SOLUTION (12.1) Known: A torsion bar has a known length and diameter. Find: (a) Estimate the change in shear stress when one end of the rod rotates through 70° relative to the other end. (b) Estimate the change in torque. Schematic and Given Data: Assumptions: 1, The bar remains straight and the torque is applied about the longitudinal axis. 2. The material is homogeneous and perfectly elastic within the stress range involved. Analysis: 1. From Table 5.1, for a torsional case (Case 2) O= Th. therefore, T= a 2. @ = (80/180)n = 1.39 rad nd4/32 = m(0.312)4/32 = 0.00093 in.4 From (Appendix C-1), G = 11.5 x 108 psi 6 3. Therefore, 7 = 1:39 %0.00093 x 11.5 x 10) = 297.32 Ib in . 4. From Eq. (4.4), for a solid round rod, t= 16T/nd? = ANE9T32) _ 49 9 si 7(0.312)° .SOLUTION (12.2) Known: A torsion bar has a known length and diameter. Find: (a) Estimate the change in shear stress when one end of the rod rotates through 75° relative to the other end. (b) Estimate the change in torque. Schematic and Given Data: Assumptions: 1. The bar remains straight and the torque is applied about the longitudinal axis. 2. The material is homogeneous and perfectly elastic within the stress range involved. Analysis: 1. From Table 5.1, for a torsional case (Case 2): =TL = 9G 8 = Je. therefore , T = R © = (75/180)n = 1.31 rad J = nd4/32 = 0(0.312)4/32 = 0.00093 in From (Appendix C-1), G= 11.5 x 108 psi 1.31 x 0.00093 x 11.5 x 10° 3. Therefore, T = Oe = 329.66 Ib in. . 4, From Eq, (4.4), for a solid round rod, t= 16T/nd® = 19G29-69) «55 3 ksi (0.312) . 12-2SOLUTION (12.3) Known: _A torsion bar spring serves as a counterbalance for a trap door with a given weight. The maximum allowable torsional stress for the spring is 50 ksi Find: (a) Determine the length and diameter of a solid steel torsion bar that would counterbalance 80% of the door weight when closed, and provide a 6 Ib-ft torque holding the door against the stop. (b) Make a graph showing gravity torque, spring torque, and net torque all plotted against door opening angle Schematic and Given Data: ‘Opened | Assumptions: The bar is straight and the torque is applied about the longitudinal axis. 3. The muteial homogeneous and perfectly elastic within the stress range involved. 3. The cross section considered is sufficiently remote from points of load application and from stress raisers. Analysis: 1. From Eq, (4.4), for a solid round rod t= 167 or d = Vietiet nd? When the door is closed, the bar will counterbalance 80% of the door weight. Thus, Te = (0.80)(60 Ib)(24 in.) = 1152 Ib in. Since a maximum allowable torsional stress is 50 ksi, d= ¥16(1152)/n4(50,000) = 0.49 in . 2. From Table 5.1, for a torsional case (Case 2) @ = 7 and K = 1 = 4G 12-3where J 0.005660 in.* 32 G = 11.5 x 106 psi (Appendix C-1) K = AT = Te= Te _ (1152-72) I im. _ 569 5 Wb in rad ae Ae 152 rad 6) _ 3G _ (0.005660)(11.5 x 10) _ Thus, L = 4G = SOO = 115.7 in 7 3. Let clockwise torque be positive. 1600- 1200- Gravity torque = 1440 cos 0 30° oP Door opening angle, @ ~ spring torque 12008 iss SOLUTION (12.4) Known: A torsion bar spring serves as a counterbalance for a trap door with a given weight. The trap door must be designed to open only 60°. The maximum allowable torsional stress for the spring is 50 ksi Find: (a) Determine the length and diameter of torsion bar that would counterbalance 80% of the door weight when closed, and provide a net torque of 12 Ib-ft when open 60° (b) Make a graph showing gravity torque, spring torque, and net torque all plotted against door opening angle. 12-4Schematic and Given Data: Ro’ Door stop 24 in 601» RI (Opened Closed Assumptions: 1. The bar is straight and the torque is applied about the longitudinal axis. 2. The material is homogeneous and perfectly elastic within the stress range involved. 3. The cross section considered is sufficiently remote from points of load application and from stress raisers Analysis: 1. From Eq, (4.4), for a solid round rod t= 16% or d= 16T/nt nd when the door is closed, the bar will counter-balance 80% of the door weight. Thus, Te = (0.80)(60 1b)(24 in.) = 1152 Ib in. Since a maximum allowable 3 torsional stress is 50 ksi, d = V 16(1152)/m(50,000) = 0.49 in . T_JG From Table 5.1, for a torsional case (case 2), @ = # and K= 5 = i 4 where J = =- = 0.005660 in 32 G=11.5 x 108 psi (Appendix C-1) For 60° opening, gravity torque = 60(24) cos 60° Thus, spring torque required, T. = 864 Ib in K AD (1152 - 864) Ib in. “a9 -L0S tad 274.3 Ib in/rad (0.005660)(11.5 x 10°) S43 237 in. a =IG Therefore, L = K 12-53. Let clockwise torque be positive. Gravity torque = 1440 cos 8 x Gravity + Spring torque Door opening angle, 8 Tie Ns: SOLUTION (12.5) Modified Problem 12.3 Known: A torsion bar spring serves as a counterbalance for a trap door with a given weight. The maximum allowable torsional stress for the spring is 350 MPa. ind: (a) Determine the length and diameter of a solid steel torsion bar that would counterbalance 80% of the door weight when closed, and provide a 8 N.m torque holding the door against the stop. (b) Make a graph showing gravity torque, spring torque, and net torque all plotted against door opening angle. Schematic and Given Data: pa 250 N R| Closed] 12-6Assumptions: 1. The bar is straight and the torque is applied about the longitudinal axis. 2. The material is homogeneous and perfectly elastic within the stress range involved. 3. The cross section considered is sufficiently remote from points of load application and from stress raisers. Analysis: 1. From Eq. (4.4), for a solid round rod t = hor a= Viet When the door is closed, the bar will counterbalance 80% of the door weight Thus, Te = (0.80)(250 N)(0.60 m) = 120 N.m. Since a maximum allowable torsional stress is 350 MPa, d= ¥16(120)/n(350 x 10%) = 0.01204 m or d = 12.04 mm z 2. From Table 5.1, for a torsional case (Case 2) @ = 1% and K = 1 where J = 2 = 2.063 x 10° m4 G =79 x 10° Pa (Appendix C-1) x =AT= Te Fede 2 12058 58 = 58.3 Naw/rad ae Ad (2.063 x 10°)(79 x 10°) 58.3 3. Let clockwise torque be positive. Thus, L = 4G = =2.79 m . 150- Gravity torque = 150 cos © Gravity + Spring torque torque (Nat 20) 5 30° E 50] Door opening angle, 8 100 Spring torque 150 -120 Modified Problem 12.4 Known: A torsion bar spring serves as a counterbalance for a trap door with a given weight. The trap door must be designed to open only 60°. The maximum allowable torsional stress for the spring is 350 MPa. 12-7Find: (a) Determine the length and diameter of torsion bar that would counterbalance 80% of the door weight when closed, and provide a net torque of 16 N.m when open 60° (b) Make a graph showing gravity torque, spring torque, and net torque all plotted against door opening angle. Schematic and Given Data: Ql ey 250N R| [Opened Closed Assumptions: 1. The bar is straight and the torque is applied about the longitudinal axis. 2. The material is homogeneous and perfectly elastic within the stress range involved. 3. The cross section considered is sufficiently remote from points of load application and from stress raisers. Analysis: 1. From Modified Problem 12.4, d = 12.04 mm . 2. From Table 5.1, for a torsional case (case 2), 8 = aa andK = 1 =JG where J = ae = 2.063 x 109 m4 G=79 x 109 Pa For 60° opening, gravity torque Thus, spring torque required, T. = AT_ 120-91 40 1.05 = 27.62 N-m/rad )-9) 19 2.063 x 10°)(79 10) _ 5 94 my . Ge Therefore, L ==? aTieD 12-83. Let clockwise torque be positive. 2004 Gravity torque = 150 cos 6 Gravity + Spring torque 20° 40° 50. Door opening angle. 6 150 -120 Spring torque SOLUTION (12.6) Known: A torsion bar has a known length and diameter. Find: (a) Estimate the change in shear stress when one end of the rod rotates through 70° relative to the other end (b) Estimate the change in torque. Schematic and Given Data: Assumptions: 1. The bar remains straight and the torque is applied about the longitudinal axis. 2. The material is homogeneous and perfectly elastic within the stress range involved. 12-9Analysis: 1, From Table 5.1, for a torsional case (Case 2): = IL = SIG 8 1° therefore , T L 2. @ = (70/180)m = 1.22 rad J = nd4/32 = 0(0.312)4/32 = 0.00093 in.4 From (Appendix C-1), G = 11.5 x 10° psi 1.22 x 0.00093 x 11.5 x 10° 3. Therefore, T = ———————_ = 290.43 Ib in. a 4. From Eq, (4.4), for a solid round rod, = 16T/nd? = 129043) = 48 7 ksi : (0.31295 SOLUTION (12.7D) Known: The web site http://www.indspring.com. Find: (a) List the mandatory specifications required to order a compression spring. (b) List other information or data important in ordering a compression spring. Analysis: The web site provides the following information (a) Mandatory specifications OUTSIDE DIAMETER INSIDE DIAMETER Load and Rate Maximum solid height Direction of helix Type of ends (by Advisory data FREE LENGTH Wire diameter in. (mm) Mean coil diameter in. (mm) No. of active coils Total no. of coils QUsw= wae ;pecial Information Type of Material Finish Squareness (free): within degrees Frequency of compression, cycles/sec., and working range, in. (mm) to in. (mm) of length Operating temp. degrees F (degrees C) End use or application Other BYR, AW 12-10SOLUTION (12.8D) Known: A compression spring is to have an outside diameter of 0.102 in., a free Iength of 1.000 in., and a wire diameter of 0.010 in. Find: Select a compression spring and determine the (a) “hole diameter to work in,” (b) load at solid height, (c) spring rate for music wire, (d) spring rate for stainless steel, (e) solid height, (f) total number of coils. Analysis: This web site http://www.leespring.com provides the following information: a, Hole Diameter To Work In: 0.109 (in) b. Load At Solid Height 0.70 (Ib) c. Music Wire Spring Rate: 0.90 (ib/in) d. Stainless Steel Spring Rate: 0.70 (bin) e. Solid Height: 0.246 (in) f. Total Number Coils: 24.60 SOLUTION (12.9) Known: A helical coil spring with given D and d is wound with a known pitch value. The material is ASTM A227 cold drawn carbon steel. Find: If the spring is compressed solid, would you expect it to return to its original free-length when the force is removed? Schematic and Given Data: | ASTM A227 I ald drawn carbon steel L r d=10mm p= 14mm D=50 Assumptions: 1. There are no unfavorable residual stresses. 2. Both end plates are in contact with nearly a full turn of wire 3. The end plate loads coincide with the spring axis, Analysis: 1. Force to compress spring solid can be calculated by using Eq. (12.7) P= 0G8 8D°N where 6/N = p-d=14-10=4mm 12-11G=79 x 10° Pa (Appendix C-1) (10 x 103)4(79 x 10°V(4 x 10 8(50 x 10° 2. The corresponding stress can be calculated by using Eq. (12.6) 8ED 3 K, 3160N for C = D/d = 50/10 = 5 Ks = 1.1 (Fig. 12.4) _ 8(3160)(50 x 107) pe (11) = 442.6 MPa (10 x 10°3)5 3. From Eq. (12.9), ts $ 0.45 Su From Fig. 12.7, Sy = 1300 MPa Thus, 0.45 Su = 585 MPa 4. Since 442.6 MPa < 585 MPa, no set should occur; therefore, spring should return to original length . Comment: Even considering the curvature (stress concentration) factor of the inner surface by using Kw = 1.3, the inner surface stress is only (1.3)(442.6) = 575.4 MPa which is still less than 585 MPa. SOLUTION (12.10) Known: A helical coil spring with given D and d is wound with a known pitch value. The material is ASTM A227 cold drawn carbon steel. Find: If the spring is compressed solid, would you expect it to return to its original free-length when the force is removed? Schematic and Given Data: | ast a227 i Cold dew carbon steel p= 10mm Assumptions: 1. There are no unfavorable residual stresses. 2. Both end plates are in contact with nearly a full turn of wire. 3. The end plate loads coincide with the spring axis. 12-12Analysis: 1. Force to compress spring solid can be calculated by using Eq. (12.7) p= 4G5 8D°N where 8/N =p-d=10-5.5=4.5 mm G=79 x 109 PA (Appendix C-1) _ 6.5 x 10)4(79 x 10°)(4.5 x 10 8(50 x 1033 2. The corresponding stress can be calculated by using Eq. (12.6) DK, nd for C = Did = 50/5.5 = 9.09 Ks = 1.05 (Fig. 12.4) 325)(50 x 10°) = 5B25)GOX IO 05) = 261 MPa n(5.5 x 103) From Eq. (12.9), ts $ 0.45 Su From Fig. 12.7, Sy = 1300 MPa Thus, 0.45 Sy = 585 MPa 4. Since 261 MPa < 585 MPa, no set should occur; therefore, spring should return to original length. . F 325N . t= ‘Comment: Even considering the curvature (stress concentration) factor of the inner surface by using Kw = 1.17, the inner surface stress is only 290 MPa which is still less than 585 MPa SOLUTION (12.11) Known: A coiled compression spring is loaded against a support. A plot of the resulting force-deflection curve is shown. Find: Briefly state the reasons the curve changes at points A, B, and C. Schematic and Given Data:Assumptions: 1. There are no unfavorable residual stresses. 2. Both end plates are in contact with nearly a full turn of wire, 3. The end plate loads coincide with the spring axis. Analysis: 1. At A, the force overcomes the spring preload, causing deflection to begin 2. AtB, significant yielding of the spring begins. (In most instances, this would indicate an improperly designed spring. 3. At, the spring closes solid. SOLUTION (12.12) Known: Experimental load-deflection characteristics of a spring are sometimes needed to validate performance predicted using empirical-theoretical equations Find: (a) Ilustrate methods for experimentally evaluating load-deflection characteristics. (b) Search the internet for accurate or fully automatic commercial testers. Describe several types. Analysis: This exercise is left to the student. A helpful reference is the article "17 Ways of Testing Springs,” C.J. McClintock, Product Engineering Design Manual, Douglas Greenwood, editor, McGraw-Hill, 1959 The article illustrates: Dead weight testing Ordnance gage incorporates "go-no-go" principle Pilot-beam testing Zero-gradient beam Spring against spring Fully-automatic testing Commercial testers aus 12-14SOLUTION (12.13) Known: A conical compression coil spring in Fig. 12.6 is made of steel wire. There are four active coils. A force is applied to compress the spring, and the stresses always remain in the elastic range. Find: (a) Which coil deflects to zero pitch first? (b) Calculate the force required to cause the deflection in (a). (©) Sketch a force vs. deflection for the spring. Schematic and Given Data: Assumptions: 1, There are no unfavorable residual stresses. 2. Both end plates are in contact with nearly a full turn of wire. 3. The end plate loads coincide with the spring axis. Analysis: 4 F_ 4‘ 1. From Eq. 12.8, k=E= 3° spn 4 Since k s 3 and d is constant throughout, the largest active coil will have the smallest value of k. Thus, the largest (bottom) coil will deflect to zero pitch first. 12-15G6, 8D3N where G = 79 GPa (Appendix C-1) From Eq. (12.7), F= = BX 10)(79 x 10°)(7 x 10) aN 8(45 x 10°3)3(1) . Flattening the smallest active coil requires (3 x 10°3)4(79 x 10°)(7 x 103) 8(20 x 10°3)3(1) Total deflection = p(N) = 7(4) = 28 mm 700 N i 3 x 103)4(79 x 10% Initial k= 8G = GOTO 5800 Nien 8DavgN 8(32.5 x 10)3(4) or k = 5.8 N/mm . 4G (3 x 10)4(79 x 10°) Final k= —fG_ = ~—_____* - 190,000 Nh DanindN 8(20 x 10331) = or k = 100 N/mm 800 7001N 600 z 8 400 200. 100 N/mm ° 0 10 20 28 30 Deflection (mm) 12-16SOLUTION (12.14) Known: A conical compression coil spring in Fig. 12.6 is made of steel wire. There are four active coils. A force is applied to compress the spring, and the stresses always remain in the elastic range. Find: (a) Which coil deflects to zero pitch first? (b) Calculate the force required to cause the deflection in (a). (©) Sketch a force vs. deflection for the spring. Schematic and Given Data: Assumptions: 1. There are no unfavorable residual stresses. 2. Both end plates are in contact with nearly a full turn of wire. 3. The end plate loads coincide with the spring axis, Analysi: 4 F_dG 1, From Eq. 12.8,k=£=93- 3° sp'n a Since k « S5 and d is constant throughout, the largest active coil will have the D smallest value of k. Thus, the largest (bottom) coil will deflect to zero pitch first. 12-17p= d1GS From Bq, (12.7), F= 238 where G = 79 GPa (Appendix C-1) = BX 109419 10°V7 109) «959.67 8(55 x 10°)3(1) 1: Flattening the smallest active coil requires pa 8% 10°3)4(79 x 10°)(7 x 10°3) 8(25 x 10)3(1) Total deflection = p(N) = 7(5) = 35 mm. 2765.43 N aig _ x 103479 x 10°) 8Davg°N 8(40 x 103)3(5) ork = 19.3 N/mm Initial k = = 19,287 N/m aig _ x 10)479 x 10%) 8Dnin?N 8(25 x 103)4(1) or k = 395 N/mm Final k = = 395,000 N/m 3000: 2765 N 395 Nimm 0 10 20 30 35 40 Deflection (mm) 12-18SOLUTION (12.15) Known: A machine uses a pair of concentric helical compression springs to support a known static load. Both springs are made of steel and have the same length when loaded and when unloaded Find: Calculate the deflection and the maximum stress in each spring. Schematic and Given Data: F=3.0kN ~ a Dy Dj.——| Dj=25 mm 4=5mm Ni=10 Assumptions: 1. There are no unfavorable residual stresses. 2. Both end plates are in contact with nearly a full turn of wire. 3. The end plate loads coincide with the spring axis. Analysis: 4, 1. From Eq. (12.8), k=-4 spn where G = 79 x 10° Pa for steel. (Appendix C-1) ko= (8 mm)4(79,000 N/mm?) 8(45 mm)3(5) = G mm)‘(79,000 N/mm?) _ ki = 39.50 N/mm 8(25 mm)3(10) = 88.77 N/mm 12-192. From Eq. (12.8), k= E or5=F 2 000 ~ GB9.5 + 88.77) Using F = k8, we can calculate the force on each spring = (88.77 N/mm)(23.39 mm) = 2076 N (39.50 N/mm)(23.39 mm) = 924 N 4. Using Fig. 12.4, we can find Ks values for each spring. For outer spring, C = 45/8 = 5.63, Ks = 1.09 25/5 = 5.00, Ks = 1.10 = 23.39 mm For inner spring, 5. From Eq. (12.6), t= 8FD k, nd = 506 MPa 820745) 99) (8) 8O2925) (1 10) = 518 MPa n(5) SOLUTION (12.16) Known: A machine uses a pair of concentric helical compression springs to support a known static load. Both springs are made of steel and have the same length when loaded and when unloaded. Find: Calculate the deflection and the maximum stress in each spring. Schematic and Given Data: F=30kN | | ! 12-20Assumptions: 1. There are no unfavorable residual stresses 2. Both end plates are in contact with nearly a full turn of wire 3. The end plate loads coincide with the spring axis. Analysis: d‘G 8D°N where G = 79 x 10° Pa for steel. (Appendix C-1) Ky = (2. mm)*(79,000 N/mm?) 1, From Eq. (12.8), k= 103.66 N/mm. 8(50 mm)3(5) , = S.mm)4(79,000 Nim?) _ 99 6 N/mm 8(30 mm)3(10) F eEog iF 2. From Eq. (12.8), k= £ or =F ____ 3,000 5= Gage + 10366) 72371 mm : 3. Using F = ké, we can calculate the force on each spring. Fo = kod = (103.66 N/mm)(23.71 mm) = 2458.0 N Fj = kid = (22.86 N/mm)(23.71 mm) = 542 N 4. Using Fig. 12.4, we can find Ks values for each spring For outer spring, C = 50/9 = 5.56 K, For inner spring, C K, 5. From Eq. (12.6), t= SED x, nd’ tq = 812458150) (7 99) = 467.94 MPa . m9) 1, = 864289) (1 08) = 357.75 MPa . n(5)° SOLUTION (12.17) Known: A helical coil spring with given D and d is wound with a known pitch value, The material is ASTM B197 beryllium copper spring wire, Find: If the spring is compressed solid, would you expect it to return to its original free-length when the force is removed? 12-21Schematic and Given Data: | ASTM B197 | Beryllium copper spring wire p= 14mm Assumptions: 1. There are no unfavorable residual stresses. 2. Both end plates are in contact with nearly a full tur of wire. 3. The end plate loads coincide with the spring axis. Analysis: 1. Force to compress spring solid can be calculated by using Eq. (12.7) p= G3 8D:N where 6/N = p-d = 14-10=4mm G = 50 x 10° Pa (Appendix C-1) 10109450 x 1094107) _ 5999 yy 8(50 x 10°) . 2. The corresponding stress can be calculated by using Eq. (12.6). += SED x, na? for C = Did = 50/10 = 5 Ks = 11 (Pig. 12.4) 3) = 8200010010 (1.1) =280.1 MPa m0 x 105) For beryllium copper spring wire without presetting, t; < 0.35 Su Also, for beryllium copper spring wire without presetting, Sy = 750 MPa and 0.35 Sy = 262.5 MPa 4. Since 280.1 MPa > 262.5 MPa, set should occur; therefore, spring would not return to original length. . Comment: By considering the curvature (stress concentration) factor of the inner surface by using Kw = 1.3, the inner surface stress is (1.3)(280.1) = 364.1 MPa which is clearly even larger than 262.5 MPa. 12-22SOLUTION (12.18) Known: A helical compression spring is to be made with given wire diameter, outside diameter, and number of active coils. The least expensive steel spring wire is to be used, and presetting will not be used. Find: (a) Estimate the maximum static load that can be applied without encountering more than 2% long-term set. (b) What is the spring rate? (c) What should be the free-length in order that the spring becomes solid when load determined in (a) is applied? (4) Would buckling problems be encountered if one end plate is free to tilt? Schematic and Given Data: Assumptions: 1. Both end plates are in contact with nearly a full turn of wire. 2. The end plate loads coincide with the spring axis. Analysis: 1. Ford = 2mm and outside diameter = 19 mm, D = 17 mm, and C = Did = 8.5 2. From Table 12.1, the least costly steel spring wire is cold drawn ASTM A227 3. From Eq. (12.9), tmax = 0.45 Sy where Sy = 1550 MPa (Fig. 12.7) Tmax = 0.45(1550) = 697.5 MPa 4. From Eq. (12.6), Fa ha where Ks = 1.06 (Fig. 12.4) _ 0(2)7(697. 5) oe 8(8.5)(1.06) 5. From Eg. (12.8), k = =122N = where G = 79 GPa (Appendix C-1) a 12-23= 24(79,000) _ 3.99 Nimm 8(17)°(10) = ‘The amount of deflection when Finax = 122 N is applied to the spring is 85 = Finax/k = Be 37.89 mm From Fig. 12.8(), Ls = Nid Ls= (N+ 2)d = (10 + 2)2 = 24 mm Therefore, Ly = Ls + 8s Lr = 24 + 37.89 = 61.89 mm . LoD = 61.89/17 = 3.64 8o/L¢ = 37.89/61.89 = 0.612 From Fig. 12.10, for the case B, no buckling should occur. . SOLUTION (12.19) Known: A helical compression spring is to be made with given wire diameter, outside diameter, and number of active coils. The least expensive steel spring wire is to be used, and presetting will not be used. Find: (a) (b) (c) @ Estimate the maximum static load that can be applied without encountering more than 2% long-term set. What is the spring rate? What should be the free-length in order that the spring becomes solid when load determined in (a) is applied? Would buckling problems be encountered if one end plate is free to tilt? Schematic and Given Data: Assumptions: 1 ¢ Both end plates are in contact with nearly a full turn of wire. The end plate loads coincide with the spring axis 12-24Analysis: 1 a 3 For d = 4 mm and outside diameter = 19 mm, D = 15 mm, and C = D/d = 3.75 From Table 12.1, the least costly steel spring wire is cold drawn ASTM A227 From Eq. (12.9), tmax = 0.45 Su where Sy = 1550 MPa (Fig. 12.7) Tmax = 0.45(1550) = 697.5 MPa 25, From Eq. (12.6), Fmax = aa where Ks = 1.13 (Fig. 12.4) s (4)°(697.5) Frnax = §(3-78y(L13) 7 1034-22 N . From Eq. (12.8), k = 4 where G = 79 GPa (Appendix C-1) 4 = £109.009) _ 93.63 N/mm 8(15)%(8) . ‘The amount of deflection when Fmax = 1034.22 N is applied to spring is, = Fak = 1034.22 = 8, = Fnadk = 1084.22 = 11.05 mm From Fig. 12.8(@), Ls = Nid = (N+2)d = (8+ 2)4 = 40 mm ‘Therefore, Lt = Ls + 8s Lr=40+ 110: 51.05 mm a 34 L/D = 51.05/15 8/Lt = 11.05/51.05 = 0.216 From Fig. 12.10, for the case B, no buckling should occur. = SOLUTION (12.20) Known: A helical compression spring with squared and ground ends is to be designed with given force and deflection requirement. Presetting is to be used. The loading is static. Fi id: Determine appropriate values for D, N, and Lt. Check for possible buckling. 12-25Schematic and Given Data: os ce Assumptions: 1. Both end plates are in contact with nearly a full turn of wire. 2. The end plate loads coincide with the spring axis. 3. The clash allowance is 10% of the maximum deflection Analysis: 1. From Eq, (12.8), k=E ~ AF _ 1000 - 500 _ y a a 8.33 N/mm 2. Since class allowance is 10% of maximum deflection, Fs = 110% of 1000 N = 1100 N 3. From Eq.(12.9), ts = 0.65 Sy 4. From Fig. 12.7, Sy ~ 1650 MPa for music wire with d = 5 mm. Thus, ts = 0.65(1650) = 1073 MPa. = 8F = ond? 6. From Eq, (12.6), * = 85 CK, or CK, = 3H = (1073)(R5? CKs= 8(1100) Therefore, C = 9.0 (Fig. 12.4) and D = Cd = 9.0(5) = 45.0 mm 9.58 7. From Eq. (12.8), N= Pe where G = 79 GPa (Appendix C-1) kt N= (5)(79,000) 8(8.33)(9.0)° 8. For ends squared and ground, Ls=Nd =(N+2)d [Fig. 12.8(4)] 8.13 + 2)5 = 50.65 mm s + Fy/k = 50.65 + 1100/8.33 = 182.7 mm 8.13 12-26SO! LoD = 182.7/45 = 4.1 3/L; =(1100 2 BLy = (L100 )182.7 = 0.72 From Fig. 12.10, we see that the end plates must be constrained parallel (case A) to avoid buckling. LUTION (12.21) Known: A helical compression spring with squared and ground ends is to be made of steel, and presetting is to be used. The loading is static Find: Determine D, d, N, and Le. Schematic and Given Data: 40 1b 90 tb Wits (Clash allowance Assumptions: 1 2 3 An: 1 es 3 Both end plates are in contact with nearly a full turn of wire. The end plate loads coincide with the spring axis. The clash allowance is 10% of the maximum deflection. alysis: From Eq, (12.9), ts = 0.65 Su = 0.65(200) With 10% clash allowance, F; = 1.10(90) 33.3 Ib/in. From Eq. (12.6), ts = BE Ck where Ks = 1.06 (Fig. 12.4) e =/8E waa a= Eck f 8(99) 2 ——48)(1.06) = 0.128 in. |720130,000) | s D = Cd = 8(0.128) = 1.02 in. . 12-27From Eq. (12.8), N= as where G = 11.5 X 106 psi (Appendix C-1) 8D°k Ny = L0:128)ULS x 109 8(1.02)3(33.3) From Fig. 12.8, for squared and ground ends, dorLs =(N+2)d Ls = (10.92 + 2)(0.128) = 1.65 in. = 10.92 : F, Las +82 + = 165 4 Oe = 462i Lp = 1.65 + 33.37 4.62 in. a From Fig. 12.10, we can see that the end plates should be constrained parallel to avoid buckling, SOLUTION (12.22) Known: ‘A helical compression spring used for essentially static loading has known d, D, and N and squared and ground ends. It is made of ASTM A227 cold drawn steel wire. Find: (a) (b) ©) Compute the spring rate and the solid height, Estimate the greatest load that can be applied without causing long-term permanent set in excess of 2%. ‘What spring free-length will result in the load determined in (b) just causing the spring to become solid? 12-28Schematic and Given Data: Assumptions: 1 Both end plates are in contact with nearly a full turn of wire. 2. The end plate loads coincide with the spring axis. Analysis: 4 1, From Eq. (12. 8), k= 2 where G = 11.5 x 10° psi (Appendix C-1) 8D°N = ODAGLS x 10°) 8(0.625)°(8) 2. To avoid set, use Eq. (12.9) t = 0.45 Sy where Sy = 215 ksi (Fig. 12.7) t= 0.45(215) = 97 ksi = 73.6 Ib in. . 3. For static loads, 8ED = SEY K, (Eq. (12.6)] or F= At C = 6.25, Ks = 1.08 (Fig. 12.4) (97,000)n(0.1) “8(0.625)(1.08) 4. Ls=(N + 2)d = (1090.1) = 1.0 in. Lr=Ls + Fyk = 1.0 + 56.4/73.6 = 1.77 in Thus, F = = 56.4 Ib . SOLUTION (12.33) Known: A particular machine requires a helical compression spring, having ends squared and ground, to support a known essentially static load. The spring constant, the stress at the design load, and D are known. The clash allowance is to be 0.10 in. Find: Determine N, d, and Lr. 12-29Schematic and Given Data: F =3in, F= 500 Ib Oks k = 200 Ibvin| Assumptions: 1. Both end plates are in contact with nearly a full turn of wire. 2. The end plate loads coincide with the spring axis. Analysis: 1. From Eq. (12.6), t= = K, assume K, = 1.06, check later 1m 80,000 = 85003) (1 96) nd? Seana 0.370 in. 2 ee D/d = 3/0.370 = 8.1 From Fig. 12.4, Ks = 1.06 ‘Therefore, d = 0.370 in. . 4 3. From Eq, (128), k=-EG_ or N= 4G. 8D3N 8kD where G = 11.5 x 10° psi (Appendix C-1) _ 0.370)411.5 x 10) _ 8200/03)" . 4. Ls =(N + 2)d = (5.0 + 2)(0.370) = 2.59 in. Expansion from solid = 0.1 + 500/200 = 2.6 in. Le = 2.59 + 2.6 = 5.19 in. a 12-30SOLUTION (12.24) Known: An automatic production machine requires a compression coil spring to keep a follower in contact with a cam with a known angular speed. When installed, the spring force is to vary between 150 and 600 N while the spring height varies over a range of 10 mm. An available supply of 4.5-mm-dia shot-peened wire is to be used, for which Fig. 12.16 applies. Clash allowance is to be 2.5 mm. The limiting stress is, 800 MPa when the spring is closed solid. Ends are to be squared and ground, and presetting is not to be used. Find: (a) Determine appropriate values for D, N, Ls, and Lt. (b) Determine the likelihood of buckling, the likelihood of encountering spring surge problems, and the approximate safety factor during normal operation. Schematic and Given Data: Assumptions: 1. Both end plates are in contact with nearly a full turn of wire 2. The end plate loads coincide with the spring axis, Analysis: - 150 _ LL 2. Fs= 600+ 45(2.5)=7125N 8, 3. From Eq, (12.5), ts = $ CKw 800 = See Ky Therefore, CKw = 8.93 From Fig. 12.4, C = 7.4 Thus, D = 7.4(4.5) = 33.30 mm dG 4. From Eq. 12.8, k=—°95 or N= snc’ 1where G = 79 GPa. (Appendix C-1) 4.5(79,000) N= 7 = 2. 8(7.4) (45) 5. Ls =(N + 2)d = (2.44 + 2)(4.5) = 19.98 mm = 712.5 _ 6. Lp= 19.98 + 45 =35.81 mm 7. Since, Ly/D = 35.81/33.30 = 1.08, from Fig. 12.10, the spring is well out of the buckling range. . 8. From Eq, (12.114), 353,004 jy, _ 353,0004.5) _ = 23,0008 Hz = 223.0008) _ ND? 2.44(33.30)7 Since resonance at 1800 rpm would involve the 35,226/1800 ~ 20th harmonic, no harmonics this high are likely to be significant. Thus, no surge problems are expected. 9. For normal operation, using Eq. 12.5 SE ae? CKy 8(600) n(45P fa 587 Hz = 35,226 rpm a t max = (8.93) = 674 MPa “rin = 67 259) = 169 MPa 10. Normal load (169, 674) nae (MPa) oO 250 500 750 1000 “nic (MPa) 12-3211, From the graph above, Dl SOLUTION (12.24D) Known: A web site http://www.acxesspring.com lists spring materials. Find: List (a) common spring materials, (b) spring materials highly susceptible to hydrogen embrittlement, and (c) processes that cause hydrogen embrittlement. Analysis: (a) High-Carbon Spring Wire: Music Wire ASTM A 228 Hard Drawn ASTM A 277 High Tensile Hard Drawn ASTM A 679 Oil Tempered ASTM A 229 Carbon Valve ASTM A 230 Alloy Steel Wire: Chrome Vanadium ASTM A 231 Chrome Silicon ASTM A 401 Stainless Steel Wire: AISI 302/304 ASTM A 313 AISI 316 ASTM A 313 17-1 PH ASTM A 313 (631) Non-Ferrous Alloy Wire: Phosphor Bronze Grade A ASTM B 159 Beryllium Copper ASTM B 197 Monel 400 AMS 7233 Monel K 500 QQ-N-286 (b) Flat High-Carbon Spring Steels: Sections under 0.015" having carbon content over 0.85 with hardness over Rockwell C47 are highly susceptible to hydrogen- embrittlement even though special plating and beating operations are employed. (©) Hydrogen Embrittlement: Hydrogen absorbed in electroplating or pickling of carbon steels, tending to make the spring material brittle and susceptible to cracking and failure, particularly under sustained loads. 12-33SOLUTION (12.25) Known: An automatic production machine requires a compression coil spring to keep a follower in contact with a cam with a known angular speed. When installed, the spring force is to vary between 150 and 600 N while the spring height varies over a range of 10 mm. An available supply of 4.5-mm-dia. shot-peened wire is to be used, for which Fig. 12.16 applies. Clash allowance is to be 2.5 mm. The limiting stress is 800 MPa when the spring is closed solid. Ends are to be squared and ground. The presetting used results in a residual torsional stress of 100 MPa. Find: Determine the approximate safety factor of the spring. Schematic and Given Data: Ax= 10mm Limiting stress = 800 MPa| ‘n= 1800 spr] Assumptions: 1. Both end plates are in contact with nearly a full turn of wire. 2. The end plate loads coincide with the spring axis. Analysis: 600 — 150 1 k= —1 = 45 N/mm 2. Fy=600 + 45(2.5) =712.5N 3. From Eq. (12.5), %»= SE¢CKy 8(712.5) 300 = 87125) cK, m(4.5)? : CKw = 8.93 4. For a residual stress (with zero external load) of tmmax = Trin normal load stresses are: [using Eq. (12.5)] t= BE CKy 100 MPa, the 12-348(600) max = 93) — 100 = 574 Tan = 5g 52193) ~ 100 = 574 MPa ~ 100 =69 MPa = 674(150) Tain = 674 9| Design overload point 280 «500 1000 isl-100,-100) (tra) 6. As shown on the plot above, the load could give a maximum stress of 720 + 100 = 820 MPa. It actually gives tmax = 674 MPa. Hence, SOLUTION (12.26) Known: A coil spring with squared and ground ends is to operate with a load which fluctuates between 3 and 9 Ib, during which the deflection is to vary by 2.5 in. Mean coil diameter is 0.625 in. Steel wire corresponding to shot-peened wire in Fig. 12.16 is to be used. The effect of presetting is not to be taken into account. Find: Choose an appropriate clash allowance, and determine appropriate values for N,d, and Li. 12-35Schematic and Given Data: F Squared ends Assumptions: i 2. 3 Both end plates are in contact with nearly a full turn of wire. The end plate loads coincide with the spring axis. The clash allowance is 10% of the maximum deflection. Analysis--Case A--with shot peening: 1 i See Fig. 12.16 For tmax/Tmin = 3, Tmax = 761.6 MPa = 110.5 ksi k = FS = 6/25 = 2.4 Ib/in From Eq. (12.5), tax = Emax? K,, Assume Ky = 1.2 110,500 = 809)0.625),,_ >) nd = 0.054 in. C = Did = 0.625/0.054 = 11.6 Ky = 1.13 (Fig. 12.4) Assume Ky = 1.13 110,500 = 320-625) 13) nd d= 0.053 in. C= Did = 11.8, Ky = 1.125 From Eg. (12.5), d = 0.053 in. 4 4 ac dG orN= 8D'N 8Dk where G = 11.5 x 10° psi_ (Appendix C-1) From Eq. (12.8), k= 12-36(0.053) ais 105) _ _ 8(0.625) (2.4) 8. Clash allowance = 10% 91 Beoia= (Dg qee = 3.3 in Solid height = (N + 3)d = (19.36 + 3)(0.053) = 1.185 in. Ly = 1.185+ 3.3 = 4.485 in. Analysis--Case B--without shot peening: 1. See Fig. 12.16: For Tmax/Tmin = 3. Tmax = 590 MPa = 85.6 ksi 2. k= FS = 6/2.5 = 2.4 lb/in. 3. From Eq. (12.5), tmax = Assume Kw = 1.2 85,600 = 820.625), 2) nd d = 0.0586 in 4. Did = 0.625/0.0586 = 10.67 w= 1.14 (Fig. 12.4) 5. Assume Kw = 1.14 35,600 = 8220-625), 14) nd d = 0.0576 in. 6. Did = 10.85, Kw = 1.14 Thus, d = 0.0576 in. 4 4 ac ac 7. Eq. (12.8), k= Fog, [eee rom Fa. (12-8). BON 8sDk where G = 11.5 x 10° psi_ (Appendix C-1) 4 a y= (0.0576)'01.5% 10) _ 97.9 8(0.625) (2.4) 8. Clash allowance = 10 % Sere pz7h-=3.3 in Solid height = (N + 2)d = (27.0 + 3)(0.0576) = 1.728 in. L 728 + 3.3 = 5.028 in. 12-37SOLUTION (12.27) Known: A coil spring with squared and ground ends is to operate with a load that fluctuates between 90 and 180 Ib, during which the deflection is to vary by 1 in. Use a steel spring wire having d = 0,200 in, and fatigue strength properties as shown on Fig. 12.16 for shot-peened wire. Presetting, and a clash allowance of 1/4 in. are to be used. Residual stresses due to presetting are not to be taken into account, Find: Determine appropriate values for N, D, and Ly. Schematic and Given Data: F 1 I , | F= 90 t0 180 1b ' { | Deftection = 1 in 1 1 | d= 0.200 in i 1 [Clash allowance = 1/4 in| i 1 Squared and F ground end Assumptions: 1 Both end plates are in contact with nearly a full turn of wire. 2. The end plate loads coincide with the spring axis. Analysis--Case A--with shotpeening: 1. From Fig. 12.16, for tmax/tmin = 2, tmax = 800 MPa = 116 ksi 2 2. From Eq. (12.5), t= 8E CKy or CK, = 24 tmax, rom Eq. (12.5), t ad? or CKy re 7(0.2)7(1 16,000) _ CKy B(180) =10.12 3. From Fig.12.4, C = 8.5 D = Cd =8.5(0.2) = 1.70 in. . 4. k=F/3 = 90/1 = 90 Ib/in. 4G 4G 5. From Eq, (12.8), k= 895 or N=—S0, 4028), BN 8kC* where G = 11.5 x 10° ksi (Appendix C-1) 0.2)C1.5 x 10) “~3OHC5 . 12-386. Le=(N+2)d= (5.2 + 20.2) = 1.44 Clash allowance = 0.25 in Working deflection = F/k = 180/90 = 2.00 in. Ly= 1.44 + 0.25 + 2.00 = 3.69 in. . Analysis--Case B--without shotpeening: 1. From Fig. 12.16, for tmax/tmin = 2, Tmax = 640 MPa = 93 ksi 2. From Eq. (12.5), ¢= BE CKy oF CK = nda 8Fmax 1(0.2)(93,000) _ CR = 380) 3. From Fig. 12.4, C = 6.5 D = Cd = 6.5(0.2) = 1.30 in. . 4. k=F/3 = 90/1 = 90 Ib/in. dG ye eG 5. From Eq. (12.8), k= or ‘rom Eq. (12.8), 8NC° 8kC* where G = 11.5 x 10° ksi (Appendix C-1) _ (0.2)11.5 x 10°) _ N= Joos tS = 6. Le=(N+2)d= ooo 2.72 Clash allowance Working deflection = PPA 180/90 = 2.00 in. Ly = 2.72 + 0.25 + 2.00 = 4.97 in. Comment: The answers given in the textbook are correct for non shot peened wire but are incorrect for shot peened wire SOLUTION (12.28) Known: A coil spring with squared and ground ends is to operate with a load which fluctuates between 45 and 90 Ib, during which the deflection is to vary by 1/2 in. Mean coil diameter is 2 in. Steel wire corresponding to shot-peened wire in Fig. 12.16 is to be used. ‘The effect of presetting is not to be taken into account. Find: Choose an appropriate clash allowance, and determine appropriate values for N, d, and Lr. 12-39Schematic and Given Data: F=45 10 9015 Deflection = 1/2 in D=2in ' i t 1 Squared and ground end, Assumptions: 1. Both end plates are in contact with nearly a full turn of wire 2. The end plate loads coincide with the spring axis. 3. The clash allowance is 10% of the maximum deflection. Analysis--Case A--with shot peening: 1. See Fig. 12.16: For tinax/Tmin 2. k= FV = 45/0.5 = 90 Ib/in. 3. From Eq. (12.5), Tax = Em? k,, Assume Ky = 1.2 116,000 = $29} 1.2) d= 0.168 in, 4. C= Did = 2/0.168 = 11.9 Ky = 1125 (Fig. 12.4) Assume Kw = 1.125 116,000 = S2%2)¢4 125) d= 0.164 in, 6. C=D/d= 12.19, Kw = 1.12 From Eq. (12.5), d = 0.164 in, o 4 HG Nad 7. From 12.8), k= orN=- oN sDk , Tmax = 800 MPa = 116 ksi where G = 11.5 X 10° psi (Appendix C-1) 12-40(0.164)4(11.5 x 105) ~~ 8(2)5(90) 8. Clash allowance = 10% Bana = (Dg = 1.1 in = 144 Solid height = (N + 2)d = (1.44 + 2)(0.164) = 0.565 in. Lr = 0.565+ 1.1 = 1.665 in. Amalysis--Case B--without shot pening: See Fig. 12.16: For Tmax/Tmin k= FS = 45/0. . Tmax = 640 MPa = 93 ksi = 90 Ib/in. 3. From Eq, (12.5), Tinax = SEP , Kw S Assume Ky = 1.2 4 = 0.181 in 4. Déd = 2/0.181 = 11.1 =113 (ig. 12.4) 5. Assume Kw = 1.13 93,000 = $0021.13) 4 = 0.177 in, 6. Did= 113, Kw= 1.13 ‘Thus, d = 0.177 in. 7. From Eq. (12.8), k= where G = 11.5 X 10° psi_ (Appendix C-1) _ T7115 x 10) 8(2)°(90) 8. Clash allowance = 10 % 901b 1 44 Booia= U-DgQ pyjgg: = 1 in = 1.96 Solid height = (N + 2)d = (1.96 + 2)(0.186) = Le = 0.737 + 1.1 = 1.837 in. 0.737 in, 12-41SOLUTION (12.29) Known: A helical compression spring is subjected to a load fluctuating between 100 and 250. Fatigue properties of the spring wire correspond to the curve for shot-peened wire given in Fig. 12.16. The spring failed in service after about 10° cycles. A replacement spring was found which was identical in all respect except that its free- length was slightly shorter. To correct for this, the spring was stretched slightly to increase its free-length to exactly that of the original spring. Find: Show by means of a tmax - Tmin plot, whether you would expect the life of the replacement spring to be the same as, less than, or greater than that of the original Schematic and Given Data: F=100250N — F= 10010 250N | F F Original spring Replacement failed in service spring stretched to after about 10° the same length as cycles the original spring Analysis Design overload points Without residual stress. In this problem, the residual stress causes the load stresses to begin closer to the fatigue limit line. Thus, the life of the replacement spring will be shorter than the original, 7 12-42Comment: Stretching the spring in tension gives residual stresses beneficial for future tensile load but harmful for future compressive load SOLUTION (12.30) Known: When the clutch is engaged, the springs must provide a clamping force of 1020 Ib (170 Ib per spring). When the clutch is disengaged the springs are all 0.10 in. shorter where a 25 Ib increase of the force of each spring is considered satisfactory. The clash allowance is to be 0.050 in. The wire size is 0.192 in. The material is to be shot-peened wire having fatigue properties as indicated in Fig. 12.16. Use a safety factor for eventual fatigue failure of 1.3. Presetting is to be used but not taken into account in the calculations. Find: Determine a suitable combination of D, N, Ls. and Lr. Schematic and Given Data: Clamping force Clamping force + AF ‘Clamping force = 170 Ib/spring 3=0.10in. 3 AF = 25 Ib/spring Clash allowance = 0.050 in 192in SF=13 Engaged Disengaged Assumptions: 1. Both end plates are in contact with nearly a full tum of wire. 2. The end plate loads coincide with the spring axis. 3. The springs have squared and ground ends. Analysis: Tax _ Fina _ 170-4 25 Le For ee 70 12-432. See Fig. 12.16 Fea = 133 selife, shot pened -== i 100 Tain (ksi) 3. From above graph, tmax = 133 ksi For SF = 1.3, use tax = 433 = 102 ksi SF, ad? CKy 4. From Eq. (12.5), tmax = 102,000 = 81195)_ cK, (0.192) CKy =757 5. From Fig, 12.4, C = 6.0 D = Cd = (6.0)(0.192) = 1.15 in. . 251b_~ 950 Ibfin in 5 dG dG 7. From Eg. (12.8), k=—"3~ or N= - 8C'N 8ck where G = 11.5 x 10° ksi (Appendix C-1) = (0.192)(11.5 x 10) _ 5 | . 8(6.0)°(250) 8. Assuming squared and ground ends, Ls = (N + 2)d = (7.1)(0.192) = 1.36 in. . ay Ly=L, + clash allowance +t = 1.36 40.05 +5335 = 2.19 in . 12-44SOLUTION (12.31D) Known: A force of 4.45 KN is required to engage a clutch similar to the one shown in Fig. 18.2. This force is to be provided by nine identical springs equally spaced around the pressure plate of the clutch. The outside diameter of the coils can be no more than 40 mm, and the length of the springs when the clutch is engaged cannot exceed 52 mm. The pressure plate must move 3 mm to disengage the friction surfaces, and the lowest spring rate reasonably possible is desired. Find: Design the springs, determining a satisfactory combination of D, d, N, wire material, type of ends, Ls, and Ly. Schematic and Given Data: = Position (310m Disengaged 9 Position 3mm [ss5e)+| See Fig. 18.2 where total clamping force = 4.45 KN Decisions/Assumptions: The clash allowance is 2 mm. The safety factor is 1.3. The ends are squared and ground Presetting is to be used but not taken into account in the calculations. The spring is made of shot-peened steel wire having fatigue properties as indicated in Fig. 12.16. Weene Analysis: 1. Design constraints are: (a) Since the lowest spring rate reasonably possible is desired, from Eq. 12.8 k=-4'G_ the largest D, largest N, and smallest d is desired. 8D3N (b) D+d<40mm (©) Ls 2 Engaged length ~ Working deflection — Clash allowance Assuming the clash allowance to be 2 mm, Ly $(62-3-2)=47 mm 12-45wR First, choose C =8.0,N= 9, and D = 35 mm. Then, d = 4.375 mm and D+d< mm. Ls = (N + 2)d = 48.1 mm which is too long. Thus, choose a smaller N. 3. Choose N = 7.5. Then, Ls = (7.5 + 2)4.375 = 41.6 mm which is satisfactory. 4. From Eq. 12.8, where G = 79 MPa for a steel wire. (4.375)4(79, 000) 8(35)3(7.5) = 11.25 N/mm 5. Lys Fossned + Lengagea = “A507? + 52 = 95.95 mm 6. Fengaged = 4450/9 = 494 N, Fuisengaged = (95.95 — 49)11.25 = 528 N Funas = nx = 528. = 1.07 = Thus, —@& = —max = 348 = 1.07 = 1 "SF nin tmin” 494 7, From Fig, 12.16, for infinite-life with shot-peening, tmax = 965 MPa. With a safety factor of 1.3, Tmax = 965/1.3 = 742 MPa. 8. Using Eg. 12.5, 8Faisens Tdisengaged = —Sapet CKy where Ky = 1.18 (Fig. 12.4) 8(528) 14.375 x 103? Therefore, Taiseng. < Tmax 9. Checking for buckling using Fig. 12.10, Li/D = 95.95/35 = 2.74. Thus, the spring will not buckle. 10. In summarizing the answers, the spring is made of shot-peened steel wire having properties as indicated in Fig. 12.16, has squared and ground ends, and = 4.375 mm Taiseng. = (8)(1.18) = 663 MPa Comment: If a lower spring rate is desired, the above steps can be repeated with different combinations of C, N, and D. SOLUTION (12.32) Known: A helical compression spring is to be designed for infinite life when subjected to a known fluctuating load. Sy, Sus, Sy, Sys, and a zero-to-maximum torsional endurance limit are known for the steel spring wire. The value of C = 7 and safety factor = 1 Find: Determine the wire diameter theoretically required: (a)_ if presetting is not used 12-46(b) if presetting is used to maximum advantage Schematic and Given Data: Assumptions: 1. Both end plates are in contact with nearly a full tun of wire. 2. The end plate loads coincide with the spring axis. Analysis: 1. For C= Did = 7, from Fig. 12.4 Kw = 1.21 2, From Eq, (12.5), Tmax = Sues CKw ‘max 810) ag 02) = ie 150 (144,144) 4. From the above graph, tmax = 99,000 psi; therefore, 2373 99,000 = or d = 0.155 in, 12-47(Note: This assumes no yielding is permitted. If slight yielding is okay, the operating point moves from a to a’ on the graph, giving slightly higher ta, which is permitted; therefore, slightly smaller d.) 5. The theoretical maximum residual = Syy/3. Assume practical limit is about Sys/4 = 25 ksi. Then from graph, tmax due to load = 120 ksi. 257 ord = 0.141 in . Therefore, 120.000 SOLUTION (12.33) Known: The specifications for a coil spring are known. Infinite fatigue life is required, using a safety factor of 1.3 applied to the maximum load only. Spring is to be preset, with a favorable torsional residual stress of 100 MPa being obtained. The fatigue strength can be represented by a line between Tmax = 600, tmin = and Tmax = Tin = 900 MPa. Find: Determine a suitable combination of d, D, and N. Schematic and Given Data: F Static Toad per spring = 3500 N Rate per spring = 40 Nimm | ounce = 150 mm Assumptions: 1. Both end plates are in contact with nearly a full turn of wire. 2. The end plate loads coincide with the spring axis. 3. Presetting is to be used but not taken into account in the calculations. Analysis: 1. First, choose a reasonable value of C, say C = 8. Thus, from Fig. 12.4 Kw = 118 2. Atthe "design overload": Using Eq, (12.5), SF Tmgx = SBE CK, = LG500 + 4150))1.3) aes 3] (g)(1.18) = 296,879/42 rm seem se) (8)(1.18) = 28,366/d2 Tmax/Tmin = 296,879/28,366 = 10.47 12-48Tyan (MPa) 0 200 400 600 800 1000 ‘tan (MPa) 4. From graph, tmax = 620 MPa. 629 = 226:87° or d = 21.88 mm” d 5S. D=Cd = 8(21.88) = 175.0 mm 6. From Eq. (12.8), k= a 3 where G = 79 GPa (Appendix C-1) NC (21.88)(79,000) 8(8) (40) = 10.55 : Comment: “A slightly modified solution with d= 22 mm would probably be preferred. SOLUTION (12.34) Known: A valve spring is subjected to the accelerations shown. The critical point for the spring is the valve lift of 0.201 in. A larger spring force is required at maximum valve lift (0.384 in.) but this is easily satisfied because the spring is further compressed. ‘The specifications of the valve spring are known. High quality valve spring wire is to be used, and full advantage taken of both shot-peening and presetting The fatigue failure will not occur if the calculated stress with spring solid is limited to 800 MPa. Ends are to be closed and ground. Find: Determine a suitable combination of d. D, N, and Ly. 12-49Schematic and Given Data: 3600 engine rpm. 1800 camshaft spm acceleration] + Van ‘Cam angle —= ‘Reversal point” Valve lift is 0.384 in, (mmaximum--on "nose of cam) 5 Ends closed and ground Maximum stress with spring solid = 800 MPa Valve lift is 0.201 i Valve spring specifications: 1. Spring length when valve is closed: not over 1.50 in 2. Spring force when valve is closed: at least 45 Ib. 3. Spring force when valve lift is 0.201 in.: at least 70 Ib 4. Spring force at maximum valve lift of 0.384 in.: at least 86 Ib but not over 90 Ib. 5. Spring outside diameter: not over 1.65 in. 6. Clash allowance: 0.094 in. 7. Natural frequency: at least as high as the 13th harmonic at 1800 camshaft rpm (ie., at least 390 Hz) Assumptions: 1, Both end plates are in contact with nearly a full turn of wire. 2. The end plate loads coincide with the spring axis Analysis: 1, For maximum fp, select highest allowable stiffness: AF___90~70 8 0.384-0.201 This gives a valve closed force of 70 ~ (109.29)(0.201) = 48.03 Ib which is = 109.29 Ibfin. satisfactory. 2. Spring rate requirement: i From Eq, (12.8), k= 4S 8DN 12-50where G = 11.5 x 10° psi (Appendix C-1) aig _ FU15 x 10 8D%k -8(109.29)D? 13,153d peas Thus, N= Since C = D/d, N= ay Spring length requirement: Valve open length = Ls + 0.384 + clash allowance < 1.50 (N + 2)d + 0.384 + 0.094 < 1.50 (N 4 2)d < 1.022 @Q) Spring diameter requirement: D+d<165 (3) Spring stress requirement: Fs = 90 + (0.094)(109.29) = 100.27 Ib From Eq. (12.5), ts = as CKy 800 MPa = 800(0.145)"= 116 ksi 8(100.27) 116,000 = =U? CKw da) 45474 2 Spring natural frequency requirement: 13,900d From Eq. (12.11), fy=———>— Hz where d and D are in inches. 13,900d __ 13,900 = 13,900d _ 13,900 5 300 H: fy 2390 Hz (5) For maximum nominal wire stress (for minimum wire mass and high fa), try to satisfy Eq. (4) with smallest Kw. From Fig. 12.4, choose C = 9 for first trial. From (4), . D = Cd = (9)(0.152) = 1.365 in. a From (3), D + d= 1.52 in. < 1.65 in.; therefore, OK. From (1), N= BASSOI52) 2.74 . From (2), (2.74 + 2)(0.152) = 0.72 in. < 1.022 in.; therefore OK. _ 13,900(0.152) =| 7 = 414 > 390 Hz; therefore OK. (2.74)(1.365) From (5), fn 12-515 + clash allowance + 90 Ib/k ‘N + 2)d + 0.094 + 90/109.23 = (4.74)(0.152) + 0.094 + 0.824 1.638 in. 1 L/D = 1.20, Fig. 12.10 shows no buckling concern 9. For comparison, try solution with C = 7. From (4), d 9 BAR = 0.13710 . D = Cd = (7)(0.137) = 0.956 in. a From (3), D + d = 1.093 in. < 1.65 in.; therefore, OK. 13,153(0.137) 7 From (1), N= From (2), (5.25 + 2)(0.137) = 0.993 in. < 1.022 in.; therefore OK. From (5), fn= = 396 > 380 Hz; therefore OK. (But not as good (5.25)(0.95 =9) (7.25)(0.137) + 0.094 + 0.824 1.911 in. a = 2.0, Fig. 12.10 shows no buckling concern. SOLUTION (12.35) Known: A cam and follower is to rotate at 10 Hz and impart a harmonic or sinusoidal oscillation to the follower. Total follower lift and weight of the oscillating parts are known. The spring diameter is limited by the available space. \d: Determine a satisfactory combination of D, d, N, material, Ls, Ly. Determine the natural frequency of the spring proposed. Schematic and Given Data: Total follower lift = 20 mm. Weight of the oscillating parts = 90 N veer Spring minimum inside diameter = 25 mm Spring maximum outside diameter = 50 mm { Frequency of rotation = 10 Hz Assumptions: 1. Both end plates are in contact with nearly a full turn of wire. 2. The end plate loads coincide with the spring axis 12-52Analysis: [The following is only one of many possible solutions] 1 Spring force = 220 + 180 sin ot Fromk=-362sno@t when @= 10 Hz Forwe (N) x=10+10sinwt Spring force required (for @= 10 Hz) The above graph shows follower displacement, x, vs. cam angle, wt. The equation with x in meters is: x = 0.01 + 0.01 sin wt Ata rotating speed of w = 10 Hz = 20n rad/s, the inertial force, F; is: Fy = mx = 90. N__[-0.01(20n)°sin at] 981 —362 sin at (in newtons) The spring is needed only to oppose the negative acceleration. Both Fi and spring force are plotted above. To compensate for small friction and gravity forces plus provide a small safety factor, select minimum and maximum spring forces of 40 N and 400 N respectively (as shown on graph). Thus, k=" And the expression for the spring force plotted is F = 40 + kx = 40 + 18(10 + 10sin cot) = 220 + 180 sin ct Select spring wire having fatigue properties shown in Fig. 12.16, and specify shot-peening. From Fig. 12.16, tmax = 710 MPa 12-538. Based on information on Fig. 12.4, tentatively select C = 8. Since a high fn is not required and since space is ample, select a generous safety factor of 1.4. Hence, design for tmax = 710/1.4 = 507 MPa ; BE, 9. From Eq. (12.5), tax = SEs CKy, rom Eq. (12.5), tings = SEs 507 = 840% (9 47) ae Therefore, d = 4.36 mm 2 D = Cd = 8(4.36) = 34.9 mm = 10. From Eq. (12.8), k=-9S, where G = 79 GPa (Appendix C-1) 8NC N= 430179.000) «4 67 . 8(18)(8) 11. Choose a dash allowance of 10 % of deflection at 400 N load; therefore, Fs = 400(1.1) = 440 N. (N + 2)d = 6,67(4.36) = 29.08 mm . s + Fe/k = 29.08 + 440/18 = 53.52 mm . 13. From Eq. (12.1 1a), f= ey where d and D are in mm _353,000d *"4.67(34.9)" L/D = 53.52/34.9 = 1.53; therefore, no buckling problem. 14. For rotation at 10 Hz, only harmonics would be in resonance during starting and stopping. Since this cam should give no harmonics, dynamics should be of no concern. 271 Hz Comment: Since fn and size limitations were easily met, one should consult the spring supplier in search of a lowest cost solution, retaining high reliability. SOLUTION (12.36D) Known: The web site http://www.mecheng.asme.org/database lists computer programs useful for developing compression springs Find: Select a spring program that is (a) potentially useful, (b) easy to use, (c) accurate and correct, and (d) relatively low in cost. Write a short description of the software program Analysis: This exercise is left for the student. 12-54SOLUTION (12.37D) Known: Helical tension springs used as a component of a mass-produced machine have improperly formed hooks, causing the load to be applied closer to the outside of the outside of the spring than to its geometric axis. Upon attempting to use these springs, it is noted that they deform permanently as soon as the maximum normal load is applied. Find: Explain why, briefly Schematic and Given Data: F Assumption: No residual stresses are present Analysis: With proper (concentric) load positioning, the maximum torque on any wire segment is F(D/2) and the maximum bending moment is zero. If the load is eccentric by an amount e, these values are increased to Tax = F(D/2 + e) and Mmax = Fe SOLUTION (12.38D) Known: A tension spring must exert an essentially static force of 135 N. The initial tension and the spring rate are known. Find: (1) Determine a satisfactory combination of D, d, N, and wire material. (2) Determine the length of the coiled section when unloaded and when the 135 N force is applied 12-55,Schematic and Given Data: Initial tension = 45 N Spring rate = 11.0 kN/m Assumption: The applied load coincides with the geometrical axis of the spring. Analysis: Because of cost (see Table 12.1), try a solution using ASTM A227 steel wire . Sy varies with d, but start with a valve in mid-range, say Sy = 1500 MPa. (Fig. ae 2. From Eq. (12.9), t: < 0.45Sy would be appropriate for a compression spring Use this value for load stress here, but because tension springs can easily be overloaded, use safety factor = 2 applied to load 3, From Fig. 12.4, try a solution with C = 9 4. From Eq. (12.6), t > SE ck, where CK, = 9.5 (Fig ao 4) (0.45)(1500) = ae @.5) Therefore, d = 3. i mm D = Cd = (9)(3.11) = 28.0 mm . For d = 3.11, Sy = 1400 MPa; therefore, SF = 1.9 not 2 6. From Eq. (12.8), k= 0G, where G = 79 GPa (Appendix C-1) ~ 3.109) 000) =3.83 a 8(11.0)(9)° 7. Unloaded length of coiled section = (N + 1)d = 4.83.11) = 15.0 mm = 8. When loaded, the first 45 N overcomes preload. The remaining 90 N elongates the spring; therefore, loaded length of coiled section = 15.0 + 90/11.0 = 23.2 mm 7 Comment: This is only one of several possible solutions 12-56SOLUTION (12.39D) Known: A wheel chair brake in its retracted position has a tension spring exerting a force of 4 N, which holds the handle against the stop-pin. When the handle is moved clockwise, pivot A drops below the axis of the spring and the spring acts to hold the brake shoe against the tire. The outside diameter is limited to 10 mm. Find: Estimate dimensions needed by scaling the drawing. Determine a satisfactory combination of D, d, N, wire material, and free-length of coiled section. Schematic and Given Data: Decision: A minimum value of k is desired for ease of operation. Assumption: The applied load coincides with the geometrical axis of the spring. Design Analysis: 1 oe From the drawing, maximum distance between spring ends ~ 35(0.707)2 = 50 mm, giving 6 = 15 mm A minimum value of k is desired for ease of operation. As a rough preliminary estimate, assume Fmax (at 5 = 15 mm) = 12. Then, k= us = 0.533 Nimm For high reliability in a safety-critical application, choose a high quality material. Assume Figure 12.16 "shot-peened” fatigue properties. Load line slope is not yet known, but estimate Tmax = 800 MPa, and apply safety factor of 2.5 to the load. From Fig. 12.4, choose C = 9 for the first trial. From Eq. 12.5, tmax = Sine CKy where CKw = 10.46 (Fig, ‘24) Tuas = SEH CKy 800 = 8022-5) (19.46) nd? Thus, d = 0.994 or d = 1.00 mm and D = Cd = 9(1.00) = 9.00 mm This just satisfies the outside diameter requirement that D + d < 10 mm. 12-57Su 6. From Eq. (12.12), assume tpiga= 0.4 22 From Fig. 12.16 and 12.7, estimate Sy ~ 1800 MPa, then % = 0.4(1800)/9 = 80 MPa 7. Fort tmax = 800 MPa at F = (12)(2.5) = 30 N, by proportion, 1 = 80 MPa corresponds to Fi = 3N. This means that the specified Fmin = 4N requires 5-—4N-3N 0533 N/mm wear, an initial deflection of (at least) 2 mm is desired (with slightly less initial tension in the spring), 8. _ By scaling the drawing, assume solid height of coiled section can be 23 mm. minus the 2 mm initial deflection. Then (N + Id = 23 mm with d = 1.00, N = 22. s or an initial § of 1.9 mm. Assume that, due to tolerances and 9. From Eq. 12.8, k=—~ 5 m3 where G = 79 GPa (Appendix C-1) k= (1)(79,000) 8(22)(9)3 Fmax = 4 + k5 = 4 + (0.616)15 = 13.24.N. Since this exceeds the initially assumed Fmax of 12N, the safety factor is reduced to 2.5 (12/13.24) = 2.3 Also, 7 = Finax . 13.24 3.31, Fig. 12.16 shows a fatigue limited tinax of caer 4 740 MPa instead of the initially assumed 800 MPa. Thus, safety factor is further lowered to 2.3(740/800) = 2.1, but this should be satisfactory. = 0.616 N/mm; hence SOLUTION 12.40) R 12.4 Known: A semi-elliptic leaf with known spring rate is subjected to a known fluctuating force. Find: Estimate the overall spring length and width of the leaf. Schematic and Given Data: F e F= 1000 to SOON = k= 20 Nim Lh Kje13 12-58