Spring Design Calculation.

With Front Suspension Spring Ratio of 0.96 and Front Suspension and tire stiffness of 30N/mm the
spring stiffness should be less than 31.25N/mm

ASTM A401 Material is used

Material Properties:

A=1974;

m=0.108;

S= A/(d^m) ( Ultimate Tensile strength of Material ) N/mm^2

Sy=0.45*S ( Yield shear strength of Material ) N/mm^2

Se=0.2*S (Endurance shear limit of Spring )

Formula:

d=12mm

D=133mm

Na = 5

C=D/d ( Spring Index )

Kw =((4*C)-1)/((4*C)-4) + (0.615/C) ( Wahls correction Factor )

G=77200 ( N/mm^2 ) ( Shear Modulus )

F=(3.142*(d^3)*Sy)/(8*Kw*D) ( N ) ( Spring Load )

k=((d^4)*G)/(8*(D^3)*Na) (N/mm) (Spring Stiffness )

Fmax= F/(1+0.15) (N )

Ks=1+(1/(2*C)) (Correction Factor for Fatigue loading )

F1=4900 ( Max load on Front tires )

F2=4477

Fa=(F1-F2)/2

Fm=(F1+F2)/2

S2=(F1*8*D*Kb)/(3.142*(d^3));

Ta=(Fa*8*D*Kb)/(3.142*(d^3));

Tm=(Fm*8*D*Ks)/(3.142*(d^3));
n=Sy/S2 (Static Factor of Safety)
ns=(Sy/((Tm-Ta)+((2*Ta*Sy)/Se))) (Fatigue Factor of Safety)
Calculation:

d=12mm ( wire diameter )

D=133mm ( Spring Outer Dia )

Na = 3 ( Number of Active Coils )

C=D/d (Spring Index )

C=11.08

S= A/(d^m) ( Ultimate Tensil strength of Material ) N/mm^2

S=1509.6 N/mm

Sy=0.45*S ( Yield shear strength of Material ) N/mm^2

Sy=754.81 N/mm

Kw =((4*C)-1)/((4*C)-4) + (0.615/C)
Kw=1.1185

F=(3.142*(d^3)*Sy)/(8*Kw*D)
F=3408.4N

k=((d^4)*G)/(8*(D^3)*Na)
k=28.351 N/mm

Fmax= F/(1+0.15)
Fmax=2964N

Ks=1+(1/(2*C)) ( Soderberg Correction Factor for mean stress)

Ks= 1.045

F1 = Max Load during Fatigue Loading.

F1 = [(2000Kg mass of Vehicle)*(Front Suspension Weight Distribution)-Unsprung mass
of Front Suspension*(9.8)]/[(Front Spring Ratio)*(number of front wheels)]

F1 = [((2000)*(0.52)-(85))*9.8]/[0.96*2]
F1 = [(1040-85)*9.8]/[1.92]
F1 = 4874 N

F2 = = [(1800Kg mass of Vehicle)*(Front Suspension Weight Distribution)-Unsprung mass

of Front Suspension*(9.8)]/[(Front Spring Ratio)*(number of front wheels)]
F2 = [((1800)*(0.52)-(85))*9.8]/[0.96*2]
F2 = 4343 N

Fa=(F1-F2)/2
Fa=265.5 N
Fm=(F1+F2)/2
Fm=4608.5 N

SSL=(F2*8*D*Kb)/(3.142*(d^3)); (Shear stress on Spring at Laden Condition )

SSL=961.6335 N/mm^2

SAL = (Fmax*8*D*Kb)/(3.142*(d^3)); ( Max allowable shear stress ).

SAL = 656.2476 N/mm^2

Sa=(Fa*8*D*Kb)/(3.142*(d^3));
Sa= 59 N/mm^2

Sm=(Fm*8*D*Ks)/(3.142*(d^3));
Sm= 943.8479

Se= 0.2*S ( Shear endurance Limit of material )

ns = SAL/ SSL (Static Factor of Safety)

ns = 0.6824

nf = (Sy/((Sm-Sa)+((2*Sa*Sy)/Se))) ( Soderberg formula to calculate the Spring

fatigue factor of safety )

nf = 0.6401

Spring Design Table:

Laden Load on each Front Spring = F2

Laden Load on each Front Spring = 4343N

-------------------------------------------------------------------------------------
Spring # 1 Spring # 2 Spring # 3 Spring # 4 Spring # 5

d (mm) 12 13 13.5 14 15
D (mm) 133 133 133 133 133
Na ( Coils ) 3 4 5 5 6
k (N/mm) 28.351 29.28 27.28 31.5 32.34
Fmax Spring 2963.8 3698 4103.8 4535.9 5412.8
( N )
ns 0.6824 0.8515 0.9449 1.044 1.2463
nf 0.6401 0.8014 0.893 0.9899 1.1816
Refrence:

Machine Design by RS Khurmi and Gupta 14 th Edition:

Design_of_Helical_Springs.pdf

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