Spring calculations sheet

Project :- Hassia - VFFS

Date :- 09.09.11
W.O. No. :-
Spring Type :- Helical Tension Spring
(For Suspending Jaws Assembly)
Designer :- SGD

Wire diameter - d :- 4.5000 mm

Mean diameter - D :- 31.0000 mm

Coil outer diameter :- 35.5000 mm 3.2609

Coil inner diameter :- 26.5000 mm

No. of effective turns :- 92.0000 nos.

Free length -l :- 414.0000 mm
Pre-stretched length :- 563.0000 mm

Modulus of rigidity - G :- 7000.0000 kgf/mm sq.

Spring rate :- 0.1309 kfg/mm

Initial tension :- 19.5061 kgf

Max stretched length :- 863.0000 mm Stroke = 300.0000

Force at max. Tension :- 58.7803 kgf

Shear stress at max. comp. :- 61.2894 kfg/mm sq.

Total No of turns 94.0000 mm

End conditions :- Half hooks

Material :- Spring steel, Grade - 3
For spring steel grade-3, this design is safe.
 Spring calculations sheet

Project :- Hassia - VFFS

Date :- 19.09.11
W.O. No. :-
Spring Type :- Helical Tension Spring
(For Suspending Jaws Assembly)
Designer :- YOGESH

Wire diameter (d) :- 4.500

Mean diameter (Dm) :- 31.000

Outer diameter (Do) :- 35.500

Inner diameter (Di) :- 26.500
Total No. of Coils (it) :- 102.000
Ineffective Coils :- 10.000
No. of Working Coils (if) :- 92.000
Solid length of spring (Ls) :- 414.000
Pre-stretched length :- 466.000

Modulus of rigidity (G) :- 8300.000

Spring rate (C) :- 0.155

Initial tension on the spring (Fo) :- 8.072

Max stretched length :- 816.000

Force at max. Tension :- 62.401

Shear stress at max. comp. :- 65.065

End conditions :- Half hooks

Material :- Cold drawn, patented, Spring steel wire, Grade-3, IS 4454
Hassia - VFFS

Helical Tension Spring

(For Suspending Jaws Assembly)

3.261
mm
mm 4.370
Stroke = 350.000
mm
mm t 54.085
Lo 425.700

nos. k 1.009
mm Lk 418.500
mm Fo 93.195
LH 3.600
kfg/mm2 ta 81.500
(Fn-Fo) 93.195
kfg/mm Ln 1026.081
kgf Fo 10.291
F 62.401
mm tk 54.570
F-Fo 52.110
kgf tkU 54.085
kfg/mm 2
tkL 8.920

Cold drawn, patented, Spring steel wire, Grade-3, IS 4454

Distance Between Two coils [pls. refer "LH" value]

Uncorrected shear stress (kfg/mm2)

Free Length of Spring (mm)

Stress Correction Factor.

Body Length (mm) [all coil closed]
Max. Permissible Initial Tension (kgf)
Distance of inside edge of hook from body of the spring (mm)
Allowable shear stress (kfg/mm2)
Max. Permissible Test Load (kgf)
Max. Permissible Test Length (mm)
Max. Permissible Initial tension (kgf)
Load on the spring (kgf)
Corrected shear stress (kfg/mm2)
Load on the spring (kgf)
Upper stress range for fatigue limit (kfg/mm2)
Lower stress range for fatigue limit (kfg/mm2)
 Spring calculations sheet

Project :- Flexibag 180TEJ

Date :- 15.12.2011
Drawing No. :- 1601003201
Spring Type :-
Helical Tension Spring
(For Stripping Assembly)
Designer :- YOGESH

Wire diameter (d) :- 4.500 mm

Mean diameter (Dm) :- 31.000 mm

Outer diameter (Do) :- 35.500 mm

Inner diameter (Di) :- 26.500 mm
Total No. of Coils (it) :- 102.000
Ineffective Coils :- 10.000
Total length of Spring :- 459.000
No. of Working Coils (if) :- 92.000 nos.
Solid length of spring (Ls) :- 414.000 mm
Pre-stretched length :- 466.000 mm
Stroke :- 350.000
Modulus of rigidity (G) :- 8300.000 kfg/mm2

Spring rate (C) :- 0.155 kfg/mm

Initial tension on the spring (Fo) :- 8.072 kgf

Max stretched length :- 816.000 mm

Force at max. Tension :- 62.401 kgf

Shear stress at max. comp. :- 65.065 kfg/mm2

End conditions :- Half hooks

Material :- Cold drawn, patented, Spring steel wire,
Grade-3, Part-I, IS 4454
 3.261

4.370 Distance Between Two coils [pls. refer "LH" value]

Stroke = 350.000

t 54.085 Uncorrected shear stress (kfg/mm2)

Lo 425.700 Free Length of Spring (mm)

k 1.009 Stress Correction Factor.

Lk 418.500 Body Length (mm) [all coil closed]
Fo 93.195 Max. Permissible Initial Tension (kgf)
LH 3.600 Distance of inside edge of hook from body of the spring (mm)
ta 81.500 Allowable shear stress (kfg/mm2)
(Fn-Fo) 93.195 Max. Permissible Test Load (kgf)
Ln 1026.081 Max. Permissible Test Length (mm)
Fo 10.291 Max. Permissible Initial tension (kgf)
F 62.401 Load on the spring (kgf)
tk 54.570 Corrected shear stress (kfg/mm2)
F-Fo 52.110 Load on the spring (kgf)
tkU 54.085 Upper stress range for fatigue limit (kfg/mm2)
tkL 8.920 Lower stress range for fatigue limit (kfg/mm2)
 Spring calculations sheet

Project :- Flexibag 400C

Date :- 15.11.2011
Drawing No. :- 2001590601
Spring Type :-
Helical Tension Spring
(For Stripping Assembly)
Designer :- YOGESH

Wire diameter (d) :- 4.500 mm

Mean diameter (Dm) :- 31.000 mm

Outer diameter (Do) :- 35.500 mm

Inner diameter (Di) :- 26.500 mm
Total No. of Coils (it) :- 110.000
Ineffective Coils :- 10.000
Total length of Spring :- 495.000
No. of Working Coils (if) :- 100.000 nos.
Solid length of spring (Ls) :- 450.000 mm
Pre-stretched length :- 466.000 mm
Stroke :- 350.000
Modulus of rigidity (G) :- 8300.000 kfg/mm2

Spring rate (C) :- 0.143 kfg/mm

Initial tension on the spring (Fo) :- 2.285 kgf

Max stretched length :- 816.000 mm

Force at max. Tension :- 52.268 kgf

Shear stress at max. comp. :- 54.499 kfg/mm2

End conditions :- Half hooks

Material :- Cold drawn, patented, Spring steel wire,
Grade-3, Part-I, IS 4454
 3.261

3.660 Distance Between Two coils [pls. refer "LH" value]

Stroke = 350.000

t 45.302 Uncorrected shear stress (kfg/mm2)

Lo 425.700 Free Length of Spring (mm)

k 1.009 Stress Correction Factor.

Lk 418.500 Body Length (mm) [all coil closed]
Fo 93.195 Max. Permissible Initial Tension (kgf)
LH 3.600 Distance of inside edge of hook from body of the spring (mm)
ta 81.500 Allowable shear stress (kfg/mm2)
(Fn-Fo) 93.195 Max. Permissible Test Load (kgf)
Ln 1078.288 Max. Permissible Test Length (mm)
Fo 10.291 Max. Permissible Initial tension (kgf)
F 52.268 Load on the spring (kgf)
tk 45.709 Corrected shear stress (kfg/mm2)
F-Fo 41.976 Load on the spring (kgf)
tkU 45.302 Upper stress range for fatigue limit (kfg/mm2)
tkL 8.920 Lower stress range for fatigue limit (kfg/mm2)
 Spring calculations sheet

Project :- Flexibag 280C Stick Pack

Date :- 15.11.2011
Drawing No. :- 2001590501
Spring Type :-
Helical Tension Spring
(For Stripping Assembly)
Designer :- YOGESH

Wire diameter (d) :- 4.000 mm

Mean diameter (Dm) :- 25.000 mm

Outer diameter (Do) :- 29.000 mm

Inner diameter (Di) :- 21.000 mm
Total No. of Coils (it) :- 112.000
Ineffective Coils :- 10.000
Total length of Spring :- 448.000
No. of Working Coils (if) :- 102.000 nos.
Solid length of spring (Ls) :- 408.000 mm
Pre-stretched length :- 423.000 mm
Stroke :- 260.000
Modulus of rigidity (G) :- 8300.000 kfg/mm2

Spring rate (C) :- 0.167 kfg/mm

Initial tension on the spring (Fo) :- 2.500 kgf

Max stretched length :- 683.000 mm

Force at max. Tension :- 45.829 kgf

Shear stress at max. comp. :- 55.948 kfg/mm2

End conditions :- Half hooks

Material :- Cold drawn, patented, Spring steel wire,
Grade-3, Part-I, IS 4454
 3.261

2.696 Distance Between Two coils [pls. refer "LH" value]

Stroke = 260.000

t 45.610 Uncorrected shear stress (kfg/mm2)

Lo 378.400 Free Length of Spring (mm)

k 1.009 Stress Correction Factor.

Lk 372.000 Body Length (mm) [all coil closed]
Fo 65.454 Max. Permissible Initial Tension (kgf)
LH 3.200 Distance of inside edge of hook from body of the spring (mm)
ta 81.500 Allowable shear stress (kfg/mm2)
(Fn-Fo) 81.163 Max. Permissible Test Load (kgf)
Ln 865.422 Max. Permissible Test Length (mm)
Fo 8.963 Max. Permissible Initial tension (kgf)
F 45.829 Load on the spring (kgf)
tk 46.020 Corrected shear stress (kfg/mm2)
F-Fo 36.866 Load on the spring (kgf)
tkU 45.610 Upper stress range for fatigue limit (kfg/mm2)
tkL 8.920 Lower stress range for fatigue limit (kfg/mm2)
 Spring calculations sheet

Project :- Flexibag 280C Stick Pack

Date :- 05.03.2012
Drawing No. :- 2001594301
Spring Type :-
Helical Tension Spring
(For Stripping Assembly)
Designer :- YOGESH

Wire diameter (d) :- 4.500 mm

Mean diameter (Dm) :- 34.000 mm

Outer diameter (Do) :- 38.500 mm

Inner diameter (Di) :- 29.500 mm
Total No. of Coils (it) :- 102.000
Ineffective Coils :- 10.000
Total length of Spring :- 459.000
No. of Working Coils (if) :- 92.000 nos.
Solid length of spring (Ls) :- 414.000 mm
Pre-stretched length :- 423.000 mm
Stroke :- 260.000
Modulus of rigidity (G) :- 8300.000 kfg/mm2

Spring rate (C) :- 0.118 kfg/mm

Initial tension on the spring (Fo) :- 1.059 kgf

Max stretched length :- 683.000 mm

Force at max. Tension :- 31.649 kgf

Shear stress at max. comp. :- 35.594 kfg/mm2

End conditions :- Half hooks

Material :- Cold drawn, patented, Spring steel wire,
Grade-3, Part-I, IS 4454
 3.261

2.924 Distance Between Two coils [pls. refer "LH" value]

Stroke = 260.000

t 30.086 Uncorrected shear stress (kfg/mm2)

Lo 425.700 Free Length of Spring (mm)

k 1.009 Stress Correction Factor.

Lk 418.500 Body Length (mm) [all coil closed]
Fo 93.195 Max. Permissible Initial Tension (kgf)
LH 3.600 Distance of inside edge of hook from body of the spring (mm)
ta 81.500 Allowable shear stress (kfg/mm2)
(Fn-Fo) 84.972 Max. Permissible Test Load (kgf)
Ln 1147.906 Max. Permissible Test Length (mm)
Fo 9.383 Max. Permissible Initial tension (kgf)
F 31.649 Load on the spring (kgf)
tk 30.356 Corrected shear stress (kfg/mm2)
F-Fo 22.266 Load on the spring (kgf)
tkU 30.086 Upper stress range for fatigue limit (kfg/mm2)
tkL 8.920 Lower stress range for fatigue limit (kfg/mm2)
 Spring calculations sheet

Project :- Flexibag 400C

Date :- 07.03.2012
Drawing No. :- 2001594501
Spring Type :-
Helical Tension Spring
(For Stripping Assembly)
Designer :- YOGESH

Wire diameter (d) :- 5.600

Mean diameter (Dm) :- 36.000

Outer diameter (Do) :- 41.600

Inner diameter (Di) :- 30.400
Total No. of Coils (it) :- 74.000
Ineffective Coils :- 10.000
Total length of Spring :- 414.400
No. of Working Coils (if) :- 64.000
Solid length of spring (Ls) :- 358.400
Pre-stretched length :- 478.000
Stroke :- 190.000
Modulus of rigidity (G) :- 8300.000

Spring rate (C) :- 0.342

Initial tension on the spring (Fo) :- 40.868

Max stretched length :- 668.000

Force at max. Tension :- 105.792

Shear stress at max. comp.(S2) :- 67.381

End conditions :- Half hooks

Material :- Cold drawn, patented, Spring steel wire, Grade-3, Part-I, IS
4454
Min. UTS(Su) 166.000

D/d 6.429
k 1.220
Stress at installed condition (S1) 26.030
(Ks1)ratio 1 0.157
(Ks2)ratio 2 0.406

Calculation of Predicted life

Ku-Ultimate Strength Factor (Process Specific,

approx. =Solid stress/minimum ultimate tensile
1 stress) (As per table) 0.700
2 S1--Iinitial Stress 26.030
3 S2-- Maximum Stress 67.381
4 Su--Minimum UTS 166.000
5 Ce--Parameter 0.576
6 Ks1--Initial Stress factor (S1/Su) 0.157
 7 Ks2--Maximum Stress factor (S2/Su) 0.406
8 y- Exponential(As per table) -0.054
Ke --Endurance Factor =[(Ku(Ks2-Ks1))(2Ku-
9 (Ks2+Ks1))]=[Ce*n^y] 0.208

ln(Ke/Ce) -1.017

1/y -18.622
10 n- Life Cycle n=exp[(1/y)ln(Ke/Ce)] 1.68.E+08
Cs-Parameter 0.776
M-Parameter -0.014
11 Ks2max--Max. Stress ratio.(=Cs*n^M) 0.596
 3.261
mm
mm 4.838
Stroke = 190.000
mm
mm t 55.253
Lo 529.760

nos. k 1.009
mm Lk 520.800
mm Fo 179.605
LH 4.480
kfg/mm2 ta 81.500
(Fn-Fo) 154.660
kfg/mm Ln 982.371
kgf Fo 17.079
F 105.792
mm tk 55.749
F-Fo 88.713
kgf tkU 55.253
kfg/mm 2
tkL 8.920

ented, Spring steel wire, Grade-3, Part-I, IS

4454
kgf/mm^2

kfg/mm2

fe

kgf/mm2
kgf/mm2
kgf/mm2
cycles
Distance Between Two coils [pls. refer "LH" value]

Uncorrected shear stress (kfg/mm2)

Free Length of Spring (mm)

Stress Correction Factor.

Body Length (mm) [all coil closed]
Max. Permissible Initial Tension (kgf)
Distance of inside edge of hook from body of the spring (mm)
Allowable shear stress (kfg/mm2)
Max. Permissible Test Load (kgf)
Max. Permissible Test Length (mm)
Max. Permissible Initial tension (kgf)
Load on the spring (kgf)
Corrected shear stress (kfg/mm2)
Load on the spring (kgf)
Upper stress range for fatigue limit (kfg/mm2)
Lower stress range for fatigue limit (kfg/mm2)