Faculty of Engineering and Technology

Department of Mechanical Engineering

MMB431 MINI PROJECT: DESIGN AND FABRICATION OF A MANUALSPRING-

ROLLING MACHINE
GROUP 3
ABSTRACT
This project report describes the design and fabrication of a spring rolling machine which can
deform a wire and turn it into a spring by rolling a metal wire manually. The motivation or
reason behind the project was that the University of Botswana physics department can use the
springs produced for their experiments in the physics laboratory. The main objectives of this
project were to design and develop an improved manual spring rolling machine that can offer
higher precision and consistency in producing coiled springs. Also, the machine should be
user-friendly, with intuitive controls and setup procedures to reduce operator errors. Increase
production rates by streamlining the rolling process without compromising quality. Lastly the
spring rolling machine should incorporate safety features to protect operators during
operation. A detailed literature review regarding already existing spring rolling machine was
used as guide as a starting point. Appropriate materials were selected, and the machine was
fabricated basing on the design, the machine was tested, and a report was made. The machine
works with the main shaft being rotated with help of hand wheel rotation. Before the hand
wheel rotation, the wire is fed through the 2mm guide hole at one end of the rotating shaft.
With one hand holding the hand wheel and another holding the adjuster, the hand wheel is
rotated, and the adjuster is consistently propelled to the other end. The spring rolling shaft
rotates as the hand wheel is rotated. The wire is therefore rolled around the rotating shaft or
the mandrel resulting in the production of a spring. Material selection was done, and material
used included square tubes, metal sheets, round tubes, round bars, flat bars, bolts, square cub
end caps and wire. Fabrication process was done, and it began with measuring, marking, and
cutting materials to be used, machine components were assembled. A manually operated
spring rolling machine was successfully done with some challenges like shortage of
materials, lack of experience in operation of machines and limited time. Lastly it was
recommended that more design software’s should be employed in the future to account for
more precision during the design process. MATLAB, ANSYS and SolidWorks could be used
for load analysis as well as computation of stress concentrations. Also, the machine could be
modified and include electrical components such as motors or flexible mechanical
components which would increase the mechanical advantage of the machine and in turn the
overall operation efficiency of the machine. The main objectives of this design were met as a
manual spring rolling machine was successfully developed to meet the problem identified.
Table of Contents
LIST OF FIGURES....................................................................................................................................4
LIST OF TABLES......................................................................................................................................4
INTRODUCTION.....................................................................................................................................5
Statement of the Problem................................................................................................................5
Objectives of the Work....................................................................................................................5
Motivation for the Work.................................................................................................................5
Scope.................................................................................................................................................5
LITERATURE REVIEW.............................................................................................................................6
DESIGN..................................................................................................................................................8
Proposed Model...............................................................................................................................8
Working Principle of the Spring Rolling Machine........................................................................9
Material Selection..........................................................................................................................10
Fabrication process........................................................................................................................10
RESULTS...............................................................................................................................................14
Final Fabricated Model.................................................................................................................14
Output of the Spring Rolling Machine.........................................................................................15
DISCUSSION........................................................................................................................................15
RECOMMENDATIONS.........................................................................................................................16
CONCLUSION.......................................................................................................................................16
REFERENCES........................................................................................................................................16
LIST OF FIGURES
Figure 1 showing the manual drawing of the spring rolling machine
Figure 2 showing the AUTOCAD drawing of the spring rolling machine
Figure 3 showing the mild steel sheet being cut by a grinder
Figure 4 showing holes being drilled in the rod by the drill press
Figure 5 showing the hand wheel
Figure 6 showing the tubes being welded to the stand legs
Figure 7 showing the designed spring rolling machine
Figure 8 showing a spring formed by the machine

LIST OF TABLES
Table 1 showing material to be used on the machine
INTRODUCTION
A spring is an object that can be deformed by a force and then return to its original shape
after a 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. The amount of deformation is
directly proportional to the force exerted. Therefore springs have many applications in our
everyday lives because of their mechanical properties. A device known a ‘Spring Rolling
Machine’ is used to make simple springs that can be used in our daily lives. A spring rolling
machine is able to deform a wire and turn it into a spring by rolling a metal wire. Rolling is a
process of bending metal wire to a curved form and can be achieved by manual or powered
tools such as a motor. In this article we focus on the manually operated device, how it was
fabricated and the operational principle of the machine.

Statement of the Problem

The existing manual spring rolling machines often result in inconsistent spring dimensions
and quality due to imprecise rolling mechanisms, and operators often face difficulties in
setting up and operating these machines, which can lead to inefficiencies and errors in the
production process. Moreover, the slow and labour-intensive nature of existing machines
hampers productivity, especially in industries requiring large quantities of coiled springs. The
current machines lack safety features to protect operators from potential hazards; these
drawbacks gave rise to the idea of an improved manual spring rolling machine.

Objectives of the Work

The main objective of this project is to design and develop an improved manual spring rolling
machine that can:
1. Offer higher precision and consistency in producing coiled springs.
2. Be user-friendly, with intuitive controls and setup procedures to reduce operator
errors.
3. Increase production rates by streamlining the rolling process without compromising
quality.
4. Incorporate safety features to protect operators during operation.

Motivation for the Work

The University can use the produced springs in Physics lab experiments.

Scope
The scope encompasses the following key activities:
1. Research and analysis of existing manual spring rolling machines and their
limitations.
2. Conceptual design of the improved machine, including mechanisms for enhanced
precision and user-friendliness.
3. Fabrication and assembly of the prototype machine.
4. Testing and validation to ensure the machine meets the defined objectives.
LITERATURE REVIEW
The manufacturing industry has seen significant advancements in recent years, with the
development of various machines and tools that enhance the efficiency and precision of
production processes. One such machine is the manual spring making machine, which plays a
crucial role in the production of springs for various applications. According to (Seby, et al.,
2016), 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. This
literature review explores the key aspects of manual spring making machines, their historical
development, design features, operational principles, and the importance of these machines in
modern manufacturing.

The history of spring manufacturing machines dates to the early 20th century when simple
manual devices were first employed for spring production. Over time, these machines
evolved in complexity and functionality. According to (Torsion Springs, 2008), It wasn’t
until after 1000 A.D that the first mechanical springs were used where the metal’s elasticity
became a true function of a device, this in the form of clocks. The clock industry takes credit
for being an early important contributor to the spring manufacturing industry. Spring
Manufacturing further advanced in the lock and guns industry starting around the 15th
century. During the Industrial Revolution, in the early 1900’s, spring manufacturing made
quantum leaps in a relatively short period of time. Helical springs were originally wound on
an arbor (as they may times are today, for short runs); however, this method of manufacturing
springs could not keep up with the rapidly growing automotive and farm equipment industry.
In a short span, less than 5 years, patents were secured for new spring making equipment that
included hand winding, tapered or conical springs, adjustable spring winders, large-diameter
coilers, automatic spring coilers and torsion spring machines. By 1940, most of the earlier
automatic machines could now produce springs at high speeds with better accuracy and less
demand for secondary or hand operations for additional bends.

Modern manual spring making machines are designed with a variety of features to ensure
precision and versatility. Key components of the machine, such as wire feeders, coiling
mechanisms, and control systems, are vital to the overall performance. (Automated Industrial
Motion, 2019) explains that as wire exits the wire guides, it meets the block guide. This
component ensures that the wire continues on the right path to the coiling point. The groove
at the bottom of a block guide must be accurately machined to match the wire’s diameter.
While the wire passes through the groove of the block guide, it passes over and around the
arbor. In single-point coilers, the arbor represents the third point of contact at the point of
coiling. Spring physics demand at least three points to coil wire; dual-point coilers have a
third point in the additional coiling point, and so the arbor is not as necessary. By sliding up
and down and moving the wire along a sloped surface, the pitch tool precisely controls the
pitch of the spring. Like the arbor, this component is also carefully machined to fit each job.
When a coil has reached its desired length, the cutter slices the wire to create a separate
spring. Depending on the coiling direction, the cutter may be positioned above or below the
arbor.

(James Spring & Wire company, 2021) stated that the evolution of spring technology and the
elasticity of objects moved forward when, in 1678, British physicist, Robert Hooke, advanced
the principle of physics that bears his name. Hooke’s Law explained the elasticity of solid
bodies, which further led to the discovery of how tension increases and decreases in a spring
coil proportional to the load applied to it—as long as the load does not exceed the elastic
limit of the material. Hooke’s Law applied to the elastic limit of material and became of
prime importance in the advancement of the components used in countless devices, machines,
and equipment. The coil spring as we know it today was patented by Richard Tredwell in
1763. Considered revolutionary at the time, it introduced a new era in spring technology that
has continued to advance through the present day. Tredwell received Great Britain Patent 792
for “Springs For Carriages”. The full patent was four pages, which included nine iterations of
a helical suspension system that clearly stated, “my new method of making and constructing
springs for the hanging of coaches”. With the introduction of the coil spring, new types of
spring technology developed, from balance springs to improved clock springs and mattress
springs. Inexpensive to replace and far more accurate, the new coiled springs were an
improvement over leaf springs which had to be separated and constantly lubricated to
maintain properly. In less than a century, Tredwell’s coil spring would prove instrumental in
the industrial revolution with the development of the steel coil spring, which, in 1857, was
first patented in America for use in chair seats. The coil spring was placed in the innerspring
mattress in 1871 by German inventor Heinrich Westphal. In addition to mass-produced
furniture, the industrial revolution paved the way for the mass production of springs and their
wider applications. Coiled springs were introduced in the manufacture of machines,
equipment to manufacture machines, and were vital in the development of the transportation
revolution with the first trains, and eventually cars and airplanes. Whether keeping a door
open or closed to absorbing shocks in cars or trains and even baby carriages, spring
applications were quickly adapted. Springs soon found their way into applications for
entertainment purposes, too. Such items as the familiar pogo stick and trampoline, and even
Rihard James’s invention of the Slinky in 1943, all rely on the coiled spring.
DESIGN
Proposed Model

Figure 1: showing the manual drawing of the spring rolling machine

 Figure 2: showing the AUTOCAD drawing of the spring rolling machine

Working Principle of the Spring Rolling Machine

The main shaft is rotated with help of hand wheel rotation. Before the hand wheel rotation,
the wire is fed through the 2mm guide hole at one end of the rotating shaft. With one hand
holding the hand wheel and another holding the adjuster, the hand wheel is rotated and the
adjuster is consistently propelled to the other end. The spring rolling shaft rotates as the hand
wheel is rotated. The wire is therefore rolled around the rotating shaft or the mandrel
resulting in the production of a spring. The internal diameter of the spring formed is equal to
the outer diameter of the mandrel, which is 15mm. The pitch of the spring is controlled by the
speed at which the operator moves the adjuster along the rod and this is maintained around
2mm whereas the length of spring is decided by the operator. After reaching the required
length of the spring the hand wheel rotation is stopped and a pliers is used to cut the wire
separating the rest of the raw material wire from the spring formed. From there the rotating
shaft is removed from the setup via the side of the hand wheel and the spring is removed from
the mandrel. The procedure is repeated for the production of more springs.
Material Selection
Table 1: showing material to be used on the machine
SI. No. Component Material type Dimension
1 Square tube Mild steel
10m long, (25 ×25 mm)
2 Metal sheet Mild steel (600 mm ×305 mm) , 3mm thick
(250 ×100 mm), 3mm times 2
3 Round tube Mild steel 500mm long, 4.1mm ID and 4.7mm OD
3 Round bars Mild steel 500mm long, 10mm dia
50mm long, 10mm dia
650mm long, 15mm dia
75mm long, 5mm dia
4 Flat bars Mild steel 100mm× 25mm , 3mm thick
100mm×75 mm , 10mm thick
100mm×75 mm , 10mm thick
5 Square cube end Plastic (25 ×25 mm)
caps(x4)
6 Wire Cold drawn 1mm dia, 2.5m long
stainless steel

Fabrication process
Measuring, marking and cutting
- A measuring tape was used to mark four lengths of 1100mm from the mild steel square
tubes and a grinder used to angle cut the sections at an angle of 25o to be used as the legs of
the table.
- From the same square tube, two 485mm sections were straight cut at an angle of WW to
serve as cross members of the legs. .
- From the same square tube, four sections of 140mm were marked with a scriber and cut
with a grinder to serve as the feet of the table.
- A 600mm by 305mm sheet was marked from 3mm mild steel sheet with a scriber and
straight cut with a grinder as shown in the figure below:
 Figure 3: showing the mild steel sheet being cut by a grinder

- Two 225mm by 100mm sheets were marked from the 3mm mild steel sheet with a scriber
and straight cut with a grinder.
- Holes were drilled on both sheets at the midpoint for the mandrel insertion using a drill
press, M15 drill bit.
- From the 10mm diameter mild steel round bar, a rod of 500mm was marked and straight cut
with a grinder.
- A tube of 500mm length was cut from the mild steel round tube using the grinder. Using the
lathe machine, rust was removed from the surface of the round tube.
- From the 15mm diameter mild steel bar, a 650mm long rod was cut. A phase was achieved
at one end of the rod. A wire guide of 2mm diameter was drilled 80mm from one end of the
rod and two other holes of 6mm diameter drilled 55mm from either ends of the rod as shown
in the figure below:
 Figure 4: showing holes being drilled in the rod by the drill press

- For the hand wheel:

 First a bar of 100mm was straight cut from the 25mm by 3mm mild steel flat bar
using the grinder
 A rod of 75mm length was cut from the 15mm diameter mild steel bar

- For the adjuster:

 Two bars of 100mm were cut from the 75mm by 10mm mild steel flat bar
 The bars were WW with an angle grinder
- Lastly a 200mm long bar was cut from the 5mm diameter steel rod

Assembly of machine components

-Before assembling the components of the machine together, the hand wheel and adjuster
were developed. For the hand wheel the flat bar was used to couple the handle to the rotating
shaft. The flat bar end was welded at an angle of 90o to the end of the rotating shaft and the
handle to the rotating shaft as shown in the figure below:
 Figure 5: showing the hand wheel

-For the adjuster, the identical pieces were welded together ensuring the angle ground parts
are on the same side to accommodate the wire. On the opposite side, the handle was welded
into the piece. The adjuster was inserted into 10mm diameter mild steel rod through the
drilled hole.
- From there assembly of the components began and welding was used for the permanent
joints.
- To assemble the components, the four sections of 140mm were cut with a grinder and
welded to the slanting legs at an angle of 90o to the ground as shown in the figure below:

Figure 6: showing the tubes being welded to the stand legs

-Two of the 1100 square tubes were spread by an angle of 25o and the square tube cross
member welded at the base of the trapezoidal shape. The same was done with the remaining
two 1100mm tubes.
-The mild steel sheet of 600mm by 305mm was welded onto the setup resulting in a stand/
table for the machine.
- From there support sheets for the mandrel and adjuster rod were welded onto the stand/
table each at a right angle with the table, at a distance of 40mm each from the outer edge
along the 305mm side.
- The round tube of internal diameter of 4.1mm was welded between the supports to further
secure them. The adjuster rod was welded in between the supports.
- The rotating shaft was inserted in its holes on the supports and one side locked with a wire
marking the end of machine components assembly.

Cathode protection
-To protect the machine against rust, the machine was then painted. Red oxide was used on
the stand and spray paint on the machine itself. This marked the completion of fabrication
and rubber caps were inserted on the feet of the machine stand.

RESULTS
Final Fabricated Model

Figure 7: showing the designed spring rolling machine

Output of the Spring Rolling Machine

Figure 8: showing a spring formed by the machine

DISCUSSION
The identified shortage of springs in physics and engineering labs for experiments requiring
springs as part of the apparatus necessitates a practical solution. In response to this need, the
development of a wire-to-spring processing machine has been proposed, aiming to provide a
sustainable and cost-effective solution to address this shortage. A manually operated spring
rolling machine was successfully done with some challenges like shortage of materials, lack
of experience in operation of machines and limited time.
The machine consistently produced springs with precise specifications during our evaluation.
The manual operation allowed for fine-tuning of the spring's dimensions, making it suitable
for applications requiring custom or specialized springs. The primary advantage of this
device is its cost-effectiveness. It requires minimal investment and maintenance, making it
accessible for small businesses, the machine's efficiency in converting wire into springs
allows for on-demand production, eliminating delays associated with lead times and orders
from external sources.
Primary objective of this machine is to utilize discarded wires found in workshops, thus
repurposing them into springs of preferred sizes. By recycling materials and efficiently
producing springs in-house, labs can reduce their dependence on external suppliers and
maintain a consistent supply of springs, ensuring the continuity and quality of experiments.
The utilization of discarded wires as the raw material for spring production not only
addresses the shortage issue but also presents an eco-friendly approach to resource
management. Recycling reduces waste and promotes sustainability, aligning with the growing
global focus on environmental responsibility. Moreover, the in-house production of springs
can lead to cost savings, as it minimizes the expenses associated with purchasing pre-made
springs.
While the concept of a wire-to-spring processing machine is promising, it presents several
challenges that must be addressed during the design and development phase. These
challenges may include the automation of the spring-making process, safety considerations,
and the design of user-friendly controls and interfaces. Furthermore, the quality and
consistency of the springs produced by the machine must meet the standards required for
experiments.

RECOMMENDATIONS
In the light of the findings presented above, we recommend that:
More design software’s should be employed in the future to account for more precision
during the design process. MATLAB, ANSYS and SolidWorks could be used for load
analysis as well as computation of stress concentrations.
Also, the machine could be modified and include electrical components such as motors or
flexible mechanical components which would increase the mechanical advantage of the
machine and in turn the overall operation efficiency of the machine.

CONCLUSION
In conclusion, the main objectives of this design were met as a manual spring rolling machine
was successfully developed to meet the problem identified. In designing the machine,
different skills acquired in the classroom were applied which paves way for application of
skills in the real engineering field. Through the development of the spring rolling machine,
springs can now be produced locally with.

REFERENCES
Torsion Springs. (2008, August 14). The History of Springs and Spring Manufacturing.
Retrieved November 2023, from katyspring.com:
https://katyspring.com/2008/08/14/the-history-of-springs-and-spring-manufacturing/
Seby, K., Chacko, N., Rajan, N. P., Thekkiniyath, S., Dev, K. E., & Vazhappily, C. V.
(2016). Design and Fabrication of Manual Spring Rolling Machine. Jyothi
Engineering College, Department of Mechanical Engineering. Thrissur: Int. Journal of
Engineering Research and Application.
Automated Industrial Motion. (2019). Retrieved November, 2023 from aimcoil.com:
https://aimcoil.com/wp-content/uploads/2019/10/All-About-Springs-FINAL-10-2019-
B.pdf
James Spring & Wire company. (2021, March 15). The Evolution and History of springs.
Retrieved November, 2023 from jamesspring.com:
https://www.jamesspring.com/news/history-of-springs/