SPRINGCONTENT * Introduction * Function and Applications * Types of spring * Terminology of helical spring * Styles of end * Stress and Deflection equation * Series and Parallel equation * Spring materials and manufacturing process * Design of helical spring * Surge in spring * Helical torsion springs * Multileaf spring pe OT pres fe I pings a min,INTRODUCTION Springs are flexible machine elements used primarily to deflect under load with the ability to return to its original shape when unloaded. They are designed to store energy, measure a force, or absorb shocks and vibrations. The popular types of mechanical springs are helical compression spring, helical extension spring, helical torsion spring, and multileaf spring. There are three criterions in design of springs which is sufficient strength to withstand external load, desired load deflection characteristic and sufficient buckling strength.FUNCTIONS AND APPLICATIONS * Springs are used to absorb shocks and vibrations, e.g., vehicle suspension springs, railway buffer springs, buffer springs in elevators and vibration mounts for machinery. * Springs are used to store energy, e.g., springs used in clocks, toys, movie-cameras, circuit breakers, and starters. + Springs are used to measure the force, e.g., springs used in weighing balance and scales. * Springs are used to apply force and control motion, e.g. in cam follower mechanism to maintain the contact between them, in clutch it provides the required force to engage the clutch.TYPES OF SPRINGS 1. Helical spring : the helical spring is made from wire, usually of circular cross-section, which is bent in the form of a helix. There are two types of helical spring- I, Helical compression spring II. Helical extension spring+ In helical compression spring, the external force tends to shortens the spring while in helical extension spring, the external force tends to lengthen the spring. * In both the cases, the external force acts along the axis of the spring and induces torsional shear stress in the spring wire. The words ‘compression’ and ‘extension’ are related to total spring and not to stresses in spring wire. * The helical springs are sometimes classified as closely-coiled helical spring and open- coiled helical spring. * A helical spring is said to be closely-ciled lial spring, when the spring wire is coiled so close that the plane containing each col is almost at right angle tothe axis of helix. (Helix angle < 10°) * A elical spring is said to be closely-coiled helical spring, when the spring wire is coiled in such a way, that there is a large gap between adjacent coil (Helix angle > 10°), ADVANTAGES * They are easy to manufacture. * They are cheaper than other types of springs. * Their reliability is high. © The deflection of snrins ‘nearly nronortional to the force actine on the spring.2. Helical torsion spring : * The construction of this spring is similar to that of compression or extension spring, except that the ends are formed in such a way, that the spring is loaded by a torque, about the axis of the coils. + Ttis used to transmit a torque (P x r) to a particular component in a machine or a mechanism. + It is used in door-hinges, brush holders, automobile starters and door locks. * The helical torsion spring resists the bending moment (P x r), which tends to wind up the spring. The bending moment induces bending stresses in the bending wire.3. Multileaf spring : A multileaf or laminated spring consists of a series of flat plates, usually of semi-elliptical shape. The flat plates, called leaves, have varying lengths. The leaves are held together by means of U-bolts and center clip. The longest leaf, called master leaf, is bent at the two ends to form spring eyes. The leaves of multileaf spring are subjected to bending stresses. They are widely used in automobile and railroad suspensions.TERMINOLOGY OF HELICAL SPRING The main dimensions of helical spring subjected to compressive force are as follows: d=wire diameter of spring (mm) D, = inside diameter of spring coil (mm) D, = outside diameter of spring coil (mm) D=mean coil diameter (mm) Therefore, — DitDo Dar* There is an important parameter in spring design called spring index. It is denoted by letter C. the spring index is defined as the ratio of mean coil diameter to the wire diameter, * The spring index indicates the relative sharpness of the curvature of the coil- ¥ A low spring index means high sharpness of curvature. When the spring index is low (C < 3), the actual stresses in the wire are excessive due to curvature effect. Such a spring is difficult to manufacture and special care in coiling is required to avoid cracking in some wires. ¥ when the spring index is high (C > 15), it results in large variation in coil diameter. Such a spring is prone to buckling and also tangles easily during handling. ¥ Therefore spring index from 4 to12 is considered better for manufacturing consideration,is Solid length : Solid length is defined as the axial length of the spring which is so compressed that the adjacent coils touch each other. In this case, the spring is completely compressed and no further compression is possible. Solid length = Nyd Where N; = total number of coils Compressed length : compressed length is defined as the axial length of the spring, which is subjected to maximum compressive force. In this case, the spring is subjected to maximum deflection 6. There should be some gap between the coils at the maximum deflected position to avoid clashing between them. The clashing allowance or total axial gap is usually taken as 15% of the maximum deflection. Sometimes an arbitrary decision is taken and it is assumed that there isa gap of | mm or 2 mm between adjacent coils under maximum load condition, in this case- Total gap = (N;,-1) x gap between adjacent coils Free length: Free length is defined as the axial length of an unloaded helical compression spring. In this case there is no external force acts on the spring. Free length = compressed length + 6 = solid length + total axial gap + 54, Pitch : The pitch of the coil is defined as the axial distance between adjacent coils in uncompressed state of spring. It is denoted by p. _ Free length (Ne-1) 5. Stiffness : The stiffness of the spring is defined as the force required to produce unit deflection. Therefore, 6. Active and inactive coils: Active coils are the coils in the spring, which contribute to spring action, support the external force and deflect under the action of force. A portion of the coil at each end, which is in contact with the seat, does not contribute to spring action and called inactive coil. These coils do not support the load and do not deflect under the action of external force. The number of inactive coils is given by, Inactive coils = (N; - N)STYLES OF END : Helical compression spring Plain ends M Plain ends (ground) (Ne 1/2) Square ends (= 2)STYLES OF END : Helical extension spring * For helical extension springs, all coils are active coils. The number of active coils (V) is the same as the total number of coils (N;).STRESS AND DEFLECTION EQUATION There are two basic equations for the design of helical springs : 1. Load-stress equation 2. Load-deflection equation Load-stress EquationThe dimensions of equivalent bar are as follows: + The diameter of the bar is equal to the wire diameter of the spring (d). + The length of one coil in the spring is (xD). There are N such active coils. Therefore, the length of equivalent bar is (tDN). + The bar is fitted with bracket at each end, The length of this bracket is equal to mean coil radius of the spring (D/2). a PD Torsional moment, My = = . 16M; ‘BPD Torsional shear stress, ty == or — ....(a stress, = Tay OF Te (8) When the equivalent bar is bent in the form of helical coil, there is additional stresses on account of following two factors: i, There is a direct or transverse shear stress in the spring wire, ii, When the bar is bent in the form of coil, the length of inner fibre is less than the length of outside fibre. ‘This results in stress concentration at the inside fibre of the coil.The resultant stress consists of superimposition of torsional shear stress, direct shear stress and additional stresses due to the curvature of the coil.There are two factors to account for these effects: Ks= Factor to account for direct shear stress Kc= factor to account for stress concentration due to curvature effect The combined effect of these two factors is given by, K=KsKe The direct shear stress in the bar is given by P _4P _8PD 05d. le ceca ) ee) 4 a+) The shear stress correction factor (Ks) is defined as, Ks = (1 + “ or (1 +5 8PD. Hence t=K (a) beast) Where K is called stress factor or Wahl factor and is given by 40-1, 0615 N= Resultant shear stress, T= 1, +t) =Load-deflection equation: The angle of twist for the equivalent bar is given by, = Met = (PD/2)(nDN) 9-16 PDN ica sarod Ben(c) The axial deflection ‘6’ of the spring, for small value of 6, is given by, 5=0x (02) The rate of spring (k) is given by, ul ea 8 8DN aC) The energy stored in the spring E = Area under load-deflection line 1 =1 5SERIES AND PARALLEL CONNECTIONS Series connection Parallel connection aan l =[o a Ff = = + -SPRING MATERIALS There are four basic varieties of steel wire which are used in springs in the majority of applications- I. Patented and cold-drawn steel wires (unalloyed) * There are two terms related to this type of spring wire which is ‘patenting’ and ‘cold drawing’. Patenting is defined as heating the steel above the critical range and followed by rapid cooling. This operation produces a tough uniform structure that is suitable for severe cold working. * They are made of high carbon steel and contain 0,85-0.95% carbon. + Least expensive, + Patented and cold-drawn steel wires are mainly used in springs subjected to static forces and moderate fluctuating forces.Il. Oil-hardened and tempered spring steel wires and valve spring wires * Oil hardened and tempered spring steel wire contains 0.55-0.75% carbon, The wire is cold drawn and then hardened and tempered. + Yalve spring wire contains 0.60-0.75% carbon. Its the highest quality of oil hardened and tempered steel wire * There are two grades of unalloyed, oil-hardened and tempered spring steel wire and valve spring wire which is SW and VW. * Grade SW is suitable for spring subjected to moderate fluctuating stresses, where as grade VW is recommended when the spring is subjected to high magnitude of fluctuating stresses. IIL. Oil-hardened and tempered steel wires (alloyed) * There are two varieties of alloy steel wires, namely chromium-vanadium steel and chromium-silicon steel. * Chromium-vanadium steel contains 0.48-0.53% carbon, 0.80-1.10% chromium, and 0.15% vanadium. These wires are used for applications involving higher stresses and for springs subjected to impact or shock loads. * Chromium-silicon spring steel contains 0.51-0.59% carbon, 0.60-0.80% chromium and 1.2-1.6% silicon. These are also used for shock or impact loading.IV. Stainless steel spring wires. * Stainless steel springs, which exhibit an excellent corrosion resistance, are ideal to work in steam or other corrosive medium. * Costly. SPRING MANUFACTURING PROCESSES * If springs are of very small diameter and the wire diameter is also small then the springs are normally manufactured by a cold drawn process through a mangle. + However, for very large springs having also large coil diameter and wire diameter (greater than 6 mm) one has to go for manufacture by hot processes, First one has to heat the wire and then use a proper mangle to wind the coils.MULTILEAF SPRING * Multileaf springs are widely used for the suspension of cars, trucks, and railway wagons. * Tt consists of flat plates, usually of semi-elliptical shape. The flat plates are called leaves of spring. + The leaves have graduated lengths. The leaf at the top has maximum length. The length gradually decreases ftom the top leaf to the bottom leaf. The longest leaf at the top is called master leaf. It is bent at both ends to form the spring eyes. Two bolts are inserted through these eyes to fix the leaf spring to the automobile body. The leaves are held together by means of two U-bolts and a center clip. * Rebound clips are provided to keep the leaves in alignment and prevent lateral shifting of the leaves during operation.THANK YOU