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Spring Design (Dynamic)

This document outlines a MATLAB script for designing dynamic helical springs, requiring user inputs for parameters such as maximum and minimum spring force, deflection, spring index, ultimate tensile strength, and modulus of rigidity. The script calculates various spring characteristics including wire diameter, mean coil diameter, alternating shear stress, and total coils, and evaluates the design's safety against fatigue using the Goodman criterion. The results are displayed, indicating whether the design is safe or requires adjustments.

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Vivek Pathak
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2 views1 page

Spring Design (Dynamic)

This document outlines a MATLAB script for designing dynamic helical springs, requiring user inputs for parameters such as maximum and minimum spring force, deflection, spring index, ultimate tensile strength, and modulus of rigidity. The script calculates various spring characteristics including wire diameter, mean coil diameter, alternating shear stress, and total coils, and evaluates the design's safety against fatigue using the Goodman criterion. The results are displayed, indicating whether the design is safe or requires adjustments.

Uploaded by

Vivek Pathak
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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clc;

clear;
disp('--- Dynamic Helical Spring Design Calculator ---');
P_max = input('Enter maximum spring force in N (P_max): ');
P_min = input('Enter minimum spring force in N (P_min): ');
deflection = input('Enter spring deflection under full load (mm): ');
C = input('Enter spring index (C = D/d, suggested: 5 to 10): ');
Sut = input('Enter ultimate tensile strength (N/mm^2): ');
G = input('Enter modulus of rigidity G (N/mm^2, e.g. 81370 for steel): ');
end_style = input('Enter end type (1=plain, 2=square, 3=plain-ground, 4=square-ground): ');
P_mean = (P_max + P_min)/2;
P_amp = (P_max - P_min)/2;
Se_dash = 0.21 * Sut;
Sy = 0.45 * Sut;
K = ((4*C - 1)/(4*C - 4)) + 0.615/C;
tau_perm = 0.5 * Sut;
d = sqrt((8 * P_max * K * C) / (pi * tau_perm));
d = ceil(d);
D = C * d;
tau_a = (8 * P_amp * D * K) / (pi * d^3);
tau_m = (8 * P_mean * D) / (pi * d^3);
n_actual = 1 / ((tau_a / Se_dash) + (tau_m / Sy));
k = (P_max - P_min) / deflection;
Na = (G * d^4) / (8 * D^3 * k);
Na = ceil(Na);
switch end_style
case 1
Nt = Na;
case 2
Nt = Na + 2;
case 3
Nt = Na + 1;
case 4
Nt = Na + 2;
otherwise
error('Invalid end style');
end

Ls = Nt * d;
gap = 0.5;
La = (Nt - 1) * gap;
Lf = Ls + deflection + La;
pitch = (Lf - d)/(Nt - 1);
fprintf('\n--- Dynamic Spring Design Results ---\n');
fprintf('Wire diameter (d): %.2f mm\n', d);
fprintf('Mean coil diameter (D): %.2f mm\n', D);
fprintf('Spring index (C): %.2f\n', C);
fprintf('Alternating shear stress (τa): %.2f N/mm^2\n', tau_a);
fprintf('Mean shear stress (τm): %.2f N/mm^2\n', tau_m);
fprintf('Factor of safety (Goodman): %.2f\n', n_actual);
fprintf('Required spring rate: %.2f N/mm\n', k);
fprintf('Active coils: %d\n', Na);
fprintf('Total coils: %d\n', Nt);
fprintf('Solid length (Ls): %.2f mm\n', Ls);
fprintf('Free length (Lf): %.2f mm\n', Lf);
fprintf('Pitch: %.2f mm\n', pitch);
fprintf('Factor of Safety: %.2f\n', n_actual);

if n_actual <= 1.5


fprintf('\n Design is SAFE against fatigue (Goodman criterion satisfied).\n');
else
fprintf('\n Design is NOT SAFE against fatigue (increase wire diameter or factor of safety).\n');
end

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