Material Selection for spring using Material Index

Tanuj Gupta
21205267
Department of Mechanical Engineering, IIT Kanpur

Introduction – Spring is a mechanical element use to store energy as a potential energy. It

is generally elastic member. There are different types of spring as per its application just like,
in car suspension system it is used to absorb shock and vibration, in toys it is used to store
energy, in spring balance system it is used to measure force, and to apply force and control
the motion of different mechanical system.

Objective – To select the best material for the application of helical spring.
Primary function –
 Stiffness
 Shear modulus/Torsional modulus
 Shear strength/Torsional strength
 tanδ
 Elongation
 Resilience
 Fatigue strength

Secondary function –
 Fracture toughness
 Hardness
 Endurance limit

Tertiary function –
 Spring Constant
 Thermal Expansion
 Young’s modulus
Constraints – Size of spring like coil diameter and wire diameter is given. Its length is also
specified.

Free Variable – Choice of material

Spring
A spring is an elastic and resilient member which deflect when the load is applied and regain
its original shape when material is removed. The main function of spring is to store energy.
Type of mechanical spring
Mechanical spring can be classified in to following types –

1. Helical Spring
2. Conical and volute Spring
3. Torsion Spring
4. Laminated or leaf Spring
5. Disc or Belleville Spring
6. Special Purpose Spring

1. Helical Spring – Helical spring is made of wire which is in coiled form as a helical
shape. It is one of the most used form of spring.

Fig.1: Helical spring

Helical spring is categorise as –

a. Closed coil helical spring – The angle of helix in the closed coil helical spring is less
than10o . This type of spring is used in tension application.
b. Open coil helical spring - The angle of helix in the closed coil helical spring is less
than10o . This type of spring is used to resist compression.

2. Conical and volute Spring – This is conical type of spring similar to helical one and
mainly used for compression application. In daily life we can see this type of spring is
used in watch or remote battery section.
 Fig 2: Conical Spring

3. Torsion Spring – In this type of spring stored energy when twisting occur. When
twisting occur a torque is generated in opposite direction when it is removed it regain
its original shape. It is widely used in clips and in mouse.

Fig 3: Torsional Spring

4. Leaf spring – It is an arc shape spring made up of different length metal strips placed
one over other it is widely used in suspension system of commercial vehicles. This
type of spring is used to bear large force in small area.

Fig 4: Leaf Spring

 5. Disc spring - Disc or Belleville spring is a conical shape washers held together by
bolt or tube. It is non-flat, conical shell spring which generally bear loads axially. This
type of spring provide high load in small area by exerting constant pressure through
the object.

Fig 5: Disc Spring

6. Special Purpose Spring – Air spring, extension spring, gas spring grater spring is
example of special purpose spring this spring is not widely used it is mainly design
for specific purpose.

Fig 6: Special Purpose Spring

Resilience - Density
Resilience is the maximum energy stored up to the elastic limit without any permanent
deformation, this energy is also released when the load is removed
1
U = σ ×∈
2
2
σ
U=
2E
Where, σ is the failure load and ∈ is the strain corresponding stress.
The material which have large value of U is good for spring.
2
σ
P 1=
E

Fig 7: Strength, Modulus of Elasticity Chart

Material Modulus of Strength σ2

Elasticity (MPa) (MPa) =P 1
E

Aluminium alloy 76 571 4290.013

Carbon fibre reinforced
Composite 150 1050 7350
Titanium alloy 120 1190 11800.83
Medium C steel 220 1190 6436.818
Ni alloy 220 1180 6329.091
Mg alloy 47 450 4308.511
Table 1: Strength, Modulus of Elasticity based performance index
From the table we can see that titanium alloy has a maximum stored energy with in the elastic
limit followed by medium carbon steel.
Minimum weight for a given energy stored

()
2
σ
ρ
P 2=
E
ρ
2
σ
P 2=
ρE

Fig 8: Specific Strength, Specific Modulus of Elasticity Chart

Material Specific Modulus Specific Strength σ

2
=P2
ρE

Aluminium alloy 0.026761 0.201056 1.510568

Carbon fibre reinforced
Composite 0.09375 0.65625 4.59375
Titanium alloy 0.025052 0.248434 2.46364
Medium C steel 0.028205 0.152564 0.825233
Ni alloy 0.025346 0.135945 0.729158
Mg alloy 0.024103 0.230769 2.209493
Table 2: Specific Strength, Specific Modulus of Elasticity based performance index
From the table we can see that CFRC has highest material index among all materials so it has
highest energy stored per unit weight followed by Titanium alloy.

Fig 9: Resilence, Price Chart

Material σ2 Cost ( C m ) σ 2 Cm
=P =P 3
ρE ρE

Aluminium alloy 1.510568 302 456.1915

Carbon fibre reinforced
Composite 4.59375 2630 12081.56
Titanium alloy 2.46364 1680 4138.914
Medium C steel 0.825233 53.4 44.06745
Ni alloy 0.729158 1350 984.3632
Mg alloy 2.209493 117 258.5106
Table 3: Cost and performance index

In this table we consider energy stored per unit weight and consider the cost parameter for
calculation of material index we can see that Medium carbon steel has best material after
considering weight and cost effect followed by Mg alloy.
Toughness vs strength
It measure the resistance of the material to resist the crack or surface abrasion.

σ
K IC=Y
√ πc
K IC
P=
σ

Fig 10: Strength, Fracture Toughness Chart

Strength (σ f )
( )
Material Fracture K IC 3
Toughness × 10 =P
σf
( K IC) (MPa.m0.5)
Aluminium alloy 41 571 71.80385
Carbon fibre reinforced
Composite 20 1050 19.04762
Titanium alloy 86.1 1190 72.35294
Medium C steel 71.9 1190 60.42017
Ni alloy 251 1180 212.7119
Mg alloy 18 450 40
Table 4: Strength, Fracture Toughness based performance index
 K IC Cm σ f
=P
Material σf Cost (₹ /kg) P 4= 2
K IC

Aluminium alloy 71.80385 302 21.68476

Carbon fibre
reinforced Composite 19.04762 2630 50.09524
Titanium alloy 72.35294 1680 121.5529
Medium C steel 60.42017 53.4 3.226437
Ni alloy 212.7119 1350 287.161
Mg alloy 40 117 4.68
Table 5: Cost and performance index
Thermal expansion-thermal conductivity chart
Almost all solid expand on heating it is a basic property of material, the relation between
thermal expansion coefficient and change is length is
1 dl
α=
l dT
Where l is linear length of spring, α is thermal expansion coefficient dT is change in
temperature.
λ
P=
α

Fig 11: Thermal Expansion, Thermal Conductivity Chart

Material Thermal Thermal λ

P 5=
Expansion Conductivity α

Aluminium alloy 24.6 185 7.520325

Carbon fibre reinforced
Composite 4 2.6 0.65
Titanium alloy 9.8 8.99 0.917347
Medium C steel 13.5 54 4
Ni alloy 14.3 14.6 1.020979
Mg alloy 28 126 4.5
 Table 6: Thermal Expansion, Thermal Conductivity based performance index

Fracture toughness - Density

K IC=Y σ c √ πa (1)

σc 4 M
= (2)
N π r3

m=π r 2 Lρ ( 3 )

r=
√ m
πLρ
(4)

Then equation (2) becomes,

σc 4M
=
N m 3 /2
π[ ]
πLρ

√
3 3
πL ρ
σ c =4 MN (5)
m3

From equation (1),

√
3 3
πL ρ
K IC=Y . 4 MN . √ πa
m3

2 2 1
ρ
m=( 4 Y MN ) 3 π 3 a 3 .( 2 /3
)
K IC

2 2 1
( 4 Y MN ) π a Is constant.
3 3 3

Thus, performance index 6,

( )
2/3
K IC
P 6=
ρ maximum
 Fig 12: Fracture Toughness, Density Chart

( )
Material Fracture Density ( ρ ) K IC
2/3

Toughness P 6=
ρ max
( K IC) (MPa.m0.5)
Aluminium alloy 41 2840 0.004187
Carbon fibre reinforced
Composite 20 1600 0.004605
Titanium alloy 86.1 4790 0.004071
Medium C steel 71.9 7800 0.002217
Ni alloy 251 8680 0.004584
Mg alloy 18 1950 0.003522
Table 7: Fracture Toughness, Density based performance index

2
3
Material offer greatest toughness to weight ratio for spring (C) = K Ic
ρ

C increase when spring offer greatest toughness to weight ratio lies towards top
left corner.
Hardness – Density

Fig 13: Hardness Testing

From the empirical relationship

σ TS=500∗HBN

STS ρ=500∗HBN

Where;
σ TS= Tensile strength
STS = Specific tensile strength
HBN = Brinell hardness

Performance index 7,

P= ( HBN
ρ ) maximum
≃ ( Hρ )
maximum
 Fig 14: Hardness, Density Chart

Material Density( ρ ) Hardness (H) H

=P
(Mg/m3) (VH) ρ

Aluminium alloy 2840 168 0.059155

Carbon fibre reinforced
Composite 1600 21.5 0.013438
Titanium alloy 4790 373 0.077871
Medium C steel 7800 415 0.053205
Ni alloy 8680 400 0.046083
Mg alloy 1950 135 0.069231
Table 8: Density, Hardness based performance index

H
=P Cm ρ
Material ρ Cost (₹ /kg) P 7=
H
Aluminium alloy 0.059155 302 17.86479
Carbon fibre
reinforced Composite 0.013438 2630 35.34063
Titanium alloy 0.077871 1680 130.8225
Medium C steel 0.053205 53.4 2.841154
Ni alloy 0.046083 1350 62.21198
Mg alloy 0.069231 117 8.1
Table 9: Cost and performance index
Thermal Expansion - Density
∆ L=α L L ∆ T (1)

2
m=π r Lρ (2)

α L m∆ T
∆ L= 2 (3)
πr ρ

2
∆ Lπ r ρ
m= (4)
αL∆ T

Shaft has fixed length. Thus, it is increase with the stress-

σL
∆ L= (5)
E

From equation (4) and (5),

2
σLπ r ρ
m= (6)
∆ TE α L

( σLπ r 2
∆T )
is constant.

Thus, performance index,

P= ( ) E αL
ρ maximum
 Fig 15: Thermal Expansion, Density Chart

Material Density( ρ ) Thermal Eα

=P 8
(Mg/m3) expansion ρ
coefficient (α )
(μstrain/oc)
Aluminium alloy 2840 24.6 0.65831
Carbon fibre reinforced
Composite 1600 4 0.375
Titanium alloy 4790 9.8 0.245511
Medium C steel 7800 13.5 0.380769
Ni alloy 8680 14.3 0.362442
Mg alloy 1950 28 0.674872
Table 10: Thermal Expansion, Density based performance index
Fracture toughness vs modulus of elasticity

The elastic energy per unit volume stored in the spring is the integral over the volume
of
1
U = σε
2
If fracture means failure then the maximum energy spring can store

( )
2 2
max c K IC
U =
2 πa E
Energy is maximize for material which has large value of
2
K IC
P=
E
 Fig 16: Fracture Toughness, Young’s Modulus Chart

Material Fracture Modulus of K 2IC

Toughness Elasticity (E) =P
E
( K IC) (MPa.m0.5)
Aluminium alloy 41 76 22.11842
Carbon fibre reinforced 150
Composite 20 2.666667
Titanium alloy 86.1 120 61.77675
Medium C steel 71.9 220 23.49823
Ni alloy 251 220 286.3682
Mg alloy 18 47 6.893617
Table 11: Fracture toughness, Modulus of Elasticity based performance index

2
K IC Cm × E
=P P 9=
Material E Cost (₹ /kg) K 2IC
Aluminium alloy 22.11842 302 13.65378
Carbon fibre
reinforced Composite 2.666667 2630 986.25
Titanium alloy 61.77675 1680 27.1947
Medium C steel 23.49823 53.4 2.272512
Ni alloy 286.3682 1350 4.714211
Mg alloy 6.893617 117 16.97222
Table 12: Cost and performance index
 Mechanical loss coefficient vs modulus of elasticity

Fig 17: Mechanical Loss Coefficient, Young’s Modulus Chart

ηE=C
P=ηE
η=Mechanical loss coefficient

Material tan(δ) E (GPa) ηE = P

Aluminium alloy 0.044 76 3.34
Carbon fiber reinforced 0.0033 150 0.495
Composite
Titanium alloy 0.002 120 0.24
Medium C steel 0.00089 220 0.1958
Ni alloy 0.0007 220 0.154
Mg alloy 0.02 47 0.94
Table 13: Mechanical loss coefficient, Young’s Modulus based performance index
 Cm
Material ηE = P Cost (₹ /kg) P 10=
ηE
Aluminium alloy 3.34 302 90.42
Carbon fibre 0.495 2630 5313.13
reinforced Composite
Titanium alloy 0.24 1680 7000
Medium C steel 0.1958 53.4 272.72
Ni alloy 0.154 1350 8766.23
Mg alloy 0.94 117 124.46
Table 14: Cost and performance index
Mechanical Loss Coefficient - Density
Mechanical loss coefficient
loss modulus
tanδ=
Storage modulus
tanδ Represent the energy dissipation of the system. It should be high so that temperature
of the system is in control.
tanδ
P=
ρ
P should be maximized as the density should be minimum.

Fig 18: Mechanical Loss Coefficient, Density Chart

Material tan(δ) Density ( ρ ) tanδ

P=
ρ

Aluminium alloy 0.044 2840 3.87324E-07

Carbon fiber reinforced 0.0033
Composite 1600 2.0625E-06
Titanium alloy 0.002 4790 4.17537E-07
Medium C steel 0.00089 7800 1.14103E-06
Ni alloy 0.0007 8680 8.06452E-08
Mg alloy 0.02 1950 1.02564E-05
Table 15: Mechanical loss coefficient, Young’s Modulus based performance index
 tanδ
P= Cm ρ
Material ρ Cost (₹ /kg) P 11= ×106
tanδ
Aluminium alloy 3.87324E-07 302 779.7090909
Carbon fibre 2630
reinforced Composite 2.0625E-06 1275.151515
Titanium alloy 4.17537E-07 1680 4023.6
Medium C steel 1.14103E-06 53.4 46.8
Ni alloy 8.06452E-08 1350 16740
Mg alloy 1.02564E-05 117 11.4075
Table 16: Cost and performance index
Thermal Expansion (α) vs Modulus of Elasticity
σ
=α t ∆ T
E
σ
=α t E
∆T
P=αE

Fig 19: Thermal Expansion Coefficient, Young’s Modulus Chart

Material Thermal Expansion E (GPa) αE = P12

(α)
(μstrain/oc)
Aluminium alloy 23.3 76 1770.8
Carbon fiber reinforced 4 150 600
Composite
Titanium alloy 9.8 120 1176
Medium C steel 13.5 220 2970
Ni alloy 14.3 220 3146
Mg alloy 28 47 1316
Table 17: Thermal Expansion, Modulus of Elasticity based performance index
Strength – Shear Modulus
τ Gθ
=
J L
G = Torsion rigidity
θ = Angle of twist of shaft
L=Length of shaft
Now put the value of section modulus and radius in terms of mass and then rearranging the
equation we get,

( )
3 1
2 L ρJ 2
m=
θπ

( )
1
τ 2
P=
G

Fig 20: Shear strength, Shear Modulus Chart

Material Strength (τ ) Shear Modulus
( )
1
τ 2
G(GPa) P=
G

Aluminium alloy 341 28 3.48

Carbon fibre reinforced 1050 60 4.18
Composite
Titanium alloy 1190 45 5.14
Medium C steel 1190 85 3.74
Ni alloy 625 86 2.69
Mg alloy 205 19 3.28
Table 18: Strength, Shear modulus based performance index

( ) ( )
1 1
τ 2 G 2
P= P 13=Cm
Material G Cost (₹ /kg) τ

Aluminium alloy 3.48 302 86.78

Carbon fibre 4.18 2630 629.18
reinforced Composite
Titanium alloy 5.14 1680 326.84
Medium C steel 3.74 53.4 14.27
Ni alloy 2.69 1350 501.85
Mg alloy 3.28 117 35.67
Table 19: Cost and performance index
Fatigue strength – Strength

Fig 21: Fatigue strength, Tensile strength Chart

σ e =K σ ut

σe
P=
σ ut

Material Strength (σ f ) Fatigue strength τe

P=
(τ e) (MPa) σf
Aluminium alloy 341 136 0.3988
Carbon fibre reinforced 1050 300 0.2857
Composite
Titanium alloy 1190 636 0.5344
Medium C steel 1190 483 0.4058
Ni alloy 625 625 1
Mg alloy 205 125 1.64
Table 20: Strength, Fatigue Strength based performance index
 τe Cm × σ f
Material P=
σf
Cost (₹ /kg) P 14=
τe
Aluminium alloy 0.3988 302 757.27
Carbon fibre 0.2857 2630 9205.46
reinforced Composite
Titanium alloy 0.5344 1680 3143.71
Medium C steel 0.4058 53.4 131.59
Ni alloy 1 1350 1350
Mg alloy 1.64 117 118.64
Table 21: Cost and performance index
Strength – Hardness

Fig 22: Tensile strength, Hardness Chart

HV =
2 F sin ( α2 )
d2
F
HV ≈
d2
HV =500 ×σ
σ
P=
HV

Material Strength (σ f ) Hardness (H)

P=
σ
(HV) HV

Aluminium alloy 341 116 2.94

Carbon fibre reinforced 1050 21.5 48.83
Composite
Titanium alloy 1190 373 3.19
Medium C steel 1190 415 2.86
Ni alloy 625 400 1.56
Mg alloy 450 135 3.33
Table 22: Strength, Hardness based performance index

σ
P= Cm × HV
Material HV Cost (₹ /kg) P 15=
σ
Aluminium alloy 2.94 302 102.72
Carbon fibre 48.83 2630 53.86
reinforced Composite
Titanium alloy 3.19 1680 526.64
Medium C steel 2.86 53.4 18.67
Ni alloy 1.56 1350 865.38
Mg alloy 3.33 117 35.1
Table 23: Cost and performance index
Performance Material Weighta
Index Aluminium Titanium Medium ge
alloy CFRP alloy C steel Ni alloy Mg alloy (ai)
P1 471.87 7350 11800.8 6436.82 6329.09 4308.51 0.05
P2 1.51057 4.59375 2.46364 0.82523 0.72916 2.20949 0.05
P3 456.192 12081.6 4138.91 44.0675 984.363 258.511 0.2
P4 21.6848 50.0952 121.553 3.22644 287.161 4.68 0.1
P5 7.520325 0.65 0.917347 4 1.02098 4.5 0.04
P6 0.004187 0.004605 0.004071 0.00222 0.00458 0.003522 0.1
P7 17.86479 35.34063 130.8225 2.84115 62.2119 8.1 0.05
P8 0.65831 0.375 0.245511 0.38077 0.36244 0.674872 0.05
P9 13.65378 986.25 27.1947 2.27251 4.71421 16.97222 0.05
P10 90.42 5313.1 7000 272.72 8766.2 124.46 0.02
P11 779.7091 1275.152 4023.6 46.8 16740 11.4075 0.015
P12 1770.8 600 1176 2970 3146 1316 0.02
P13 86.78 629.18 326.84 14.27 501.85 35.67 0.15
P14 757.27 9205.5 3143.7 131.59 1350 118.64 0.1
0.02P15 102.72 53.86 526.64 18.67 865.38 35.1 0.02
15 15

∑ P i ai 2557.299 41466.77 16154.58 783.384 9889.92 1202.798

∑ ai=1
i=1 i=1

From the above performance we can see that medium carbon steel has least value so it is
most suitable material for spring application point of view as well as medium carbon steel is
economical to use in a daily life appliences. After medium carbon steel we ca see that Mg
alloy has second least value so that it is also favourable material after medium carbon steel up
to some extemt.
To design a helical spring of maximum force of 1200 N The deflection of the spring
corresponding to maximum force is 28 mm. The spring index can be taken as 6. The spring is
made up of steel wire the ultimate design strength and modulus of rigidity of the material is
1090 and 81370 N /mm2 respectivelly. The permissible shear strength for the spring wire is
should be taken as 50% of the ultimate tensile strength.

P = 1200 N
C=6
δ=28 mm
D = 42 mm
2
Sut =1090 N / mm

G = 81370 N / mm2
τ =0.5 S ut

Wire diameter
τ =0.5 S ut =0.5 ×1090 = 545 N / mm2

4 C−1 0.615
K= +
4 C−4 C
4 (6)−1 0.615
K= + =1.2525
4(6)−4 6

τ =K
( )
8 PC
πd
2

545=1.2525
( 8× 1200×
πd
2
6
)
d=6.29 mm≈ 6.5 mm

No of active coils

8 P D3 N
δ=
G d4

8 × 1200× 423 × N
28=
81370 ×6.54
N=5.71 ≈ 6 coils
Total no. of coils
It is assumed that spring has square and the ground end. The number of inactive coil is 2.
Therefore
N t =N +2

N t =8 coils

Free length of spring

The actual deflection of the spring is given by
3
8PD N
δ=
G d4
3
8(1200)(42) 6
δ=
81370× 6.54
δ =29.38 mm
Solid length of spring
L=N t d=8 ×6.5

L=52

It is assumed that there will be gap of 1 mm between consecutive coils. When spring is
subjected to maximum force total number of coil is 8
Total axial gap between the coil is ¿ ( 8−1 ) × 1=7

Free length=Solid length+Total axial gap+ δ

Free length=52+7+29.38=88.38 mm

Pitch of the coil

Free length
Pitch of the coil=
N t −1

88.38
¿ =12.62 mm
8−1
Design again fluctuating load
The mean force Pm and amplitude force Pa is given as
1
Pm= ( P max + Pmin )
2
1
Pa= ( P max−P min )
2

The mean stress is calculated by mean force by using shear correlation factor

τ m=K s ( 8 Pm D
πd
3 )
K s = 1+( 0.5
C )

τ=
( )
8PD
πd
3
Kw

K w =1.12

δ c Gd
τ min= Kw
π D2
Assume deflection in spring is range of 14 - 28 mm
14 × 81370× 6.5
τ min= 2
× 1.12
π × 42 ×8

τ min=155.809 N /mm 2
28 ×81370 × 6.5
τ max= 2
×1.12
π × 42 × 8
2
τ max=311.618 N / mm

( τ min +τ max ) 2
τ m= =233.713 N /mm
2

( τ max −τ min ) 2
τ a= =77.90 N /mm
2
Endurance stress of medium carbon steel is 360 MPa our generated stress in the spring is less
than the endurance value so our spring is design with in the safe limit.
Innovation –
 Medium carbon steel is one of the best material for mild corrosive environment.
However coating of Nickel alloy can be done for to increase the life of spring.
 If spring is used in such an environment where salt water is present so coating of
Nickel Cobalt alloy is to be done.
 Zinc coating provides corrosion resistance with minimum risk of hydrogen
embrittlement.
 Low temperature heat treatment can be done to improve the toughness and the fatigue
life of the spring.

Conclusion – Medium Carbon steel is the best material for the application of the spring.
When I find the material index of material – density and between two properties with
consider cost is an important parameter we find that medium carbon steel has the lowest
value so it is most suitable among all the six material which is shortlisted to analyse it
performance based on different indexes. For increasing the service life of spring some coating
is also done which make the material resistance to the external environment and improve its
mechanical properties up to some extent.
References
[1] Michael F. ASHBY, Material selection in mechanical Design, Butterworthm
Heinemann, 1999.
[2] CES Edupack.
[3] https://www.springhouston.com/services/corrosion-and-wear-prevention.html
[4] http://www.springhouston.com