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33 views33 pages

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Adem Sham
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Chapter Four

Mechanical Springs
Learning Outcomes
At the end of this chapter, you should be
 Understand the major principles behind the
function of mechanical springs and design
different types of springs.
 Definition of mechanical springs

 Functions of mechanical springs

 Materials of mechanical springs

 Considerations for selecting spring materials

 Types and its applications of mechanical springs

 Design of various types of springs


Mechanical Springs
• Spring is an elastic machine element, which deflects under the
action of the load and returns to its original position after the
load is removed.
• It can take any shape and form depending on its applications.

Why we need Mechanical Springs


• To absorb the shock load
• To store energy
• To measure force
• To return motion
• To control vibrations
Functions of Springs
 To absorb shock or impact loading: E.g. Vehicle suspension springs,
Railway buffer springs, Carriage springs, Vibration mounts for machinery.

To store energy: E.g. Springs used in clocks, toys, movie cameras, circuit
breakers and starters.
 To measure forces: Spring balances,

To apply forces to and to control motions: Springs in Brakes, Clutches,


Cam & followers, Rocker arms
Spring Materials

Patented and cold drawn steel wires

Oil hardened and tempered steel wires and valve spring materials.

Oil hardened and tempered steel wires (Alloyed)

Stainless steel spring wires.


Selection of Spring Materials

The selection of spring materials depends on


 Load acting on the spring

 Range of stress through which the spring operates.

 Environmental conditions: Temperature, corrosion etc.

 Severity of deformation while making the spring.

 Expected fatigue life

 Limitations on mass and volume of spring


Types of Springs and Its Applications
Types of Springs Applications

Helical Springs Railway industry, suspension systems

Conical Springs Electrical contacts such as; push buttons and battery contacts

Volute springs Military tanks

Torsional Springs Clocks, automotives, medical equipment, door hinges

Leaf springs Suspension systems of railway carriages and automobiles

Disc/Belleville springs Clutch springs

Air springs Trucks


Types of Springs and Their Applications
• Based on their constructions and line of action of applied load, springs
broadly classified in to three groups
1. Helical springs
2. Leaf springs
3. Disc springs
1. Helical springs
• Are also known as coil springs.
• They are made up of a wire or rod coiled into a helix.
• It is primarily intended for axial direct compression or tension loads.
• Are made of round, square, or rectangular cross-sections.
• The common purpose to use this Helical spring is to handle the compressive
and tensile load.
Types of Helical Springs
Helical springs can be classified into four categories according to load
condition:
• Compression helical springs
• Tension helical springs
• Torsion Springs
• Spiral springs
A. Compression helical springs
Compression springs are open-coil helical springs with a constant coiled
diameter and variable shape that resists axial compression.
This type of spring resists compressive or push force when the helical coil
is pressed or squeezed by the load.
Contin.....
• A helical spring is called an open-coiled helical spring if its wire is
coiled in such a way that there is a large gap between the two
consecutive helices or turns.
• The spring can take a compressive load. This is also known as an open
coil spring.
Application of compression coil
✓ Motorcycle suspension
✓ Pen
✓ Lock
✓ Couches
✓ Lighter
B. Tension spring
It is just opposite to a compression spring attached with U-shaped or I-shaped
hook typically at the one end side or can be both end side.A helical spring is
called a close-coiled helical spring if the pitch distance between any two
consecutive helices or turns is small.
The plane containing each coil is nearly perpendicular to the axis of the helix. In
this case, the helix angle should be small.
Application of Tension Spring
✓ Lever mechanism
✓ Counterbalancing of garage doors
✓ Weighing machine
✓ Vise-grip pilers
✓ Garage door assemblies
C. Torsion spring

Torsional helical spring is similar to compression helical spring and used for
torsional load. When a twisting moment is applied, the wire of the spring wound
and the diameter of the spring coils decreases.
Their ends are shaped to transmit torque. These types of springs tend to wind up
by the load. They can be either helical or spiral in shape. This torsion spring is
mostly used in circuit breakers.
Application of torsion springs
✓ Mousetrap
✓ Automobile starters
✓ Brakes
✓ Clutches
✓ Rocker switches
✓ Clothespin
✓ Door hinges
D. Spiral spring
contin...
• This type of spring is basically used in the constant rotational mechanism
or in the constant releasing of force. Spiral spring is also known as clock
spring or constant force spring.
• It consists of a flat strip wound in the form of a spiral and is loaded in
torsion. One end of this spring is fixed rigidly to the spindle.
• The other end of the spring is tied at the part to be moved. By the motion
of the spindle, the spring opens up slowly and moves the part.
• The spring is made of high-carbon steel (H.C.S.). They are hardened and
tempered. These springs are used to apply low-magnitude torque and to
transmit rotational motion.
Application of spiral spring
• Toys
• Several measuring
• instruments
• Watch
• Window regulators
• DC motors
• Automotive seat recliners
2. Leaf Springs

Leaf spring is a commonly used and traditional type of spring in


automobile industries or vehicles where metal plates of different lengths
are kept together with the help of bolts and clamps.
A leaf spring consists of a number of thin curved plates or leaves or
laminations of uniform cross-sections, but of varying lengths. These thin
plates of unequal steel strips are piled one on top of the other. The leaf
spring is supported at the ends and loaded at the center.
Contin...
The longest leaf fastened to the support is called the main leaf or main plate.
Its ends are bent to form an eye to which shackles are fastened.
The most common type of leaf spring is the semi-elliptical leaf spring. These
springs are also called carriage springs or built-up springs.
It is commonly used for vehicle suspension or heavy vehicles and this spring
is also known as Laminated spring, Invented in England in the 18th century.
Materials used to manufacture leaf springs are- Chrome vanadium steel,
Silicomanganese steel, and Carbon steel.

Types of Leaf springs


Quarter elliptic leaf spring Semi-elliptic leaf spring
Transverse leaf spring Helper Spring
Application of Leaf Spring
Leaf springs used in
Absorbing shocks Railway
Vehicles Trucks
Trolleys Power press
Forging process

3. Disc spring
Conti....
Disc spring is dynamically or statically loaded to its axis and requires less
space for installation and can bear larger loads, thus this spring has more
advantages compared to other springs.
Application of Disc spring
Slip clutch Overload clutches
High-pressure valve Drill bit shock absorber
Design of Helical Springs
A helical spring is a length of wire or bar wound into a helix.
There are mainly two types of helical springs :
i. Close-coiled ii open-coiled.
1. Close-coiled helical spring with ‘Axial load’

A. Circular section wire springs:


The figure below is shown a close-coiled helical spring loaded
with an axial load W.
Conti…
Conti…
•
Conti…
Deflection (δ)

Wahl’s correction factor (K):

Wahl’s correction factor considers the effect of curvature of spring


and direct shear in the design process.
Conti…
Where, K is found from experiments and is given by

Stiffness of the spring (k)


Conti…
Energy stored U:

Again energy stored


Close-coiled helical spring with ‘Axial twist’
When a twisting couple is applied to the spring parallel to the axis of
the spring wire it produces a bending effect on it.
Serious and Parallel Connections of Springs
The figure shows two springs connected in series and parallels.
Serious Connection Parallel Connection
Each spring will be subjected to When subjected to load, W, they will
load W and the total extension extend equally say by an amount δ.
produced will be the sum of The load will be shared such that,
extensions of two springs.
THE END
THANK YOU!

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