Springs &

Flywheels
Springs
Springs - refer to mechanical components that are specifically designed to store and
release mechanical energy. They are elastic devices that can deform under the
application of force and then return to their original shape when the force is removed.

Type of Coil Actual no. of Solid Length Free Length

Coils
Ground End n nd np
Plain ends n (n+1)d np+d
Squared and n+2 (n+2)d np+2d
Ground ends
Squared ends n+2 (n+3)d np+3d
Stress in Coil Springs of Round Wire

8𝐾𝐹𝐶 16𝐹𝑟𝑚
𝑆= 𝑆=
𝜋𝑑𝑤 2 𝜋𝑑𝑤 3

Spring Index

𝐷𝑚 𝐷𝑜 − 𝑑
𝐶= =
𝑑 𝑑

𝐷𝑜 + 𝐷𝑖
𝐷𝑚 =
2
Spring Factors

Wahl’s Factor
4𝐶 − 1 0.615
𝐾= +
4𝐶 − 4 𝐶

Bergtrasser Factor
4𝐶 + 2
𝐾𝑏 = ≈ 0.99𝐾
4𝐶 − 3

Concentration Factor/Shear Stress Factor

1
𝐾𝑠 = 1 +
2𝐶
Spring Factors

Curve Correction Factor

𝐾
𝐾𝑐 =
𝐾𝑠

Spring Rate/Spring Constant

𝐹
𝑘=
𝛿
Spring Deflection for Round Wires

8𝐹𝑐 3 𝑛𝑐 64𝐹𝑟𝑚3 𝑛𝑐
𝛿= =
𝐺𝑑𝑤 𝐺𝑑𝑤 4
Length of the Spring

𝐹𝐿 = 𝑆𝐿 + 𝛿𝑚𝑎𝑥
𝐹𝐿 = 𝐶𝐿 + 𝛿

Impact Load on Springs

1 2
𝑊 ℎ+𝛿 = 𝑘 𝛿
2

Bodies with Velocity

1 2
1 2
𝑚𝑣 = 𝑘𝛿
2 2
Strain Energy of a Spring

1 2
𝐸 = 𝑘𝛿
2

Springs in Series

𝐹𝑡 = 𝐹1 = 𝐹2 = 𝐹3
𝛿𝑡 = 𝛿1 + 𝛿2 + 𝛿3

Springs in Parallel

𝐹𝑡 = 𝐹1 + 𝐹2 + 𝐹3
𝛿𝑡 = 𝛿1 = 𝛿2 = 𝛿3
Leaf Springs

Single Leaf (no graduated leaves)

6𝐹𝐿
𝑆=
𝑏𝑛𝑡 2

𝑆𝐿2
𝛿=
𝐸𝑡

Multiple Leaves
18𝐹𝐿
𝑆= 2
𝑏𝑡 (2𝑛𝑔 + 3𝑛𝑓)

𝑆𝐿2
𝛿=
4𝐸𝑡
Leaf Springs

Single Leaf (no graduated leaves)

6𝐹𝐿
𝑆=
𝑏𝑛𝑡 2

𝑆𝐿2
𝛿=
𝐸𝑡

Multiple Leaves
18𝐹𝐿
𝑆= 2
𝑏𝑡 (2𝑛𝑔 + 3𝑛𝑓)

𝑆𝐿2
𝛿=
4𝐸𝑡
Semi-Elliptical Leaf Springs

3𝐹𝐿
𝑆=
2𝑏𝑛𝑡 2
 Sample
Problems
Determine the maximum shearing stress in a helical spring composed of 20 turns of ¾
in diameter wire on a mean radius of 3in when the spring is supporting a load of 400
pounds. Use G=12 x 10^6 psi.
A. 17,152 psi
B. 12,450 psi
C. 10,450 psi
D. 8.709 psi
A large coil spring (k = 10 lb/in) is elongated, within its elastic range by one foot.
Stored energy in foot pounds is nearest to:
A. 10
B. 60
C. 40
D. 80
A high alloy spring having squared and ground ends and has a total of 16 coils and
modulus of elasticity in shear of 85 GPa. Compute the Wahl factor. The spring outside
diameter is 9.66 cm and wire diameter is 0.65 cm.
A. 1.058
B. 1.10
C. 1.185
D. 1.2
A spring with 12 active coils and a spring index of 9 supports a static load of 220 N
with a deflection of 12 mm. The shear modulus of the
spring material is 83 GPa. What is the theoretical wire diameter?
A. 18 mm
B. 16 mm
C. 14 mm
D. 20 mm
Compute the deflection of a 18 coils helical spring having a load of 100 kgs. The
modulus of elasticity in shear of spring is 96.62 GPa. OD of 9.256 cm and with
diameter of 9.525 mm. The spring is square and ground ends.
A. 90.39 mm
B. 101 mm
C. 112 mm
D. 14 mm
Compute the maximum deflection of a 20 coils helical spring having a load of 75 kgs.
The spring is a square/ground ends with modulus of elasticity in shear of 79.84 GPa
outside diameter of 101.6 mm wire diameter of a 9.525 mm.
A. 140.7 mm
B. 112.7 mm
C. 15.17 mm
D. 126.7 mm
A three extension coil springs are hooked in series that support a single weight of 100
kgs. The first spring is rated at 0.400 kg/mm and the other 2 lower is rated at 0.64
kg/mm. Compute the total deflection.
A. 563 mm
B. 268 mm
C. 156 mm
D. 250 mm
A Mercedes Benz gas engine valve spring is to have a mean diameter of 3.81 cm and
a wire diameter of 0.635 cm The maximum load it will have to sustain is 45.45 kg with
corresponding deflection of 1.27 cm. The spring is to be made of tempered steel wire.
Determine the no. of coils to be used. Use modulus of rigidity equal to 11.6 x 10^6 psi.
A. 7.4
B. 8.1
C. 10.4
D. 14.4
A helical spring having a squared and ground ends has a total of 24 coils and material
modulus of elasticity in shear of 89 GPa. The spring has an outside diameter of 12 cm
and a wire diameter of 0.65 cm. Compute the maximum deflection that can be
produced in the spring due to a load of 60 kg.
A. 870 mm
B. 954 mm
C. 999 mm
D. 1030 mm
Flywheels
Flywheel - is a mechanical device used to store rotational energy. It consists of a
heavy rotating disk or wheel that is mounted on an axle. The primary function of a
flywheel is to maintain a consistent rotational speed and provide smooth and
continuous energy output in applications where there may be fluctuations or variations
in the input power or torque.
Total Weight of the Flywheel

𝑊𝑓 = 𝑊𝑟𝑖𝑚 + 𝑊𝑎𝑟𝑚𝑠 + 𝑊ℎ𝑢𝑏

Weight of the Rim

𝑊𝑟𝑖𝑚 = 𝜌𝜋𝐷𝑚 𝑏𝑡

Density of Flywheel Materials

𝑘𝑔
𝐶𝑎𝑠𝑡 𝑖𝑟𝑜𝑛 = 7,200 3
𝑚
𝑘𝑔 𝑙𝑏
𝑆𝑡𝑒𝑒𝑙 = 7860 3 = 0.284 3
𝑚 𝑖𝑛
Kinetic Energy Released

1 2 2
1 𝑊 2 2
1 𝑊 2
𝐾𝐸 = 𝑚 𝑉1 − 𝑉2 = ∗ 𝑉1 − 𝑉2 = ∗ ∗ 𝜋𝐷𝑚 𝑁12 − 𝑁22
2 2 𝑔 2 𝑔
𝑊
= 𝐶𝑓 𝑉𝑎𝑣𝑔 2
𝑔

Kinetic Energy in terms of Inertia

1 2 1
𝐾𝐸 = 𝐼𝜔 = 𝑚𝑘 2 𝜔12 − 𝜔22
2 2
Mass Moment of Inertia

For Hoops
𝐼 = 𝑚𝑘 2

For disc
1
𝐼 = 𝑚𝑘 2
2
Coefficient of Fluctuation

𝑉1 − 𝑉2 𝜔1 − 𝜔2 𝑁1 − 𝑁2
𝐶𝑓 = = =
𝑉 𝜔 𝑁

𝑉1 + 𝑉2
𝑉 = 𝑉𝑎𝑣𝑔 =
2

𝑉 = 𝜋𝐷𝑚𝑁
𝜔 = 2𝜋𝑁
Punching Stress of a Flywheel

𝐹
𝑆=
𝜋𝐷𝑡

Shearing Stress of Plate

𝐹
𝑆=
𝐿𝑡

Energy Needed to Punch

1
𝐸 = 𝐹𝑡
2
Power

𝐸
𝑃=
𝑡

Pressure Required for Punching

𝑃 = 𝑘𝑑𝑡

For steel, k=80

For brass, k=65
 Sample
Problems
A flywheel weighing 457 kg has radius of 375 mm. How much energy in N -m does the
flywheel loss from 3.0 rev/sec to 2.8 rev/sec?
A. 368 N-m
B. 1472 N-m
C. 150 N-m
D. 38 N-m
A flywheel has a diameter of 1.5 m, and mass of 800 kg. What torque in N-m, is
needed to produce an angular acceleration of 100 revolutions per minute per second?
A. 225
B. 974
C. 1158
D. 2356
A punching machine flywheel accelerates from rest with 7 rad/sec^2. In 10 seconds,
how many radians are achieved?
A. 45
B. 35
C. 250
D. 350
A flywheel weighing 910 kg has a radius of gyration of 1524 mm. The shaft journals
are 304.8 mm in diameter and have a coefficient of friction of 0.06. After the wheel
reaches 120 rpm, the driving force is withdrawn and the wheel slows to 60 rpm. How
much energy thus the wheel loss?
A. 125 kN-m
B. 140 kN-m
C. 130 kN-m
D. 150 kN-m
A shearing machine requires 150 kg-m of energy to shear a steel sheet, and has a
normal speed of 3 rev/sec, slowing down to 2.8 rev/sec during the shearing process.
The flywheel has a mean diameter of 75 cm and weighs 0.018 kg/cm. The width of the
rim is 30 cm. If the hub and arms of the flywheel account for 15% of its total weight,
find the thickness of the rim.
A. 1 cm
B. 5 cm
C. 4 cm
D. 3 cm
How many 5/16-inch holes can be punched in one motion in a steel plate made of
SAE 1010 steel, 7/16 inch thick using a force of 55 tons. The ultimate strength for
shear is 50 ksi and use 2 factor of safety.
A. 5.8
B. 3.7
C. 5
D. 6.2
The flywheel on a press rotating at 100 rpm is slowed down to 90 rpm during a
punching operation that requires I second for punching portion of the system cycle.
Compute the angular deceleration in rad/sec-sec the flywheel undergoes. Given the
angular velocities for 120 rpm is 10.47 rad/sec. And for 90 mph 942 rad/sec.
A. -1.36
B. -1.26
C. -1.05
D. -0.93
A cast iron flywheel is rotated at a speed of 1200 rpm and having a mean rim radius of
1 foot. If the weight of the rim is 30 lbs. what is the centrifugal force? Use factor C = 41
A. 14,800 lbs
B. 15,000 lbs
C. 14,860 lbs
D. 14,760 lbs
The mass of a disc flywheel is 175 kg and its radius of gyration is 380 mm. Find the
torque required to attain a speed of 500 rpm from rest in 30 seconds.
A. 40.10 Nm
B. 35.66 Nm
C. 44.12 Nm
D. 38.48 Nm
Find the pressure needed to punch a 3.5 -in diameter hole from a 1.5-in thick steel
plate.
A. 520 tons
B. 420 tons
C. 320 tons
D. 300 tons