PDF Ksi D S D S D D FD K S K D S DD

SECTION 4 - SPRINGS
HELICAL COMPRESSION SPRINGS
DESIGN – LIGHT, MEDIUM SERVICE
271. A solenoid brake (Fig. 18.2, Text) is to be actuated by a helical compression

spring. The spring should have a free length of approximately 18 in. and is to
exert a maximum force of 2850 lb. when compressed to a length of 15 in. The
outside diameter must not exceed 7 in. Using oil-tempered wire, design a
spring for this brake, (wire diameter, coil diameter, number of active coils,
pitch, pitch angle, “solid stress”). General Electric used a spring made of 1 in.
wire, with an outside diameter of 6 in., and 11 ½ free coils for for a similar
application.
Solution:
For oil tempered wire, Table AT 17
146
su = 0.19 ksi , [0.032 <
Dw < 0.5]
D w
“solid stress” = 0.6 s u
design stress, (average service)
s sd = 0 .324su

0.324(146) 47.304
ssd = 0.19
= 0.19
ksi
Dw Dw

Dw + Dm ≤ 7

F = 2850 lb = 2.85 kips
 8FD  47.304
s s = K  3m  = 0.19
 π Dw  Dw
say K = 1.3
 8(2.85
)(7 − Dw ) 47.304
s s = 1.3 3 = 0.19
 D
π w
 D w

Dw = 1.062 in > 0.5 in

47.304
use ssd = = 54 ksi
ksi
(0.5)0.19
 8(2.85
)(7 − Dw ) 
s s = 1.3  = 54
 π Dw3 
Dw = 1.015 in

say Dw = 1.0 in
 8(2.85) Dm 
s s = 1.3 3
 = 54
 π (1) 
Dm = 5.72 in

240

SECTION 4 - SPRINGS
say Dm = 5.0 in

OD = Dm + Dw = 5.0 + 1.0 = 6 in < 7 in.

Dm 5.0
C = = =5
Dw 1.0

δ = Free length – Compressed length = 18 in – 15 in = 3 in.
8 FC 3 N
c
δ = GDw

3
G = 10,500 ksi , Dw > in
8
3
8(2.85)(5) N c
δ = 3 =
(10,500)(1)
N c = 11.05

say N c = 11.5
3
8(2.85)(5) (11.5)
δ = = 3.12 in
(10,500)(1)
Free length = 15 + 3.12 = 18.12 in
At 2.85 kips
 8FDm 
s s = K  3 

 π
D w 

C = 5
4C − 1 0.615 4(5) − 1 0.615
K = + = + = 1.3105
4C − 4 C 4(5) − 4 5
 8(2.85)(5) 
s s = 1.3105 3
 = 47.55 ksi
 π (1) 
Permissible solid stress
0.6(146)
s = 0.6s =
(0.5)0.19 ksi = 99.93 ksi
so u
F
k =
using δ
or let δ T = Free length – Solid height
47.55 99.93
=
3.12 δ T
δ T = 6.56 in
δ T = Free length – Solid height = (P − Dw ) N
c

6.56 = (P − 1)(11.5)
P = 1.570 in
241

SECTION 4 - SPRINGS
1
use P = 1 in
2
Pitch angle,
P  1.5 
λ = tan −1 = tan −1   = 5.5
o
< 12
o
, o.k.
π D  π (5) 
For actual solid stress

δ T = (1.5 − 1)(11. 5) = 5.75 in.
47.55 s so
=
3.12 5.75
sso = 87.63 ksi < 99.93 ksi , ok
Summary of answer:
Dw = wire diameter = 1 in.
Dm = coil diameter = 5 in.
N c = no. of active coils = 11 1/2
P = pitch = 1 ½ in.
o
γ = pitch angle = 5.5
sso = solid stress = 87.63 ksi
272. A coil spring is to be used for the front spring of a automobile. The spring is
to have a rate of 400 lb./in., an inside diameter of 4 3/64 in., and a free length
of 14 1/8 in., with squared-and-ground ends. The material is to be oil-
tempered chrome vanadium steel. Decide upon the diameter of the wire and
the number of free coils for a design load of F = 1500 lb . Be sure “solid
stress” is all right. How much is the pitch angle?
Solution:
Table AT 17 Cr-V steel
su = 168 ksi , [0.032 < Dw 0.437]

D w0.166
average service
ssd = 0 .324su

0.324(168) 54.432
ssd = 0. 166
= 0.166
ksi
Dw Dw

Max “solid stress” = 0.6su
242

SECTION 4 - SPRINGS
3
ID = Dm − Dw = 4 in = 4.046875 in
64
Dm = Dw + 4.046875 in

 8FD 
s s = K  3m  = s sd
 π Dw 
Assume K = 1.3
F = 1500 lb = 1.5 kips
54.432  8(1.5 )( Dw + 4.046875) 
s sd = 0.166
= 1.3 
D
w  π Dw3 
Dw = 0.747 in > 0.437 in

use
󰀵󰀴󰀮󰀴󰀳󰀲
󰁳󰁳󰁤 =
󰀰󰀮󰀱󰀶󰀶
󰁫󰁳󰁩 = 󰀶󰀲󰀮󰀴󰀵 󰁫󰁳󰁩
(
󰀰󰀮󰀴󰀳󰀷 )
 8(1.5 )( Dw + 4.046875) 
s sd = 1.3 3
 = 62.45
 π
Dw 
Dw = 0.724 in
3
use Dw = in
4
3 3 51
Dm = + 4 =4 in
4 64 64
 8FDm 
s s = K  3 

 π
D w 

4C − 1 0.615
K = +
4C − 4C
 51 
4 
Dm  64 
C = D =  3  ≈ 6.4
w
 
 4 
4(6.4 ) − 1 0.615
K = + = 1.235
4(6.4) − 4 6.4
  51  
( )
 8 1. 5  4  
s s = 1.235
 64   = 53
.64 ksi < 62.45 ksi , (o.k.)
  3 
3

 π   
  4  
8 FC 3 N c
δ =
GDw

243

SECTION 4 - SPRINGS
3
G = 10,500 ksi , D w > in
8
F 1500
δ = = = 3.75 in
k 400
3
8(1.5)(6.4 ) N c
δ = 3.75 =
 3 
10,500  
( ) 4 
N c = 9.4

Table AT 16, Total coils = N c + 2 = 9.4 + 2 = 11.4 for square and grounded end.
Summary of answer:
Dw = wire diameter = ¾ in.
No. of free coils = 11.4
To check for solid stress.
0.6(168)
Permissible solid stress = 0.166
= 115
.65 ksi
(0.437 )
Free length = PN c + 2 Dw
 3 
Solid height = Dw ( N c + 2 ) =   (11.4) = 8 .55 in
 4 
 󰀱 
 󰀱󰀴 − 󰀸󰀮󰀵󰀵 
Solid stress = (󰀵󰀳󰀮󰀶󰀴 ) 󰀸  = 󰀷󰀹
󰀮󰀷󰀴 󰁫󰁳󰁩 < 󰀱󰀱󰀵
󰀮󰀶󰀵 󰁫󰁳󰁩 (safe)
 󰀳󰀮󰀷󰀵 
 
 
Pitch:
1
PN c + 2 D w = 14 in
8
 3  1
P(9.4) + 2   = 14
 4  8
11
P = 1.343 in = 1 in
32
Pitch angle,
 11 
 1 
−1 P 32
λ = tan
= tan
−1
  = 5.1 o
< 12
o
, o.k.
π D 
 π 4 51  
  64  
244

SECTION 4 - SPRINGS
273. A coiled compression spring is to fit inside a cylinder 5/8 in. in diameter. For
one position of the piston, the spring is to exert a pressure on the piston
equivalent to 5 psi of piston area, and in this position, the overall length of the
spring must not exceed (but may be less than) 2 in. A pressure of 46 psi on the
piston is to compress the spring ¾ in. from the position described above.
Design a spring for medium service. Specify the cheapest suitable material,
number of total and active coils for square-and-ground ends, and investigate
the pitch angle, and “solid stress”.
Solution:
 8FDm 
s s = K  3 

 π
D w 

5 Dw
OD = Dm + D w = in −
8 2
5
Dm + 1.5 D
w = in
8
2
 π  5 
F 1 = (5)   = 1.534 lb
 4  8 
2
 π  5 
F 2 = (46 + 5)    = 15.647 lb
 4  8 
Using hard-drawn spring wire, Cost Index = 1

s sd = 0 .324su (0.85)

140
su = 0.19 ksi
Dw
,
[0.028 < Dw < 0.625]
70
Max “solid stress” = 0.19 ksi
Dw
140 38.556
s sd = 0.324(0 .85) 0.19 = 0.19
Dw Dw
 8FC  38.556 38,556
s s = K  2 
= 0.19
ksi = 0.19
psi
π
D
 w  D w
D w

 8(15.647)C  1.81
K  = 38,556 Dw
 π 

K (39.845
)C = 38,556 Dw
1.81

Dm + 1 .5D
w = 0.625

CDw + 1 .5 D
w = 0.625

0.625
Dw =
C + 1.5
245

SECTION 4 - SPRINGS
4C − 1 0.615
K = +
4C − 4 C
1.81
 4C − 1 0.615   0.625 
 + (39.845)C = 38,556 
 4C − 4 C   C + 1.5 
 4C − 1 0.615  1.81
 + (C + 1.5) C = 413.3
 4C − 4 C 
C = 7.035
0.625 0.625
Dw = = = 0.0732 in
C + 1.5 7.035 + 1.5
Table AT 15, w = 0.0720 , W & M 15
D in
Dm = 7.035(0. 0720) = 0.5065
in

For N c
8(F
2 − F 1 )C N c
3
δ 2 − δ 1 =
GDw

6
G = 11.5 ×10 psi
3
3 8(15.647 − 1.534)(7.035) N c
− = =
δ 2 δ 1 4 (11.5 ×10 )(0.0720 )
6

N c = 15.8

Table AT 16,
Total coils = N c + 2 = 15. 8 + 2 = 17.8
Solid height = ( N c + 2) Dw = (15.8 + 2)(0.0720 ) = 1 .28 in
Free length = 2 + δ 1
8(F 1 )C N c
3
δ 1 =
GDw

3
8(1.534)(7.035) (15.8)
= =
δ (11.5 ×10 )(0 .0720) 0.082 in.
1 6
Free length = 2 + 0. 082 = 2.082 in

8( F 2 )C N c
3
δ 2 =
GDw

3
8(15.647 )(7.035) (15.8)
δ 2 = = 0.832 in.
(11.5 ×106 )(0.0720)
Solid Height ≤ Free Length - δ 2
Solid Height ≤ 2.082
− 0.832 in
Solid Height ≤ 1.25 in
But Solid Height > 1.25 in.
Therefore change material to Oil-tempered spring wire, Cost Index = 1.5
246

SECTION 4 - SPRINGS
Table AT 17
146
su = 0.19 ksi , 0.028 <
Dw < 0.5
D w
87.5
Max “solid stress” = ksi
D w0.19
146 47.304
s sd = 0.324
0.19
= 0.19
Dw Dw

 8FC  47.304 47,304
s s = K  
2 
= 0.19
ksi = 0.19
psi
π
D
 w  Dw
D w

 8(15.647)C  1.81

K   = 47,304 Dw
 π 
K (39.845
)C = 47,304 D
1.81
w
0.625
Dw =
C + 1.5
4C − 1 0.615
K = +
4C − 4 C
1.81
 4C − 1 0.615   0.625 
 + (39.845)C = 47,304 
 4C − 4 C   C + 1.5 
 4C − 1 0.615  1.81
 + (C + 1.5) C = 507.1
 4C − 4 C 
C = 7.684
0.625 0.625
Dw = = = 0.0680 in
C + 1.5 7.684 + 1.5
Table AT 15, Dw = 0.0625 in , W & M 16
Dm = 7.684(0. 0625) = 0.48025
in

15
say Dm = 32 = 0.46875 in
D 0.46875
C = m = = 7.5
Dw 0.0625

 8FC 
s s = K  
2 
π
D
 w 
4C − 1 0.615 4(7.5) − 1 0.615
K = + = + = 1.1974
4C − 4 C 4(7.5) − 4 7.5
 8(15.647 )(7.5) 
s s = 1.1974 2 
= 91, 600
psi = 91.6 ksi
 π (0 .0625 ) 
For N
c
247

SECTION 4 - SPRINGS
8(F
2 − F 1 )C N c
3
δ 2 − δ 1 =
GDw

6
G = 11.5 ×10 psi
3 8(15.647 1.534)(7.5) N c
3
−
δ 2 − δ 1 = =
4 (11.5 ×10 )(0.0625)
6

=
N c 11.32
Table AT 16, squared and ground ends
Total coils = N c + 2 = 11.32
+ 2 = 13.32
Solid height = ( N c + 2) Dw = (11.32 + 2 )(0.0625) = 0.8325
in
Free length = 2 + δ 1
8(F 1 )C 3 N c
δ 1 =
GDw

3
8(1.534)(7.5) (11.32)
δ 1 = = 0.082 in.
(11.5 ×106 )(0.0625)
+ = = +
Free length = 2 0.082 2 .082 in P(11.32) 2(0.0625)
11
P = 0.1729 in ≈ in
64
Pitch angle,
P  0.1729 
λ = tan −1 = tan −1   = 6.7 < 12 , o.k.
o o
π D  π (0.46875) 
Solid stress
 2 − 0.8325 
s so = (91.6)  = 142.6 ksi
 0.75 
87.5
Permissible solid stress = 0.19
= 148
.8 ksi > 137.5 ksi , safe.
(0.0625)
Summary of answer:
Suitable material = Oil-Tempered Spring Wire
Total Coils = 13.32
Active Coils, N c = 11.32
274. A helical spring is to fit about a 11/16-in. rod with a free length of 2 ¾ in. or
less. A maximum load of 8 lb. is to produce a deflection of 1 ¾ in. The spring
is expected to be compressed less than 5000 times during its life, but is
subjected to relatively high temperatures and corrosive atmosphere. Select a
material and determine the necessary wire size, mean coil diameter, and
number of coils. Meet all conditions advised by Text.
248

SECTION 4 - SPRINGS
Solution:
For 5000 cycles < 104 cycles, use light service
Use stainless steel, type 302 (Cr-Ni), ASTM A313 – for relative high temperature and
corrosive atmosphere, Table AT 17.
s sd = 0 .32su
(i)
170
su = 0.14 ksi , [0.01 < Dw < 0.13]
Dw
97
su = 0.41 ksi , [0.13 < Dw < 0.375]
Dw
Maximum “solid” so = 0 .47 su
 8FDm 
s s = K  3 

 π
D w 

F = 8 lb
11 Dw
Dm − Dw = +
2 16
Dm − 1.5 D
w = 0.6875 in

− =
CDw 1 .5Dw 0.6875
0.6875
Dw =
C − 1.5
4C − 1 0.615
K = +
4C − 4 C
170
assume su = 0.14 ksi
Dw
0.32(170) 54.4 54,400
s sd = 0.14
= 0.14
ksi = 0.14
psi
Dw Dw Dw

 4C − 1 0.615   8(8)C  1.86
 +  = 54,400 D
 4C − 4 C   π 
w
 4C − 1 + 0.615  64C  = 54,400 0.6875 

1.86
    
 4C − 4 C  π   C − 1.5 
 4C − 1 0.615  1.86
 + (C − 1.5) C = 1330
 4C − 4 C 
C = 12.919
0.6875
Dw = = 0.0602 in
12.919 − 1.5
Use Table AT 15, w = 0.0625 in , 16 W & M
D
Dm = 12.919(0. 0602) = 0.8074
in

25
say Dm = in = 0.78125 in
32
249

SECTION 4 - SPRINGS
11
Dm − Dw >
16
0.78125 − 0.0625 > 0.6875

0.71875 > 0.6875
Dw
0.71875 − 0.6875 = 0.03125 = , o.k.
2
C = Dm = 0.71875 = 12.5

Dw 0.0625

[0.0625
< 0.13]
, therefore, s =
170
ksi is o.k.
u 0.14
Dw
 8FC 
s s = K  
2 
π
D
 w 
4(12.5) − 1 0.615
K = + = 1.1144
4(12.5) − 4 12.5
 8(8)(12.5) 
s s = 1.1144  = 72
2 
,648 psi
 π (0.0625) 
3
δ = 8(F )C N c
GDw

6
G = 10.6 ×10 psi
3
3 8( 8)(12.5) N c
δ = 1 =
4 (10.6 ×10 )(0.0625)
6
N c = 9.3

To check for solid stress and pitch
Minimum solid height = Dw N c = (0.0625 )(9.3) = 0.58125
in
(72,648) 
3
2 − 0.58125 
Solid stress =  4  = 90,000 psi = 90 ksi
3
1
4
(0.47)(170)
Permissible solid stress = = 117
.8
ksi > 90 ksi , o.k.
(0.0625)0.14
Free length = PN c , minimum
3
P(9.3 ) = 2
4
P = 0.2957 in
Pitch angle,
P  0.2957 
λ = tan −1 = tan −1   = 7.5 < 12 , o.k.
o o
π D  π (0. 71825 ) 

Summary of answer
Material, Stainless Steel, Cr-Ni. ASTM A313
250

SECTION 4 - SPRINGS
Dw = 0.0625 in , 16 W & M

25
Dm = in
32
N c = 9.3

275. In order to isolate vibrations, helical compression springs are used to support a
machine. The static load on each spring is 3500 lb., under which the deflection
should be about 0.5 in. The solid deflection should be about 1 in. and the
outside coil diameter should not exceed 6 in. Recommend a spring for this
application; include scale, wire size, static stress, material, number of coils,
solid stress, and pitch of coils.
Solution:
Use Music wire (The best material)
Table AT 17
190
su = 0.154 ksi , [0.004 <
Dw < 0.192]
Dw
Maximum “solid” sso = 0.5su
Light service, s sd = 0 .405su
0.405(190) 76.95 76,950
ssd = 0. 154
= 0.154 ksi = 0.154
psi
Dw Dw Dw
 8FC 
s s = K  
2 
π
D
 w 
F = 3500 lb
OD = Dm + Dw = 6 in

(C + 1) D w = 6
6
Dw =
C + 1
 
 4C − 1 0.615   8(3500 )C  76,950
ss =  +  =
C    6    6 
0.154
 4C − 4
  C + 1    C + 1 
π
 
 4C − 1 0.615 
[C (C + 1) ] = 235.9
1.846
 +
 4C − 4 C 
C = 5.635
6
Dw = = 0.9043 in > 0.192 in
5.635 + 1
76.950
use s s = = 99
,216 psi
(0.192)0.154
251

SECTION 4 - SPRINGS
 
 4C − 1 0.615   8(3500 )C 
ss =  +   = 99,216
 4C − 4 C   π  6  
  C + 1  

 4C − 1 0.615  2
 + C (C + 1) = 400.8
 4C − 4 C 
C = 6.205
6
Dw = = 0.8328 in
6.205 + 1
13
Say Dw = in = 0.8125 in
16
Dm = (6.205)(0 .8125) = 5. 042 in

Say Dm = 5 in
Dm 5
C = = = 6.154
Dw 0.8125

4(6.154) − 1 0.615
K = + = 1.2455
−
4(6.154) 4 6.154
 8FC 
s s = K  2 

π
D
 w 
 8(3500 )(6.154) 
s s = 1.2455 2  = 103 ,481 psi > 99,216 psi , not o.k.
 π (0. 8125 ) 
Use Dm = 4.5 in
Dm 4.5
C = = = 5.5385
Dw 0.8125

4(5.5385) − 1 0.615
K = + = 1.2763
45.5385 − 4 5.5385
s s = 1.2763 8(3500)(
)(5.5385
2 )  = 95 ,435 psi > 99,216 psi , o.k.
 π (0.8125) 
To check for solid stress
(0.5)(190)
Permissible solid stress = = 122 .488 ksi = 122,488 psi
(0.192)0.154
 1 
Solid stress =  (95,435) = 190,870 psi
> 122, 488 psi , not ok
 
0. 5
Use
 0.5 
s sd = 122, 488  = 61,244 psi
.  1 
252

SECTION 4 - SPRINGS
 
 4C − 1 0.615   8(3500 )C 
ss =  +   = 61,244
 4C − 4 C   π  6  
  C + 1  

 4C − 1 0.615  2
 + C (C + 1) = 247.4
 4C − 4 C 
C = 5.1
6
Dw = = 0.9836 in
5.1 + 1
Say Dw = 1.0 in
Dm = (5.1)(1 .0) = 5 .1 in

Say Dm = 5 in
Dm 5
C = = =5
Dw 1

 8FC 
s s = K  
2 
π
D
 w 

4 5 − 1 0.615
K = ( ) + = 1.3105
4(5) − 4 5
 8(3500 )(5)
s s = 1.3105 2  = 58, 400 psi > 61,244 psi o.k.
 π (1. 0 ) 
Use Dw = 1.0 in , Dm = 5 in
 1 
Solid stress =  (58,400) = 116,800 psi
< 122, 488 psi , o.k.
 
0. 5
8(F )C 3 N c
δ =
GDw

(Table AT 17)
G = 12 ×106 psi
8(3500 )(5) N c 3

δ = 0.5 =
(12 ×10 )(1.0)
6
N c = 1.7143

say N c = 1.75
Free length – Solid length = Solid Deflection
PN c − Dw N c = 1 in

P(1.75) − (1 )(1.75) = 1
9
P = 1.5714
in ≈ 1 in
16
Pitch angle,
253

SECTION 4 - SPRINGS
 9 
−1 P −1
 116 
λ = tan = tan   = 5.68
o
< 12
o
, o.k.
π D  π (5) 
 
Summary of answer.
Scale, k = F = 3500 = 7000 lb in

δ 0.5
Wire size, Dw = 1.0 in
Material = Music Wire
Solid sress = 116,800 psi
9
Pitch of stress = P = 1 in
16
CHECK PROBLEMS – LIGHT, MEDIUM SERVICE
276. The front spring of an automobile has a total of 9 ½ coils, 7 3/8 active coils
(square-and-ground
(square-and-gro und ends),
ends), an inside diameter of 4 3/64 in.,
in., and a free
free length
of 14 ¼ in. It is made of SAE 9255 steel wire, OQT 1000oF, with a diameter
of 43/64 in. Compute (a) the rate (scale) of the spring; (b) the “solid stress”
and compare with a permissible value (is a stop needed to prevent solid
compression?). (c) Can 95 % of the solid stress be repeated 105 times without
danger of failure? Would you advise shot peening of the spring?
Solution:
8 FC 3 N c
(a) δ =
GDw
43 3
Dw = in > in
64 8
G = 10.5 ×106 psi
D
C = m
Dw

Dm − D w = ID

43 3
Dm − =4 in
64 64
23
Dm = 4 in
32
23
4
C = 32 = 7.0233
43
64
254

SECTION 4 - SPRINGS
3
N c = 7
8
(10.5 ×10 )  43 

6
k = rate =
F
=
GDw
=
 64  = 345 lb in
3  3 
3
δ 8C N c
8(7.0233)  7 
 8 
(b) “Solid Stress”

 43  1 
Solid height = N c = ( Dw )(Total Coils ) =   9  = 6.3828 in
 64  2 
Solid deflection = Free length – Solid height = 14 ¼ - 6.3828 = 7.8672 in.
Solid Force = F so = 7.8672 (345) = 2714

lb
 8F so C 
Solid Stress = K  2 

 π
D w 
4C − 1 0.615
K = +
4C − 4 C
4(7.0233) − 1 0.615
K = + = 1.212
4(7.0233) − 4 7.0233
 
 
8( 2714 )
)(
(7.0233 )
s s = 1.212  = 130,322 psi
  43 
2

 π   
  64  
Permissible value, s s = s ys = 0.6 sy , [ Dw > 0.5 in]
SAE 9255, OQT 1000 oF
s y = 160 ksi su = 180 ksi
,
s ys = 0.6(160) = 96 ksi = 96,000
psi < 130,322 psi

Therefore a stop is needed to prevent solid compression.
(c) s sd = 0 .324su (105 cycles)

s sd = 0.324( 180) = 58 .32 ksi

0.95s so = 0.95(130,322) = 123,800 psi = 123
.8 ksi > 58.32 ksi

There is a danger of failure, shot peening is advisable
s ys = 1.25(96,000) = 120
,000 psi
≈ 0.95s so

277. An oil-tempered steel helical compression spring has a wire size of No. 3 W
& M, a spring index of 4.13, 30 active coils, a pitch of 0.317 in., ground-and-
squared ends; medium service. (a) What maximum load is permitted if the
recommended stress is not exceeded (static approach)? Compute (b) the
255

SECTION 4 - SPRINGS
corresponding deflection, (c) “solid stress,”. (d) pitch angle, (e) scale, (f) the
energy absorbed by the spring from a deflection of 0.25 in. to that of the
working load. (g) Is there any danger of this spring buckling? (h) What
maximum load could be used if the spring were shot peened?
Solution:
Table AT 17, oil-tempered
146
su = 0.19 ksi , [0.032 <
Dw < 0.5]
Dw
87.5
Maximum “solid” s so = 0.19
ksi
Dw
s sd = 0 .324su (medium service)
Table AT 15, No. 3 W & M

Dw = 0.2437 in

C = 4.13
Dm = CDw = 4.13(0.2437
) = 1 .0 in
 8 F sC 
(a) s s = K  2 

π
D
 w
4C − 1 0.615
K = +
4C − 4 C
4(4.13) − 1 0.615
K = + = 1.3885
4(4.13) − 4 4.13
0.324(146)
s s = ssd = = 61. 858 ksi = 61,858 psi
(0.2437 )0.19
 8(F )(4.13) 
s s = 61,858 = 1.3885 2 
 π (0.2437 ) 
F = 252 lb
8 FC 3 N c
δ =
GDw

6
G = 11.5 ×10 psi
N c = 30

3
8(252)(4.13) (30 )
δ = = 1 .52 in
(11.5 ×10 )(0.2437 )
6

(c) For solid stress . Square-and-ground end)
+ = + =
Free length = PN c 2 Dw
(0.317)(30) 2(0.2437 ) 9.9974 in
256

SECTION 4 - SPRINGS
Solid height = Dw N c + 2 Dw = (30 + 2 )(0.2437 ) = 7.7984

in
Solid deflection = 9.9974 – 7.7984 = 2.199 in.
 2.199 
Solid stress = (61,858) = 89,491 psi
 1.52 
87.5 87.5
Maximum “solid” s = ksi = ksi = 114.4 ksi > 89.491 ksi , o.k. safe
so
Dw0.19 (0.2437 )0.19
P  0.317 
(d) λ = tan −1 =
−
tan 1   = 5.76
o
< 12
o
, o.k.
π D  π (1) 
F 252
(e) scale = k = = = 166 lb in
δ 1.52
1
(f) U s = k (δ 22 − δ 12 )
2
k = 166 lb in
δ 1 = 0.25 in
δ 2 = 1.52 in
1
U s = (166)[(1.52)2 − (0.25)2 ] = 186. 6 in − lb
2
(g) i 6.18 Free length = 9.9974 in

Mean Diameter = Dm = 1.0 in
Free length 9.9974
=
= 9.9974 > 4
Mean Diameter 1.0
There is a danger for spring buckling
(h) Shot peened, Table AT 17

s sd = (61,858)(1
.25) = 77 ,322 psi

s s = 77,322 = 1.3885
8(F )(4.13) 
2 
 π (0.2437 ) 
F = 314 lb
280. It is desired to isolate a furnace, weighing 47,300 lb., from the surroundings
by mounting it on helical springs. Under the weight, the springs should deflect
approximately 1 in., and at least 2 in. before becoming solid. It has been
decided to use springs having a wire diameter of 1 in., an outside diameter of
5 3/8 in., 4.3 free coils. Determine (a) the number of springs to be used, (b)
the stress caused by the weight, (c) the “solid stress”. (d) What steel should be
used?
Solution:
257

SECTION 4 - SPRINGS
Dw = 1 in

3
Dm + Dw = 5 in
8
3
Dm = 4 in
8
3
C = Dm = 4 8 = 4.375
Dw 1

8 FC 3 N c
(a) δ =
GDw
Assume N c = 4.3
3
G = 10.5 ×106 psi , Dw > in
8
3
8 F (4.375) (4.3 )
δ = 1.0 =
(10.5 ×10 )(1) 6
F = 3645 lb
W 47,300
No. of springs = = = 13
F 3645
W 47,300
(b) F = = = 3638 lb
13 13
 8 F sC 
s s = K  2 
 π Dw 
4C − 1 0.615
K = +
4C − 4 C
4(4.375) − 1 0.615
K = 1.3628
4(4.375) − 4 + 4.375 =
 8(3638)(4.375) 
s s = 1.3628 2
 = 55,235 psi
 π (1.0 ) 
 2 
(c) “Solid Stress” = s s = 55,235  = 110,470 psi
 1 
(d) s ys ≈ 110,470 psi

s ys 110,470
s y = = = 184,117 psi = 184.117 ksi
0.6 0.6
From Table AT 7,
Use AISI 8760, OQT 800 oF, s y = 200 ksi
258

SECTION 4 - SPRINGS
VARYING STRESS APPROACH
DESIGN PROBLEMS
282. A spring, subjected to a load varying from 100 lb. to 250 lb., is to be made of oil-
tempered, cold-wound wire. Determine the diameter of the wire and the mean
diameter of the coil for a design factor of 1.25 based on Wahl’s line. The spring
index is to be at least 5. Conform to good practice, showing checks for all
significant parameters. Let the free length be between 6 and 8.
Solution:
F max = 250 lb

F min = 100 lb
1 1
F m = (F max + F min ) = (250 + 100) = 175 lb = 0.175 kip
2 2
1 1
F a = (F max − F min ) = (250 − 100) = 75 lb = 0.075 kip
2 2
Wahl’s line
1 s ms − sas 2s as
= +
N s ys sno

8KF a Dm 8KF aC
s as = =
π Dw3 π Dw2
8 KF m Dm 8 KF mC
s ms = 3
= 2
K cπ D K cπ Dw
w
C = 5
4C − 1 0.615
K = +
4C − 4 C
4(5) − 1 0.615
K = + = 1.31
4(5) − 4 5
Fig. AF 15, C = 5
K c = 1.19

For oil-tempered wire,
87.5
s ys = 0.19
Dw
,
[0.032 < Dw < 0.5]
47
s no = 0.1
Dw
,
[0.041 < Dw < 0.15]
30
s no = 0.34
Dw
,
[0.15 < Dw < 0.625]
=
N 1.25
259

SECTION 4 - SPRINGS
8(1.31)(0.075)(5) 1.251
s as = =
π Dw2 Dw
2

8(1.31)(0.175)(5) 2.453
s ms = =
(1.19)π Dw2 Dw2

30
say s no = 0.34
ksi
D
w
1 s ms − sas 2s as
= +
N s ys sno

 2.453
− 1.251   1.251 
 2
 2 
2 
1  D w  D
 w 
= +
1.25  87.5   30 
 0.19   0.34 
 Dw   Dw 
1 1 1
= 1.81
+ 1.66
1.25 72.8 D 11
.99 Dw
w
Dw = 0.2857
in > 0.15 in

Table AT 15,in
use No. 1, W & M
w = 0.2830
D

Dm = CDw = 5(0.2830

) = 1. 415 in
7
say Dm = 1 in
16
Check for Free length
6 in < Free length < 8 in
 7 
Free length = 4 Dm = 4 1  = 5.75 in
 16 
Increase Dm
1
Dm = 1 in
2
 1 
Free length = 4 Dm = 4 1  = 6 in , o.k.
 2 
Summary of answer
Dw = 0.2830 in

1
Dm = 1 in
2
283. A carbon-steel spring is to be subjected to a load that varies from 500 to 1200 lb.
The outside diameter should be between 3.5 and 4 in., the spring index between 5
to 10; approximate scale of 500 lb./in. Choose a steel and for a design factor of
1.4 by the Wahl line, find the wire diameter. Also determine the number of active
260

SECTION 4 - SPRINGS
coils and the free length for squared-and-ground ends. Conform to the general
conditions specified in the Text.
Solution:
For carbon steel, Table AT 17
91
s ys = 0.1 ksi , [0.093 <
Dw < 0.25]
Dw
s no = 49 ksi , [0.093 <

Dw < 0.25]
Dw0.15
F max = 1200 lb

F min = 500 lb
1 1
F m = (F max + F min ) = (1200 + 500) = 850 lb = 0.85 kip
2 2
1 1
2 2
OD = 3.5 ~ 4.0 in
C = 5 ~ 10
Wahl’s line
−
1 = s ms sas + 2s as
N s ys sno

Figure AF 15, C = 5 ~ 10
Assume K = 1.2 , K c = 1.125
8KF a Dm
s as =
π Dw3
8 KF m Dm
s ms = 3
K cπ Dw

OD ≈ 3.75 in
Dm = 3 . 75 − Dw

8(1.2)(0.35)(3.75 − Dw ) 1.0695(3.75 − Dw )
s =
as
π D3
= Dw3
w
8(1.2)(0.85)(3.75 − Dw ) 2.3088(3.75 − Dw )
s ms = =
(1.125)π Dw3 Dw
3

− Dw 
 3.75 − Dw 
 3.75
(2.3088 − 1.0695) 3
 2(1.0695) 3

1  Dw  +  Dw 
=
1. 4  91   49 
 0.1   0.15 
 Dw   Dw 
1 3.75 − Dw 3.75 − Dw
= +
1.4 73.4285 Dw2.9 22.9079 Dw2.85

Dw = 0.6171
in > 0.25 in
Use
261

SECTION 4 - SPRINGS
91
s ys = = 104
.53 ksi
(0.25)0.1
49
s no = = 60
.33 ksi
(0.25)0.15
 3.75
− Dw   3.75
− Dw 
(2.3088 − 1.0695) 3
 2(1.0695
) 3 
1 =  D
w
 +  Dw 
1. 4 104.53 60.33
1 3.75 − Dw 3 .75 − Dw
= +
1. 4 84.346 Dw3 28.205 Dw3

1 3.75 − Dw
=
1. 4 21.137 Dw3

Dw = 0.5935 in

use
19
Dw = in
32
3
Dm + Dw ≈ 3 in
4
19 3
Dm + = 3 in
32 4
5
Dm = 3 in
32
 5 
3 
Dm  32 
C = = = 5.316
Dw  19 
 
 32  . o.k.
19
Wire Diameter Dw = in , Carbon Steel
32
Number of coils:
8 FC 3 N c
δ =
GDw

3
G = 10.5 ×106 psi = 10,500 ksi , Dw > in
8
F GDw
= k =
δ 8C 3 N c

(10.5 ×10 )  19 
6
500 =  32 
3
8(5.316) N
c
N c = 10.4
Table AT 16, square-and-ground ends
262

SECTION 4 - SPRINGS

Solid height = Dw N c + 2 Dw
Total Coils = N c + 2
 19 
Solid height = Dw N c + 2 Dw = (10.4 + 2)  = 7.3625 in
 32 
F 1200
δ = = = 2.4 in
k 500
Min. Free length = 2.4 + 7.3625 in = 9.7625 in
Use Free length = 10 in
To check for pitch angle.

 19 
P(10.4) + 2   = 10
 
32
P = 0.8474 in
 
P  0.8474 
λ = tan −1 = tan −1  = 4.885
o
< 12
o
, o.k.
π Dm  π  3 5  

  
32  
Solid stress:
δ T = solid deflection = 10 − 7.3625
= 2.6375 in

δ T = (500)(2.6375
F = k ) = 1319
lb
4C − 1 0.615
K = +
4C − 4 C
4(5.316) − 1 0.615
K = + = 1.29
4(5.316) − 4 5.316
 5 
8(1.29)(1319 ) 3 
ss =
8KFDm
=
 32  = 23
,033 psi = 23.033 ksi < s ys (= 104.53 ksi )
3
π Dw3  19 
π  
 32 
284. A helical compression spring, made of oil-tempered, cold-wound carbon steel, is

to be subjected to a working load varying from 100 to 300 lb. for an indefinite
time (severe). A mean coil diameter of 2 in. should be satisfactory. (a) Using the
static approach, compute a wire diameter. (b) For this wire size, compute the
factor of safety as given by the Wahl line.
Solution:
263

SECTION 4 - SPRINGS
Table AT 16,
For carbon steel,
182
su = 0.1 ksi , [0.093 <
Dw < 0.25]
Dw
91
Max. “solid” s ys = 0.1
ksi
Dw
49
sno = 0.15
ksi , [0.093 <
Dw < 0.25]
Dw
Dm = 2 in.

F max = 300 lb

F min = 100 lb
(a) F = 300 lb
= 0.3 kip
(0.263)(182) 47.866
severe service, ssd = 0.263su = 0. 1
= 0. 1
ksi
D
w Dw
 
s s = K  8 F s C
2 
 π Dw 
4C − 1 0.615
K = +
4C − 4 C
Dm
C =
Dw

Dm 2
Dw = =
C C
 
 
 4C − 1 0.615   8(0.3)(2)  47.866
ss =  +
 =
 4C − 4 C 
  2 
3
  2 
0.1
 π 
 C     C 

 4C − 1 0.615  2.9
 4C − 4 + C  C = 233.84

C = 6.075
2
Dw = = 0.3292 in > 0.25 in
6.075
47.866
Therefore use ssd = = 54 .984 ksi
(0.25)0.1
264

SECTION 4 - SPRINGS
 
 
 4C − 1 0.615   8(0.3)(2 ) 
ss =  + = 54.984
C    2  
3
 4C − 4
 π   
  C  
 4C − 1 0.615  3
+ = 287.9
 C
 4C − 4 C 
C = 6.136
2
Dw = = 0.3259 in
6.136
21
say Dw = in
64
91
(b) s ys = = 104
.53 ksi
(0.25)0.1
49
sno = = 60
.33 ksi
(0.25)0.15
F m = 1 (F max + F min ) = 1 (300 + 100) = 200 lb
= 0.2 kip
2 2
1 1
2 2
Dm 2
C = = = 6.095
Dw  21 
 
 64 
Figure AF 15
K c = 1.15

K = 1.25
K  8F m Dm 
s ms =  3 
K c  π Dw 
 
 
1.25  8(0.2)(2) 
s ms = = 31.34 ksi
1.15   21  
3
 π   
  64  
8KF a Dm
sas =
π Dw3
265

SECTION 4 - SPRINGS
 
 
8(0. 1)(2 )
s as = 1.25  = 18.02 ksi
  21  3
 π   
  64  
Wahl’s
1 smsline
− sas 2sas
= +
N s ys sno

1 31.34 − 18.02 2(18.02)
= +
N 104.53 60.33
N = 1.38
285. A helical spring of hard-drawn wire with a mean diameter of 1 ½ in. and square-
and-ground ends is to be subjected to a maximum load of 325 lb. (a) Compute the
wire diameter for average service. (b) How many total coils are required if the
scale is 800 lb./in.? (c) For a minimum load of 100 lb., what is the factor of safety
according to Wahl line? Would it be safe for an indefinite life?
Solution:
Table AT 17,
Hard-drawn wire,
140
su = 0.19 ksi , [0.028 <
Dw < 0.625]
Dw
70
Maximum “solid” ss = s ys = 0.19
ksi
Dw
(0.9)(47)
sno = 0.1
ksi , [0.041 <
Dw < 0.15]
Dw
sno =
(0.9)(30) ksi , [0.15 < D < 0.625]
0.34 w
Dw
Average service
0.2754(140) 38.556
(a) ssd = 0.85(0.324)su = 0.2754
su = 0.19
= 0.19
ksi
D
w Dw
F = 325 lb = 0.325 kip
1
Dm = 1 in
2
 8 FDm 
s s = K  
π D 3
w
 
266

SECTION 4 - SPRINGS
4C − 1 0.615
K = +
4C − 4 C
1. 5
Dw =
C
 
 
 4C − 1 0.615  8(0.325)(1.5) 38.556
s = 
 4C − 4 + C    1.5   =  1.5 
s 3 0.19
 π     
  C    C 
 4C − 1 0.615  2.81
 + C = 97.05
 4C − 4 C 
C = 4.586
1. 5 1.5
Dw = = = 0.3271 in < 0.625 in
C 4.586
21
Dw = in
64
D 1.5
(b) C = D =  21  = 4.57
m
w
 
 64 
4(4.57) − 1 0.615
K = + = 1.345
4(4.57 ) − 4 4.57
3
8 FC N c
δ =
GDw
F GDw
= k =
δ 8C 3 N c
k = 800 lb in = 0.8 kip in
 21 
0.8 = (11,500)
 64 
84.573 N c
N c = 6.2
70
(c) s ys = = 86.5 ksi
0.19
 21 
 
 64 
(0.9)(30)
sno = = 39.44 ksi ,
0.19
Dw > 0.15 in
 21 
 
 64 
F m = 1 (325 + 100) = 212.5 lb = 0.2125 kip
2
267

SECTION 4 - SPRINGS
1
F a = (325 − 100) = 112.5 lb = 0.1125 kip
2
K c = 1.212 , Fig. AF 15
K = 1.345
 
 
K  8F m Dm  1.345 8(0.2125)(1.5)
s ms = K c  π Dw3  = 1.212  3
 = 25.5 ksi
 21 
 π   
  64  
 
 
 8 F m Dm   8(0.1125)(1.5) 
s as = K  3 
= 1.345 = 16.36 ksi
 π
D w 
  21 
3

 π   
  64  
1 sms − sas 2sas 25.5 − 16.36 2(16.36)
= + = +
N s ys sno 86.5 39.44
N = 1 .07 < 1.15[N min ]
Not safe for indefinite life.

286. A helical spring is to be subjected to a maximum load of 200 lb. (a) Determine
the wire size suitable for medium service if the material is carbon steel ASTM
A230; C = 6 . Determine the factor of safety of this spring according to the Wahl
line (b) If the minimum force is 150 lb., (c) if the minimum force is 100 lb., (d) if
the minimum force is 25 lb.
Solution:
For carbon steel ASTM A230

Table AT 17
182
s = ksi , 0.093 <
D < 0.25
u
Dw0.1
[ w
]
91
s ys = 0.1 ksi , [0.093 < Dw < 0.25]
Dw
49
sno = 0.15
ksi , [0.093 <
Dw < 0.25]
Dw
Medium Service
ssd = 0 .324su
 182  58.968 58,968

(a) s sd = 0.324 
0.1 
=
0.1
ksi = 0. 1
psi
D
 w  Dw D w
268

SECTION 4 - SPRINGS
 8 FDm 
s s = K  3 

 π
Dw 
4C − 1 0.615
K = +
4C − 4 C
4(6) − 1 0.615
K = + = 1.2525
−
4(6 )lb 4
F = 200 6
 8(200)(6 )  58,968
s s = 1.2525 2  = D 0.1
 π
Dw  w
Dw = 0.2371 in
Table At 15, use Dw = 0.2437 in , No. 3 W & M

Dw = 0.2437
in < 0.25 in , o.k.
Factor of safety.
91 91
s ys = ksi = ksi = 104.8 ksi
Dw0. 1
(0.2437 )0 .1
49 49
sno = 0.15 ksi = ksi = 60
.56 ksi
Dw (0.2437 )
1
(a) F m = (200 + 150) = 175 lb = 0.175 kip
2
1
F a = (200 − 150) = 25 lb = 0.025 kip
2
Figure AF 15, K c = 1.156
K  8F mC  1.2525  8(0.175)(6) 
s ms =   =  2 
= 48.8 ksi
K c  π Dw2  1.156  π (0.2437 ) 
 8 F C   8(0.025)(6) 
s as = K  a 2  = 1.2525 2 
= 8.1 ksi
π
 w D  π (0 .2437 ) 
1 sms − sas 2sas
= +
N s ys sno
1 48.8 − 8.1 2(8.1)
= +
N 104.8 60.56
N = 1.525
1
(b) F m = (200 + 100) = 150 lb = 0.15 kip
2
F a = 1 (200 − 100) = 50 lb = 0.05 kip

2
269

SECTION 4 - SPRINGS

K  8F mC  1.2525  8(0.15)(6 ) 
s ms =   =  2  = 41.8 ksi
K c  π Dw2  1.156  π (0.2437 ) 
 8 F a C   8(0.05)(6) 
s as = K  2 
= 1.2525 2
= 16
.11 ksi
π
 w D  π (0 .2437 ) 
1 sms − sas 2sas
= +
N s ys sno
1 41.8 − 16.11 2(16.11)
= +
N 104.8 60.56
N = 1.287
1
(c) F m = (200 + 25) = 112.5 lb = 0.1125 kip
2
1
F a = (200 − 25) = 87.5 lb = 0.0875 kip
2
K  8F mC  = 1.2525  8 (0.1125)(6)  = 31
s ms =  π D 2  1.156  2 
.36 ksi
K c
 w   π (0. 2437 ) 
 8 F C   8(0.0875)(6) 
s as = K  a 2  = 1.2525 2 
= 28.2 ksi
π
 w D  π (0 .2437 ) 
1 sms − sas 2sas
= +
N s ys sno
1 31.36 − 28.20 2(28.20)
= +
N 104.8 60.56
N = 1.04
CHECK PROBLEMS
A Diesel valve spring is made of 3/8-in. chrome-vanadium steel wire, shot-peened; inside
diameter is 3 in., 7 active coils, free length is 7 3/8 in., solid length is 4 1/8 in., length
with valve closed, 6 ¼ in., length when open, 5 1/8 in. (a) Compute the spring constant
and the factor of safety as defined by the Wahl criterion (see § 6.13, Text ). ). (b) Is there
any danger of damage to the spring if it is compressed solid? (c) What is the natural
frequency? If this spring is used on a 4-stroke Diesel engine at 450 rpm, is there any
danger of surge? Compute the change of stored energy between working lengths.
Solution:
For chrome-vanadium steel wire, shot-peened, Table AT 17
270

SECTION 4 - SPRINGS
(1.25)(168)
su = 0.166
ksi , [0.032 <
Dw < 0.437]
Dw
(1.25)(100)
s ys = 0.166
ksi , [0.032 <
Dw < 0.437]
Dw
(1.25)(49)
sno = 0.15
ksi , [0.028 <
Dw < 0.5]
D
w
3
Dw = in = 0.375 in
8
(1.25)(100)
s ys = ksi = 147.1 ksi
(0.375)0.166
(1.25)(49)
sno =
ksi = 70.96 ksi
(0.375)0.15
8 FC 3 N c
(a) δ =
GDw
F GDw
= k =
δ 8C 3 N c
G = 11.5 ×106 psi
N c = 7
Dw = 0.375 in
Dm − Dw = ID = 3 in
Dm = 3.375 in
Dm 3.375
C = = = 9
Dw 0.375
k = spring constant
k =
GDw
=
(11.5 × 10 )(0.375) = 105
6
.64 lb in
8C 3 N c 8(9) (7)
3
3 1
δ 1 = 7 − 4 = 3.25 in
8 8
δ 1 = (105
F 1 = k .64 )(3.25) = 343
.33 lb
3 1
δ 2 = 7 − 6 = 1.125 in
8 4
δ 2 = (105 .64)(1.125) = 118
F 2 = k .85 lb
1
F m = (343.33 + 118.85) = 231.09 lb
= 0.231 kip
2
1
F a = (343.33 − 118.85) = 112.24 lb = 0.11224 kip
2
K  8F mC 
s ms = K  π D 2 
c  w 
271

SECTION 4 - SPRINGS
4C − 1 0.615
K = +
4C − 4 C
4(9) − 1 0.615
K = + = 1.162
4(9 ) − 4 9
K  F C   
s ms = 8 m
= 1.162 8 0.231 92 = 39.8 ksi
K c  π Dw2  1.10  π ( (0.375)() ) 
 8 F a C   8(0.11224)(9 ) 
s as = K  2 
= 1.162 2  = 21.3 ksi
π
 w D  π (0. 375 ) 
1 sms − sas 2sas
= +
N s ys sno
1 39.8 − 21.3 2(21.3)
= +
N 147.1 70.96
N = 1.377
(b) max. “solid” s s = s ys = 147.1 ksi
Min. Solid Height = Dw N c = (0.375 )(7 ) = 2. 625 in

3
Solid deflection = 7 − 2.625 = 4.75 in.
8
δ = (105.64)(4.75) = 501.8 lb = 0.5018 kip
F = k
 8 FC   8(0.5018)(9) 
Solid stress = s s = K  2 
= 1.162  2 
= 95 ksi
< 147.1 ksi
π
D
 w  π (0. 375) 
There is no danger of damage
(c) Natural frequency
For steel
14,050 Dw
φ = 2
cps
N c Dm
14,050
φ = 2
cps
N cC Dw
14,050
φ = 2
cps = 66 cps
(7 )(9) (0.375)
 2π 
For 450 rpm, φ = 450  = 47 cps
 60 
66
= 1.4 < 12 , there is danger of surging.
47
272

SECTION 4 - SPRINGS
1 1
(d) U s = k (δ 12 −
δ 22 ) = (105.64) [(3.25 )2 − (1.125)2 ] = 491 in − lb
2 2
289. A helical spring is hot wound from 5/8-in. carbon-steel wire with an outside
diameter of 3 ¼ in. A force of 3060 lb. is required to compress the spring 1 ¾
in to the solid heigh. In service the spring is compressed so that its
deformation varies form

the Wahl criterion? (b) Is ½
thein.“solid
to1 1/8 in. (a)
stress” What
safe? is the (c)
Compute factor
the of safety
pitch by
angle,
(d) the change of stored energy between the working lengths, (e) the factor of
safety if the spring is peened?
Solution:
For hot-wound carbon steel wire

5
Dw = in
8
Table AT 17
91
s ys = 0.1 ksi , [0.093 <
Dw < 0.25]
Dw
91
s ys = = 104.5 ksi , Dw > 0.25
ksi in.
(0.25)0.1
49
sno = 0.15
ksi , [0.093 <
Dw < 0.25]
Dw
49
sno =
ksi =
60.33 ksi , Dw > 0.25
in.
(0.25)0.15
117
Permissible solid stress = ss = 0.31
ksi , [ Dw > 0.375
in.] § 6.3
Dw
117
ss = 0.31
= 35.4 ksi
ksi
(0.625)
F 3060
(a) k = = = 1748 .6 lb in
δ 1.75
 1 
δ 1 = (1748
F 1 = k .6)  = 874.3 lb
 2 
 1 
δ 2 = (1748
F 2 = k .6 )1  = 1967.2 lb
 8 
1
F m = (1967.2 + 874.3) = 1420.7 lb = 1.4207 kip
2
1
F = (1967.2 − 874.3) = 546.4 lb = 0.5464 kip
a
2
273

SECTION 4 - SPRINGS
5
Dw = in = 0.625 in
8
1
Dm + Dw = 3 in
4
Dm = 2.625 in
Dm 2.625
C = Dw = 0.625 = 4.2
4C − 1 0.615
K = +
4C − 4 C
4(4.2 ) − 1 0.615
K = + = 1.3808
4(4.2 ) − 4 4.2
K c = 1.234
K  8F mC  1.3808  8(1.4207 )(4.2 ) 
s ms =   =   = 43.5 ksi
K c  π Dw2  1.234  π (0.625)2 
 8F a C   8(0.5464 )(4.2) 
s as = K  2 
= 1. 3808  2  = 20.7 ksi
π
D
 w   π (0.625) 
1 sms − sas 2sas
= +
N s ys sno
1 43.5 − 20.7 2(20.7 )
= +
N 104.5 60.33
N = 1.106
(b) Permissible solid stress = 135.4 ksi
F = 3.060 kip
 8FC   8(3.060)(4.2 ) 
Solid stress, s s = K   = 1.3808  = 115.7 ksi < 135.4 ksi , safe
 π Dw   π (0.625) 
2 2
3
(c) Solid deflection = 1 in
4
(P − Dw ) N c = 1.75 in
8 FC 3 N c
δ =
GDw
G = 10.5 ×106 psi , hot-wound
F GDw
k = =
δ 8C 3 N c
274

SECTION 4 - SPRINGS
1748.6 =
( 10.5 ×10 )(0.625) 6
3
8(4.2 ) N
c
N c = 6.332
(P − 0.625)(6 .332) = 1.75
P = 0.9014 in
Pitch angle
P P
tan λ = =
π Dm π CDw
P  0.9014 
λ = tan −1 = tan 1 
−
 = 6.24
o
π CDw  π ( 4.2 )(0. 625) 
1 1
(d) U s = k (δ 12 −
δ 22 ) = (1748.6 )[(1.125)2 − (0.5)2 ] = 888 in − lb
2 2
(e) When peened
s ys = 12.5(104
.5) = 130
.6 ksi
sno = 1.25(60
.33) = 75
.4 ksi
1 = 43.5 − 20.7 + 2(20.7 )
N 130.6 75.4
N = 1.38
ENERGY STORAGE
293. A 10-lb. body falls 10 in. and then strikes a helical spring. Design a hard-
drawn carbon steel spring that will absorb this shock occasionally without
permanent damage. Determine appropriate values of wire diameter, coil
diameter, pitch, free length, closed length, and the maximum stress under the
specified conditions, and scale. Let C = 7 .
Solution:
For hard-drawn carbon steel, Table AT 17

182
su = 0.1 ksi , [0.093 <
Dw < 0.25]
Dw
91
Max. “solid” ss = 0.1 ksi , [0.093 <
Dw < 0.25]
Dw
36.855
ssd = (0.50)(0.405
)su = 0.1 ksi
Dw
ss2V
U s = 2

4 K G
275

SECTION 4 - SPRINGS
4C − 1 0.615
K = +
4C − 4 C
4(7) − 1 0.615
K = + = 1.213
4(7 ) − 4 7
 π Dw2 
V ≈  (π Dm ) N
4 
c
  N
π 2 Dw2 D m c
V =
4
Dm = CDw
π 2CDw3 N c
V =
4
8 FC 3 N c
δ =
GDw
(h + δ )
U s = W
 8FC 
s s = K  
π D 2
w
 
s sπ Dw2
F =
8KC
 ssπ Dw2   8C 3 N c 
δ =    GD 
 8 KC  w 
s sπ DwC 2 N c
δ =
KG
2 2 3
 ssπ DwC 2 N c  s π CD N c
U s = W h +  = 16K 2G
s w
 KG 
Wh
N c = 2 2 2 2

ss π CD w
− s sπ
Dw C W
16K 2G KG
36.855
when s s = 0. 1
ksi
Dw
Wh
N c = 0.9 2

(36.855)2 π 2CD w2.8 36.855π D C W
−
w
2
16K G KG
(0.010)(10)
N c = 2

(36.855) π (7 ) D2 2 2. 8
w
36.855π D 0w.9 (7 ) (0.010)
−
16(1.213) (11,500)
2
(1.213)(11,500)
0.10
=
N c 0.3466 Dw2.8 − 0.004067 D w0.9
276

SECTION 4 - SPRINGS
combination of Dw and N c

Gage No. W & M Dw N c Dw N c
12 0.1055 991.2 105
11 0.1205 312.1 37.6
10 0.1350 166.1 22.4
9 0.1483 108.0 16.0
16. 0
8 0.1620 75.2 12.2
7 0.1770 53.7 9.5
6 0.1920 40.2 7.7
5 0.2070 31 6.4
4 0.2253 23.4 5.3
3 0.2437 18.1 4.4
Use Dw = 0.2437

in < 0.25 in , N c = 18.1
45
Dm = 7 Dw = 7(0.2437 ) = 1.7059 in = 1 in
64
2
36.855π D 0.9C 2 N 0. 9 2
δ = s sπ DwC N c = w c
2.066 in
= 36.855π (0.2437 ) (7 ) (18.1) =
KG KG (1.213)(11,500)
36.855
ss = 0.1
= 42 .44 ksi
(0.2437 )
91 91
s so = 0.1 = = 104
.8 ksi
Dw (0.2437 )0.1
Solid deflection
 104.8 
= (2.066) = 5 .1 in
 42.44 
(P − Dw ) N c = 5.1
(P − 0.2437 ) (18.1) = 5.1
P = 0.5255 in
17
say P = = 0.53125 in
32
Minimum Solid Height = Dw N c = (0.2437 ) (18.1) = 4 .41 in
Assume squared and ground end
Solid height = Dw N c + 2 Dw = (0.2437 )(18
.1) + 2(0.2437 ) = 5 .0 in
Solid deflection = (0.53125 − 0.2437
)(18.1) = 5 .2 in
Free length = 5.0 in + 5.2 in = 10.2in
Summary of answer:
Dw = 0.2437 in , No. 3 W & M
277

SECTION 4 - SPRINGS
45
Dm = 1 in
64
17
P= in
32
Free length = 10.2 in
Closed length = 5 in
Maximum stress = 42.44 ksi
294. A helical spring, of hard-drawn steel wire, is to absorb 75 in-lb of energy
without being stressed beyond the recommended value of average service. Let
C = 6 . Decide upon satisfactory dimensions; Dw , Dm , N c , free length, pitch
angle, solid stress, volume of metal, possibility of spring buckling.
Solution:
For hard-drawn steel wire, shock load, average service

140
su = 0.19 ksi , [0.028 <
Dw < 0.625]
Dw
Max. “solid” s s = 70
0.19
ksi , [0.028 <
Dw < 0.625]
Dw
 140  19.278
)(0.85)(0.324)
s sd = (0.50)(0.85)(0.324)su = (0.50  = ksi
 D 0.19 
D 0. 19
 w  w
ss2V
s s2π 2 Dw3 CN c
U s = =
4 K 2G 16 K 2G
C = 6
4C − 1 0.615
K = +
4C − 4 C
4(6) − 1 0.615
K = + = 1.2525
4(6 ) − 4 6
U s = 75 in − lb = 0.075 in − kip
 19.278  π 2 Dw3 (6 ) N c
U s = 0.075 =  0.19  2

 Dw  16(1.2525 ) (11, 500 )
2.62

0.9837 = Dw N c
Table AT-15
W&M Dw N c Dw N c
278

SECTION 4 - SPRINGS
9 0.1483 146 21.65

8 0.1620 116 18.79
7 0.1770 92 16.28
6 0.1920 74 14.21
5 0.207 61 12.63
4 0.2253 49 11.04
3
2 0.2437
0.2625 40
32.7 9.75
8.58
1 0.2830 26.9 7.61
0 0.3065 21.8 6.68
2-0 0.3310 17.8 5.89
3-0 0. 3625
0.3625 14.0 5.075
4-0 0.3938 11.3 4.45
5-0 0.4305 8.95 3.85
Use Dw = 0.4305 in , 5-0 W & M

N c ≈ 9
9
D = 6(0.4305) = 2.583 in
≈2 in
m
16
19.278
ss = = 22
.63 ksi
(0.4305)0.19
70
Max. Solid Stress = s so = 0.19
= 82
.16 ksi
(0.4305)
2
s sπ DwC 2 N c (22.63)(π )(0.4305)(6) (9 )
δ = = = 0.6885 in
KG (1.2525)(11,500)
 82.16 
Solid deflection =  (0.6885) = 2 .5 in
 .63 
22
(P − Dw ) N c = 2.5
(PP=−00..7083
4305 )(9) = 2.5
in
45
say P = = 0.703125 in
64
Solid deflection = (0.703125 − 0
.4305)(9 ) = 2.453625
in
 2.453625 
Solid stress = 22.63  = 80.65 ksi
 0.6885 
7
Minimum Solid Height = Dw N c = (0.4305)(9 ) = 3.8745 in ≈ 3
in
8
 45  21
Minimum Free Length = PN c =  (9 ) = 6.328125
in ≈ 6 in
 64  64
Pitch Angle
279

SECTION 4 - SPRINGS
 45 
P  
λ = tan −1
= tan
−1
 64  =5 o
< 12
o

π Dm  π  2  
9
  16  
Volume
 2   2

V ≈  π Dw (π Dm ) N c =  π (0.4305)  π  9   (9) = 10.55 in3
 2 16
 4   4     
Summary of answer:
Dw = 0.4305 in , No. 5-0 W & M
9
Dm = 2 in
16
N c = 9
21
Free length = 6 in
64
Pitch Angle = λ = 5 o
Solid Stress = 80.65 ksi

3
Volume of metal = 10.55 in
Possibility of spring buckling
21
6
64 = 2.47 < 4 , no possibility
9
2
16
CONCENTRIC HELICAL SPRINGS
297. Two concentric helical springs are to be subjected to a load that varies from a
maximum of 235 lb. to a maximum of 50 lb. They are to fit inside a 1 5/8 in.
cylinder. The maximum deflection is to be ¾ in., and the deflection when
compressed solid is to be approximately 1 in. Using the “static approach” for
severe service (maximum load), determine the wire diameter, mean coil
diameter, number of coils, solid length, and free length of both springs. (Start
with oil-tempered wire and assume a diametral clearance between the outer
D
spring and the cylinder of w , assume a similar clearance between springs.
2
Search for a suitable spring index and wire size.)
Solution:
For oil-tempered wire

Table AT 17
280

SECTION 4 - SPRINGS
146
su = ksi , [0.032 <
Dw < 0.5]
Dw0.19
87.5
Max. “solid” ss = 0.19
ksi , [0.032 <
Dw < 0.5]
Dw
Severe service
0.263(146) 38.398
s sd = 0.263s = u 0.19
Dw = 0.19
Dw ksi
F = 235 lb = 0.235 kip
δ o = δ i
8F oC o3 N co 8F i C i3 N i
=
GDwo GDwi
Assume, C o = C i
3GDwo
F o =
32C 3 N co
3GDwi
F i = 3

32C N ci
 8 F oC 
s so = K  2 

π D
 wo 
 8F C 
s si = K  i 2 
 π Dwi 
D D
C = mo = mi
Dwo Dwi
4C − 1 0.615
K = +
4C − 4 C
D
Dmo − Dwo − wi = Dmi + Dwi
2
Dmo − Dmi = D wo + 1.5Dwi
D
1.625 − wo = Dmo + Dwo
2
Dmo + 1 .5 D wo = 1.625
CDwo + 1 .5D wo = 1.625
1.625
Dwo =
C + 1.5
1.625C
Dmo =
C + 1.5
CDwo − CDwi = Dwo + 1.5 Dwi
(C − 1) Dwo = (C + 1.5)D wi
281

SECTION 4 - SPRINGS
1.625(C − 1)
Dwi =
(C + 1.5)2
1.625C (C − 1)
Dmi =
(C + 1.5)2
 8 F oC  38.398
s so = K  2 
= 0.19
ksi
 π D 1.81 D
wo wo
15 .08 Dwo
F o =
KC
 8F i C  38.398
s si = K  2 
= 0.19
ksi
π
D
 wi  D wi
1.81
15 .08 Dwi
F i =
KC
F o + F i = F = 0.235 kip
1.81 1.81
15.08 Dwo 15.08 Dwi
+ = 0.235
KC KC
1.81 1.81
15.08 D wo
+ 15.08 D wi
= 0.235KC
1.81 1.81
 1.625  1.625(C − 1) 
15.08  + 15.08  = 0.235KC
 C + 1.5   C + 1 .5 
 1 (C − 1)1.81   4C − 1 0.615 
154.52 1.81
+ 3.62 
= 0. 235 + C
 (C + 1.5 ) (C + 1 .5 )   4 C − 4 C 
C = 5.328
1.625(5.328 − 1)
Dwi = = 0 .1509 in
(5.328 + 1.5)2
1.625
Dwo = = 0.2380 in
5.328 + 1.5
= =
Table AT 15, use Dwi 0.1620 in , No. 8 W & M and Dwo 0.2625 in , No. 2 W & M
13
Dmo = CDwo = (5.328)(0.2625 ) = 1.3986 in ≈ 1 in
32
7
Dmi = CDwi = (5.328)(0.1620 ) = 0.8631
in ≈ in
8
 7 
 
C i =
Dmi
=
 8 
= 5.401
Dwi 0.1620
 13 
1 
C o =
Dmo
=
 32  = 5.357
Dwo 0.2625
282

SECTION 4 - SPRINGS
1.81
15.08 Dwo
F o =
K oC o
4(5.357) − 1 0.615
K o = + = 1.287
4(5.357) − 1 5.357
1.81
15.08(0.2625)
F o = = 0 .194 kip
(1.2871).(815.357 )
15.08 Dwi
F i =
K i C i
4(5.401) − 1 0.615
K i = = 1.2843 +
4(5.401) − 1 5.401
15.08(0.1620 )
F i = = 0. 081 kip
(1.2843)(5.401)
F o + F i = 0.194 + 0.071 = 0.275 kip > 0.235 kip , ok
3GDwo
F o =
32C 3 N co
( )( )
0.194
= 3 11,500 0.32625
32(5.357) N
co
N co = 9.5
3GDwi
F i =
32C 3 N ci
3(11,500)(0.1620 )
=
0.071 3

32(5.401) N
ci
N ci = 15.6
87.5
Max. solid stress, sss = 0.19
ksi ,
Dw
87.5
s = .82 ksi
(0.2625)0.19 = 112
sso
87.5
sssi = = 123
.65 ksi
(0.1620)0.19
Stress
38.398
ssi = = 54
.26 ksi
(0.1620)0.19
38.398
sso = = 49
.51 ksi
(0.2625)0.19
Solid stress
sso = 49.51
 1  = 66.01 ksi < 112.82 ksi
 0.75 
283

SECTION 4 - SPRINGS
 1 
ssi = 54.26  = 72.35 ksi < 123.65 ksi
 0.75 
Solid length
Dwo N co = (0.2625 )(9.5) = 2 .5 in
Dwi N ci = (0.1620 ) (15.6) = 2 .53 in
assume solid length = 3 in

Dwi ( N ci + xi ) = (0.1620)(15
.6 + xi ) = 3 in
xi = 2.92
Total coils = 15.6 + 2.92 = 18.52
Dwo ( N co + xo ) = (0.2625)(9 .5 + xo ) = 3 in
xo = 1.93
Total coils = 9.5 + 1.93 = 11.43
Free Length = 3 in + 1 in = 4 in
Summary of answer:
Outside wire.
Dwo = 0.2625 in , No. 2 W & M
13
Dmo = 1 in
32
N to = 11.43
Solid length = 3 in
Free length = 4 in
Inside wire.
Dwi = 0.1620 in , No. 8 W & M
7
Dmi = in
8
N ti = 18.52
Solid length = 3 in
Free length = 4 in
298. Two concentric, helical compression springs are used on a freight car. The
larger spring has an outside diameter of 7 in., a free length of 7 1/8 in., and is
made of a 1 ¾ in. steel bar. The smaller has an outside diameter of 4 1/8 in., a
free length of 6 13/16 in. , and is made of 7/8 in. steel bar. The solid height of
each spring is 5 ¼ in. and the forces required to compress them solid are
15,530 lb. and 7,000 lb., respectively. The working load on the two springs is
11,350 lb. Determine (a) the number of free coils in each spring, (b) the stress
in each spring when compressed solid, (c) the stresses induced by the working
284

SECTION 4 - SPRINGS
load. Notice that the outer spring deflects 5/16 in. before the inner one takes a
load. (d) What energy is absorbed while changing deflection from that at the
working load to that when the springs are compressed “solid”?
Solution:
ODo = 7 in
Dwo = 1 3 in
8
1
FLo = 7 in
8
1
ODi = 4 in
8
7
Dwi = in
8
13
FLi = 6 in
16
1
(a) Solid height = D N = 5 4 in
w T
5.25
N To = = 3.82
1.375
5.25
N Ti = =6
0.875
(b) F o = 15,530 lb

F i = 7000 lb
 8FC 
s s = K  2 

π
D
 w
Dmo = 7 − 1 3 = 5.625 in
8
D 5.625
C o = mo = = 4.091
Dwo 1.375
4(4.091) − 1 0.615
K o = + = 1.393
4(4.091) − 4 4.091
1 7
Dmi = 4 − = 3.25 in
8 8
D 3.25
C i = mi = = 3.714
Dwi 0.875
4(3.714) − 1 0.615
K i = + = 1.442
4(3.714) − 4 3.714
285

SECTION 4 - SPRINGS
Solid stress
 8(15,530)(4.091) 
s so = 1.393 2
 = 119
, 203 psi
 π (1 . 375 ) 
 8(7000)(3.714) 
s si = 1.442 2
 = 124
,689 psi
 π (0 . 875 ) 
(b) Stresses induced by working load
F i + F o = 11,350 lb

15,530
k o = = 8283 lb in
 1 1 
7 −5 
 8 4 
7000
k o = = 4480 lb in
 13 1 
6 − 5 
 16 4 
5
δ o − δ i = = 0.3125 in
16
F i = k iδ i = 4480δ i
F o = k oδ o = 82 83 (0.3125 + δ i )
i + 8283(0 .3125 + δ i ) = 11, 350 lb
F i + F o = k oδ o = 4480δ
δ i = 0.6865 in
δ o = 0.3125 + 0.6865 = 0.9990 in
F i = (4480)(
)(0.6865
) = 3076
lb
F o = (8283 )(
)(0.9990
) = 8275
lb
Stresses
 8(8275)(4.091) 
s so = 1.393 2
 = 63
,516 psi
 π (1.375) 
 8(3076)(3.714) 
s si = 1.442 2
 = 54
,792 psi
 π (0.875 ) 
(d) Energy
1
U so = k o (δ o2 2 − δ o21 )
2
1 1
δ o 2 = 7 − 5 = 1.875 in
8 4
δ o1 = 0.9990 in
1
U = (8283) (1.875)2 − (0.999)2 = 10,427
in − lb
2
[ ]
so
286

SECTION 4 - SPRINGS
1
U si = k i (δ i22 − δ i21 )
2
13 1
δ i 2 = 6 − 5 = 1.5625 in
16 4
δ o1 = 0.6865 in
1 2 2
U = 2 (4480 ) (1.5625) − (0.6865) = 4, 413
in − lb
[ ]
si
TORSION-BAR SPRINGS
299. A torsion-bar similar to that shown is to be used for the front spring of an
automobile. Its rate should be 400 lb./in. of deflection of the end of the arm
o
which is e = 10 in. long. It is made of AISI 9261,OQT 900 F, and the
maximum repeated load is 1500 lb. perpendicular to the centerline of the arm.
The support is such that bending of the bar is negligible. (a) Determine its
diameter and length so that no permanent set occurs due to a 30 % overload
(limited by a stop). Use s ys = 0.6s y , but check with equation (c) § 6.3, Text , if
appropriate. (b) Determine the factor of safety according to the Soderberg
criterion if the load varies from 1200 lb. to 1500 lb.; minimum r d = 0.1 ,
D d = 3 . (c) The same as (b) except that the bar is shot-peened all over. What
other steps may be taken to improve the fatigue strength?
Problem 299, 300
Solution:
e = 10 in
o
For AISI 9261, OQT 900 F
s y = 192 ksi
su = 215 ksi
s ys = 0.6s y = 115
.2 ksi = 115, 200 psi
287

SECTION 4 - SPRINGS
16T
(a) ss =
π d 3
T = Fe = (1.3)(
)(1500 )(10) = 19,500
in − lb
16(19,500)
115, 200 =
π d 3
=
d 0.95 in
use d = 1 in
117 117
§ 6.3 ss = = 0. 3 = 117 ksi ≈ s ys
Dw
0.3
(1)
(b) Soderberg Criterion

1 sms K f sas
= +
N s ys sns
sns = (0.6 )(0.5 )(215) = 64
.5 ksi
Figure AF 12, r d = 0.1 , D d = 3
K t = 1.45
K f ≈ K
t = 1.45
1
F m = (1500 + 1200) = 1350
lb
2
T m = (1350)(10) = 13,500
in − lb = 13.5 in − kips
16(13.5)
sms = 3
= 68.8 ksi
π (1)
1
F a = (1500 − 1200 ) = 150
lb
2
T a = (150)(10) = 1500
16(1.5)
sas = 3
=7
.64 ksi
π (1)
1 68.8 (1.45)(7.64)
= +
N 115.2 64.5
N = 1.30
(c) Shot-peened
s ys = 1.25(115
.2) = 144
ksi
sns = 1.25(64
.5) = 80
.6 ksi
1 68.8 (1.45)(7.64)
= +
N 144 80.6
N = 1.625
288

SECTION 4 - SPRINGS
300. A solid steel torsion bar is loaded through a 10 in. arm as shown. The load F
perpendicular to the center-line of the arm varies from 500 to 1000 lb.,
7
200,000 cycles. The bar is d = in. in diameter and 30 in. long; let D d = 3 ;
8
r d = 0.1 ; (a) Determine the maximum stress in the bar, the angular
deflection, and the scale (lb./in.) where F is applied. The support is such that
bending of the bar is negligible. (b) Select a material and heat treatment for
this bar for a minimum N = 1.2 , Soderberg criterion.
Problem 299, 300

Solution:
Fig. AF 12, K f = 1.45
1
F m = (1000 + 500) = 750
lb
2
1
F a = (1000 − 500) = 250
lb
2
T m = (750 )(10) = 7500
T a = (250 )(10) = 2500

(log K f ) 3 (log1.45 ) 3
K fl = n = (200,000 ) 1.33
K f 1.45
16T
ss =
π d 3
16(7.5)
sms = 3
= 57 ksi
 7 
π  
 8 
16(2.5)
sas = 3
= 19 ksi
 7 
π  
 8 
(a) s max = sms + K fl sas = 57 + (1.33)(19) = 82 .27 ksi
289

SECTION 4 - SPRINGS
TL 64TL
θ = =
JG π d 4G
64(500)(10)(
)(30)
θ mi
min
n = 4
= 0.4533 rad
 7 
π   (11.5 ×106 )
 8 
θ ma
max
x = 64(1000 4 )(10 )(30 ) = 0.9066 rad
 7 
π   (11.5 ×106 )
 8 
F 1000
scale = = = 110 .3 lb in
θ e (0.9066)(10)
1 sms K f sas

(c) = +
N s ys sns
0.085
 106 
sns = (0.6 )(0.5)su   = 0.344su
 200, 000 
s ys = 0
.6s y
1 57 (1.33)(19)
= +
1. 2 0.6s y 0 .344su
o
Use AISI 8760, OQT 800 F
s y = 200 ksi
su = 220 ksi
N = 1.24
HELICAL SPRINGS – NON CIRCULAR SECTION
301. A spring is to be designed of square oil-tempered steel wire and subjected to a
repeated
13/32 in.maximum
Determineload
(a) of
the325
wirelb.;size
mean
for coil diameter,
average 1 ½(b)
service, in.;the
deflection,
required
number of active coils, (c) the solid height, free length, and pitch (the ends are
squared and ground, the “solid stress” must be satisfactory, and the pitch angle
not excessive). (d) What amount of energy is stored when the load is 325 lb.?
Express in in-lb. and Btu.
Solution:
For oil-tempered wire,

146
su = 0.19 , [0.032 <
Dw < 0.5]
Dw
=
Max. “solid” s s
0.6su
290

SECTION 4 - SPRINGS
(a) average service,

b = Dw , t = b
K q FDm (3b + 1 .8t ) 2.4 FDm
ss= = K q
2b 2t 2 b3
s sd = 0. 324su , average service
K q 2.4 FD
m = 0.324 146
2b 3 b 0.(19 )
F = 0.325 kip
1
Dm = 1 in
2
K q = 1.25 (assumed)
 2.4(0.325)(1.5) 0.324(146)
1.25
 b
3  = b
0. 19

b = 0.2902 in
Table AT 15, use b = 0.313 in , # 1 wire size
D 1.5
C = m = = 4.8
b 0.313
Figure AF 15, K q = 1.275
2.45FDm3 N c 2.45FDm3 N c
(b) δ = =
Gt (b − 0.56t )
3
0.44Gb 4
3
13 2.45(0.325)(1.5) N c
=
0.44(11,500)(0.313)
4
32
N c = 7.34
(c) Solid height = b( N c + 2) = 0.313( 7.34 + 2 ) = 2 .92 in
Free length = PN c + 2b

F = 0.325 lb
 2.4 FDm   2.4(0.325)(1.5) 
s s = K q  3  = 1.275  3  = 48.65 ksi
 b   (0.313) 
0.6(146)
solid stress = = = 109
.2 ksi
(0.313)0.19
109.2  13 
solid deflection = =   = 0.91 in
48.65  32 
(P − b ) N c = 0.91
(P − 0.313)( 7.34) = 0.91
P = 0.437 in
291

SECTION 4 - SPRINGS
7
use P = in
16
 7  27
Free length = PN c + 2b =  (7.34) + 2 (0.313) = 3.837 in
≈3 in
 16  32
 7 
P  16 
tan λ = =
π Dm π (1.5)
λ = 5.3 o
< 10
o
(0.325)
1 1 1 13 
(d) U s = k δ 2 = F δ =   = 0.066 in − kip = 66 in − lb
2 2 2  32 
66
U s = = 0.085 Btu
778
302. A coil spring, of hard-drawn carbon steel, is to deflect 1 in. under a load of
100 lb. The outside coil diameter is to be 1 in. Compute the number of active
coils, (a) if the wire is round, 5/32 in. in diameter, (b) if the wire is square,
5/32 in. on the side, (c) if the wire is rectangular 1/8 x 3/16 in., long
dimension parallel to the axis, (d) If the wire is rectangular 3/16 x 1/8 in.,
short dimension parallel to the axis. (e) What is the maximum stress in each of
the above springs under the 100-lb load? (f) What is the ratio of the
approximate volumes, square- or rectangular-wire to round wire spring?
Solution:
Dm + Dw = 1 in
5
(a) Dw = in
32
Dm = 1 − 5 = 27 in
32 32
 27 
 
Dm  32 
C = = = 5.4
Dw  5 
 
 32 
8 FC 3 N c
δ =
GDw
3
8(100)(5.4) N c
1=
6  5 
(11.5 ×10 ) 
 32 
N c = 14.3
292

SECTION 4 - SPRINGS
5
(b) Square, b = in
32
5 27
Dm = 1 − = in
32 32
2.45FD3m N c
δ =
0.44Gb 4
3
 27 
2.45(100)  N c
1=  32 
4
 
5
0.44(11.5 ×106 ) 
 32 
N c = 20.5
3 1
(c) b = in , t = in
16 8
1 7
Dm = 1 − t = 1 − = in
8 8
3
δ = 2.345FD N
m c
Gt (b − 0.56t )
3
 7 
2.45(100)  N c
1=  8 
3
 
(11.5 ×106 )    − 0.56  
1 3 1
 8  16  8 
N c = 16.1
1 3
(d) b = in , t = in
8 16
Dm = 1 − t = 1 − 3 = 13 in
16 16
3
2.45FDm N c
δ = 3
Gt (b − 0.56t )
3
 13 
2.45(100)  N c
1=  16 
3
 
(11.5 ×106 )    − 0.56  
3 1 3
 16   8  16  
N c = 11.5
(e) Maximum Stress
293

SECTION 4 - SPRINGS
8 FC
For (a) ss = K
π Dw3
4(5.4) − 1 0.615
K = + = 1.284
4(5.4) − 4 5.4
 
 
s s = 1.284 8(100)(5.34 )  = 72,320 psi
  5  
 π   
  32  
FD m (3b + 1 .8t ) 2.4FD m

For (b) s s = K q 2 2
= K q
2b t b3
 27 
 
C = Dm
=
 32 
= 5.4
b  5 
 
 32 
K q = 1.25
  27  
 2. 4(100) 
s s = 1.25   32   = 66,355 psi
  5 3 
   
  32  
FD m (3b + 1.8t )
For (c) s s = K q
2b 2t 2
 7 
 
D
C = m =
 8 
=7
t  1 
 
 8 
K q = 1.1
  7  
 (100 )  
  8   3 3  + 1.8 1  = 68,992 psi
s s = 1.1    
  3  2  1  2    16   8 
 2    
  16   8  
FD m (3b + 1.8t )
For (d) s s = K q
2b 2t 2
 13 
 
C = Dm
=
 16 
= 4.33
t  3 
 
 16 
294

SECTION 4 - SPRINGS
K q = 1.2
  13  
 (100 )  
  16   3 1  + 1.8 3  = 63,232 psi
s s = 1.2    
  1   3  2    8 
2
 16 
 2    
  8   16  
(e) Ratio of the approximate volumes
For (a) Round wire

 π 
V a =  Dw (π Dm )N
2
c
 4 
 π  5  2    27 
V a =      π   (14.3) = 0.727 in
3
 4  32     32 
For (b) Square wire
V b = b 2 ( π Dm )N
c
2
 5  π 
V b =   27   (20.5) = 1.327 in
3
 32    32  
For (c) rectangular wire
V c = bt (π
Dm )N c
 3  1    7 
    π   (16.1) = 1.037 in
3
V c = 
 16  8    8 
For (d) rectangular wire
V d = bt ( π Dm )N
c
 1  3    13 
 (11.5) = 0.688 in
3
V d =    π 
 8  16    16 
Ratio of volume
Square to round wire
V b 1.327
= = = 1.825
V a 0.727
Rectangular to round wire (long dimension parallel to the axis)
V c 1.037
= = = 1.426
V a 0.727
Rectangular to round wire (short dimension parallel to the axis)
V d 0.688
= = = 0.946
V a 0.727
295

SECTION 4 - SPRINGS
TENSION SPRINGS
305. Design two tension springs for a spring balance with a capacity of 200 lb.
Each spring supports a maximum load of 100 lb. The outside diameter must
not exceed 1 ¼ in. and the total length including end loops must not exceed 9
½ in. Select a material and determine the dimension, including wire diameter,
number of coils, and free length.

Solution:
Table AT 17, assume oil tempered wire
146
su = 0.19 ksi
Dw
87.5
s ys = 0.19
ksi
Dw
0.8(87.5) 70
ssd = 0.19
= 0.19
ksi , [0.032 <
Dw < 0.5]
D w Dw
F = F i + k δ
ss = 8K cFD m

π Dw3
2r D
C = m = m
Dw Dw
8 F aC 3 N c
δ =
G Dw
G

Dw
k =
8C 3 N
 G Dw  8 F aC 3 N c 
k δ =  3    = F a
 8C 
N GD w 
F = 100 lb
= 0.10 kip
a
Figure AF 15, assume K c = 1.2
8K cF i Dm 8K cF a Dm
ss = 3
+
π D w π Dw3
8 K cF a C
ss = K csi +
π Dw2
OD = Dm + Dw = 1.25 in
1.25
Dw =
C + 1
§ 6.21, assume si = 18 ksi
ssd = s s
296

SECTION 4 - SPRINGS
70 8(1.2)(0.1)C
0.19
= (1.2)(18) +
Dw π Dw2
0.19 2
70(C + 1) 8(1.2 )(0.1)C (C + 1)
= 21.6 +
(1.25)0.19 π (1.25)
2
0.19 2
67.1(C + 1) = 21 .6 + 0.1956C (C + 1)
67.1(C + 1)0.19 − 0 .1956C (C + 1)2 = 21.6
C = 6.7
1.25 1.25
Dw = = = 0.1623 in
C + 1 6.7 + 1
Table AT 15, use Dw = 0.1620 in , 8 W & M
Dm = CDw = (6.7 )(0.1620
) = 1. 085 in
say Dm = 1.0 in
Dm 1.0
C = = = 6.17
Dw 0.1620
si = 17.7 ksi
To check, Fig. AF 15, K c = 1.15

8(1.15)(0.10)(6.17)
ss = 1.15(17.7) + 2
= 89.20 ksi
(
π 0.1620 )
70
ssd = = 98 .92 ksi > 89.20 ksi , o.k.
(0.1620 )0.19
Total length = Dw N c + 2 ( Dm + Dw )

9.5 = (0.162) N c + 2(1.0 + 0.162)
N c = 44.3 coils
Free length = Dw N c = (0.1620) (44.3) = 7 .18 in
Summary of answer:
Material, oil-tempered wire
Dw = 0.1620 in , 8 W & M
N c = 44.3 coils
Free length = 7.18 in.
306. Two helical tension springs are to be used in scales for weighing milk. The
capacity of the scales is 30 lb., each spring carries 15 lb. with a deflection of 3
9/16 in. The springs are made of No. 14, W & M steel wire, outside diameter,
29/32 in. (a) how many coils should each spring have? (b) What is the
maximum stress in the wire? What material should be used?
297

SECTION 4 - SPRINGS
Solution:
k δ = 15 lb
9
δ = 3 in
16
(a) Table AT 15, No. 14 W &M
Dw = 0.0800 in
29
Dm = OD − Dw = − 0.0800 = 0.82625 in
32
Dm 0.82625
C = = = 10.328
Dw 0.0800
8( k δ )C N c
3
δ =
GDw
3
9 8(15)(10 .328) N c
3 =
16 (11.5 ×10 )(0.080) 6
=
N c 24.8
(b) F = F i + k δ
π si Dw3
F i =
8 Dm
§ 6.21, C = 10.328
si = 11,272 psi
3
π (11,272)(0.08)
F i = =2 .743 lb
8(0.82625)
F = 2.743 + 15 = 17.743 lb
8K c FDm 8(1.09)(17.743)(0.82625)
ss = = 3
=
79,476 psi
π (0.080)
3
π D w
ss 79,476
s ys ≈ = = 99,345 psi = 99.345 ksi
0.8 0.8
Table AT 17, use Hard drawn wire
70 70
s ys = 0.19 = = 113 ksi
> 99.345 ksi
Dw (0.080)0.19
307. A tension spring for a gas-control lever is made of Dw = 0.078 in steel wire;
inside diameter, 0.609 in.; number of coils, 55; free length including end
loops, 5 9/16 in. When the spring is extended to a length of 6 5/16 in., it must
exert a force 5 ½ lb.; it must extend to (a) the initial tension, (b) the stress in
the spring caused by the initial tension (compare with the recommended
298

SECTION 4 - SPRINGS
maximum values), (c) the stress caused by the 5 ½-lb load, (d) the maximum
stress. What material should be used? (e) What energy is absorbed from the
point where the load is the initial tension until the spring’s length is 6 5/16 in.?
(Data courtesy Worthington Corporation.)
Solution:
=
Dw 0.078 in
Dm − Dw = 0.609 in
Dm = 0.609 + 0.078 = 0.687 in
Dm 0.687
C = = = 8.8
Dw 0.078
N c = 55
8 FC 3 N c
δ =
GDw
1
F = 5 lb
2
5 9
δ = 6 16 − 5 16 = 0.75 in
3
8(k δ )(8.8) (5)
δ = 0.75 =
(11.5 ×10 )(0.078)
6
k δ = 2.244 lb
(a) F i = F − k δ = 5.5 − 2 .244 = 3.256 lb

8F i C 8(3.256)(8.8)
(b) si = = 2
= 12
,000 psi
π (0.078)
2
π D w
§ 6.21, C = 8.8
si = 13,300 psi > 12,000 psi , ok
(c) F = 5.5 lb
8K c FC
ss =
π Dw2
C = 8.8
Figure AF 15
K c = 1.1
8(1.1)(5.5)(8.8)
ss = 2
= 22
,284 psi
π (0.078)
(d) maximum stress
k = k δ = 2.244 = 2.992 lb in

δ 0.75
299

SECTION 4 - SPRINGS
F = k ′
5 9
δ ′ = 9 − 5 = 3.75 in
16 16
F = F i + k δ ′ = 3.256 + (2.992
)(3.75) = 14 .476 lb
8K c FC 8(1.1)(14.476)(8.8)
ss = = 2
= 58,651 psi
π (0.078)
2
π D
w
Table AT 16
s 58,651
s ys ≈ s = = 73,300 psi = 73.3 ksi
0.8 0. 8
Table AT 17, use Hard drawn wire
70 70
s ys = 0.19 = 0.19
= 113.658
ksi > 73.3 ksi
Dw (0.078)
1 1
(e) U s = k δ 2 = (2.992 )(0.75)2 = 0.8415
in − lb
2 2
TORSION SPRINGS
308. A carbon-steel (ASTM A230) torsion spring is to resist a force of 55 lb. at a

radius of 2 in.; the mean diameter is to be 2 ½ in. Compute (a) the diameter of
o
the wire for average service, (b) the number of coils for a deflection of 180
under the given torque, (c) the energy the spring has absorbed when the force
is 55 lb.
Solution:
T = M
= Fa
F = 55 lb
a = 2 in
T = M = (55) (2 ) = 110 in − lb
Dm = 2.5 in
182
Table AT 17, su = 0. 1
ksi , [0.093 <
Dw < 0.25]
Dw
Average service
 182  117.936 117,936
s d = (1.6)(0.405)su = 0.648  = 0.1 ksi =
0.1  0. 1
psi
D
 w  D w
Dw
KMc
(a) s s =
I
For round wire, assume K c = K ci = 1.08 , Table AT 18
Dw
=
c 2
300

SECTION 4 - SPRINGS
I π Dw3
=
c 32
(1.08)(110)(32) 117,936
ss = 3
= 0.1

π D w Dw
Dw = 0.2060
in < 0.25 in
Table AT 15, use Dw = 0.2070 in , No. 5 W & M

r D 2
To check: = m = = 9.66 > 9 , ok
c Dw 0.2070
Table AT 18, K = 1.08
(1.08)(110)(32)
ss = 3
= 136
,430 psi
π (0.2070 )
117,936
ssd = = 138, 054 psi
> 136,430 psi
(0.2070 )0.1
Therefore, use No. 5 W & M, Dw = 0.2070 in
M π Dm N c
=
(b) θ EI
6
E = 30 ×10 psi
π Dw4
I =
64
θ = 1 80 = π
o
64 MDm N c
θ = 4

EDw
64(110
)(2) N c
π =
(30 ×10 )(0.2070)6 4
N c = 12.29
1 1
(c) U s = T θ = (110 )(π ) = 172. 8 in − lb
2 2
312. A pivoted roller follower is held in contact with the cam by a torsion spring.
The moment exerted by the spring varies from 20 lb-in to 50 lb-in. as the
o
follower oscillates through 30 . The spring is made of AISI 6152 steel, OQT
o
1000 F. What
What should be the value of Dw , Dm , and N c if the factor of safety
is 1.75 based on the Soderberg line? Would this be a conservative or risky
approach?
Solution:
o
AISI 6152,
su = 184 ksiOQT
1000 F
301

SECTION 4 - SPRINGS
s y = 173 ksi

sn = 0.5s u = 92 ksi
1
M m = (50 + 20
) = 35 lb − in
2
1
M a = (50 − 20
) = 15 lb − in
2
assume K = 1.08
32 KM m 32(1.08)(35) 385
sm = = = psi
π Dw3 π Dw3 3
Dw
32 KM a 32(1.08)(15) 165
sa = = = psi
π Dw3 π Dw3 Dw
3
1 sm sa
= +
N s y sn
1 385 165
= +
1.75 173,000 Dw3 92 ,000 Dw3
Dw = 0.1916 in
Table AT 15, use Dw = 0.1920 in , No. 6 W & M
To solve for K
32(35)K
sm = 3
= 50, 369K psi
π (0.1920 )
32(15)K
sa = 3
= 21, 587 K psi
π (0.1920 )
1 50,369 K 20,587 K
= +
1.75 173,000 92,000
K = 1.0868
Table AT 18 K ci = K = 1.0868
> 9 , ok
r = Dm = 9.32
c Dw
Dm = 9.32(0.1920
) = 1.7894
in
7
use Dm = 1 in = 1.875 in
8
∆ M π Dm N c 64∆ MDm N c
∆θ = = 4

EI EDw
30π 64(50 − 20 )(1.875) N c
=
180 (30 ×10 )(0.1920)
6 4
N c = 5.93
Summary of answer:
Dw = 0.1920 in , No. 6 W & M
302

SECTION 4 - SPRINGS
7
Dm = 1 in
8
N c = 5.93 , N > 1.4 , therefore conservative.
FLAT AND LEAF SPRINGS
315. A cantilever flat spring of uniform strength, Fig. 6.20, Text , is to absorb an
energy impact of 500 ft-lb. Let the thickness of the steel, AISI 1095, OQT 900
o
F, be ½ in. and let the maximum stress be half of the yield strength. (a) Find
the width b of the spring at the widest point in terms of the length L .
Determine values of b for lengths of 36 in., 48 in., 60 in., and 72 in. (b)
Determine the deflection of the spring for each set of values found in (a).
Solution.
Fig. 6/20
6 FL
s B =
bh 2
6 FL3
δ =
Ebh3
o
AISI 1095, OQT 900 F, s y = 104 ksi , Table AT 9
s B = 0.5s y = 0.5(104
) = 52 ksi =
52,000 psi
1
U s = F δ
2
2
s B bh
F =
6 L
 s Bbh 2  L3 s B L2
δ = 6 
 Ebh 3 = Eh
 6 L 
1  s B bh 2  s B L2  1  sB2 bhL 
U s =   =  
2  6 L  Eh  12  E 
U s = 500 ft − lb
= 6000 in − lb
303

SECTION 4 - SPRINGS
(52,000)2 b
1 
  L
6000 =
1  2 
6
12 30 ×10
2
bL = 1598 in
1598 in 2
b=
L
1598 in 2
L = 36 in , b = = 44.4 in
36 in
1598 in 2
L = 48 in , b = = 33.3 in
48 in
1598 in 2
L = 60 in , b = = 26.6 in
60 in
1598 in 2
L = 72 in , b = = 22.2 in
72 in
s B L2
(b) δ =
Eh
(52,000)(36)2
L = 36 in , δ = = 4.4928 in
(30 ×10 )  1 
6
 2 
(52,000)(48)2
L = 48 in , δ = = 7.9872 in
(30 ×106 )  1 
 2 
(52,000)(60)2
L = 60 in , δ = = 12.48 in
6  1 
(30 ×10 ) 2 

(52,000)(72)2
L = 72 in , δ = = 17.9712 in
(30 × 106 )  1 
 2 
317. One of the carbon contacts on a circuit breaker is mounted on the free end of
a phosphor-bronze beam ( µ = 0.35 ). This beam has the shape of the beam
9 1 1
shown in Fig. 6.24, Text , with b = 1 in. , b′ =
in. , L = 4 in. , and h = in.
16 2 16
When the contacts are closed, the beam deflects ¾ in. Compute (a) the force
on the contacts, (b) the maximum stress.
Solution:
304

SECTION 4 - SPRINGS
Figure 6.24
6FL 3WL
s= 2 =
bh bh 2
K 1 FL3 (1 − µ
) K 1WL (1 − µ )
2 3 2
δ = =
3 EI 6 EI
 9 
 16 
b′ 
= = 0.5625
b 1
Figure 6.25, K 1 = 1.14
(a) Force on contacts = F

K 1 FL3 (1 − µ 2 )
δ =
3 EI
E = 16 ×106 psi (phosphor bronze)
bh3
as a beam, I =
12
3 2
−
δ = 4 K 1 FL (13 µ )
Ebh
3 2
3 4(1 .14)F (4.5) 1 − (0.35)
= 3

(16 ×106 )(1)  1 
4
 16 
F = 8 lb
6 FL 6(8)(4.5)
(b) s = = 2
= 55,296 psi
bh 2
(1)
1 
 
 16 
318. A cantilever leaf spring 26 in. long is to support a load of 175 lb. The
construction is similar to that shown in Fig. 6.22 (a), Text. The leaves are to
o
be 2 in. wide, 3/16 in. thick; SAE 9255 steel, OQT 1000 F; 107 cycles (§
6.26). (a) How many leaves should be used if the surfaces are left as rolled?
(b) The same as (a) except that the leaves are machined and the surfaces are
not decarburized. (c) The same as (b), except that the surface is peened all
over. (d) Which of these springs absorbs the most energy? Compute for each:
(e) What are the load and deflection of the spring in (b) when the maximum
stress is the standard-test yields strength?
Solution:
Figure 6.22 (a)
6 FL
s A = bh 2
305

SECTION 4 - SPRINGS
6 FL3
δ A =
Ebh3
1b′
b = N
F = 175 lb
b′ = 2 in
h = 3 in
16
L = 26 in
o
§ 6.26, SAE 9255, OQT 1000 F
su = 180 ksi
s y = 160 ksi
3
t = in = 0.1875 in
16
sd = 83.75 ksi
(a) As rolled, Figure AF 5
Surface factor = 0.275

sd = 0.275(83.75 ) = 23 ksi =
23,000 psi
6 FL
s A =
bh 2
6(175)(26)
23,000 = 2

 3 
N 1 (2) 
 16 
N 1 = 16.88
say N 1 = 17
(b) Machined,
Surface Figure
factor = 0.75 AF 5
sd = 0.75(83.75) = 62.8 ksi = 62,800 psi
6 FL
s A =
bh 2
6(175)(26)
62,800 = 2

 3 
N 1 (2) 
 16 
N 1 = 6.2
say N 1 = 7
(c) Peened surface, (b)
306

SECTION 4 - SPRINGS
sd = 1.25(62.8) =
78.5 ksi = 78,500 psi
6 FL
s A =
bh 2
6(175)(26)
78,500 = 2

N 1 (2) 3 
 16 
N 1 = 4.95
say N 1 = 5
1
(d) U s = F δ
2
F = 175 lb
6 FL3
δ = 3

EN 1b′h
For (a) N 1 = 17
6(175)(26)3
δ = 3
= 2.745 in
(30 ×10 )(17)(2)  3 
6
 16 
1
U s = (175)(2.745 ) = 240 in − lb
2
For (b) N 1 = 7
3
6(175)(26)
δ = 3
= 6.666 in
 3 
(30 ×10 )(7)(2)
6

 16 
1
U s = (175)(6.666
) = 583 in − lb
2
For (c) N 1 = 5
3
6(175)(26)
δ = 3
= 9.332 in
(30 ×10 )(5)(2)  3 

6
 16 
1
U s = (175)(9.332
) = 817 in − lb
2
answer – spring (c)
(e) s d = s y = 160 ksi , N 1 = 7 (b)
307

SECTION 4 - SPRINGS
6 FL 6 FL
sd = 2
= 2

bh N 1b′h
6 F (26)
160,000 = 2

(7)(2 )
3 
 
 16 
load F = 505 lb
3
6(505)(26 )
δ = 3
= 19.24 in
(30 ×106 )(7)(2)  3 

 16 
319. The rear spring of an automobile has 9 leaves, each with an average thickness
o
of 0.242 in. and a width of 2 in.; material is SAE 9261, OQT 1000 F. The
length of the spring is 56 in. and the total weight on the spring is 1300 lb.
Assume the spring to have the form shown in Fig. 6.22 (b), Text . Determine
(a) the rate of the spring, (b) the maximum stress caused by the dead weight.
(c) What approximate repeated maximum force (0 to F max ) would cause
5
impending fatigue
load expected in 10
during the cycles,
ordinarythe
lifenumber of applications
of a car? (If the leavesofare
thecold
maximum
rolled
to induce a residual compressive stress on the surfaces, the endurance limit as
su 2 should be conservative.)
Solution:
Figure 6.22 (b)
3FL
s A =
2bh 2
3FL3
δ A =
8 Ebh3
F = 1300 lb
h = 0.242 in
N 1 = 9
b′ = 2 in
L = 56 in
F 8 Ebh3
(a) Rate , k = = 3

δ A 3 L
8(30 × 106 )(9)(2)(0.242)
3
8 EN 1b′h 3
k = = =
116.21lb in
3 L3 3(56)
3
3FL 3(1300 )(56)

(b) s = 2 N b′h2 = 2(9 )(2 )(0.242)2 = 103
A ,590 psi
1
308

SECTION 4 - SPRINGS
o
(c) SAE 9261. OQT 1000 F
su = 192 ksi
192
sn = = 96 ksi
2
3FL
s A =
2 N b′h 2
1
3F (56)
96,000 = 2

2(9)(2)(0.242)
F = 1200 lb
321. The front spring of an automobile is made similar to Fig. 6.23, Text . The
average thickness for each of the 6 leaves, 0.213 in.; material is SAE 9255,
o
OQT 1000 F. The load caused by the weight of the car is 775 lb. (a) What
stress is caused by a force of twice the dead weight? (b) What load would
stress the spring to the yield strength?
Solution:
Figure
6FL6.233WL 3WL
s= 2
= 2
= 2

bh bh N 1b′h
W = 775 lb , N 1 = 6 , b′ = 2 in , h = 0.213 in
36 in
L = = 18 in
2
(a) W = 2(775
) = 1550
lb
3(1550)(18)
s= = 153
,740 psi
(6)(2)(0.213)2
o
(b) SAE 9255, OQT 1000 F
=
s y 160 ksi
6FL 3WL 3WL
s= 2
= 2
= 2

bh bh N 1b′h
3W (18)
160,000 =
(6)(2 )(0.213)2
W = 1613 lb
- end -
309

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HELICAL COMPRESSION SPRINGS

DESIGN – LIGHT, MEDIUM SERVICE

271. A solenoid brake (Fig. 18.2, Text) is to be actuated by a helical compression

say Dm = 5.0 in

For actual solid stress

su = 168 ksi , [0.032 < Dw 0.437]

To check for solid stress.

Using hard-drawn spring wire, Cost Index = 1

Free length = 2 + 0. 082 = 2.082 in

Therefore change material to Oil-tempered spring wire, Cost Index = 1.5

number of coils. Meet all conditions advised by Text.

 4C − 1 + 0.615  64C  = 54,400 0.6875 

C = Dm = 0.71875 = 12.5

π D  π (0. 71825 ) 

Dw = 0.0625 in , 16 W & M

Scale, k = F = 3500 = 7000 lb in

CHECK PROBLEMS – LIGHT, MEDIUM SERVICE

(10.5 ×10 )  43 

(b) “Solid Stress”

Solid Force = F so = 7.8672 (345) = 2714

(c) s sd = 0 .324su (105 cycles)

Table AT 15, No. 3 W & M

(c) For solid stress . Square-and-ground end)

Solid height = Dw N c + 2 Dw = (30 + 2 )(0.2437 ) = 7.7984

(g) i 6.18 Free length = 9.9974 in

(h) Shot peened, Table AT 17

VARYING STRESS APPROACH

Dm = CDw = 5(0.2830

s no = 49 ksi , [0.093 <

Free length = PN c + 2 Dw

To check for pitch angle.

284. A helical compression spring, made of oil-tempered, cold-wound carbon steel, is

Not safe for indefinite life.

For carbon steel ASTM A230

 182  58.968 58,968

Table At 15, use Dw = 0.2437 in , No. 3 W & M

F a = 1 (200 − 100) = 50 lb = 0.05 kip

Figure AF 15, K c = 1.156

For chrome-vanadium steel wire, shot-peened, Table AT 17

(b) max. “solid” s s = s ys = 147.1 ksi

Min. Solid Height = Dw N c = (0.375 )(7 ) = 2. 625 in

(c) Natural frequency

deformation varies form

For hot-wound carbon steel wire

(b) Permissible solid stress = 135.4 ksi

π CDw  π ( 4.2 )(0. 625) 

For hard-drawn carbon steel, Table AT 17

combination of Dw and N c

Use Dw = 0.2437

For hard-drawn steel wire, shock load, average service

9 0.1483 146 21.65

Use Dw = 0.4305 in , 5-0 W & M

Solid Stress = 80.65 ksi

CONCENTRIC HELICAL SPRINGS

For oil-tempered wire

(C − 1) Dwo = (C + 1.5)D wi

assume solid length = 3 in

(b) F o = 15,530 lb

(b) Stresses induced by working load

F i + F o = 11,350 lb

Problem 299, 300

(b) Soderberg Criterion

Problem 299, 300