242 Design of Machine Ek 4.1. INTRODUCTION ‘A spring is defined as an elastic body whose function is to distort when loaded and to its original shape when the load is removed. ‘The important applications of the springs are as follows : @) To apply forces as in brakes, clutches and spring loaded valves. (ii) ‘To measure forces as in spring balances. (iii) To store energy as in watch springs. * Gy) To absorb shock and vibrations as in car springs and railway buffers. * (vy) Tocontrol the motion by maintaining contact between two elements as incams and fol 4.2 TYPES OF SPRINGS (1) Helical Springs : Helical springs are made up of a wire coiled in the form of a heli primarily intended for compressive or tensile load. The helical springs have the fol advantages = = (i) These are easy to manufacture. (ii) These are available in wide range (iii) These are reliable. (iv) These have constant spring rate. (v) Their performance can be predicted more accurately. (vi) Their characteristics can be varied by changing dimensions. (2) Conical and involute springs. (3) Torsion springs. (4) Laminated or leaf springs. (5) Disc or bellevile springs. (6) Special purpose springs.Springs 243, 43 TERMS USED IN COMPRESSION SPRINGS Solid Length : When the compression spring is compressed until the coils come in contact with each other, then the spring is said to be solid. Solid length = id Where i d = diameter of spring wire Free Length : The free length of a compression spring is the length of the spring in the free or unloaded condition free length L2(i+n)dt+y+a where a ‘Total number of turns and ‘learance i = number of active turns or coils y = maximum deflection Spring Index : The spring index is defined as the ratio of mean diameter of coil to the diameter of wire. D Spring index c = — where D = Mean coil diameter. Spring Rate : The spring rate is defined as the load required per unit deflection of the spring iB Spring rate F, = > where y = axial deflection, Pitch : The pitch of the coil is defined as’ the axial distance between adjacent coils in un- compressed state 2d ~ for squared and ground end. Pitch p = Where i = number of active turns and /, = free length SPRING MATERIALS The selection of spring materials depends upon the following factors: Expected fatigue life oad acting on the spring vironmental conditions in which the spring will operate age of stress through which the spring will operates Severity of deformation encountered while making the spring. Limitations on mass and volume of spring. sur basic varieties of steel wires are used in springs. They are, ted and cold drawn steel wires (unalloyed) hardened and tempered spring steel wires and valve spring wires (unalloyed) ardened and tempered steel wires (alloyed) less steal spring. wires for normal corrosion resistance.244 Design of Machine Elements -® The patented and cold drawn steel wires are mainly used in springs subjected to static fore Four grades of this wire are commonly used. Springs subjected to static or low load cycles, Lis used. Springs subjected to moderate-load cycles, grade 2 is used. Springs subjected to moderna dynamic loads, grade 3 is used. Springs subjected to severe stresses, grade 4 is used. Forunalloyed, oil hardened and tempered spring steel wire and value spring wires two are used. They are SW and VW. Springs subjected to moderate fluctuating stresses grade S’ used and grade VW is recommended for springs subjected to high magnitude of fluctuating stresse For higher temperature applications alloyed varieties of oil hardened and tempered stee wires are used. Stainless steel springs are ideal to work in steam or some other corrosive medit because of its excellent corrosion resistance. Nonferrous materials such as brass, phosphor-brom: silicon-bronze, monel and beryllium copper are also used as spring wires. Some of the cold helical spring wires are music wire, oil-tempered wire, hard-drawn spring wire, chrome sili chrome vanadium, silicon manganese and stainless steel. 4.5 STRESS IN HELICAL SPRINGS OF CIRCULAR WIRE [VTU, Junesduly 2014, June/July 25 Consider a helical compression spring made of circular wire and subjected to an axial load as shown in Fig. 4.1(a) Let, D = Mean diameter of coil d = diameter of spring wire = number of active coils. = Modulus of rigidity. = Axial load on the spring = Maximum shear stress on the spring ‘Spring Index = Deflection of the spring F Sin a MO x. Fig. 41Sorings 245 Now consider a quadrant of a coil of a round wire spring as shown in Fig. 4.1(b). The load 'F acting along the axis of the spring which has a mean diameter’D' produces a torsional moment 'T oM,. ” M, or T 1 @) E This torsional moment is also equal to 7— t, FD o Ts Seo 1d T 168 d ) Zi - = stress produced ina member twisted by a couple in pure shear, 11) This torsional shear stress diagram is shown in Fig. 4.1 (c). In addition to the torsional shear stress the following stresses are also act on the wite Direct stress due to load ®) Stress due to curvature of wire. Load Direct shear stress due to load 'F = eas ioe ag Z a ot, = ae The direct shear stress diagram is shown in Fig. 4.1 (d) The resultant shear stress induced in the wire t=, +7, 8FD | 4F is, t= ay toe Positive sign is used for inner edge of wire and negative sign is used for outer edge of wire. . . : F 8ED 4F Maximum shear stress induced in the wire t = "43 + Tay 8FD[,, d]_ 8ED[,, 1 — |1+—— | => |1+— som ad? 2p]~ nd? 2 8ED 20s Tak, (A) 1 where k, = 1+ 5. = Shear stress factor.246 Design of Machine Elements ‘The resultant diagram of torsional shear stress and direct shear stress is shown in Fig. 4.1 (@) Form the above equation it can be observed that the effect of direct shear stress i. is appreciable for springs of small spring Index'e’. Also the effect of wire curvature is neglect equation (A). In order to consider the effect of both direct shear as well as curvature of the wire, stress factor 'k’ introduced by 'A.M. Wahl' may be used. The resultant diagram of torsional direct shear and curvature shear stress is shown in Fig. 4.1 (f) 8FD -. Maximum shear stress induced in the wire t = =e _k 4c-1 0.615 + where k = = Wahl's stress factor. 4c-4" ¢ Ey [pues [ries] [oueg) Fl I I Fig. 4.1(c) : Torsional shear Stress diagram ‘Fig. 4.1(d) : Direct shear Stress diagram y Os Fig. 4.1(e) : Resultant torsional and direct shear Fig. 4.1( f ) Resultant torsional d shear stress diagram curvature shear stres: The values of k for a given spring index may be obtained from the graph shown i 11.3, From that we can see, the Wahl's factor increases Very rapidly as the spring index d The Wahl's stress factor may be considered as composed of two sub-factors k,Springs 247 ok ok k where k, = Stress factor due to shear. k, = Stress concentration factor due to curvature. 4.6 DEFLECTION OF HELICAL SPRING OF CIRCULAR CROSS SECTION WIRE Total length of wire / = length of one coil x Number of active coils [VTU, Dec 2013/San 2014] -. b= mDi D *. Axial deflection of spring y =0— where @ = angular deflection. We know, Dt Ge) Dy oe 2 D ite th (=o Gy :. Angular deflection @ = aati ‘ D_ 16FD?.i D Hence axial deflection y = o5 ="Gar 2 = ==> 11.5 (a) Stiffness F, = = --- 11.7 (a) ECCENTRIC LOADING OF SPRINGS When the load is offset by a distance 'e' from the spring axis, then the safe load on the spring D D where D is the meah diameter be obtained by multiplying the axial load by the factor 5248 "Design of Machine Ele 4.8 SURGE IN SPRINGS When one end of a helical spring is resting on a rigid support and other end is loaded suddem then all the coils of the spring will not deflect equally because some time is required fo Propagation of stress along the spring wire. In the beginning, the end of the coil of the sp contact with the-applied load takes up whole of the deflection and then it transmits a large its deflection to the adjacent coils, In this way a wave of compression propagates through the. to the supported end from where it is reflected back to the deflected end. If the applied load is fluctuating type as in the case of valve spring in internal combustion engine and if the time inter between the load application is equal to the time required for the wave to travel from one end other end, then resonance will occur. This results in'very large deflection of the coils correspondingly very high stresses. Under these conditions the spring may fail. This phenome: is called ‘Surge’. Surging may occur in belical spring which have loads applied repetitively at a rate ¢ the natural frequency of the spring. To avoid this it is advisable that the natural frequency of spring be atleast 20 times the frequency of the applied load. The natural frequency for springs between two plates is given by, d ee eu, (20.78 old DDHB) iD? Vw Or Frequency of vibration of valve spring per minute f, = 84.627.) (20.774 New DDH ‘The surge in springs may be eliminated by using the following methods, (i) By using friction dampers on the centre coils so that wave propagation dies out. (ii) By using springs.of high natural frequency. Gii) By using springs having pitch of the coils near the ends different from than at the centre have different natural frequencies. 4.9 EXPRESSION FOR STRAIN ENERGY STORED IN A BODY WHEN THE LOA IS APPLIED GRADUALLY The strain energy stored in a body is equal to the work done by the applied load in stretcl the body. Fig. 4.2 shows load extension diagram of a body under tensile load up to elastic li The tensile load F increases gradually from zero to the Value of F and the extension of the be increases from zero to the value of y. The load F performs work in stretching the body. This we will be stored in the body as strain energy which is recoverable after the load F is removed. Let F = Gradually applied load y = Extension of the body (spring) A = Cross-sectional area 1 = Length of body V = Volume of the body E = Young's modulusSorings 249 Strain eneigy stored in the body © = Stress induced in the body Extension ——» Fig. 42 Now, work done by the load = Area of load extension curve 1 = Area of A" OAB => Fy 6) Load F = Stress x Area= oA. Extension y = strain x length = Stress = ey Ee sees =5) E E strain Substituting the values of Fand y in equation (i) o lo 1 oO Work done by the lod = 5 oAx 5 x= 5Al ee = 5g Y [volume v= An Since work done by the load in stretching the body is equal to the strain energy stored in the 2 2B 1 ++ Strain energy stored in the body U = 5 Fy i) 49.1 Proof Resilience The maximum energy stored in the body without permanent deformation [i.e., up to elastic Snir] is known as proof resilience. Hence in equation (ii) if 6 is taken at elastic limit, then we will == proof resilience.250 Design of Machine Elements - 2 o eh ~. Proof resilience = nS volume where o = stress at the elastic Limit, Total strain ener; Modulus of resilience = strain energy per unit volume = a i ‘Volume 410 SYMBOLS USED IN HELICAL COMPRESSION SPRING D,| BD] D, Pitch u Fig. 4.3 = Free length of spring = Diameter of spring wire Mean diameter of coil Outer diameter of coil Inner diameter of coil Pitch Load on the spring or Axial force mo SS opasSprings 251 i = Number of active coils # = Total number of coils 1 = Permissible shear stress or design shear stress y = Deflection . G = Modulus of Rigidity c = Spring Index Kk = Curvature factor or Wah's stress factor k,orF, = Stiffness of spring or Rate of spring a = Clearance — 25% of maximum deflection. or a = Total gap = (i — 1) x Gap between adjacent coils Gap between adjacent coils = 0.5 to 2 mm 4, = Torsional yield shear strength (stress) Factor of safely Minimum load Maximum load Maximum deflection Deflection for the load range ‘Number of additional coils > Table 20.6 (Old DDHB) Acceleration due to gravity _ (Table 20.14 New DDHB) Volume Mass of the spring Mass density of the spring y, = Initial deflection or initial compression p= DESIGN OF HELICAL SPRINGS The design of a helical compression spring involves the following considerations : © Modes of loading - i.e., whether the spring is subjected to static or infrequently varying load « alternating load. The force deflection characteristic requirement for the given application. re any space restriction. Required life for springs subjected to alternating loads. Esvironmental conditions such as corrosive atmosphere and temperature. omy desired, Jdering these factors the designer select thé material and specify the wire size, spring ex. number of turns, spring rate, type of ends, free length and the surface condition.262 Design of Machine Elements - Il A helical compression spring, that is too long compared to the mean coil diameter, acts as a” flexible column and may buckle at a comparatively low axial force. Springs which cannot be: designed buckle-proof must be guided in a sleeve or over an arbor. This is undesirable because th friction between the spring and the guide may damage the spring in the long run. It is theref preferable, if possible, to divide the spring into buckle proof component springs separated bj intermediate platens which are guided over an arbor or in a sleeve. Free length Mean coil diameter Free length Mean coil diameter I, < 26 [Guide not necessary] > 2.6 [Guide required] 4.12 DESIGN PROCEDURE FOR HELICAL COMPRESSION SPRING OF CIRCU! CROSS-SECTION 1. Diameter of wire : 8FDk Shear stress Cas 20.22/11. 7 nd 4c-1 0615 i Wahi's stress factork = 5 + or 'k' from Fig. 20.5 DDHB) ---- 20.23/11 D © = where d = diameter of spring wire il From Table 20.12 (Old)/11.2; select standard diameter for the spring wire. 2. Mean diameter of coil : Mean coil diameter D = cd Outer diameter of coil D, = D +d Inner diameter of coil D, = D-d 3. Number of coils : 8FDS.i q aa “a where i=Number of active turns or coils -—- 20.29/11 Axial Deflection y = x , Free length : Free length /, 2 (i+n)dt+y+a 20.5% Clearance a = 25% of maximum deflection ora = (i'~1) x Gap between adjacent coils y = Maximum deflection [ Assume squared and ground end ©. Number of additional coil n = 2 5. Stiffness or Rate of spring : Page 288 Old Page 20.19 Ni atG 20: B : F Stifiness of spring F, = — PES os. si!Springs 253 6. Pitch: ---- From Table 20.14/1L.4 20.53. ¢ Note : 1. For natural frequency of vibration of helical spring, When one end is fixed : 1: PF, 1 [Fg 1 [ake —\— — fo or J 20.75/11. 224 ee eV que aa 20.75/11.22(@) When both ends are fixed : 1 RF, 1 pre 1 [kg faa eal w Onl Ww -—-20,76/11.22(b) bee Mass m= Volume x Mass density where volume V = moi(4n0”) =~ 20.33/11.9 47D, Weight W = Volume x Weight density = ~“—1 — 20478 Density of steel p = 7.81 gm/ce = 7.81 x 10 kg/mm! -—- Table 2.10 > The factor of safety based on torsional yield strength (1,) is 1.5 for springs subjected to static forces. 4, +: Permissible shear stress = = 7 Assuming o,, = 0.75 6,,and 1, = 0.5770, (aoe. =036,, 15 = Permissible shear stress is approximately 30% of the ultimate tensile strength. Or use fomulae 20.472, 20.47b or 20.47¢ from New DDHB. END CONDITION While forming the ends of the helical compression spring, four methods are commonly used. ~ are plain ends, plain and ground ends, square ends and square and ground ends. Therefore, calculating the number of active tums, the end turns should be subtracted from the total t of turns. For plain end number of additional coils n= 0 1 For plain and ground end number additional coils n = =>254 Design of Machine Elements: For square end number of additional coils n = 2 For square and ground end number of additional coils n = 2 Example :4.1_ Design a helical compression spring to support an axial load of 3000 N The deflection under: is limited to 60 mm. The spring index is 6. The spring is made of Chrome-vanadium steel and safety is equal to 2. Data: F = 3000N; y=60mm; e=6; FOS=2 Solution : From Table 20.10 (New)/11.5 for Chrome-vanadium steel 1, = 690 MPa = 690 N/mm? (0.69 GPa) G = 79 GPa = 79000 N/émm? 690 27 345 N/mm? 1. Diameter of wire Shear stress t = — ‘Wahl's stress factor k= + 4c-4 Spring Index ¢ = d 8x3000x6d x 1.2525 2. 345 = ——3-———— + d= 12.89 mm ad Select standard diameter of wire from Table 20.12 (Oldy/11.2 d= 13mm 2. Diameter of coil c= +. Mean diameter of coil D = 78mm Outer diameter of coil D, = D+d=78+13=91 mm Inner diameter of coil D. = D-d=78-13=65 mm 3. Number of coils or turns Deflection y = 20.29/1 8x3000% 78° xi 60 = = 13° x 7900Springs 255 . Number of active tums i = 12 4, Free length : 1, > G@+ndty+a = 20,53/11.18 n = Number of additional coils Clearance a = 250h of maximum deflection = => x 60.313 = 15.078 mm 100 [Page 288 Vol.I Old or Page 20.19 New Vol.1] Assume squared and ground end °. n=2 )00x 78° x12 ‘Actual marimnadiidetlecnion'y =< 12 69 573m =~ 20,29/11.5(a) 13479000 Actual free length /, > (12 + 2) (13) + 60.573 + 2 x00513=257 72mm Pitch fy=2d _ 25772-2113 =p 193mm -—- From Table 20.14 (New)/11.4 6. Required stiffness or Required rate of spring F 3000 R= ¥ 7 60 =50 N/mm === 20:30/11.7(a) Actual stiffness or Actual rate of spring je = 1379000 _ 49.53N /mm 20.30/11. 7(@) 8x 12X78 Sering specifications Material Chrome vanadium steel Gi) Wire diameter d= 13mm Mean coil diameter D = 78 mm (iy) Free length /, = 257.72 mm Total number of tums i’ (xi). Style of ends - squared and ground © Pitch p= 19.31 mm (vili) Required rate of spring F, = 50 N/mm, Se Actual rate of spring F, = 49.53 N/mm (©) Actual maximum diflection y = 60.573 mm A helical valve spring is to be designed for an operating load range of approximately 90 to 135.N. The on of the spring for the Load range is7.5 mm. Assumea spring index of 10 and factor safety=2. Design spring. Maximum load F, =135.N; Minimum load F, = 90 N; y'=7.5 mm; ¢ = 10; FOS =2 mn: Assume chrome-vanadium alloy steel From Table 20.10/11.5 1, = 0,69 GPa = 690 MPa = 690 N/mm?256 Design of Machine Elements G = 79 GPa = 79000 MPa = 79000 N/mm? t, _ 690 2 t = > = — =345 N/mm? ¢ FOS 2 ceed —— : YE 75x135 ; Maximumdeflestion y, = —F = 73599 =225mm -— 20.31/Fig. Design the spring for maximum load and maximum deflection 1. Diameter of wire > 8E,Dk Shear stress t = nd? —-- 20.22/11 4c-1 0615 _ 4x10-1 , 0615 Stress factor k = en + = 4x10—4 ert 10 = 1.1448 a= 20.23/1 D Spring index = 7. D=ed=10d 8 37 mm 135 «10d 1.1448 iagtaagiat ne Select standard diameter of wire from Table 20.12 (Old)/11.2 . Diameter of wire d = 3.4mm 2. Diameter of coil Mean diameter of coil D = cd= 10x 3.4=34 mm Outer diameter of coil D, = D+d=34 +3. Inner diameter of coil D, = D-d=34~3¥ 3. Number of coils “345 = 8E,D4i y= HG E 8x1 acd pos eer 3.4* x 79000 +. Number of active tums i = 6 4, Free length 1, > Gtn)dty+a ~~ 20.53/ a = 25% of maximum deflection = a x 24,125 = 6.03 mm ‘Assume squared and ground end; -. Number of additional coil n = 2 +; Total number of coils i’ =i+2=6+2=8 3 ‘Actual maximum deflection y, = ees =24125mm 4* 79000 2 1, 2 ©+2)34 424.125 +6 03 2 57.355 mmSprings 257 5. Pitch =2d _ 57355-2%34 ee. = 6 = 8.426 mm -—- From Table 20.14 (New)/1L.4 6. Required stiffness or Required rate of spring E 135 Yo 225) 7. Actual stiffness or Actual rate of spring FE 6Nimm = 20.30/11.Ta) dé _ 34* x 79000 fi’ gxquagy DONT am --= 20.30/11.1@) & Total length of wire (= KDI where i=i+n=6+2=8=nx34x8 = 854513 mm Seample : 43 Design a valve spring for an automobile engine, when the valve is closed, the spring produces a ‘Gece of 45 N and when it opens, produces.a force of 55 N. The spring must fit over the valve bush ‘which has an outside diameter of 20 mm and must go inside a space of 35 mm. The lift of the valve is 6 sex The spring index-is 12. The allowable stress may be taken as 0.33 GPa. Modulus of rigidity 80 20 mm 32.5mm<35 mm +. Safe Le., possible 3. Number of coils Maximum deflection y, = SEDs 2 aa he ceases i= 8.68 : 25° 80,000 :. Number of active coilsi = 9 3 4, Free length 1, > G+n)dtyta -- 20.531 a = 25% of maximum deflection = = x 34.2=8.55 mm _ 8x55230? x9 Actual maximum deflection y, = —= 342 25° x80,000 ‘Assume squared and ground end Number of additional coils. n = 2 ; Total number of coils, i! =i+2=9+2=11 ce ly = O42) 25 4342.48.55 51,270.25 mm 5. Pitch a 4o*€ == From Table 20.6 (Old) Table 20.14 (New. 7025-2%2. 2 ES ao 9 6. Required stiffness or Required rate of spring Hg 2 5: 2.7% 1667) 2220; y yo 2 39 72667 Nin 2030/1 7. Actual Spring rate fe Se 100 cee ie = 20.30/11 ° gD? 8x9x30' mm 8, Total length of wire | = mbit where i! =i+n=9+2=11 =m x 30x 11 = 1036.725259 le: 4.4 ‘Geand wire cylindrical compression spring has an outside diameter of 75 mm. It is made of 12.5 er steel wire. The spring support an axil load of 5000 N, Determine Sima shear stress. “See! deflection, if the spring has 8 coils with squared - ground end and is made of SAE 9260 aiso the pitch of coils and ‘ie natural frequency of vibration of the spring if one end is at rest. Take G = 79.34 GPa =8; d=12.5 mm; F = 5000 N; Material - SAE 9260 G = 79.34 GPa = 79340 MPa = 79340 N/mm? D, = 75mm; shear stress 8E,Dk Shear stress t = 5 =~ 20.22/11.1(4) D+d; 75=D+125 ~. D=625mm. D_ 625 Suis 1 Be oe ee ee ialona0 ie BUAS=a | enh ANo= as Ge a, o 85000 62.51.3105 p= 2533.95 Nim? nx? éeSection sexed and ground end n = 2 itn ; 8=i+2;+ i=6=numberof active coils 8FD%i 8x 5000x625? x6 ee ee 8302 2011 5 15 Gat 79340125" ese eo eat ste) = z --= From Table 20.6 (Old) or Table 20.14 (New)/11.4 1 = G+udt+yta : eo a5 a = 25% of maximum defiection = 755 x 30.25 = 7.5625 mm sl, > (+2) 12.5+30.25+7.5625 ; 2 137.8125mm 137.8125—2x12.5 Ss = 188mm260 Design of Machine Elem 4, Natural frequency Natural frequency of vibration when one endiis at rest eee AR te 2E8 20.75/11.22 = onVm ~2nV Wo” ge F _ 5000 RS = 3025 = 165.28925 N/mm = 165289.25 N/m ‘Mass m = Volume x density 2 Volume V = xDi (=) == 203: 81 x 10 kg/mm’ for steel —- From Table 2.10/1.1 16.6 x 10% N/mm? Mass density p = 7.81 gm/ce Weight density y= 76.6 kN/m: cM = 1XO2Z5SX6XEX X 7.81 x 10%= 1.129 kg. 4 1 [216528925 Neate = oo 242 Pe a owe Dy ee mnie Sait Example : 4.5 ‘The spring loaded safety valve for a boiler is required to blow off at a pressure of 1.3 diameter of the valve is 65 mm and maximum lift of the valve is 17.5mm. Design a suitable com spring for the valve, assuming spring index to be 6 and providing initial compression of 30mm. t= 0.45 GPa and G = 84 GPa. meter of valve = 65 mm; y'=17.5mm c= 6; y,= 30mm (0 MPa = 450 Nimm?; G =84 GPa = 84000 MPa = 84,000 Némm* Solution : Maximum deflection y, = y, +y' = 30+ 17.5 =47.5 mm-— Refer Fig. 20.6 rr Minimum Load F, = P, x Area of valve = 1.3 x 7 x 65° =4313.8N Ry! 2 F=f;

Gi+n)dtyta -— 20.53/11.18 a = 25% of maximum deflectio1 25 To X 22.15 = 5, Too % 22-75= 5.6875 8x400x 30° x13 Actual i de tion y, = —— ——_ —- = 22.75mm. ctual maximum deflection y, = “oo Assume squared and ground end -. n=2; -. Total number of coils, i'=i+n=13+2=15 vi 1, = (13 +2)5 + 22.75 + 5.6875 ; 1,2 103.4375 mm = Pitch a = 7.1875 mm --- From Table 20.6 (Old) or Table 20.14 (New/I1.4 stiffness or Required rate of spring = 18.75 N/mm, =~ 20.30/11.7(a) ‘Setual spring rate 5* «79000 exiaae 4 N/mm =~ 20.30/11.7(a) 13% =itn=13+2=15) 247 © spring controlled lever is shown in Fig. 4.5(a). The spring is to be inserted with an initial jon to produce a force equal to 125 N between the right end of lever and the stop. When the force at 'A’ reaches a value of 200 N the end of the lever moves downward by 25 mm. the spring index as 8 find (i) Spring rate (li) Size of wire (iii) Outside diameter of spring ember of active coils (v) Free length and (vi) Pitch.264 Design of Machine Elements Solution : ee 200m, 200m, W, = 200N sn ‘Taking moments about '0' for minimum load Fig. 4.5(a) ‘A “ W, x 400 = F, x 200 eo F Me = 125x400 = F, x 200 SPRING : F, = 280N (@) Taking moments about '0' for maximum load W, x 400 = F, x 200 j_200+200=400_ 200 x 400 200 200 : F, = 400N By similar A* principle from Fig. 4.5(b) ge es ® 200 Fig. 4.5 < Maximum deflection y, 2031 1. Spring rate eae 2. Size of wire c Assume ASTM A 229 —41 steel wire (Oil tempered wire) from Table 20.10/11.5 1, = 0.55 GPa=550 Nim? G = 79 GPa= 79000 MPa = 79000 N/mm? Assume factor of safety = 1.5 oe Ras = 366.67 N/mm? Shear stress t = Stress factor k Spring index ¢ = 5 ; -. D=ed=8d 8x 400 x 8d x 1.184 ¢, 366.67 = gs sd =5.13 Select standard diameter from Table 20.12 (Old)/11.2 ad = 5.6mmSprings 265, 3. Outside diameter of coil Mean diameter of coil D = 8d=8x5.6=44.8 mm. Outside diameter of coil D, = D+d=44.8 x 5.6=50.4 4 Number of active coils ¢ 8E,D4i Maximum deflection y, = “Ziq =-+-20.29/11.5(a) 8x 400% 448" xi 5.6* x 79000 Number active tumsi = 9 S. Free length 4 1,2 (i+n)d+y +a; Actual maximum deflection y = Seed =3333mm Clearance a= 25% of maximum deflection = 0.25 x 33.33 = 8.3325 Assume squared and ground end <. Number of additional coiln = 2 Total number of turns i? = i+n=9+2=11 * I, = 11X56 +33.33 48,3325 31 = 103.2625 mm & Pitch 2d _ 1032625-2%56 pe = = 10.23: z ~--- From Table 20.6 (Old) or Table 20.14 (New)/11.4 ‘Spring specifications ) Material - ASTM A 229 — 41 steel wire (i) Wire diameter d = 5.6 mm %=) Mean coil diameter D = 44.8 mm iy) Free length f, = 103,2625 mm Total number of turns i’ = 11 (vi) Style of ends - squared and ground ©) Pitch p = 10.23 mm Ezample : 4.8 A closed helical spring is to have a stiffness of 1 N/mm, maximum load of 40 N and maximum stear stress of 130 N/mm’, The solid length is 45 mm, Find the diameter of wire and number of coils s-quired. Take G = 80 GPa = 80 x 10'MPa Data : F, = 1 N/mm; Solid length = 45 mm; F =40N; G= 80 GPa = 80000 N/mm’; t= 130 N/mm? Getation : Rate of spring F, = Maximum deflection y =266 Design of Machine Elements ~ Shear stress 7 Assume k ~ 130 ‘= Mean coil diameter. D ‘Maximum deflection y ie, 40 See Solid length i'd Assume plain end Sub in equation (B) From (C)i -+ Number of active turns i Since plain end, number of addi <+ Total number of coils i! Check : Spring index ¢ Stress factor k W " f 8FDk Ra 1.25 8x40xDx125 rt ne 1.021 8ED4i aG 8x40x(1.0214") (i) d* x 80000 from A 0615 4x14.7368-1 0.615 ec 4x14.7368—4 _ grDk _ 8%40x56x 1.0963 nd? nx38* 113.96 Nimm? < 7,,, (ise., 130 N/mm’) Safe.Springs 267 Example : 4.9 Design a spring used in a recoil system so as to absorb 120 Nm of energy with a maximum force ° £3000 N. Assume spring Index 8 and factor of safely is 2 Data: U = 120Nm= 120x 10°'Nmm; ¢ ; F=3000N ae Solution : Assume ASTM ~ A229 —41 steel wire (Oil tempered wire) From Table 20.10/ 11.5 %, = 0.55 GPa = 550 MPa = 550 N/imm? G = 79 GPa=79000 MPa = 79000 N/mm? W = > Fy = 20.32a/11.8 be 2 120% 10° = $ x 3000 y y = 80mm = Maximum deflection © Diameter of wire 8ED Shear stress t= “DE <= 20.22/11,1¢d) nd 4c-1 0615 _ 4x8-1 0.615 Suess factor k = G—a+—— = Gg g tg = te D Springindex ¢ = = +. D=cd = 8d 8x3000%8dx 1184 8 =; nd cet standard dia from Table 20.12 (Old)/11.2 od = 17mm = Diameter of coil Mean 8d=8 x 17= 136 mm D+d=136+17= 153 mm 36-17 = 119 mm meter of coil D Outer diameter of coil D, Inner diameter of coil D, = Namber of coils 8EDi Maximum deflection y= aq ==. 20.29/11 5(a) 136° wae 8.74 17 £79000 =. Number of active tums i & Free length 1, 2 G+n)d+y+ta : = 20.53/11.18268 Design of Machine Elements: Assume squared and ground end; -. Number of addition coils n = 2 Total number of coils? = i+n=9+2=11 8x3000* 136° x9 Actual maximum deflection y 5 =82.35mm 174 x 79000 Clearance a = 25% of maximum deflection = 0.25 x 82.35 & 1). (11) (17) + 82.35 + 20.6 ; 1, > 289.95 mm 5. Pitch me d e 28995—217 =28.44mm ~--- From Table 20.1: 6. Required rate of spring Fo= 5 = eal =37.5 Nimm : --- 20.30/11 2 Yen 80. 7. Actual rate of spring, a’ _17* «79000 = 3643 Ni ~~ 20300 ° © SD? 8x9x136 as 8. Total length of wire 1 = mDi! =x 136x 11 = 4699.82 mm Spring specifications (Material - ASTM A 229 ~41 steel wire ii) Wire diameter d = 17 mm (iii) Mean coil diameter D = 136 mm (iy) Free length f, = 289.95 mm (v) Total number of turns i! = 11 (vi). Style of ends - squared and ground (vii) Pitch p = 28.44 mm Required stiffness of spring F, = 37.5 (x) Actual rate of spring F, = 36.43 Némm. (X) Total length of wire /= 4699.82 mm Example : 4.10 A railway wagon weighing 50 KN and moving with a speed of 8 km/hr has to be stopped b buffer springs in which the maximum compression allowed is 220 mm. Find the number of coils in each spring of mean diameter 150 mm. The diameter of spring wire is 25 mm. Take § GPa, Also find the shear stress. (VTU, Dec. 09/Jan'10, Dec. 2012, June/i Data: Weight of moving body W = 50 kN =50,000N y = 8 km/hr = 8000/3600 = Number of springs = 4 i 220mm Se 150mm. @ = 25mm 84 GPa = 84,000 MPa = 84,000 N/mm? 1.2222 m/sec = 2222.222 mm/sec269 50000 Kinetic Energy “9810 10 x (2222.2227 = 12584790 Nmm Total kinetic energy 12584790 + Energy stored by each spring = “Nussber of springs“ g =3146197.5 Nm 1 Atso, Energy absorbed by each spring = 5 Fy -—~ 20.32(a)/11.8 1 ie., 3146197.5 = 2 x Fx 220 = Axial force on each spring F = 28601.8 N © Nember of turns 8ED'i Deflection y = —z— =~ 20.29/11.5(a) G 8x286018%150° xi 2) = ee ie = 220 ISR oe -. Number of active tums i = 10 Assume squared and ground end = Number of additional coil n = 2 °. Total number of turns i = Shear stress +n=10+2=12 20.22/11.1(d) ‘Shear stress t = Spring index ¢ = 1S x6-1 0.615 = iu + = 1.2005 Stress factork = 6 8% 28601.8%150x 1.2525 ea = eee i/o Semple : 4.11 A loaded narrow gauge car weighs 18 kN and moving at a velocity of 80 m/minis brought to rest % = buffer consisting of two helical springs. In bringing the car to rest the spring undergoes a ‘s=pression of 200 mm. The allowable shear stress is 0.3 GPa and the spring index is 8. Design a settable spring. Take G = 84 GPa, ena: Weight of moving body W = 18 kN = 18,000 N ¥ = 80 m/min = 80/60 = 1.3333 m/sec = 1333.333 mm/sec Number of springs = 2; y= 200mm + = 0.3 GPa =300 Nim? ¢ = 8; G=84GPa=84000 MPa270 Design of Machine Elements - Il Solution : ie 1 1W Kinetic Energy = 5 Mv= 5-7 Ue a ae . = ee a x 133.333? = 1630988.8 Nmm SS \ Total Kinetic energy 16309888 -. Energy absorbed by each spring = “Nurser ofsprings = «)”~~«(= 8154944 Nm 1 Also, Energy absorbed by each spring = = Fy ~~ 20.32a/11 1 ie, 8154944 = > x Fx200 . Axial force on each spring F = $154,944 N 1. Diameter of wire 8EDk Shear stress t = —~ 20.22/11.1 4o-1 0615 _ 4x8-1 0615 Stress factor k = [+ = gg tg = Ld ; D Springindex c = 7 =. D=8d 8x8154.944x8dx1184 4 300 = Sg: ie, d=25.6 mm Standard diameter of wired = 26mm From Table 20.12 [OLDJ/11.2 2. Diameter of coil Mean diameter of coil D = 8d=8 x 26 = 208 mm Outer diameter of coil D, = D+ d= 208 +26 = 234 mm Inner diameter of coil D, = D—d = 208-26 = 182 mm 3. Number of coils 5 8ED*i Deflection y = “ag 2029/1 7 8x 8154.94 x 208? xi hie, 200 = Ser agpo9 i= 13.076 ©. Number of active coilsi = 14 4. Free length 12 G+njdty+a 205 ‘Assume squared and ground end ; . Number of addition coils n= 2 3 : 1 ‘Acial mikizaum deflection y = 28154944208 514 9 9 14 t2mm * 26! x 84000 : <. Total number of turns i! = it+n=14+2=16sorings 271 25% of deflection = 0.25 x 214.12 16 x 26 + 214.12 + 53.53 683,65 mm ‘Clearance a wow Pitch 683.65-2 x26 14 = 45.12 mm ~-— From Table 20.14/11.4 6. Required rate of spring y 200 FE $154.944 => = 40.775 Nimm 7. Actual rate of spring 4 4 84000 ree & oe 4000 _ 38086 N/mm = 20.30/11. 1(a) ° SID? 814x208 8. Total length T= nDi' = x 208 x 16 = 10455.22 mm Spring specifications i) Wire diameter d = 26 mm (i) Mean coil diameter D = 208 mm iii) Free length /, = 683.65 mm (iy) Total number of turns i' = 16 ¥) Style of ends ~ squared and ground (vi) Pitch p= 45.12 mm vii) Required rate of spring F, =40.775 Nimm. (viii) Actual rate of spring F, = 38.086 N/mm Example : 4.12 A load of 2000 Nis dropped axially on a closed coiled helical spring from a height of 250mm. The spring has 20 effective turns and it is made of 25 mm diameter wire. Find the maximum shear stress produced in the spring and the amount of compression produced. Take c = 8 and G = 84 GPa (VTU December 2010) Data: ‘Weight of falling body W = 2000N: h =250 mm; G=84 GPa = 84 x 10° Nimm? 20; d=25 mm; c=8 Selution : Potential Energy = (h+ y) W = (250 + y) 2000 = 5% 10° + 2000 y = Energy stored by the spring 1 Also energy stored by the spring = 5 Fy ~--- 20,32(@/11.8 1 9 Fy = 5x 10°+2000y (Number of springs = 1) ie, Fy = 105+ 4000y 8RD%i _ 8xFx200°x20 Deflection y =272 Design of Machine Elements - If 2 ¥ = 0.039F Sub in equation (A) 01039 F = 10+ 4000 x 0.039 F ; ie. F = 25.635 x 10°+ 4000F -. F-4000 F ~ 25.635 x 10° = 0 2 Sas: Dg = Hono 4000% + 4a 25.635%<10° ~. 2x1 ‘Taking positive value Axial load on the spring F = 7443.8 N 1. Shear stress Shear stress T = ~~ 20.22/18 f = —— t+ = ~ = 1.184 Stress factor k i = 4x8-4 3 1.18% 8x 7443.8 x 200 x 1184 pS = 287.274 Nim? RX25 2. Compression or deflection From (B) y = 0.039 F=0.039 x 7443.8 = 290.3 mm Example : 4.13 Design a spring for an elevator shaft at the bottom of which 8 identical springs are set in to absorb the shock of the elevator in case of failure. The weight of elevator is 60 kN and the weight ofelevator is 20 kN. The elevator has a free fall of 1.5 m from rest, The spring is made diameter rod. Determine the maximum stress in each spring, if the spring index is 6. Each spr 15 active turns. Take G = 84 GPa Data: Number of springs = 8; Weight of elevator = 60 KN = 60,000 N Weight of counter weight = 20 kN=20,000 N; h= 1.5 m= 1500 mm; d=25 mm | es =15; G=84GPa= 84000 MPa = 84000 N/mm? Solution : i ‘Weight of fallingbody W = Weight of elevator Weight of counter Wt = 60,000 — 5 = Spring index ¢ = | +. D=ed=6x25=150mm Total potential energy = W (h + y)=40,000 [ 1500 + y] = [60x 10°+4 x 10®y9 : by cach spring = —20WP-E _ 60x10" +4x108.y TEE, SRY at 9D DE reer OC EE 8 = 75x10 +5x10°y 1 Also, energy stored by each spring = > Fy =Soiings 273 . TSX 10° +5 x 10'y ie, Fy Deflection y Sub in equation (A) 0.012343 F* ic F Taking positive sign Axial force on each spring F & Deflection From (B) Deflection y ‘© Shear stress Wat's stress factor k = Maximum allowable shear stress t = Free length 10' F—1215.264 x 10° = i= Gitn)dtyta Sesame squared and ground end ; ‘Total number of tums i’ Clearance a Rate of spring = ee To 15x 10°+ 10x 10 y —(A) SED'i 8x Px 150° x15 dG ~ 25*x84,000 = 0.012343 F -——- (B) -— 20.29/11.5(a) 15 x 10°+ 10 x 10° x 0.012343 F 1215.264 x 10° + 10 F oO +10" £ y(lo*) +4x 11215264 x 108 2x1 402174N 0.012343 F = 0.012343 x 40217.4 = 496.4 mm 8EDk nd? = 20.22/11.1(d) & =1 4c—4 8x 402174 x150x12525 mx 25° = 1231.4 Nimm* -~ 20,53/11.18 . Number of additional coil n=2 i+n=15+2=17 25% of maximum deflection = 0.25 x 496.4 = 124.1 17x 25 +496.4 + 124.1 ; 2 1045.5 mm 2d 10455-2x25 TR gp 29637 mm -— Table 20.14 (New)/11.4 40217.4 4964 = 81.018 N/mm ~~ 20.30/11.7(a)274 Design of Machine Elements - Il vi. Total length of wire J=nDi' = mx 150x 17 = 8011.06 mm Spring Specifications i) Wire diameter d = 25 mm ii) Mean coil diameter D = 150 mm iii) Free length /, = 1045.5 mm iv) Total number of turns i' = 17 v) Style of ends — squared and ground vi) Pitch p = 66.37 mm vii) Spring stiffness or Rate of spring F, = 81.018 N/mm Example : 4.14 ‘A single plate friction clutch transmits 20 kW at 1000 rpm, There are 2 pairs of friction surfaces having a mean radius of 150 mm. The axial pressure is provided by six springs. If the springs are compressed by 5mm during declutching, design the spring, Take c= 6,¢= 0.42 GPa, G = 80 GPa 1=0.3. Data: N = 20kW c=6 n = 1000 rpm + = 0.42 GPa = 420 MPa i = number of active surfaces = 2 R,= 150mm D, = 300mm Number of springs = 6 y = 5mm Solution : Clutch N Torque M, = 9550 x 1000 x — 550 x 1000 x 20 = 191000 Nmm : 2 1000 : a Also, M, = 5 1F,D, i for dise dutch ~--- 19.84/13.96 1 191000 = 5 x0.3xF, x 300 x2 F, = 2122.22 N= Axial force Axial f ee = eae TN + AdalTorre onsset SPeve-SSiNumberofspiings = 6" 1, Diameter of the wire EDK Shear stress t = ——5 —- 20.22/11 nd Stres factor k = D __ 83537 x 6d x 12525 Springindex ¢ = 7 =6 -. D=6d = 420 =pSotings 275 d = 4mm = diameter of wire Diameter of c« 6d=6x4= 24mm D+d=2444= 28mm 4—4= 20mm Mean diameter of coil D Outer diameter of coil D, Inner diameter of coil D. = D—d= Number of turns 8FD* Deflection y = “3g ~~ 20,29/11.5(a) 24? xi pe i=2et 4% 80000 Number of active terms or coils i=3 4. Free length . Pitch 6. Stiffness 7. Total length of wire and specification of spring wire are as calculated in earlier Examples. Example : 4.15 A single plate friction clutch is to be designed for a vehicle. Both sides of the plate are’to be fective. The clutch transmits 30 kW ata speed of 3000 rpm and should cater for an overload of 20%. The intensity of pressure on the friction surfaces should not exceed 0,085 N/mm’ and the surface speed =the mean radius should be limited to 2300 m/min. The outside diameter may be assumed as 1.3 times side diameter and yt = 0.3. If the axial thrust is to be provided by six springs of about 25 mm coil ameter design the springs selecting the wire from the following gauges. Safe shear stress is limited to #2 GPa and modulus of rigidity 84 GPa. SWG 4 a 6 hs 8 9 10 bu 12 Dia 5.893 | 5.385 | 4.877 4.47 4.064 | 3.658 | 3.251 | 2.546 | 2.642 Number of active surfaces for clutch i=2; N=30 kW; Number of springs = 6 5 mm; Over load = 20%; G = 84 GPa = 84000 MPa 0.42 GPa =420 MPa; v = 2300 N/imin N 9550 x 1000 x — x12 0 20% overload) Torque M, 30 9550 x 1000 x soo % 1.2-= 114600 NumDesign of Machine Elements 1 Fordise clutch, M, = 5 WED, i -—- 19.84/13:94 1 1 Assume uniform wear D, = 5 (D,+D,)= 5 (3D, +D,)=1.15D, £ F.= 5 ™pD,@,-D) 1 = 3 ®X 0.085 D, (1.3D, ~D,) =0.04 D2 + 114600 = 5 x0.3x0.04D,x 1.15, x2 Inner diameter of friction surface D, = ©. Quter diameter of friction surface D, Check 102.5 mm 163.25 mm MDgN _ €x115x 2025x3000 60000 — 60000. 36.58 m/sec = 2195 m/min < 2300 m/min . Safe , Axial Force F, = 0.04. D,? = 0.04 x 202.5" = 1640.25 N . Roaeton each peng ee Pa AOS aN er Number ofsprings 6 = Axial load on each spring Spring : i) Diameter of wire Shear stress ¢-= = —~ 20. xd : Assume k = 1.25 8x 273.375X 25x 125 Oy Se a Sm axd From the given table select SWG 8 wire +. Diameter of wire d = 4.064mm Check 4 D 25 Springindex © = J = 7ogq = 6.1515 Suess factor k = 2XSUSISoA, 0615. ag co Stress factor ke = pO 4x61515=4 61515 8 273.375x 25x 12456 Sue x4.0642ings : 277 ie, t, = 322.96 Nimm?. ‘safe. =) Number of Coils 8ED‘i Deflection y = “Te ~~ 20,2911.5(a) Assume allowable compression, y = 5 mm — 8X273375x25° xi 52 oe 4.064" 84000 . Number of active tums i =4 © Free length ®) Pitch Stiffness ») Total lengths and specification of spring wire are as calculated in earlier Examples. iple + 4.16 Design the spring for the Hartnell type spring loaded governor for the following particulars. ss of each ball = 2.97 kg, length of vertical or ball arm is 150 mm, length of sleeve or horizontal arm 112.5 mm. The governor is begin to lift at a speed of 240 rpm and the maximum speed is 7.5% higher that. The maximum radius of rotation is 150 mm and the minimum radius of rotation is 100mm. allowable stress on the spring material is 0.42 GPa and modulus of rigidity is 84 GPa. Take c= 8. For Governor. For spring m=2.97kg; r,=100mm = 0-1 meter 7 = 0.42 GPa = 420 MPa a=150mm=0.15 m; r,= 150mm =0.15 meter; G = 84 GPa = 84000 MPa; c =8 b= 112.5 mm = 0.1125 m 75 N, = 240 rpm; N, = 240+ x 240 = 258 rpm 100 2nN, Y @ Fj=mo?r, = m (2284) f =297% (24) x01 = 1876N g 27258)? F,=mo,r, = (22) es dor : =) (0.15) =325.2N on NOE 60 Taking moments about ‘O’ for maximum radins neglecting the obliquity of arms and mass of ball «0.1125 Bo icb.; 252K 015= 2 pe ee eae 867.2N278 Design of Machine EI Governor axis Fig, 46 ‘Taking moments about ‘O° for minimum radius Fi, xa = tx ; 187.6 x 0.15 = ih x 0.1125 F, = 500.27N AF OB, B, and OA, A, are similar Ba Ey a as A\A, a "015-017 O15 y' = 0.0375. meter=37.5 mm = Deflection for the load range By _ 8672x375 F, 8672-50027 Design the spring for maximum load and maximum deflection. . Maximum deflection y, =88.627mm = 20.31)Sexings 279 1) Diameter of Wire Shear stress t Stress factor k =~ 20.22/11.1¢d) 0615 - 4c-4" ¢ 4x8-1 0.615 42 21.184; 0= 4x84" 8 & 8x8672x8dxL184 mxd* -~-- 20.23/11.2(a) Decd=8d ; d= 7.06 mm Select std diameter from Table 20.12 (Old DDHB) +, Diameter of wire @ Diameter of coil Mean diameter D Outer diameter D,=D +d Inner diameter _D,=D—d Number of turn w Maximum deflection y, = ie, 88.627 = Number of active turns i Free length Pitch Rate of spring “ek = 75mm &d=8x7.5=60 mm 60+ 7.5 =67.5 mm 60-7.5 = 52.5 mm 8F,D'i dG == 20.29/11,5(a) 8x 867.2 x 60° xi 75' 84000 =16 b= 16,72 Total length of wire and specification of spring wire are as calculated in earlier Examples. Reample : 4.17 Ina free rolling conveyor shown in Fig. 4.7 a crate loaded with non-frogile material 300 N reaches ‘s25on A ata velocity of 3 m/sec and is normally unloaded at section B. In case it gets away from B, a = of helical buffer spring at C are expected to arrest the motion of crate. It is suggested that the sesmes may be set up with an initial compression of about $0 mm and that compression of spring due “= mpact of load may be limited to 150 mm. Design the spring. Take G = 80 GPa, t = 0.8 GPa and =< od 0 300 N: v= G 3 m/sec = 3000 mm/sec; y, = 50mm; y 80 GPa = 80000 N/mm’; 1 =0.8 GPa = 0.8 x 1000 = 800 MPa; c= 6 = 150mm280. Design of Machine Elements - Solution : 900mm. 300, a fre 2% 9910 * (3000) = 137614.679 Nom PE. =Mgh=Wh = 300 x 900 =27 x 10'Nmm . Total energy = KE + PE = 137614.679 + 27 x 10*=407614.679 Nmm Energy stored ou each Sociayy xO 93807939 Nam 2 (Number of sprin 1 Also, Energy stored by each spring = 5. Fy 1 Average force x deflection = a @+E)y' y: Ry, y, = y, ty! =50+ 150 = 200 Fy, Maximum deflection 1 Us 7 Gy tFyy=5 FW, tyy 1 3 Fo (50 + 200) 150 10, 8697 N/mm = Rate of spring 10,8697 x 50 = 543.5 N 10.8697 x 200 = 2174 N . Minimum load F, = 543.5 N Maximum load F, = 2174 Maximum deflection y, = 200mm Design the spring for maximum load and maximum deflection. 1) Diameter of wire Shear stress t =4c-1 0615 4x6-1 0.615 4c-4¢ | 4x6-4. OG Stress factor k = 1.2525 " D Spring index c = = :. D=cd=6d 8x 2174 x 6d x1.2525 Seana Sess Select Std diameter from Table 20.12 (Old)/11.2 ». d=7.5 mm = diameter of wire 2 Diameter of coil Mean diameter of coil D = 6d=6x 7.5 =45 mm Outer diameter of coil D, = D+ d=45+7.5=52.5mm Inner diameter of coil D, ‘Number of turns - 800 = d=7.21 mm 8D Maximum deflection y, = a =~ 20.29/11,5(a) 8x2174%45? xi ic, 200 = yg 3 i= 31.94. fe, 200 = 75480000 one . Number of active tumsi = 32 Free length. Pitch Rate of spring Total length of wire and specification of spring wire are as calculated in earlier Examples. ue * The spring used in an automobile engine has to exert 500N when the valye is closed and 600N the valve is opened. The displacement of the valve is Smm., The engine crankshaft rotates at 8000 ‘Design the spring if permissible stress in the material of the spring is 300MPa. The ratio of mean ameter to the wire diameter is 6. The specific weight and the modulus of rigidity of the spring ‘al ar 7.35 x 10 N/mm! and 8 x 10* MPa, respectively. The ends of the spring are square and Inspect the suitability ofthe spring for thisengine. At what speed ofthe engine does the spring te? (VTU July 2006) u Minimum load F, = 500N Maximum load F, = 600N D / = 5mm; =e=6 Automobile Engine. <. 4 stroke engine Crank shaft speed = 8000 rpm ‘+ = 300 MPa = 300 N/mm’; G = 8 x 10° MPa =8 x 10' N/mm? Specific weighty = 7.35 x 104 /mm? Square and ground end. y282 Design of Machine Elements - Il Solution Design of spring 6005 aca oan ----20.3UFig, 112 600-500 Design the spring for maximum Joud and maximum deflection ‘Maximum deflection y, = 1, Diameter of wire 8, Dk 302 uP 202UI1AG Shear stress t 5 0.615 4x6-1 = 1.2525 --- 20.23/11.2( i ‘Wahl's stress factor k Ce Sat in Spring index © = 5 De 8x 600% 6d x 1.2525 Hence 300 = ime «. Wire diameter d = 6.186 mm Select the standard wire diameter from Table 20.12 (Oldy/11.2 od = 63mm 2. Diameter of coil Mean diameter of coilD = cd=6%63= 378mm Outer diameter of coilD, = D+d=37.8 463 =44.1mm Inner diameter of coil D, = D-d=37.8-6.3 = 31.5mm 3, Number of coils an Maxiraum deflection y, = one e 9029/11. een 8x 600%37.8" xi ae 63" x8x10" ie,i = 14.583 =. Number of active turns i = 15 4, Free length 1, > G+n)dtyta For square and ground end, number of additional coils n=2 Actual maximum deflection y, = OOS = 3086mm 63° x8x10' 25 Clearance a = 25% of maximum deflection = 755 * 30.86 =7.715mm (15 +2) 6.3 + 30.86 + 7.715 2>145.67S5mmSprings 283 5. Pitch 2d =—= From Table 20.6 (Old) Table 20.14 (New)/L1.4 145675—2x63 -—S 8.872 mm. 15 6. Requird rate of spring or Required stiffness of spring E, a WOT oNmn --- 20.30/11.7{a) Yo 30 7. Actual rate of spring va + < 80000 19.44N /mm 20.30/11.7(a) iF Sige rf 4 8iD* 8x15x378 8. Total length of wire 2 = xDi where i =i+n=15+2=17 = 37.8 x 17 =2018.8mm Check for buckling or stability of the spring I, _ 145675 RAR Gag = 3.854 1 From Figure 20.8/11.7(a) for a = 3.854 and Built in ends factor K, = 0.63 -, Critical axial load that can cause bucking F, = F,K, = 20 x 0.63 x 144.6 = 1821,96N Since the critical load 1821.96N is more than the maximum load of 600N, the spring will not buckle snd hence safe, Critical speed The fundamental or critical frequency of the spring when both ends are fixed 1 2k ae im = FV ass =141 Jo Hz — -- 20.76/11.22) ee Diy 20.54/11.19(a) Weight ofthe active col of a holical spring W = " 20478 igen? = _ 1x63 ese ea an F, = 20 N/mm = 20000.N/m f= 1.41 8.708 Hz, ©. Critical speed = 8.705 x 60 = 5992.3 rpm284 Design of Machine Elements - I Since the cam shaft speed is half of the engine speed for four stroke engine, the speed of the engine at which the spring resonate = 5922.3 x 2 = 1184.6 rpm. Lower engine speeds are not likely to set up surge action, because of the damping effect of the spring material between the impulses. [other dangerous speeds 844.6 11844.6 44.6 3 = 5022.3 rpm, sas = 2961.15rpm } ‘The design of spring is safe, since the crank shaft speed is 8000 rpm which is far from 11844.6 rpm 5922.3 rpm. Example : 4.19 Design a helical compression spring required for a spring loaded safety valve mounted on pressure vessel. The spring is subjected to an initial compression of 50mm at the time of assembly will open by 10mm when the pressure approaches 6MPa. The diameter of the valve is 25mm. int would be 1 = 3948.2 rpm and — (VTU Jan/Feb, 2 Take G = 79.34 GPa and 1, = 0.69 GPa. Factor of safety = 1.5 Date: Initial compression y, = 50mm; y’ = 10mm Maximum pressure P, = 6MPa = 6N/mm? Diameter of the valve = 25mm Solution : 4, = 0.69 GPa = 690 MPa = 690 N/mm? G = 79.34 GPa = 79340 MPa = 79340 N/mm? t “Allowable shear stress = 2% = 9% = 60N/mm? Fos 5 Maximum deflection y, = y, + y’=50+10=60mm Refer Fig: 20.6 Maximum Load F, = P, x Area of c/s of the valve = 6x 7 x25'=2045.243N Design the spring for maximum load and maximum deflection 1. Diameter of spring wire 8R,Dk : Sat = 20.22/11. =1 0615 _4x6-1 0615 Allowable shear stress t Stress fuctork = 7 — ©. axbra tpn 12525 —- 2025/1 ; D Spring indexe = “D = 6d 8x 2945.243x 6d x 12525 110 = d = 11.07mm Select the standard diameter of wire from Table 20.12 (Old)/11.2Songs 285 =. Diameter of spring wired = 12mm 2. Diameter of coil Mean diameter of coil D = 6x 12=72mm Outer diameter of coilD, = D+d=72+1 Inner diameter of coil D, D-d=72-12=60mm 3, Number of turns 4mm. : 8B,D%i Maximum deflection y, = — 5 —-- 20.29/11 5(@) ne 8x 2945,243x 72> te 00> 134 79340 11.22 12 Free length, pitch, Rate of spring, Total length of wire and Specification of spring wire are as calculated er Examples. Example : 4.20 ‘The spring loaded safety valve for a boiler is required fo blow off at a pressure of 1 MPa. The ameter of the valve is 60mm and the maximum lift of the valve is 1Smm. Design a suitable compression spring for the safety valve providing an initial compression of 30mm. :. Number of active turn: Data : Blow off pressure P, = 1MPa; y’ = 15mm Initial compression y, = 30mm Diameter of the valve = 60mm Solution : Load on the valve when it just begins to lift F, x Area of c/s of the valve t = 1x 7 x 60 = 2827.4334N Maximum deflection y, = y,+ y’=30+15 = 45mm Refer Fig. 20.6/Fig. 11.4 Also maximum deflection y, 20.31/Fig. 11.4 ie, 45 = ie, F,— 2827.4334 = 0.3333F, Maximum load F, = 4241.15N Design the spring for maximum load and maximum deflection similar to the previous Example.286 Design of Machine Elements - II Example : 4.21 Design a helical compression spring for a service load ranging from 2250 N to 2750 N. The axial deflection of the spring for the load range is 6mm. Assume a spring index of 5, permissible shear stress ‘of 420 Mpa and modulus of rigidity of 84 kN/mm?, [VTU, June/July 2011] Data: Maximum load F, = 2750N; y' =6mm; c=5 Minimum load F, = 2250N; t= 420 Mpa = 420 N/mm? G=84kN/mm? =. 84 x 10° N/mm? Solution : YF _6x2750 F,-F (2750-2250) Maximum delection y, = =33 mm ---- 20.31/Fig. 14 Design the spring for maximum deflection and maximum load 1. Diameter of wire 8F,Dk Shear streest = —7> > 20.22/11.1G ad 4 Stress factork = oe 1.3105 D Spring index e = >= 5 +. D=Sd aes HORNS Pent ++ Diameter of spring wire d = 10,452mm Select standard diameter of wire from Table 20.12 (Oldy11.2; +. d=10.5mm 2. Diameter of coil Mean diameter of coil D = 5d=5 x 10.5=52.5mm Outer diameter of coil D,=D+d=52.5+105=63 mm Inner diameter of coil D,=D-d =525-105=42mm 3. Number of coils 85D": 3 Maximum deflection y, = ice =~ 20.29/11. a 8x2750%52.5* xi ie, 3 = —— oe 105" x 84x10 ie, i= 10.584 +. Number of active coils i = 11 4, Free length i, = Gtndty,ta 20.Sorings 287 82750525? x11 a <—=343mm 105* x84x10 Actual maximum deflection y, = 2 25 Clearance a= 25% Maximum deflection =“), *343 = 8.575 mm ‘Assume squared and ground end ¢ Number of additional coil n = 2. ood, = (11 + 2)10.5 + 34.3 + 8.575 2 179.375 mm 5. Piteh =2d _ 179375-2x105 p= au a = 14.4 mm Table 20.14/11.4 6. Required stiffness or Required rate of Spring F, _ 2750 B= y, = gg =8333N/mm =~ 20.30/11.7(a) 7. Actual stiffness or Actual rate of spring aG 1 84000 gop SS RED over --~- 20.30/11.7(a) 2 8x11x525 8, Total length of wire 1 = mDi=nx 52.5 x 13 where = 2144, 137 mm Spring specification i) Wire diameter d= 10.5 mm (ii) Mean coil diameter D = 52.5 mm iii) Free length /, =179.375 mm (iy) Total number of turns i = 13 ¥) Style of end - Squared and ground (i) Pitch p= 14.4 mm “i) Required rate of spring F, = 83.33 N/mm (viti) Actual rate of spring F, = 8.182 N/mm 4.14 CONCENTRIC OR COMPOSITE SPRINGS A concentric spring is used for one of the following purposes: i) To obtain greater spring force within a given space. ii) To insure the operation of a mechanism in the event of failure of one of the springs, Assume both the springs are made of same material, then maximum shear stress induced in oth the springs is approximately the same