A

DISSERTATION REPORT ON

“ANALYTICAL AND EXPERIMENTAL STUDY OF CONICAL

COMPRESSION SPRINGS WITH DIFFERENT MEAN COIL
DIAMETER”

Submitted in partial fulfillment of the requirement

for the degree of

MASTER OF TECHNOLOGY
(MECHANICAL-DESIGN ENGINEERING)

Submitted by
MR. NITIN RAMCHANDRA SALUNKHE
(PRN No.: 2016MTEMEDE016)

Under the guidance of

Prof. V. P. SUTAR
Department of Mechanical Engineering

WALCHAND COLLEGE OF ENGINEERING, SANGLI

(An Autonomous Institute)
2017-2018

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 DECLARATION

I hereby declare that the dissertation report entitled “Analytical and Experimental Study of
Conical Compression Springs with Different Mean Coil Diameter” submitted by me to
Walchand College of Engineering, Sangli as a partial fulfillment for the degree of Master of
Technology in Mechanical- Design Engineering under the guidance of Prof. V. P. Sutar . I
further declare that the work reported in this project has not been submitted and will not be
submitted, either in part or in full, for the award of any other Degree/Diploma in this institute
or any other institute or university.

Date: NITIN RAMCHANDRA SALUNKHE

Place: Sangli. (2016MTEMEDE016)

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 CERTIFICATE

This is to certify that the dissertation work entitled “Analytical and Experimental Study of
Conical Compression Springs with Different Mean Coil Diameter” submitted by “Mr.
Nitin Ramchandra Salunkhe (PRN No.:2016MTEMEDE016)” in partial fulfillment of the
requirement for the degree of “Master of Technology (Mechanical – Design Engineering)”
is a record of his own work carried out under my supervision during the year 2017-18.

Date: Prof. V. P. Sutar

(Guide)

The candidate has completed all the required phases of evaluation and performed
satisfactorily. Hence, recommended for the partial fulfillment of the requirement for the said
degree.

Head
Mechanical Engg. Department Chairman Internal Examiner

External Examiner Dean Academics

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 ACKNOWLEDGEMENT

I would like to express my gratitude towards my project guide Prof. V. P. Sutar for his
guidance during my project work, and to the college, especially to the Mechanical
Engineering Department for making all the facilities available to me. I am deeply thankful to
him for giving me a definite direction and moral support, without which this dissertation work
would not have been completed. His valuable suggestions and co-operative nature during the
course of present investigation would remain encouraging throughout my life.

I am also thankful to Head of Department Prof. Dr. U. A. Dabade for valuable support in all
aspects for completion of my thesis.

I extent my sincere thanks to other faculty members and non-teaching staff of Mechanical
Engineering Department for their valuable advice in every stage of this project. Finally, last
but not the least my friends for their moral support, without which I would not have
succeeded in finishing my project work.

NITIN RAMCHANDRA SALUNKHE

(2016MTEMEDE016)

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 ABSTRACT
Mechanical springs are the resilient member capable of providing large elastic deformation. A
spring is basically defined as an elastic body whose function is to distort when loaded and to
recover its original shape when the load is removed. Mechanical springs are of various types
such as helical spring, leaf spring, torsion spring etc. Helical springs are the mostly used
vibration isolation for body. Conical compression springs are the helical springs having small
taper angle provided for better characteristics than that for cylindrical helical springs.

The thesis work consists of analytical and experimental study of conical compression spring
with respect to its stiffness non-linearity, transmissibility, isolation properties and shear stress
analysis on the inner side of spring.

Cylindrical or straight helical compression springs have linear load-deflection behavior and
that for conical compression springs are showing cubical nonlinearity. This effectively shows
better isolation properties than cylindrical helical springs. Maximum shear stress for helical
springs occurs at the inner side. It was calculated theoretically and by using plane rosette
gauge experimentally strain at inner side of conical compression springs is determined.

Keywords: Conical Compression Spring, Nonlinear Stiffness, Shear Stress Analysis of

Conical Spring Transmissibility, Vibration Isolation

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 Title Page i
Declaration ii
Certificate iii
Acknowledgement iv
Abstract v
Contents vi
List of Figures vii
List of Tables x
CONTENTS

Chapter Page
Title
No. No.
1. INTRODUCTION 1-7

1.1 Mechanical Springs 1

1.2 Relevance 2

1.3 Objectives of the Project 3

1.4 Proposed Work 3

1.5 Available Facilities 3

1.6 Nomenclature of Conical Compression Spring 5

2 LITERATURE REVIEW 6-7

STATIC ANALYSIS OF CONICAL COMPRESSION

3 8-19
SPRING

3.1 Linear Cylindrical Spring 8

3.2 Linear Conical Spring 10
3.3 Nonlinear conical spring 10
3.3.1 Linear Region 11
3.3.2 Nonlinear Region 11
3.4 Experimental Verification 12
3.4.1 Static Analysis on UTM 13
3.5 Static Analysis by Analytical Method 14
Plots of Load v/s Deflection Curve Obtained by
3.6 15
Experimentally and Analytically

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4 MOTION TRANSMISSIBILITY 20-27

4.1 Transmissibility 20
4.2 Vibration Isolation 22
4.3 Experimental Transmissibility Curve 24
5 STIFFNESS MODELLING 28-33
6 STRESS ANALYSIS 34-46
6.1 Shear Stress in Helical Compression Spring 34
Stress Measurement of A Conical Coil Spring under Static
6.2 45
Load using Strain Rosette Gauge
6.2.1 Structure of Strain Gauges 38
6.2.2 Principal of Strain measurement with strain gauges 39
Gauge Selection Based on Measuring Object Material and
6.2.3 40
Measurement Environment
6.3 Experimental Setup Arrangement 41
6.3.1 Wheatstone Bridge Circuit 42
6.3.2 Calculations for 3 Element Rosette Analysis 42
6.3.3 Experimental Methodology 43
6.4 Observation Table 45
6.5 Results Table 46
7 CONCLUSION 47
REFRENCES

PUBLICATIONS
WORK PLAN

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 LIST OF FIGURES

Fig.No. Name of Figure Page No.

1.1 Spring As Shock Absorber 1

1.2 Shooting Pistol 2
1.3 Railway Wagon 2
1.4 Photograph Of Conical Compression Spring 5
3.1 Spring Coil Behaves Essentially As A Straight Bar In Pure 10
Torsion
3.2 Load-Deflection Characteristics of Conical Spring 9
3.3 Linear Behavior n Free Coils 11
3.4 Spring Testing On UTM 13
3.5 Load–Deflection Graph Of Spring 1 13
3.6 Load–Deflection Graph Of Spring 2 15
3.7 Load–Deflection Graph Of Spring 3 16
3.8 Load–Deflection Graph Of Spring 4 16
3.9 Load–Deflection Graph Of Spring 5 17
3.10 Load–Deflection Graph Of Spring 6 17
3.11 Load–Deflection Graph Of Spring 7 18
4.1 Schematic Of Mass-Spring-Damper System 20
4.2 Vibration Isolation Systems 23
4.3 Theoretical Transmissibility Curve 23
4.4 Photograph of Motion Transmissibility Measuring Test Setup 24
4.5 Experimental Transmissibility Curve 27
4.6 Theoretical Transmissibility Curve Plotted on MATLAB 27
5.1 Load-Deflection Curve For Hardening 28
5.2 Load-Deflection Curve For Softening 29
6.1 Stresses In Spring Wire (A) Pure Torsional Stress (B) Direct 34
Shear Stress (C) Combined Torsional , Direct & Curvature
Shear Stress
6.2 Structure of Strain Gauge 38
6.3 Photograph Showing 3 Element Strain Rosette Gauge 41
6.4 Block Diagram of Measuring Setup 41

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6.5 Wheatstone Bridge Circuit 42
6.6 3 Element Plane Grid 0-45-90 Rosette Strain Gauge 42
6.7 Rosette Gauge Attached on Inner Side Of Spring 44
6.8 Photograph Showing Testing Arrangement 44
6.9 Circuit Board Having 3 Wheatstone Bridge 45

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 LIST OF TABLES

Sr.No. Name of Table Page No.

3.1 Conical Compression Spring Dimensional Characteristics 13

3.2 Stiffness For Various Springs 18
4.1 Calculations And Readings On Transmissibility Test-Rig. 26
6.1 Theoretical Max. Shear Stress For Cylindrical Helical Spring 36
6.2 Theoretical Max. Shear Stress For Conical Helical Spring 37
6.3 Strain Gauge Element Combination 39
6.4 Strain Gauge Selection Based On Material Of Test Specimen 40
6.5 Strain Gauge Selection Based On Resistance 40
6.6 Experimental Strain Readings On Coil 43
6.7 Principal Strain, Shear Strain (Micro Strain) And Maximum Shear 45
Stress Values
6.8 Analytical Max. Shear Stress And Experimental Max. Shear Stress 46
Values