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Lecture 8 Springs

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16 views29 pages

Lecture 8 Springs

Uploaded by

sylvestergriffdths
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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1

MECHANICAL ENGINEERING
DESIGN II
MED260S

Chap. 8 Mechanical Spring


Desing

Lecturer Mr B Tshibangu

2024
Helical Spring 2

⚫Helical coil spring with round wire


⚫Equilibrium forces at cut section anywhere in the body of the
spring indicates direct shear and torsion

Fig. 10–1
Stresses in Helical Springs 3

⚫Equilibrium forces at cut section


anywhere in the body of the spring
indicates direct shear and torsion
⚫Torsional shear and direct shear
⚫Additive (maximum) on inside fiber
of cross-section

⚫Substitute
terms
Fig. 10–1b
Stresses in Helical Springs 4

Factor out the torsional stress

τ = 1+ d 
 8FD 
3 
 2D  
π
Define Spring Index d

Define Shear Stress Correction Factor


1 = 2C +1
K s = 1+
2C 2C
Maximum shear stress for helical spring
Curvature Effect 5

⚫Stress concentration type of effect on inner fiber due to curvature


⚫Can be ignored for static, ductile conditions due to localized
cold- working
⚫Can account for effect by replacing Ks with Wahl factor or
Bergsträsser factor which account for both direct shear and
curvature effect

⚫Cancelling the curvature effect to isolate the curvature


factor
Deflection of Helical Springs 6

Use Castigliano’s method to relate force and deflection

Total deflection y is:

Spring rate k, also called the scale of the spring is:


Fig. 10–1a
Or k=F/y
Formulas for Compression Springs With Different Ends 7

Table 10–1

Na is the number of active coils


Set Removal 8

⚫Set removal or presetting is a process used in manufacturing


a spring to induce useful residual stresses.
⚫The spring is made longer than needed, then compressed to
solid height, intentionally exceeding the yield strength.
⚫This operation sets the spring to the required final free length.
⚫Yielding induces residual stresses opposite in direction to
those induced in service.
⚫10 to 30 percent of the initial free length should be removed.
⚫Set removal is not recommended when springs are subject
to fatigue.
Some Common Spring Steels 9

⚫Hard-drawn wire (0.60-0.70C)


◦ Cheapest general-purpose
◦ Use only where life, accuracy, and deflection are not too
important
⚫Oil-tempered wire (0.60-0.70C)
◦ General-purpose
◦ Heat treated for greater strength and uniformity of properties
◦ Often used for larger diameter spring wire
⚫Music wire (0.80-0.95C)
◦ Higher carbon for higher strength
◦ Best, toughest, and most widely used for small springs
◦ Good for fatigue
Strength of Spring Materials 10

⚫With small wire diameters, strength is a function of diameter.


⚫A graph of tensile strength vs. wire diameter is almost a straight
line on log-log scale.
⚫The equation of this line is

where A is the intercept and m is the slope.

⚫Values of A and m for common spring steels are given


in Table 10–4.
Strength of Spring Materials 11
Estimating Torsional Yield Strength 12

⚫Since helical springs experience shear stress, shear yield strength


is needed.
⚫If actual data is not available, estimate from tensile strength
⚫Assume yield strength is between 60-90% of tensile strength

0.6Sut  Ssy  0.9Sut


⚫Assume the distortion energy theory can be employed to relate
the shear strength to the normal strength.
Ssy = 0.577Sy
⚫This results in

⚫Music wire and hard-drawn steel spring wire have a low end
of range Ssy = 0.45Sut .
Mechanical Properties of Some Spring Wires (Table 10–5) 13
Helical Compression Spring Design for Static Service 14

⚫Limit the design solution space by setting some practical limits

⚫Preferred range for spring index

⚫Preferred range for number of active coils


Helical Compression Spring Design for Static Service 15

⚫To achieve best linearity of spring constant, preferred to limit


operating force to the central 75% of the force-deflection curve
between F = 0 and F = Fs.
⚫This limits the maximum operating force to Fmax ≤ 7/8 Fs
⚫Define fractional overrun to closure as ξ where

⚫This leads to

⚫Solving the outer equality for ξ = 1/7 = 0.143 ~ 0.15


ξ,
⚫Thus, it is recommended that
Summary of Recommended Design Conditions 16

⚫The following design conditions are recommended for


helical compression spring design for static service

where ns is the factor of safety at solid height.


Design Flowchart for Static Loading 17

Continue on next slide


Design Flowchart for Static Loading 18

Continued from previous slide


Design Flowchart for Static Loading 19
Critical Frequency of Helical Springs 20

⚫When one end of a spring


is displaced rapidly, a
wave called a spring surge
travels down the spring.
⚫If the other end is fixed,
the wave can reflect back.
⚫If the wave frequency is
near the natural frequency
of the spring, resonance
may occur resulting in
extremely high stresses.
⚫Catastrophic failure may
Fig. 10–4
occur, as shown in this
valve-spring from an over-
revved engine.
Fatigue Loading of Helical Compression Springs 21

⚫Zimmerli found that size, material, and tensile strength have no


effect on the endurance limits of spring steels in sizes under 3/8
in (10 mm).
⚫Testing found the endurance strength components for infinite life
to be

⚫These constant values are used with Gerber or Goodman


failure
criteria to find the endurance limit.
Fatigue Loading of Helical Compression Springs 22

⚫For example, with an unpeened spring with Ssu = 211.5 kpsi,


the Gerber ordinate intercept for shear, from Eq. (6-42), is

⚫For the Goodman criterion, it would be Sse = 47.3 kpsi.

⚫Each possible wire size would change the endurance limit since
Ssu is a function of wire size.
Torsional Modulus of Rupture 23

⚫The torsional modulus of rupture Ssu will be needed for


the fatigue diagram.
⚫Lacking test data, the recommended value is
Stresses for Fatigue Loading 24

⚫From the standard approach, the alternating and midrange


forces are

⚫The alternating and midrange stresses


are
Example 1 25
Example 1 26
Example 1 27
Example 2 28
Example 2 29

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