SPRINGS

A spring is defined as an elastic machine element, which deflects under the action of the load
and returns to its original shape when the load is removed.

Applications of springs

• Springs are used to absorb shocks and vibrations, e.g., vehicle suspension springs,
railway buffer springs, buffer springs in elevators and vibration mounts for
machinery.

• Springs are used to store energy, e.g., springs used in clocks, toys, movie-cameras,
circuit breakers and starters.

• Springs are used to measure force, e.g., springs used in weighing balances and scales.

• Springs are used to apply force and control motion.

• In the cam and follower mechanism, spring is used to maintain contact

between the two elements.

• In engine valve mechanism, spring is used to return the rocker arm to its
normal position when the disturbing force is removed.

• The spring used in clutch provides the required force to engage the clutch.

In all these applications, the spring is used either to apply the force or to control the motion.
 Types of Springs
Helical spring
The helical spring is made from a wire, usually of circular cross-section, which is bent
in the form of a helix. There are two basic types of helical springs; compression spring and
extension spring as shown in Fig. 1.

(a) Compression Spring (b) Extension Spring

Advantages of Helical Springs

• Easy to manufacture.

• Cheaper than other types of springs.

• Reliability is high.

• Deflection of the spring is linearly proportional to the force acting on the spring.
 Helical torsion spring
• A helical torsion spring (Fig. 2) is similar to that of compression or extension spring,
except that the ends are formed in such a way that the spring is loaded by a torque
about the axis of the coils.

Fig.2 Helical Torsion Spring;

• Helical torsion spring is used to transmit torque to a particular component in the

machine or the mechanism.

Multi-leaf or laminated spring

• A multi-leaf or laminated spring consists of a series of flat plates, usually of semi-

elliptical shape as shown in Fig. 3.

• The flat plates, called leaves, have varying lengths. The leaves are held together by
means of U-bolts and a centre clip.

• The longest leaf is called the master leaf, is bent at the two ends to form spring eyes.

• The leaves of multi-leaf spring are subjected to bending stresses. Multi-leaf springs
are widely used in automobile and railroad suspensions.

Fig.3 Semi-elliptic Leaf Spring;

 Terminology Of Helical Springs
• For a helical spring (Fig.
4) subjected to
compressive force :
d = wire diameter of spring (mm)

Di = inside diameter of spring coil (mm)

Do = outside diameter of spring coil (mm)

D = mean coil diameter (mm)

• Spring index is denoted by the letter C. The

spring index is defined as the ratio of mean coil
diameter to wire diameter.

The spring index indicates the relative sharpness of the curvature of the coil. A low
spring index means high sharpness of curvature.
 ➢ When the spring index is low (C < 3), the actual stresses in the wire are excessive due
to curvature effect.

➢ When the spring index is high (C > 15), it results in large variation in the coil
diameter.

➢ A spring index from 4 to 12 is considered best from manufacturing considerations.

(i) Solid Length:

• It is the axial length of the spring which is so compressed that the adjacent coils touch
each other.

• The spring is completely compressed and no further compression is possible.

Solid length = Nt x d

where,

Nt = total number of coils

Compressed Length
 • It is defined as the axial length of the spring, which is subjected to maximum
compressive force. (maximum deflection δ. )

• There should be some gap or clearance between the adjacent coils. The gap is
essential to prevent clashing of the coils (clashing allowance is usually taken as 15%
of the maximum deflection).

In this case, the total axial gap is given by,

Total gap = (Nt – 1) x Gap between adjacent coils

Free Length

• The axial length of an unloaded helical compression spring.

• In this case, no external force acts on the spring. Free length is an important
dimension in spring design and manufacture. It is the length of the spring in free
condition prior to assembly. Free length is given by,

free length = compressed length + δ

= solid length + total axial gap + δ

Pitch of the coil is the axial
distance between adjacent coils
in uncompressed state of spring
 Stiffness
Stiffness of the spring is
defined as the force required
to produce unit deflection
k= stiffness of the spring
(N/mm)
W= axial spring force
δ= axial deflection of the
spring
The total turns of the spring include the Inactive turns and Active turns

Active Turns or coils : The coils or turns which undergo deformation when external force is
applied, are called as active turns (N)

In active Turns or coils (N') : The coils which are in contact with the seat where load is
applied or at the support and they do not deflect when the load is applied. The number of
Inactive coils depend upon the end conditions.