Unit 4 Problems (Springs)
Unit 4 Problems (Springs)
Example 1. A compression coil spring made of an alloy steel is having the following specifications:
Mean diameter of coil = 50 mm; Wire diameter = 5 mm; Number of active coils = 20. If this spring is
subjected to an axial load of 500 N; calculate the maximum shear stress (neglect the curvature effect) to
which the spring material is subjected.
Solution. Given: D = 50 mm; d = 5 mm; n = 20; W = 500 N
Example 2. A helical spring is made from a wire of 6 mm diameter and has outside diameter of 75 mm.
If the permissible shear stress is 350 MPa and modulus of rigidity 84 kN/mm2, find the axial load which
the spring can carry and the deflection per active turn.
Solution. Given: d = 6 mm Do = 75 mm τ = 350 MPa = 350 N/mm2 G =84 kN/mm2 = 84 × 103 N/mm2
Example 3. Design a spring for a balance to measure 0 to 1000 N over a scale of length 80 mm. The
spring is to be enclosed in a casing of 25 mm diameter. The approximate number of turns is 30. The
modulus of rigidity is 85 kN/mm2. Also calculate the maximum shear stress induced.
Solution. Given : W = 1000 N ; δ = 80 mm ; n = 30 ; G = 85 kN/mm2 = 85 × 103 N/mm2
Example 5. Design a helical compression spring for a maximum load of 1000 N for a deflection of 25
mm using the value of spring index as 5. The maximum permissible shear stress for spring wire is 420
MPa and modulus of rigidity is 84 kN/mm2.
Take Wahl’s factor,
K={[(4C-1)/(4C-4)]+[0.615/C]} where C = Spring index.
Solution. Given : W = 1000 N ; δ = 25 mm ; C = D/d = 5 ; τ = 420 MPa = 420 N/mm2 ;
G = 84 kN/mm2 = 84 × 103 N/mm2
1. Mean diameter of the spring coil
Let D = Mean diameter of the spring coil, and
d = Diameter of the spring wire.
Example 6. Design a close coiled helical compression spring for a service load ranging from 2250 N to
2750 N. The axial deflection of the spring for the load range is 6 mm. Assume a spring index of 5. The
permissible shear stress intensity is 420 MPa and modulus of rigidity, G = 84 kN/mm2.
Neglect the effect of stress concentration. Draw a fully dimensioned sketch of the spring, showing details
of the finish of the end coils.
Solution. Given : W1 = 2250 N ; W2 = 2750 N ; δ = 6 mm ; C = D/d = 5 ; τ = 420 MPa = 420 N/mm2 ; G
= 84 kN/mm2 = 84 × 103 N/mm2
1. Mean diameter of the spring coil
Example 7. Design and draw a valve spring of a petrol engine for the following operating conditions :
Spring load when the valve is open = 400 N Spring load when the valve is closed = 250 N
Example 8. Design a helical spring for a spring loaded safety valve ( Rams bottom safety valve) for the
following conditions: Diameter of valve seat = 65 mm ; Operating pressure = 0.7 N/mm2; Maximum
pressure when the valve blows off freely = 0.75N/mm2; Maximum lift of the valve when the pressure
rises from 0.7 to 0.75 N/mm2 = 3.5 mm ; Maximum allowable stress = 550 MPa ;Modulus of rigidity =
84 kN/mm2; Spring index = 6. Draw a neat sketch of the free spring showing the main dimensions.
Solution. Given: D1 = 65 mm ; p1 = 0.7 N/mm2 ; p2 = 0.75 N/mm2 ; δ = 3.5 mm ; τ = 550 MPa = 550
N/mm2 ; G = 84 kN/mm2 = 84 × 103 N/mm2 ; C = 6
1. Mean diameter of the spring coil
Let D = Mean diameter of the spring coil, and d = Diameter of the spring wire.
Since the safety valve is a Rams bottom safety valve, therefore the spring will be under tension. We
know that initial tensile force acting on the spring (i.e. before the valve lifts),
Example 9. A safety valve of 60 mm diameter is to blow off at a pressure of 1.2 N/mm2. It is held on its
seat by a close coiled helical spring. The maximum lift of the valve is 10 mm. Design a suitable
compression spring of spring index 5 and providing an initial compression of 35 mm. The maximum
shear stress in the material of the wire is limited to 500 MPa. The modulus of rigidity for he spring
material is 80 kN/mm2. Calculate : 1. Diameter of the spring wire, 2. Mean coil diameter, 3. Number of
active turns, and 4. Pitch of the coil.
Take Wahl’s factor,
K={[(4C-1)/(4C-4)]+[0.615/C]} where C = Spring index.
Solution. Given : Valve dia. = 60 mm ; Max. pressure = 1.2 N/mm2 ; δ2 = 10 mm ; C = 5 ; δ1 = 35 mm ;
τ = 500 MPa = 500 N/mm2 ; G = 80 kN/mm2 = 80 × 103 N/mm2
Example 11. A closely coiled helical spring is made of 10 mm diameter steel wire, the coil consisting of
10 complete turns with a mean diameter of 120 mm. The spring carries an axial pull of 200 N.
Determine the shear stress induced in the spring neglecting the effect of stress concentration. Determine
also the deflection in the spring, its stiffness and strain energy stored by it if the modulus of rigidity of
the material is 80 kN/mm2.
Solution. Given : d = 10 mm ; n = 10 ; D = 120 mm ; W = 200 N ; G = 80 kN/mm2 = 80 × 103 N/mm2
Shear stress induced in the spring neglecting the effect of stress concentration
We know that shear stress induced in the spring neglecting the effect of stress concentration is,
Example 12. At the bottom of a mine shaft, a group of 10 identical close coiled helical springs are set in
parallel to absorb the shock caused by the falling of the cage in case of a failure. The loaded cage
weighs 75 kN, while the counter weight has a weight of 15 kN. If the loaded cage falls through a height
of 50 metres from rest, find the maximum stress induced in each spring if it is made of 50 mm diameter
steel rod. The spring index is 6 and the number of active turns in each spring is 20. Modulus of rigidity,
G = 80 kN/mm2.
Solution. Given : No. of springs = 10 ; W1 = 75 kN = 75 000 N ; W2 = 15 kN = 15 000 N ;
h = 50 m = 50 000 mm ; d = 50 mm ; C = 6 ; n = 20 ; G = 80 kN/mm2 = 80 × 103 N/mm2
We know that net weight of the falling load,
P = W1 – W2 = 75 000 – 15 000 = 60 000 N
Let W = The equivalent static (or gradually applied) load on each spring which can produce the same
effect as by the falling load P.
Example 13. A rail wagon of mass 20 tonnes is moving with a velocity of 2 m/s. It is brought to rest by
two buffers with springs of 300 mm diameter. The maximum deflection of springs is 250 mm. The
allowable shear stress in the spring material is 600 MPa. Design the spring for the buffers.
Solution. Given : m = 20 t = 20 000 kg ; v = 2 m/s ; D = 300 mm ; δ = 250 mm ;
τ = 600 MPa = 600 N/mm2
1. Diameter of the spring wire
Let d =Diameter of the spring wire.
We know that kinetic energy of the wagon
Example 16. A concentric spring for an aircraft engine valve is to exert a maximum force of 5000 N
under an axial deflection of 40 mm. Both the springs have same free length, same solid length and are
subjected to equal maximum shear stress of 850 MPa. If the spring index for both the springs is 6, find
(a) the load shared by each spring, (b) the main dimensions of both the springs, and (c) the number of
active coils in each spring. Assume G = 80 kN/mm2 and diametral clearance to be equal to the
difference between the wire diameters.
Solution. Given : W = 5000 N ; δ = 40 mm ; τ1 = τ2 = 850 MPa = 850 N/mm2 ; C = 6 ;
G = 80 kN/mm2 = 80 × 103 N/mm2
The concentric spring is shown in Fig. (a).
Example 17. A composite spring has two closed coil helical springs as shown in Fig. The outer spring is
15 mm larger than the inner spring. The outer spring has 10 coils of mean diameter 40 mm and wire
diameter 5mm. The inner spring has 8 coils of mean diameter 30 mm and wire diameter 4 mm. When the
spring is subjected to an axial load of 400 N, find 1. compression of each spring, 2. load shared by each
spring, and 3. Shear stress induced in each spring. The modulus of rigidity may be taken as 84 kN/mm2.
Solution. Given : δ1 = l1 – l2 = 15 mm ; n1 = 10 ; D1 = 40 mm ; d1 = 5 mm ; n2 = 8 ;D2 = 30 mm ;
d2 = 4 mm ; W = 400 N ; G = 84 kN/mm2 = 84 × 103 N/mm2
1. Compression of each spring
Since the outer spring is 15 mm larger than the inner spring, therefore the inner spring will not take any
load till the outer spring is compressed by 15 mm. After this, both the springs are compressed together.
Let P1 be the load on the outer spring to compress it by 15 mm.
We know that compression of the spring (δ),
Example 19. Design a leaf spring for the following specifications : Total load = 140 kN ; Number of
springs supporting the load = 4 ; Maximum number of leaves = 10; Span of the spring = 1000 mm ;
Permissible deflection = 80 mm.Take Young’s modulus, E = 200 kN/mm2 and allowable stress in spring
material as 600 MPa.
Solution. Given : Total load = 140 kN ; No. of springs = 4; n = 10 ; 2L = 1000 mm or L = 500 mm ;
δ = 80 mm ; E = 200 kN/mm2 = 200 × 103 N/mm2 ; σ = 600 MPa = 600 N/mm2
We know that load on each spring,
Example 20. A truck spring has 12 numbers of leaves, two of which are full length leaves. The spring
supports are 1.05 m apart and the central band is 85 mm wide. The central load is to be 5.4 kN with a
permissible stress of 280 MPa. Determine the thickness and width of the steel spring leaves. The ratio of
the total depth to the width of the spring is 3. Also determine the deflection of the spring.
Solution. Given: n = 12 ; nF = 2 ; 2L1 = 1.05 m = 1050 mm ; l = 85 mm ; 2W = 5.4 kN = 5400 N or
W = 2700 N ; σF = 280 MPa = 280 N/mm2
Thickness and width of the spring leaves
Let t = Thickness of the leaves, and b = Width of the leaves.
Since it is given that the ratio of the total depth of the spring (n × t) and width of the spring (b) is 3,
therefore
Example 22. A semi-elliptical laminated vehicle spring to carry a load of 6000 N is to consist of seven
leaves 65 mm wide, two of the leaves extending the full length of the spring. The spring is to be 1.1 m in
length and attached to the axle by two U-bolts 80 mm apart. The bolts hold the central portion of the
These dimensions are at the middle of the connecting rod. The width (B) is kept constant throughout
the length of the rod, but the depth (H) varies. The depth near the big end or crank end is kept as 1.1H
to 1.25H and the depth near the small end or piston end is kept as 0.75H to 0.9H. Let us take
Depth near the big end, H1 = 1.2H = 1.2 × 35 = 42 mm
and depth near the small end, H2 = 0.85H = 0.85 × 35 = 29.75 say 30 mm
∴ Dimensions of the section near the big end = 42 mm × 28 mm Ans.
and dimensions of the section near the small end = 30 mm × 28 mm Ans.
Since the connecting rod is manufactured by forging, therefore the sharp corners of I-section are
rounded off, as shown in Fig. (b), for easy removal of the section from the dies.
2. Dimensions of the crankpin or the big end bearing and piston pin or small end bearing
Let dc = Diameter of the crankpin or big end bearing,
lc = length of the crankpin or big end bearing = 1.3 dc ...(Given)
pbc = Bearing pressure = 10 N/mm2 ...(Given)
We know that load on the crankpin or big end bearing
= Projected area × Bearing pressure = dc .lc . pbc = dc × 1.3 dc × 10 = 13 (dc)2