Worked Examples On Springs

WORKED EXAMPLES ON SPRINGS
Example 1 (22 marks)

An engine valve spring made from a 4 mm diameter VSQ wire comprises of seven active coils,
square and ground, with mean coil diameter, D = 36 mm. The initial compression, y i = 18 mm;
valve lift (yu – yi) = 12 mm; clash defection, yc = 40 mm; stress at clash, τc = 90% of torsional
yield.
Draw the load deflection graph and determine:
(a) Torsional yield stress. [5]
(b) Load at clash deflection, initial and maximum spring loads. [6]
(c) The free length of the spring. [2]
(d) The spring constant. [2]
(e) The fundamental frequency of the spring (β = 1; ρ = 7860 kg/m3). [3]
(f) The ratio of the fundamental frequency to the force frequency if the engine is 4-stroke
and running at 1800 r/min maximum. Comment on your answer. [3]
Solution:
Q
(a) The minimum UTS is given by 𝜎𝑡 = ; where Q = 1734 and x = 0.1 for a 4 mm
dx
1734
diameter VSQ wire (Table 9.5). 𝑈𝑇𝑆 = = 1509 MPa.
40.1
Torsional yield stress,

yi = 18 mm
τy = 0.433(UTS) = 0.433 x 1509 = 653 MPa. yu = 12+yi = 30 mm
yc = 40 mm
τc = 0.9 τy = 0.9 x 653 = 587.7 MPa. Pc
Pu
(b) Spring index, C = 36/4 = 9.
4×9−1 0.615 Pi
∴ 𝐾= + = 1.162
4×9−4 9
τπ𝑑2 587.7×106 × π×0.0042

Load at clash, 𝑃𝑐 = 8KC
= 8×1.162×9
= 353.1 N
yi yu yc
P𝑢 y𝑢 30
P𝑐
= y𝑐
⇒ 𝑃𝑢 = 40 × 353.1 = 264.8 N
Load deflection Graph
P𝑖 y𝑖 18
P𝑐
=y ⇒ 𝑃𝑖 = 40 × 353.1 = 158.9 N
𝑐
2
(c) Free length of spring, L = (n+2)d + yc = (7+2)x4 + 40 = 76 mm
2
𝑃𝑢 −𝑃𝑖 264.8−158.9
(d) Spring constant, 𝑘 = y𝑢 −𝑦𝑖
= 12×10−3
= 8825 N/m
𝛽 𝑘
(e) Spring frequency, ωs is given by: 𝜔𝑠 = 2 √𝑚 ; where: β = 1; k = 8825
𝜋 𝜋
N/m; 𝑚 = 𝐴𝐿𝜌 = 4
𝑑2 . 𝜋𝐷𝑛. 𝜌 = 4
0.0042 × 𝜋 × 0.036 × 7 × 7860 = 0.078 kg.
1 8825
𝜔𝑠 = 2 √0.078 = 168.2 cycles.
1 1800
(f) Force frequency, 𝜔𝑓 = ( ) = 15 cycles.
2 60
𝜔𝑠 168.2
Required ratio: 𝜔𝑓
= 15
= 11.2
Comment: The ratio obtained is less than the recommended (15:1) to avoid resonance
with other harmonics. Hence resonance is likely.

2.1 An extension spring with mean coil diameter of 10 mm is made from music wire of 1.2
mm in diameter. The spring has 46 active coils and full round hooks and is wound with
an initial tension which induces a stress of 90 MPa in the wire. Calculate:
(a) The spring rate. [3]

(b) The ultimate tensile strength and the torsional stress at yield. [3]
(c) The initial tension and the force required to overcome it. [5]
2.2 A semi-elliptical spring, 900 mm long, is made up of 7 graduated leaves and 1 extra-full
length leaf. The leaves are 6 mm thick. Determine:
(a) The plate width if the deflection is 54 mm under a central load of 1680 N; [4]
(b) The maximum stress in the extra-full length leaf if this has been pre-stressed to give
the same stress in all the members; [3]
(c) The stress in this plate assuming no pre-stressing; [2]
Solution:
D 10
2.1 (a) Given: D = 10 mm and d = 1.2 mm; ⇒ C = d
= 1.2 = 8.33
Gd 79×109 ×1.2×10−3
The spring rate k = 8C3 n = 8×8.333×46
= 445.68 N/m
Q 2215
(b) Torsional yield stress τy = 0.433(UTS) and UTS = = = 2154 MPa
dx 1.20.154
Hence τy = 0.433 x 2154 = 932.5 MPa.

(c) Ks = 1 + 0.615/C = 1.074
πd2τi π×1.22 ×10−6 ×90×106
Pi = 8Ks C
= 8×1.074×8.33
= 5.69 MPa.
Force to overcome initial tension;

πd2 τy π×1.22×10−6 ×932.5×106
P= 8Ks C
= 8×1.074×8.33
= 58.9 MPa.
2.2 Given: 2L = 900 mm (L = 0.45m); ng = 7, nx = 1 (n = 8); t = 0.006m.

(a) For y = 0.054 m, P = 840 N;
12PL3 12PL3 12×840×0.453
y = (2n )bt3 E
⇒ b = (2n )yt3 E
= 17×0.054×0.0063 ×200×109
= 0.0232 m (24 mm)
g +3nx g+3nx
(b) For pre-stressing of the extra full-length leaf, n = 8;

6PL 6×840×0.45
σx = nbt2 = 8×0.024×0.0062
= 328.1 MPa.
(c) For no pre-stressing of the extra full-length leaf;

18PL 18×840×0.45
σx = (2n 2 = 17×0.024×0.0062
= 463.2 MPa
g +3nx )bt

Design a recoil spring of a 125 mm gun in order to sustain a maximum load of 32 kN using a
compression spring with rectangular wire, the longer side being 3½ times the shorter, with
the shorter side parallel to the axis of the spring. The following specifications are given:
maximum load is three times the initial load (i.e when the gun is set to fire); travel during the
recoil is 220 mm; mean coil diameter is 112 mm; maximum wire stress is 580 MPa; spring
index is 3 and G = 80 GPa.
Determine:
(a) The sizes of the cross-section of the wire strip. [6]
(b) The number of active turns. [6]
(c) The free length, if at maximum loading there is a clearance of 4 mm between
the coils. (NB: Free length = solid length + total deflection + total clearance
between coils). [2]
Solution:
(a) Given: Maximum load, Pmax = 32 kN; Pmax = 3Pi; yu – yi = 220 mm;
b = 3½ t; D = 112 mm; τ = 580 MPa; C = 3; G = 80 GPa.
PD(3b+1.8t) 13.8PD
τ=K = K since b = 3½ t.
2b2 t2 32t3
4C−1 0.615 4×3−1 0.615

K= + = + = 1.58
4C−4 C 4×3−4 3
1 1
13.8KPD 3 13.8×1.58×28×103 ×0.120 3
Thus, t = ( ) =( ) = 0.0154 m (say 16 mm)
32τ 32×630×106
Therefore, b = 4 x 16 = 64. Spring cross section is 16 x 64.

(b) Initial compression load is Pi = ¼ Pmax= 28/4 = 7 kN
Pu −Pi 28−7
The spring rate k = yu −yi
= 0.26
= 80.77 kN/m
Pmax. 28
Maximum deflection: Ymax. = = = 0.347 m 2
k 80.77
2.45PD3 n y(b−0.56t)t3G 0.347×(64−0.56×16)×10−3 ×0.0163 ×80×109

From y = ∴n= = = 52.8
(b−0.56t)t3G 2.45PD3 2.45×28×103 ×0.123
The spring will be squared and ground with 53 coils.

2
(c) Free length L = (n+2)t + 347 + (n+1)4 = 55 x 16 + 347 + 54 x 4 = 1443 mm

Worked Examples On Springs

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WORKED EXAMPLES ON SPRINGS

Example 1 (22 marks)

Torsional yield stress,

τπ𝑑2 587.7×106 × π×0.0042

Example 2 (20 marks)

(a) The spring rate. [3]

Hence τy = 0.433 x 2154 = 932.5 MPa.

Force to overcome initial tension;

2.2 Given: 2L = 900 mm (L = 0.45m); ng = 7, nx = 1 (n = 8); t = 0.006m.

(b) For pre-stressing of the extra full-length leaf, n = 8;

(c) For no pre-stressing of the extra full-length leaf;

Example 3 (20 marks)

4C−1 0.615 4×3−1 0.615

Therefore, b = 4 x 16 = 64. Spring cross section is 16 x 64.

2.45PD3 n y(b−0.56t)t3G 0.347×(64−0.56×16)×10−3 ×0.0163 ×80×109

The spring will be squared and ground with 53 coils.

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