Design analysis of cylindrical spring

A 0 2 5 J AYA N T R A O
A O 3 1 M AYA N K S H U K L A
A 0 3 5 YA S H Z A N K H A R I YA
Introduction

Suspension system reduces the effect of travelling over the rough ground
Consists of tires, tire air, springs, shock absorbers and linkages
A spring is an elastic material body which stores the energy
The springs are broadly classified on the type of pitch
 Constant pitch
 Variable pitch
Selection of Material

Alloy steel wire springs are being used for spring

applications
Chrome Vanadium ASTM A231
Music Wire ASTM A228
Chrome Vanadium ASTM A231 is a promising replacement
to Music Wire ASTM A228 as the spring material.
Assumptions and Formulae
As the spring index is 7 Sr. Formulae
No.
Upper outer diameter of spring, 41 mm
Lower outer diameter of spring, 71 mm 1 Spring index

Height of the spring, 204 mm 2 Wahl stress factor

Diameter of spring wire, 8 mm 3 Maximum shear
stress
Pitch of spring at start, 16 mm
Pitch of spring at end, 8 mm 4 Deflection of spring
Pitch of spring at the quarter middle, 13 mm 5 Solid length Ls = n x d
Weight of spring (W), 300 kg or force applied, 2940 N 6 Spring rate
Numbers of coils (n), 17 7 Number of active coils
 Mesh analysis of spring
 Finite element method has been used for discretization of the entire body into small grids of shapes like trigonal, tetrahedral, hexagonal, etc.

In the proposed research, finite element method was used automatic tetrahedrons for generating mesh.

 Bottom of spring was kept fixed, and the load was applied at the top surface of the spring.

 The direction of applied load was in downward direction

 The applied load ranged between 60 kg and 300 kg and the time interval for the processing in the form of steps was 1 to 5 s.

 The fig. Below shows the tetrahedral mesh of size 2 mm throughout the spring.
Design analysis of Spring: Total deformation
 Total deformation analysis accounts for deformation occurring in the shape of the spring
due to application of load.

 From the total deformation contour, it was identified that the spring bends sideways as the
load was applied.

 The analysis shows the deformation distribution coded as colors throughout the spring.

 The blue color shows the minimum amount of deformation.

the red color defines the maximum amount of deformation.

 The figure shows the coded result of total deformation occurring at varying loads.
Continued….
 Minimum deformation - Red

Maximum deformation - Green

 Average deformation - Blue

 X-axis-the interval (in seconds)

 Y-axis-the value of deformation (in mm).

 A nonlinear characteristic behavior of stress was inferred from the graph due to
the application of load with respect to the steps (in seconds)
Design analysis of Spring: Von mises stress
 The stress analysis gives the amount of stress induced
in the spring when load is varied.

 These observations were taken in a similar fashion as

done in the total deformation analysis.

 The stress was evaluated by von mises stress analysis

method which deals with the brittle behavior of steel.

 The graphical analysis shown in graph gives the stress

analysis in the form of minimum, maximum and
average stress through different colors i.e., red, green
and blue, respectively.

 The x-axis gives the interval in the form of seconds

and the y-axis represents the value of stresses in MPa.

 The graph shows nonlinear characteristics of stress

due to the application of load with respect to the steps
in seconds.
Design analysis of Spring: Von mises stress

The table describes the theoretical values of stress and deflection

at every instant due to the application of load in different
intervals while the other two figures shows the data in graphical
form.
 Conclusions
This research showed a design modification of the spring used in suspension system in two-wheeler vehicles and defined a
new material to meet the environmental as well as man-made challenges.
The results inferred from this work has been listed below:
1. This study has been carried out between the theoretical values to the simulation-derived values for chrome vanadium
steel spring having variable pitch.
2. The maximum shear stress of chrome vanadium steel spring has been observed as 984 MPa and minimum value as
196.956 MPa on application of 300 kg and 60 kg of load, respectively.
3. The deflection pattern of the chrome vanadium steel spring was analyzed through analytical method and showed
maximum deflection of 195 mm and minimum deflection of 39 mm on application of 300 kg and 60 kg load,
respectively.
The research findings conclude that the alloy spring material can effectively replace the existing high carbon steel material
to enhance the performance of the suspension system.