to the negatively charged spring, where they bond chemically.
Electroplating makes carbon steel springs brittle, so shortly after plating (less than four hours) they
must be baked at 325-375°F (160-190°C) for four hours to counteract the embrittlement.

(8) Packaging. Desired quantities of springs may simply be bulk packaged in boxes or plastic bags.
However, other forms of packaging have been developed to minimize damage or tangling of
springs. For example, they may be individually bagged, strung onto wires or rods, enclosed in
tubes, or affixed to sticky paper.

Various mathematical equations have been developed to describe the properties of springs,
based on such factors as wire composition and size, spring coil diameter, the number of coils, and
the amount of expected external force. These equations have been incorporated into computer
software to simplify the design process.

1.5.4 QUALITY CONTROL IN SPRING MAKING

Various testing devices are used to check completed springs for compliance with specifications.
The testing devices measure such properties as the hardness of the metal and the amount of the
spring's deformation under a known force. Springs that do not meet the specifications are
discarded. Statistical analysis of the test results can help manufacturers identify production
problems and improve processes so fewer defective springs are produced.

Approximately one-third of defective springs result from production problems. The other two-
thirds are caused by deficiencies in the wire used to form the springs. In 1998, researchers reported
the development of a wire coil ability test (called FRACMAT) that could screen out inadequate
wire prior to manufacturing springs.

Computer-operated coiling machines improve quality in two ways. First, they control the
diameter and pitch of the spring more precisely than manual operations can. Second, through the
use of piezoelectric materials, whose size varies with electrical input, CNC coiling heads can
precisely adjust in real time to measurements of spring characteristics. As a result, these intelligent
machines produce fewer springs that must be rejected for not meeting specifications.
1.6 PROBLEM CREATED IN PRODUCTION OF SPRING

Depending on what kind of spring you want to design, and depending on where it will be used,
your design will be limited:

FOR ALL SPRINGS:

 A spring under load is stressed. If you put too much stress on a spring, its shape will
deform and it will not return to its original dimensions.
 The material from which the spring is made will have an effect on the strength of the
spring: it will also have an effect on how much stress the spring will withstand. The
section on spring materials will tell you more about this.
 When you heat spring wire (which you always do), it may change its dimensions. Again,
the section on materials will tell you more about this.

FOR COMPRESSION SPRINGS:

 If the spring will set solid (compress all the way, so that all the coils touch each other) at
the limit of its travel, the diameter of the wire times the number of coils cannot be greater
than the space allowed, unless you want the spring itself to act as a mechanical stop to the
motion.
 Springs that operate in a high-temperature environment (like for instance inside an
engine) will need to be made slightly longer to compensate for the fact that the heat may
have an effect on the length of the spring. The section on finishing will tell you more
about this.
 As a compression spring assumes a load and shortens, the diameter of the active coils will
increase. This is only a problem when the spring has to work in a confined space.

FOR EXTENSION SPRINGS:

 There should be some mechanical limit on how far the spring will extend, or the spring
will lose its shape and not return to its initial condition with all coils closed.
  Extension springs operating in a high-temperature environment may have to be coiled
extra-tight, as the heat will tend to weaken the spring. The section on extension
springs will tell you more about this.

FOR TORSION SPRINGS:

 When torsion springs assumes a load, the diameter of the coil body will decrease. If the
spring has something inside the coil, it will act as a mechanical stop to the action of the
spring.

1.7 IMPORTANT PRECAUTION TAKEN IN SPRING MANUFACTURING

Springs under load want to return to their original shape. The same goes for spring wire. Spring
wire will try to straighten itself out if given the chance: don't let your body get in its way.

SMALL WIRE

Small wire (diameter less than about .025") will not hurt you if it hits you. On the other hand,
small wire is nothing more than an edge, waiting for something to cut. Don't use your hand to try
to stop wire that's moving, especially if it's moving under power (like being pulled by a lathe).
Instead, wait till it stops moving. Gloves are an excellent idea, too.

MEDIUM WIRE

Medium wire (diameter from about .025" - .312") is too wide to act as an edge, and usually not
massive enough to break bones, but it can raise quite a knot if you get in its way. Again, always
keep track of where the ends of the wire are, and if they start to move, get out of the way.

HEAVY WIRE

Heavy wire (diameter greater than about .312") needs respect. If it gets loose, it can EASILY
break bones, or worse.

STAINLESS STEEL

Stainless steel is a lot softer than other types of wire. When cut, the end of the wire is like a knife
edge. Always keep track of where the end of the wire is, and keep your hands away from it while
it's moving.

HANDLING WIRE
The two most dangerous times are when you're breaking open a coil of wire and when you're
actually winding a spring.

BREAKING OPEN COILS

Once you have your wire, you'll need to take it out of its coil. The coil may be wrapped in paper
— take that off first.

Under the paper, the wire will be tied. Light wire will be tied with string. Medium wire will be
tied with tie wire. Large wire will be tied with metal bands. Whatever size wire you have,
remember that the coil should have only two ends. One will be on the inside of the coil, and the
other will be on the outside. You'll normally use wire from the inside, to avoid tangling. Always
make a hook on the “inside” end so it's easy to find again:

Figure 4:- Handling Small Wire in Coils

To break open a coil of small (up to about .125") wire, cut all the ties except two. Don't cut the
closest tie holding the outside end of the wire, and the tie most directly opposite to that one.

To remove wire from the coil, start with the end on the inside of the coil: this will keep the coil
from tangling. Grab the end of the wire and cut off the hook. Pull it slightly, until you can see the
gap between it and the rest of the coil. Grab the wire at the gap and pull the end free from the tie
holding it. Repeat this process, working around the coil, until you have the length you need.

MEDIUM-SIZED WIRE

(.125 - .312") can be handled the same way, except that you should keep three ties instead of two.
When uncoiling wire larger than .250", you should lay the coil flat on the ground and always stand
in the center of the coil, for safety.

LARGE WIRE

(.312 - .625") needs special handling. First of all, you'll probably be using a hoist or forklift to
move the coil, because of the weight. Lay the coil on top of something (a 2x4 or a pipe works
great) to keep one end off the ground so that you can pick it up when you're done. Stand inside the
coil from now on!

Then, take a length of tie wire and double it over. Loop it twice around the coil, right next to the
second tie holding the inside end of the wire. Pull it tight and twist it so that you have a 'pigtail'
and the tie wire is too tight to move by hand. Then, cut the first two original ties. Grab the end of
the wire and flip it over the coil, so that it sticks out.
 Figure 5:- Handling large Wire in Coils

Go to the next tie and repeat this process, working your way around the coil until you have the
length you need. You can use heavy bolt cutters or an acetylene torch to cut the wire.

If heavy wire gets away from you and starts to come undone all by itself, the very best thing to
do is

 Run like hell, and

 Pray it doesn't hit you.

COILING

If you're using a lathe to make your springs, you'll be standing there, letting the lathe pull the
wire. The lathe will do what you want, but it will not know to stop if things get out of control.
So, before you start the lathe, figure out what you're going to do if things go haywire. Know how
to stop the lathe, and know which way you can safely run.

Never reach over the wire to get to your lathe controls, especially when working with heavy
wire. Reach under it and avoid injury if your wire guide breaks.

Keep the lathe speed DEAD SLOW: with heavy wire, 10 rpm is about right.

Don't grab onto wire that's being fed into the lathe. Stop the lathe and back it off until there's no
tension in the wire before you put your hands near.

NEVER try to guide wire by hand. Use tooling.

When you're done

After you've removed wire from a coil, the coil will be looser than it was before. Before you put
it away, retie it so that it doesn't tangle up or uncoil by itself. For light wire, use string. For medium
size wire, use tie wire. For heavy wire, use tie wire doubled over, looped around the coil twice,
and tied in a “pigtail”:
Lastly, make a hook in the “inside” end of the wire, so you can find it again easily when you need
to.

Storing Wire

Safety first: always store your wire someplace where kids can't get at it.

Common sense second: keep your wire dry. Steel wire will rust if it gets wet.

More common sense: keep your wire tight. When you're finished working with a coil of wire, make
a hook in the inside end (so you can find it again easily) and tie the coil securely. Be especially
careful with heavy wire, which should be tied with at least six doubled strands of tie wire, each
looped around the coil twice and cinched tight.

Still more common sense: if you live in an area that has earthquakes, tornadoes, hurricanes, etc.,
be sure that you chock your coils of wire so that they don't get loose and start to move around
when mother nature starts acting up.

1.8 LITERATURE REVIEW

A spring is a device that changes its shape in response to an external force, returning to its
original shape when the force is removed. The energy expended in deforming the spring is stored
in it and can be recovered when the spring returns to its original shape. Generally, the amount of
the shape change is directly related to the amount of force exerted. If too large a force is applied,
however, the spring will permanently deform and never return to its original shape.
 We all know about spring but spring is using in different places from long time. There are several
types of springs. One of the most common consists of wire wound into a cylindrical or conical
shape. An extension spring is a coiled spring whose coils normally touch each other; as a force is
applied to stretch the spring, the coils separate. In contrast, a compression spring is a coiled spring
with space between successive coils; when a force is applied to shorten the spring, the coils are
pushed closer together. A third type of coiled spring, called a torsion spring, is designed so the
applied force twists the coil into a tighter spiral. Common examples of torsion springs are found
in clipboards and butterfly hair clips.

Still another variation of coiled springs is the watch spring, which is coiled into a flat spiral
rather than a cylinder or cone. One end of the spring is at the center of the spiral, and the other is
at its outer edge.

Some springs are fashioned without coils. The most common example is the leaf spring, which
is shaped like a shallow arch; it is commonly used for automobile suspension systems. Another
type is a disc spring, a washer-like device that is shaped like a truncated cone. Open-core cylinders
of solid, elastic material can also act as springs. Non-coil springs generally function as
compression springs.

Very simple, non-coil springs have been used throughout history. Even a resilient tree branch
can be used as a spring. More sophisticated spring devices date to the Bronze Age, when eyebrow
tweezers were common in several cultures. During the third century B.C., Greek engineer
Ctesibius of Alexandria developed a process for making "springy bronze" by increasing the
proportion of tin in the copper alloy, casting the part, and hardening it with hammer blows. He
attempted to use a combination of leaf springs to operate a military catapult, but they were not
powerful enough. During the second century B.C., Philo of Byzantium, another catapult engineer,
built a similar device, apparently with some success. Padlocks were widely used in the ancient
Roman Empire, and at least one type used bowed metal leaves to keep the devices closed until the
leaves were compressed with ketches next significant development in the history of springs came
in the middle Ages. A power saw devised by Villard de Honewort about 1250 used a water wheel
to push the saw blade in one direction, simultaneously bending a pole; as the pole returned to its
unbent state; it pulled the saw blade in the opposite direction.
 Coiled springs were developed in the early fifteenth century. By replacing the system of weights
that commonly powered clocks with a wound spring mechanism, clockmakers were able to fashion
reliable, portable timekeeping devices. This advance made precise celestial navigation possible for
ocean-going ships.

In the eighteenth century, the Industrial Revolution spurred the development of mass-
production techniques for making springs. During the 1780s, British locksmith Joseph Bramah
used a spring winding machine in his factory. Apparently an adaptation of a lathe, the machine
carried a reel of wire in place of a cutting head. Wire from the reel was wrapped around a rod
secured in the lathe. The speed of the lead screw, which carried the reel parallel to the spinning
rod, could be adjusted to vary the spacing of the spring's coils.

Common examples of current spring usage range from tiny coils that support keys on cellular
phone touch pads to enormous coils that support entire buildings and protect them from earthquake
vibration.

After that too many changes according to application of work came in the spring & with that
change in the method of spring manufacturing. At present for different application and purpose
different size, shape, strength of springs large range available in the market.

According to use of spring are required to make a manufacturing system & we required different
mechanism for different spring.

CHAPTER 2

2.1 INTRODUCTION ABOUT OUR PROJECT

As we all know very well spring is using widely in all places. Springs are in machinery,
automobile, electrical, civil and also in all other branches in one or other application purpose. So
spring is very important mechanism due to its application. Spring application is shock absorbing,
load resting, and elasticity; regain its original shape after removal of force and many more.

Manufacturing of spring is very difficult and costly process. In spring manufacturing we also
required taking too much care to achieve a good quality of spring. Too much wastage is done
during spring manufacturing due to bad processing. Spring application is such type that we need
good properties of spring & to achieve these properties we must going good manufacturing
machine and good processing system.

As there is too much difficulty we observe we decided to make a spring manufacturing machine.
This machine works at a good efficiency and also removes the problem generated in manufacturing
process. For that purpose we collected all information related to spring in chapter 1. Chapter 1
describes all the information related to spring and spring manufacturing process. After completing
this 1st chapter we decided to made a machine can solve the entire problem generated in spring
manufacturing system.

Our project aim is just improve spring manufacturing system by a good machine and process
system. By this machine we can improve system and it can improve the production system too. On
large scale in practical approaches of this machine can made revolution in the field of spring
manufacturing system. Now chapter 2 we are going to give all the information of our project.

2.2 LIST OF PART REQUIRED FOR SPRING MAKING MACHINE

We want to make multipurpose production machine which is easy, safe, and efficient for
industrial use.

For this project preparation we must need some basic parts listed below.

 Reduction gear Motor,

  MS framing,

 Gear box support stand,

 Sprocket,

 Chain drive,

 Spur gear box,

 Gear mounted shaft,

 Guiding support shaft

 Guiding threaded shaft

 Guide

 Guiding threaded shaft mounting nut

 Bush,

 Wire.

2.3 WORKING OF OUR PROJECT

We are making a spring making machine. In our machine we use part listed in 2.2. now
arrangement of all part is as describe below.

We made the base frame from rectangular pipe of heavy bar because we required a vibration
proof base. Now on that base we fitted chuck and speed giving motor in one end and feed giving
motor and arrangement in other end. On one end first of all we fitted chuck base of rectangular
pipe and on that fitted chuck straight in horizontal direction. Then we fitted reduction gear in the
back side of chuck and on that motor stand is fitted. On that motor stand motor is fitted and it is
connected with the gear box with the help of belt drive. So our speed giving part of spring machine
is finish.

Then we fitted gear reduction gear box on the other side of machine. On that gear box we fitted
the motor stand on the speed variable motor is fitted and it is connected with the gear through the
belt drive. On the other end of gear box lead screw is fitted and other end of lead screw is fitted in
the bottom side of chuck in the bearing.

Now we fitted guide on the same distance on the both side of lead screw and on that we fitted
the carriage. Both end of guide welded in the frame so it is straight in horizontal direction. Then
we fitted straight bar guide on the carriage.

Now connection of both motor given on the same line. Now when we start the machine speed
giving motor start rotating in chuck bar is fitted is also start rotating. We start the other motor and
run it on constant speed then carriage is start moving on lead screw.

Now we fit the end of wire in the end of bar near to chuck and it other bend fit in the bar guide.
When we start machine wire start binding on the bar and so on spring is made. Pitch of spring is
depending upon the speed of feed giving motor.

2.4 DESCRIPTION OF PART USED IN SPRING MAKING MACHINE

SR. PART NAME MATERIAL DIMENSION QUANTITY

NO.
1 Reduction gear Motor, ---- RPM 2000 ----
 2 MS framing MS Used 40*20mm rectangular pipe 1
length 62cm, width
36cm, height 14cm
3 Gear box PVC Gear reduction ration 1:3

4 Gear box support stand MS 40*20mm rectangular pipe length 2

36cm
5 Sprocket HSS (1) Bigger :- 2
(2) Smaller:-
6 Chain drive HSS Length 20cm 1

7 Spur gear box PVC Bigger gear diameter 25mm, no of 1

teeth 56, smaller gear diameter
14mm, no of teeth 28
8 Gear mounted shaft HN8 Diameter 20mm, length 16cm 1

9 Guiding support shaft SS Diameter 30mm, length 42cm 1

10 Guiding threaded shaft HSS Diameter 20mm, length 44cm 1

11 Guide MS Length 24cm, width 40mm, 1

thickness2mm
12 Guiding threaded shaft HSS 20mm nut 2
mounting nut
13 Bush HSS Outer diameter 50mm, inner hole 1
diameter 30.5mm
14 Wire COPPER Copper wire 3 meter

2.5 MACHINERY REQUIRED FOR PROJECT PREPARATION

In preparation of our machine following machinery are required which used by us for
making different parts of our machine.

 Lathe machine,
  Cutter machine,

 Arc Welding machine,

 Drilling machine,

 Hand Grinder machine,

 Milling machine,

 Riveting equipment,

 Other fasteners fitting equipment,

 Vernier caliper, micrometer screw gauge, measure tap, and other measuring equipment.

2.6 BUILD UP MATERIAL

(1) MS FRAME

(i) First of all MS plate cut as per drawing by using HEXO cutter machine.
(ii) Then edge finishing done by using hand grinder machine.
(iii) Then pieces of MS plate welded as per drawing.
 (iv) Then finishing of MS frame done by hand grinder machine.

(2) REDUCTION GEAR

(i) Reduction gear fitted on the frame.

(ii) On the less speed outer shaft chuck is fitted.
(iii)Alignment of chuck is inspected.
(iv) Chuck fitted very strongly on the shaft.
(v) Motor fitted on the top side of reduction gear box on the motor stand.
(vi) Alignment of motor shaft and reduction shaft match and belt drive fitted on it.

(3) SPUR GEAR BOX

(i) On other end of machine motor stand fitted with the help of fasteners.
(ii) Motor fitted on the motor stand.
(iii)Reduction gear fitted in front of motor.
(iv) Belt drive mounted on gear box input and motor.

(4) LEAD SCREW AND CARRIAGE FITTING.

(i) Lead screw is fitted on the small reduction gear.

(ii) Other end of lead screw is fitted in the frame below the chuck.
(iii)On the both end of lead screw carriage guide is fitted with the welding.
(iv) In the carriage guide bushing is fitted.
(v) On that bushing carriage is welded.
(vi) On the carriage wire guide is fitted.

2.7 PART DESCRIPTION USED IN PROJECT

(1) REDUCTION GEAR MOTOR,
Reduction gear motor is used to decrees the speed of the motor. It is as shown in the figure.
 FIGURE: - 2.7.1 REDUCTION GEAR MOTOR
(2) MS FRAMING
MS framing is used to fit all other parts used in the machine. It is as shown in the figure.

FIGURE: - 2.7.2 MS FRAMING

(3) SPUR GEAR BOX

Spur gear is fitted before the spring making shaft here the output of the gear box is work as a
chuck on which shaft is mounted. Here we need slow speed so we used gear box to reduce speed
and increase torque. Gear box is reduction type spur gear box. By this gear box we reduce the
speed of the rotating shaft. Gear box is as shown in the figure.
 FIGURE: - 2.7.3 GEAR BOX
(4) GEAR BOX SUPPORT STAND
Gear box stand is the stand on which the gear box is fitted. Here it is made from 20*40mm
rectangular pipe. It is as shown in the figure.

FIGURE: - 2.7.4 GEAR BOX SUPPORT STAND

(5) SPROCKET
Bigger Sprocket is mounted on the output shaft of reduction motor and input shaft of gear box.
And the smaller sprocket is mounted on the threaded shaft. So the speed of threaded shaft is
reducing by this sprocket arrangement. We can vary the pitch value by changing the number of
teeth of the sprocket.
 FIGURE: - 2.7.5 SPROCKET
(6) CHAIN DRIVE
Chain drive is fitted between to sprocket so power is transferred to the threaded shaft easily.
Chain drive is as shown in below figure.

FIGURE: - 2.7.6 CHAIN DRIVE

(7) GEAR MOUNTED SHAFT
This is a shaft on which our sprig is mounted so as per requirement of the inner diameter of the
spring we can change the shaft diameter. Here the shaft we used shown in the figure.

FIGURE: - 2.7.7 GEAR MOUNTED SHAFT

(8) GUIDING SUPPORT SHAFT
Guiding support shaft is fitted at the left side of the threaded shaft which guide the bed in the
required direction it is as shown in the figure.

FIGURE: - 2.7.8 GUIDING SUPPORT SHAFT

(9) GUIDING THREADED SHAFT
Here threaded shaft is work as a lead screw. By this we can provide the constant distance gap
travel to the tool post. It is as shown in the figure.

FIGURE: - 2.7.9 GUIDING THREADED SHAFT

(10) GUIDE
Guide is work as a tool post on which the wire guiding tool post is mounted. It is as shown in the
figure.

FIGURE: - 2.7.10 GUIDE

(11) GUIDING THREADED SHAFT MOUNTING NUT
It is a contact making between the guide and the threaded shaft. It is used to provide the
constancy feed application for the threaded shaft.

FIGURE: - 2.7.11 GUIDING THREADED SHAFT MOUNTING NUT

(12) BUSH
Bush is used to make fitting between the guiding shaft and guide or tool post. It is as shown in
the figure.

FIGURE: - 2.7.12 BUSH

(13) WIRE
Wires are used to make contact between the motor and the battery. It is used to give the electric
supply to the motor.

FIGURE: - 2.7.13 WIRE

2.9 FITTING OF ALL PART ARRANGEMENT

Fitting of all part arrangement is shown in figure.

FIGURE: - 2.9 FITTING OF ALL PART ARRANGEMENT

2.10 FUTURE WORK

We carried out this project successfully. We are inspired to make this project in practical
approach. So we work on the limitation which still presents in our project & we try to remove it.
We work hard to remove all the limitation in time limit which we have. We also learn to much
things & practical approaches during completion of project.

Still some limitation present in our machine. We think lot to solve problem in it & many
limitation solve by our great group work. Our group is try to make this machine in real production
purpose & we try to made such kind of machine which can used in workshop for spring
manufacturing purpose. On large scale application of this machine leads a great revolution in the
field of spring manufacturing.

Demands of the rapidly growing computer and cellular phone industries are pushing spring
manufacturers to develop reliable, cost-effective techniques for making very small springs. Springs
that support keys on touch pads and keyboards are important, but there are less apparent
applications as well. For instance, a manufacturer of test equipment used in semiconductor
production has developed a micro spring contact technology. Thousands of tiny springs, only 40
miles (0.040 in or 1 mm) high, are bonded to individual contact points of a semiconductor wafer.
When this wafer is pressed against a test instrument, the springs compress, establishing highly
reliable electrical connections.

Medical devices also use very small springs. A coiled spring has been developed for use in the
insertion end of a catheter or an endoscope. Made of wire 0.0012 in (30 micrometers or 0.030 mm)
in diameter, the spring is 0.0036 in (0.092 mm) thick—about the same as a human hair. The
Japanese company that developed this spring is attempting to make it even smaller.

The ultimate miniaturization accomplished so far was accomplished in 1997 by an Austrian

chemist named Bernard Krautler. He built a molecular spring by stringing 12 carbon atoms
together and attaching a vitamin B12 molecule to each end of the chain by means of a cobalt atom.
In the relaxed state the chain has a zigzag shape; when it is wetted with water, however, it kinks
tightly together. Adding cyclodextrin causes the chain to return to its relaxed state. No practical
application of this spring has yet been found, but research continues.
 CHAPTER 3

3.1 PROJECT PLANNING

Activity Description of activity Who will Planned dates Actual dates Who has/
No. perform? Have
Start End Start End performed
Date Date Date Date ?
1 Allocation of
project
2 Study of project
contain
3 List of work to Do

4 Master schedule

5 Part list used in

project
6 Part collection
distributed
7 All parts collected

8 Assemble of all
parts
9 Collected extra
needed parts
10 Re assemble all
parts
11 Run project

12 Monitoring by
faculty
13 Suggestion given
by faculty
14 Final assembly of
project
15 Final Run project
3.2 COST ESTIMATION

SR PART DESCRIPTION QUANTITY MATERIAL PRICE

NO.

1 REDUCTION GEAR MOTOR, 1

2 MS FRAMING 1

3 GEAR BOX 1

4 GEAR BOX SUPPORT STAND 1

5 SPROCKET 2

6 CHAIN DRIVE 1

7 SPUR GEAR BOX 1

8 GEAR MOUNTED SHAFT 1

9 GUIDING SUPPORT SHAFT 1

10 GUIDING THREADED SHAFT 1

11 GUIDE 1

12 GUIDING THREADED SHAFT 2

MOUNTING NUT
13 BUSH 1
14 WIRE 3 meter MS 250
15 WELDING COST ---- ---- 1200

16 PART COLLECTING ---- ---- 600

TRANSPORTATION COST
17 ASSEMBLING COST ---- ---- 800
18 FINISHING COST ---- ---- 650
19 TRANSPORTATION CAST ---- ---- 2000

20 PART MANUFACTURING COST ---- ---- 1500

21 OTHER COST ---- ---- 1800

 TOTAL COST 18,350/-

CHAPTER 4

4.1 FLOW PROCESS CHART

SYMBOL: - operation transport delay inspection store

SR. DESCRIPTION SYMBOL REMARK

NO.

1 ALL PARTS IN STORE COLLECTED

IN
WORKSHOP
2 MS PLATE MOVE IN CUTTING
SHOP FOR CUTTING
OPERATION
3 MS PLATE CUT AS PER
DRAWING
4 INSPECTION OF MS PLATE
CARRIED OUT
5 MS PLATE MOVE TO WELDING
SHOP
6 MS PLATE WELDED AS PER
DRAWING
7 WELDED JOINT FINISHING BY
HAND GRINDING
8 REDUCTION GEAR OF 1:50 IS
FITTED
9 ON THE FRONT SHAFT OF
REDUCTION GEAR CHUCK IS
FITTED
10 ALIGNMENT IS INSPECTED
11 SIDE SHAFT OF GEAR PULLEY
IS FITTED
12 MOTOR STAND IS FITTED ON
THE TOP OF GEAR BOX
13 ON THE STAND MOTOR IS
FITTED
14 ON MOTOR SHAFT PULLEY IS
FITTED
15 ALIGNMENT OF BOTH THE
PULLEY IS INSPECTED
16 BELT DRIVE IS FITTED ON
BOTH PULLEY
17 FITTING IS INSPECTED
18 OTHER END OF FRAME STAND
FOR VARIABLE MOTOR IS
FITTED
19 ON THAT STAND MOTOR IS
FITTED
20 MOTOR FITTING INSPECTED
21 ON THE SHAFT OF MOTOR
PULLEY IS FITTED
22 SECOND REDUCTION GEAR IS
FITTED IN FRONT OF MOTOR
23 ON THAT REDUCTION GEAR
SHAFT PULLEY IS MOUNTED
24 ALIGNMENT ON BOTH THE
PULLEY IS INSPECTED
25 BELT DRIVE IS MOUNTED ON
BOTH THE PULLEY
26 LEAD SCREW FITTED ON THE
SECOND REDUCTION GEAR
BOX SHAFT
27 OTHER END OF LEAD SCREW
FITTED WITH BARRING IN THE
OTHER SIDE FRAME
28 GUIDE WELDED ON THE BOTH
SIDE OF LEAD SCREW
29 ON THAT GUIDE BUSHING IS
FITTED
30 ON THAT BUSHING CARRIAGE
IS FITTED
31 MOVING ALIGNMENT OF
CARRIAGE IS INSPECTED
32 TOOL GUIDE IS FITTED ON
CARRIAGE
33 ALL PARTS FITTING
INSPECTED
34 MACHINE MOVE TO STORE MOVE IN
STORE
TOTAL OPERATION 22 02 00 08 02
 4.2 OPERATION PROCESS CHART
LEAD SCREW & CARRIAGE FITTED REDUCTION GEAR FITTING MS FRAMING

lead screw fitted on shaft chuck fitted on the gear box 8 saw to rough length
15 1

6 Lead screw Chuck alignment inspected 3 Grinding Prepare length 2

alignment inspected

Carriage guide Motor stand fitted 10 frame Joint edges of pieces 3

16 fitted on the both
side of lead screw

Carriage guide Motor fitted on stand 11 Joint welded by welding 4

7 fitting
inspected

Carriage fitted on Belt mounted on both pulley 12 Welding joint inspected 1

17 the lead screw by
welding
Fitting of that parts inspected 4 joint finishing by grinding 5
18 Belt drive fitted
through motor &
other shaft
2nd gear box fitted 13 all joint work one by
6
One in same sequence

Alignment of gear
8 box motor and belt
drive inspected Variable speed Motor fitted 14 Checkout all 2

9 Inspection
dimensionof total Inspeation of all part fitting gear box fitted on the frame
project carried out 5 7

PROJECT MOVE TO STORE

4.3 WORK CARRIED FOR PREPARATION OF PROJECT
1. ALL PARTS IN STORE
2. MS PLATE MOVE IN CUTTING SHOP FOR CUTTING OPERATION

3. MS PLATE CUT AS PER DRAWING

4. INSPECTION OF MS PLATE CARRIED OUT

5. MS PLATE MOVE TO WELDING SHOP

6. MS PLATE WELDED AS PER DRAWING

7. WELDED JOINT FINISHING BY HAND GRINDING

8. REDUCTION GEAR OF 1:50 IS FITTED

9. ON THE FRONT SHAFT OF REDUCTION GEAR CHUCK IS FITTED

10. ALIGNMENT IS INSPECTED

11. SIDE SHAFT OF GEAR PULLEY IS FITTED

12. MOTOR STAND IS FITTED ON THE TOP OF GEAR BOX

13. ON THE STAND MOTOR IS FITTED

14. ON MOTOR SHAFT PULLEY IS FITTED

15. ALIGNMENT OF BOTH THE PULLEY IS INSPECTED

16. BELT DRIVE IS FITTED ON BOTH PULLEY

17. FITTING IS INSPECTED

18. OTHER END OF FRAME STAND FOR VARIABLE MOTOR IS FITTED

19. ON THAT STAND MOTOR IS FITTED

20. MOTOR FITTING INSPECTED

21. ON THE SHAFT OF MOTOR PULLEY IS FITTED
22. SECOND REDUCTION GEAR IS FITTED IN FRONT OF MOTOR

23. ON THAT REDUCTION GEAR SHAFT PULLEY IS MOUNTED

24. ALIGNMENT ON BOTH THE PULLEY IS INSPECTED

25. BELT DRIVE IS MOUNTED ON BOTH THE PULLEY

26. LEAD SCREW FITTED ON THE SECOND REDUCTION GEAR BOX SHAFT

27. OTHER END OF LEAD SCREW FITTED WITH BARRING IN THE OTHER SIDE FRAME

28. GUIDE WELDED ON THE BOTH SIDE OF LEAD SCREW

29. ON THAT GUIDE BUSHING IS FITTED

30. ON THAT BUSHING CARRIAGE IS FITTED

31. MOVING ALIGNMENT OF CARRIAGE IS INSPECTED

32. TOOL GUIDE IS FITTED ON CARRIAGE

33. ALL PARTS FITTING INSPECTED

34. MACHINE MOVE TO STORE

4.4 CPM AND PERT :- ( CRITICAL PATH METHOD)

4 6

1 2 3

5 7 8 9 10 11

1) SELECTION OF PROJECT
2) MARKET SURVEY
3) PROCESS PLANNING
4) DESIGN & DRAWING
5) SELECTION OF MATERIAL
6) SELECTION OF MACHINE TOOLS
7) TRANSPORTATION OF MATERIAL
8) PROCESS ON MATERIAL
9) FLOW PROCESS CHART
10) COSTING
 CHAPTER 5

ADVANTAGES OF PROJECT

 Can make the wide range of pitch of spring.

 No noise produces.

 Easy to operate,

 Fast work cycle,

 Different diameter set by different shaft

 Less heavy machine.

 Run by battery so work anywhere.

 Less input supply required.

5.3 CONCLUSION

By the use of this machine we can improve the production process system and by improving this
system we can increase the profit made by this machinery. We can also increase our plant
productivity by implement of this system. This machine is very useful in production of such kind
of spring of wide range in less time and with a great output.