BATAAN PENINSULA STATE UNIVERSITY

COLLEGE OF ENGINEERING AND ARCHITECTURE

Department of Mechanical Engineering

Machine Design 1

Design of Spring

MachDesign1-BRIANJTUAZONME
Spring

❑ it is an elastic body, whose

function is to distort when
loaded and to recover its
original shape when the load is
removed.

❑It is a device made of an

elastic material that undergoes
a significant change in shape,
or deformation, under an
applied load.

MachDesign1-BRIANJTUAZONME
 Uses

❑Absorb energy or shock loads as in automobile chassis springs

and railroad bumper springs.
❑Act as a source of energy as in clocks.
❑Produce pressure or force, as in maintaining pressure between
the friction surfaces of clutches and as in keeping cam follower
in contact with the cam.
❑Absorb vibration
❑Act as a load measuring devices, as in spring balances power
dynamometers and instruments such as in gages, meters and
engine indicators.
MachDesign1-BRIANJTUAZONME
 Types of Spring

Helical Springs
• are made up of wire coiled in the form of
helix and is primarily intended for
compressive or tensile loads. The
advantages of helical springs are: easy to
manufacture, available in wide range,
reliable, constant spring rate, the
performance can be predicted more
accurately, and the characteristics can
be varied by changing dimensions.

MachDesign1-BRIANJTUAZONME
Types of Spring

Conical and Volute Springs

• are used in special applications where telescoping spring or
spring with a spring rate that increases with load is desired.

MachDesign1-BRIANJTUAZONME
 Types of Spring
Torsion Spring
• maybe helical or spiral type. The helical type
maybe used only in applications where the
load tends to wind up the spring and are used
in various electrical mechanism. The spiral type
is also used where the load tends to increase
the number of coils and when made of flat strip
are used in watches and clocks.
Laminated or Leaf Springs
• consist of a number of flat plates of varying
lengths held together by means of clamps and
bolts. The major stresses produced in leaf
springs are tensile and compressive stresses. MachDesign1-BRIANJTUAZONME
 Types of Spring

Disc or Belleville Springs

• consist of a number of conical discs held
together against slipping by a central bolt or
tube. They are used in application where
high spring rates and compact spring units
are required. The major stresses produced in
disc or Belleville springs are tensile and
compressive stresses.

MachDesign1-BRIANJTUAZONME
 Design of Spring
Spring Index
- is the ratio of mean diameter to the wire diameter in a coil spring
Dm Do − d w Di + d w
C= = =
dw dw dw
Coil or Pitch angle (α)
- the angle between coil and the base of the
spring.
P
 = tan −1

Dm
Length of Wire

L = Dm nc
MachDesign1-BRIANJTUAZONME
Design of Spring

Angle of Twist (torsional deflection) of coiled wire

TL 16 FC 2 nc
= = 2
JG dw G
Deflection (deformation) of coil spring
8 FC 3 nc
 = Rm =
d wG
Spring constant/rate/modulus/scale/gradient
- is the ratio of load to deflection
d wG
F
k= = 3
 8C nc
MachDesign1-BRIANJTUAZONME
 Design of Spring
Maximum Stress in the coil spring
- due to torsional and direct shear stresses

Tc F 8 FDm  d w  8 FDm
 max = + = 3 
1+ = K
J Aw  d w  2 Dm   d w 3

 0 .5 
Shear stress concentration Factor: K  1 + 
 C 
- for small wire diameter & large spring radius

4C − 1 0.615
Wahl ‘s stress concentration Factor: K = +
4C − 4 C
- takes into account spring curvature effects

MachDesign1-BRIANJTUAZONME
 Li - Installed or preloaded length
Lw - Operating or Working Length
Design of Spring
Spring constant/rate/modulus/scale/gradient
- is the ratio of load to deflection
F Fw − Fi Free Length (Lf)
k= = – is the length of spring in free or unloaded condition.
 w Shut or Solid Length (Ls)
Fi – installed or initial force – when the compression spring is compressed until the
coils come in contact with each other, then the spring is
Fw – operating or maximum said to be solid.
working force
Fi
i
Fw
w
s
Lf Li LCA
Lw
Ls
MachDesign1-BRIANJTUAZONME
Design of Spring
Length of Clash Allowance (LCA)
• It is the difference in spring length between maximum working LCA = δs − δw
load and spring solid positions.
• It is a length in terms of percentage of the total spring LCA = CA × δw
deflection at maximum working load.
• Usually a 10% clash allowance is provided. CA × δw = δs − δw
δs − δw
CA =
Fi δw
i
Fw
w
s
Lf Li LCA
Lw
Ls
MachDesign1-BRIANJTUAZONME
Design of Spring
Buckling
• may occur in compression spring during spring
deflection and results in severe instability in the
spring.
• As the spring is further compressed, the instability
becomes greater until the spring gives and buckles
in a non-axial direction.

Critical axial load that will cause buckling may be approximated by:
Fcr = kL f K L
Slenderness factor , KL
– a factor depending on the ratio of Lf / Dm
*If the spring slenderness ratio is over 4 then it is likely that your
spring will buckle unless the spring is properly guided

MachDesign1-BRIANJTUAZONME
Types of Ends Coil

Total no. of
Types of Ends Coil Solid length Free length
turns (n)
Plain and Ground end nc ncd ncp
Plain end nc ( nc+1) d ncp + d
Squared & Ground end nc + 2 ( nc+2) d ncp + 2d
Squared end nc + 2 ( nc+3) d ncp + 3d

MachDesign1-BRIANJTUAZONME
 Spring System

Series System Parallel System

FT = F1 = F2 = F3 FT = F1 + F2 + F3
 T = 1 +  2 +  3  T = 1 =  2 =  3
1
ke = k e = k1 + k 2 + k 3
1 1 1
+ +
k1 k 2 k 3
Equivalent Spring Constant

MachDesign1-BRIANJTUAZONME
 go 1m 2
PE = m H KE = v
gc 2 gc
Design of Spring
Impact Loading (Conversion of Energy into Spring Potential Energy)

go 1m 2
m H= v
gc 2 gc
1 2
W h + δ = kδ = 𝐸𝑠𝑝𝑟𝑖𝑛𝑔 - spring potential energy
2
Problem
A body weighing 100 lbs falls from a height of 6 in and
strikes a 200 lb/in spring. The deformation of the spring is:

Solve for 𝛅: 0 = δ2 − δin − 6in2

1 2
W h + δ = kδ δ − 3in δ + 2in = 0
2
Given: δ = 3 in δ = −2 in
W =100 lbs 1 lbs 2
100 lbs 6 in + δ = 200 δ
h = 6 in 2 in
k = 200 lbs/in
6in + δ (in) = δ2 MachDesign1-BRIANJTUAZONME
 no. of coils = no. of turns
Problems
1. A coil spring has 10 coils. The ends are squared and ground. Determine the
number of active coils. 8
Given: Solve for nc:
n =10 n = nc +2 ⇒ nc = n −2
Squared & Ground Ends
nc = 10 −2 = 8
2. A coil spring has a free length of 350 mm and solid length of 338 mm,
respectively. Determine the working deflection if the clash allowance is 20%?
Given: Find for 𝛅𝐬 :
Li = Lf = 350 mm δs = Lf − Ls
LS= 338 mm
CA = 20% δs = 350 mm − 338 mm = 12 mm

Solve for 𝛅𝐰 :
δs − δw δs δs δs 12 mm
CA = ⇒ CA = − 1 ⇒ CA + 1 = ⇒ δw = = = ______ mm
δw δw δw CA + 1 0.20 + 1
MachDesign1-BRIANJTUAZONME
 Dm Do − dw Di + dw 0.5 4C − 1 0.615
C= = = K≈ 1+ or K = +
Problems dw dw dw C 4C − 4 C

3. A helical coil spring has wire diameter of 1/8 inch and spring index of 8.
Determine the outer diameter of the coil. 1.125”
Given: Solve for Do:
dw =1/8 inch Do − d w Do Do
C= ⇒C= −1 ⇒ C+1 = ⇒ C + 1 dw = Do
C=8 dw dw dw
Do = _________inch

4. A helical coil spring has a mean diameter of 1 inch and a wire diameter of 1/8
inch. Determine the stress concentration factor. 1.184
Given: Find C: Solve for K:
Dm =1 inch Dm 1 in K=
4C − 1 0.615
+
dw =1/8 inch C= = 4C − 4 C
dw 1ൗ in
8
4 8 − 1 0.615
C = ______ K= +
4 8 −4 8
K = ____________
MachDesign1-BRIANJTUAZONME
 F dw G
k= = 3
δ 8C nc
Problems
5. A helical coil spring has a mean diameter of 1 inch and wire diameter of 1/8 inch.
The maximum stress is 60 ksi and the stress concentration factor is 1.19. determine the
direct shear load it can support? 38.67
Given: Solve for F: 3 lb 1 3
3 60 × 10 π in
Dm =1 inch 8FDm τmax πdw in2 8
dw =1/8 inch
τmax = 3 K ⇒ 8DmK
=F =
8 1 in 1.19
πdw
𝜏𝑚𝑎𝑥= 60 ksi
F = ____________lbs
K = 1.19
6. A helical coil spring has a mean diameter of 1 inch and wire diameter of 1/8 inch. It
can support a load of 38.7 lb. Determine the number of active coils if the axial
deflection is 1 inch. (G=12.5 x 106 psi) 10
Find C:
Given: Solve for nc: Dm 1 in
Dm =1 inch F dw G δdw G C= =
dw 1ൗ in
dw =1/8 inch = ⇒ nc = 8
δ 8C3 nc 8C3 F
F = 38.7 lb C = ______
1 lb
δ = 1 in 1 in 8 in 12.5 × 106 in2
G=12.5 x 106 psi nc = = ________
8 8 3 38.7 lb
 Dm Do − dw Di + dw F dw G
C= = = k= = 3
dw dw dw δ 8C nc
Problems
7. A helical steel spring has a maximum load of 800 lbs and corresponding deflection
of 2 inches, if it has 8 active coils and an index of6, what minimum shear strength of
the spring material is required? (G=12.5 x 106 psi) 78 ksi
Given: Find dw: Solve for 𝛕𝐦𝐚𝐱:
F = 800 lbs F dw G F 8C3 nc
δ = 2 in = ⇒ = dw 8FDm
δ 8C3 nc δG τmax = 3 K
nc = 8 πdw
C=6 800 lbs 8 63 8
dw = 8FC
G = 12.5 x 106 psi lb
2 in 12.5 × 106 in2 τmax = 2K
πdw
Find K: dw = ______in 8 800 lbs 6
4C − 1 0.615 τmax = ______
K= + π ______in 2
4C − 4 C

4 6 − 1 0.615
lb
K= + τmax = _________ 2
4 6 −4 6 in
K = ____________
 F F
k= ⇒δ= FT = F1 = F2
Problems δ k

8. A coil spring is subjected to a direct shear load of 40 kN. The deflection caused
was 254 mm. Determine the spring gradient. 157
Given: Solve for 𝐤:
F = 40 kN F 40 × 103 N N
δ = 254 mm k= = = ________
δ 254 mm mm
9. Two extension springs are hooked in series and supports a load of 0.45 kN. One
spring has a constant of 0.009 kN/mm and the other have a constant 0.018
kN/mm. Determine the deflection of the load. 75
Given: Solve for 𝛅𝐓:
FT = 0.45 kN F 1 F2
k1 = 0.009 kN/mm δT = δ1 + δ2 ⇒ δT = +
k1 k2
k2 = 0.018 kN/mm
FT FT 0.45 kN 0.45 kN
δT = + = +
k1 k2 0.009 kN kN
0.018
mm mm
δT = ____________mm
Practice Problem
Three extension springs supports a load of 0.45 kN. One spring is rated as of 0.09
kN/mm in series with two springs in parallel each has a constant of 0.18 kN/mm.
Determine the deflection of the load. 6.25