Machine Element Design & Process - I

MEEG 315

Module VI : Mechanical Springs

Lecture 15 : Stresses in Springs

 DISCLAIMER
The presentation contains extraction of contents from books, technical paper,
studies and other public domain.

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 Mechanical Spring
Stresses in Spring:
Types of Spring Major Stresses
Helical Shear Stress.
Conical Shear Stress.
Torsion Tensile and Compressive.
Leaf Tensile and Compressive.
Disc Tensile and Compressive.

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 Mechanical Spring
Stresses in Helical Spring of Circular Wire:
Let,
D = Mean diameter of the spring coil.
d = Diameter of the spring wire.
n = Number of active coils.
G = Modulus of rigidity for the spring material.
W or F = Axial load on the spring.
𝜏𝜏= Maximum shear stress induced in the wire.
C = Spring index = D/d.
P = Pitch of the coils, and
δ = Deflection of the spring, as a result of an axial load “W”.

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 Mechanical Spring
Stresses in Helical Spring of Circular Wire:

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 Mechanical Spring
Stresses in Helical Spring of Circular Wire:
Three kinds of stresses induced:

1. Torsional Shear Stress (𝜏𝜏1 )

𝑇𝑇𝑇𝑇
𝜏𝜏1 =
𝐽𝐽

𝑑𝑑
where,
𝐷𝐷 𝜋𝜋𝜋𝜋4
T= 𝐹𝐹 J= 𝑟𝑟 =
2 32 2

8𝐹𝐹𝐹𝐹
𝜏𝜏1 =
𝜋𝜋𝑑𝑑 3

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 Mechanical Spring
Stresses in Helical Spring of Circular Wire:
Three kinds of stresses induced:

2. Direct Shear Stress (τ2 ):

Load F 4F
τ2 = = πd2
=
Cross−sectional area of wire πd2
4

Resultant Shear Stress:

8FD 4F 8FD d 8FD 1
τ = τ1 + τ2 = 3 + 2 = 3 1 + = 1+
πd πd πd 2D πd3 2C
8FD 1
τ= Ks 3 where K s = 1 + =Shear stress factor
πd 2C

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 Mechanical Spring
Stresses in Helical Spring of Circular Wire:
Three kinds of stresses induced:
3. Curvature of wire:
• The curvature of the spring, implies that there is an
additional stress on the inside of the coil.
• This effect is severe for small values of spring index C.
• The analysis was first published by Wahl and hence called
Wahl factor “K” which is multiplied with 𝜏𝜏 to get the stress
on the inside of the spring.

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 Mechanical Spring
Stresses in Helical Spring of Circular Wire:
• Axial deflection of the spring (𝛿𝛿):
D
δ= θ.
2
D
Tl F. 2 πD.n 16FD2 n
where, θ=angular deflection = = π 4 =
JG D G G.d4
32
8FD3 n 8FC3 n
∴ δ= =
G.d4 G.d

• Stiffness of spring
- Load required to produce unit deflection

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 Mechanical Spring
Concentric or Composite Springs (Parallel)
• One spring inside another
• Adjacent coils wound in opposite direction
• to illuminate any tendency to bend

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 Mechanical Spring
Concentric or Composite Springs (Parallel)
Purpose
• To obtain greater spring force within a given space
• To ensure the operation of a mechanism in the
event of failure of one of the spring
• To step up or step down spring force as in
governors of variable speed engine

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 Mechanical Spring
Concentric or Composite Springs (Parallel)
Uses
• In automobile clutches
• In wall spring in aircrafts
• Heavy duty diesel engines
• Car suspension system

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 Mechanical Spring
Concentric or Composite Springs (Parallel)
• Deflection in both spring is same

K t = K1 + K 2

Spring index should be same for both

the springs

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 Mechanical Spring
Concentric or Composite Springs (Series)

1 1 1
= +
K t K1 K 2

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 Mechanical Spring
Exercise 16.1
• A compression coil spring made of an alloy steel is having
the following specifications:
Mean diameter of coil (D) = 50 mm;
Wire diameter (d) = 5 mm;
No of active coils = 20;
If the spring is subjected to an axial load of 500N;
Calculate the maximum shear stress to which the spring
material is subjected. (Neglect the curvature effect).

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 Mechanical Spring
Hints:

Spring index = 10 (Use Eq. 11.2 c)

Shear stress = ? (Use Eq. 11.1 a)

Stress factor = ? (Use Eq. 11.2 d)

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 Mechanical Spring
Exercise 16.2
• Design a helical compression spring to support an axial
load of 3000 N. The deflection under load is limited to 60
mm. The spring index is 6.The spring is made of chrome
vanadium steel and factor of safety is equal to 2.
HINTS:

From Table 11.8: For Chrome vanadium Steel

N
τy = 690 MPa = 690
mm2
G=0.07845*106 N/mm2

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 Mechanical Spring
Hints
𝜏𝜏𝑦𝑦 690
Shear stress (𝜏𝜏) = = = 345 N/mm2
𝐹𝐹𝐹𝐹𝐹𝐹 2

Diameter of wire (d) = ? = 12.89 mm ~ 13 mm

(Use Eq. 11.1 a) {K=1.2525; D=6d}

Diameter of coil (D) = 78 mm

Outer diameter of coil = 91 mm

Inner diameter of coil = 65

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 Mechanical Spring
Hints

No. of coils, i or n = ? = 11.8 ~ 12

(Use Eq. 11.5 a) {y=60, D=78}

Free length = ?
Assume squared and ground ends, n’=n+2 [Table 11.7]
∴ LF = n′ . d + δmax + 0.15 δmax = 251 mm => 251 mm

Pitch = ? = 19.30 mm

Stiffness or rate of spring = 50 N/mm (Use Eq. 11.7 a)

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 Mechanical Spring
Exercise 16.3
• A helical spring of rate 10 N/mm is mounted on top
of another spring of rate 8N/mm. Find the force
required to give the total deflection of 45mm.
Hints:
1 1 1
= + 𝐾𝐾𝑡𝑡 = 4.44 𝑁𝑁/𝑚𝑚𝑚𝑚
K t K1 K 2

For deflection of 45 mm, the force required is 4.44x45 = 199.99 N ~ 200 N

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 Mechanical Spring
Exercise 16.4
• The larger of the two concentric springs made of 38
mm diameter round bar has a mean coil diameter of
228 mm and 6 active coils. The inner spring has a wire
diameter of 25 mm, spring index of 5, and the number
of active coil 9.
Free height of the outer spring is 19 mm more than the
inner. Find the deflection of each spring for a load of
90 kN. Take G = 77 x 103 Mpa.
Calculate the load carried by each spring.

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 Mechanical Spring
Hints:
K t = K1 + K 2
77000∗38 C=228/38=6
Stiffness of outer spring, K1 = =311.012 N/mm
8∗63 ∗6
Use Eq. 11.7 a
77000∗25
Stiffness of inner spring, K 2 = =213.88 N/mm C=5
8∗53 ∗9

Total load = Load shared by outer spring for 19 mm deflection +

Load shared by outer spring for further defection + Load shared by
inner spring for further defection

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 Mechanical Spring
Hints:
Load causing 19 mm defection of outer spring = 311.012*19
= 5909.22 N

Remaining Load= 90,000-5909.22 = 849090.78 N

It is shared by two springs in proportion to the stiffness.

Load shared by outer spring=311.012*849090.78 / (311.012+213.88)

=50311.191 N

Total load on outer spring=50311.191+5909.22=56220.411 N

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 Mechanical Spring
DIY
• Research on different types of spring material.
• Examples: 23.2, 23.3, 23.6, 23.19, 23.20
A textbook of Machine Design : RS Khurmi

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 Mechanical Spring
DIY
• An engine indicator has a plunger diameter of 19
mm. The indicator spring attached to this plunger is
to be compressed 13 mm when the steam pressure
is 70 N/cm2. Assuming the spring index to be 6,
design the spring.

Assume
The Spring has square and ground end.
G = 78 x 105 N/cm2
τ = 55000 N/cm2

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