FME461

Engineering Design II
Dr.Hussein Jama
[email protected]
Office 414

Lecture: Mon 8am -10am

Tutorial Tue 3pm - 5pm

7/4/2019 1
Spring design
 Types
 Factors in spring design
 Materials
 Torsional

7/4/2019 2
Types of Springs

7/4/2019 3
Types of spring cont.

7/4/2019 4
Types of springs cont.

7/4/2019 5
Types of springs cont.

7/4/2019 6
Spring Design
F  ky
kF/y

1 1 1 1
  
k series k1 k 2 k3
k parallel  k1  k 2  k3

7/4/2019 7
Factors in spring design
 High strength
 High yield
 Modulus may be low for energy storage
 Cost
 Environmental factors
 Temperature resistance (e.g. valve springs)
 Corrosion resistance

7/4/2019 8
Common materials for springs

7/4/2019 9
Influence of diameter on
ultimate stress

7/4/2019 10
 Influence of diameter on
ultimate stress cont.

Sut  Ad b
Sus  0.67Sut

7/4/2019 11
Design of helical compression
springs  Length nomenclature
 Free
 Assembled
 Solid or shut height
 Working deflection

7/4/2019 12
Stresses in Helical Spring

7/4/2019 13
Stresses in Helical springs
cont.
At the inside of the spring Substituting for

Gives

4<C<12
Defining the spring index

Therefore the stress is

Equation(1)

7/4/2019 14
Effect of curvature on Stress
 Equation (1) is based on the wire being
straight
 However the curvature increases the stress
on the inside of the wire
 For static stress the effect of curvature can
be neglected
 For fatigue the effect of curvature is important

7/4/2019 15
Effect of curvature cont.

Wahl factor

Bergstrasser
factor

The results of the two equations differ by less than 1%.

Bergstrasser factor is preferred due to simplicity

7/4/2019 16
Deflection
 The external work done on an elastic member
in deforming it is transformed into strain, or
potential, energy. If the member is deformed a
distance y, and if the force-deflection
relationship is linear, this energy is equal to
the product of the average force and the
deflection, or

 This equation is general in the sense that the

force F can also mean torque, or moment,
provided, that consistent units are used for k.
7/4/2019 17
Deflection cont..

 By substituting appropriate expressions for k,

strain-energy formulas for various simple
loadings may be obtained. For tension and
compression and for torsion,

7/4/2019 18
Deflection of a helical spring
 Using Castigliano’s theorem, strain energy is
equal to

 Substituting

7/4/2019 19
Deflection cont.
 Using the spring index

 Spring scale is

7/4/2019 20
Spring design – end treatment
 End details affect active coils
 Plain ends
 Squared ends
 Squared
 Ground

7/4/2019 21
Number of active coils

7/4/2019 22
Stability of a column

Euler Formula

7/4/2019 23
Stability of a spring
 We know a column will buckle when the load
is too large
 A compression coil spring will also buckle

 ycr is the deflection corresponding to onset of

instability

7/4/2019 24
Deflection cont.
Is called the effective slenderness ratio

Alpha = end condition constant

Lo is the spring length
D is the Coil diameter

7/4/2019 25
Instability cont.
 End constraint alpha given by

7/4/2019 26
Instability cont.
 For absolute stability

 For steels it turns out

 For square and ground ends

7/4/2019 27
Static design flow chart

7/4/2019 28
Flow chart cont.

7/4/2019 29
Recommended design
conditions

Figure of merit (fom)

7/4/2019 30
Materials for springs
 Yield strength for static loading
 Depends on set
 Before set removed use Wahl factor
 After set removed no stress concentration used

7/4/2019 31
Properties for fatigue
 Fatigue Strength
 Torsion is relevant loading- could use von Mises
stress
 Materials testing specific to helical compression
springs is available, however
 Correct for temp., reliability, environment

7/4/2019 32
Properties - endurance
 Endurance Strength (steels) unlimited cycles
 For high ultimate strengths, endurance limits max
out at 45 kpsi (unpeened) and 67.5 kpsi (peened)
 Small wires have high ultimate strength
 Tests have been done specific to spring wire
 Temperature may require compensation
 Corrosion
 Reliability

7/4/2019 33
 S-N and Modified Goodman

7/4/2019 34
Designing springs
Requirements Design Choices
 Functionality  Index C
 Stiffness  Material
 Lengths  Wire and coil
 Diameter diameter
 Forces
 Number of turns
 Reliable operation
 End treatment and
 Static factor of safety
constraint
 Fatigue factor of safety
 Buckling and surge  Set and shot peen
 Manufacturability Constraints (other)
• Bend radius
7/4/2019 35
Helical extension spring
 Similar in most ways to
compression springs
 Usually wound to be closed
coil at zero force
 Thus a preload is required
to stretch any, i.e. y=k(F-Fi )
 Spring hook is a source of
failure in bending and
torsion
 No set is used
 One coil not considered
active

7/4/2019 36
End stresses
Bending stress:
16 DF 4 F
 A  Kb  2
d 3
d
4C12  C1  1 2 R1
Kb  ; C1 
4C1 (C1  1) d

Torsional stress:

8DF
 B  K w2
d 3
4C2  1 2 R2
K w2  ; C2 
4C2  4 d
7/4/2019 37
Design for fatigue
 Data available for springs with loading from
zero to some compresion value
 Application often has preload… how to use?
 First construct (or find) S-N curve
 Next construct Mod-Goodman chart
 Apply load line for given preload and design
stress
 Find factor of safety to failure point

7/4/2019 38
Goodman curve

7/4/2019 39
A word about torsional springs
 The wire in a torsional spring is primarily in
bending
 Spring constant is rotary M=k
 Loading should act to wind up coil
 Design process resembles compression
springs

7/4/2019 40
Torsional

7/4/2019 41
Homework
 Read chapter 10 of Shigley

7/4/2019 42