6 Springs

Springs
A spring is an elastic member whose primary function

is to deflect under load & thus absorbs energy. It
recovers its original shape when the load is removed.
Springs may be used to;
1. cushion the effect of a shock or impact loading.
2. To maintain contact between two elements such as
a cam & its follower.
3. To measure forces as in spring balance, or to apply
forces as in brakes, clutches, cylinder valves, etc.
4. To store energy as in watch springs.
P R Venkatesh Mech Dept RVCE Bangalore
Types of Springs
Springs are mainly classified as;
1. Helical compression springs
2. Helical extension springs
3. Torsion springs
4. Laminated or leaf springs
5. Disc or Belleville springs.

Compression Springs
Extension springs
Torsion
springs

Semielliptical Leaf Springs
Disc or Belleville Springs
Stresses in Helical Spring of circular wire
Consider a helical compression spring made of
circular wire subjected to a load ‘F’ as shown in fig.
d
T
F
D
Let D= Mean diameter of the coil
d=Diameter of the spring wire
i=Number of active coils
G=Modulus of rigidity of spring material
c=spring index=(D/d)
=Maximum shear stress induced in the wire
y=deflection of the spring
The action of the force tends to
(i) rotate the wire, thereby causing torsional stresses
‘ ’ in the wire.
(ii) Cause direct shear stress ‘ ’ due to direct shear force.
FD
(i) Twisting moment T which is equal & opposite to the
2
d3 1
resisting moment of the circular wire where
16
1 torsional shear stress produced by a couple in pure shear.
8FD
Equating the two, we get 1
d3
4F
(ii) Direct shear stress 2
d2
Hence the maximum stress induced in the wire
8FD 4 F 8FD d 8FD 1
1 2 1 1
d3 d2 d3 2D d3 2C
Taking the stress concentration due to curvature of the
spring wire into account,
K 8FD 4C - 1 0.615
where k Wahl' s stress factor
d3 4C - 4 C
D
' C' being the spring index
d
Axis of spring
combined stress taking curvature

Pure shear stress Direct shear stress
effect into account
For the equations, refer Page 169.

shear stress ......11.1d Page 169
Wahl’s factor K…….11.2a Page 169
Spring index C ………11.2c Page 169
Deflection of helical spring :
Tl
By torsion equation, angle of twist
GJ
FD
where the twisting moment T
2
Length of the wire l Di
d4
Polar moment of inertia J . Substituti ng the above values,
32
FD Di 32 16FD 2i
2 G d4 Gd 4
D D 16FD 2i 8 FD 3i
Axial deflection y 4 4
11.5a Page 170
2 2 Gd Gd
Spring scale OR Spring rate OR Stiffness
F d 4G
F0 3
11.7 a Page 170
y 8iD P R Venkatesh Mech Dept RVCE Bangalore
Problem 1
Design a helical compression spring to support an
axial load of 3000 N, the deflection under the load
being limited to 60 mm. The spring index is 6. The
spring is to be made of chrome-vanadium steel & a
factor of safety is 2.
Data: F=3000N, y=60 mm, C=(D/d)=6, FOS=2
e/FOS) where e is elastic limit in torsion for

chrome-vanadium steel.
From Table 11.8, page 153, for chrome vanadium steel,
(Column. No 9 & 10)
Elastic limit in torsion e =690 Mpa
Rigidity modulus G=78450 Mpa
Applying Factor of safety of 2, the allowable shear stress
=(690/2)=345 Mpa (N/mm2).
1. Diameter of the wire:
8FDK 8 FCK D
Shear stress (as C )
d3 πd 2 d
where K Wahl' s stress factor
4C - 1 0.615
K 1.2525
4C - 4 C
8 3000 6 K
345 d 12.89mm 13mm
πd 2
2. Mean diameter of the coil :
D Cd 6 13 78 mm
Inside dia of coil Di ( D d ) (78 13) 65mm
Outside dia of coil D o ( D d ) (78 13) 91mm
3.Number of active turns (coils) :
8FD 3i 8 3000 783 i
Deflection y 4
60 4
i 11.8 12 turns
Gd 78450 13
4.Free length of the spring : For squared & ground ends, free length
lo (i 2)d y a 11.18 a Page 174
where a clearance between wo rking coils under maximum load
Take a 25% of maximum deflection 25% of 60 15 mm
lo (12 2)13 60 15 257mm

Table 11.4 Page 189
Different types of spring coil ends
Plain end Ground Square end Square & Ground

lo 2d 257 2 13
5. Pitch : p 19.25 mm T 11.4 (d ) P 189
i 12
6.Stiffness or Spring rate :
F 3000
Fo 50N/mm
y 60
Specifications :
(i) Material : Chrome - Vanadium steel
(ii) Wire diameter d 13 mm
(iii) Mean coil diameter D 78mm
(iv) Free length lo 257mm
(v) Total number of turns i ' 14
(vi) style of ends : - Squared & ground
(vii) Pitch p 19.25 mm
(viii) Spring rate Fo 50P RN/mm
Venkatesh Mech Dept RVCE Bangalore
Problem 2
Design a helical compression spring for a safety valve.
The valve must blow off at a pressure of 1.2 Mpa &
should lift by 3 mm for 5% increase in pressure. The
valve diameter is 60 mm. The maximum allowable
shear stress is 400 MN/m2 & the modulus of rigidity
is 82.7 GPa. Take spring index as 8.
Data: p1= 1.2 Mpa, p2=1.05p1=1.26 Mpa,
valve dia Dv=60 mm , C=(D/d)=8, G=82.7x103Mpa
pa
2
Dv 602
Initial load on the spring F1 p1 1.2
4 4
F1 3392.92 N
2
Dv 602
Maximum load on the spring F2 p2 1.26
4 4
F2 3562.57 N
F2 F2 F1
From fig 11.4a, page 170, '
where y' is the compression
y2 y
of the spring as force changes from F1 to F2 . Here y' 3 mm
F2 y ' 3562.57 3
y2 63mm
F2 F1 (3562.57 3392.92)
Now, for design, maximum load & corresponding deflection
have to be considered. Hence F 3562.57 N, y 63 mm.
1.Diameter of the wire :
8 FDK
Shear stress 3
d
4C - 1 0.615 4 8 - 1 0.615
K 1.184
4C - 4 C 4 8-4 8
8 3562.57 8d 1.184
400 3
d 14.66 15mm
d
2.Mean Diameter of the coil :
Mean coil dia D 8 d 8 15 120 mm
Inside dia of coil D i ( D d ) (120 15) 105mm
Outside dia of coil D o ( D d ) (120 15) 135mm
3.Number of active coils :
8 FD 3i 8 3562.57 1203 i
y 63 i 5.35 6 turns
Gd 4 82.7 Mech10
P R Venkatesh
3
15
Dept RVCE
4
Bangalore
4.Free length of the spring :
lo (i 2)d y a (6 2)15 63 0.25(63)
lo 198.75mm
( clearance 25% of maximum deflection)
5.Pitch of the coil :
lo 2d 198.75 2 15
p 28.125mm
i 6
6.Stiffness or spring rate :
F 3562.57
Fo 56.55 N/mm
y 63 P R Venkatesh Mech Dept RVCE Bangalore
Energy stored by a spring: When a spring is gradually
loaded from zero to maximum force F within the elastic
limit, the work done by the force in stretching the spring
is stored as ‘Strain energy or Resilience’ denoted by ‘U’.
1
U Fy , where y is the deflection of the spring.
2
Load F stress area A
Deflection y Strain length l where

E
E elastic modulus, l length of the spring
2
1 l
Strain energy U A V
2 E 2E
where V A PlR Venkatesh
Volume of the spring
Mech Dept RVCE Bangalore
Load F
0
Deflection y
Work done on the spring=shaded area=(1/2) x F x y

Proof Resilience :
The maximum energy stored in the body witho ut
permanent deformation (i.e. upto elastic limit) is
known as ' Proof Resilience'.
Hence if the elastic limit stress is e , then
2
Ve
Proof resilience .
2E
Total strain energy
Modulus of resilience
volume of the elastic body
2 2
Ve 1 e
2E V
P R Venkatesh Mech Dept RVCE Bangalore 2E
Note:
1. When ‘n’ springs are used to absorb the energy
of a body of mass ‘m’ moving at a velocity ‘v’,
the kinetic energy of the moving body is
converted into strain energy (or resilience) of
the spring.
1 2 1
Hence we can equate mv Fy n, where
2 2
n number of springs used (in parallel)
F force on each spring
y deflectionof springs
2. When ‘n’ springs are used to absorb
the energy of a freely falling body of
weight ‘W’ the potential energy of the
falling body is converted into strain
energy (or resilience) of the spring.
1
Hence we can equate W(h y) F y n
2
where
F Force on each spring,
h height of fall,
y deflectionof springs,
n number of springs (set in parallel)
Problem 3
A railway wagon weighing 40 KN and moving
with a speed of 10 Kmph has to be stopped by
four buffer springs in which the maximum
compression allowed is 200 mm. Find the
number of turns in each spring of mean diameter
150 mm. The diameter of the spring wire is 25
mm. Take G=82.7 Gpa.
Velocity of wagon v :
1000 5
v 10 kmph 10 10 2.778 m/sec
3600 18
1 W 2 40 103 2.7782
Kinetic energy v 15733Nm
2 g 2 9.81
K .E 15733 103 Nmm
1
Equating K.E & Resilience of the springs ' U' F y n
2
where n number of springs (in parallel)
3 1
15733 10 F 200 4
2
Load on each spring F 39333 N
1.Number of active turns :
3 3
8 FD i 8 39333 150 i
y 4
200
Gd 82.7 103 254
i 6.08 6 turns
(Assume sqaured & ground ends)
lo (i 2)d y a (6 2)25 200 0.25(200) 450 mm
3.Pitch of the coils :
lo 2d 450 2 25
p 66.67 mm
i 6
F 39333
4.Stiffness : Fo 196.66 N/mm
y P R Venkatesh
200Mech Dept RVCE Bangalore
Problem 4
Design a spring for an elevator shaft at the
bottom of which 8 identical springs are set in
parallel to absorb the shock of the elevator in
case of failure. The weight of elevator is 60 KN &
the counter weight is 20 KN. The elevator has a
free fall of 1.5 m from rest. The spring is made of
25 mm diameter rod.
Determine the maximum stress in each spring, if
the spring index is 6 & each spring has 15 active
turns. Take G=84 Gpa.

Weight of falling body :
W Weight of elevator - counter weight (60 - 20) 40 KN
D
Spring index C Mean coil dia D Cd 6 25 150mm.
d
Potential energy W (h y ) 40 103 (1500 y )
1
Energy absorbed by the 8 springs F y 8
2
Equating P.E & Resilience of the springs
3 1
40 10 (1500 y ) F y 8
2
F y 15 106 104 y (i)
Deflection of spring :
3 3
8 FD i 8 F 150 15
y 4 3 4
0.01234F
Gd 84 10 25
Substituti ng for y in (i), we get
F(0.01234F) 15 106 104 (0.01234F)
F2 1215.56 106 104 F F 2 104 F 1215.56 106 0
Solving, load on each spring F 40217.4 N
Deflection y 0.01234F 0.01234 40217.4
y 496.4mm
Shear stress induced in the spring
8 FDK 8 40217.4 150 1.2525 2
1231. 4 N/mm
πd 3 253
SURGE IN HELICAL SPRINGS
• When one end of a helical spring is resting on a rigid
support & the other end is loaded suddenly, that end
coil takes up whole of the deflection.
• Then it transmits a large part of it to adjacent coils
which propagates a wave of compression to the fixed
end, which is reflected back to the deflected end.
• If the applied load is of fluctuating type as in case of
valve spring, & the frequency of load application is
equal to the frequency of the compression wave
through the spring, Resonance occurs.
• As a result of this, very large deflections & high stresses
occur due to which the spring may fail.
• This phenomenon is known as Surge in springs.
Surge in springs may be eliminated;
(i) By using friction dampers to suppress the
wave propagation.
(ii) By using springs of high natural frequency.
(iii)Using different pitch for coils at the center
& the end coils so as to have different
natural frequencies.

The natural frequency of the spring when one end is at rest
1 2 Fo g
f , where F0 is in N/mm, g 9810 m/sec2
2 W
Fo
f 22.3 Hz 11.22 a Page 177
W
where W weight of spring Weight density volume
For steel, Mass density 7800 kg/m 3
weight density 7.65 10-5 N/mm 3
d2
Volume of spring V Di 11.9 Page 171
4
The natural frequency of the spring when both ends are fixed,
1 2 Fo g Fo
f 31.5 Hz 11.22(b) Page 177
W W
Problem 5
The spring used in an automobile engine has to exert
500N when the valve is closed and 600 N when the
valve is opened. The displacement of the valve is
5mm. The engine crankshaft rotates at 8000 rpm.
Design the spring for permissible shear stress of 300
Mpa. The spring index is 6, the density of spring
material 7.35x10-5N/mm3 & rigidity modulus is 80 Gpa.
The ends are square & ground.
Inspect the suitability of the spring for this engine. At
what speed of the engine does the spring resonate?

Note:
1. After complete design, Suitability of spring is
checked w.r.t buckling or Crippling load Fcr given
by equation Fcr=Fo Kl lo----11.19a Page 175,
where load factor Kl is obtained from fig 11.7(a)
page 175. For safe design, Fcr > F.
2. As the cam shaft speed which controls the
valves is half the engine speed, the engine
speed for resonance=2xNatural frequency of
valve springs.

Data: F1=500 N, F2=600N, y’=5 mm, C=6, =300 Mpa
Specific weight or weight density=7.35x10-5 N/mm3
End styles: square & ground.
Solution: The spring must be designed for maximum
load i.e. F2, & deflection y2.
F2 y ' 600 5
y2 30 mm.
F2 F1 600 500
1. Diameter of the wire :
8FDK 8 600 6d 1.2525
Shear stress 300
πd 3
d 3
d 6.186 mm 6.3 mm (Standard size)

2. Mean diameter of the coil :
D Cd 6 6.3 37.8 mm
Inside dia of coil D i ( D d ) (37.8 6.3) 31.5mm
Outside dia of coil D o ( D d ) (37.8 6.3) 44.1mm
3.Number of active turns (coils) :
8FD 3i 8 600 37.83 i
Deflection y 4
30
Gd 80 103 6.34
i 14.58 15 turns
4.Free length of the spring : For squared & ground ends,
free length lo (i 2)d y a 11.18 a Page 174
where a clearance between working coils under maximum load
Take a 25% of maximum deflection 25% of 30 7.5 mm
lo (15 2)6.3 30 0P.25 (30) 144.6mm
R Venkatesh Mech Dept RVCE Bangalore
lo 2d
144.6 2 6.3
5. Pitch : p
i 15
p 8.8mm T 11.2(d ) P152
6.Stiffness or Spring rate :
F 600
Fo 20N/mm
y 30
Check for buckling :
lo 144.6
Fcr Fo kl lo where load factor kl for 3.83
D 37.8
and for built in ends (fig.11.3, page 157), is 0.63
Fcr 20 0.63 144.6 1822N 600N (max load)
Hence the design isP Rsafe.
Venkatesh Mech Dept RVCE Bangalore
The natural frequency of the spring when both ends are fixed :
1 2 Fo g F
f 31.5 o Hz
W W
where W weight of spring Weight density volume
πd 2 6.32
Volume of spring πDi V 2
37.8 15 55527mm 3
4 4
W 7.35 10 5 55527 4.08N
Spring rate Fo 20N/mm
Hence natural frequency of springs(camshaft)
20
f 31.5 69.74 Hz Critical speed 69.74 60
4.08
Critical speed of cam shaft 4185 rpm.
Critical speed of engine at which the springs surge
2 critical speed of camshaft 8370 rpm.
As the engine speed 8000 rpm, (below 8370),the springs are safe
for operation. P R Venkatesh Mech Dept RVCE Bangalore
Helical springs of Non circular Cross sections
Rectangular or square cross section springs are
used to obtain greatest load capacity in limited
space.
F b
b=width
h
h=depth m=(b/h)
Spring index
C=D/b if b<h
Fig 11.2 (b)

Page 156 D
• For rectangular cross section refer equations 11.14,
11.14a & 11.14b page 140 & 141.
• For square cross section springs, refer equations, 11.16
& 11.17 page 141.
Problem 9
A diesel engine weighs 800 KN is mounted on 16
springs in order to prevent vibration of the
building. The section of the spring is rectangular
with side ratio=1.8 & the longer side is parallel
to its axis. Each spring has 4 active coils & spring
index is 6. Determine (i) the cross section (ii)
Deflection of spring (iii) Maximum coil dia. Take
G=80 Gpa & =300 Mpa.
800 103
Load on each spring F (as there are 16 springs) 50000N
16
1.Diameter of the wire :
KFD (1.5h 0.9b)
Shear stress ' 2 2
bh
4C - 1 0.615 D b
K where C as 1 (given h 1.8b);
4C - 4 C b h
4 6 - 1 0.615
K 1.2525
4 6-4 6
1.2525 50000 6b(1.5 1.8b 0.9b)
300 2 2
b 37.5mm
b (1.8b)
Mean coil dia D 6 b 6 37.5 225 mm
Height of cross section h 1.8b 67.5 mm.
2.Deflection under load :
2.83iFD 3 (b 2 h2 ) 2.83 4 50000 2253 (37.52 67.52 )
y
b 3h 3G 37.53 67.53 80 103
y 29.63mm P R Venkatesh Mech Dept RVCE Bangalore
3.Inside & outside (maximum) dia of coil
Di ( D b) (225 37.5) 187.5mm
Do ( D b) (225 37.5) 262.5mm (Max dia of coil)
Note :
Shear stress induced if shorter side is parallel to axis;
put h 37.5mm & b 67.5 mm (i.e.interchange the values)
in the equation of shear stress.
1.2525 50000 225(1.5 37.5 0.9 67.5)
'
67.52 37.52
' 257.3Mpa

Problem 10
A railway car weighing 18 KN and moving at a speed
of 72m/min is brought to rest by a buffer consisting
of 2 helical springs of square cross section. In
bringing the car to rest, the spring undergoes a
deflection of 0.25m. The allowable shear stress for
the steel wire is 0.3 Gpa. Spring index=6. Rigidity
modulus G=84 Gpa. Design the spring and show the
dimensioned sketch of the spring section.
Load on each spring :
Given W 18KN 18 103 N, Velocity of rail car V 72m / min
72
V 1.2m / sec. Deflection y 0.25 m 250 mm
60
3
1 W 1 18 10
K.E of rail car V2 1.2 2 1321.1Nm
2 g 2 9.81
K.E of rail car 1321.1 103 Nmm
1
Resilience or Energy stored by springs U Fy n
2
1
where n number of springs. Here n 2, U F 250 2 250F N mm
2
Equating the K.E of rail car to energy stored by the springs,
1321.1 103 250F Load on each spring F 5284.4N

1.Cross section of the spring :
2.4 KFD
Shear stress ' 3
 Eq.11.16, page 141
h
4C - 1 0.615 D D
K where C or (as b h for square section);
4C - 4 C b h
4 6 - 1 0.615
K 1.2525
4 6-4 6
2.4 1.2525 5284.4 6h
300 3
h b 17.82mm 18 mm
h
Mean coil dia D 6 h 6 18 108 mm
2.Number of active coils :
' 5.66iFD 3 5.66 i 5284.4 1083
y 4
250
hG 184 84 103
Number of active turns i 58
P R Venkatesh .51
Mech 59Bangalore
Dept RVCE turns
lo (i 2)h y a (Assuming square & ground ends)
lo (59 2)18 250 0.25(250) 1410.5 mm
4.Pitch of the spring :
lo 2h 1410.5 2 18
p 23.3 mm
i 59
5. Spring rate or Stiffness :
F 5284.4
Fo 21.14N/mm
y 250

Springs subjected to Fatigue loading
• The helical springs are never subjected to
reversed loading (tensile to compressive and vice
versa) but only repeated loading which may vary
from zero to maximum.
• Hence the Soderberg diagram is modified for
springs as shown in fig, where the failure line
starts from the point ( en/2, en/2) as
mean stress=stress amplitude= en/2 , where en
is the endurance limit in torsion.
• The soderberg relation can be obtained by
drawing a safe line parallel to failure line by
applying a suitable factor of safety F.S
Torsional shear stress
en
a m
Time
Pulsating stress cycle

Stress amplitude
A
Soderberg
failure line
C
en
Soderberg
P safe line
R
S Q
O en
D B
m y F.S
y
Mean stress
Modified Soderberg diagram for helical springs
Consider a point P on the safe line. From similar
triangles PQD & ASB, we have,
en
PQ AS PQ AS a 2
QD SB OD OQ OB OS y en
m y
F .S 2
a en
y 2 y en
m
F .S
Upon simplification we get,
1 m a 2 a
which is the modified equation for springs
F.S y en

Note:
• The shear stress amplitude is calculated by the
stress equation by replacing F by (Fmax-Fmin)/2
• For calculating stress amplitude, the Wahl's stress
factor K must be used.
• The mean shear stress is calculated by the stress
equation by replacing F by (Fmax+ Fmin)/2
• For calculating mean stress, the shear stress
factor K must be used. (K 1+0.5/C)

Problem 11
The load on a steel helical compression spring
varies from 500 N to 1200 N. The spring index is
6 & the desired design factor of safety is 1.3.
Determine the required wire size by taking the
yield shear stress as 690 MN/m2 & the
endurance limit stress as 300 MN/m2.
Data: Fmin=500 N, Fmax =1200 N, C=6, n=1.3,
en=300 Mpa, y=690 Mpa.
1.Mean stress & stress amplitude :
8D Fmax Fmin
Mean shear stress τ m K
d3 2
1 0.5
where K Shear stress factor 1 1 1.0833
2C C
8 6d 1200 500 14068.86
m 1.0833
d3 2 d2
8D Fmax Fmin
Amplitude of shear stress τ a K 3
d 2
4C - 1 0.615 4 6 - 1 0.615
K 1.2525
4C - 4 C 4 6-4 6
8 6d 1200 500 6697.87
τ a 1.2525
d 3 P R Venkatesh2Mech Dept RVCE Bangalored 2
Soderberg equation :
1 m a 2 a
F .S y en
1 14068.86 6697.87 2 6697.87

2 2
1.3 d 690 d 300
1 55.335
2
1.3 d
wire diameter d 8.48mm 8.5mm
Mean coil diameter D 6d 6 8.5 51 mm.
Problem 12
A helical compression spring is made of 6 mm dia
stainless steel wire & carries a fluctuating load.
The spring index is 6 & the factor of safety is 1.5.
If the average (mean) load on the spring is 500N,
find the permissible values of the maximum &
minimum loads. The tensile strength of the wire
is 1350 N/mm2. Take shear strength at yield as
0.5 ut & the shear endurance limit as 0.22 ut.
Data:
wire dia d=6 mm
Spring index C=6 i.e. D=6d=6x6=36 mm
Factor of safety F.S=1.5
Average or Mean load=(Fmax+Fmin)/2=500 N
Given en=0.22 ut=0.22(1350)=297 Mpa
y=0.5 ut=0.5(1350)=675 Mpa
To find: Fmax & Fmin

Mean stress & stress amplitude :
8 D Fmax Fmin
Mean shear stress τ m K
d3 2
1 0.5
where K Shear stress factor 1 1 1.0833
2C 6
8 36
m 1.0833 3
500 229.883Mpa
6
8 D Fmax Fmin
Amplitude of shear stress τ a K 3
d 2
4C - 1 0.615 4 6 - 1 0.615
K 1.2525
4C - 4 C 4 6-4 6
8 36 Fmax Fmin
a 1.2525 3
Fa 0.532Fa where Fa
6 P R Venkatesh Mech Dept RVCE Bangalore 2
Modified Soderberg equation for helical springs :
1 m a 2 a
F .S y en
1 229.883 0.532Fa 2 0.532Fa

1 .5 675 297
1
0.3406 2.794 10 3 Fa
1 .5
Fmax Fmin
Amplitude of force Fa 116.69 N 116.69 N
2
i.e.( Fmax Fmin ) 233.38N But by data Fmax Fmin 1000N ,
Solving, Fmax 616.69 N & Fmin 383.31N
Leaf springs
• Leaf springs are made out of flat plates.
• These can support lateral loads and act as a structural
member in addition to absorbing shocks.
• For flat springs (single leaf) (fig 11.10 page 180)
equations refer Page 179, equation numbers 11.27(a) to
11.34.
• For multi leaf springs (fig 11.11, P 181) refer Page 180,
equation numbers 11.28(a) to 11.28 (c).
• For laminated springs (fig 11.12, P 182) refer equations
11.30(a) to 11.32c, Page 182.

h F
Front view
b Top view
Fig 11.10 (a) Page 180 (Cantilever spring)

b-= width of plate, h= thickness of plate, l= length of
plate or distance of load F from fixed end.
Consider a single plate fixed at one end and loaded at the other end.
The maximum bending moment M F l
bh3
I 12 bh2 M
Section modulus Z Bending stress
c h 6 Z
2
F l 6 Fl C1 Fl
 Eq11.27 (a ) page 179
bh2 bh2 bh 2
6
where C1 6 from T 11.9 P 198
The maximum deflection for a cantilever with concentrated load
at the free end is given by
Fl 3 Fl 3 4 Fl 3 C2 Fl 3
y 3
 Eq11.27(b) P 179
3EI 3E bh Ebh3 Ebh 3
12
where C 2 4 from T 11.9 P198
F b'
F
h h
l Front View
l
Top View b'

b=ib'
A plate of width ‘b’ can be sliced into a number of slices i of

width b’ stacked one below the other. Such a stack of leaves
is called multi leaf springs.
For multi leaf springs , replace the term b by ib’ in the
equations.
Problem 13
Design a cantilever spring of length 0.6 m to
absorb 800 Nm of energy with a deflection of
0.1m. The permissible stress in the leaves is 600
Mpa. E=206.8 Gpa. Take total number of leaves
as 10.
Data: Energy absorbed U=800 Nm
l=0.6m=600 mm, y=0.1m=100 mm, =600 Mpa
E=206.8 Gpa=206.8x103 Mpa, no of leaves i=10.
width of plate b=ib’=10b’ where b’=width of each
leaf.
Fy F 0.1
Energy stored by the spring U 800
2 2
Force at the end of cantilever F 16000 N.
C1 Fl
Maximum stress 2
where C1 6 from Table 11.9, P 198
ib' h
(For cantilever type a in fig 11.10 (a), page 180
6 16000 600
600 2
b' h 2
9600mm 3
 (1)
10 b' h
C 2 Fl 3 4 16000 6003
Deflection y 3
100
Eib' h 206.8 103 10 b' h 3
b' h 3 66.847 10 3 mm 4  (2)
Dividing eq (2) by eq (1), we get h 6.963 mm 7 mm.
i.e thickness of leaves h 7 mm.
9600
Width of the leaves b' 195.18mm 196mm.
7 Dept RVCE Bangalore
P R Venkatesh Mech
2
F
h Front view
2l
b Top view
Fig 11.10(d) P 180 (Simply supported beam spring)

Consider a simply supported beam of length 2l with a central load ' F'.
F
The maximum bending moment M l
2
bh3
I 12 bh2 M
Section modulus Z Bending stress
c h 6 Z
2
F l
2 3Fl C1 Fl
 Eq11.27(a ) page 179
bh2 bh2 bh 2
6
where C1 3 from T 11.9 P 198
The maximum deflection for a simply supported beam with concentrated load
F at the centre is given by
3
Fl 3 F 2l 2 Fl 3 C2 Fl 3
y 3
 Eq11.27(b) P 179
48EI 48 E bh Ebh3 Ebh 3
12
where C 2 2 from T 11.9 P 198
Determine the width & thickness of a flat spring
carrying a central load of 3500 N. The deflection is
limited to 30 mm. The spring is supported at both
ends at a distance of 650 mm. The allowable stress
is 345 N/mm2 & modulus of elasticity 207 Gpa. The
spring is of constant thickness & varying width.
h
2l

Data : F 3500N, 2l 650 l 325 mm, σ 345 Mpa, y 30mm
Maximum stress in the spring
C1 Fl
2
 Eq11.27(a) page 179 where C1 3 from T 11.9 P198
bh
(for type (e) beam, Fig 11.10, page 180)
3 3500 325
345 2
bh 2
9.8913 103
 (i )
bh
The maximum deflection' y' is
C2 Fl 3
y 3
 Eq11.27(b) P 179 where C 2 3 from T 11.9 P 198
Ebh
3 3500 3253
30 3 3
bh 3
5 .8043 10 4
 (ii)
207 10 bh
5.8043 104
(ii) (i ) gives h 3
5.868mm 6mm.
9.8913 10
9.8913 103
Width of plate (at the Pcenter) b 2
R Venkatesh Mech Dept RVCE Bangalore
275mm
6
Laminated cantilever springs
A laminated spring is obtained by slicing the
triangular plate as shown & placing the slices one
below the other.
Such an arrangement makes the spring compact
so that the space occupied by the spring is
considerably reduced.
A triangular plate is chosen as the stress will be
uniform throughout. (Beam of uniform strength).

A triangular plate shown can be sliced (as shown by dotted lines)
& stacked to build a laminated leaf spring.
F
l
l
h
h
Full length
leaf
Graduated
leaves
b=ib' b'

Prove that the stress induced in full length leaves of a
laminated spring is 50% more than the stress induced in the
graduated leaves.
Let
if = the number of full length leaves
ig = the number of graduated leaves
b’= width of each leaf
h= thickness of each leaf
l=length of the cantilever
F= applied force at the free end of cantilever
Ff = the load shared by full length leaves
Fg = the load shared by graduated leaves
f = stress induced in the full length leaves
g = stress induced in the graduated leaves
y= deflection of the spring.

For graduated leaves obtained from a triangular plate,
6 Fg l
the bending stress g  (i ) (For type (b) beam fig 11.10, P 180)
ig b' h 2
Also the deflectionin the graduated leaves
6 Fg l 3
yg 3
 (ii) Similarly for the full length leaves,
Ei g b' h
6Ff l
the bending stress f 2
 (iii) & the deflectionin full length leaves
i f b' h
4Ff l 3
yf 3
 (iv) As the deflectionis same for both the full length
Ei f b' h
& the graduated leaves, i.e. y g y f , equating (ii) & (iv ),
6 Fg l 3 4Ff l 3 Fg 2 ig 2 ig
Fg Ff
Ei g b' h 3 Ei f b' h 3 Ff 3 if 3 if
2ig 2ig 3i f
But Fg Ff F Ff 1 F Ff F
3i f 3i f
3i f F
Ff  Eq No 11.29 (c), page 181
2ig 3i f P R Venkatesh Mech Dept RVCE Bangalore
3i f 2i g
Fg (F Ff ) F F F  Eq11.29 (b) P 181
2ig 3i f 2i g 3i f
Substituti ng the values of Ff & Fg in the equations of stress,
6l 2ig
Stress in graduated leaves g F
ig b' h 2 2ig 3i f
12Fl
σg  Eq11.30 (b), page182
b' h 2 (2ig 3i f )
6l 3i f
Stress in full length leaves f F
i f b' h 2 2ig 3i f
18Fl
σf  Eq11.30 (a ), Page 182
b' h 2 (2ig 3i f )
σf 3
1.5 Stress in full length leaves is 50% more than that of graduated leaves
σg 2
6 Fg l 3 4Ff l 3
Deflection y g yf
Ei g b' h 3 Ei f b' h 3
(As the deflectionis same for both the full length & the graduated leaves)
6l 3 2ig 12Fl 3
y 3
F 3
 Eq 11.30 (c), page 182
Ei g b' h 2ig 3i f b'P h E(2ig Mech
R Venkatesh
3i f Dept
) RVCE Bangalore
Semi elliptic laminated Springs
It is most commonly used in automobiles & may
be analyzed as a double cantilever with a load
(F/2) at the ends, where F is the load applied at
the central load.
The width of the central band must be deducted
from span 2l to obtain the effective length of
cantilever.
The equations for stresses induced in full length
leaves, graduated leaves, deflection are given in
Page 182, (11.31a,11.31b, & 11.31c)
2L F/2
F/2
Eye
Master leaf
Central band
Extra full length

leaves
Rebound clip
Graduated leaves
F
Semi elliptic Automotive Leaf Spring

Nipping of Spring leaves (Equalization of stresses)
• The stress in the full length leaves is 50% greater than
that in the graduated leaves.
• For best advantage, all the leaves should be equally
stressed.
• This can be achieved by giving a greater radius of
curvature for full length leaves than the graduated leaves
before assembly. The gap or clearance between the
leaves is called ‘Nip’
• By this, all the leaves are pre stressed due to bolt load
when assembled with the help of a clip bolt.
• When an external load is applied, the pre stress in the
full length leaves is first relieved & then stressed in the
opposite direction, while the graduated leaves are
stressed in the same direction of the load.
• Thus the stresses in both the leaves can be equalized by
adjusting the initial gap ‘c’.
F/2 F/2
Fb Full length leaf
C=Nip
Fb Fb
/2 /2
F
Graduated leaf

Derive expressions for bolt load ‘Fb’, nip ‘c’ & the
equalized stress in a semi elliptic leaf spring.
Upon the application of load F, the total deflection
of graduated leaves will exceed the deflection of full
length leaves by an amount equal to nip or clearance
‘c’. i.e. c=yg-yf.
Let
Fb be the bolt load applied for assembling the leaves
F be the maximum load
b’=width of each leaf, h=thickness of each leaf
l= Effective length, E=elastic modulus of spring.

6 Fg l 3 4Ff l 3
We know that nip c yg yf c 3 3
 (i )
Ei g b' h Ei f b' h
As the nipping equalizes the stressesin the leaves, g f
6Ff l 6 Fg l Fg ig ig
2 2
Fg Ff
i f b' h i g b' h Ff if if
F F ig ig if
But the total load Fg Ff Ff Ff Ff
2 2 if if
if F if F
Ff where i (ig i f ) Total number of leaves.
2(ig if ) 2i
ig F
Similarly Fg . Substituti ng Fg & F f in equation (i) for ' c'
2i
6 Fg l 3 4Ff l 3 3Fl 3 2 Fl 3 Fl 3
c  Eq 11.32a P 182
Ei g b' h 3 Ei f b' h 3 Eib 3
' h Mech
P R Venkatesh Eib 3
' hRVCE Bangalore
Dept Eib' h 3
The load on the clip bolts Fb required to close the gap ' c' is determined by the fact that
Fb
' c' is equal to the sum of initial deflectionof the leaves under the load
2
Fl 3 4l 3 Fb 6l 3 Fb
ib' h 3 E Ei f b' h 3 2 Ei g b' h 3 2
F 2 Fb 3Fb 2 Fbig 3Fbi f Fb (2ig 3i f )
i if ig i f ig i f ig
i f ig F
Load on the clip bolt Fb  Eq 11.32b Page 182
i(2ig 3i f )
Fb
Equalized stress σ Stress in full length leaves due to F - pre stress due to
2 2
6Ff l 6l Fb
σ substituting for Ff & Fb , we get
i f b' h 2 i f b' h 2 2
6l 3i f F 6l i f ig F
i f b' h 2 2ig 3i f 2 i f b' h 2 2i( 2ig 3i f )
3Fl
σf σg 2
 Eq 11.32 c Page 182
ib' h P R Venkatesh Mech Dept RVCE Bangalore
A truck spring has 12 number of leaves , two of
which are full length leaves. The springs are 1m apart
and the central band is 70 mm wide. The central load
is to be 6KN with a permissible stress of 200 Mpa.
Determine the thickness, width & deflection of the
steel spring leaves if the ratio of total depth to width
of the spring is 3. E=206 Gpa.
Data: F=6KN=6000 N
Number of full length leaves if=2
Total number of leaves i=12,
Ratio of total depth to width =(ih/b’)=(12xh)/b’=3
Or b’=4h
Hence number of graduated leaves ig=12-2=10
Effective length l=(1000-70)/2=465 mm,
Max stress Mpa, E=206x103 N/mm2
Since the leaves are not pre stressed,maximum stress
occurs in the full length leaves; Hence σ f 200Mpa
9 Fl 9 6000 465
200
b' h 2 (2ig 3i f ) 4h h 2 (2 10 3 2)
h 10.65 11mm
Thickness of the leaves h 11 mm,
width b' 4h 4 11 44 mm.
Deflection of the spring
6 Fl 3 6 6000 4653
y
b' h 3 E (2ig 3i f ) 44 113 206 103 (2 10 3 2)
y 11.54mm
A locomotive spring has an over all length of 1100 mm and
sustain a load of 75 KN at its centre. The spring has 3 full
length leaves and 15 graduated leaves with a central band
100 mm wide. All the leaves are to be stressed to 0.4 Gpa
when fully loaded. The ratio of total spring depth to width
is 2. Determine (i) Width & thickness of leaves (ii) nip or
clearance to be provided (iii) Load exerted on the band by
the clip bolt after assembly. Take E=206.8 Gpa
Data: F=75KN=75000 N
Number of graduated leaves ig=15
Total number of leaves i=(15+3)=18
Ratio of total depth to width =(ih/b’)=(18xh)/b’=2
Or b’=9h
Equalized stress Gpa=400 Mpa,
E=206.8x103 N/mm 2
3Fl 3 75000 500
Equalized stress σ 2
400
ib' h 18 9h h 2
Thickness of the leaves h 12mm
Hence width of leaves b' 9h 9 12 108 mm.
Initial gap or nip ' c'
3 3
Fl 75000 500
c 13.5mm
ib' h 3 E 18 108 123 206.8 103
Load on the band Fb
ig i f F 15 3 75000
Fb 4807.7 N
i (2ig 3i f ) 18(2 15 3 3)
A multi leaf spring with camber is fitted to the chassis of an
automobile over a span of 1.2 m to absorb shocks due to a
maximum load of 20 KN. The spring material can sustain a
maximum stress of 0.4 Gpa. The spring has 2 full length
leaves out of 8 leaves. The leaves are assembled with bolts
with a central band of width 150 mm. Design the spring
for a maximum deflection of 50 mm. Take E=206.92 Gpa.
Data: F=20KN=20000 N
Total number of leaves i=8
Number of graduated leaves ig=8-2=6
Deflection y=50 mm
Equalized stress Gpa=400 Mpa,
E=206.92x103 N/mm2
3Fl 3 20000 525
Equalized stress σ 2
400
ib' h 8 b' h 2
b' h 2 9843.75mm 3  (i )
6Fl 3
Deflection y
b' h 3 E(2ig 3i f )
6 20000 5253
i.e. 50
b'h 3 206.92 103 ( 2 6 3 2 )
b' h 3 93242.56 mm 4  (ii)
9843.75
(ii) (i ) gives h 9.5 mm, Hence width b' 2
109mm
9.5
Initial gap or nip ' c'
Fl 3 20000 5253
c 18.7mm
ib' h 3 E 8 109 9.53 206.92 103
Load on the band Fb
ig i f F 6 2 20000
Fb 1666.67 N
i (2ig 3i f ) 8(P2R Venkatesh
6 3 Mech2)Dept RVCE Bangalore

6 Springs

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Springs

A spring is an elastic member whose primary function

P R Venkatesh Mech Dept RVCE Bangalore

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combined stress taking curvature

For the equations, refer Page 169.

e/FOS) where e is elastic limit in torsion for

P R Venkatesh Mech Dept RVCE Bangalore

Plain end Ground Square end Square & Ground

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Deflection y Strain length l where

Work done on the spring=shaded area=(1/2) x F x y

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d 6.186 mm 6.3 mm (Standard size)

Fig 11.2 (b)

P R Venkatesh Mech Dept RVCE Bangalore

P R Venkatesh Mech Dept RVCE Bangalore

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Pulsating stress cycle

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P R Venkatesh Mech Dept RVCE Bangalore

P R Venkatesh Mech Dept RVCE Bangalore

1 14068.86 6697.87 2 6697.87

P R Venkatesh Mech Dept RVCE Bangalore

1 229.883 0.532Fa 2 0.532Fa

P R Venkatesh Mech Dept RVCE Bangalore

Fig 11.10 (a) Page 180 (Cantilever spring)

Top View b'

A plate of width ‘b’ can be sliced into a number of slices i of

Fig 11.10(d) P 180 (Simply supported beam spring)

P R Venkatesh Mech Dept RVCE Bangalore

P R Venkatesh Mech Dept RVCE Bangalore

P R Venkatesh Mech Dept RVCE Bangalore

P R Venkatesh Mech Dept RVCE Bangalore

P R Venkatesh Mech Dept RVCE Bangalore

Extra full length

Semi elliptic Automotive Leaf Spring

Fb Full length leaf

P R Venkatesh Mech Dept RVCE Bangalore

P R Venkatesh Mech Dept RVCE Bangalore

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