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Spring Design

This document discusses the design of helical springs. It defines key dimensions of helical springs like wire diameter, inside diameter, pitch, and mean coil diameter. It describes different types of springs and focuses on helical compression springs. The document discusses how to calculate spring stiffness and stresses in helical compression springs. It provides equations to calculate maximum shear stress based on spring geometry, applied force, and material properties. The goal is to teach readers how to design helical springs and select suitable materials to withstand stresses.

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abas
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250 views

Spring Design

This document discusses the design of helical springs. It defines key dimensions of helical springs like wire diameter, inside diameter, pitch, and mean coil diameter. It describes different types of springs and focuses on helical compression springs. The document discusses how to calculate spring stiffness and stresses in helical compression springs. It provides equations to calculate maximum shear stress based on spring geometry, applied force, and material properties. The goal is to teach readers how to design helical springs and select suitable materials to withstand stresses.

Uploaded by

abas
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Outline

1. Introduction.
2. Types of Spring.
3. Helical Spring Dimensions.
4. Stresses and Deflections in Helical
Compression Spring.
Objectives

At the end of this lesson, we should be able to :

1. Design of helical spring.


• To find the stresses, dimensions and
deflection of the spring.
• Select suitable material of spring.
INTRODUCTION
 A spring is defined as an elastic part that deflects under the action of
the load and returns to its original shape when the load is removed. It
can take any shape and form depending upon the application.

 Functions:

 (1) To apply force and to control motion. e.g. springs used in cam and
follower, engine valve, clutch).

 (2) To absorb shocks and vibrations. e.g. springs used in vehicle


suspension, railway buffer, buffer springs in elevators and vibration
mounts for machinery.

 (3) To store energy. e.g. springs used in clocks, toys, movie-cameras,


circuit breakers and starters.

 (4) To measure force. e.g. springs used in weighing balance and scales.
TYPES OF SPRING

 Wire springs
 Helical springs of round or square wire.
 Flat springs, or special-shaped springs, and there are
variations within these divisions.
 Cantilever and Elliptical types, flat spring washers,

The discussion in this chapter is mainly restricted to helical


springs
HELICAL SPRING DIMENSIONS
The main dimensions of a helical spring subjected to compressive force are
shown in Fig. 4.1 They are as follows:
d = wire diameter of spring (mm)
Di = inside diameter of spring coil (mm)
Do = outside diameter of spring coil (mm)
D = mean coil diameter (mm)
Therefore,

(4.1)

 The ratio of mean coil diameter to the


diameter of wire for the spring is called the
spring index C.
Fig. 4.1 Dimensions of Spring
(4.2)
 The pitch of the coil is defined as the axial distance between adjacent
coils in uncompressed state of spring. It is denoted by p. It is given by.

 The stiffness of the spring (k) is defined as the force required to produce
unit deflection. Therefore,

where,
k = stiffness of the spring (N/mm)
P = axial spring force (N)
δ = axial deflection of the spring corresponding to force P (mm)
There are various names for stiffness of spring such as rate of spring, gradient
of spring, scale of spring or simply spring constant.
Spring Lengths

Fig. 4.2 Various Lengths of a Helical Compression Spring.


End Details

Fig. 4.3 Four Styles of End-Coil Treatments for Helical Compression Springs
Stresses in Helical Compression Spring
The free-body diagram in Fig 4-4 shows that there will be two components
of stress on any cross section of a coil; a torsional shear stress from the
torque T and a direct shear stress due to the force F. These two shear
stresses have the distributions across the section shown in Fig. 4-5 (a) and (b).
They add directly, and the maximum shear stress τmax occurs at the inner
fiber of the wire's cross section, as seen in Fig. 4-5 (c).

(4.5a)

Fig.4.4 Forces and Torques on the Coils of


a Helical Compression Spring
We can substitute the expression for spring index C from equ. 4.2
in equ. 4.5a :

(4.5b)

Fig.4.5 Stress Distributions Across Wire in a Helical Compression Spring


Ks = direct shear factor. (Neglecting the effect of curvature)
 We learned that curved beams have a stress concentration on the inner
surface of curvature. While our spring is not loaded as a beam, the same
principle applies, and there is higher stress at the inner surface of the
coil.
 WAHL determined the stress-concentration factor for this application and
defined a factor Kw which includes both the direct shear effects and the
stress concentration due to curvature.
(4.6a)

(4.6b)

 This combined stress is shown in Fig 4.5 (d)


 Since Wahl's factor Kw includes both effects, we can separate them into a
curvature factor Kc and the direct shear factor Ks using

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