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MINISTRY OF DEFENCE
ON
ISSUED BY
DIRECTORATE OF STANDARDISATION
DEPARTMENT OF DEFENCE PRODUCTION
MINISTRY OF DEFENCE
‘H’-BLOCK, NIRMAN BHAWAN P.O,
NEW DELHI – 110 011
GOVERNMENT OF INDIA
MINISTRY OF DEFENCE
ON
ISSUED BY
DIRECTORATE OF STANDARDISATION
DEPARTMENT OF DEFENCE PRODUCTION
MINISTRY OF DEFENCE
‘H’-BLOCK, NIRMAN BHAWAN P.O,
NEW DELHI – 110 011
MEMBERS ASSOCIATED WITH THE FORMULATIOM OF THIS DOCUMENT
1. This Joint Services Specification has been approved by Shri. K. Tamilmani, Chief
Executive, Centre for Military Airworthiness and Certification (CEMILAC), and Chairman,
Aeronautical Stores Standardisation Sub Committee in the Sub Committee meeting held on
26 Aug 2010.
2. The following members have been associated in preparation of this Joint Services
Specification: -
(2) Dr. V. Arun Kumar, Sc, ‘G’ & Jt. Head Propulsion Div, NAL, Bangalore
(3) Shri G Gouda, Sc, ‘G’ & Regional Director RCMA (Engines), CEMILAC,
Bangalore
0. FOREWORD
1. SCOPE
2. RELATED DOCUMENTS
3. TERMINOLOGY / DESCRIPTION
4. MATERIAL
5. SPECIFICATIONS / DIMENSIONS
6. TOLERANCES
8. MARKING
9. INSPECTION
10. VALIDATION
0.1 This specification has been prepared by the Aeronautical Stores Standardisation Sub
Committee (Aero SSSC) on the authority of the Standardisation Committee, Ministry of
Defence.
0.2 This specification is approved by the Ministry of Defence and is mandatory for use by
Defence Services.
0.3 This JSS would be used for manufacture, quality assurance inspection and
procurement of the item.
0.4 The Quality Assurance Authority for the item covered by this JSS is Director General
of Aeronautical Quality Assurance (DGAQA), ‘H’ Block, Nirman Bhawan P.O., New Delhi–
110 011. Enquiries regarding this specification relating to any contractual conditions shall be
addressed to the Quality Assurance Authority named in the tender or contract. Other
enquiries shall be referred to: -
The Director,
Directorate of Standardisation,
Ministry of Defence,
‘H’ Block, Nirman Bhawan P.O,
New Delhi – 110 011.
0.5 Guidelines given in the following paragraphs are to present Helical Compression
Spring to assist the designers, Quality Assurance Authority and procurement agencies in
selecting helical compression spring. Different aspects of helical compression spring such as
terminology / descriptions, material, specifications / dimensions, tolerance, workmanship and
finish, marking, inspection, validation tests have been provided in this document. An attempt
has also been made to provide technical details related to construction / manufacture and
design considerations for helical compression springs.
0.8 This specification holds good only for the supply order for which it is issued.
0.9 Directorate of Standardisation Website. All the approved JSS/JSGs are available
on the Directorate of Standardisation Website www.defstand.gov.in. Defence Organisation
desirous of producing a copy of this document are requested to approach Director,
Directorate of Standardisation for obtaining user id/password to access the website.
1. SCOPE
1.1 This JSS gives the methodology to select a suitable Helical Compression Spring as
per the requirement. It consists of related documents/ standards, terminology / description,
material, specification / dimensions, tolerance, workmanship and finish, marking, inspection,
validation tests, etc.
2. RELATED DOCUMENTS
(e) “Manual on Design and Application of Helical and Spiral Springs”, SAE,
1997.
(f) IS: 7906 (Part I): 1997: Design and Calculations for springs made from
circular section wire and bar.
2.3 Copies of the American Society for Testing Material and Miscellaneous References
can be obtained on payment from: -
3. TERMINOLOGY / DESCRIPTION.
Wire Diameter, d Outer Diameter, Do
Inner Diameter, Di
Mean Diameter, Dm
Fig. 1
Pitch,m
Free Length, Lo
3.1 For the purpose of this specification the following definitions and abbreviations have
been used:
(a) Spring: Mechanical device designed to store energy when deflected and to
return the equivalent amount of energy when released.
(c) Helical Compression Spring: It is an open coil helical spring that offers
resistance to a compressive force applied axially. In general they are made from wire
of circular, square, or rectangular cross section.
(d) Load (P): The force exerted upon or by a spring in order to achieve the desired
movement in a mechanical component or to maintain force system in equilibrium.
The load can be static or dynamic in nature.
(e) Deflection per Coil ( ): The total deflection of the spring is divided by the
number of active coils.
(f) Active Coils: The number of coils that are considered for supporting the loads.
This does not include the ground flat three-quarters of the coil at each end.
(g) Total Coils: It is the number of active coils plus the part of coils forming the
ends, which are ground flat.
(h) Free Length (Lo): The overall length of a compression spring in the unloaded
position (Fig. 1).
(j) Solid Length (Lc): The overall length of a compression spring when all coils
are completely compressed and are in contact.
(k) Total Deflection: It is the movement of a spring from free position to its
maximum operating position.
(l) Outside Diameter (Do):It is the maximum diameter of the spring coil (Fig. 1).
(m) Inside Diameter (Di):It is the minimum diameter of the spring coil (Fig. 1).
(n) Mean / Pitch Diameter (Dm):It is the average diameter of the spring coil (Fig.
1).
(o) Pitch (m): The distance between centers of adjacent active coils of a spring in
the unloaded position (Fig. 1).
(p) Spring index (w): The ratio of the mean spring diameter to the diameter of the
wire (spring index = Dm/d, Fig. 1).
(q) Spring Stiffness / rate (k): The load required to deflect a compression spring
by one unit length. It is also referred to as “Spring constant”, “Gradient” or
“Load factor”.
(r) Spring Tolerances: The allowable variations are from a given dimension.
(s) Load Margin Factor: The ratio of the applied load to the load required to
compress the spring to its solid length.
(t) Direction of Helix: The direction of helix is right hand when the coil recedes
in a clockwise direction as viewed from one side and left hand when it recedes
in a counterclockwise direction.
(u) Stress Relief: Removal of residual stresses caused during the forming
operation by applying a low-temperature heat treatment.
4. MATERIAL
4.1 There is a wide range of spring materials available. The selection of material for a
particular application can be made based on the distinctive characteristics of the materials
such as corrosion resistance, high temperature operation, good electrical properties, fatigue
etc. A few of the mostly used spring materials are mentioned in Appendix A.
5. SPECIFICATIONS / DIMENSIONS
5.1 The following are the guidelines for specifying the dimensional and load data on
engineering drawings, which satisfy specific design requirements:
(a) No Load Specified: Load capacity of the spring is not specified. However, the
free length, coil diameter and the total number of coils are specified with the
tolerance. The manufacturer is required to furnish a spring, meeting these
dimensional data. It is designer’s responsibility to satisfy the required load capacity
of the spring.
(b) One Load Specified: This is applicable where the spring is required to
develop a particular load within a specified tolerance. The manufacturer is required to
meet the load requirement, the free length and the total number of coils is not
restricted. This type of spring is generally used where the spring develops the
specified load in initial assembly and is not subjected to further deflection.
(c) Two Loads Specified: This is applicable where the spring is required to
develop a particular load, within a specified tolerance at each of two different
compressed lengths. The manufacturer is required to meet the load requirements, the
free length and the total number of coils is not restricted.
(d) Spring Stiffness/ Rate Specified: This type of specification is applied where the
spring rate is the most significant characteristic, for example in calibrated scales. The
manufacturer is required to meet the prescribed spring rate but the free length and the
total number of coils are permitted to vary.
(e) Coil Diameter: In this type of springs it is required to specify any one of the
following dimensions with tolerance value such as, inner diameter, outer diameter.
(f) Direction of Helix: Specify the direction of helix as “LEFT HAND” (LH), or
“RIGHT HAND” (RH) as applicable otherwise specify as “OPTIONAL”.
(g) Types of Ends:
(i) Plain Ends (Open ends not Ground): This type of ends results in largest
eccentricity of loading and is used only when accuracy of loads is not
important (Fig 2.a).
(ii) Squared Ends (Closed ends not Ground): In this case, load eccentricity is
less. It is used on light wire spring and heavier wire where the spring index
exceeds 13 (Fig 2.b).
(iii) Plain Ends Ground (Open Ends Ground): Have High eccentricity of
loading and tangle during shipping. They are sometimes used where the solid
height is very limited and it is necessary to have as many active coils as
possible in the least space (Fig 2.c).
(iv) Squared and Ground (Closed Ends Ground): It provides a level seat and
reduces the tendency to buckle (Fig 2.d).
6. TOLERANCES
6.1.1 Load and spring rate tolerances for cold-wound helical compression springs are listed
in Table 4. The spring rate is taken as the average load increase per unit length of deflection
between 20 to 60 percent of the total deflection of the spring without exceeding the elastic
limit.
6.2.2 Other tolerances for hot-wound compression springs as given by the SAE spring
committee are as follow:
6.2.3 These height tolerances are limited to springs with free height not over 36 in.,
not over six times free to solid deflection, and not less than 0.8 times outside diameter.
7.1 The surface of the spring should be in quenched and tempered form. It should be
free from defects.
8. MARKING
8.1.1 It shall be stamped on springs with wire diameter of 15 mm and above in such a way
that it should not affect the life and functioning of the spring.
9. INSPECTION
(x) Cracks: Springs manufactured from wire less than 0.064" / 1.625 mm
in diameter shall receive a close visual examination using X 5
magnification. All springs manufactured from the wire over 0.064" /
1.625 mm in diameter shall undergo a crack test to the relevant NDT.
(xi) Squareness: For the springs which ends are ground shall be measured
by keeping the spring on a surface plate against a square and measuring
the largest deviation from the top end coil and the square by using feeler
gauges.
(xiii) Bow: When a spring is placed horizontally over a surface plate, and
the maximum deviation measured using feeler gauges between the surface
plate and any coil is the measure of bow.
10. VALIDATION
(a) Load Deflection Test: The spring (where the Rate is important) response for
through out its working length on application of load shall have the linear
characteristics. A graph shall be drawn between load and deflection for minimum of
4 points and shall show the linear curve.
(b) Fatigue (Endurance) Test: The spring shall be subjected to 106 cycles of
loading and unloading between the working compressions lengths and shall not show
any evidence of failure.
10.2.1 Functional test shall be carried out on the spring for the performance of the end
application.
11.1 The items bears a Defence Store Catalogue Number as given below :- DS Cat Part
No. 5360-041 905.
12.1 Any suggestions for improvement in this document may be forwarded to:
The Director,
Directorate of Standardisation,
Ministry of Defence,
‘H’ Block, Nirman Bhawan P.O,
New Delhi – 110 011
Appendix – ‘A’
(a) Monel
(b) K-Monel
(c) Inconel
(d) Inconel X
Springs can be made by cold or hot forming processes. In general, the light
duty springs (approximately wire diameter up to 12 mm) are manufactured by cold drawn
process. General information on a few operations is mentioned below.
(b) Scragging: After the coiling, the spring shall be compressed 4-5 times to its
solid length.
(c) Stress Relieving: Cold formed spring coils should normally be heat-treated for
the purpose of stress relief and enhancing the elastic limit. Springs that are made
from pre-hardened wire such as Music wire, Oil tempered, hard drawn, corrosion
resisting are stress relieved by heating at low temperatures from 200 to 3500 C to
reduce the residual stresses that are formed during coiling operation. For springs
made of annealed wire are hardened and tempered in a manner similar to tool steel.
(d) Cold Set To Solid: This process is to stabilize the free length of a compression
spring, so that subsequent accidental, compression to solid height will not change the
loads at working deflections.
(e) Grinding: End coils are ground in order to make the spring stand upright,
obtain a good seat against a contacting part, reduce buckling, exert more uniform
pressure against the mating part. The end coil grinding can be achieved in a disc-feed
or paddle-feed machine where accuracy of the process should be ensured.
(f) Shot Peening: The fatigue life of springs can be improved by shot peening
process in which the springs are tumbled in an enclosure and also exposed to the shot
projected at high velocity. This process is applied to all highly stressed springs made
from steel and non-ferrous materials. Shot peening will increase the spring life at
least 30 %. All heat-treating and stress relieving processes should be done before shot
peening, except where electroplating is required.
(g) Surface Finishing: The surface finishing can be applied to the springs after it
is heat treated at low temperature and stress relieved. The surface finishing process
includes deburring, polishing, scouring, burnishing, electroplating, etc.
Appendix-‘C’
(c) Buckling: - It is the tendency for a spring to fly our sidewise due to buckle
when they are made too long. So it is necessary to choose the spring proportions in
such a way the working load will always less than critical buckling load or if it is not
practical, guides must be provided to prevent sidewise motion.
Buckling spring deflection,
G 2
0 .5 E π .Dm
δ k = L0 . . 1− 1− .
G 0 . 5 + G ν .L0
1− E
E
Where δ k is the buckling spring deflection, Lo is the free length, G is the
modulus of rigidity, E is the elastic modulus, ν is the seating coefficient
(d) Diameter Change:- For a compression spring, the coil diameter increases
slightly when it is compressed.
m 2 − 0.8m.d − 0.2d 2
∆De = 0.1
D
Where ∆De is the increase in coil diameter,
L −d
m, pitch = 0 for springs with ends closed machined flat and ground
n
L − 2.5.d
= 0 For springs with ungrounded ends
n
d is the wire diameter of the spring
(f) Impact: In some cases, spring may be exposed to impact loads, which results
in excessive stress in the spring. The increase in shear stress due to impact with a
velocity v may be written as,
2.ρ .G
∆τ = v. .
g