Definition of spring: Spring act as a flexible joint in between two parts or bodies

Objectives of Spring

1. Cushioning , absorbing , or controlling of energy due to shock and

vibration.

• Car springs or railway buffers

• To control energy, springs-supports and vibration dampers.

2. Control of motion
• Maintaining contact between two elements (cam and its follower)
In a cam and a follower arrangement - a spring maintains contact between the
two elements.
It primarily controls the motion.
• Creation of the necessary pressure in a friction device (a brake or a clutch)
• Restoration of a machine part to its normal position when the applied force is
withdrawn (a governor or valve)
• A governor system uses a spring controlled valve to regulate flow of fluid through
the turbine, thereby controlling the turbine speed.

3. Measuring forces - Spring balances, gages

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4. Storing of energy- In clocks or starters
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07/05/2020 Courtesy: A textbook on machine design, R.S.Khurmi 12
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Compression Springs
1) Type of ends?

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Compression Springs

Ground Section
Free Length
Mean Diameter

Outside Dia.
Inside Dia.
12 ½ Coils
Pitch Space Between Coils
Size of Material

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Types of Springs

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Types of spring cont.

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Types of springs cont.

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Types of springs cont.

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Spring Design
F  ky
kF/y

1 1 1 1
  
k series k1 k 2 k3
k parallel  k1  k 2  k3

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Factors in spring design
 High strength
 High yield
 Modulus may be low for energy storage
 Cost
 Environmental factors
 Temperature resistance (e.g. valve springs)
 Corrosion resistance

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Common materials for springs

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Influence of diameter on
ultimate stress

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Design of helical compression
springs  Length nomenclature
 Free
 Assembled
 Solid or shut height
 Working deflection

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Stresses in Helical Spring

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Stresses in Helical springs cont.
At the inside of the spring Substituting for

Gives

4<C<12
Defining the spring index

Therefore the stress is

Equation(1)

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Effect of curvature on Stress
 Equation (1) is based on the wire being
straight
 However the curvature increases the stress
on the inside of the wire
 For static stress the effect of curvature can
be neglected
 For fatigue the effect of curvature is important

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Effect of curvature cont.

Wahl factor

Bergstrasser
factor

The results of the two equations differ by less than 1%.

Bergstrasser factor is preferred due to simplicity

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Deflection
 The external work done on an elastic member
in deforming it is transformed into strain, or
potential, energy. If the member is deformed a
distance y, and if the force-deflection
relationship is linear, this energy is equal to
the product of the average force and the
deflection, or

 This equation is general in the sense that the

force F can also mean torque, or moment,
provided, that consistent units are used for k.
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Deflection cont..

 By substituting appropriate expressions for k,

strain-energy formulas for various simple
loadings may be obtained. For tension and
compression and for torsion,

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Deflection of a helical spring
 Using Castigliano’s theorem, strain energy is
equal to

 Substituting

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Deflection cont.
 Using the spring index

 Spring scale is

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Spring design – end treatment
 End details affect active coils
 Plain ends
 Squared ends
 Squared
 Ground

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Number of active coils

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Materials for springs
 Yield strength for static loading
 Depends on set
 Before set removed use Wahl factor
 After set removed no stress concentration used

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Properties for fatigue
 Fatigue Strength
 Torsion is relevant loading- could use von Mises
stress
 Materials testing specific to helical compression
springs is available, however
 Correct for temp., reliability, environment

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Properties - endurance
 Endurance Strength (steels) unlimited cycles
 For high ultimate strengths, endurance limits max
out at 45 kpsi (unpeened) and 67.5 kpsi (peened)
 Small wires have high ultimate strength
 Tests have been done specific to spring wire
 Temperature may require compensation
 Corrosion
 Reliability

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Designing springs
Requirements Design Choices
 Functionality  Index C
 Stiffness  Material
 Lengths  Wire and coil
 Diameter diameter
 Forces
 Number of turns
 Reliable operation  End treatment and
 Static factor of safety
constraint
 Fatigue factor of safety
 Buckling and surge
 Set and shot peen
 Manufacturability Constraints (other)
• Bend radius
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Helical extension spring
 Similar in most ways to
compression springs
 Usually wound to be closed
coil at zero force
 Thus a preload is required
to stretch any, i.e. y=k(F-Fi )
 Spring hook is a source of
failure in bending and
torsion
 No set is used
 One coil not considered
active

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End stresses
Bending stress:
16 DF 4 F
 A  Kb  2
d 3
d
4C12  C1  1 2 R1
Kb  ; C1 
4C1 (C1  1) d

Torsional stress:
8 DF
 B  K w2
d 3
4C2  1 2 R2
K w2  ; C2 
4C2  4 d
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Design for fatigue
 Data available for springs with loading from
zero to some compresion value
 Application often has preload… how to use?
 First construct (or find) S-N curve
 Next construct Mod-Goodman chart
 Apply load line for given preload and design
stress
 Find factor of safety to failure point

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A word about torsional springs
 The wire in a torsional spring is primarily in
bending
 Spring constant is rotary M=k
 Loading should act to wind up coil
 Design process resembles compression
springs

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Torsional

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