Mechanics of Deformable Bodies

Module : Helical Springs

Dr Neeraj Grover
Assistant Professor, MED
Email: neeraj.grover@thapar.edu
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The content of this presentation for the course “Mechanics of Deformable Bodies”
posted by Thapar Institute of Engineering & Technology is only for the purpose of
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production.
 Lecture Contents and Learning Outcomes
 Springs: Definition and Objectives
Helical
 Classification of Helical Springs Springs

 Close-coiled Helical Springs

Mechanics of
 Illustrative Examples Helical Springs

 Open-coiled Helical Springs

 Illustrative Examples
Design of Helical
Springs
 Springs
Definition of spring: Spring act as a flexible joint in between two parts or bodies

Objectives of Spring
1. Cushioning , absorbing , or controlling of energy due to shock and vibration.
 Car springs or railway buffers
 To control energy, springs-supports and vibration damper
2. Control of motion
 Maintaining contact between two elements (cam and its follower)
 Creation of the necessary pressure in a friction device (a brake or a clutch)
 Restoration of a machine part to its normal position when the applied force is withdrawn (a
governor or valve)
3. Measuring forces: Spring balances, gages
4. Storing of energy: In clocks or starters
Classification of Springs
Differences between close coiled and open coiled helical spring
 Close-coiled Helical Springs

 Helical angle is very small.

 Pitch between two adjacent turns is small
 Bending effect on the spring is neglected
 Close-coiled helical springs stand purely torsional stresses
 Close-coiled Helical Springs
Assumptions:
• Since angle of helix is small the action on any cross-section is
approximately a pure torque
• The bending and shear effects may be neglected, spring is under torsion

Twisting moment on the wire T W R

 d 3
Twisting moment on the wire from torsional equation T
16
 d 3 16 W  R
W R  
16  d3
 Close-coiled Helical Springs
16 W  R

Length of One coil =  D  2 R d3

Total length of the wire: l  2 R  n

  max
2 
Strain energy stored by the spring: U    volume
 4G
 
2
 16WR  1  2  32W 2 R2 32W 2 R3n
U  3 
   d  2 Rn   Rn 
  d  4G  4  Gd 4
Gd 4
 Close-coiled Helical Springs
1
Work done on the spring  W 
2
1 32W 2 R3n
Equating the work done om spring to the energy stored W  
2 Gd 4
64WR3n
Therefore, deflection of the spring 
Gd 4

W Gd 4
Therefore, stiffness of the spring k 
 64R3n
 Illustrative Examples
A close-coiled helical spring has to absorb 50Nm of energy when compressed 5 cm. The coil diameter is eight
times the wire diameter. If there are ten coils, estimate the diameters of coil and wire and the maximum shear
stress. (G = 85,000 N/mm2)
Solution: 1
U  Wx
2
1
50  100   W  5 8WD  max
2   max  108 N / mm 2
4
W  2000 N d d

D  8d ; n  10
Substitute in 8WD /  d 4  Gx /  D 2 n
8  2000  8d  / d 4  85, 000  50  /  8d 2 10
d  19.3mm

D = 8d = 154 mm
 Dr Neeraj Grover
Assistant Professor, MED
Email: neeraj.grover@thapar.edu
 Mechanics of Deformable Bodies
Module : Helical Springs

Dr Neeraj Grover
Assistant Professor, MED
Email: neeraj.grover@thapar.edu
 Close-coiled Helical Springs
1
Work done on the spring  W 
2
32W 2 R3n
Strain Energy Stored U
Gd 4

64WR3n
Therefore, deflection of the spring 
Gd 4

W Gd 4
Therefore, stiffness of the spring k 
 64R3n
 Illustrative Examles
A close-coiled helical spring of round steel wire 10 mm in diameter having 10 complete turns
with a mean diameter of 12 cm is subjected to an axial load of 200 N. Determine: (a) deflection
of the spring (b) maximum shear stress in the spring (c) stiffness of the spring. Take G = 80 GPa
Solution:
64WR3n 64  200  603 10
Deflection of the spring    34.5mm
Gd 4 8 10 10
4 4

16 W  R 16  200  60
Maximum Shear Stress in the spring     61.1N / mm2

d3  103

W Gd 4 W200
Therefore, stiffness of the spring k  k   5.8N / mm
 64R3n  34.5
 Open-coiled Helical Springs
Let α=Angle of helix, Length of wire (L)=πDn/cosα, OX=Polar axis (axis of twist),
inclined at an angle α to horizontal OH, OY = Bending axis, inclined at an angle α
to vertical OV, All the axes OX, OY, OH and OV are in vertical plane inclined at an
angle α at O.

If axial load W and an axial torque T applied to spring, the later tends to increase
Adopted from: G. H. Ryder
‘Strength of Materials’ 3rd edition.
curvature. The couple WD/2 about OH and torque T will act at O.

Assumption: Effect of shearing due to force W may be neglected.

Resolving these couples about the axes OX and OY, the combined twisting couple is

 WD / 2  cos   T sin 

and the combined bending couple  T cos   WD / 2  sin 
 Open-coiled Helical Springs
Total strain energy due to bending and
twisting 2 2
WD / 2  cos   T sin   L T cos   WD / 2  sin   L
U 
2GJ 2 EI

By Castigliano's Theorem

Axial deflection x  U Adopted from: G. H. Ryder

‘Strength of Materials’ 3rd edition.
W

Axial rotation U

T
 Open-coiled Helical Springs contd…
Usually loading is either W only or T only, therefore the general solution is:

(a) Axial load only: (b) Axial torque only:

 U   U 
x    
 W T 0  T W 0
2 WD / 2  cos   cos  .L 2   WD / 2  sin      D / 2  sin   2 T sin   sin  .L 2 T cos   cos  .L
    
2GJ 2 EI 2GJ 2 EI
 
 WD 2 / 4 cos 2  / GJ  sin 2  / EI  
 TL sin 2  / GJ  cos 2  / EI 
 
 8WD 4 n / d 4 cos  cos 2  / G  2 sin 2  / E   
 32TDn / d 4 cos  sin 2  / G  2 cos2  / E 
J  d 4
/ 32; I   d 4 / 64   U 
x 
 T W 0
 U 
   2 T sin   D / 2  cos  .L 2 T cos      D / 2  sin   L
 T T 0  
2GJ 2 EI
2 WD / 2  cos   sin  .L 2   WD / 2  sin   cos  .L
   TDL / 2  sin  .cos   1 / GJ  1 / EI 
2GJ 2 EI
 WD / 2  sin  .cos  1/ GJ  1/ EI 
 
 16TD 2 n sin  / d 4 1/ G  2 / E 
 
 16WD 2 n sin  / d 4 1/ G  2 / E 
 Worked Example 2
An open coiled helical spring is made having ten turns wound to a mean diameter of 120 mm. The wire
diameter is 10 mm and the coils make an angle of 30˚ with a plane perpendicular to the axis of the coil. Find
(a) Axial extension with a load of 100N, and (b) the angle free end will turn through with this load if free to
rotate. E = 208,000 N/mm2, G = 83000 N/mm2.
Solution:
(a) Axial extension: (b) Angle of rotation of free end
 8WD 4 n  cos 2  2sin 2  
x 4    16WD 2 n sin   1 2 
 d cos   G E  G  E
   d4  
 8  100  1203  10  cos 2 30o 2sin 2 30o  16  100  120  10sin 30o  1
2
2 
 
   
 104 cos 30o 
 83000  104  83000 208000 
  208000 
16  144  1202  5
x  18.3mm   0.1205  0.098
104
 0.026radian

 1.480
 Dr Neeraj Grover
Assistant Professor, MED
Email: neeraj.grover@thapar.edu