Tutorial 5 Josephine Bakewa ID – A00224059

What are the objectives of a spring?

The primary objective of a spring is to store and release mechanical energy, typically through
compression, tension, or torsion. The specific objectives of a spring can vary depending on the
application, but some common objectives include:
1. Provide a restoring force: A spring can provide a force that opposes deformation and returns
a system to its original state. For example, a spring in a suspension system of a vehicle
provides a restoring force that keeps the wheels in contact with the road.
2. Absorb shock or impact: Springs can also be used to absorb energy from a shock or impact,
preventing damage to the system. For example, springs are used in shock absorbers in
vehicles to absorb the impact of uneven road surfaces.
3. Control motion: Springs can be used to control the motion of a system by adding resistance or
damping. For example, springs in a door hinge can control the speed and motion of the door.
4. Maintain a constant force: Springs can be designed to maintain a constant force over a certain
distance or range of motion. For example, a constant force spring can be used to ensure
consistent tension on a cable or wire.
5. Provide flexibility: Springs can provide flexibility in a system, allowing for movement or
adjustment. For example, springs in a mechanical keyboard provide flexibility and resilience
for the keys.
Overall, the objectives of a spring are to provide a reliable and efficient means of storing and releasing
mechanical energy for a wide range of applications.

What is the curvature effect in a helical spring? How does it vary with spring index?

The curvature effect in a helical spring refers to the unequal shearing strain that occurs in the inner
and outer segments of a spring when it is subjected to torsion. This effect arises because the inside
length of the spring segment is relatively shorter than the outside length, particularly in springs where
the wire diameter is comparable to the coil diameter. As a result, there is a greater shearing strain in
the inner segment than in the outer segment.

The curvature effect varies with the spring index, which is the ratio of the mean coil diameter to the
wire diameter. When the spring index is low, the coils are less tightly wound and the curvature effect
is less pronounced. As the spring index increases, the coils become more tightly wound and the
curvature effect becomes more significant. At very high spring indices, the curvature effect can cause
localized plastic deformation or even failure in the wire. Therefore, it is important to consider the
curvature effect when designing helical springs, especially those with high spring indices or subjected
to high stresses.
What are the major stresses in a helical spring?

The major stresses in a helical spring include:

Bending Stress: This stress occurs due to the bending of the wire as the spring is compressed or
extended. The maximum bending stress is usually located at the innermost and outermost layers of
the wire, where the curvature is the greatest.
Torsional Stress: This stress occurs due to the twisting of the wire as the spring is subjected to a
torsional load. The maximum torsional stress occurs at the surface of the wire.

Shear Stress: This stress occurs due to the shearing of the wire as the spring is compressed or
extended. The maximum shear stress is usually located near the neutral axis of the wire.

Residual Stress: This stress is present in the wire due to the manufacturing process of the spring, such
as coiling and heat treatment. Residual stress can affect the performance and reliability of the spring.

It is important to design a helical spring that can withstand these stresses without experiencing plastic
deformation or failure. The choice of materials, wire diameter, coil diameter, number of coils, and
spring index can all affect the stress distribution in the spring.

Define the types of springs with images and its applications.

Helical springs- consists of a
wire wound in a helix shape,
with the ends of the wire either
touching or crossed over each
other. These springs can be
designed to exert force in
either compression or tension,
depending on the direction of
the helix and the way the ends
are finished.
Working Principle: When a
helical spring is compressed or
stretched, it stores potential
energy within its coils. The
amount of energy stored is
proportional to the force
applied to the spring, as well as
the distance that the spring is
compressed or stretched.
When the force is released, the
spring returns to its original
shape, releasing the stored
energy in the process.
Torsion spring-
Torsion springs are helical
springs that are designed to
resist twisting forces. These
Construction: Helical springs are used
in construction applications, such as
door hinges, window mechanisms,
and elevator systems
Automotive Suspension:
Helical springs are
commonly used in
automotive suspension
systems to absorb shock
and provide a smooth ride
Industrial Machinery:
Helical springs are used in
a wide range of industrial
machinery applications,
including compressors,
pumps, and shock
absorbers.
Consumer Goods: Helical
springs are used in a
variety of consumer goods,
such as watches, toys, and
furniture.
Aerospace: Helical springs
are used in aerospace
applications, such as
landing gear, engines, and
satellite systems.
Medical Devices: Helical
springs are used in a
variety
of medical devices, such as
implantable devices,
prosthetics, and surgical
instruments.
springs work by applying
torque or twisting force along
the axis of the spring, which
causes it to deflect or deform.
Extension Springs:
Extension springs are helical
springs that are designed to
resist tensile forces. These
springs work by applying a
force that stretches the spring,
which causes it to deflect or
deform
They are commonly used
in a wide range of
applications including
hinges, clothespins, and
door handles.
They are commonly used
in a wide range of
applications including
garage doors, trampolines,
and toys.
Constant Force Springs:
springs that generate a
constant force throughout
their deflection range.
They are made of flat spring
steel strip and are typically
formed into a spiral shape.
Working principle: curvature
of the strip changes as it is
wound into a spiral, creating a
built-in tension that is released
when the spring is extended or
deflected. This built-in tension
provides a nearly constant
force throughout the deflection
range of the spring.
Belleville Springs:
Belleville springs are conical
disc springs that are designed
to handle high loads in small
spaces.
Working principle: based on
the principle of elastic
deformation. When a load is
applied to the spring, the
washer is flattened and the
spring deflects in the axial
direction. The deformation of
the spring results in a restoring
force that is proportional to the
amount of deformation. This
makes the Belleville spring an
Retractable Devices:
Constant force springs are
commonly used in
retractable devices, such
as tape measures,
retractable pens, and cable
reels, to provide a
consistent and reliable
retraction force.
Automotive Industry:
Constant force springs are
used in a variety of
automotive applications,
such as in seat belts and
tensioners, to provide a
constant force and
maintain a consistent level
of tension.
Medical Devices: Constant
force springs are used in
various medical devices,
such as in orthodontic
braces, catheters, and
implantable devices, to
provide a constant force
over an extended period of
time.
Valves and Pumps:
Belleville springs are
commonly used in valves
and pumps to maintain
constant pressure and to
prevent leaks.
Clutches and Brakes:
Belleville springs are used
in clutches and brakes to
apply and release pressure
on friction plates.
Aerospace: Belleville
springs are used in
aerospace applications,
effective solution for such as in landing gear
applications that require high mechanisms and wing
force in limited space. flaps, to provide high force
in limited space.

Power Plants: Belleville

springs are used in power
plants, such as in turbine
and generator assemblies,
to provide high force in a
compact space.

Heavy Machinery:
Belleville springs are used
in heavy machinery, such
as in mining and
construction equipment,
to absorb shock and
vibration.
Leaf spring- a type of spring
that are commonly used in the
suspension systems of vehicles,
particularly in heavy-duty
applications such as trucks and
trailers. Leaf springs are made
up of several thin, flat, and
curved metal plates that are
stacked on top of each other
and clamped together at both
ends.
Working principle:
based on Hooke's Law, which
states that the force exerted by
a spring is directly proportional
to the distance that the spring
is compressed or extended.
When a load is applied to a leaf
spring, the plates of the spring
bend and store potential
energy. As the load is removed,
the spring returns to its original
shape and releases the stored
energy, creating a restoring
force.
Vehicle Suspension: Leaf
springs are widely used in
the suspension systems of
vehicles, particularly in
heavy-duty applications
such as trucks and trailers.
They provide a smooth
ride by absorbing the
shock and vibration of the
road.
Agriculture Equipment:
Leaf springs are used in
agricultural equipment,
such as plows and
cultivators, to provide
suspension and dampening
of shocks and vibrations.
Construction Equipment:
Leaf springs are used in
construction equipment,
such as cranes and
excavators, to absorb
shock and vibration and
provide a smoother
operation.
Railway Industry: Leaf
springs are used in railway
industry, such as in railcars
and locomotives, to
provide suspension and
absorb the shock and
vibration of the track.
Military Vehicles: Leaf
springs are used in military
vehicles, such as tanks and
armored personnel
carriers, to provide
suspension and absorb the
shock and vibration of
rough terrain.
Mechanical Fasteners
Define mechanical fasteners (complete explanation). Are hardware devices that are used to join or
connect two or more objects together. They can be made of a variety of materials, including metal,
plastic, and composite materials, and can take many different forms. Some common types of mechanical
fasteners include screws, bolts, nuts, washers, rivets, and clips.

The primary function of mechanical fasteners is to hold objects together securely, even when subjected
to high stress or loads. They are used in a wide range of applications, from assembling electronic devices
to constructing bridges and buildings. Mechanical fasteners are often preferred over other joining
methods, such as welding or adhesives, because they are generally easier to install and remove, require
fewer specialized tools, and are often more cost-effective.

Sketch a standard threaded nomenclature of a bolt, label and explain the parts.

The main parts of a bolt are:

1. Head: The head of the bolt is the top portion that is turned with a tool, such as a wrench or
socket, to tighten or loosen the bolt. It is usually hexagonal in shape, but can also be square,
 round, or other shapes depending on the specific application.

2. Shank: The shank of the bolt is the unthreaded portion between the head and the threaded
portion. It is often referred to as the "neck" of the bolt.

3. Threaded portion: The threaded portion of the bolt is the section that is inserted into a
threaded hole or nut to create a secure connection. The threads are usually cut into the bolt
using a thread-cutting tool or a thread-rolling machine.

In addition to these main parts, there are also several other elements that are important to the
nomenclature of a bolt, including:

4. Thread pitch: The thread pitch is the distance between the crest of one thread and the crest
of the next thread. It is usually expressed in threads per inch (TPI) or millimeters per thread
(MPT).

5. Thread diameter: The thread diameter is the major diameter of the thread, which is the
distance between the crests of the opposite threads. It is also known as the nominal
diameter.

6. Overall length: The overall length of the bolt is the distance from the bottom of the head to
the end of the shank.

7. Thread length: The thread length is the length of the threaded portion of the bolt, measured
from the end of the shank to the start of the head.

A helical spring of wire diameter 6mm and spring index 6 is acted by an initial load of 800N. After
compressing it further by 10mm the stress in the wire is 500MPa. Find the number of active coils. G =
84000 MPa.

Solution:
 8 FD
T max= ( K W ) 3 where, T max=stress
πd

4 C−1 0.615
KW = +
4 C−4 C

D= C ( springindex ) × d

d=wire diameter

F= force