SAND2019-7616PE

Design Optimization of Helical Compression Springs

to Mitigate Axial Twist
Dr. Jordan E. Massad & Devin S. Plagge
Raleigh, NC Sandia National Laboratories
July 16, 2019 Albuquerque, NM
ENERGY ivffSla Sandia National Laboratories is a multimission laboratory managed and operated by National Technology and Engineering Solutions of Sandia, LLC., a wholly
owned subsidiary of Honeywell International, Inc., for the U.S. Department of Energys National Nuclear Security Administration under contract DE-NA0003525.

Industrial Mathematical & Statistical o ing or op

 Sandia National Laboratories
Core Purpose: help secure a peaceful and free world
through technology.
Provide objective, multidisciplin
assessments for complex proble '
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* * * *

Focus on solutions with large 1 * * *

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science and technology content.

Create prototypes for productio
and operation by industry.

U.S. DEPARTMENT OF

NERGY
IMSM Workshop 2019 Massad, Plagge (1)
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Science & Engineering

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 Research Disciplines Drive Capabilities

High Performance Science & Technology Products Renewable Systems &

Computing Energy Infrastructure

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Previous Teams' Analyses
Rocket Sled Track Switch Concept(2010)
Fsled (Fspring Ffriction + Fcontact Fdrag

x(o)=o,.i(o)=o
0= 1{a(t)(m°+ e6„,) —(m°+ e6„,)(:+-
0(x°+ eh)) —(P°+ e6p) — (k°+ e6k)(x°+ eh)

Quantified Significance of Spring Forces

dh d dh dh 0
s&m(e—)h—f(x + ch) — —C(x°+ eh)(e—) — —C(x + eh)
dt de dt dt

Helical Compression Springs (2015)

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4m k(pi)
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Optimized Spring Manufacturability

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 Sandia
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There's a Twist!
racK Switch Concept(2010)
14/1-.1; Ffi-lctron Fcontact + r(,

• 1 •
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A spring optimized for

performance and manufacturability...

...may not be optimized for

implementation and integration.

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There's a Twist!
• Ideal: helical compression springs generate only an axial
force when compressed.
• Practice: helical compression springs tend to twist slightly
about their axis when compressed.
U ncom pressed Compressed

►
> Twist, Moment

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Axial Twist Complications

• Spring twist action can generate unintended forces on mating

parts.
• Compressing spring for installation:
twist action can misalign mating Compressed
parts.
• Resisting the twist can lead to
pent-up spring forces that
alter intended spring
behavior.
• Stick-slip friction of rotating
end coils could lead to erratic
axial spring forces. ii
Twist, Moment

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Mitigate the Axial Twist?

• Allow spring to twist unconstrained when compressed.

• Reduce friction to let end coils slide on mating surfaces:
unreliable; may have to introduce lubricants.
• ngineer mecnanisms to rotate with spring (freely rotating
mounts, etc.): complicates overall design and assembly.
• Radically redesign the helical compression spring.
• Machined springs offer advanced designs that eliminate axial twist;
may not meet stringent tolerances c lab+
' 39 11
• Radical designs are likely incompatik AM&
"••••••••••••••.----

spring industry's current guidelines.

Are there conventional designs

that mitigate axial twist? J -

IMSM Workshop 2019 Image: Helical Products Co., heli-cal.com Massad, Plagge (8)
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What Determines Axial Twist?

Wire Diameter
Boundary Conditions
1

Coil Spacing (Pitch)

End Coil Conditions Free Length

Spring Deflectio

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Map Spring Properties to Axial Twist?

ar Conditions

Number of Coils.

Coil Spacing (Pitch)

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Model-based Approach Desired
Wire Material Pro• rtie

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Empower Uncertainty Analysis

Probabilistic Z,'3
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Output .1:2 2
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Response

IMSM Workshop 2019 Uncertainty Quantification (UQ) Massad, Plagge (12)

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What Sandia Wants to Know
How can axial twist be mitigated in
conventional helical compression springs?
Some Questions to Address
■ What is a computationally-efficient model of axial twist as a
function of spring parameters?
■ What is an optimal spring when axial twist is considered?

Addressing this problem can help enhance our analysis

capabilitiesfrom spring design through implementation.

■ Banner: what is the range of axial twist resulting from multiple

spring parameter tolerances?
■ Hulk: are there spring designs that maximize the probability of
spring performance under uncertain conditions?
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