SPRINGS

A spring is a resilient
member capable of
providing large elastic
deformation.

A spring is defined as
an elastic body whose
function is to distort
when loaded and to
recover its original
shape when the load is
removed.
 Springs: Applications
Cushioning, absorbing/controlling of energy due to shock and
vibration

Railways buffers
Springs in athletic shoes
Suspension springs in automobiles and trains
 Springs: Applications
Control of motion, maintaining contact between two elements

creation of necessary pressure in

cam-follower clutch
 Springs: Applications
Storing energy

Clock springs
 Springs: Applications
Measuring forces

Spring balance
 Types of springs
(According to shape)

1. Wire Springs – Helical springs (cylindrical/conical in shape)

(square and round)

2. Flat Springs – Disc/Bellevelle springs

3. Special-shaped springs – Leaf springs, etc.

 Helical springs
(Most popular type of spring)
1. Compression spring – External force tends to shorten the spring

2. Extension spring – External force tends to lenghten the spring

3. Torsion spring – Transmits torque to a particular component

Helical springs can also be classified as :
1. Closely-coiled helical spring :
Coiling is so close that the plane containing each coil is almost at
right angles to the axis . (Helix angle < 10°)

2. Open-coiled helical spring :

Coiling is coarse (Helix angle > 10°)

Advantages of helical springs:

1. Easy to manufacture and cheaper
2. Reliability is high
3. Load deflection plot is linear
 Design Considerations of Helical Springs

 Space into which the spring must fit and operate.

 Values of working forces and deflections.
 Accuracy and reliability needed.
 Tolerances and permissible variations in specifications.
 Environmental conditions such as temperature,
corrosive atmosphere.
 Cost and qualities needed.
 Terminology of Helical Springs

C – Spring index = D/d

Indicates relative
sharpness of the
curvature of the coil

When C < 3, stresses in the wire are excessive due to curvature

effect. Such spring is difficult to manufacture and cracking must be
For practical applications:
avoided while manufacturing.
4 < C < 12
When C > 15, large variation in the coil diameter. Prone to buckling
and tangling
Axial length of spring when it is fully compressed

Solid length = Ntd

Axial length of unloaded helical compression spring
LF = Solid length + Maximum compression + Clearance between adjacent coils
(or clash allowance)
= Ntd + δmax + 0.15 δmax Nt = Total no. of coils/turns

Alternatively,
LF = Ntd + δmax + (Nt – 1) × 1 mm (if clearance taken as 1 mm)
Axial length of spring when it is subjected to maximum compressive force
in service

Assembled length : Length in assembly with some preload

Pitch of coil (p)
Axial distance between adjacent coils in uncompressed state of
spring.

p = LF / (Nt - 1)

Stiffness of spring (also rate of spring, spring constant)

Force required to produce unit deflection.

k = P/δ

P = axial spring force (N)

δ = axial deflection of spring corresponding to force P (mm)
Active coils (Na)
Coils in the spring which contribute to spring action and deflect
under the action of force.

Inactive coils
Portion of the end coils which is in contact with the seat and does
not contribute to spring action.
End Styles for helical compression springs

Na = N t Na = N t - 1 Na = N t - 2 Na = N t - 2
S.L. = (Nt + 1)d S.L. = Nt d S.L. = (Nt + 1)d S.L. = Nt d

N.B. 1)The end is designed in such a way that the stress concentration at the
bend is minimum.
2) For helical extension springs, all coils are active coils.
 Stresses in Helical Springs

Tension loading scenario Compression loading scenario

 External force F induces

τ2
Spring axis

Spring axis
Tension loading scenario Compression loading scenario

For both tensile and compressive loading, maximum shear stress

(τ1 + τ2) always occurs at the inner side of the spring
 Shear stress concentration factor

d + =
 Stresses in helical spring with curvature effect
 Stress concentration type of effect on inner fiber due to curvature
 Can be ignored for static, ductile conditions due to localized
yielding and stress relieving
More pronounced for larger wire diamter for a given spring
diameter (steep turn)
 Can account for effect by replacing Ks with Wahl factor which
accounts for both direct shear and curvature effect
Spring axis
 Spring Deflections
For the equivalent bar the angle of twist θ:

Therefore,

For axial deflection δ :

It is the load- deflection equation.

So,
P
Load-Deflection
Now, spring stiffness k:
curve
Area under load-deflection
curve is the strain energy E:
d
 Springs in Series & Parallel

Springs in parallel: combined stiffness

Gives,

Springs in parallel

Springs in series: combined stiffness

Springs in series
Gives,
 Design of Compression Springs

Design parameters to be calculated: (i) wire diameter d; (ii) mean coil

diameter D; (iii) number of active coils N.

D & d depend on load-stress equation:

N depends on load-deflection equation:

FOS: points to be considered are (i) springs being used for well defined
deflections forces can be accurately calculated and chance of overloading
is less; (ii) overloading if any may ultimately reduce the spring to that of
solid length and therefore, no chance of major damage remains; (iii) on
the other hand extension spring is used with overload stops. These factors
suggest that higher values of FOS are not required.
Generally the value is 1.5 on torsional yield strength. So,
Assuming, Syt =0.75 Sut & Ssy = 0.577 Syt
 Design of Compression Springs
Steps to be followed:
a) Estimate P, δ or k.
b) Select material to estimate Sut and τ.
c) Assume a value of spring index C, which is normally 8 – 10 and
not less than 3.
d) Calculate the Wahl factor K.
e) Determine d from: (Select standard d from Table)
f) Determine D from:
g) Determine N from when G = 81370 N/mm2
h) Select end style to assess no. of inactive coils and find total no. of coils Nt .
i) Then find the solid length from:
Steps to be followed contd.
j) Assume a gap of 0.5 to 2 mm between adjacent coils. Total gap is from:

k) Find the free length of the spring from:

l) Calculate the pitch of coil from:

m) Determine the rate of spring from:

f) If the compression is too long it should be checked against buckling.

To make compression springs buckle proof they are guided by sleeves
over or arbor inside the springs. Thumb rules for using guides are:
Guide not required. Guide required.
Thank You