Design of Helical compression spring in Bike

CHAPTER 1
INTRODUCTION
The automobile frame and body are mounted on the front and rear axis not directly through the
spring and shock absorber.Spring gives a relatively large elastic deflection. It is made from round
wire and wrapped in cylinder from a fixed pitch.

Spring are elastic body that can be twisted pulled by some force that can return to their riginal
shape when the force is released. It is a spiral wound wire with constact coil diameter. In helical
spring the gap between successive coils are larger.

A helical compression spring is a common machine component that is used to exert a specific
force at a specified height. Helical compression spring design decisions are driven by maximum
torsional stress, fatigue life, natural frequency.

Compression springs are the most common type of spring used in the engineering industry. They
are open coiled springs which are relatively easy to design and manufacture.

Compression springs can be made from round or square wire, although round is considerably
cheaper and easier to manufacture. We keep a vast selection of material sizes and types in stock,
from standard spring steels to nickel alloys, all of which can be used to manufacture compression
spring.

Control of motion in machines &„ Reduction of transmitted forces as a result of Reduction of

transmitted forces as a result of impact or shock loading „

The most common compression spring, the straight metal coil spring, has the same diameter for
the entire length. Other configuration options for compression coil springs include hourglass
(concave), conical and barrel (convex) types. The straight coil spring configuration is the
standard coil type for Compression Springs.

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Design of Helical compression spring in Bike

CHAPTER 2
DESIGN CALCULATIONS
1.Assumed dimensions:
1.1 Absorb energy (U) =120N-M

1.2 Spring index (C) =8

2.Loads:
Maximum force (F) =3000N
3. Material:
Steel wire ASTM – A229-41(Modulus of rigidity(G)=79Gpa, Shear stress(τ)
=0.55Gpa, Young’s modulus (E)=210Gpa, Density=7900).
Reason: Steel wire that provides high tensile strength coupled with good to superior
corrosion resistance.
4. Design of Helical compression spring:

A: Deflection
U=1/2FY

120×e3=1/2×3000×Y

Y=800mm (maximum deflection)

B: Diameter of wire
Shear stress (τ) = 8FDK/πd*3

Stress factor (k) = 4C-1/4C-4+0.615/C

= 4×8-1/4×8-4+0.615/8

=1.184

Spring index(C) =D/d

D=cd
D=8d

275=8×3000×8d×1.184/πd*3

d=17mm

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Design of Helical compression spring in Bike

C : Diameter of coil
Mean dia = 8d = 8×17 = 136mm

Outer dia = D+d = 136+17 = 153mm

D:Number of active turns

Y=8FD*3i/d*4G

80=8×3000×136*3×i/17*4×7900

i=9

E:Total no of coils
i’ = i+n = 9+2 = 11 (assume n=2 for sqare and round end)

F :total length of wire

L=πDi=π×136×11=4500.32mm

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Design of Helical compression spring in Bike

CHAPTER 3
2 D DRAWINGS

Figure -3.1 ISOMETRIC VIEW Figure-3.2 FRONT VIEW

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Design of Helical compression spring in Bike

CHAPTER 4
3 D MODELLING

Figure 4.1 HELICAL COMPRESSION SPRING IN BIKE

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Design of Helical compression spring in Bike

CHAPTER 5
RESULTS AND DISCUSSION
Deflection of compresssion spring : y =800mm

Diameter of wire:D = 17mm

Number of active turns: i = 9

Total no of coils: i’=11

Total length of wire l = 4500.32mm

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Design of Helical compression spring in Bike

CHAPTER 6
CONCLUSION
Helical compression springs in shock absorber is to resist shock obtained from the bumping of
road . Spring produces a large deflection.Most springs are made up of steel.The deflection in the
spring decreases with reduction in stress when change in certain parameter.The number of turns
affect the deflection and stress adversly. As the number of turns increases the deflection
decreases and stress also decreases.

If helical spring is to be used in corrosive environments, then corrosive prevention methods like
colour coatings, use of grease on the coil surface etc. are to be adhered to. In order that a helical
spring functions well during its intended service life, fatigue failure is to be avoided as far as
possible. This goal can be fulfilled to a great extend by carefully avoiding the above mentioned
factors that lead to fatigue failure of a helical compression spring.

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Design of Helical compression spring in Bike

REFERENCES
1.William H Crouse / Donald L Anglin” Automotive Mechanics”McGraw Hill
th
Education,10 edition.

2.R.S.Kurmi and J.k Gupta “Machine Design” 7th edition.

3.RajendraKarwa“MachineDesign”9thedition.

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Design of Helical compression spring in Bike

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