MICROFICHE REFERENCE LIBRARY

A project of Volunteers in Asra

f...gc.i.n.g_.D e s i Gin and Cal c y llil t j on by: R.E. Warr.ing

Pllbl. i sh ed by:

Model ana Allied Publications Argus Books Limited

P.o. Box 35, Wolsey House Wolsey Rd., Hemel Hempstead He~tfoldshire HP2 4SS England

Paper copies are S 2.25~

Available from:

META Publications P.O. Box 128

Marblemount, WA 98267 USA

Reproduced b¥ permission of Model and Allied Publications.

Reproduction of this microfiche document in any form is subject to the same restrictions as those of the ociginal document.

I 1 j

J 1

~ J

I I

1 i

t t

I ~

R. H. WARRING

Spring Design and Calculation

Model &. Allied Publications Limited

'3-35 Bridge Stre-Bt H-emet Hampstead, Herts., Eng~and

Modil::l~ & A IILSd Pu bll.,;.a~ IO"~ ltd Bo::tQk D ivi sion

S~al[on. Road, Ki I')gs Lan.gl-ey ""e-r1f ordsl'lHl!!-" Ef'lQI and

FII'~l PlJblL:!;i.he-d 1 973

©:R H, Warring 1973

~5BN 0 e5242 J'27 6

Pnnted afld rnade in £ng~afld by ~<lge Bn;JISo (NQrwio:: h) Ltd., Norw ich

CONTENTS

1 Spring Matenals
2 Simple F~at Sp6:1~'js
3 Helical Spdngs
4 Tapered Helical Springs
5 Torsion Sprinus 3 7 11

19

21

6 Clock Spr.ngs 24

7 Co nstan1 Force S prin gs 27

8 M ulti pte Leaf Sp' i P1~ s 31

Appendix A.

Spring Termioology 33

Appendix B

Wire Sizes a nd V atues of d a and d 4 36

Tab~e j

Spring Mate.rials and tneir

Me c ha n i ea I P ropernes 38

Table u

Wah r s Cor rection Facto r K for Round W~re H~I;cal

Coil Springs 39

Table IH

Correction Factors for Rec:tang u I ar Wi re He ~i ca~

Coi~ Springs 39

Table IV

S tress Correction Facto rs fo r T orsio n S pri ngs

39

Table V

Design Va ~ ues for "T ensa tor" S pri ngs

39

----- --.~ .. - ...

SPRING MATERIALS

1

T~H~ so ·Ing insss "}f rnacals is .-~Iated in a general way to thei r hardness. Lsac. for example. is rC sol: ,-newl, wit to v i,'t~aUV no 'spring' orcpernes. Th« same Wit r- a~,.HT.inlum. Lxtre~ll~ hardness, 'jl1 the other hand, aqain results in luck. ot ·s:-:'iing· ~'I·opertif'::;' necauce t",~ material is brittle rather than 'elestir.. The fdnGe of suitable sprinq materials are thus those w;·lich combine R,! '~table. ila(dness wi~h 'el-.s.icitv'.

11 ~s ;) I so i m ~ J~t.ar. r, ; f spr i n 9 n~: torma rH:" e is to be co nsjsten t, th at the material rstams tt~ oftf-l:l1al p'opert~es, M~ny metal'. are subject to 'work- hard.?ni~~,J' or ~ ch3ng~ O! hardness when ~1i"c'S,sed - .3nd all work i r-g So p_". ngs (lF€! SOU bjcc t ':" o r:: yc.les .~ f s t r 3:S"l. B -ass. for exa m pie. is a .neta I wi"! ~ chi S re I.a~~ ..... e ~y :0:: of L b d t ~-e p ... - ~ued s i ressi rt4J or ·WOf lsi ng· c a lIS'S!S n s ha ~ dness A'I.l ~ r1 C rf~~ se, w: ~; l til':' m t:ta I becom I P Ig more spri n 9 y as a ccnsequence Thua wnilst soft brass is Quite useless as a spring matet i?t tu I r y _ h t..i r de I!~' d b . EltS ~f)S5esse:. ~ re ason a bl y good sprin 9 pr O~oEJoj nes.

The h.3rd ne 5 ~ of marl V ru etals can ajs 0 be i m proved l: l tI eat t reatme m, End .~.s a result their spring ptGpertie:!' enhanced This is quite COmmon p. ~(;tic:e HI the preuaration co[ basic spri!1g 'stock'. Heat. however. can .a I so ~ .ud u ce ~ he OPPD~:: ~ res U I t. Th us a hard, s I:JI i n gy meta r Can orte n be oermauerit!» softer-e d by heating and sr,",)w cooling (or annealinq). On the other ~.:tr;d. he~tillS and rapi('l cc .. ,:,ling Q spririq materiel can ~ n crease hs hcud ness t!:J \ he po i n t of bnrt teness. Wi t no LIt co nsid f r 8b~e ~;:tp€:r~~nce in the iechniq ues ::if heat treatment. therefore. sprin9 rnaterlats should afways ba used ·:1S .sr_

Wit h s u ita bl e k n ~w ledg l. h cwever. processed spr i ng s rna 'II often be hea! treated 10 advantsqe - e.g. to remove iri .ernal stresses remaining • n the m~; !e,"j~. aft-3 reo ld w or htrl ~ to sh ape: c r fa rrn. Th e tempe retu re and met hod of ne-at t reat ~I:e"" t e mployed is depe nden 1 0 n th e Com ~ pcsitiou of the spri~g rnata.ial and rbe method of spring application,

Another form of t~'3'atment which can produce ernbrittlernent in a s pri ng is else no rtl atmg, T hi s a pplies partie u lar I y rn th £II case of c:a roo n stee I s pr.ngs.. where plati n g may SO met ~mes by t hou:g ht des .ra b I e to provide resistance to corrosion. ff such springs are p:ated, regardless of the method used they require to be baked lrnmediarelv after platin-g to dri ve Out h yd roge-l1 a bsor bed by the m ateria ~ du ring plating, Any h'/drog e n rerna i n IJl9 ~n the p a res of the s pri ng mate r1 ai wi t I cause e rnbrittla me nt. Si r.)i ~a r COm r •• e nt a no I ies to plat€ d steel wirer used as a spfing materia I_

The rc:nge of true spring materials is fairly Hmited. Ordinary carbon steel rendered in 'spriflg temper' form is the most common choice for ge nara I pu r pose sc rin 9 S 0 i a II types. I n the cas e of wi re, the n ecessa ry rem pe r rna y be prod u ced by the meth od of fa bricatio n - e.g, cold

3

SPRING MATERIALS

draw i n g. The sori n 9 tem pe J rn ay. howeve r, be fu rt he-r j mproved by heat treatment or oil tarnparinq. Such spring materials are suitable for use un d e r OJdi n srv tern per atu res, in norma I stress ranges - •. e. wit hou t the limit of proportionality of the material {see later} _ For use under higher stresses. 0 ... hi 9 he r tempera t ures, specie I a 110 y stee I s may be need ed .

Where cor ros i on rna V be a p robtem, the c ho i ce of sta I n :es.s stee I or non ~ fer rou S s pri ng mate r~ al s rna y be ne cessa ry - the termer wh ere hig h st resses h ave to be carri ed by th e s prin g. and the I one J !or lower cost. easier workinq, wh-ere stresses are not so high- BefYU~um copper is an at rr act i ve ch 0 i ce where h ig h res ista n ce to stress and ccrrosion are necessary. .a nd 9 a ode lectric a leo nd u cti vi ty is a lso req ... ired. If electrical co nd u ctivitv is th e rna t n req u ireme nt, phosp hor- bro tlze provides a ch e a per a tte mauve: and brass even lower cos t (a ~t houg h bras sis a 'margjnat· spriflg material. even at full 'spring temper'). A nickel alloy (e -9 - m on el ) may be s pecifie d wh e re hig h tem per atu res have to be a CeO rn modata-d-

M echa n ic a I Consi de r atio ns

However good the spring material, there are limits OV@J which it can be ex pected to work consistent! y an d sh ow a long 's pri ng· Ii fe. The crit ica I fa eta J i nvo Ived is the 03CttJ~ I Stress bor n by the mate ri a 1 w he n

Fig_ t

,

S;h'oir'l __ ...

4

SP RING MATE R IA LS

the spring is. wotk~r'Jg. Up to a certain point with i(1creasing stress the correspondinq strein in the material fOflows a linear relauonsbip >F~g 1. 8 e yond thi 50 limit Of propor tionillity t his. Ii near reI a t i on s h. p i10 to nge r ~ ppl i es ij n d s u biecti ng the m a r9:~i a I to t hese hi 9 he r stress val ues may per n1 ene n U y ch a nge ~ he m ec han ica I properties 0 f th e mater i el.

Tho lim i t of propcrt ion alit 'If lh u s represe nts the uppe r st ress I rmi t for t he mate r. a I I n pta c rice. a: lower Ii mit • s nor ma Ily em plo ved - 80 per cent of the Jimit of prcportionalitv - to allow a safety factor in spring design.

Working within thiS limit will then ensure a consistent performance from a spri 11 9 rnatenai.

This, however, 0 n I y pre-se nts par ~ of th~ pictc re. Th e strengt h of allY mater i el is d i ffere n t fo r d ~fferen t ways in w h i chi t is st ressed. Maxim urn Sit re rlg t his uSU a IIV a 'ria Ua b le w he n stressed in pu re compression, w.th a n almos t sl m. fa r va I u e w he n stressed • n pure tension. If su bj e G t to tw isti rlg or torsion J the materia! stren gl h ava i I a ble is consldera b I V reduced.

Basicallv, in fact the life of a ~pr.ng depends on four maio fr;ctors:

(i) The manner in which the spring material is stresse-d.

(i i) The m Jxi mum worki ng Stress.

(,! i) The ran ge of st. ess aver w h ic h the sprm 9 ma ter i al is wo rked.

(i v) the n u m be r 01 cvclr.s of stress or th e effects of f adg u eon m aten a ~ pro pert i es.

Items (i) and (il) are directly related. Once the manner in which the rnateri a I is stressed j So establ i shad, a safe m a XI rnu m work in 9 stress can be este blishe d fOT a panic u I ar rnateri al - see Ta b I e r.

The- stress range is more d lffic u 11 to esta blis h. In genera t the hlg her

t he range of st res S ova r W hi ch th e $P ring is worked. the [ower sho 1J1d be the m a ximu m permissi b I e stress to ensu re long sp~ i og life. However, this w j Il var y with both d .Here n ce sin materia I prope rt LeS and heat treatment an d wi t h trequen cy of worki og. For si rnptic ity of desig n it is best to ad opt r safe' fi 9 ures which err on t he side of un deresurnatin g , m ateri al pe rforma nee, such as 9 ~ve n in Ta ble I.

Wt1 i lst mater ia t strength a nd stress determ in e the load w hie 11 ea n be earned by a 5 pd ng of given geometry. .a nd the I ife of the spdng, def lectio n char acterist i cs are dete rmi ned by I he modu I i of th e material. Again this depends on the manner in which the spring material is deflected or stretched. If r he spr. ng mate ri al is under tens i on, then ~t is the modulus of elasticity of Young's modu Ius w hie h is t he para meter involved. Fo r a s prin 9 materia I su bject toto rs~ on 1t is the roo duJus of (igiditr wh ic h is .nvolved in cal culatin 9 defle ct. on .

Val ues of mod u lu s of elasti city (E) and mod u lu:s of r ig ld it V (G) have, the refore, to be know n for the s pri n 9 mate rials u sed before the full

5

SPFUNG MATER IALS

Dt=rformanc€ c'f a sp'i .... ~ can be evaluated. These are also given in fa bl e I. Th e mad u III So of e I a snc i t y large I y govern s the materia I perfc rman ce of flat spr i ngs and torsio n s p ri n g s, T he mod u Ius of rig id f ty gover ns th e mate ria t perform arlee i n he I.ca I spri,.,g s, The a ctu ai SUes s prod uced !n it spring. on the other hand. is dependent only On the load cerried by the spring and the spr.ng g~omatry, All these individual parameters ap-pear in the spring desig n formulas in subsequent chapters.

Formulas and Uoits

5 prin g de sig n pro portions are not sorneth ~ ng ! hat can be 'g uessf m ated' wi than y d egte e of accu rae V - an d tri al- and - erro r desig n can prod uce a su ccesslon of faU u re-s L T hV5 th is book 0 n S pri ng des ig 11 is fu U Of formu las, as th eon Iy ac cu rate met hod of Pied ktlng s orin 9 perlo rman ce. However r all are sssentiallv orectice! working tormutes, and all are QU it e str a i 9 htforwa rd to use. E ac h ce I ClJ lati On is n oth ing more e I a bor ate than an a,ithmetical calculation - aided by a slide rure or log t.ables,

No units are given with the formulas. si nee these foitow quite ~og &ca' I y depend&ng on w nettle r VOti i;lf e WOt kLOg to Eng '.s h or metric st a ndards. M ost Q uan tit i es are li naa r dime n s io ns, and it is on I V n ecessa ry to re me m be r th a t stress va I ues, etc, sh ould be re Ild ered in th e sa m e un its. Th u s fo r worki n 9 wit h a ltd i me nsio ns in in ches, stresses, etc, must be in pounds per square inch. Answers wilt then work out ~o9ica Uy in t he rig ht units.

Fo! exa m ple, th e deflection pe' coi ~ of a heli C 81 co mprssa i on spri ng ~S 9~\ren by

8PD3 defle ction = ._Gd4

where P is the load

D .$ the mean coil diameter d 1S the wire diameter

G is the mod u Ius of ri gid ity of the spri ng materia I.

I n English units, P would be in pounds. Olmensions D and d would be in inches, To be consistent. G must then be in pounds per squats i r1C h. The d eflect len. ca I cui ated fro m the fcrrnu la. is aneth ar linea r d imens i on an d so woul d beg ~ve n d1 reedy in in ches ..

U sing metric units the no i nt to wate his th at the mod u h.J S 0 r stress v.a lues used (0 r calculated) are t n the sa me Lin i ts as the linea, d imensions. The latter, for example, will usually be in millimetres. Moduli and 51 ress fig ure 5 rna v. h cwever, be QU oted ln k t1ogr6 ms :per square cemimetre and wO uld nee d adi usti ng for cons i ste n'Cy whe n ~ sed wit h m i Iii metre linea r units.

SIMPLE FLAT SPRINGS

2

--~~---

The basic form of a simple flat spring is shown in Fig. 2. The following are the 1wo. design formulas concerned.

Stress (tension)

6PL

4PL3 Defle ~ti on = . ~,~Ebt::l

in co n'S1 stern units - i.e. Stress is given in Ibjsq .in when P is in pounds and l band , are in inches. The modulus of elasticitv (E} .s in lb/sq.in.

Fig. 2

ll)Ql;l (P) _....... -------..-~

____ l .~- ------

As a gelle r a I guide it 1.0 i lows that: St ress i n the spri ng materia I i ncreases i n dire ct proporti on to spri n s Ie nqth, and in in verse proporti On to IN i dt h an d (t h i ckness) ;;;!, Th us, tor exam pie. increas i n Q the th i ckness oi the spri 11 9 will deere ase the stress more effec1 i valy t ha n i nCfsas,ng th e w id t h. 0 effectio n increases wit h the: ell be 0 f the Ie ngt h (th us small changes in length wrll have a marked effect on deflection); but ca n be decreased by i ncreasl ng th e widt h 0 r t h i ckness (t he tatte r being m uc h rno re effective in stiffe n irtg th e s pri ng) .

Des. gnP roced ure

The design of a simple Hat spriog commonly calls for a certain deflec· tio n not to be ex ceed ed u nde r a give n load. The length (L) of the s prin 9 may a 150 be predete r mi ned. Q r ca n be 9 i ve n .a suite bte value. The formula for Deflection can then be rearranged as a solution for bt~r viz:

bt.3 :;:;: 4PL;)

E x deflection

All values on the right hand side of this equation are known (the value of E following from the spring material selected) .. and Can thus be ca! c ulatsd as a sing Ie quafl. tit y - say X

7

SIMPLE fLAT SPRINGS

We 1hen have

bt" .-; X

From this point. either 'quesstirnate' a value of b and from this calculate th~ cortespcndinq va!u-9 ot t to satisfy the eouation: or 'guesstimate' t and from this calculate b. The latter is the usual method sj flee t hick ness is governed by th e stan d ard si zes 0 f materia Is avai lab~e, and thus there is a choice of specific values of t (e.g. 20 swg. '8 swg. etc.): Note: See Appendix B for tabular values of P.

Any solutions derived by the above method will glV9' spring properlions s.at.sfyillg the- defl@chon under load requirements, I t is now necessa ry toe n te r t hes e val ue s j n the 5 t res S form u ia togethe r \At! t h load (P) an d ca tcu late th e st ress resu lti rlg. Prov.d in 9 this is lower t ha n th e rna X i m u m per rn: ss ibj e stress for the materi al u sed, then the $P ri ng 9 eo me It y is sarisfacto tv . I f th e cal cu lated st reS sis highe' th ant he maximum permissible stress, then the $pr.rtg geometry must be recelcu lated from the def!ection formula, using different values. This .s simplest ~t the spri ng len g th is 1 eft unalte red - 11 is then 0 n ~y necessary to re r .. .HfI to t he fa rm u~ a

bt:::! ;;;: X

and use a greater thickness to calculate a new value for b. Check jf this reduced the stress to below the maximum permissible value. I f not try again.

Square Wire Sprjngs

U ~ the same Io rm u tas a nd proced 1I re. substitu t i ng a::l fer bt2 in t he stress fo rrnu ta .a nd ,;.4 fOr bfl in the Deflecti on form u~ a; w here a -::- di mensio n of sn uars.

Round Wire Flat Springs

Exact I V th e sa rna fo rrn u tas (a nd desl 9 n procedure) fo Ilow in th e case of a flat spring made trom round wire - Fig. 3 - except that band t are replaced by the wire diameter (d).

6PL . 4PL:J

Suess ~ ~ Deflect ron ::5" Ed'"

Flat Spring Supported at Each End

Th e stress and d eflectic n formulas a r€ mod i t ied when a tr at spr i ng is supported a t both end s - F.g. 4 - a nd be come

3PL Stress = ~ 2bt;i

PL;J Deflec t i on = 4E.bt";!

De-sig n proced u re is th e sam e ag ai n.

5IMPL£ fLAT SPRINGS

Fig. 3

p

--_.;;.-,..___

\_ ---

~.-

p

Fig_ 4

---

.. - \. .---

I n the case of a frat sprjng made from round wire, suoported at both ends, bl2 in the 'Stress' formula is replaced by d 3; and bt~ in the 'Deflection' formula is repla-ced by d"

Des.ign of Contact Springs

A co nrac t s p ri ng IS si mpl y a flat s orin 9 desiqnad to appl y a cert a in pressure at .a particular point (conta-ct point) alonq its length - Fig. 5. ~ l cs n be d erlveo fro m the sta lid ard J Stress· form u I a, few ritta n as a SO lu no n fo r tea d ( P) Of actual co ntact pressu re prod I,J ced when de fleeted. vi:z

bt.2$ P=~

6L

p

9

~ig_ 6

SIMPLE FLAT SPRINGS

.too .------

zoo

150 ~---
300 --~
~

. 1-.- _. _. __ ..

,

~

, 50 t--------t- --~

10

HElICA.L SPR INGS

where- S is the des i 9 r'I max ~m u ~ workl ng 51 rsss to r the rnateri a I to be used ( .. e. use 80 per cent of the limit of proportionalitv of the spring material from Table f)

The s i m ples t way of lac k.1 i 11 9 desig n is to fi x s uita ble value s of sprinq length L and width (b). from which the requ ired material th'ckness can be calculated. IT th1$ y~eld5i a. not standard thickness. then the- neerest standard thickness ttl p or down} can be adopted, and the correspo nd in 9 w idt h re - c ale u tated to provid e t he re Q u ired contact pressure.

It ca n a ls 0 be i ostr u ct i ve. havi n 9 d eeid ed 0 n a s uita ble spr i n 9 length and width. to calculate the maximum contact pressure available Over a ran.ge of thicknesses for different spring materials. This is done in Fig. 6 for a sprirlg l-ength of 2" and width i"~ and clear~y mdicates (he s!Jperiorit y of bervrj i u m coppe r as a co nract sprjn 9 mate r • .a l.

limitations to flat Spring Ca'cutations

Whilst the des.ign formulas provKie accurate theoretical soluuons, actual per to rmanc e may be modi fied sornew hat by the rna nne r in w hk h the end (Of ends) of a flat spring is (are) clamped.

r n the case of contact spring s, perle rrna nee may be fu rther mod ff~@d by t he fact t ha t sue h s pr.n gs are not necess a ri Iy stm p Ie bea m s h a pes, but may be irregular in wkjth. Calculation applied to such shapes is te d ious. ~ t is best to desig n the s pl;n 9 on the basis of a . meal1· Or 'tvpical' width and check the performance by practical experiment

----------- - .. -----~---.--~~- -~~.-

HELICAL SPRINGS

! n th e case of he! i ca! 5 p ri tlg s w hie hare eft her compressed or extended under load, the spr i ng rnateri a I is stressed intorsion a nd so the fo! lowi ng has ic f ormu I as apply for rou nd wi re s pr.n 9 s:

T . I SPD orS~Qn a s.tress = --. :rtd·~

8PD~ DeUection - Gd4· x N

where P !!!!!! 10 ad

D :!!!! me and iameter of spri ng d !!!:! wire diameter

G ;-::- mod u I us of ,ig id itv of sp rif] 9 material. N :!!!! n umber of acti "Ie co i ~s in the spri ng {see also Fig_ 7)

3

H':;UCAl SPRINGS

F~g, 7

p

....

.....

\ \

I

J

The sti ffness of a he I ic a I spnn g. t heretore, rs pro po rt i on al to the lounh power 0' the wi re d iameter, a nd varies I nversel vas the cube of th e mea n d lamete r. Bot h d and D thu s have a marked effect 0 n spring pe rforrnance: Us i n 9 a wi re size On lyon e g.aug eo IJ pea n apPffl crably reduce the deflecti on, and \1'. ce versa, Si m flarly, on Iy a srna U increase in sprin 9 diameter D ea n consider ab I yin crease the d eflect~on ~ or a sma II dec rsas 8 i n D ca n rna k.e th 8 8 prin g muC h stiffe J-

The latta r effect particu1 ativ, sh OU Id be born e in mind whe n rna k.tng a he Ii ca I spring by Wfap pin g arou n d a rnand ret. There wi I j be an mevita bl e 'sp ri ng hac k.. resu Iti ng in a sp r~ n 9 ij n oe r dia meter S LIe greater tha n that of th e mandre LAn u ndersize rnand rei ~ s thus req ul red to form a sprinQ of ,equ i red d. anlete r. The dey ree of u.,d ersi:ze c an only be estimated fro m ex pefie nee sil'l ce It w.11 \l'ary wit h the qua lity of the s.pting m Me Ji al used. a nd .a tao th e eol Ii ng tschn iqua.

The nu ~be ~ of active coi Is is t hose act ua Ily 'we rk Fn g r as a sprin g, Usua.l pracuce IS to allow! of a turn (or 1 complete turn] at each end

12

f ~g, 8 lj!;N ~LON S~ I N G l:NO~

1.01'19 rQUn.t.:I 1!F\d hook on {l!!rHI'I:!

~ ~

E":..I r!!nrj~ r!:,r o!: r;II'\

i!' ither r:::o!nll'e- Of "ide

~

Cooed C'f'rd wi th

~ha'1 ~; '.''!'I ~yr:

HEliCAL SPRINGS

Pl[] in ~nd'~

all

lQl'l!il ~quC1 e ~d hor;j;: Ot'.r ce nt r C"

==iW

$t:'D;7rt Qn.d. 'XU\o!rgloQ IQ 01;1.1 ~ form! 1'19

~ ~~

eo"Qr;I .r::nd w i ~Ior 'S'fo' j""el ho-;J.;.

1"3

~ rulill

©=G

Coned C'l'Ir::E to fr-;)id 1orr.g <j.'f'I t"'l!Il ~~

~

C-or'rt-a I!:t'IIoj .,...Hh

";'tIIi ... 0l boI!

Eye Qnd hook ~hoQ.,.,.n ot r ight ~~:g I O!'j;

; v.1 e~ cc:r ii drt QI'Id :smoll ~!! ~ (:..(!r'rtn!r

H {: LlCA L S pf:t I N OS

in the case of a plai n compression spring to produce para1lel ends. Thus. 9 eometrica I ~y the spring h as a tete I n II rnber of col Is equal to N + l-t (or N + 2). the number of active COi[S being calculated for t~e required d ef loe ctio n pe rforrnen ce. E;II; W nsi on s p rin gSF 0 n ttl €" otber ha nd. co m r I"l"IlJn Iy hav e a II th e co i Is I active', th e end s be iog mad e off at rig h tang les to the mai n coil. e.g. see Fig. 8.

Allother i rn portan t pa r a meter is the sprin g rote (or 10 ad rate). whi c h is sim ply the toad divided by th e de Ue ct i on.

S pri ng. Rate .= p

d eflec no 11

Gd4

=

8ND3

Where th e spr i n 9 is of const a nt d. a meter and th e co.i s are eve n Iy pitched. the spring rate is constant. A spring can be g.ven a variable rate by 1 aperin '9 the coi Lor u si ng a va r i ebi e pitch. Con sta n t rate spr ~ ngs are the more usual, and much easier to work out.

Basically .. spring design mvolves caiculatinq the spring diameter and wire size rec u ire d to Q ive a safe mate ri al stress fo r the load to be carried. It is then simply it matter of dec~ing how many coits are req lJi red (i. e. how many active turns) to give t he necessary spri ng rate or 'stiffness in pounds per inch of movement. This may also be affected by th e amou n t of free move me nt availab] e fQ r the S D ri ng.

Th e sa me consi d er ati ons a ppl V to bot h com pressio nan d e)(te nsi on spri ngs, with on ~ d ifferen ce. E xtensi 0 n sp ring s may be wou Jld with initia I tsnsio Fl. which I n so me cases can be as h;g has 25 per cent of the safe load. To open the coils of the spring this ~oad must be applied, an d 0111 y the remsinde« 0 f t he load is the n avai la ble for deflection. This does. not mod ify the spr.ng desig n forrnota - merely tha va ~u e of the a pp lied load effecti V9 i n produc i n 9 def lecti on.

Whi lst the worki ng for mu I as are str aig htfolWard. spring desig n is com pticated by ttl e fact tha t three variao las are i nvo lved in th e sp ring geometry - d iamats r {D), wi re d iamete r (d) and n u-n be r of active coils (N). HOWEver, only D and d appear in tne Stress formula which is the on 8 to sta rt with. So here it is a case of • g uesstl mati n g' on e flgu n:: and caicu lati n g the other 0 n that basis.

D Mig.... P roCedur'8 0) Either

(a) fix a va I u e fo r 0 and c ale u late d fo r the sere valu e of work.ng stress from

14

i-U:uCAl SPRINGS

(Note: From the value of d3 so found the corresponding wire diameter can be found from the tables of Appendix E:i - there is no need 10 work out the cube root of the answer to the formula)

or

(b) fi)L the vatue of d (from an estimated suitable Or readily available W, re ~~ -..:e ). a fld from this c ale u late the re qu ired value Of 0 from

n:Sd;J o = 8P

{Note: Ag.;_in you call ~oo-k up d3 directly in the tables of Appendix B.)

(ii) Check that the sizes are practical. 'For examote. if the value of D .s fixed the calculated value of d may be a non-standard wire size, ln this C~S~, recalculate For the nearest standard size to yield an acceptable value of S. This can be avoided by ti>::ing the value of d to start with. but could vield an impractical value for D.

(j'i} Having arrived at suitable values for D and d, caieulate the fl u m be r of active tu rn s req u ired fo r the def lect i on to be acco mm odatsd.

G d 4 X deffection

N ~ SPO:)

(Note: you can look up vetuss of d4 directly in the Appendix tables).

That in fact is all there featly .5 to designing helicar compression or exten sio n springs, provid ed ex trerne ilCCU rae y is not rec u ired _ Rem em ber to add on i or 1 turn to each ~nd for closed end compression springs_

Mo re Act:: u rate Working

Stress calculation by the above method assumes that the spring material ~ S stresse d ~ r'I pure 1¢ rsion - I n fact fu rt he r stress is add ed beca use of (he- curvature i fl the w~re. Thus the true stress in the material is higher than predicted from simple calculation, viz

True stress = K x S

whe re K IS a cone-clio n facto r fo r wire cu rvature (n orrnai IV kn own a s th 8' Wah ~ correctio n factor).

Uoiortllnate~y .. the vatue of K depends on the spring geometry and t h us the spri n 9 di emete r (0) a nd wire d ia mete r (d) have to be determ. ned before itl e correction factor ca n be found.

4c - I 0·615

K= +-~

4c + 4 c

wh ere c = 0 I d (w h ich ratio is also known as the spring ~ ndex) .

15

HELICAL SPRINGS

Hav'ng determined a suitable size of spring" therefore. the true stress should be calculated, using lhe Wanl correction factor calculated as above. I f this true stress works out higher than the maximum perrniss: bie male ria r stress, the n the whole spr i ng geo met rv must be reealc LJ lated through.

To save a lot of wor~ing, values of K are shown graphically against spring index in Fig. 9, and also in Table IL

So'id Height of Spring

Tile solid O~ "closed' length of a helical spring follows by multiplyil1g wire diameter (d) by the total number of coils {N + ·dead" turn at each end. where applicable). This. l-ength may be reduced somewhat by grinding the 'dead' turns flat on a closed end sprinq see Fig. 10.

Helical Spri ngs ill Rectangular Wire Section

Similar formulas apply, with wire width (b} and thickness (a) replacing d - F~g. 1 1. A tso add i t i on el st ress facto rs a re ~ ntrod u cad to take In to accou n t th e add i li 0 na I stresses ~ rnoerted by bendi n 9 recta n 9 u I ar secti on W fre i I1tO a he lie al coi I.

PDKK

Stress ~ :z

2a~b

Values of K2 and K:I are gi\o"en in Table III. The spring index, for determining the value of K the Wahl correction factor K, is 'found as fellows.

For rectangular wire coiled on edge, C = D/a For rectanqular wire coiled on flat C = D/b

For non - c ritica I ap plic a t i on s th e dasig n of hel i ca I coi I spring s wou nd from recta ngul a r sectic n wi r8 ca n ignore t he correction s to stress, by ad opti ng an appreci ably lower value of m a ximu m pe rmissi ble materia I stress" T hi s wi ~ I no t uti lise the full sprin 9 pote nti a I of the mate ria I... but ccnside rab I y si m p lifies c a tc u tano n.

PD St reSS = 2a :lb

Hi

Fig_ 9

1.7

1.S
}
..:.
J:
OJ
.~ 1.4
.Jo..
"'E...
-
i
1,3 r

HeL.l CAL S.Pr;lIN GS

1----1-- T--~

;

I

W(lh,I"; -I;¢I rec I ion fCl'l" ~ I 'I!:~

I, ~,.. H~ 1 iI::ul GoH ~pr il'l'9::' i .

I, -ii'+

i I !. ---- -- - I i

; I r . i I I

i : I I I .

I 1 : i :! ! I

I I .: I

: I·' 1

'-:--~-;-- r •

1 _ I I I

_J ,- ' -++-1

t I .

1.:2 t-----i---+---+--+---

t , 1 !t--------4- --+--+--

2

4 5

7 S

9 10 11 12 1 J 1.(

17

~ _.-

HELICAl. SPRINGS

Fig. 10

gfOO I"Id nO!
\
I
I
(
I
I porcl lel
j
J
"r:N3iJd II 'I1.Irr'l gt~IJ.f'Id fll;l t Energy Stored in Helical Springs

The energy stored in a compression or extension spring can easily be ca I cut a ted from

P )( d ef~ecti on Energy = ----~- 2

Fig. 11

wl.-e -coil ed on fl at

18

TAPERED HELICAl SPRrNGS

4

With the tapered or conical spring .. eae h coil is of different diameter. This gives the spring a variable rate. The stress imposed by any load ca us. n Q defle cnon is als 0 va ri a bl e from C oi i to C oi I. Fa r des.g n pu J poses it. s the maximum stress, w h ie h is most important. Thi s wi II occ uri n th e la rg sst active co i I - Fig, 1 2 - a nd the stress is larg 81 y teosio n.

8PD

M.a){, st ress » :rrcFJ' )..': K

wh&re K is the Wah 1 correction factor

( Note: :sjn ce stress IS pro portion a r to spri n 9 d La meter D. • t foUow s tha t the st ress I n an y coil ca n be c elcu latad b¥ using the appropriate coi I diameter: also that the maximum stress will occur when 0 is a ma)C.imom. i.e. equal to that 01 the tarQest coil).

Fi-g. 12

• -

~ _ . - 01 .. ------< • ..-1;\ (~arge!lol ~t i VI!! I;;.g,i.}

Oef lecti on II nde r a co nsta nt load wi I ~ vary, I n the case of a co mpression sprinq, first the largest ceil WLl1 bottom, then the next ~argest and so on - F.9. 13. An extension spring wiB 'open' in a similar pro-

gTess~ve rna n ne r,

. 8PD~N

T ota ~ defiec t. on = 01:

Gd'"

where D.2 i $ the mea n d j emete r of the sm allest

active coil

N is the number of active turns

19

1 argluif g"'tL ..... ~ ~Qli~ I;Jo1 t(1(1"!5. Hrst

TAPERED I-tELICAL SPRlNGS

,

'70

p

I

p

I

~"-"l~

,--Io-------L... sol id foIe ight

_______,.::""J

This formula can also be rewritten in terms of the maximum load to close th e s pr; ng so I id

p .::..: Gd'" x deflect. on

mu 8D3N

z

Th e desig n of 18 pere d s prinqs, t herefo"e~ follows the same lines as for hel~ ca I coi ~ sprin 9S (Section 3). us in:;i these mod i fied form u las-

So I id Heig ht

The s.ol id heig ht of a ta perad spri n 9 is less tha n that of a hel ica I spri ng since the individual turns 'stack' to a certain e:dent - Fig, 14_ Th@

Fig. 14

20

TQRS10N $p~It4GS

eftective height (y I per cor~ can be determined f.rom the right L angled tr i ang te show n, w he re

d2 !!!:. XZ r V~

Or y = v:d~ - )(2

The solid heijght of the sprinq tnen follows as Solid height = Ny

where N = number of active turns,

Remember to add 2d to this to account for one 'dead' turn at each end in the case of springs. with closed ends.

TORS!QN SPRtNGS

5

A he~,~al torsion spting is designed to provide an angular dettscticn 0", a n arm at One end of the sprlnq _. s€e F~g_ 15 - the other end of the s pri n 9 be, n g a n c hored _ The s l&ff ness of sue h a spnn g {Of its res lsta n ce to d efle ctio n is dire c tl y propo rtiona I to the fourth powe r of the w ~fe

Fig. 15

T

t 1

R

p

diameter: and lnverselv propornonal to its diameter, The co~j diameter 15 commonly fixed (e.g. the: spring has to fh over a shaft Or spindle): and thus choice of d iffe ren t w~ re sizes WI' I have a con s idarable effect On spring performance.

21

TORSION SPRINGS

The fo ~~owi n 9 baste fo rrnu las ap pi y;

32PA

Stress = )( K

1I:d3 4

W her8 K 4 is t h s stress correction fact or "to r ro u nd wi re sprinqs in torsion (see Table IV)

3665PRON A ng u lar d ef lect i on (degrees) - ~~E-d-III--

where E = Young's modulus

spring mate ria I

of

Desig n calcu larion s are aga i n based on work ing th e so rin 9 mate ria l wi t h. n a cee pt able l im~ts of St ress. Th e force {P) acting 0 n the spri n 9 is appi~ed over a radius {R}r equal to the effective ~el"lgth of the free arm ott he SPfP r19'. Oes~g n c alcul ations ca P1 proceed as taU ows:

(i} Knowtng the force to be accommodated and the spring arm teverage required (R), use the stress torrnuta (w.thout correct-on factor K4) to calculate a suitable Wire size:

32PR 1 0-18P R

d:!::::!! !!!!!----

1tS S

where S is the maxmum permiSSible m ateri al stress,

(li) Adjust to a standard wire si:ZEL If nacassarv,

n i.) Ca tc u I ale the ang u I a1'" deflectio n of such a s pri ng. us i ng a s pee if ie d val u e 0 f di amete r D" hom th e def leet; 0 n form ul a. and ~g no r.ng the factor N_ This will give the deflection per coil. Then simply find out how many coils are needed to produce the required deflection-

T hi s stag e may.. of COIJ rse, be vaned _ The load m ornent P R may be the critic a I f actor ~ i.e. t h B sprinq ~ s req u ired to axe rt (Q r resIst) a certain force (P) at a radius R with a specific deflection. In this case" ha v ~ng adopted a specific value for Dr the deflection formuia can be used to find a solution for the number af turns required.

(iv) Having arrived at a possible spring geometrv" recalculate the I(ue SUes S as a check, using th e co rrectrcn factor K4·

I f necessa ry, read] us t the spring geometr V to red uce the stress and recatcu late the spri ng.

I f the spring .5 to be thted over s shaft Or spindle a check. shou1d also be made that .n its bgl1tened position it does not bind on the shaft.

22

TORSION SP~IN~S

Ftna~ mean d,arneter :=; 0 ~ ~,

where N, is the final number of turns when tightened.

Thi s ; S 5. m pis enouq h to w or k 0 ut. A d eflec uon of x degrees is e q 1.1 i va len t to x/360 turns,

)( N, = N + 360

Remember that the f;na~ inne.r djame~er of the coil wm be equal to the final mean diamater minus d.

Thus

Torsion Sprio99 in Rectangular Section Wire

Exactly the same procedure is involved, except that the bask formulas are modified sl~ghtly (see also Fig. 16).

6PR Strass > -- )( K

a::ii:b "S

. 2160PRDN

Angular def~ecuan (degrees} = Ea3b

Square wire section &S sirnplv a special case of rectangular wire section where a .. b_

Fig. 16

23

CLOCK SPRINGS

Energy Stored in Torsion Springs

This is easily calculated from the deflection and moment.

PR x deflectlon (degrees)

Stored energy ~ 115

Th e s a me fotmu fa eppl i es to bot h rou n d and rectao 9 LJ I a r 'r/'J .re sactio n s.

CLOCK SPRtNGS

6

A clock spring is .a spedai type of spiral Or torsion 5pt'jng. wound from fla t stri p. M ai n interest is in the tu r nlog mome n t Of torque, and the powet such a spring can develop.

Th e stress deve loped j n the s pri n 9 materia I ell n be ca lcul ated fro m the sprin 9 d i men sions ina c tose w 0 u nd and 1u U V re leased co nd itions. If R .... is the radius of a particular point; n the spring in a fully wound condition and RoJ the -radius of the same point in an unwound condition, a close a ppr ox imation to the stress is give 11 by:

Bending stress (So} = E ~(R: - ~J

(se e Fig _ 1 7 for n otanons)

Fig. 17

fl.ll iy released

ftJ.11 Y woutl.d

pointX

Poir'lll X

Note t ha t ; tis the materia~ stress in bend i n 9 (0 r torsion) w h ic h ap plies • n th i s case, not the tensi Ie stress (whi ch is tower),

24

ClOCl< SPRINGS

The . De nect~o n I form u la ca n be rendered in te rms of ~ hen umbe r of turns (T) the spring can be- wound up.

T or 6PRL nEeb

this can also be rewritten in terms of thE~ stress (Sb)

T ::::; LStJ_

nEt

(see Fig. 18 fOf notation}

Fig. 18

D-efll!o;:.l ioo -::.. t'IIu~r oQf turm ..... OVl'Id up

Unwound

b

!

1

I

i

I .

I i

~-R----1

This is by far the more convenient form .. but is not strictlv correct sine e it doe s not a~ low for the effe ct of c urvatu re 0 n stress (see T orslon Springs) _ The complete form u1 a fo r n u moo r of turn sis thus

T= LS~ n:EtK~

w he re K ~ is the curvat u re stress

fa ctor (see Ta ble V)

The le .. .,gt h of spri ng (l) ca n be de rived fro m basic geometry.

L ~ nDN

where N :;;;;; number of active coils

25

CLOCK SPR~NGS In the fu~ly wound condition

( Ru - R .... )

D ~ 2 R~'" -2~

but

tJ - R = Nt

I""II.J Yt

or RlI = Nt + R .....

~ Nt .~ A,. - RoI)

Thus 0 ~ 2 \ R u + 2

=- 2Ru + Nt

S u bstit uti ng in the fi rst form u: a

L x: 1rN (2R~ + Nt)

These formulas can be used to determine the required spring ge ornetrv. with the mec han leal ou tpu r g lven bv

Turn. ng rno ment o.r torq ue 0 = P R ~

~f the applied torque is known. then the number of turns to wind up the sprinq also fo ltows d i rec t Iy as

6QL T=-- 1tEt~y

Ho rsepower Ca I cu tat io Il

Th e stored energ y j n a dock sprin 9 can be re~eased at va rious rates. according to the manner in whic h the movement is governed or restrai ned.

Note the relatlonshin between number of turns (T) and stress.

No. of turns (T) to produce

S. LS

stress • n sp ri ng materi 81 ;:: -e

It t

nEtT suess (S) = l

Thus

also:

. 1tSbt2

Energ y per revo luti on = -6

To dererm i n e the en erg V prod u ceo by a ctcck s pri ngF proceed as foltows:

0) Care u ia re fef1 gth l from t he .gee metry

.26

CO...,STANT FORCE S'PRINGS

(ji) Calcu late stress produced from the number of turns available to wind up (this must not exceed the maximum pefmis.sible bending Stress of the material} _

(iir} From the stress cetculate the energy per revo~ution (EJ

If the energy per revolution (Er) is determined in units of inch- pounds (whic h will foUow using ir.cn units for tile spring ge-ometry aJ'ld stress in lb/sq.in).

'Et x rpm Horsepower ;;;;; 3: 9 6. 000

or say

as a suitable approximation.

The time for which the spring w,~1 develop power also follows as T/rpm, in minutes -- i,E!'. the number of turns which can be wound on. divided by the rate of unwindinq in revolutions per minute-

The whole series. of calculations can, of course. be worked in reverse. That is. startinq with a horsepower output requirement arid a known value of maximum permissible stress. suitable geometric proportions to r the s p ri n 9 ce [l bed eterrni ned. togeth e r wit h the" u mbe r of ·w.nding· turns available for the required rate of revolution and number of complete revolutions,

Note: as a pr acncai d esig n feature the d i,a meter of the i nne r coi I of the spring. in the fuHy wound condition, should not be less than 12 times the spring str: o thickness. That is, the spr.ng should be wound on an arbor of this rninirnu m size, H wound up to a smaller diameter the spri ng 1 s i. k ely to suffer fro m fat,g IJ e effects.

------~--~---~--~------------------------~ ~~------

CONSTANT FORCE SPR'NGS

7

Constan t force springs are asp ec i a I tvp e 0 f fj a t stri p spri n g. presn essed to have a 1.10 i for m tenden C y to CUT I alon g its whol e- !engt n.' The V can be used in two ways (see also Fig. 19),

(i) Rolled ont Q a bus h i n9 to for m a constant force e xtenslon spr i n 9, because the reststance to unrolling is the same at any extension.

(i r) Reverse r wound aeo und a second dru m to provfde a constant torque spr ing, 0 r con st a 11 t to rq U e spr ing motor,

• Sp,i ngs 01 tni:!i- typ..:!! ;;Ire mad e by Ten!jiiirtGr li mued, Acron Lane, H ar le5d'!:!.r'II, london, NW' O. Thev are ikn ow n as: Tensstor' s.prings ill"ll this COUfl1cy; and ·Ne.g·ate ( s.pring9- in A.rn:eti ca.

2"1

CONSTANT FORCE SPA INGS

Fig. 19

by ~II ing (11'\10 01,:1 1)1,,1 ~ i I'I~ Gt ~QoOI pIOOUClI!!S 0- C flI'I"!;l-;]rl t fore..:!! ~ dl!!n-5 i 00 ~r i ng

-~~

" ~t\

i j

b>, r-!V-E!1"54!' w i:l"ld i 1"19 O()ta. 0 'afger iClrlllTll pro-dUo;A::$ IJ c oo~tal'"ll torque ~F4" in'9 motor

Constant torce springs of this type have the advantage of beinq more co mpac t when re I a xed, compared wit h hel ica I spri ngs. pi u s t he fact th i;l t v@ry 1 On 9 e xten sion s are poss i ble _ Eithe r end ca n be fj xed to produce an extension spring as shown diagrammatically i I) fig. 20- The fi xed free -end co nfig u ration, for e xa m pie, has proved panic u le r Iy effec tive for br us h spr i n g son e lectrlc motors.

Fig. 20

,

CONST A N 1 'FOli CE SP RI NO S

The constant to/que or spr~ng motor form is particularly interesting since it offers a performance far superior to an ordinary ctockwcrk m otor, pertic ul ar~y in th e lenqt h of r u 0 possi bl e .a n d the greale r mechanical efficiency because 01 the absence of i ntercoil friction. Its performance can also be predicted quite accurately.

Extension Spring DesIgn

Fig_ 21 shows the static parameters of a 'Tensator' ex-tension sprjng_

F'g. 21

strip width::. b

:. t

____ L. __

bobbin -

· .

Ii'

· I I I

· f- r---- l_ <!!) 01 .------l

l ... - :~~J ·

The toad to extend can be celcuteted directly from the load factor for the material (see Table V) and the spring width and thickness-

p:;;: Qbt

The work;ng extension of the spring (X) will be specified. but can also be determiner' from the actual iength of spring strip.

X ':::!:. L·- 60:;:

where L is the tota~ length of spring.

(Now' this formula allows for 1:} dead turns on the coil).

The foHDwing formulas can a~so he used to deterrnlne D'f and D2•

D1 = .,.,/1·275(X + 4-750~1 t + D~

I" design this Should be increased by at laast 10 peT cent to be on the sale sid e. r 0 .a' low ",0 r a i r space betwee n t he co i Is.

O~ = 1 ·2 x natural free diameter of spring.. as made-

29

CONSTANT FORCE. SPR.iNGS

Torque Motor Design (see F.g. 22)

Th e torq u e 00 t pu t (M) ava ,i ab1 e from a constan t torq u e 'Ten sator' spring motor i s gi ven by t he far mu I a

M = ~bt 03 2

wh@J@ a is the load factor (see T-able

V)

The horsepower output can be derived from the rate 01 unw~nding. as wit h cI ock w or k. motors (see S ection 6}_

Fig. 22

-- - E;:<=n.11"~..::1 r!.t1Jn~ --.-~

.

str ip ~ ldth _. b

I

I---~ D3 -- ... .,

~ °4

The following formulas w.11 also be useful in design- 6t

Sf

where Sf = bending factor (see Table V}

=~t

Optr rnu m val ue of 03

Optimum vaiue of t

Optimum centre distance = D, ; D, + 30t

D;2 = 1· 2 times natural free diameter of spring .. as made D, = ",11-275Lt .... D;

where L =: totat length of spring D 4 = ~/T-275Lt + D~

L ~ 11 (D~N + tN2) approx

where N :;::: number of workIng revolutions of D:.l

30

MUlT1PLE lEAF SPRINGS

8

Basicatlv a lamlnated spring consisting of a number of ind lvidua: teaves is no different to a 51rgle ~eaf spring. except that the additional leaves inc tease the effective t h ic kness and ~ h u s red uce bot h deflecno n 8 n d stress i n the i nd ivld ua i leave s for a 9 iven loa d. Stress ca I cu tat i on s a re usu a I' y based 0 n 1 he a ss u m ption of a pro po rt ioo.ate load on e a c. h I e-af (l.e. proportionate to the number 0-1 leaves).

Fig. 23

quorter -I!'J l: pll4;

~"--C-'p"4

...... l --- --'1

I ----

L--·

I t-.-

I

I

-- .1:.. .. - _. --...j

Three common configurations fer multiple leaf spr~ngs are shown in Fig_ 23- The follow~ng deflection formulas apclv:

Half elliptic;

Qua rtsr ell i pti c:

4PL3 Deflection = ---

Ebt:3n

D f~ . _ Pl3

e secnon - 2Eben

where E :::: modulus ot elasticitv of so ri ng materi ai

n = number of leaves

Half elliptic C8l1tileveJ:

MULTIP'LE lEAF SPRINGS

Th e cones pond • ., 9 stress for m u I as .a r€' (the rnaterl a j be i n 9 stressed in bending as with simple flat springs).

Half all ipli c:

1·5 Pl stress == b;2

t n

Quarter elliptic:

6PL Stress =-bt2n

Halt eiiiptlc Cantilever:

3PL Stress =-bl~n

The re are sever a I possi hie des ig n a pp roaches. lf t he th i ckness of ea-ch leaf (t) is decided. the spring w~dth (b) necessary to produce the requ ired d eflectioo wit h 2.. 3. 4, etc '. teaves ca n be ca leu latad, usi n 9 the appro pri ate def lsctio n to rm I.J la _ For axa m pie. 1 n the cs se 0 f a quarter elliptic spring

4PLa

b=-~-----

E t.J n x. del lect i on

Th is wit ~ give suitabl e spr i n 9 9 cornet ry wi l h 2, 3. 4 leaves. et CO, f tom which the most attractive can be selected. This value of b can then be used in th e stress form u I a to cnec k. tha 1 the max. mum perm issl b I e materia I stress is n ot exceed ad. ~ f so. the nan a ltern ative sol urlo n must be ad opted (e. 9 _ more leave sand srna I ~e r width); Or the ca lc u I ations re-done starting with a different (higher) value of thickness (t).

Sometimes it is simpler to work directlv from the load the spring will carrv, which can be arrived at by rewritinq the stress formulas:

load ca pa bi I ity:

H If 11-. bt~nSIl-

a eo •• pnc = 1.5l

a II" bt2nSp

uarrer e ipnc = 6L

H If ~I' . C 'I bt;:;!nS~

a e~ ipnc anti ever = 3 L

where Sj1 is th e max i mum oermiss i b le materia I stress in bending,

A serie s of alternatlve spr iog desig"s ca n the n be worked 0 ut in

32

APPENDIX A

terms 01 different values of width (b). thickness (t) and number of leaves, al~ of which would be capable of carrying the required load. 't j 5 the n a matte r of eslcu J ati n 9 the de '~ectioo of eac h of these spr.ngs and deciding 011 the most suitable one. I f none give a suitable value 10 r deflecti on, the n fu rt her alte rn at i ves must be worked OU t b eari I1g in mind:

spring stiffness i ncre asss i n di rec t pro porti 0 n to spri ng width {b) and n umber of leaves (n):

,n crease S ; n d tree t pro po rt ion to the cube of the teaf thickness.

APPENDIX A SPRLNG TERMINOLOGY {and standard units)

load (P) is the force in pounds (or kirograms) exerted on Or by 3 spring producing or modify.ng motion, Of maintaining a force system in equilibrium, Load 1$ directly proportional to dsilecticn and is limited by the elastic limit of the spring material,

Deflectio n is the maximu m movement of a spring from its free length or free position to a specified operating position. I n the case of helical co~ ~ spdngSF deilect.on per co. I is equal to the total deflection divided by the number of active Coils,

Rate or load rate is equal to load divided by deflechonF and is thus inversely proportional to the number of active coils in a coil spring.

Free length ~s the true dimenslonal ~engt h of a spring in ~ts un!oaded position.

Solid height is the geometric height (or length) of a col I spring when it is ful~y compressed,

Active coils - the number of coils in a coi I spring wh.ch deflect under -oad. End turns or parr- turns on 3 cornpression spring whiCh do not take par t i 0 d eflectio n are referre d to as ' dead I coi ls,

P itc his the spac fn 9 or pite h d i men s ion between adj acen t acn ve coi Is in a coi I spring _ Pitch determines the number of col Is per unIt length, S pring tat e is a lso de,oe ode n ton p ite h, be i n9 s u bstenn a II 'Y constan t if the pitc h is constan r.

33

APPENDIX A

Stress is the ope rating stress 0 n the spri n 9 materi a I unde r working cond i ti ons. I t is importan t bot h to use the right stress value for the materia I (e .9_ de pe nd ing 0 n whether the sprm 9 material is being su b ject to te n si 0 n or compressio n~ bendi n9 0 r torslo n a I loadi n 9); .a nd a Is 0 e nsu re that a maxi m urn perm iss i ble stress l.g u re is not exceed ad. The I ana r depend s on bot h load .a nd heq u e n ty of deflection.

Mean diameter (0) The mean diameter of a helical coil spring is spec.ned as the diameter to the centreline of the coil. The overall diameter of a coi l spring is thus equal to D + d: and the inner diameter of a coil spring to D - d. Note that diameters can vary with working in the case of a torsion spring.

Wire diameter (d) the actual diameter or wire size used in a spnng made from round wire.

S pri ng index. This IS the r at~ 0 Did and is used to determ ine stress correct io n fa et ors where th e stress load i ng 0 n a spring is not slm p:e ( e.q: he! ic a I COm pression and exte n si on so ri n gs. a nd torsion S pri ngs) .

34

APPENDIX B: WIRE SIZES AND VALUES OF d3 AND d~
--~
~ - -:-.- ----_.- ----
oj
s: .... -(I' ,,, d" ~4 l ~:~ r" tJ''' .,j.
1
~. --- ------- .- - - ---
.l.l .0 01or. o 000001 o..':Q ,() ., 0 00 IX'O' I)()I)I) I} 06-1) .[) ClOO:!"'600 o 00001 2.9600
32 001' ., 000()("l1 J:3' I:)OL~l.11~l o %1 e 0002:2699 o QOoo, J84-~B
J.-O 00 I;I~~ .0 (l(IOCiO', j ~~ 0() 000:)0002"07:1-0 e I;IB::!: o OOI;l~::'j~ .. t~ (I 0001)1 -4 111H
(I (I rJ G ()(l{IOOl1 !l'~ 0- OO(l{lt.i"jO"'~~ 1 I'} (lB:i! D 00'.)2' 5005 o OODD r 5 ~:5:ro
:!"8 0014 :;. OOOOOi7ol.4 o OOOOOCh:l3a41 {:. 16 0064 O·(;OD].a.~, '* o 0OOOllij.nn
e (I~5 o ",}OO(I Cl3:!; 7 5- o C()OO(l(lIJ~:""I6:i'5 (;IM6 o OOO;'"!:7ol6:."1 (:0 0000 .. J.g'50~
J:iI" CI (116: 11 eooo (1 ""0 !il!i ,';I O()(IoaOOfi!:.~ re o (1-66 I) (lOO2'.fI.j'~(I. (I- (I(I(IOf ss 74 r
I) (I~-' -0 -:)'):)00 4. 91 :3 -0 ClGOOOOOEl:!:52: I) (l€;jI (J 0DI)0J 0 O? 15 Q OOOOLO'!i' 1
.::"'5 (1m!) () (KlQOQ56P 1~ OO(II;n;!CI1 ()4-!jI7.ti- o(). oe & (l0M:;!:14.4.;:1 -I) ()(t(I(I/l ~~, 4-
(I. 01-91 1;}~£1 () 0iXl00I) 1 :) o-::l ~ 1 (10 06g 01) (01)3 28.S' o 00002266701}
o 020 o 0000081X1(1 o (01)0001 &001}0 {I ()'O o I)IJro4JOO -:;. 00002400' (10
Co 02' o OOQOO5'2'51 (I- 000000' ~4:11' IV" oJ, -0 .;::qo::l-~ 1 91, o OOOOZ!}4 ,"'! "1
::-4. I) (I:::-~ of) 00.;:10 ~ ()e,4:9 o OOUOOOi3;";£'!>9 ,~ 0() ()oj::;! (I «to:!n:;!~ -:) OQ(I(I'l'-a nos
I) C2l; I) eeco 1 :2 ~ Eo 7 1) OOO{I (1(12")" 9 8 40 o ()orJ (I I)I](t3 8 9PiYo! 0;) 00002S1"!182
~J 1} O£~ o QlJOO136H ~ OOODODJ;J;l 700 " 1J,4 1,;1 'Il1J040~21 OI;lI;lW2"~1io
I) O!S (1) 00(10 ~ 5Eo~"fI IJI (00000391)620 01) <'1.!,. (I W...-i2" es I) OQ(J031 &4(115
O~Eo 1.1~1)'~7(i. -0 (I I){I('.(IO 0:. 5 59 ee -o.:Y,'l. o Lt(:(I4:! I! 91 e: -0 ()(}OO~3;~·a..n
o (12)" ()·(}(Ir.l(ll ~~e=J 1)·QO(IOOO!;'3l4.~ -0 (107,. o 1)QQ45EoS) .;:0·0000:];51 "530
~1 o (I 2 I!: 0·{lOO(l2~ £152 O·OClQ{l0Cl614fiM 007 B o I)C(I.A H5!io I) (r~:37r"11-:;·,
I) 0::"9 I) OO(IO:? 4..1 Et9 o 000000 mnw oms. "'II·~5I!O" o o(;r()I):.:I.Ja9~'
I
11 ';>30 CI.:;w;:x::<I2/OCQ o OOOOlJI;I8 ~ 000 1-4 o oeo (l-o-..""(Io~':Oo o l)I):)I).to~
CI (!-031 o I')(}tJ(Io 2 9 ~!il1 o 00.:)(100 g:n ~:<- a- oal .:) 00:. ~::H.;": n DOi:ID4"l0401l::'
211 :;. d.!:? i). OC'<JOO ~ 7 601- 01} 1(}(I(KI0'l 04858 o 08:l o 0tXJ.~_'·1 ::f,t o OOOO~Eo1122
00:';;3 1;1 -I).'XI(J J ~ 9:3; i' o 00000' , 8592: I} OBl o (1005-7)"'9 o 001):}d1451t3
-0 D14 (I «tOO 3 9:Nt4 .:) aoOO(l r :}:3~ZI I) 084 G 0iJQ0I...I~2·/1' (I oI):):Xt.G $17 H 1
1;1005 C ~:28r!; 1J·(;t;")[]o:)oJ, ~"J(l6;;:' (1095 (1) (lOO-&'~~:! o OI)OO52ZI;>I)I;-
20 000(; o 0CIC6!I (j -:; 6 Ilo o 00tXI011111"i11132 o 1;191!i -0 rlIJ 0 Kl ~ 0 6 L) OCOQ!!:04 JOOI:I;
0031 O~SJ o I(}I'J(J(JO 1 81' 'I 6 o Ol!:7 o (I(.1t}I!I58~0 C ~:r28gs
0·OJ8 1;1 -I)I)LIII)5-' 9 72 o 1!J00(I(I2(18~1" (10 0813 (1) 001""168' ~1 ... OOOl)5"!1g159Eo
0-00::1 CI ODOO5~19 O~2::l.'J-44. o OOg o (' - · .. 0-4"3-r o l'(I{!I)62"7":':2l
19 e 0.110 e (:I (:I1}1}B 4 1:;1 co 1;1 t';::<I)(Io:U'!!I60oo 0(18(1- IJ IiJO(In~ o 00 (h_ '6 S-6-' QD
0041 (10 (tt){)[)6S.·n"ll (I DDOOO:;!:BO! -5.1113 htg,l (I «tCi/5"lS i' (:H}(t<IOI~:. ~ 50 J ~ n
0(1..:12 o 1)Q"JO~"i0 B8 o i)IOO(JI}J1 'I .70 13 0·1]'302 D 00017&3 .. 9 (;0 0Q{M)71 ,'391
o tulJ 1:;1 I:IOOOjI"O'1 (I. (:()I).';I:)J 4 , :&.:8 0 {;I 003 OOOO~16 Q·00007..:1&:O:;2
(I I}(J!I (I. 0000B5.184 CJ, CIDl)OOj 7.11 P.:1 (10 1;1 ()~ () ()IJQ-83 o !!I B 1;1 oc.£I<J:' so 7 <II:-l
0·0iI!;; e OOOO!!ol ,1S C~l~ Q (150$ 1;1 OO(l6$~J8 o Moos' o4!Oe;
(J D4ti CI·CIOOO97:3:36 o 0D00044·n.ll1!l 1;1 ()!1t6 o-tIIXItI E: 4 t 4 -0 .;}()IIr.la4!tl4 j
(1.1).11;' (:0 (01)'111)]823 (10 1)[l00{)4BJ %S. O·:CI!II~ (I 1)00.91267 OOf.lOO88~W
HI; (I: cP!I:a. G CIO(I" Co5-;1-1 IJ 00OOO5J.DB42 D O~ G~.i'19 D QOO(]'9Z2:JIE;[I
o 1)4"9 o 00011 i'IIj,4Si 0- :'JI)OOO!"6~ 00 o Q9S1 Q 0I:'IY.)1' (130 o 0 CtOO:!Ei 1;1 $ 915
(I. I)S(II () ·oocn 1SOO!1 I) 0iJ IX! oEi 1 &1)1):) 01.:)1) o 00,1)1)000 o (:()O woo:)
0051 o 0001: l:;! IllS a. ooccoe -;tt!i~1 IJ pOt .;)-oO'MOsO I:) ClOO'()4M
O.IJ52 .:t OOOl.,;j,;)l61 o oeooovsr rs 0·1'(11 Q OO'Ofi11t 0·00010e2:4
1;1 O!53 o DOO1 <IISS8 c O(;tIXI:;II 'jI a"!Jo"!.> 0-10:); c 001 (II !I':H:3 a 001)11255
00$4. IJ 1)1)1) 1 !j.;'.i15 0~50..31 1 Z (:0 ~Od. {) 001. , 241s.t1 0- 00011699
o (ISS o 0001 Ei6J8 IJ 0(I(I(II19 Hi(ll!'1 O-cM o DO' p:iM2 I'} 000' ~, ss
I 11 C O--!;fi o 00-1)1 i' 5-152 CI o()DCJOoO!II:fO ~"5- o .. 06 0. 001l'!1 ~ 02 (J 00012625
I 00$ o OOQ1.a.~,~ (I. IJOOO 1 i) ~ sse e 'Or o 00 L 12"5(I0Il Q.OOO-' 3' os
,
I o 051!1 ., fll"'l.'}1"9~' L 00000, , :-1111; ~ 0'1.09 o (l01204'!f;i'' (I. 0001 ::I&:I~
o (159 o :."oo.:.~:]:8 01'.«>01 ~ .. ~~~ -J ()., os I) O(Il" g,!:«i () 000-,41 U!
L ........... _-_._ .. -
_._- --------_. 35

APPENDIX B: WIRE SIZES AND VALUES OF d3 AND d4
~ -.&.. .... -_ .......
r·
• oj d
•
: 11'1'9 'II d" 1;14 l ..... g in d"" ,j1
._._-
0·1 '0 0'0013310 o 0061.t@ .. 1 I :0- () 11110 o 004():9&O lI·~~3;1!i
CJo1n 0·OO1J~11S- (I. 0001 511!1l 01)·18-1 (I ~1733: -D 0IJ0C>6 J ~ 90
0112 {)·001 4(I.t 9 o (,(1015135 I 0·111;1:2 00042$1 So {I 00<IIII a 915
O· 11:J O·OO1 ..... 2!1 o (IQQ, 1Sl0S 0·1"3oJ (I 0().t.J:l 0 ')" -0. C(IIO ~ G5 51 1
o 11" {)·OO14B115 o (:01)1)1 I!iEls(! 0·1 SolI () ~"1-(;r!;11 (). 0091 23 3;51
0·11 !I -O·O(n $2(1~ Q OO<U149C1 () HI'S Q 004.$9~1 0·0001<1'2'(:1
11 o 116 00·001 !5.$0!7 (I OO(H g HII5 0·166 o OO4IEi74l 0·oao1!ig~~
(1117 {)·00"'I80115 o 0(IQ-18n~ (I H:;~ G 1JO.t6Sr:;. 0·000771&1)
O·11a OOOl~O O·OOQI!;Ilae O·1&E1 o (t;).t"41. 00·00079659'
0·1 '9 0·0015852 IH100 .... 0053 o ies Q~8Ue (I. 0(I(Iql. 1 ~ 7' 3
0·1 :20 o OO"'Ineo n 0002013:6 0·110 o 00t9t J{) 0~~~1
0·121 o oo117t05 1) OOOZl 4J'ij 0·111 0·~2 o ·(I(I(I8:5~
01n 'iJI·OO1IH"68 -0 OOOnt!03 1[0172 o j)9S~ (:I. OCICI$" S. i'
oJ) ~ll O·OCI1&$09I () OOO:!::u:89 o '13 o OO611n O~9SH
D·124 O·OO1906S .0 000 23; 1M2 0'1011. o OO'5~B:O (II 00091 SOlI
01)125 O·OO,g~l 1I)·1XI02:441 .. on~ 1;I.~J.5-3'I o 00937B"909
1) llti n 00 29CJO,jI Q-oog.2~~ 1 o rrs o (Io:)t.4!11;8- II) (I(I{I!3 '; !} 5- ,
().~ 2]1 0- 00 2(i.4&I'I 000020014 GH7 o OO~64'S2 (J. IlOOgOO!>,
'0 912.8 o 002(.U4' .;) 0Cr0268411111 q·'7e o OOSij.J"S;jJ I} OO'OOJUI
lI)·l;nlr (lOO:!:145:i' 'I) lXICIi~~ 011$1 (r. Qr:)!r 7 j. '!:r:) (10 00' 02:fi{l3
r£Ir ~~,j) 0002"'"910 Cl-00021S-!i$1 Cl-180 C OOEr~:2(t o OOH)4"Mti
9'] 1 0·0CI;U431 o 0IJrD2 '!t4:5 11 o ~ 81 o OO:591~'!Jo1 (J. 001 0::'34E1
o tJ2 o 0D.r.l0(l0 o rOOOOOO150 I;)- 19" e (l(II'jQ 2;jJ 15 000109)'20
Q·I3-3 I;I-OOl"J:5-215 CI 1XIQ31 :2$0 Q 11:13 o 1)00 1 Z8'5- (1000112151
(Jo.1;)4 0·C«i! ... ~. o OOOln.t2 0·194 0·0052"2~!S -0·001 1 "'I5Zl
(Io·1~S O·~~ Q.OOOO321~ (n~ (I. (:rC)(i;}.J 1 ~ 000117'3!';r
o l:3B (HI02!51~tr -0 0003421 o CI·l!l8 O· ()rC)$.43.rI!I 0·00' l:91Se.8
0131 o 00215114 o (J(ICI:J!'ji 228 o 13~ CI eees 3 9.2 Q 001 2:.2283
0·131 o 00219:i:E!I' 0·00031:i2'1J':'" O·,;jJ;jJ (I oJXKi 15 ...... 1 0OOlN~O
O·l:!!I 'I)·0CI-215~ o 000l731O O·HI~ O·(lr;H;t~' J 0·00' 2 ~!&9!;11
01.0 o 004!'.w.o I) (II)O:J.8 4 1 6 0·190 0·6rilr8S~ 0·00'"300'
(H4' o 0Q2.8i0j..2 (10 00<:tJ ts2'5- o 1 '!11 () 00tS 9t' 7 '!I e ootssos
-0·1.4;2 0·0028533; -o.~"S' IS o '92 (I 001 0 H!I I}OO1J5iIO
{)·143: Or 00292.012" () 1X'04181 r6 -(I·1~ a. 1):)" 1t9r' 0- 00l.3-8~S
"9 0·14 •• o 002:9:NO .:) I)()Q4 2 9!Jr3 O·l:9J.1 o OOJ:KI1.ri1 0·OOt410'5
0146 [} [.ICr3rDrI85 0~-rl205 1) 1 '!IrS o OOJ'414'!J. I) OOU..45.!1
1H~ 0003H21 o 0Cr04~3, o 1 '!Jo6 I(]r 00715295 o OOU1!i@
Clr·14]1 o OOJ;1765 () QI)I)4 H!9! 00· 1 g., 000115454 o OO?SOO1
O·14a 0·0032'.13 () -ODIN.191 g. 01~ o OO~]'I5Z4 ., 00' !'}J.jI(Io
OU9 O· 0Q:l:3 c);;r 3' o ()OO.jI:!I21!11!1 :)·1" o OOJeJl3(:rI). I)OOt~4!
o UiO {). 003-:l1!&OO o 00(I5(II!I2 Eo (1·200 (l00B00CI O·OO1SOO
0:- 1 $~ D OOJ,jJ"-2!1!i O·~~S8S1 'S 0·.21 ~ o~e Qr·OOz.o:O
o ,!5l ~HIO:3!5-1181 o..,OO!5J379
a 1!5J (I·OOJ!SotI1M a o:J06.t'9E1 ill O· zsz (II 012"'80 O·W21381
n 154 O·OOOISS:Uo I) ClOOIS1!245 J 0· zez o- 1I)60(I(l 'O·OIHOOJ
l 0'" 0·00372390 o 000IS1120
o 15di O·OOOlge40 D· coos 912 2 '* , o <%io$ 0·02100!0 (I·oo-seol I
0·lS7 (II oora:Q9ISIO O· eooso 7:57 0-300 (I·1)1~OOO -0. (100.1 00
.Q·l!8 o OO3!1144.1O O·OOOISZ3ZO
.0 1M' o 1XI4£I""970 -0·000&3913 0 0·324 0- Cl'3.$.00(1- {I·01100r;l _j
~.--. L. IIMIDiLl:.. :=!il"'l1ill'lllli MA I t:t'liIAL::::ii AND fHElft MECHANICAL P~OPE'RTIES

1J16I:h.IJ'> or I.-ql~ ' ...

G i ~;~o"j ,r.::,

L,rn.1 oJ~ ~lo:o~I~,(:o""I~I'~", Ito ~ Ir 1"

~';;I~o!;I .... _.p up ro 0(.'0 1·-IfLlo 011 '~I'fI~tod :iolo::~1 ,"""oI'f:

HwQ -!i1;N':n n~1'"1 'N'I~ >I-!o,n!0:>5J Jlel!!· 18 :9 WII'£' 5r .... ,"'w 'II!!~ r.;!1 ..... ,~

I::; t.o\OI"nA "~~~,,,,,,, PI'H).-!,I>"(li t'l'o}fI~.

li3-u~

""r.-co~1

il::l.,.II'~ I;.Q~P\"rPIi.(1ro,o,o1 "!i,hO'·

- C"o!Io'"I I J-!". I ~;!o'I"'9 o"i!,'~~I·;o,ll

r Uo;c- 6(:0 PO::I O!:~r"li ffi ~tll" ·,,'·u'" 1"1 -!1 ..... :r,:"I -:::. 'Uol r.O~~.'C~ -;11II""'H:pj

TABLE u WAHt·S COR-
RECTION FACTOR K FoR
ROUND WIRE HELICAL COIL
SPRINGS
._._-
. Spring IndF.:!-x Old K
r _._-_. -----
2 2·06
I
I :3- , ·58
4 ~ 40
I 5 1 ·)1
6 1·25
1 8 1·H3
j 10 1 ·14
~2 1 ·12
! 10 1·0:9
I 20 1·0,
l 25 1 06
;
..J Mool:"~ co, ~·.~L L.I~·

E \:~I:SL:l ·1"11

10':

'"

~"II"~"'I·

.eo ow ·W.o-w '~:Jo.Q(D

9Q ~ 2(11X1O ~ 2"!).Oc-J

, 21).1XJ(I , 00. roo 100 IXlO

I_!.O. tto QOOI so C<IO

J:(I (lOCI. IXIO J.{I 000..:::00 :!::) oeo IXlO 2"~ 00000) 2" 9 (I(lQ 00 [) ac 1)00 eoo 1 s IXIO.-:)oo

~ 000.000 :i" 5 OC(I (XII) : 06-- 1 B. 500.0DiJ' , 6.000 -IX:(

, :!".ow.1.Xl{) ~ 1 .500. CQ:) < 1 '5IXI 000

RJ: .. 1. ;)(II) I 1 .!!rOO VO!) 1 1 !Y:'KI~:'L1P. o(j ~:)Q to,:. :;SO:::o-tOu g. (0-;)0 00t)

I) 7.1XI:} CIC(I s soo ooo

TABLE III CORRECTION FACTORS fOR RECTANGULAR WIRE H'EliCAL COil SPRINGS

---_. ..
Number Stress D~flecliort
of aei ill'E! Iacior factr.)f
cons t::;1 K:J
1·0 4'SO 5·55
1·9 4-2-B 4·01
2·0 3·90 3·32
2·5 3·71 3-07
3·0 3·60 2·92
4,0 3·45 2·76
6·0 3·30 2·61
10,0 3·15 2·S0 j
2Q 3'09 2-40 ,
50 3·04 2-38 !
100 3·02 2·37 _j TABtE IV STRESS CORR£CnON TABLE V DESIGN VALUeS fOR
FACTORS FOR TORSION SPRINGS IEN~ATOR' SPRINGS
I [ Dosig. ---,
S tl'C'S'S SW~:·:;~
Noumber factor fur factor fOr Carbon Stai"less
of activo tOul"'ld ri!'CC~l'Igtllar ~ I~ nQ. oi s.Eee-1 stt::e~
: evcl es 0 S. Q S~
coils wirE! K .. wire l(~ 1
.- _ ... _ ...
2 1·6' 1·54 5000 521 0·023 660 0·027
3 1 '33 1 2:9- 10,000 418 0020 502 0·023
4 1·23 1·2-0 20.000 271 0,015 350 0·019
~ 1·18 1-l5 40,000 H39 0-010 233 o-oiz
6 1·14 1-12 70.000 123 0·009 151 0·009
8 1, 10 1 09 100.000 101 0,008 87 0·008
10 1-08 1·007 ,000,000 e~ 70
12 1-06 1·06-
1-5 1 05 , '04
20 1-09 , .00.
25 1 04 1·03
30 , -0:3 1·02
ab-ove 30 1·0 1 ,0 37