DESIGN OF MACHINE

ELEMENTS
DESIGN OF SPRINGS
LECTURE: 2
Presented By:
Jagdip Chauhan
Assistant Professor
MED, GJUS&T, Hisar
 DESIGN OF HELICAL SPRING:
Helical Spring can be design by two ways:
1. Load stress equation
2. Load deflection equation
 Load stress equation: for deriving by stress equation the helical spring is converted into
a bar. The dimensions of equivalent bar as follows:
i. The diameter of the bar is equal to the wire diameter of the spring (d).
ii. The length of one coil in the spring is πD, (where D is Mean coil diameter); for N
active coils length of the bar is πDN.
iii. The bar is fitted with a bracket is equal to mean coil radius of the spring (D/2).
The force P acting at the end of the bracket
induces torsional shear stress in the bar.
The torsional moment Mt is given by,

The torsional shear stress is given by,

=
(a)
When the equivalent bar is bent in the form of helical
coil, there are additional stresses on account of
following two factors:
i. There is direct or transverse shear stress in the
spring wire.
ii. When the bar is bent in the form of coil, the length
of the inside fiber is less than the length of the
outside fiber. This result in stress concentration at
the inside fiber of the coil.
The resultant stress consists of superimposition
of torsional shear stress, direct shear stress and
additional stresses due to the curvature of the
coil. The stresses in the spring wire on account
of these factors are shown in Fig.
Equation (a) does not take into consideration the effect of direct shear stress and stress
concentration due to curvature effect. It requires modification. We will assume the following
two factors to account for these effects:

= factor to account for direct shear stress

= factor to account for stress concentration due to curvature effect

The combined effect of these two factors is given by,

K= .,
where K is the factor to account for the combined effect of two factors.
As shown in Fig. (b), the direct shear stress in the bar is given by,
= = ()
Superimposing the two stresses of expressions (a) and (b), the resultant shear stress in the spring
wire is given by,

=
+ ()
= (1+ )
The shear stress correction factor () is defined as,

= (1+ ) = (1+ )
= ()
AM Whal derived the relation for resultant stress, which includes torsional shear stress, direct
shear stress and stress concentration due to curvature. The equation is given by,
= K ()
* This is called as Load stress Equation

Where, K is called as stress factor or Whal factor.

Whal factor is given by,

K= +

Where, C is Spring index.

Load deflection Equation:
The angle of twist (Ɵ) for the equivalent bar, is given by :
Ɵ=
Where,
Ɵ = Angle of twist
= Torsional Moment PD/2
= Length of the bar (πDN)
J = Polar moment of inertia (π
G = Modulus of rigidity
Substituting the values in above equation:

Ɵ=

Ɵ=
Load deflection Equation:
The axial deflection ‘δ’ of the spring, for small values of Ɵ, is given by :
δ = Ɵ X Length of the bracket
=Ɵ
Substituting the value of Ɵ in previous equation:

δ=
This equation is called as Load deflection equation.
Rate of spring is given by: K = P/ δ,
Hence, K =
 δ=
This equation shows the δ is directly proportional to the P.
So, the Load deflection curve will be given by:
The area under the line gives the stored energy in the spring.
Say,
E = area below the Load deflection line
= Area of triangle OAB
= ½ OB X BA
=½δXP
Where, E is strain energy stored in spring
 SPRING CONNECTION:
 There are two types of spring connection.
1. Series Connection
2. Parallel Connection
 The objective of connection are:
1. To save space
2. To change the rate of spring at
a certain deflection Series Parallel Connection
Connection
3. To provide a fail-safe system
 SPRING CONNECTION:
 There are two types of spring connection.
1. Series Connection
2. Parallel Connection
 The objective of connection are:
1. To save space
2. To change the rate of spring at
a certain deflection Series Parallel Connection
Connection
3. To provide a fail-safe system
Series connections:
Figure shows two springs, with spring rates K1 and K2, connected in series. For
series connection,
1. The force acting on each spring is same and equal to external force
2. The total deflection of the spring combination is equal to the sum of the
deflections of individual springs.
Therefore,

Where, δ1 & δ2 are the deflections of two spring.

And : δ= ; = +
Or,
= + + ……….. (Where, K is combined stiffness) Series
Connection

=
Parallel connections:
Figure shows two springs, with spring rates K1 and K2, connected in parallel. For
parallel connection,
1. The force acting on the spring combination is equal to the sum of the forces
acting on individual spring
2. The deflection of individual springs is same and equal to the deflections of the
combination.
Therefore,

Where, δ1 & δ2 are the deflections of two spring.

And : P =K. δ; K.δ = K1 δ + K2 δ
Or, Parallel

K = K1 + K2 + ……….. (Where, K is combined stiffness) Connection

Thanks