412 Design of Machine Elements

Example 10.6 A railway wagon moving at a t = 0.5 (1250) = 625 N/mm2

velocity of 1.5 m/s is brought to rest by a bumper 4C - 1 0.615 4( 6) - 1 0.615
consisting of two helical springs arranged in K= + = +
parallel. The mass of the wagon is 1500 kg. The 4C - 4 C 4( 6) - 4 6
springs are compressed by 150 mm in bringing the = 1.2525
wagon to rest. The spring index can be taken as 6. From Eq. (10.13),
The springs are made of oil-hardened and tempered
steel wire with ultimate tensile strength of 1250 Ê 8 PC ˆ Ï 8(11 250)(6) ¸
t=K Á or 625 = (1.2525) Ì ˝
N/mm2 and modulus of rigidity of 81 370 N/mm2. Ë p d 2 ˜¯ Ó pd2 ˛
The permissible shear stress for the spring wire can
be taken as 50% of the ultimate tensile strength. \ d = 18.56 or 20 mm (i)
Design the spring and calculate: Step II Mean coil diameter
(i) wire diameter; D = Cd = 6 (20) = 120 mm (ii)
(ii) mean coil diameter;
(iii) number of active coils; Step III Number of active coils
(iv) total number of coils; From Eq. (10.8),
(v) solid length; 8(11 250)(120)3 N
8 PD3 N
(vi) free length; d= or 150 =
(vii) pitch of the coil; Gd 4 (81370)(20) 4
(viii) required spring rate; and N = 12.56 or 13 coils (iii)
(ix) actual spring rate.
Step IV Total number of coils
Solution It is assumed that the springs have square and ground
Given m = 1500 kg v = 1.5 m/s d = 150 mm ends. The number of inactive coils is 2. Therefore,
C = 6 Sut = 1250 N/mm2 G = 81 370 N/mm2 Nt = N + 2 = 13 + 2 = 15 coils (iv)
t = 0.5 Sut
Step V Solid length of spring
Step I Wire diameter Solid length = Ntd = 15(20) = 300 mm (v)
The kinetic energy of the moving wagon is absorbed
by the springs. The kinetic energy of the wagon is Step VI Free length of spring
given by, The actual deflection of the spring is given by,
1 1 8 PD3 N 8(11 250)(120)3 (13)
KE = mv2 = (1500)(1.5)2 = 1687.5 J or N-m d= = = 155.29 mm
2 2 Gd 4 (81370)(20) 4
= (1687.5 ¥ 103 ) N-mm (a)
It is assumed that there will be a gap of 2 mm
Suppose P is the maximum force acting on each between adjacent coils when the spring is subjected
spring and causing it to compress by 150 mm. The to the maximum force of 11 250 N. Since the total
strain energy absorbed by two springs is given by, number of coils is 15, the total axial gap will be
È1 ˘ È1 ˘ (15 – 1) ¥ 2 = 28 mm.
E = 2 Í P d ˙ = 2 Í P (150 )˙ = (150P) N-mm Free length = solid length + total axial gap + d
Î 2 ˚ Î2 ˚
(b) = 300 + 28 + 155.29
= 483.29 or 485 mm (vi)
The strain energy absorbed by the two springs is
equal to the kinetic energy of the wagon. Therefore, Step VII Pitch of coils
(150 P) = 1687.5 ¥ 103 free length 485
P = 11 250 N Pitch of coil = = = 34.64 mm
( N t - 1) (15 - 1 )
The permissible shear stress for the spring wire (vii)
is given by,
 Springs 413

Step VIII Required spring rate Step I Wire diameter

P 11 250 There are eight springs in parallel. The force acting
k= = = 75 N/mm (viii)
d 150 on each spring is given by,
Step IX Actual spring rate 2400
P= = 300 N
Gd 4 (81370)(20) 4 8
k= 3
= = 72.44 N/mm (ix)
8D N 8(120)3 (13) The permissible shear stress for the spring wire
is given by,
Example 10.7 An automotive single plate clutch t = 0.3 Sut = 0.3 (1390) = 417 N/mm2
consists of two pairs of friction surfaces, one between
the friction lining and the pressure plate and the 4C - 1 0.615 4 ¥ 8 - 1 0.615
K= + = + = 1.184
other between the friction lining and the flywheel 4C - 4 C 4¥8-4 8
as shown in Fig 10.19. Eight identical helical From Eq. (10.13),
compression springs, arranged in parallel, provide
the required axial thrust on the friction surface. The Ê 8 PC ˆ Ï 8(300) (8) ¸
t=K Á 417 = (1.184) Ì ˝
Ë p d 2 ˜¯
or
total spring force exerted by all springs is 2400 N Ó pd2 ˛
and the corresponding deflection of each spring
is approximately 15 mm. The spring index can be \ d = 4.17 or 5 mm (i)
taken as 8. The springs are made of patented and Step II Mean coil diameter
cold-drawn steel wire with ultimate tensile strength
D = Cd = 8(5) = 40 mm (ii)
of 1390 N/mm2 and modulus of rigidity of 81 370
N/mm2. The permissible shear stress for the spring Step III Number of active coils
wire can be taken as 30% of the ultimate tensile From Eq. (10.8),
strength. Design the springs and calculate: 8 PD3 N 8(300)(40)3 N
(i) wire diameter; d= or 15 =
(ii) mean coil diameter; Gd 4 (81370)(5) 4
(iii) number of active coils; \ N = 4.97 or 5 coils (iii)
(iv) total number of coils;
Step IV Total number of coils
(v) solid length;
It is assumed that the springs have square and ground
(vi) free length;
ends. The number of inactive coils is 2. Therefore,
(vii) pitch of the coil;
Nt = N + 2 = 5 + 2 = 7 (iv)
(viii) required stiffness of the spring; and
(ix) actual stiffness of the spring. Step V Solid length of spring
solid length = Ntd = 7(5) = 35 mm (v)
Step VI Free length of spring
The actual deflection of the spring is given by,
8 PD3 N 8(300)(40)3 (5)
d= = = 15.10 mm
Gd 4 (81370)(5) 4
It is assumed that there will be a gap of 1 mm
between the adjacent coils when the spring is
subjected to the maximum force of 300 N. The total
Fig. 10.19 Clutch Mechanism number of coils is 7. Therefore, the total axial gap
will be (7 – 1) ¥ 1 = 6 mm.
Solution Free length = solid length + total axial gap + d
Given P = 2400 N for 8 springs d = 15 mm C = 8 = 35 + 6 + 15.10
Sut = 1390 N/mm2 G = 81 370 N/mm2 t = 0.3 Sut = 56.1 or 57 mm (vi)
 Springs 415

Example 10.9 A safety valve, 50 mm in diameter, From Eq. (10.13),

is to blow off at a pressure of 1.5 MPa. It is held on Ê 8 PC ˆ Ï 8 (4123 . 34 )(6 )¸
t = KÁ or 450 = 1.2525 Ì ˝
its seat by means of a helical compression spring, Ë p d 2 ˜¯ ÔÓ pd2 Ô˛
with an initial compression of 25 mm. The maximum
lift of the valve is 10 mm. The spring index can \ d = 13.24 or 14 mm (i)
be taken as 6. The spring is made of patented and Step II Mean coil diameter
cold-drawn steel wire with ultimate tensile strength
of 1500 N/mm2 and modulus of rigidity of 81 370 D = Cd = 6(14) = 84 mm (ii)
N/mm2. The permissible shear stress for the spring Step III Number of active turns
wire should be taken as 30% of the ultimate tensile From Eq. (10.8),
strength. Design the spring and calculate: 8 PD3 N
(i) wire diameter; d =
Gd 4
(ii) mean coil diameter;
(iii) number of active turns; Substituting values of P1 and d1,
(iv) total number of turns; 8(2945.24)(84)3 N
(v) solid length; 25 =
(81370)(14) 4
(vi) free length; and
(vii) pitch of the coil. \ N = 5.6 or 6 turns (iii)
Solution Step IV Total number of turns
Given C = 6 Sut = 1500 N/mm2 It is assumed that the spring has square and ground
G = 81 370 N/mm2 t = 0.3 Sut ends. The number of inactive coils is 2. Therefore,

Step I Wire diameter

Nt = N + 2 = 6 + 2 = 8 turns (iv)
Let P1 and d1 denote the initial spring force and Step V Solid length of spring
deflection respectively when the valve just begins Solid length = Nt d = 8(14) = 112 mm (v)
to blow off.
p Step VI Free length of spring
P1 = (50) 2 (1.5) = 2945.24 N The maximum deflection of the spring under the
4
force of 4123.34 N is given by,
d1 = 25 mm
Let P2 and d2 denote the spring force and 8 PD3 N 8(4123.34)(84)3 (6)
d = = = 37.53 mm
deflection respectively when the valve is open. Gd 4 (81370)(14) 4
d2 = d1 + valve lift = 25 + 10 = 35 mm
It is assumed that there will be a gap of 2 mm
Also,
between the adjacent turns, when the spring is
Pµd
subjected to the maximum compression. This gap
Therefore,
is essential to avoid clashing of the coils. The total
P2 d 2 P2 35
= or = number of turns is 8. Therefore, the total axial gap
P1 d1 (2945.24 ) 25 will be (8 – 1) ¥ 2 = 14 mm
P2 = 4123.34 N (maximum force) Free length = solid length + total axial gap + d
The permissible shear stress for the spring wire = 112 + 14 + 37.53 = 163.53 mm
is given by, or free length = 165 mm (vi)
t = 0.3 Sut = 0.3 (1500) = 450 N/mm2
Step VII Pitch of coils
4C - 1 0.615 = 4(6) - 1 + 0.615 free length 165
K= + 4(6) - 4 6 Pitch of coil = = = 23.57 mm
4C - 4 C (Nt - 1) (8 - 1)
= 1.2525 (vii)