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IS 7906-7 (1989): Helical compression springs, Part 7:

Quality requirements for cylindrical coil compression
springs used mainly as vehicle suspension springs [TED 21:
Spring]

“!ान $ एक न' भारत का +नम-ण”

Satyanarayan Gangaram Pitroda
“Invent a New India Using Knowledge”

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है”
ह
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“Knowledge is such a treasure which cannot be stolen”
 IS 7906 ( Part 7 ) : 1989

( Reaffirmed 2004 )
Indian Standard
HELICAL COMPRESSION SPRINGS
PART 7 QUALITY REQUIREMENTS FOR CYLINDRICAL COIL COMPRESSION
SPRINGS USED MAINLY AS VEHICLE SUSPENSION SPRINGS

( Second Reprint NOVEMBER 1996 )

UDC 621-272.272:669.14-422.11:629.11.012.852

0 BIS 1990
BUREAU OF INDIAN STANDARDS
MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002

Junuury 1990 Price Group 3

Springs Sectional Committee, EDC 75

FOREWORD

This Indian Standard ( Part 7 ) was adopted by the Bureau of Indian Standards on 10 February
1989, after the draft finalized by the Sprin-gs Sectional Committee had been approved by the
Mechanical Engineering Division Council.

Vehicle suspension springs are generally produced, in large-scale manufacture, on largely automatic
production lines. The production tolerances thus obtained are generally closer than to that given
in IS 7906 ( Part 5 > : 1989.

They are subjected to statistical relationships which, according to lengthy examination? allow
prior calculations to be made. This standard is intended to enable the permissible deviations to
be established, of functionally important characteristics in the design of vehicle suspension
springs.

This standard is one of a series of standards on helical coiled compression springs. The other
standards in the series are as follows:

IS 7906 ( Part 1 ) : 1976 Helical compression springs: Part 1 Design and calculations for
springs made from circular section wire and bar

IS 7906 ( Part 2 ) : 1975 Helical compression springs: Part 2 Specification for cold coiled
springs made from circular section wire and bar

IS 7906 ( Part 3 ) : 1975 Helical compression springs: Part 3 Data sheet for specifications for
springs made from circular section wire and bar

IS 7906 ( Part 4 > : 1987 Helical compression springs: Part 4 Guide for selection of standard
cold coiled springs made from circular section wire and bar

IS 7906 ( Part 5 ) : 1989 Helical compression springs: Part 5 Specification for hot coiled
springs made from circular section bar (first revision )

IS 7906 ( Part 6 ) : 1978 Helical compression springs: Part 6 Design and calculation for
springs made from rectangular section bar steel

IS 7906 ( Part S ) : 1989 Helical compression springs: Part 8 Method of inspection of hot
coiled compression spr’ings made from circular section bars

In the preparation of this standard considerable assistance has been derived form DIN 2096
Part 2-1979 ‘Cylindrical coil compression springs made from round rods - Quality requirements
for mass production’, issued by the Deutsches Institut fiir Normung (DIN >.
 IS 7906( Part 7 ) : 1989

Indian Standard
HELICAL COMPRESSION SPRINGS
PART 7 QUALITY REQUIREMENTS FOR CYLINDRICAL COIL COMPRESSION
SPRINGS USED MAINLY AS VEHICLE SUSPENSION SPRINGS

1 SCOPE c) Bar diameter ( d) from 9 to 18 mm.

1.1 This standard ( Part 7 ) lays down permissi-
ble deviation of spring parameters of hot coiled
cylindrical compression springs made from
round bar steel and produced on large scale.
1.2 This standard is applicable to springs meet-
ing with the following conditions:
a) Large-scale production, mini~mum lot size
5 000 pieces.
b) Barr length (I) up to 4 300 mm.
d) Length of unloaded spring ( free length )
( Lo ) up to 600 mm
e) External coil diameter ( De ) up to 180 mm.
f) Number of active coils ( n ) from 5 to 12.
g) Total spring deflection ( sc ) 180 mm and
more.
h) Spring index ( FV) from 6 to 12.
2 TERMINOLOGY
The following symbols and units shall apply:

Symbol D_kignation Unit

A, Permissible deviation of coil diameter mm
AF Permissible deviation of the spring force F N
at specified spring length L
At Permissible deviation of the spring rate R N/mm
A nt Permissible deviation of the total number
nt of coils
D,De -ID{
Mean coil diameter mm
2
D, External coil diameter mm
Di Internal coil diameter mm
F Spring force N
F e the0 Theoretical spring force associated with solid length Lc N
F prUl Spring force at test length Lprur N
F,,F, Spring forces at spring lengths L1, Ls N
L Spring length mm
La Length of bending surface mm
L, Solid length, shortest possible spring length mm
( all coils in contact )
LPWl Test length mm
Lo Length of the unloaded spring ( free length ) mm
Ll, La Lengths of spring.under forces F,, F2 mm
Q Quality grade coefficient
R Spring rate N/mm
b Deviation of spring form from the cylindrical ~form mm
d Diameter of bar mm
do Diameter of bar at ends of spring mm
k, Factor used in determination of the permissible -
deviation of the spring rate R
1 Length of bar mm
n Number of active coils -
nt Total number of coils -
s Spring deflection mm
SC Total spring deflection to solid mm
length L,
D -
w=-- Spring index
d

1
16 7906 ( Part 7 ) : 1989

3 TESTING AND PERMlSSIBLE 3.2 Spring Force

DEVIATION OF SPRING FORCE AND The spring force must be checked in the range
SPRING RATE of the spring deflection of:
0’3 x SCto 0’7 X SC
3.1 Test Arraogement
Permissible deviation of the spring force :
For test purposes, the springs are held in seat- AFprut = + (0’0 1 x Fc two+ Q. Fprut) -41)
ing fixtures. In the case of springs having ends For coefficient Q:
closed and formed flat plane parallel seating
fixtures are used, having a centmlizing feature Quality grade A : Q = 0’01
for the internal diameter of ‘the end coils. Quality grade B : Q = 0’02
Springs whose end coils terminate with the full The quality grade A requires greater effort in
thickness of the wire are held in seatings with order to keep within the narrower tolerances.

FIG. 1 SEATING FIXTURE FOR COIL COMPREWON SPRINGSHAVING

ENDS WITHOUTTANGS*

helical abutment surfaces, which centralize the The tolerance zone of a quality grade can further
end coils on the internal diameter and support be sub-divided into test groups. The quantitative
them over an angle of 270” ( see Fig. I and distribution of spring among these test groups is
Fig. 2 ). obtained from the statistical distribution to-
gether with the standard deviation belonging to
the particular production lot.
The tolerance zone of each test group ( group
width ) should be 20’02 Fprut, and should be
at least 60 N.
In consideration of deviations which are possible
in the cross-checking of spring forces, ,the limits
of tolerance may be exceeded by 0’01 Fprut,
including those of the individual test groups.
As an alternative to the sorting of springs into
FIG. 2 SEATING FIXTURE FOR COIL COMPRESSION test groups, they may be grouped in pairs. The
SPRINGS HAVING ENDS WITH TARGS*
maximum force difference between the springs
of a pair is then d 0’5 AF.
3.3 &ragging
The pitch m’ of the seating fixture should corres- Each and every spring shall be scragged three
pond to the diameter of the bar from which the times in quick succession. The scragging height
end coils are wound. should be as indicated in the spring drawing/
data sheet. In case, there is no such indication,
For angle 270” : m’ = 0’75 X do the spring shall be scragged home. The scrag-
Before the spring force and spring rate are ging load in each case should not exceed 1.5
checked, the springs are to be compressed to times the theoretical axial load corresponding to
solid length Li, ataieast once.
, b ,-c ,:“‘“‘I::‘“l”m,, . p

De-2 De-2do-3 Length 2xdo do 0’75xdo <0’5xd,,

of tang

*Tang&isthe term applied to the straight run-out ends of the bar.

2
 IS 7906(Part 7 ):1989

3.4Spring Rate
3.41 Spring Rate with Linear Characteristics
O.OLO
The spring rate shall be tested in the range of
spring deflection from 0’3 SC to 0.7~~.
0 038
The spring rate R is defined as the differential
quotient: 1 0.036
R_nF j 0.036
As
n
The difference in spring deflection As used in = O-032
testing should be 50 mm. 8
L 0.030
Permissible deviation of the spring rate:
&z=fkRX R . ..(3)
2
0.028 i i i i i i i i i i
4 5 6 7 8 9 10 11 12
The factor kR is essentially a function of the NUMBER OF EFFECTIVE TURNS n-
number of effective turns and may be taken from 4
the accompanying graph ( see Fig. 3 ) or calcu-
lated from the expression: Fro. 3 FACTOR kR AS A FUNCTION OF THE
NUMBER OF EFFECTIVE TURNS
% = 0’047 14 + . ..(4)
linear characteristics, since the determination of
3.4.2 Spring Rate with Progressive Character-
AF
istics only one differential quotient z does not
In the case of coil compression springs with describe the form of the rate characteristics.
and determi- 1 Testing is, therefore, generally carried out in
progressive characteristics, testing
nation of the -permissible devrations are not Laccordance with the following scheme ( see
possible in the same way as for springs with 1 Fig. 4 >.
F, the@

SFfilNC- DEFLECTION 5 - -SPRING LENGTH, L

FIG. 4 DIAGRAM OF PROCEDURE FOR INSPECTIOM TESTING OF COMPRESSION SPRINQS

WITH PROGRESSIVESRATE CHARACTERISTICS
IS 7906 ( Part 7 ) : 1989

where: 6 PERMISSIBLE TOTAL NUMBER OF

TURNS
1) Compress spring to solid length Ic and
unload The permissible deviation of the total number
2) Compress spring to length L1 and read off of turns is:
associated spring force Fl Ant=f0’012X?lt . ..(8)
3) Compress spring to length Lprur and read The corresponding permissible deviation in mm
off associated spring force FDrpruf is:
4) Compress spring to length Lz and read off Ant x Drr
associated spring force Fa
The corresponding permissible deviation in
5) Unload spring degree is:
The spring lengths must lie. in the range of spring Ant x 360
deflection
In special cases, for example with springs whose
0’3 x SCto 0’7 x SC end turns terminate with the bar at its full thick-
The permissible deviation AFprur of the spring ness, and which are not held in rotatable spring
force Fpm is calculated from equation (1) with seating fixtures, a special quality with reduced
coefficient Q from 3.2. tolerance can be agreed:
Permissible deviations of the spring forces F1 Ant =&0.005X nt . ..(9)
and F,:
7 DEVIATIONS OF FORM
AF 1,2=&l-3 ( 0’01 Fc timo+QF~, ,, ) . ..(5)
Unlike the practice in IS 7906 ( Part 5 ) : 1989
4 BAR DIAMETER tolerancing ofthe quantities el and e, is dispen-
sed with, for vehicle suspension springs. Instead
For vehicle suspension springs, only bars with of this, a check can be agreed on the deviation
the machine-finished surface are employed. b from cylindrical form on the unloaded spring.
Because of the stringent requirement for accuracy This deviation of form is tested as shown in
of the spring rate, the bar diameter is not tole- Fig. 6 by insertion ~of the spring into. a check-
ranted. The spring manufacturer is thereby ing sleeve.
afforded the opportunity to make a manufactur- Permissible deviation of the cylindrical form is:
ing adjustment.
b=O’O15x Lo
5 TESTING AND PERMISSIBLE DEVIA-
TION OF THE END-TURN DIAMETER
According to the method of assembly adopted
in a particular application ( spring ends centra-
lised from the internal or external diameter ),
either the internal coil diameter DI on the exter-
nal coil diameter De is toleranced. The permis-
sible deviations of the end coil diameter are:
ADe= &0’012 De . ..(6)
If the internal turn diameter DI is toleranced, the
external turn diameter De is still measured, in
the same way~( see Fig. 5 with 2 ):

FIG. 6 CHECKING OF THEFORM DEVIATLON

:__-__
-c3.3
__..-.-__-_ The deviation from the cylindrical form varies
in amount and position with loading of the
spring. This depends not only on the geomet-
FIG. 5 EXAMPLEOPMW.SUREMENT OF THE rical properties of the spring (slenderness ratio,
EXTERNALDIAMETBROFTHEENDTURN spring index, number of turns, pitch of turns )
but also on the conditions of production, and
is not susceptible to accurate determination in
Di is then given by the equation advance. Whenever any detriment to the func-
Di = De-2do . ..(7) tioning of the spring is to be expected from this

4
 IS 7906 ( Part 7 ) : 1989

cause; agreement should be reached between the b) Tolerance of planarity of the end coil. D:-
spring manufacturer and user, concerning the formation of 2 percent is permitted on the
critical envelopes surface range and loading length of the bearing surface.
range.
I
8 TOLERANCE ON DEVELOPED PROFILE RADIUS
OF END COILS OF SPRINGS

Coils having open end with a pitch different LENGTH OF BEARING

from active coils shall have the following tole- SURFACE L,
-
rance:
a) Tolerance on the inclination a of the end
coils 9 FATIGUE TEST
Tolerance on a = 1’5 percent of bearing
length of the last coil. Fatigue test shall be carried out as per agreement
between the supplier and the purchaser. Where
no value is specified it is recommended that load/
0: 1.5% L, length relaxation after 350 000 cycles shall not
r- i
RADIUS exceed 3 percent.

5
llureau of Indian Standards

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harmonious development of the activities of standardization, marking and quality certification of goods
and attending to connected matters in the country.

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implementing the standard, of necessary details, such as symbols and sizes, type or grade designations.
Enquiries relating to copyright be addressed to the Director (Publications), BIS.

Review of Indian Standards

Amendments are issued to standards as the need arises on the basis of comments. Standards are also
reviewed periodically; a standard along with amendments is reaffirmed when such review indicates that
rlo changes are needed; if the review indicates that changes are needed, it is taken up for revision. Users
of Indian Standards should ascertain that they are in possession of the latest amendments or edition by
referring to the latest issue of ‘BIS Handbook’ and ‘Standards Monthly Additions’.

This Indian Standard has been developed from Dot : No. EDC 75 ( 4905 )

Amendments Issued Since Publication

Amend No. Date of Issue Text Affected

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