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Contentfile 1825
Contentfile 1825
i
= Stress in the inner fiber, N/mm
2
o
= Stress in the outer fiber, N/mm
2
Consider a part of the curved beam between two radial planes ab & cd subtending
an angle at the centre of curvature when the beam is subjected to bending
moment.
M as shown in fig, the plane cd rotates with respect to ab through an angle &
takes new position fg. The outer fiber are slanted due to compression and inner
fibre are elongated due to tension. Now, consider a fiber of depth dy & cross-
sectional area dA at a distance y from the neutral axis. The original length of strip
at a distance y from the neutral axis is (R
n
+ y). It is shortened by an amount yd.
Sixth semester Mechanical Design of Machine Elements -II
Jagadeesha T, Associate Professor, St Joseph Engineering College, Vamanjoor, Mangalore
The strain across cross section dA would be
Stress in the fibre is given by within elastic limit
or = E E- Youngs modulus
Sixth semester Mechanical Design of Machine Elements -II
Jagadeesha T, Associate Professor, St Joseph Engineering College, Vamanjoor, Mangalore
At the outer fiber,
o
= - MC
o
A e R
o
At inner fibre
i
= + M
b
C
i
are the required equations.
A e R
i
Show that, for a thick curved beam of circular cross-section 2 rd = ri + ro
Where rd mean reciprocal radius rd.
Problem 1. The section of a crane hook is rectangular in shape whose width is
30mm & depth is 60mm. The centre of curvature of the section is at a distance of
125mm from the inside section & the load line is 100mm from the same point. Find
the capacity of the hook if the allowable stress in tension is 75 N/mm
2
Ans : 8480 N is the capacity of hook.
Problem 2. A crane hook of trapezoidal cross-
section has an inner fiber width = 120mm, depth
= 100mm & inner radius = 120mm. Calculate
the width if stresses are numerically equal at
inner & outer fibers. Also determine the
capacity of the hook, if the permissible stress is
100MPa.
Ans : width = 28mm
Capacity of hook =
Sixth semester Mechanical Design of Machine Elements -II
Jagadeesha T, Associate Professor, St Joseph Engineering College, Vamanjoor, Mangalore
Problem 3. A crane hook shown in figure below is made of 30mm diameter steel
rod. The distance between the centroidal axis of the rod & the centre of curvature of
the hook is 50mm. Determine the load F so that the maximum stress in the rod is
not to exceed 40 N/mm
2
.
Ans : Capacity of F = 1557 N
Problem 4. . A crane hook has trapezoidal cross-section. The maximum tensile
stress occurs at point P as shown in figure. Determine i) the distance of centre of
curvature to centroidal axis. ii) B M for section AA iii) Distance from centre of
curvature to the neutral axis. iv) Area v) Maximum tensile stress ( point P) vi)
maximum stress at point Q.
Sixth semester Mechanical Design of Machine Elements -II
Jagadeesha T, Associate Professor, St Joseph Engineering College, Vamanjoor, Mangalore
Problem 5. A section of frame for a punch press is shown in figure below.
Determine the capacity of the press if the maximum tensile stresses in the frame
is not to exceed 60MPa.
Problem 6. A section of a C clamp is shown in figure. What force F can be
exerted by the screw if the max tensile stress in clamp is limited to 140 MPa.
Problem 7 A portable hydraulic inverter has a
maximum riveting force of 70 kN. The U frame
is made cast steel with an ultimate stress of
480 MPa and a yield point in tension of 240
MPa. Consider only the secion AA and
determine the following
1. Bending moment
2, Distance from centroidal axis to neutral axis
3. Direct tensile force
4, Maximum tensile force and location
5. Maximum shear stress and location
Sixth semester Mechanical Design of Machine Elements -II
Jagadeesha T, Associate Professor, St Joseph Engineering College, Vamanjoor, Mangalore
Problem 8 The C frame of a 100 KN capacity press is shown in figure. The material
of frame is grey cast iron whose ultimate tensile stress is 200 MPA and FOS =3.
Determine the maximum stress at both inner fibre and outer fibre.
Problem 9.Ring is made from a 75mm dia
bar. The inside dia of the ring is 100mm. if
the load acting on the ring is 20kN as shown
in figure. calculate the maximum shear
stress and its location.
Problem 10 : An off set bar is loaded as shown in figure.
The weight of the bar can be neglected what is the
maximum offset ( dimension x) if the allowable stress in
tension is limited to 70 MPa. Where will the maximum
tensile and shear stress occur.
Sixth semester Mechanical Design of Machine Elements -II
Jagadeesha T, Associate Professor, St Joseph Engineering College, Vamanjoor, Mangalore
Problem 11: A supporting structure for a
movable crane has dimensions shown . Find the
load P of the crane , if the maximum stress in
critical section AA is not to exceed 35 MPa.
Problem 12: same as problem 11. Take
P=10000N determine the maximum stress.
Problem 13: same as problem 11. Take circular
cross section of dia 100,mm instead of
rectangular cross section.
Problem 14: An S link of unequal radii is made from
20mm diameter and it is loaded as shown. Determine
the location and magnitude of maximum tensile and
shear stress. Mean radius of small radii is 80mm and
that of bigger loop is 100mm.
Problem 15: Figure indicates the section of a frame of a drill press, indicating the
magnitude of the force F that can be exerted if the maximum tensile stress is 80
MPa. In section XX.
Problem 16 The G-
clamp illustrated
above is made from
a steel whose
design stress is 50
MPa. It is supposed
to sustain a force, P,
of 750 N. Can it ?
80 mm
100 mm
20mm
2000 N
2000 N
Drill Press
Sixth semester Mechanical Design of Machine Elements -II
Jagadeesha T, Associate Professor, St Joseph Engineering College, Vamanjoor, Mangalore
CHAPTER 2
LEARNING OBJECTIVES
Introduction to different types of spring used
Discuss the applications of springs
To derive the expression for the shear stress and direct shear stress
To derive the expression for deflection of helical springs
To design compression and tension helical springs
To design springs for fluctuating loads
To design concentric springs
To design leaf spring and concept of equalized stress in leaf springs
Introduction
A spring is defined as an elastic body, whose function is to distort when loaded and
to recover its original shape when the load is removed. A spring is a mechanical
device which is used for efficient storage and release of energy.
Application of springs
To absorb or control energy due to either shock or vibration as in
automotives, railways, aircrafts, landing gears and vibration dampers etc.
To apply forces, as in brakes, clutches and spring loaded valves , spring
watches.
It is used to return the mechanical part to its orginal position , when it has
temporarily displaced like springs used in valves, clutches and linkages.
To control motion by maintaining control between two elements as in CAMS &
followers.
To measure forces as in spring balances and engine indicators.
To store energy as in watches, toys movie cameras.
TYPES OF SPRINGS
1.HELICAL SPRINGS
Helical springs are made of wire
coiled in the form of helix and are
primarily intended for
compressive or tensile loads. The
cross-section of wire from which
the spring is made may be
circular, square or rectangular.
The two forms of helical springs
are compression helical spring
and tension helical spring as
shown in figure.
Sixth semester Mechanical Design of Machine Elements -II
Jagadeesha T, Associate Professor, St Joseph Engineering College, Vamanjoor, Mangalore
Helical springs are said to be closely coiled, when the helix angle is very small (< 10
o
),
where as in open coil helical spring the helix angle is large
Advantages.
These springs are easy to manufacture.
They are available in wide range.
They are highly reliable.
They have constant spring rates.
Their performance can be predicted more accurately.
There characteristics can be varied by changing dimensions.
2. Conical and Volute springs
The conical and volute spring shown in the figure are used in special applications where the
spring rate increases in increase in load. Another feature of these types of springs is the
decreasing number of coils results in an increasing spring rate. This characteristic is
some times utilized in vibrations problems where springs are used to support to body that
have varying mass.
3. Torsion springs
These springs may be of helical or spiral type as
shown in figure. Helical types of springs are used
where the load tends to wind up the springs and are
used in electrical mechanisms. Spiral type is used
where the loads tends to increase the number of
coils and are used in watches and clocks.
4. Laminated or Leaf springs
.
The laminated or leaf spring (also known as flat
spring) consists of a number of flat plates (known
as leaves) of varying lengths held together by
means of clamps and bolts. These types of springs
are most used in automobiles.
5. Disc springs
These springs consists of a number of conical discs held
together by a central bolt or tube as shown in figure. These
springs are used in applications where high spring rates and
compact spring units are required
Sixth semester Mechanical Design of Machine Elements -II
Jagadeesha T, Associate Professor, St Joseph Engineering College, Vamanjoor, Mangalore
TERMS USED IN COMPRESSION SPRINGS
Solid length: When the springs are compressed until the coils come in contact with each
other, then the spring is said to be solid. The solid length of a spring is the product of total
number of coils & the diameter of the wire. Mathematically,
Solid length =
Free length
Free length of a
compression spring is the length of
the spring in the free or unloaded
condition & is equal to the solid
length plus the maximum deflection
or compression of the spring & the
clearance between the adjacent
coils.
Free length - Lf = solid length + max. Deflection + clearance between adjacent coils.
Spring index
It is defined as the ratio of the man diameter of the coil to the diameter of the wire.
Spring index = C = D/d
Spring Rate spring rate (stiffness/spring constant) is the defined as the load required per
unit deflection of the spring.
Spring Rate, K= F/ F- load, N
- Defection, mm
Pitch: Pitch of the coils is defined as the axial distance between adjacent coils in un
compressed state.
STRESS IN HELICAL SPRING AND CIRCULAR WIRE.
Sixth semester Mechanical Design of Machine Elements -II
Jagadeesha T, Associate Professor, St Joseph Engineering College, Vamanjoor, Mangalore
Consider a helical compression spring made of circular wire & subjected to an axial load F,
as shown in figure.
Let,
D = Mean diameter of the coil
d = Diameter of the spring wire,
n = number of active coils,
G = Modulus of Rigidity for the spring material,
F = Axial load on the spring,
= Max. Shear stress induced in the wire,
C = spring index = D/d
p = pitch of the coils
= deflection of the spring.
Consider a point of the spring shown in fig (b). The load F tends to rotate the wire & as a
result twisting moment (T) is developed in the wire, & thus torsional shear stress is induce
d in the wire.
Let us consider that part of spring is in equilibrium under the action of two forces F &
twisting T.
In addition to the torsional shear stress (1) induced in the wire, the following stresses also
act on the wire. Direct stress due to the load. F, & Stress due to curvature of wire
Shear stress = 8FD .K
d
3
Where K = 4C - 1 + 0.615 ; Wahl stress Conc. Factor
4C - 4 C
Sixth semester Mechanical Design of Machine Elements -II
Jagadeesha T, Associate Professor, St Joseph Engineering College, Vamanjoor, Mangalore
Deflection of helical springs of circular wire.
Let l = total active length of wire = D n
= Angular deflection of the wire due to Torque t.
Therefore, Axial deflection of the spring = D/2 ----------- (1)
Also from the Torsion equation, we have,
Therefore = 8FD
3
n = 8FC
3
n where n is the number of active coils.
Gd
4
G.d
Design Procedure for Helical Springs.
Sixth semester Mechanical Design of Machine Elements -II
Jagadeesha T, Associate Professor, St Joseph Engineering College, Vamanjoor, Mangalore
1. Diameter of the wire:
2. Mean diameter of the coil:
(a) Outer diameter of the coil:
(b) Inner diameter of the coil:
3. Number of coils:
4. Free length
5. Stiffness or Spring Rate
6. Pitch:
PROBLEMS
(1) Design a helical compression spring to support an axial load of N. The deflection under
load is limited to 60 mm. The spring index is 6. The spring is made of chrome-vanadium
steel & FOS = 2.
Spring specifications
(i) Wire diameter
(ii) Mean diameter
(iii) Free length
(iv) Total no of coils
(v) Style of ends = squared & ground
(vi) Pitch - p
(vii)Spring rate
(viii)Material Chrome- vanadium
(2) Design a helical compression spring for a max. load of 1000N for a deflection of 25mm
using the spring index as 5. the max permissible shear stress for spring wire is 420 N/mm
2
&
G = 8410
3
N/mm
2
Sixth semester Mechanical Design of Machine Elements -II
Jagadeesha T, Associate Professor, St Joseph Engineering College, Vamanjoor, Mangalore
(
3) A railway carriage weighing 40KN & moving at 8km/hr is to be brought to rest by 2 buffer
springs. The compression between the coils must be twice the wire diameter. Assume spring
index as 8. And allowable shear stress for the spring material = 450N/mm. Take G = 0.8 * 10
N/mm. Design the spring?
(
4) A railway carriage weighing 20KN & moving at 2.5 km/hr is to be brought to rest by buffer
springs. Find how many springs each of 15 coils will be required to store the energy of
motion during a compression of 150mm. The available size of wire is 20mm. The mean
radius of coil is 100mm.
(
5) A bumper spring consists of 2 helical steel springs of square cross section brings to rest a
railway carriage weighing 50KN & moving at 1.5 km/hr. In doing so the springs are
compressed by 200mm. The mean diameter of coil is 6 times the side of square section.
Design the spring if the permissible shear stress is 345 MPa and Modulus of rigidity is 78
MPa.
6) A loaded narrow cart weighing 7.5 kN and moving with a velocity of 1m/second is brought
to rest by a bumper consisting of 2 helical steel springs of square section. The mean coil
diameter of spring is 6 times the side of square . the spring are compressed by 150mm.
While bringing the car to rest. The permissible shear stress in spring is not to exceed 400
MPa. Find the following
Mean load on each spring
Side of square section of wire
Mean dia of coil
No of active coils, take G = 82 Gpa.
7) A load of 2KN is dropped axially on a helical spring from a height of 250mm. the spring
has 20 turns, & it is made of 25mm diameter wire. The spring index is 8. Find the max.
Shear stress induced in the spring 7 the amount of compression produced. Take G =
82.7GN/mm
8) Design a helical spring for a spring loaded safety valve for the following conditions:
(i) Diameter of the valve = 65mm
(ii)Operating pressure = 0.7N/mm2
(iii) Max. Pressure on the valve = 0.75N/mm2
(iv) Max. lift of the valve when pressure = 3.5mm rises from 0.7 to 0.75 N/mm2
(v) Max. Allowable stress = 550MPa
(vi) Spring index = 6
9) The valve spring of an I.C Engine is 40mm long, when the valve is open & 48mm long
when the valve is closed . The spring loads are 250N when the valve is closed & 400n when
the valve is open. The inside diameter of the spring is not to be less than 25mm & take FOS
Sixth semester Mechanical Design of Machine Elements -II
Jagadeesha T, Associate Professor, St Joseph Engineering College, Vamanjoor, Mangalore
= 2. Assume spring index to be 6 &G = 79.34103MPa & yield shear stress = 690N/mm2.
Design the spring
Assignment Questions
(1) A helical spring made from 6.3mm diameter steel wire has an outside diameter of
57.3mm with squared & ground ends and has 12 coils. The allowable shear stress is
827MPa. Determine the following
(i) Spring rate
(ii) Free length
(iii) Pitch
(2) The following data refers to the valve of a petrol engine
Length of the spring when the valve is open 40mm
Length of the spring when the valve is closed 48mm
Spring load when the valve is closed 350N
Spring load when the valve is open 220N
Spring index 6.8
(3) The maximum shear stress allowed is 150MPa & the modulus of rigidity is 84GPa. The
ends are squared & ground and the gap between the adjacent coils is 0.1 times the wire
diameter. Determine the following
(i) Wire dia
(ii)Mean dia
(iii) Number of coils
(iv) Free length
(v) Pitch
Design of springs for fluctuating loads
Force acting on the spring in many applications varies in magnitude in time. Let us consider
a spring subjected to fluctuating force as shown in the figure. The load varies from F
max
to
F
min
The mean force =
F
min
F
max
TIME
Force
Sixth semester Mechanical Design of Machine Elements -II
Jagadeesha T, Associate Professor, St Joseph Engineering College, Vamanjoor, Mangalore
A helical compression spring is subjected to purely compressive forces. In general, the
spring wires are subjected to pulsating shear stresses. Let S
en
be the endurance limit in
shear. For cold drawn steel wires S
en
= 0.21x
en
and
u y
42 . 0 =
For oil hardened
tempered steel wires S
en
= 0.22x
en
and
u y
45 . 0 =
where
en
is the ultimate tensile
strength is shown below:
The mean stress
m
is plotted on the abscissa while the stress amplitude
a
on the ordinate.
Point A will co-ordinate (
2
S
,
2
S
en en
) indicate the failure point of spring wire in a pulsating
stress cycle fatigue test. Point B indicates failure under static conditions i.e. when the stress
reaches the torsional yield strength
y
. The line AB is called the line of failure. To consider
the effect of FOS a line of CD is drawn from point B in such a way that
N
y
Hz
Problem A disc cam 250mm diameter rotates off centre with eccentricity of 20 mm and
operates the roller follower that is carried by the arm as shown in the figure. The follower is
held against the cam by means of an extension spring. Assuming that the force between the
follower and the cam is 300 N at the lowest position and 500 N at the highest position of
follower. The spring index is 6. determine the wire diameter, outside diameter of spring and
no. of active coils. The maximum shear stress may be taken as 250 MPa and Modulus of
rigidity 82.7 Gpa.
Sixth semester Mechanical Design of Machine Elements -II
Jagadeesha T, Associate Professor, St Joseph Engineering College, Vamanjoor, Mangalore
Problem A helical coil spring made from 6.3 diameter steel wire has an outside diameter of
57.3mm with square and ground ends has 12 coils. The length of the spring is such what
when it is compressed the torsional stress is 827 MPa. Determine the spring rate , Free
length , critical frequency . The density of material is 7800 kg/m
3
and G = 0.8x10
5
MPa.
Concentric springs
Concentric springs are closed coil helical springs
forced one inside the other. They are used to
obtain greater load carrying capacity or to obtain
certain load deflection characteristics. Figure
shows two springs placed one inside the other.
When springs are nested , the mechanism
contnues even if one of the springs break. The
conditions to be satisfied by the concentric spring
as follows.
1. when the springs are of equal free length
and made of same material, then
maximum shear stress in the springs are
equal.
2. The deflection is same for both the spring
Sixth semester Mechanical Design of Machine Elements -II
Jagadeesha T, Associate Professor, St Joseph Engineering College, Vamanjoor, Mangalore
2
2
1
2
1
d
d
F
F