Department of Mechanical Engineering

Academic Year (2021-2022)

Subject
Elements Of Machine Design (EMD)
(22564)
Micro Project Report On
Study Of Different Springs Used In Heavy Vehicles..

Bhole S.D Jadhav P.S Mane R.A Dhas A.A

Instructed By: Head of Department:

Prof.Chavan U.D Prof.Hawaldar A.I
Principal
Prof.Bhoite P.D
 INTRODUCTION
Following are the five different types of Suspension springs used in heavy
vehicles:-

❖ Leaf springs
❖ Coil spring
❖ Torsion spring
❖ Air bags
❖ Rubber spring

1. Leaf Spring

Leaf spring consists of a number of leaves, made of steel plates, of increasing lengths
from the centre. All the leaves are clamped by a centre bolt at the centre and side
almost at the sides so that the leaves are in position.

Leaf spring
from
almost
theatcentre.
theconsists
sides
All so
the
ofthat
aleaves
number
the are
leaves
ofclamped
leaves,
are in by
made
position.
a centre
of steel
bolt
plates,
at theofcentre
increasing
and side
lengths

The main leaf is the longer one having bent ends, called the spring eyes. The spring
eye is connected to the frame by a shackle. The centre portion of the spring is
connected to the front axle by U-bolt.

Types of Leaf springs

Following are the different types of leaf springs.

 ❖ Semi-elliptical spring
❖ Quarter-elliptical spring
❖ Three-quarter elliptical spring
❖ Transverse spring
❖ Full elliptical spring
❖ Platform type spring

1.1 Semi-elliptical Springs

Semi-elliptical springs are usually used in all the vehicle. Particularly in trucks,
semi-elliptical springs are fitted in front and rear axles.

But in cars, they are fitted on the rear axle only and the independent suspension is fitted
on the front axle. Semi-elliptical springs are cheaper and require less repairing. They
increase the range of spring action and last for a long time.

1.2 Quarter-elliptical Spring

Quarter-elliptical springs were used in old small cars, like Chrysler cars. This type of
spring consists only a quarter portion of the full elliptical spring and fitted with the frame
by the bolt.

1.3 Three quarter elliptical Spring

Three quarter elliptical spring is the combination of semi-elliptical and quarter elliptical
springs. This types of springs was used in old cars.

1.4 Transverse Spring

transverse spring in just like the semi-elliptical spring but inverted in shape. One end of
the spring in joined with chassis frame by shackle, and the other end with the axle. It is
also fixed with frame by the bolts at the centre.

1.5 Full-elliptical Spring

Full elliptical springs are consists of two semi-elliptical springs joined together
oppositely. This type of spring was used in old cars. They do not maintain correct axle
alignment.

1.6 Platform Type Spring

Platform type springs consist of two semi-elliptical springs. They are fitted with chassis
frame by shackle at one side and the other side is fitted with an inverted semi-elliptical
spring. In this arrangement, the weight of the car is divided into three points.

2. Helper Spring

Helper spring is just like a semi-elliptical spring but without eyes at the ends. It is fitted
with the main springs particularly on the rear axle of the truck to carry the heavy load.
The ends of the helper spring touch the brackets fitted on the frame when the truck is
heavily loaded.

3. Coil Springs
Coil springs are made of spring steel. These are described with the independent
suspension system.

While providing a wide variety of spring rates, they can be accommodated in all type of
confined spaces. As compared to leaf springs they weigh only half the weight required
for doing the same job.
They can also store twice the energy per unit volume in comparison to leaf springs but
to control the accelerating, braking and cornering, anti-roll bars or radius roads should
be provided. The pan-shaped brackets or spring seats attached to the rear axles are
used to seat the coil spring. Spring seats incorporated into the frame are similarly used
for compressing springs against them.

The suspension is also used in combination with torque tube or torque rod drive. As
regards energy storage i.e. energy stored in a given weight of spring, coil and torsion
bar springs are superior to the leaf springs.

4. Torsion Spring
A torsion spring is also used in an independent suspension system. Torsion suspension
spring has a rod which acting under the torsion by taking shear stresses.
One end of the bar is connected to the frame and another end is connected to the wheel
arm and supported in the bearing. The end of the wheel arm is connected to the wheel
hub. When the wheel hits a bump, it starts vibrating up and down, thus a torque on the
torsion bar start acting as a spring.

5. Air Bags

The airbags and rubber springs are used in foreign cars. Air suspension, hydraulic
suspension and hydrogen gas suspension systems are also used in foreign vehicles.

6. Rubber Springs

The rubber springs are used in suspension because it saves greater energy per
unit weight than the steel.

Spring Measurements and Specifications:-

Spring measurements and spring specifications for compression, extension and 'torsion'
springs are below.
Follow the guidelines below for the type of spring you have to determine your springs
measurements and spring specifications.
How to measure Compression Springs, Coil Springs and Helical Springs (These spring
types are all the same)
To Measure your coil springs correctly See diagram to the right for explanation.
You will need to know the four (4) spring specifications below:
1. Wire diameter
2. Outer diameter
3. Free Length (length of spring)
4. Number of total coils

Closed and Squared Ends

The last coil is closed touching the previous coil closed and squared ends is the most
economical of all end types and works well for standing up normal size springs. Closed
and squared ends do NOT work well if you have a spring with a small outer diameter
you should choose closed and ground ends so it will stand up vertically straight.
Closed and Ground Ends
The last coil is closed and ground flat touching with the previous coil. Closed and
ground ends help the spring stand up vertically straight. This type of end lets your spring
stand up straight and gives an even surface of contact to the spring base. A good
choice for precision springs though a bit more costly than closed and squared ends
because additional labor needs to be performed to grind the ends of the spring flat.
Double Closed Ends
The last two coils on each end are closed to help stabilize the top and bottom of the
spring. Double closed ends aids your springs footing especially when you have a large
outer diameter coupled with a fine or smaller diameter wire when compressing or
traveling to stacked height where all the coils are touching. Double closed ends help
your spring ends from sliding over or slipping under the previous coil, it keeps the coils
stacked up on top of each other correctly.
This is an great economical choice to prevent buckling and stabilizes your spring.
Open Ends
The ends of the spring are open and have space or pitch in-between them. This is a
good option if you need more force out of your spring but don't have the room for it. An
open ended spring makes all of your coils active thus getting the all the force out it. This
kind of spring end requires that you place it in hole or on a shaft to make it work. Their is
usually no extra cost for this type of end thus making it an economical choice.

**************