Design Handbook

Engineering Guide To SpringDesign

1987 Edition

AssogffilfiS l0Mainstreet, Brisro,,.*::$il3: &ffi&ffiffi$ ffi

section
I I 3 Eor to Use the Handbook

Table of Contents
Page

Selccdng Spring Configurations hrsh. Pull. Twist or Energy Stofage Applications: CommonAvailable Configurations. Spring Materials Common Specifications,Elastic Modulus, Magnetic Characteristics, Heat Treatment, Stress Relaxation, Corrosion, Coatingsand Finishes.SpringWire: Tensile Properties,Cost and Availability. Sprine Strip: Strength,Formability and Edge Condition. Reidual Stress, Fatigue and Reliability Load-CarryingAbility, FatigueTerminology, Modified GoodmanDiagram, Weibull Analysis, Load Loss. Eelical Compression Springs GeneralDefinitions, Squareness, Parallelism, Hysteresis,Design Equationsfor Spring Rate and Stress,Bucklinl Choice of Operating Stress for Static and Cyclic Applications, Dynamic Loading Impict and Resonance, RectangularWire, StrandedWire, Variable Diameter, Variable Pitch and Nested Springs,CommercialToleranc, Hot-Wound Springs DesignConsiderations,End Configurations, Materials, Choice of Operating Stress,Tolerances. Eelirnl Extension Springs Initial Tension, Types of Ends and Dimensions, Design Equations,Choice of OperatingStressfor Static and Cyclic Applications, Commercial Tolerances. Garter Springs Joint Design, Design Equationsand Tolerances. Helical Torsion Springs Mean Diameter, Length, Design Equations for Rate and Stress,End Configurations,Natural Frequency,Choice of Operating Stress for Static and Cyclic Applications, Double Torsion and Rectangular Wire Springs, ioleranc, f,staining Rings External and Internal Types, Ends, Design Equations, Choice of StressLevel, Tolerances. Belleville Spring Washers Load-Deflection Characteristics, Mounting, Design Equations.Choiceof StressLevel for Static and Cyclic Applications, Stackingand Tolerances. Flat Springs . . Design Considerationsand Equations for Cantilever and Simple Beams, Choice of StressLevel and Tolerances. Specid Spring Washers Design Considerations and Equations for Curved, Wave and Finger Washers, Choice of StressLevel and Tolerances. Power Springs GeneralDesign Considerationsand Equations, OperatingStressfor Power and hestressed Power Springs. Constant Force Springs Extension Type_, Design Equations, Mounting and Tolerances,Motor Type Design Equations for "A" and "B" Type Motors, OperatingStress and Tolerances. Spird Springs Design Equations for Hair Springsand Brush Springs. Volute Springs Design Equations and Choice of Operating Stress Level. Wire Forms GeneralInformation and How to Specify. IndexandReferencelnformation .......1 Glossary of Spring Terminology, Bibliography, Trademarks, Conversion Factors, Abbreviations and Symbols, HardnessScaleConversions,Index and Lists of Thblesand Illustrations.

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5 7

t 9

l0 ll

12

13

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f6 17 It 19

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Spring Configurations Selecting Tabb 2-1. Spring Configurations.

T\'PT. COTNCUNATION (Section5)
t

Tv?u
A.rTION
Beam (Section 12)

cor'if"IstJ&ATIoli

ACTt0:ri

Helical Compression
Round and Recrangular \t-ire Constant Pitch
V

Cantilever, Rectangular Section Push-wide load and deflection range-constant rate'

hrsh or pull-wide range of loads, low deflection range.

cantilever, TrapezoidalSection
Pl

_ =* :
Conrcal ::
I

Barrel

,: = ::=/ :/ ^
.>

Push-wide load and deflection range. Conical spring can be made with minimum solid height and with constantor increasing rate. Barrel, hourglass, and variable-pitchspringsused to minimize resonant surging and vibration.

SimpleBeam

ffi
rwist<onstantrate'

9) Helical Torsion (Section

Hourglass

# r.-.1r.-fi --.r--

#
Push-high loads, low deflections-choice of rates (constant, increasing, or decreasing). Push-light loads, low deflection-uses limited radial space. Ptrsh-higher defl ection s than bellevilles.

frS RoundorRectang",." ffi (2'il[

wire
Spiral (Section16)
Hairspring

,^

Variable-PitchI

@
w

Twist.

Spring Washer

(Section and13) ll

Brush

rwistorhrsh'

Belleville

/--\

\:r'
Vx ql
/raR

:ili',y:,::;'@
\/

Twist---exerts torque over many turns. Suppliedin retainer.

\lare

5lotted

rye
ft\1 V

ad)
Prestressed Power (Section 14)
15) Constant (Section

Removedfrom retainer.

Finger

hrsh-for axial loading of bearings.

Curved

/R / l \ \ -:
(Section 17)

Twist--+xerts torque over many turns.

Push-used to absorb axial . end play.

Suppliedin retainer. Removedfrom retainer.

Volute

Push-may have an inherently high friction damping.

Force Spring Motor

Level Torq

Twist+xerts close-toconstant torque over many turns.

AssogFifig/&sAnss ffi

Spring Materials Chemical and Physical Characteristics While certain materials have come to be regarded as ry.i.ng materials, they are not specially design-d alloys. Spring materials are high strength alloys wtrictr ofien exhibit the greatest strength in the alloy system. For example: in steels, medium and high-carbon steels are regarded as spring materials. Beryllium copper is frequently specified when a copper base alloy is required. For titanium, cold-worked and aged Ti-l3v-llCr-3At is Tahle 3-1 Typical Properties of Common Spring Materials.
Y,o*qt* Modulrrs S {l} MPr | {ed} il{odnkm of Rlddly G {l} lWPr | {Dd} &lcr .lesl Corr&rc. Mtf {t} *iY,lty ttl *1ffir5{tbl,tu'; % f*c$ $ias lioruelly .tvrlhblc {2} Min. Mrr. i mm {hr.} i mm {h.}

used. The energy storage capacity of a spring is proportional to the square of the maximum operating stress level divided by the modulus. An ideal spring material has high strength, a high elasticlimit and a low modulus. Becausesprings are resilient structures designedto undergo large deflections, spring materials must have an extensive elastic range. Other factors such as fatigue strength, cost, availability, formability, corrosion resistance, magnetic permeability and electrical conductivity

Com*on lihme Carbon Steel Wires: Music (5) Hard Drawn (5) Oil Tempered Valve Spring Alloy Steel Wires: Chrome Vanadium Chrome Silicon StainlessSteel Wires: Austenitic Type 302 hecipitation Hardening l7-7 PH NiCr A2E6 Copper Base Alloy Wires: PhosphorBronze (A) Silicon Bronze (A) Silicon Bronze (B) Beryllium Copper Spring Brass, CAz6/u. Nickel Base Allovs: Inconelo Alloy 600 Inconel Allov X750 Ni-Span-C@ Monilo Allov 400 Monel Alloy K500 Carbon Steel Strip: AISI 1050 l06s 1074, 1075

r t ' l]

id

rdl

id

r'rp|nl. ,:,.,ilil1fua S{r&eG ,fi ..fcrycr. i,,'i , ({} Qt&y, , ot 3F t l

207 207 207 207 207 207 193 203 200 103 103 t17 128 lr0

(30) (30) (30) (30) (30) (30) (28)

79.3 79.3 79.3 79.3 79.3 79.3 69.0 75.E 7r.7 43.4 38.6 4.1

( l l .s) ( l l .s) ( l 1 .5) (l1.5)

7.86 (0.2E4) 7.85 (0.2E4) 7.E6 (0.2E4) 7.86 (0.284)

7 5

(0.250) a 0.10(0.004)6.35 0.13(0.00s) 16 (0.625) c 0.s0(0.020) 16 (0.62s) c (0.250) a 1.3 (0.0s0) 6.35 0.50(0.020) r (0.435) a r b l 0.50(0.020) 9.5 (0.375) arb 0.13(0.00s) 9.5 (0.375) b 0.08(0.002) r2.5 (0.500) b o.lm(0.016)5 (0.200) b
b b b b b

r20 150 r50

150

250 250 300 300 425 475 500 600 950

( l 1 . 5 ) 7.86 (0.284) ( l 1 . 5 ) 7.86 (0.2E4)

220 245 2@ 315 510

(2e.s) (2e)
(15) (15) (17) (1 E .5 ) (1 6 ) (3l) (3l) (27) (26) (26) (30) (30) (30) (30) (30) (28) (29.s)

(1 0. ) 7.92 (0.286) (l l) 7 . E l (0.2E2)

(10.4) E.03 (0.290)

2 2 2

+8.t
42.0 75.E 79.3 62.9 6.2 6.2
79.3 79.3 79.3 79.3 79.3 69.0 75.8

(6.3) (5.6) (6.4) (7.0) (6.0)

8.86 (0.320) l 5 E.s3 (0.308) 7 E.75 (0.316) t 2 8.26 (0.298) 2r 8.53 (0.30E) t7
1.5 I

(0.004) 0.10 12.5 (0.500) 0.10(0.004) 12.5 (0.s00) 0.r0 (0.004) z.5 (0.500) t (0.003) 0.0E 12.5 (0.500) 0.10(0.004) 12.5 (0.500)

9s 95 95 205 95
320 595 9s 230 2ffi 95 95 r20 r20 9s 315 370

200 200 2m 400 200

700 ll00 200 450 500 200 2W 250 250 200 600 700

2r4 2t4
lE6 179 r79 207 2W 2W 207 207
193 203

(lt) 8.43 (0.304) ( l 1 . 5 ) 8.25 (0.298)

(e.7) 8.14 (0.2%) (e.6) 8.83 (0. 319) (e.6) E.46 (0.306)

r.5

3.5 3
7 7 7 7 7

(0.004) 0.10 l2.s (0.500) b 0.10(0.004) 12.5 (0.500) b 0.10(0.004) r2.5 (0.500) b 0.05(0.002) 9.s (0.375) b 0.05(0.002) 9.5 (0.375) b (0.010) 3 0.25 (0.003) 3 0.0B (0.003) 3 0.0E 0.08(0.003) 3 0.10(0.004) l (0.125) b (0.125) b (0.125) b (0.125) b (0.040) a

r09s
Bartexo StainlessSteel Strip: Austenitic Types 301, 302 Precipitation Hardening l7-7 PH

( l l . s ) 7.E6 (0.2E4) ( l 1 . 5 ) 7.86 (0.284) ( l 1 . 5 ) 7.E6 (0.2E4)

(l r.5) 7.E6 (0.2E4)

( l 1 . 5 ) 7.86 (0.284)

(10) (11)

7.92 (0.2E6) 7 . 8 1 (0.282)

)
7

(0.003) 1.5 (0.063) b 0.0E 0.08(0.003) 3 (0.125) b

Copper BaseAlloy Strip: Phosphor Bronze(A) BerylliumCopper

103 r28

(1 5 ) (1 8 .5 )

43 48

(6.3) E.16 (0.320) l 5 (7.0) 8.26 (0.298) 2 l

0.08(0.003) 5 (0.18E)b 0.08(0.003) 9.5 (0.375) b

9s 205

200 400

(l) Elastic moduli, density and electrical conductivity can vary with cold work, heat treatment and operating stress. These variations are usually minor but should be considered if one or more of these properties is critical. (2) Diameters wire; thicknesses strip. for for (3) Typicd surface quality ratings. (For most materials, special processes can be specified to upgrade typical values.) a. Maximum defect depth: 0 to 0.5Vo of d or t.

b. Maximum defect depth: l.$Vo of d or t. c. Defect depth: less than 3.5Voof d or t. (4) Maximum service temperatures are guidelines and may vary due to operating stress and allowable relaxation. (5) Music and hard drawn are commercial terms for patented and cold-drawn carbon steel spring wire. INCONEL, MONEL and NI-SPAN-C are registeredtrademarksof International Nickel Company, Inc. BARTpi is a registered trademark of Theis of America. Inc.

H Assog5ifiS &ffienans

Spring Materials can also be important and must be consideredin light of cost,benefit. Consequently,careful selectionsmust te made to obtain the best compromise. Table3- I lists some commonly used alloys along with dau for material selectionpurposes.Data on mechanical propenies are presentedin the Spring Wire and Spring (Pages18 and 20 respectively). Strip subsections Specifications have been written by many national and intern a t i o n a l o r g a n i z a t i o n s .T h e s e s p e c i f i c a t i o n s r e a cross-referenced AssociatedSpring specificationsin to Table 3-2r However, correlation between the specifications is only approximate.AssociatedSpring specificat i o n s w e r e d e v e l o p e de x c l u s i v e l y f o r h i g h q u a l i t y material for spring applicationsand are generally more detailedand stringentthan other specifications. Surface quality has a major influence on fatigue strength and is often not clearly delineated on national specifications.It is important to use only those materials uith the best surface integrity for fatigue applications, particularly those in the high cycle region. In steel alloys, for which processingcosts are a large fraction of product cost, surface quality can vary over an appreciable range. Depth of surface imperfections, such as seams,pits and die marks, can be up to3.5% of diameter for commercial spring wire grades (ASTM A-227 and A-229). Various intermediate qualities can be obtained. Highest levels are representedby music and valve spring quality grades which are virtually free of surface imperfections. Decarburization, which can also adversely affect fatigue performance, follows a similar pattern. Surface quality of spring materials is a function of the care exercised in their production and processes employed. Materials produced with a high level of surface integrity are more costly than commercial grades. Elastic Modulus The modulus of elasticity in tension and shear is vital to spring design. Table 3-1 lists recommendedvaluesfor commonly used spring alloys. For most steels and agehardenablealloys, the modulus varies as a function of chemical composition, cold work and degree of agrng. Usually variations ar0 small and can be compensatedfor by adjustment of reference parameters of the spring design, (e.g. number of active coils, and coil diameter). For most materials,moduli are temperature-dependent and vary inversely with temperature by approximately per ZVc 55'C (100"F).Sincenonambienttemperaturetesting is costly, design criteria should be specifiedat room temperature after having made appropriate compensation for the application temperature. Certain nickelchromium-iron alloys are designed to have a constant modulus over the temperaturerange from -5o to 65'C (-50" to 150'F) and are exceptions to the above rule. For true isotropic materials, the elastic moduli in tension (E) and shear (G) are relatedthroughPoisson'sratio by the expression: E Magnetic Characteristics For most applications, the question of "magnetic or not" is adequatelyansweredwith the use of a permanent magnet. For some applications,even very low levels of magneticbehavior can be detrimental. Then, it is desirable to know the magnetic permeability of candidate materials and reach agreement between parties on a maximum allowable value. Table 3-3 lists approximate values for a number of low permeability materials along with other frequently used alloys. Since permeability can be altered by cold work, some variation can be expected. In general, low permeability materials are more expensive so designersshould specify low levels only when absolutely necessary.Often, nitrogen strpngthened manganese stainless steels are good choices because they have good strength at moderate cost. Heat Treatment of Springs Heat-treating temperatures for springs can be divided into two ranges. Low temperature heat treatments in the 175'to 510'C (347'to 950'F) range are appliedto springs after forming to reduce residual stresses and stabilize parts dimensionally. For carbon steels, stainless steels and some age-hardenablealloys, low temperature heat treatments are used to increase or restore the set point. Electroplated carbon steel parts are heat-treated at low temperatures prior to plating, and baked afterward to reduce the susceptibilityto hydrogen embritflement. Most low temperature stress relieving and age-hardening of springs are done in air and a moderate amount of oxide may be formed on the part. No detrimental effects of this oxide have been noted. High temperature heat treatments are used to strengthen annealed material after spring forming. High-carbon steels are strengthenedby austenittzing in the temperature range 760'to 900"C(1480"to 1652"F),quenching to form martensite and then tempering. Some nickel base alloys are strengthenedby high temperature aglng treatments. Becausesubstantialoxidation occurs at these elevated temperatures,it is advisableto prevent excessive oxidation by using an appropriate protective atmosphere. Heat treatments suitable for many commonly used materials are listed in Table 3-4. Selection of a temperature within a given range can only be made after considering the material, size, strength level, application conditions and desired characteristics.For additional guidance,Associated Spring engineersshould be consulted. Unless otherwise noted, 20 to 30 minutes exposureat temperature is sufficient to obtain the bulk of the stress-relieving effect. Many spring-like parts involve forms which preclude the use of prehardened material. In these cases, soft or annealedmaterial must be used and heat-treated attain to spring propertiesafter forming. Thin high-carbon and alloy steel parts become distorted when hardened by quenching. Distortion may be reduced by fixture tempering; however,this process is costly and should be avoided if at all possible by using pretempered materials.

il

P:6-r

sothat, for common spring materials,any one of the parametersmay be approximated usingthe other two.

AssgFifig &ffi*ffiwsffi

Spring Materials Table 3-2. Related SpringMaterial Specifications.

.twoeint*d $tri'n* Spring Wire AS-5 AS-10 AS.2O AS-25 MusicWire Oil Tempered CarbonSteel Cold Drawn CarbonSteel
Oil Tempered Carbon Steel*

Corrrnon Trldr F{ams

saa
1085 Jl78 1066 J316 1066 J r1 3 1070 6150

ASTM 1228
L229

AM,S

Mfliarl'

Ihderd

EN

Britlih 8S
or 1408 5216 520r 3 2803,grade

fieffirlr

':f,},[H,

,lltfsrye .tI$
G3522, SWP-A,B, V

5tL2

s4@9

QQv/470 (obsolete)

17223, Sheet I 1.1200

QQw428
49B 5115

17223,Sheet G3560, 2, 1.1230 B swo-A,

A227
42,30

17222, 1408 Sheet I 5216NS or HS 1.0500

sw-A, c B,

G3521,

2803, I Grades & 2 w-22826 QQw412 47

50

L7223. 2 Sheet G3561,

swo-v
G3565,

AS-32 AS-33
AS-35

Oil Tempered Chrome Vanadium*

tr32

A232

&50

17225, 50CrV4 17225, 67SiC15

swocvry
G3566,

Oil Tempered 9254 Chrome Silicon* n57

Stainless Steel

A40l

QQw4l2 48A
QQw423 58A (obsolete)

swosc-v sus302
sus63IJl
G4314, G43T4,

30301 A 3 1 3 ; 5688 30302 Type301, J230 Type302

J2T7

2056

1.4300 1.4310 t7224

AS.36 AS44 AS-45 AS-55 AS-60A. AS-60C AS-70 Spring Strip AS-100

r7-7PH
InconelX-750

A'313, 5678 I}pe 531

5698.5699 4725, Cond.A QQW-530, Cond.A QQW-321, n@

t7224, 1.4568

CopperBeryllium cA-t72 Bt97 SpringBrass

2873, cBl0l
2786,

1766,6, 2.t247.55 17660, 2.0265 17662, 2.1030.39

cA-2@ BTY,

n60

czrw
2873, PBlO2
970, Part5

Phosphor Bronze cA-510B159,

#5rc

4720

QQw40l

Phosphor Brorue
Chromium Steel

cA-52r #521
s160H A'304
A689 1095

A682 A684

5r2l 5t22

s-7947
Annealed Cold-Rolled

44D

csl00

1449,Part38,

17232, | .t274 l.t2r0

G3311, SK4M G3311, s75CM G33ll, s50cM

AS-l0l

r074 A682 1075 A684

1050 1065 Bartex
Stainless Steel

5r20
5085 5115

Parrt38, t7222, 42E. 14/19,

cs.cs80
cs50
l$g,

AS-102 AS-103 AS-105 AS-135-A AS-135-B AS-136

A682 A684 A682 A684

Paft3B,

42F

cs60. cs70

1440,Part38,

17222, l.1230 t7224, 1.4310 1.4300 t7224, 1.4568

G3311, s65CM

1085

30301 At77 30302

5517 5 5 1 85 5 1 9 s-5059 , 5528 s-25043 5529Spring Cond. A Temper 5542 N 7786

QQS-766 58A

Parrt4, 14,y'l9, 302-S-25

G43r3, sus-301-csP sus-302-csP

G4313,

t7-7 PH

sus-631-csP

AS-144 AS-145 AS-155

InconelX-750 Copper SpringBrass

cA-r72 8194,
#r72

4s30(AT) 4s32(LtzHT) 4507. vzH

4510 Spring Temper

QQC-533 QQB-613, Comp.2 TIzH QQB-750, Comp.A

2870, cB101 2870, czt08

r7666, 2.1247.55
17660, 2.026s 17662, 2.1030.39

cA-260 836,
f260

AS-1@A

Phosphor Brorze

cA-5r0 8103,
#510

2870, PB1O2

AS-160C

Phosphor Bronze cA-521 8r03, #521

*Valve spring quality.

f&ffi*ffffis MAssogb?ifi8

Spring Materials T&

iffi -{.!r Brzsscs.Bronzes Carbon Srcels Flglol t lnconel -{,lloys:

3-3. Magnetic Characteristicsof Some Materials.

Prfm**rbility rr W Onrr*tdn Room Temperesrre

I Nonmagnetic > 500 1.00003s l.0t 1.0006 1.0035 >30 >12 >40 1.0il r.004 Nonmagnetic

Tempering is an effective stress-relieving treatment and results in negligiblelevels of residual stress.Some spring materials, such as beryllium copper and l7-7 PH, are strengthened after forming by age hardening. This provides a good stressrelief, but may also cause distortion unless special techniquesare used. Environmental Considerations Frequently, operating environment is the single most important consideration for proper spring material selection. For successful application, material must be compatible with the environment and withstand effects of temperature and corrosion without an excessive loss in spring performance. Corrosion and elevated temperatures decrease spring reliability. The effect of temperature on spring materials is predictable and discussed below. Compatibility of spring materials and spring coating systemswith corrosiveenvironments is discussedin general terms. For specific applications, the designer is urged to rely upon previous experience or consult with Associated Spring engineers. Stress Relaxation Primary concern for elevatedtemperature applications of springs is stress rela:ration. Stress relaxation is the loss of load or available deflection that occurs when a spring is held or cycled under load. Temperature also affects modulus, tensile and fatigue strength. For a given spring, variables which affect stress reloration are: stress, time and temperature, with increases in any parameter tending to increase the amount of rela;ration. Stress and temperature are related exponentially to relaxation. Curves of relaxation versus these parameters are concave upward as is shown in Figures 3-1 and 3-2. Other controllable factors affecting relaxation include: 1. Alloy Type - more highly alloyed materials are generally more resistant at a given temperature or can be used at higher temperatures. 2. Residual Stress - residual stresses remaining from forming operations are detrimental to relaration resistance. Therefore, use of the highest practical stressrelief temperatures is beneficial. Shot peening is also detrimental to stress relaxation resistance. 3. Heat Setting - various procedures can be employed to exposespringsto stressand heat for varying times to prepare for subsequentexposures. Depending on the method used, the effect is to remove a usually large first-stage relaxation and/or to establish a residual stress system which will lessen relaxation influences. In some cases,the latter approach can be so effective that in application, compression springs may "grow" or exhibit negative relaxation. Increase in free length does not usually exceed I to ZVo. 4. Grain Size - coarse grain size promotes relaxation resistance. This phenomenon is used only in very high temperature applications. Becauseso many variablesare involved, it is impossible to cite comprehensive data in a publication of this type, but Table 3-l does show approximatemaximum service

6m
5r_<

x--50
Staintess Steels: Tlpe 301, spring temper Tfpe 302, spring temper 631 07-7 PI{) XV-28: Nitroniso 32* \*itronic 50* Titanium Alloys

il

' \ itrogen-strengthenedmanganesestainless steels. ELGILOY is a registered trademark of Katy Industries, Inc. NITRONIC is a registeredtrademark of Armco., Inc.

Tabb 34. Typical Heat Treatments for Springs After Forming.

. Patented and Cold-Drawn Steel Wire TemperedSteel Wire: Carbon AllorAusteniticStainlessSteel Wire 1114 . ,,,,,,, ,,

Hent,lftma-ffii: tC, , ,:,

; r l'. ,".,,; t' :

l:;i::T
l:zs-rso lsruzso 600-800
I 45G950

190-230 2G400 3t5-425 23L510

PrecipitationHardening StainlessWire rll-7 PH): Condition C 480/l hour ConditionA to TH 1050 760/l hour cool to l5oC followed by 565/ I hour Vonel: .{lloy'496 Allo.v K500, Spring Temper Inconel: .{lloy'600 Allol X-750: * I Temper SpringTemper Copper Base, Cold Worked (Brass, Phosphor Bronze, etc.) Beryllium Copper: hetempered (Mill Hardened) SolutionAnnealed, Temper Rolled or Drawn

900/l hour 1400/l hour. cool to 60"F followed by 1050/l hour

30L315 57ffio 5254 hours 98014hours I 40G510

750-950

7301 hours l350l16hours 16 4 6501 hours n00l4 hours

t75-205 20s 3r5t2-3 hours

3sG400 400 6W/2:3hours

Annealed Steels: Carbon(AISI 1050to 1095) 800$30* 1475-t525* .{,llol'(AISI5150H6150,9254) 830{85* 1525-1625* -Time depends heating equipment on and sectionsize. Partsare austerutizedthen quenchedand temperedto the desired hardness.

o'"TFlfi8AH*ffilE$ H

Spring Materials Fig.3-1. RelaxationversusInitial Stressfor Spring Materials.

l8 ( psi) lnitiolstress 103 125 100 7'5 150

Fig. 3-2. Relaxation versus Temperature Spring Mafor terials.

l8 250 (" Exposure temperqture F) 350 300 400

g
Corbon steel Ploinsprings -Chrome silicon ' $

l4

-.Shor-peened -Shot-peened
ond Heot set

fl .l
g

Corbon steel Ploinsprings Shot-peenedcrrr Shot-peened ond Heot sei

Chrome silicon m g

f g

_f

3 a

,f
.

fl
of Exposure 100 hours ot l49oC (300"F) Stressescolculoted ot room femPeroture E t f I o I

'

r2

8 r o
.9
o x o
^ Q

.gt
f

;rl g.u I
/

8ro c
.9 o x oc 8

d,

lt

ilr

200

800 600 400 Initiqlslress(MPo)

1000

120

r40

160

r80

Exposuretemperoture(t)

temperatures for many commonly used materials. It should be remembered that, if a material is used at its maximum temperature, a substantial reduction must be made in applied stress from that used at room temperature. Corrosion The effect of a corrosive environment on spring performance is difficult to predict with certainty. General corrosion, galvanic corrosion, stress corrosion and corrosion fatigue reduce life and load-carrying ability of springs. The two most common methods employed to combat effects of corrosion are to specify materials that are inert to the environment and to use protective coatings. Use of inert materials affords the most reliable protection against deleterious effects of all types of corrosion; however, this is often costly and sometimesimpractical. Protective coatings are often the most costeffective method to prolong spring life in corrosive environments. In special situations, shot peening can be used to prevent stresscorrosion and cathodic protection systems can be used to prevent general corrosion.

s Tahle 3 -5. Guidefor SeIecting Minimum Thickne sesfor Zinc and Cadmium Coatings.
Zixon tranerd Srnel Part PerQ8rA325 t$ Cedmirrron LuardStscl Prrrs per QQ'"I4I6 {Z} 'Sl*.i

ilfisirnur$ 3 Th*nm m*n,till.l

0.025 (0.0010)

S*li,$pqry Tr*Sr''L $rn$,,ill&turry! ffi,:iH$4ry l*;1ltry& .*Ilri*h h:ftrr'..fion Thiekamrfiilf,$ Brr :White :n$d,rnar,{lnJ l}pr,' C
A B

r92
%

c
A B

r92
96

0.013 (0.00050)

96

0.013 (0.000s0) 0.005 (0.00020)

c
A B

0.008 (0.00030) B 36 0.005 (0.00020) B

96

96

36

(l) Requirements for zinc coating (electrodeposited). (2) Requirements for cadmium plating (electrodeposited)' Finish Type: A. Without supplementary chromate or phosphatetreatment. B. With supplementary chromate treatment. C. With supplementary phosphate treatment.

ffiessog51ffifu*ffiffi$

Spring Materials Coatings may be classified as galvanically sacrificial or simple barrier coatings. Sacrificial coatings for high carbon steel substratesinclude zinc, cadmium (and alloys thereof) and, to a lesser degree, aluntinum. Due to its toxicity, cadmium coating should only be specified when absolutely necessary.Because sacrificial coatings are chemically less noble than steel, the substrateis protected in two ways. First, the coating acts as a barrier between substrate and environment. Second, galvanic action between coating and substrate cathodically protects the substrate. This characteristic allows sacrificial coatingsto continue their protective role even after the coating is scratched, nicked or cracked. The amount of damagea sacrificial coating can sustain and still protect the substrateis a function of the size of the damagedarea and the effrciency of the electrolyte involved. The salt spray life criteria for three thicknesses of sacrificial coatings are shown in Table 3-5. Use of conversion coatings, such as chromates,lengthensthe time of protection by protecting sacrificial coatings. SaIt spray (fog) is an acceleratedtest and results may, or may not, correlate with corrosive activity in the actual environment. The test is useful as a control to ensure the coating was applied properly. Metallic coatings are normally applied by electroplating. Since most high hardnesssteels are inherently very susceptibleto hydrogen embrittlement, plating must be carried out with great care to minimize embrittlement and subsequentdelayed fracture. A baking operation after plating is also essential.The designershould observe these points during design and specification: l. Minimize sharp corners and similar stress-concentration points rn design 2. Keep hardnessas low as possible. 3. Keep operating stressdown, in accordancewith lowered hardness value. 4. Specify plating thickness, depending upon requirements. Specify that parts be baked after plating. 6 . Consider use of HEPrM strips to monitor the plating operation. Residual stress from forming operations must be reduced by stress relief at the highest practical temperature. Otherwise the combined effect of residualtension and hydrogen absorbed during plating can induce cracking even before plating is completed. Similar cautions apply if acid cleaning procedures are contemplated. Mechanicalplating provides an effectivemeansof zinc or cadmium protection with minimum hydrogen embrittlement. It is particularly recommended where parts have high residual stress, have been hardened above HRC48 and are used with high static loads. The process can only be applied to parts that do not tangle and have a clean, fully accessible surface. Hydrogen embrittlement, although unlikely, is still possible if parts are cleanedby pickling. When appropriate,coatingsof zinc, tin, cadmium, or an alloy of cadmium can be applied by mechanical plating processes. Cadmium, zinc or more commonly alloys of the two can be applied to steel spring wire during its production, and under some circumstances this alternative is highly desirable. It is best suited to small diameter wire and, in general, for the production of springs not requiring grinding. Springs are almost always in contact with other metal parts. In a corrosiveenvironment, it is important that the spring material be more noble than components in contact with it. Table 3-6 shows a partial list of alloys in increasing order of nobility. When any two alloys are placed in contact in the presence of an electrolyte, the less noble alloy (higher on the list) will be attacked. The anack will be significantly more vigorous than that of the electrolyteactingby itself. Table 34. Order of Nobility. G*lvnnic Serics $itb,,'gl$ Magnesium Zinc Aluminum Cadmium Steel or Iron Cast Iron StainlessSteel, series 300 (active) Hastelloy@ C Nickel (active) Inconel (active) Hastelloy B Brasses,Bronzes Monel Nickel (passive) Inconel (passive) StainlessSteel, series 300 (passive) Titanium gs,,se*ry8t8r. te ,gneh Least noble (+), Anodic

ffi

Most noble (-),

Cathodic

HASTELLOY is a registeredtrademark of Cabot Corporation.

ffi{*, Yffiffi
fFJ','r. iil;-

Spring Materials The list of coatingswhich protect the base material by acting as a barrier to the environment is extensive and increasesas new finishes and techniquesare developed. Table 3-7 shows protection available from some of the common barrier finishes. This information is not for selection purposes;it simply shows the rangeof protection afforded. In fact, the hours of salt spray protection may only be valid for the specimenand test conditions employed in this series of tests. The tests were conducted on springs which had undergone 4 million cycles in a fatigue test prior to salt spray exposure. While coatings frequenfly increase in effectiveness as their thicknessesare incrbased, cautions are in order. Tendencies to crack increase as coating thickness increases,and the coating increasesthe size of the spring. For example, coatings increase the solid height and diametral clearancesrequired for compression springs. Brittle coatings such as epoxy can chip under impact, leaving unprotectedspots. Tough coatingssuch as vinyl resist chipping, but bruises, tears or abrasions can expose the base material and trap corrosive agents. This allows corrosionto continue after exposure,and in these circumstances coated springsoccasionallyexhibit shorter lives than uncoated springs. Frequently oils, waxes or greasesprovide adequate protection. Effectivenessof these coatings is often dependent on the nature of the surface to be protected. In general,lustrousor smooth parts will not retain oils, and waxes, paraffrn-based oils or greasesare recommended. Steelscan be phosphatecoatedby a conversionprocess. Phosphate coatings have a high retention for oils, greasesor paints. The combination of a phosphate and oil coating becomesa colTosion inhibitor more effective than either of the components. A similar effect is obtained by retaining or deliberately forming oxides on metal surfacesto hold corrosion inhibitors or lubricants. Oil tempered spring wire is a notable example of this technique. Spring Wire Tensile properties of spring wire vary with size (Figure 3-3). Common spring wires with the highest strength are ASTM 228 and ASTM 401 materials. ASTM A313 Type 302, A232 and A230 materials have slightly lower tensile strength with surface qualities suitable for fatigue applications. Hard-drawn (ASTM 227) and oil tempered (ASTM 229) are also supplied at lower strength levels and are most suitable for static applications. Most spring wires can be wrapped on their own diameter (bent around a pin with a diameter equal to the wire diameter). Exceptions include some copper-based alloys and large diameter and/or high strength alloys. Becausestress relieving increasesyield strengthof cold drawn spring wire, all sharp bends of this grade material should be made prior to stress relief. Tahles3J.
hotective Materiat

SaIt Spray Resistance of Common Barrier Finishes.

Stsnderd SaIt Spray Test Resistancc,hours Description Dark colored, usually dipped, cured by baking. Usually applied by spraying. Air dried. Hard finish; applied by spray, brush or dip; cured by air or baking. Lubricating, rustinhibiting, hard drying and nondrying oils. Chemical treatment converting steel surface to iron phosphate crystalline surface. Affords a bond for oils and paints. Electroplated or mechanically plated.

Paints: Japan Lacquer Enamel Paint

15-20 31100 5G400 2s-300

Oils, waxes Phosphateswith supplemental oils, waxes, etc. Cadmium, zinc

l-300 2440

24-100

This information is basedon laboratory-controlled applicationsand test. The protective material selected,cleanliness of parts, method of application, subsequentoperations and part usage affect performance.The choice of a spring finish must also consider shipping, assembly,end use and total cost.

ffiA"o#fil,&F'*ffiK$

Spring Materials Tabk 34. PreferuedDiameters for Spring Steel Wire.

ftrril Hrrtnct M*trk Sillri {ftm, Sr*cnd Third PrEfrnmr Prcfcrcns

EnglicbSirrs {la.) First $cmrd hrcfcrrnc hefttwmcc 0.004 0.005 0.006 0.008 0.009 0.010 0.01l 0.012 0.013 0.014 0.015 0.016 0.0r7 0.01E 0.019 0.020 0.021 0.022 0.024 0.026 0.028 0.030 0.031 0.033 0.035 0.038 0.040

0.10 0.r 2
0.16

0.1 I 0.r 4
0 .r 8

0.20 0.22 0.25 0.2E 0.30 0.35 0.40 0.45 0.50 0.55 0.60 0.65 0.70 0.80 0.90 1.0 I.l t.2
1.4

Spring Strip Most flat springsare made from AISI grades 1050,1065, 1074and 1095steel strip. These compositions are listed in ASTM specifications A.682 and A684. Tensile strength and formability characteristics are shown in Figure 3-4. The vertical inclined bands delineate three strength levels as functions of stock thickness and hardness. Horizontal curves indicate minimum bending radii required for the strength levels they intersect. Interpolations can be made between any two bands or lines for intermediate levels. Formability criteria are given for relatively smooth bends made at reasonablebending rates. Operations which apply forming forces other than smooth bending, or have impact characteristics, may require larger radii to prevent fracture. Four-slide part manufacture, progressive die work and secondary forming are examples of operations that often produce less than ideal bending.

Table34. Ranking of Relative Costs of CommonSpring Wires.

ffii;$ Wir! ffi,,#.2.mu
ll&wc

t.6
1.8

Snt t

2.0

') ',
2.5 2.8 3.0

2.1 2 .4 2.6
3.2

0.u2 0.045 0.u7 0.04E 0.051 0.055 0.059 0.063 0.057 0.072 0.076 0.08r 0.085 0.092 0.098 0.102 0.r05 0.1r2 0.120 0.125 0.130 0.135 0.140 0.148 0.156 0.t62 0.170 0.t77 0.192 0.200 0.207 0.218 0.225 0.250 0.262 0.2E1 0.306 0.312 0.343 0.362 0.375 0.406 0.437 0.459 0.500 Patentedand Cold Drawn ASTM A227 ASTM A229 Oil Tempered Music Carbon Valve Spring ASTM A,228 ASTM A23O

,,,,,,il1,,,,,,: -Wrm,i,t 1

:::,,.,,:::: !|1}...'It*',...
Izrrn

1.0 1.3 2.6 3.1 4.0 7.6 8.0

ll

1.0 1.3
1.4 1.9

3.5 3.8 4.2 4.5 4.8 5.0 5.5 6.0 6.5 7.0 7.5 E.5 9.0 9.5 10.0 r1.0 12.0 13.0 14.0 15.0 16.0

ASTM A4OI Chrome Silicon Valve StainlessSteel (Type 302) ASTM A3l3 (302) PhosphorBronze ASTM StainlessSteel (Type 631) ASTM A 313(631) (17-7 PII) Beryllium Copper Inconel Alloy X-750 ASTM BI97

3.9 4. 7 6.7 8. 7

27 44

t7 31

Table3-10. Standard Tolerances Spring Wire. for

Dlrrmttr: rnar{ln,} tohrw: ulur,{lil;} tl&#m:Ost ,d"Mnrrr:
,,il;il,,,{*n.}

(o.ooo4) 0.514.71 (0.020-0.028) 0.olo (0.0284.078) t 0.015 (0.0006) 0.71-2.00

(0.0784. tE) 2.00-3.00 I 3.00{.00 (0.118J.240)
6.0G9.00 (0.24G4.354) (0.37s4.62s) 9.50-r6.00
+
f

(0.000+) 0.010 (0.0005) 0.015 (0.0008) 0.020 (0.0012) 0.030 (0.002) 0.050 (0.0028) 0.070

(0.000E) 0.020 (0.0011E) 0.030

r 0.050(0.00197) + 0.070(0.00276)

Most spring wires can be purchased to tighter tolerances. Music wire and most nonferrous materials are regularly made to closer tolerances.

ffiAssEslf;g&ffi*ffws

SpringMaterials Direction of bending with respect to rolling direction is an important consideration. Formability of strip is greater in transverse than in longitudinal directions (Figure 3-5). If a part is designedwith two identical bends at 90" to each other, it is common practice to orient the part so that both bends are made at 45oto rolling direction. Dmensionless parameter2rlt, often referred to as bendfactor, is frequently used as a measureof formabilit1'. Materials with low values are more formable than materialswith high values. This measureis only a guide since it does not allow for tooling considerationsand complex strains associated with forming operations. Spring steels are nonnally produced to specifiedhardnesslevels which are related to tensile strength (Figure 3{). Composition is not shown in Figure 34 because the lowest carbon level (AISI 1050)can be used at high strengthlevels and the highest carbon level (AISI 1095) canbe temperedto the lowest strengthlevels. In general, higher carbon levels are used when strength is critical and lower carbon levels when formabilitv is critical. Fig. 34. Minimum TransverseBending Radii for Various Tempers and Thicknessesof Tempered Spring Steel. Hardness levels above HRC 50 result in high strength but are not generally recommended due to notch sensitivity. Surfaceand edge smoothnessbecomecritical and plated parts become highly susceptible to static fracture due to trapped hydrogen. Parts which cannot be made within formability limits of pretempered strip are made from annealedstrip and hardened and tempered after forming. To maintain critical dimensions,it is often necessaryto fixture temper these parts. Sharp bends are not only diffrcult to fabricate but are also undesirablein service because stress of concentration. The formability limits of annealedspring steels are presented in Table 3-1 1. In flat spring designs where the edge of the strip becomes an edge of the part, the type of edgeis important, particularly for cyclic applications. Common types of edges available are shown in Figure 3-7. Slit edge (No. 3) and deburred (No. 5) are preferred for blanked parts and static applications. No. I round edge is recommended for cyclic applicationsto reduce the stressconcentration and eliminate the edge flaws due to slitting. Configurations shown in Figure 3:7 are approximate, and it is advisableto use both the numerical designation and a description when specifying edge condition. Commercial thickness tolerances for spring steel strip presentedin Table 3-12. Many flat springsand spring EIre washer designscan tolerate this variation. Sincethe load varies as the cube of the thickness, critical designsmay require closer tolerances. Fig. 3-6. TensileStrength versus Hardness of Quenched and Tempered Spring Steel.
l0 k9. DPH or Vickers (VHN) 350 450

ff

E E
o

1.0
o
J

S o.7s
.c
F

44

46

48

50

52

Rockwel Hordncss(HRC) I

Fig. 3-5. orientation of Bend Axis to Rollins Direction for Transverseand Longitudinal B-ends.
-) lndicotesDirectionOf Rolling

24o E_
al

2zo *,
g 6

N 1 : 2 r

Ntn
---t,.
Tronsverse Bend Also known os ocross the groin, p e r p e n d i c u l o rt o t h e r o l l i n g direction. Eosy or good woy.

2oo+
.o

Nrffi
Longitudinol Bend Also known os with the groin, porollel to rolling direction. Hord or bod woy.

,o g

r8o E 5
160

t40

120

28 32 36

40

444648 50 52 54

Rockwell Hordness (HRC)

Spring Materials Other Spring Materials A variety of materials other than carbon steel strip is used for flat springs(Table 3-13). When high conductivity is required, copper base alloys are usually specified. Stainlesssteelsare used in applicationsrequiring heat or corrosion resistance.Typical tensile strength levels'for these alloys after heat treatment are shown in Table 3-13. Bend factors and tensile elongationsare for alloys in "as received" condition prior to final heat treatment. Specifyrng Hardness Hardness tests are used extensively to inspect strip and flat springsand it is necessaryto specify the correct scale. Recommended hardness scales for steels are presented in Table 3-14. To obtain accurate readings free from the effect of the anvil, it is important to limit the thickness of the material for each hardness scale as shown in Figure 3-8 for hard materials and Figure 3-9 for soft materials. Fig.3-7. EdgesAvailable on Steel Strip.
No. I Edge

_l l :l
)

SQUARE Stondord moximum corner rodius:0.08 mm (0.003') ROUND Stondord

No.3 Edge

NOR'VIAL SIIT AS

BLUNT ROUND Speciol

'No.5 Edge

OVAL
Speciol

_l
No.3DEBURRED

_l
Table3-11. Formability of Annealed Spring Steels.

BROKEN CORNERS Speciol

*Iffi r0s
Ntll ,

AI$I T065 Hrlt

Annwkd ($tardflrd lsw{st mnx.)

*IS,*qid tfrs : t: . :, ::,:il,{i A

.i..'t,,.,. tt,..'I: ...[-{i .,.,

'::il$#$

Ttulcknmr {(} mrn (in,l

Di:recti*n nf: Ssn6

Ann*n|ed rd {*ta tpr*iffit rnnx.)

*nn tr$st.
lmregt ,,
t.!l{x"}i

Annerlsd Aaar*bd {sp l.; {ffiid 'lwnst , bnffit'.

filflX,l*

,, ,.l{illffit::,, .i#ffiffi'. :..,,i,[Ufte$: . ',.m&X;},,' : ,.,'1114.1g;)i,: ,,,r,s**:l} ,, ,,,.ifm.i|,*

,,.{W.,,.. t
0 3 0 I 0 I 0 0

,,,i{ffi:
I 4

1 . 9m m (0.076)-over 0.9 -1 .89 m m (0.036{.075")

I ll
I

2 4
I 2

0 3 0 I 0 0 0 0

2 4
I 2

0 0 I 0 I 0 0

2 4
I 2 I IU2 1 I

3 ) 2 3
1 2 I I

ll
I

0 2 0 I 0 U2

0.374.89mm (0.0154.035) 0.2-O.36 mm (0.008{.014j

il il

0 I 0 0

0 IU2 0 0

Formability is determined slowly bendinga sampleover l80ountil its by ends are parallel. The measureddistance between the ends is Nt. For example, N1 = 4 and t:2, then Nr/1 = 2 if *Availableas Barco-Form@ from WallaceBarnesSteelsubsidianv of Theisof America, Inc.

Tolerances. Table 3-12. TyoicalHigh-CarbonStrip Thickness

Thhkns*: mrn{in,} Srrip t?.7*?6.1 (0.50*?.99)

'#*tqgry,,Pffi;1iffi. rl;,, t#idth:

t | rnm.{tor.} 76,3*]S4.fl f3 jfffl*12.00) (0.00025) 0.906 (0.0m35) 0.009 (0.00050) 0.013 0.0r3(0.000s0) (0.00075) 0.019 (0.001s0) 0.038 (0.00200) 0.051 (0.002s0) 0.063

0. l0-0.25 (0.004-0.010)

0.005(0.00020)

0.25-0.5(0.010-0.020) I 0.5 l-0.76(0.020-0.030) (0.030-0.erc) 0.7Gt.02 t .02- .s2(0.040-0. | 060)

(0.060-0. | .52-2.03 080) (0.0E0-0.00) 2.03-2.s4 l

(0.00025) 0.006 (0.00035) 0.009 (0.00040) 0.010 (0.00050) 0.013

0.025(0.00100) (0.001s0) 0.038

(0. 2.54-3.r8 r00-0. 125)

(0.00200) 0.051

Precisionrolled high-carbonsteelstrip is availablecommerciallyat tolerances considerablvlessthan the valuesstatedabove.

Spring Materials FA. J-d. Ilinimum Safe Thicknesses Hardness Testfor ing Hard Materials.
( DPH I ks) 500 600 900 800 .r_----t0.040

Fig. 3-9. Minimum Safe Thicknesses Hardness Testfor ing Soft Materials.
DPH( I kg)

r00

r20

r40

2 E

i =
o

r
0.020
F

2 P
i

iS
'7 E

0.0r 0

E
.

;E
.= :

,til
at

o . E =

5 E

35 40 45 50

55 60 65 70 Hordness N.umber

60

65 70 7s 80 Hordness Number

85

Tabb 3-13. Typical Properties of Spring Temper Alloy Strip.

,,,,,:8fsd , , :, .';F l'{.1 ,}

ldfrtrr,*$l Steel, spring temper Stainless301 Stainless302 Monel 400 Monel K500 Inconel 600 Inconel X-750 Copper-Beryllium Ni- Span-C BrassCA 260 PhosphorBronze I1J PH RH95O l7J PH Condition C
(l ) Before heat treatment.

Tendlc@rySr

ntra {rtr rd}

(246) r70o (r89) 1300
(189) 1300

in c50 c40 c40

895

t:l:t ,;,',,,., .,rif.1;tl:':.,,rr,t;,,,;,,;,;:. :.,fst.m|,. ,,, h,qns., b)

2 8 5 2 40 2 20 2 6 3
J

b
:l,:t;i1,,::,

5 3 4 5 5 2 3 5 2
J

20.7(30) (28) 19.3 (28) 19.3 (26) 17.9 17.9(26) 2r.4(3r)

0.30 0.31 0.31 0.32 0.29 0.29 0.29 0.33 0.33 0.20 0.34 0.34

(151) 1040
(152) 1050 (189) 1300 1400(203)

(100) 6e0 (r74) rz0o

c34 c30 c35 c40 c42

B90 890

2r.4(3r)
12.8(18.5)

r8.6(27)
ll (16) (1s) 10.3 20.3(2e.s) 20.3(29.s)

620 (e0) 6e0(100) (210) 1450 (239) 1650

c4
c46

6 1

2.5 flat 2.5

Tsblc3-14. Recommended Hardness Scales for Hard and Soft Spring Alloys.
Thickness:mm {in.} "tnncrlcd Stcd and Finnfcrmnr Albys C A 30N r5N DPH

(0.035) over 0.89 and (0.025-0.034) 0.64J.86 (0.01 0.35{.61 5-0.024) (0.0084.014) 0.204.36 Under 0.20(0.008)

B 457 307 r5 T DPH

Assogfrlfi8 ffi &tr*ffiws

Helical Compression ngs Spri

'.,

..:

,,11

q
*

,t,, ,:;,.;;
',

: ::

li:',

1 *<,

!n,
-

ff
k* Asso8Ftfigi%Fr*'Fs

}
I

I I -

Helical Compression Springs Introduction Helical compressionspringsare used to resist applied compressionforces or to store energyin the push mode. They have the most common spring configuration and are found in many applications such as auiomotive, aerospace and consumer goods. While the most prevalent form o-fcompression spring is a straight cylindri-d spring made from round wire, many other forms are produced. Conical, barrel, hourglass or cylindrical forms Ere available, with or without variable spacing between coils. Suchconfigurationsare usedto reducesolid height, buckling and surging, or to produce nonlinear load deflection characteristics. Energy storage capacity is greater for round wire compression springs than for rectangular wire compression springs and can be increased by nesting. Rectangular wire is sometimesemployed to reduce solid heightor increasethe spaceeffrciencyof the design.Most die springs are made from rectangular wire for this reason.The SPEC line of springscontainshundredsof compressionspring designsusing wire sizesfrom 0.15 to 5.26 mm (0.006" 1o 0.207') diameter music or stainlesssteel wire. Specifying SPEC springssavesdesigntime, reduces cost for low volume applications and offers improved delivery. Helical Compression Spring Terminologr Special terminology has evolved in the spring industry to describefeaturesof helicalcompression springs.These terms are defined and the relationship between terms is reviewedin Figure 5-1. Communicationbetweendesigner and springmaker is improved if these common terms are used. Spring Diameter Outside diameter, inside diameter and mean diameter are all used to describe helical compressionspring dimensions. Mean diameter is equal to the sum of O.p. and I.D. divided by two, and is employed in spring design calculations for stress and deflection. The O.D. is specified for springs that operate in a cavity, while the I.D. is specified for springsthat operateover a rod, seat or shaft. Minimum diametral clearance between the spring and cavity or rod is: 0.05D - when D. is greater than 13 mm (0.512') 0.10D- when D. is less than 13 mm (0.512,) D. is the diameter of the rod or cavity. Fig. 5-1. Dimensional Terminology for Helical ComDiameter increases when a spring is compressed. Although the increase in diameter is usually small, it must be considered when minimum clearances are established. The increase in diameter is a function of initial spring pitch and can be estimated from the following equation where p : pitch.
O.D.4*1;6 =

P2-d:
*2 tl

+ d

(s-t)

If the spring ends are allowed to unwind, the O.D. at solid may be greater than calculated by this equation. Long springs buckle (see Figure 54, page 35) and may require lateral support and larger diametral clearances. Spring Index Spring index is the ratio of mean diameter to wire diameter or radial dimension of the cross section (Figure 5-15, page 40). The preferred index range is 4 to lZ. Springs with high indexes tangle and may require individual packagrng, especially if the ends are noi squared. Springs with indexes lower than 4 are diffrcult to form. Free Length Free length is overall spring length in the free or unloaded position (Figure5-1). If loads are not critical, free length should be specified. When definite loads are required, free length should be a referencedimension that can be varied to meet load requirements. Pitch is the distance between centersof adjacent coils and is related to free length and number of coils. Type of Ends Types of ends available are: plain ends, plain ends ground, squaredendsand squaredends-ground (Figure 5-2).To improve squareness and reduce buckling during operation, a bearing surface of at least 270" is required. Sguared and ground springs are normally supplied with a bearing surface of 270 to 330". Additional grinding results in thin sections."squared ends only" are preferred on springs with small wire diameters (less than 0.5 mm or 0.020), a large index (gtreaterthan 12) or low spring rates. Squared ends cost less to manufacture than squared and ground ends.

fi

an.h1

,
A

l |

+r Il f",.
d L r

-T

i Porollel s m ( e p )

nssgpffi,&gmp$ffi

Springs Helical Compression Number of Coils Total number of coils should be specified as a reference number. For springs with squaredends, the total number of coils minus two is the number of active coils. There is some activity in end coils, but during deflection someactive material comesin contact with the end coils and becomes inactive. Experience indicates that this equation is a good approximation. The number of active coils in springs with plain ends is greater than those with squaredends and dependsupon the seatingmethod employed. Some useful guidelinesfor estimatingthe number of active coils are presented in Table 5-1. Solid Height Solid height is the length of a spring with all coils closed. For ground springs, solid height is the number of coils multiplied by wire diameter. For unground springs, solid height is the number of coils plus one, Fig. 5-2. Typesof Endsfor Helical CompressionSprings. multiplied by wire diameter (Table 5-1). If critical, solid height should be specified as a maximum dimension. After allowances are made for plating or other coatings, it is good practice to add one-half of the wire diameter to determine maximum solid height. With larger wire sizes and fewer coils, this allowancecan be decreased. Solid height is often measuredby applying a force equal to 110 to l5Vo of the calculatedload at solid. If solid heigtrt is not critical, this dimensionshould be omitted. Direction of Coiling A helical compression spring can be either left or righthand coiled. If the index finger of the right hand can be bent to simulate direction of coil; so that the fingernail and coil tip are approximately at the same angular position, the spring is right-hand wound (Figure 5-3). If the index finger of the left hand simulatesthe coil direction, the spring is left-hand wound. If direction of coiling is not specified, springs may be coiled in either direction. Nested springs with small diametral clearancesshould be coiled in opposite directions. Squarenessand Parallelism springscan be meaof Squareness helical compression sured by standing a sample spring on end on a horizontal flat plate and bringing the spring against a straightedge at right angles to the plate. The spring is rotated to produce a maximum out-of-square dimension e, (Figure 5-l). Normally squared and ground springs are square within 3owhen measuredin the free position. Squareness should be checked at both ends. Specifying squareness or parallelism in the free position does not assuresquareness or parallelism under load. Parallelism (Figure 5-1) refers to the relationship of the ground ends, and is determined by placing a spring on a flat plate and measuring the maximum difference in free length around the spring circumference ep. Hysteresis Hysteresis is the loss of mechanicalenergy under cyclic loading and unloading of a spring. It results from frictional losses in the spring support system due to a tendency of the ends to rotate as the spring is compressed. Hysteresis for compressionsprings is low and Fig.5-3. Direction of Coiling Helical Compression Springs.

ffi@ffiffi@
PloinEnds Coiled Right-hond Squoredond Ground Ends Coiled left-hond Squoredor ClosedEnds Not Ground, Coiled Righrhond PloinEndsGround Coiled Lefi-hond

Table 5-1. Guidelines Dimensional Characteristicsof for Compression Springs.

Ttxtqd':SS$
Ollftior
:,Oif,;1

,Di

'

,, ,,,fhfu,,:, . , f i , . , $gurd Ouly {tr{t:,,$K[{l {G

(Nr + l)d
Ntd (Nt

',',,,,G
Ntd*

r.sc*d
,"

Solid Height (Lr) Pitch (p) Active Coils (NJ Total Coils (Nt) Free Length (Lr)

+ l)d

Lr-d N.
Lr-d p
Na

Lr
Nt

Lr-3d
Na

Lr-2d
Na

L r r p
Na+l

Lr-3d p

Lr-2d p

N"*2
pNa+3d

N"+2
pN6+2d

pNt+d

PNt

(:-f

-Coiled Right-hond

-*--) ( ---fL---

-l-

*For small index springslower solid heights are possible.

Coiled Left-hond

WA"SS;$ &ffi&ffiffi$

HelicalCompression Springs
the contribution due to internal friction in the spring material itself is generally negligible. Spring Rate Spring rate for helical compression springsis defined as the changein load per unit deflection and is expressed as shown:
, r
: - : -

Stress Wire in a helical compression in spring is stressed torsion.Torsionalstressis expressed as:

t:H*-

(s4)

gD3N.

(s1)

This equation is valid when the pitch angle is less than l5o or deflection per turn is less thanD/4. For large deflections per turn, a deflection correction factor (Reference 3, page 102) should be employed. The load deflection curve for helical compression springsis essentially a straight line up to the elastic limit, provided that the amount of active material is constant. The initial spring rate and the rate as the spring approachessolid often deviate from the averagecalculated rate. When it is necessary specify a rate, it should be to specified between two test heights which lie within 15 ro 85Voof the full deflection range (Figure 54). When compressionsprings are used in parallel, the composite rate is the sum of the rates for individual springs. For compressionsprings in series, the rate is calculatedfrom:

Bending stressesEuepresent but can be ignored except when the pitch angle is greater than 15oand deflection of each coil greater thanD/4 (Reference3, page 102). Under elastic conditions, torsional stress is not uniform around the wire cross section due to coil curvature and a direct shear load. Murimum stress occurs at the inner surfaces of the spring and is computed using a stress correction factor. The most widely used stress correction factor Kwr is attributed to Wahl. It is shown below and in Figure 5-5. 4C - I 0.615 r(wr:4c-4 c

(s-s)

In some circumstancesafter yielding occurs, resultant stressesare distributed more uniformly around the cross section. Then, a stress correction factor Ks,2 which accounts only for the direct shear component is used. Kwz:1+

0.5 C

(s4)

k-

- J - - I -

(s-3)

kr

kz

kr"'kn

This relationship is often used to calculate the rate for springs with variable diameters. The technique involves dividing the spring into many small increments and calculating the rate for each increment. The rate for the whole spring is computed from the rate of the increments according to the equation above. Fig. 54. Typical Load Deflection Curve for Helical Compression Springs.

In other circumstances,such as static loading at elevated temperatures, stress distribution tends to become uniform around the cross section and can best be estimated by using no correction factor. Use of different stress correction factors can lead to confirsion. In published data, it is essentialto know which stress correction factors were used. (The stress correction factor used by a designer must be the same as that used to develop the data.) Methods to calculate stress for different applications and the use of stress correction factors will be Fig. 5-5. Wahl SrressCorrection Factorsfor Round Wtre Helical Compression and Extension Springs.
2.2
I 4C-1 ., Awr=4c-4I 0.615 c

2.0
For 2e/o set point or fotigue n q

J r.8
o

Kw2=l*t

; Y
o o
I

For springs with set removed

't.6

I
{*,*'

t r.4 3

I 6 C=D/d

Assosl$lfi8&ffi*ffiffiffi

Helical CompressionSprings discussedin the following paragraphson choice of operating stresses. loads When deflection is known, loads are determined by multiplying deflection by the spring rate (Equation 5-Z). When the stress is known or assumed,loads are determined from Equation 5-4. The procedure used to determine loads of variable rate springs is complex. In this case, the load deflection curve is approximated by a series of short chords. The spring rate is calculated for each chord and multiplied by deflection to obtain the load. The load is then added to that calculated for the next chord. The processis repeateduntil load has been calculated for the desired value of deflection (Figure Critical buckling conditions are shown in Figure 5-7 for axially loaded springs with squared and ground ends. Curve A is for springs with one end on a flat plate and the other end free to tip (Figure 5-8). It indicates that buckling will occur when the spring design is above and to the right of the curve. A tendency for buckling is considerablyless for springs compressedbetweenparallel plates as shown in curve B. For applicationsrequiring springs with a high aspect ratio and large deflections, several springs can be used in series in a tube or over a rod, with guides between the springs to prevent binding. Choice of Operating Stress - Static Conditions For static applications, the yield strength or stress relaxation resistance of the material limits the loadcarrying ability of a spring. The spring is required to operate for a limited number of cycles, and the velocity of the end coils is low to preclude high stressesdue to surgtng or impact conditions. Maximum allowable torsional stressfor helical compression springs usedin static applications is presented in Table 5-2 as a percentage of the tensile strength for common spring materials. For springs that do not contain beneficial residual stresses induced by set removal, maximum allowable torsional stress values are from 35 to SVo of the tensile strength. To calculate the stressbefore set removal, it is necessary to use the Ks,1 correction factor. If the calculated stress at solid is greater than the indicated percentageof tensile strength, the spring will take a permanent set when deflected to solid. Amount of set is a function of the amount that calculated stress at solid exceeds the indicated percent of tensile strength. Fig. 5-7. Critical Buckling Condition Curves.

s4).

Loads should be specifiedat a test height. Becausethe load deflection curve is often not linear at very low loads or at loads near solid, loads should be specified at test heights between 15 and 85% of the full deflection range (Figure 54). Loads are classified as static, cyclic or dynamic. In static loading applications, the spring is expected to operate between specified loads only a few times. Frequently, springs in static applications remain loaded for long periods of time. In typical cyclic applications, springs are required to cycle between specified loads from 10,000 more than a billion cycles. During dynamto ic loading, the rate of load application is high and causes a surge wave in the spring which will induce stressesthat exceed the value calculated from Equation 5-4. Buckling of Compression Springs Compression springs that have lengths greater than four times the spring diameter can buckle. If properly guided, either in a tube or over a rod, buckling can be minimized. However, friction between the spring and tube or rod will affect the loads, especially when the aspect ratio (I4lD) is high. Fig. 54. Load Deflection Curve for a Variable Rate Spring.

CD 0, o

.9
u q,

o ii o
d,

f1

t2 f3 Defleaion --1.

f4

ps = krfr + kz(fr - fr)...ks(fs- fr)

Helical CompressionSprings To increase the load-carrying ability of springs in static applications,it is common practice to make the spring longer than its required free length and to compressthe spring to solid. This causesthe spring to set to the desiredfinal length and inducesfavorable residualstresses. This processis called removing set or presettingand can be conducted at either room or elevated temperatures. The loss of deflection from the free position to solid by cold set removal shouldbe at least lVo.If the set is less, it is diffrcult to control the spring's free length. Ratios of stress greater than 1.3 lead to distortion and do not appreciably increase the load-carrying ability. This is illustrated schematicallyin Figure 5-9. Allowable torsion stresses springswith set removed in (Table 5-2) are significantly hiefier than for springs that have not had set removed. It is important to note that because yielding has occurred during presetting, the stressis relatively unifonn around the cross section and it is calculatedusing the Kwz stresscorrection factor. Set removal is an added springmaking operation which increasesthe manufacturing cost but gfeatly increasesthe energy storage capacity of the spring. Set removal is common for critical springs made from premium materials. In some instances, springs have the set removed during an assembly operation. Fig.54. End Conditions Used to Determine Critical Buckling.
A End Free to Tip

If the calculatedstressusing the Ks,2stress correction factor exceedsthe percentageof tensile stength indicated in Table 5-2, the spring cannot be made. In this case, it is necessary to either lower the stress by altering spring design or selecting a higher strength material. In some applications, maximum operating stress is limited by material stress relaxation resistance and amount of load loss that the design can tolerate. When load is constant, these designs are limited by material creep resistance. When the spring is compressed at a fixed test height, stress relaxation resistance of the material is limiting. Designs limited by stress relaxation resistanceaxemore common than designslimited by creep resistance.It is suggested that creep-limited designsbe reviewed by Associated Spring engineers. loss acStress relaxation is defined as percent load cording to the following relationship:

il

= vokelaxation

x too

(sJ)

B End FixedAgoinst Tipping

ffi m
@

P++

R
cations.

ry

ffi
--'/A
- V A

rA_-H

P" is load at test height before testing. Pr is load at test height after testing. Typical stress relaxation data (Figure 5-10) indicate that at high stresses, some spring materials such as music wire exhibit appreciable stress relaxation after only 100 hours at temperatures as low as 100"C(zn"q. These data are only representative of the conditions indicated. Stress relaxation is affected by material, spring processingvariables, time, temperatureand stress. Associated Spring engineers should be contacted for critical applications involving stress rela,ration resistance. When set is removed at an elevated temperature, the process is called heat setting. It significantly improves the stress relaxation resistance of springs (Figure 3-2, page 16) at moderate temperatures and is frequently a more cost-effective method for achieving low levels of stress relaxation than specifying a more costly spring material. Fig. 5-9. Spring l-oad-Carrying Ability versusAmount of

\\ \\\\\\ \\\
Fixed End

Table 5-2. Maximum Allowable Torsional Stresses for HeIicaI CompressionSprings in Static Applinot Bendingor buckling stresses included.

E
d

o E s o .D
c

Maximun EaoI Tcmile Mitsrirk Patented and cold drawn carbon steel Hardenedand tempered carbon and low allov steel Austenitic stainless steels \onferrous allovs
::..,B rc.r5tl ,{Ktvi}

r $ct Erurgrcd fi[#r] 60-70 65-75

o 3n tn o o
tt g

0.6 0.4 0.2

o o

Stresses Are Colculoted At Solid.

o
.t1
ol d,

55-65

1. 0
55-65

r.l

r.2

1.3 1.4
c

1.5

Stress Before Set Removol "t:ffi:i,

Assog&ifi8 f&ffi#ffiffis ffi

Springs Helical Compression Choice of Operating Stress - Cyclic Applications In cyclic applications, the load-carrying ability of a spring is limited by material fatigue strength. Velocity of end coils is low compared to the natural frequency. To selectthe optimum stresslevel, it is necessaryto balance spring cost versus reliability. Reducingoperating stressspring reliability as well as cost. A complete es increases knowledge of operating environment, expected life, stressrange, frequency of operation, speedof operation and permissible levels of stress relaxation are required in order to make the best choice between cost and reliability. Becausemaximum stress is at the wire surface, any surface defects such as pits or seams severely reduce fatigue life. Shot peening improves fatigue life and minimizes the harmful effect of surface defects, but it does not totally remove them. Maximum allowable design stressesfor fatigue applications should be calculated using the Kwr correction factor and are shown for common spring materials in Table 5-3. These values are for a stress ratio of 0 in an ambient environment with no surging. Note that shot peeningincreasesthe fatigue strength by as mudr asZVo at lives of 10 million cycles. Values in Table 5-3 are guidelines for designers and of shouldonly be used in the absence specific data. Most springsdesignedto recommendedstress levels will exceedthe indicated lives; however, in the absenceof detailed information on material, manufacturing method and operating conditions, it is not possible to quantify the reliability level. Fatigue Life Estimation Example Fatigue life at other stress ratios can be determined from Table 5-3 according to the procedures outlined in Section 4. A short example illustrates the procedure: Estimate the fatigue life of a not-shot-peened helical compression spring loaded sinusoidally at a rate of one cycle per second.The spring is flooded with oil and operates at a maximum temperature of 40'C (104"F). The material is ASTM A228 wire and ends are squared and ground. The design is given here: d = 1.00mm (0.039') C = 8 I+ = 20.5 mm (ref) (0.807') Lr : 17.5mm (0.689? Lz: l0 mm (0.394') L,:8mm(0.315') Nt:8 Spring rate is determined from equation:
d . t= GEtr o=3'2Nimm , f*tiglrr Llfr {*yrhr}

Stressesare calculated using Equation 5-4 and are:

s=#r*,

Sr : 232 MPa Sz : 810MPa S, : 955 MPa

Tensile strength of the wire is 2180MPa (Figure 3-3, page 19). The stress at solid is 44Voof the tensile strength. Referring to Table 5-2, the maximum stress allowable before sit removal for ASTM A228 is 45% of tensile strength. Therefore, the spring can be made and does not require set removal. To estimate the fatigue life, it is necessary to: l. Plot an S-N curve on a modified Goodman diagram (Figure 5-11) using the data from Table 5-3 for notshol-peened springs and a tensile strength of 2180 MPa. 2. Plot point A on the 45" line at 67Voof the tensile strength. 3. Plot the stressrange coordinates, point B. 4. Estimate the life by drawing a line through AB. At the intersection of this line with the vertical axis, point C, ' draw a horizontal line to intersect a S-N curve. The point of, interse'Jon, D, is the estimated life of 2,500,000 cycles. Dynamic Loading - Impact -When a spring is loaded or unloaded, a surge wave is established which transmits torsional stress from the point of loading along the spring length to the point of iestraint. The surg wave travels at a velocity approxi-mately I / l0 of a normal torsional stress wave. Velocity of the torsional stresswave (V1) is given by:

Vr = 10.1./9 m/sec (or) Vr : ./9 p in./sec 64) - - Y p Y

Velocity of the surge wave V. varies with material and spring design, but is usually in the range of 50 to 500 m/sec. The surge wave limits the rate at which a spring can absorb or release energy by limiting impact velocity V. Impact velocity is the spring velocity parallel to the Tabte 5-3. Maximum Allowable Tbrsional Stesses for Round Wire Helical CompressionSprings in Cyclic Applications.
Pcrccat af Ttuih S&eagth

i:

I=

*$rll{ A?p8',*s rtrd $teinllrs $e?cl

l{mfrrrous

A$TM AEN d llld;$hot-, f,,e,nd

Al3Z

Loads are calculated from be: x P , : ( 2 0 . 5- 1 7 . 5 ) 3 . 2 : x P 2: ( 2 0 . 5- 1 0 . 0 ) 3 . 2 : P,= (20.5 8) x 3.2:40

the deflections and found to 9 . 6N 3 3 . 6N N

I$5 t06 r$?

tlot Shot F*ilrrd

'fu.',
f*md

shd.
PoGnGd

This information is basedon the following conditions:no surging,room temperatureand noncorrosiveenvironment-

36
''J

3{1

4? 39 3S

at *0 t?,

49 4? 4S

=g = ratio Stress in fatigue Pi,lil+ s maxlmum

wnsso5ff1ffi ,'ffi,m*ffirys

Helical Compression Springs Fig. 5-10. Spring RelaxationDataforVarious preset roomtemperature tested hours were Materials. Springs at and lM o indicated temperatures. initial stress Kwtcorrected. The is
MusicWire,ASTM4228, 1.57 mm (0.062") rl40 Stoinless Sreel302 Wire, ASTMA313, 1.57 mm (.062") 140

r30 ? 8oo

r30 r20

3
! 7oo ar,
s

o-

l-roo3
o v,

=
o tn

CL

o o a.n o

600

l-80 s s00 400

0
Reloxolion, Lood Loss (o/o)

Reloxolion, Lmd Loss (o/o)

Wire,ASTMA401, 1.57 ro 3.76 mm (0.062,'to Chrome-Silicon O.l4S").

r000

VonodiumWire, ASTMA232, 1.57 io 3.76 mm (0.062"to 0. 140") Chromium l-140

I

140

*9
=
rtl al

r30
i

i-r 20
llo i.
0 4

ll0

roo3
9 0 ;
E

=
rt

g*" 1,. j

i-rooI

8 0 = 70 60

10

Reloxotion,LoodLoss("/o)

CorbonVolve SpringWire, ASTM A230, l. 57 to 3.76 mm (0.062"ro 0.148,,)

Inconel Alloy X 750 Wire, 1.93mm (0.075')

t
r20

tt

i ^ oi-----<,t, e/

ilo? '100 =
v,

70 60 50

r5

Reloxolion, Lood Loss (o/o)

SPrings Helical ComPression spring axis and is a function of stress and material constants shown as: IT (or) v = 10.tt{ft m/sec V = tV#

in./sec(s4)

This is a surprising result becauseimpact velocity and stress are independentof the spring configuration. For steels, impact velocitY reduces to: V:*m/sec (or) v:*in./sec 6-tot

phehigh velocities are frequently subject to resonance nomena (page 39). -'Wh;; itreiatio'of the weight to be accelerated to the weijtrt of the spring is lesslhan 1, surge-wave theory (Figure 5-12). ;";;;"iy frea-icls-design performance velocities, an energy Ai frigtt iveight ratios and lower is ujed to predict velocity of a weight projected t"d; th;- rprng "ia o, deflection of the spring when il;are rei.pu.t"o uv u ."rr. velocity and deflection lated as: For horizontal loading:
( s- 11)

If a spring is compressedto a given stress level and releasediistantanebusly, the maximum spRqg velocity as tti stressdivided by 35.5. Similarly, if il;6;;rseo is loaded at a known velocity, instantaneous u tpting stresscin be calculated.At very high loading velocities, instantaneous stress will exceed the stress calculated from the conventional static formula (Equation 5-4) and *ifi fitnit design performance. Thesg equatigns for impu.t u.focity are bttt' concerned with the_primary surge *uu". Frequently, this wave will reflect from the other at end of the-spring, in.t."ring stress. Springs loaded

r: 3l.ovfY.- (or)r: v,ffii"'

For vertical loading:
(s-12)

-m w. -/w w r: 31.6v#i + u mm (or) f : v{*[ + 1-m'

w/g is the mass that is being accelerated or decelerated "nO-V is the axial velocity of the spring'

Fatigue Ltfe' Fig. 5-11. Modified Goodman Diagram for Estimating

(103Psi) Minimum Stress

:=
4 o A

=
o tn E E x o

o o ttl E t

.E x
o

StressCycles

Helical Compression Springs These equations assumethat the spring is massless and should only be used when the spring mass is less then 114 of the mass to be acceierated. When the ratio of spring load to weight is less than 4. the energy required to acceleratethe spring itself becomes appreciable. By assuming that all mass of the springis concentratedat the moving end, Equations5-10 and l-l I can be corrected by substituting (W + W,/3) for W where W, is the spring weight. Qnamic Loading - Resonance Resonanceoccurs in a spring when the frequency of the cyclic loading is near natural spring frequency or a multiple of it. Resonancecan increase individual coil deflectionand stresslevels well above amountspredicted by static or equilibrium analysis. Resonancecan also causespring bounce, which results in loads considerably lower than calculated at the minimum spring deflection. To avoid resonance,natural spring frequency should be at least i3 times the operating frequency. The natural frequency of a compressionspring ls lnversely proportional to the time required for a surge wave to traverse the spring. For a compression spring without damping and with both ends fixed: For a vibration isolation system, the essential characteristic is that the natural frequency of the springmass system be as far as possible from the disturbing frequency. Filtering of disturbing forces may be calculated as: % offorce transmitted: +, a / n ) ' - I x 100 6-14) (n

where no is the frequency of the disturbingforce and n the natural frequency of the spring-mass system (Figure 5-13). If rq/n is lessthan l, the denominator Equation 5-14 in should be changed to I - (no/n)2. Note that the frequency n in this equation is the frequencyof the springmass system and not the natural spring frequency. In fact, the most commonly used equation neglecti the splng weight and is only deflection dependenr. The general equation is:

n:

15'8 (or) .E metric n: j,p 7r YP

ensrirn6-ts)

(s-r3)

" : %#,ry'

ror n: $fi!} steel

l4oood F

metric

n = gD2N" ,./qg: for steelrr: \ p

ffiF

English

n is in hertz. If a spring cannot be designed the natural frequency so is more than 13 times operating frequency, or if the springis to serve as a vibration damping device, it must utilize one of several methods of energy absorption. Generally,these are friction devices in which the spring rubs against another element such as an internal damper coil, arbor, housing or another portion of the spring. Variablepitch springs and springs in combination aie also occasionally used to avoid or minimize resonant frequencyeffects. Fig. 5-12. Velocity of an Object Propelled by a Compression Spring.
1.4
For moss rotios of : Over 4 - use cose (i ) t l -4 - use cose (2) 'l | | Under - use cose (3) t l t d Moss Theory (2) | I I
I

Special Springs Previously in this section, design considerationsfor round wire helical compression springs of uniform diameter were discussed.These design techniquesare modified below and applied to many special spring configurations. Special springs are chosen to fulfill a unique set of design criteria. Springs from rectangular wire and stranded wire as well as variable diameter springs with conical, hourglassand barrel shapes,zlrdiscussedbelow. Helpful guidelines for nested springs are also reviewed. RectangUlar Wire In applications where space is limited and particularly where solid height is restricted, springs designedfrom rectangularor keystonedwire are often selected.Associated Spring manufactures hundreds of rectangular wire spring designs.These springs are commonly referred to as die springs and are available for immediate delivery. Fig. 5-13. Transmissibilityof Spring Mounting.

\\
4

\o

9 1

sts
e

1.0

Concenirole

5 r 'Er
J-F fl!\'\ n /

ot
0.6
\Mortt"ss

t
Vo = Velocity

0.4
Vm = Moximum Velocity

<
3

Spring Theory(l )

x l0O = 7o of Force tronsmitted

| l

3.0 2
Moss Roiio PiW,

3.5

Asso(;iated,r.*

Sprinq r'l.##*trile#$

y!'n, T3

Helical CompressionSprings Springs made from rectangular wire, with the width of the rectangle perpendicular to the spring axis, store more energy in a smaller space than equivalent round wire springs. Even though stressdistribution around the rectangular cross section is not as uniform as the round wire section, the energy storage capacity is higher because more material can be incorporated into the allocated space.Rectangularwire is more costly than round wire, but less costly than keystoned wire. Keystoned wire is processed specially so that deformation during spring winding or coiling causes the cross section to become approximately rectangular. Distortion of the cross section can be estimatedfrom the equationpresentedin Figure 5-14. However, distortion dependsupon the manufacturing technique employed and this equation is at best an approximation. Axial dimensional change of the wire must always be consideredwhen calculating solid heights of rectangularsprings. The rate for a compression spring made from rectangular wire is expressedas follows: Stranded Wire Springs Long springs with many coils, when subjected to higb rates of load application Etsin automatic weapons, encounter shock wave motion and can literally be torn apart. Stranded-wire springs are often the most successful solution to such problems because of the frictional resistancebetween the strands. To function properly, the helix of a spring must be opposite in direction to the helix of the strands, so that the strandsbind together when the spring is compressed. The stranded-wire spring may be wound with 2, 3 or more strands. Springs with four or more strands are made with a center wire core to assure necessary stability. Ends should be soldered,brazed or welded to prevent unraveling. Recognizingthat a stranded-wire spring can be considered as single-wire springs aranged in parallel, spring rate is derived on the basis given by: ,

= k: p/rffi*,
s--*ftr,or#*.

*:

KnGda

8DN

(s-r7)

Since the wire is loaded in torsion, the rate is the same whether the wire is wound on flat or on edge (Figure 5-15). Values for the constant K2 are shown in Figure 5-16. Stressis expressed as:

where K : correction factor and n = number of strands. For a three-strand spring, K = 1.05. Fig. 5-15. RectangularWire Compression Spring Wound on Flat or Edge.

(s-r8)

-l - T r nI l.| | rt

till.
_lSpringWound=9 c -

Values for Kr are shown in Figure 5-16, while values for the stress correction factor for springs wound on the flat (Kr) and springs wound on edge (K.) are shown in Figure 5-17 and 5-18. When rectangular wire is produced by rolling round wire or if the cross section of the wire deviates significantly from a rectangle, additional correction factors are required. Whenever a round wire cannot be usedbecause solid height exceedsspecifications,it the is possibleto try a rectangularwire coiled on edgewhere: , _ L l+b/t and d is equal the wire diameter for the equivalent round wire spring. A typical value for a width to thicknessratio of 2 may be assumedin the initial design calculations. Fig. 5-14. Wire Cross Section Before and After Coiling
Keyslone

? t l ; < 1l - D h a c i . i i l , ' - - t l lt l I *

t tF
t

Dt2-*, S p r i n g W o u n d " = 9 On Edge

l*-u-

Fig.5-16. Constantsfor Rectangular Wire in Torsion.

il

l0

Before Coiling

l-l
l-l

Spring Axis

Rectongulor b

K2

I-] l
b1

/r,
/ / /

After Coiling

l-l l

/
l

I 0 t,=t(C+'5)

0.r0

0.20

0.40 K' ondK,

0.50

0.60

0.70

ffiAssogFifig R**Fs /#i,

Helical Compression Springs An approximation for torsional stress in each wire of the strand is given by Equation 5-4:
S =;;l(qr1

8PD--

Maximum allowable stress after set removal should not exceed 55 to 60% of the material tensile strength. Wire diameter (d,) for a single strand in a stranded wire spring is less than the wire diameter for a monolithic spring with the same mean diameter and rate.
lr,lumber of Strands

Wire Size

2 3

4 Stress in the stranded-wire spring is also less than the stress in an equivalent monolithic spring. Fig, 5-17. Stress Correction Factors for Rectangular Wire Compression SpringsWound on FIat.
r.5

d, greaterthan 0.79 d d. greaterthan 0.69 d d, greaterthan 0.63 d

Yariable Diameter Springs Conical, hourglass and barrel-shaped springs (Figure 5-19) are used in applications requiring a low solid height, increasedlateral stability or resistance to surgxng. Conical springs can be designed so that each coil nests wholly or partly into an adjacent coil. Solid height can be as low as one wire diameter. Rate for conical springs usually increases with deflection (Figure 5-20) because progressivelyas the the numberof active coils decreases spring approaches solid. By varying the pitch, conical springs can be designedto have a uniform rate. Rate for conical springsis calculated,as indicated previously, by consideringthe spring as many springs in series. Rate for each turn or fraction of a turn is calculated using Equation 5-2. Rate for a complete spring is then determined, remembering that the spring rate follows the series relationship given previously in Equation 5-3. To calculate the highest stress at a given load, the mean diameter of the largest active coil at load is used. Solid height of a uniformly tapered, but not telescoping, spring with squared and ground ends made from round wire can be estimated from:

il

Lr:N".,ffi
\ \

+2d

(5-re)

1.4

where u : the O.D. large end minus the O.D. small end divided by 2N".
-c=,1

t
v

;
.9
I

1.3

Fig.5-19. Typical Conical, Barrel SpringsRespectively.

and Hourglass

3 o

1.2
C=8 C- l0 C- l2
't.5

I
2.0 2.5 Rotio b/t 3.0 3.5 4.0

r.0

Fig. 5-18. ,StressCorrection Factors for Rectangular Wire Compression Springs Wound on Edge.
1.5

Fig. 5-20. Typical Load Deflection Curve for Variable Diameter Springs (Solid Line).

\
:

g
Y

1.4

\ \ \ \ \ \ \ \ \ \
I C=3
I

! .9

1 . 3\

g
I o

r.2

N
\ \ \ \ \
'r.5
2.0

C=4
-14 C=6

C=10-

-:y
C=12

1.0

2.5
Rotio b/t

3.0

Assogslfig lhff*ffiffisffi

Helical CompressionSprings Designing a variable diameter spring so that adjacent coils rub against one another during deflection increases resistanceto resonancephenomena may also shorten but spring life due to wear. Barrel and hourglass springs are calculated as two conical springs in series. Variable Pitch Variable pitch springs (Figure 5-21) are used to achieve a variable rate similar to that shown in Figure 5-20 or in dynamic applications where the cyclic rate of load application is near the natural spring frequency. As turns of lesser pitch becomeinactive during deflection, the natural frequency of a spring changes. Throughout the cycle, the spring has a spectrum of frequency responseand not a single resonantfrequency. Thus, surging and spring resonance Ere minimized. Nested Compression Springs Helical compressionspringsare often used in combination becauseof spacelimitations and resonanceconsprings can store siderations.A nest of compression more energy but will have lower natural frequencies than a single equivalent spring. Nested springs are not recommendedwhen the diametral space is so restricted that a single spring would have an index of 5 or less. apply to nestedsprings: The following design practices 1. To prevent internesting,the springs should be wound alternately left and right-hand. 2. Clearancebetween springsmust be at least twice the diameter tolerance. 3. The most efficient distribution of load between individual springs varies with their indexes and the clearances between them. For a first approximation in designing a nest with two springs,one-third of the load should be on the inner spring and two-thirds on the outer spring. 4. Solid heights and free heights should be about the same for all springs. These practices result in springswith approximately the same index. Commercial Tolerances Standard commercial tolerancesfor free length, diameter and load are presentedin Tables 54, 5-S and 5{. Tolerance on squareness 3o. These tolerances repreis sent a good trade-off between manufacturing costs and performance in most applications. Certain premium methods can be used to spring materials and processing Fig. 5-21. Typical Variable Pitch Helical Compression Spring. achieve tighter tolerances. If the application requires tighter tolerances, required tolerancelevels should be the discussedwith an Associated Spring engineer. For fatigue applications, spring life is often specified. Unless otherwise stated, life is interpretedas the Srolife. This is the life at which 9Vo of the springs are expected confidence level basedon Weibull to survive with a 50Vo analysis. Acceptable Quality l-cvel (AQL) Quaitv levels are often expressed by an AQr, (for example MIL-STD-l05, Sampling hocedures and Tables for Inspection by Attributes). Only critical attributes should be subject to an AQL on the drawing. Unnecessarily tight AQL's will increase manufacturing and inspection costs. If tolerances must be close for proper functioning and if, for instance, nonconforming parts can be discarded at assembly, a standard AQL will minimize the parts cost. Springs assembled automatically often require tight AQL on dimensions, while springs used in instruments and critical machines often require tieht AQL on loads and life. A close liaison between Aisociated Spring engineers and the designerduring design and prototype phases is the best way to ensure optimum quality. Packaging Normally, compression springs and other custom parts are packaged in bulk. Compression springs with high pitch angles and large indexes are subject to tangling. Tangling not only makes it diffrcult to separate springs upon arrival but can also cause distortion. SpeciA pictcigrne systemssuch as the Spring FlowrM system where springs are packaged in rows (Figure 5-22) is one method to prevent tangling. Another method is to place springs on adhesive-coatedcomrgated panels. There are Toble54. Free Length Tolerances of Squared and Ground Helical CompressionSprings.
I!*ur*lbar of Aeli?e Coi.l'* par rnrfi{in.} ffinrmt* 4 t:rntu/nm {h.ltn,} of fr&cril E

ro

t2

T{

,5

0.02 (0.5) 0.04 (l) 0.08 (2) 0.2 (4) 0.3 (E) 0.5 (12) 0.6 (16) 0.8 (20)

0.010 0 . 0 1 l 0.012 0.013 0.015 0.0r6 0.016

0 . 0 1 l 0.013 0.015 0.016 0.017 0.018 0.019

0.013 0.015 0.017 0.019 0.020 0.022 0.023 0.016 0.018 0.021 0.023 0.024 0.026 0.027 0.019 0.022 0.024 0.026 0.028 0.030 0.032

0.02r 0.024 0.027 0.030 0.032 0.034 0.036

0.022 0.026 0.029 0.032 0.034 0.036 0.038 0.023 0.027 0.031 0.034 0.036 0.038 0.040

for For springsless than 12.7mm (0.500) long, use-the-tolerances 12-7 mm (0.500). For closedends ndt glound, multiply abovevaluesby 1.7'

!r'n:nl other packagingmethodsused to prevent tangling and reduce shipment bulk. Em to Specitv Tbere are many ways to specify compressionsprings. Becauserhe number of variablesis large, it is useful for the designerto usethe specificationchecklist on the next page to be sure that all critical aspects are specified. Compression Spring Desrgn Example Given: Squaredand ground compressionspring to work in a hole DH : 40 mm (1.575') and exert Pr:275 N (61.8 lbfl at a height of Lt : 60 mm (2.362') and Pz : 500 N t lll lbf) at a height of Ia : 50 mm (l .96y). Application: sadc at room temperature. Material: oil tempered wire ASTI1 N29. Spring must not set when compressedto solid height. A. First estimatethe wire diameter by solving equation (Equation A, page33) using approximatevalues for = unknown factors and Kq,1 1. Then, calculateO.D. and D. Substitute this wire size in the load deflection equation (Equation 5-2, page 33) and solve for N". Repeat this process until a satisfactory solution is obtained. l. Rearrangng Equation 5-4 for uncorrected stress:

HelicalCompression Springs - 4.2- 33.8mm D = 38.0

59- ?-T:22.5 = Rate k = N/mm -50

60N": |rJ""=

c =? = # : 8 . 0
8m
Gd4

(7.93 x 104) (4.2)o =

8G3*8n22i)

3.55

B. Find amount of space left between L2 and L5: 1. Compareto f2. 2. Find the corrected stress at solid height. 3. Compare to tensile strength of material. See Figure 3-3, page 19. L , : 5 . 5 5x 4 . 2 : 2 3 . 3 )1\ P, , I4: * Lt : + 60 :72'2 mm kt zL:t fz: 72.2- 50 : 22.2mm Lz - L, : 50 - 23.3:26.7 mm f, = 72.2 - 23.3 : 48.9 mm 15%of 48.9 : 7.3 mm 4C - l .615

A: T o _ vlz.ssPD
l. Assum" ,.nril. strength of ASTM Al2}gis 1500MPa and S: = 700 MPa uncorrected:

K w r :f f i +

a:=

1.18

'/ffi,
Y

P ,: f . x k : 4 8 . 9 x 2 2 . 5 : 1 1 0 0 N
cr _ 2.55P,D___ (2.55)(il00)(33.8)(1.18) b' : -5-K*t : 1510 MPa 4 . Tensile strength of 4.2 mm diameter wire : 1400 MPa. Before set is removed,ma:cimumallowable torsionai stress is 5Vo of TS or 700 MPa (Table 5-2, page 35). S, = 1510is greater than 700 MPa, and the spring will set. C . Because (L, - L,) : 26.7> 0.15f, :7.3, there is more spaceavailable. Try a larger preferred wire size (Table 3{, page 20) of 4.8 mm. TS = 1400 MPa, D : 38.0- 4.8 : 33.2mm, C = 6.9 N":

d -

r r - - T . ! r r l l l l

700

3. For clearance, assumeO.D. :0.95 Ds: O.D. : 0.95x 40 : 38.0 mm Tablc 5-5. Coil Diameter Tolerances of Helical Compressionand Extension Springs.
$pring lrdn {D/d} t IB L2 l{ t6 0.38 0.05 0.05 0.08 0 . 1 0 0 . 1 3 0 . 1 5 0 . l E ( 0 . 0 1 t (0.002) (0.002)(0.003)(0.004) (0.00s) (0.006) (0.007)
4 6

Wirc IXa.,

Tolemmffr: t:mm:,(lui)

E(iD.)

0.58 0.05 0.08 0.10 0 . 1 5 0 . 1 8 0.20 0.25 r0.023) (0.002) (0.003)(0.004)(0.006) (0.007)(0.008)(0.010)

(7.93 l0a)(4.8y x :

0.E9 0.05 0 . 1 0 0 . 1 5 0 . l E 0.23 0.28 0.33 r0.035)(0.m2) (0.004)(0.006) (0.007) (0.00e) (0 .0 1 l )(0.013) 1.30 0.08 0 . 1 3 0 . 1 8 0.25 0.30 0.38 0.43 (0.05 (0.003) (0.005) (0.007) (0.010)(0.012)(0.0r5) (0.017) r) 1.93 0.10 0.lE 0.25 0.33 0 . 4 1 0.48 0.53 (0.076) (0.004) (0.007) (0.010)(0.013)(0.016) (0.019) (0.021) :.90 0 . 1 5 0.23 0.33 0.46 0.53 0.9 0.74 r 0 . 1 1 4 (0.006) (0.00e)(0.013) ) (0.01E) (0.021)(0.025)(0.029) 1.y 0.20 0.30 0.43 0.58 0 .7 1 0.84 0.97 (0.171) (0.008) (0.012) (0.017) (0.023) (0.028)(0.033)(0.038)
6.3,( 0.28 0.38 0.53 0 . 7 1 0.90 1.07 1.24 (0.250) ( 0 . 0 1 l )(0.01s) (0.021) (0.028) (0.035) (0.042) (0.049) 9.53 0.41 0 . 5 1 0.66 0.94 t.l7 1.37 1.63 ( 0 . 3 7 t (0.016) (0.020) (0.026) (0.037) (0.046) (0.054) (0.064) 11.70 0.53 0.76 r.02 r.57 2.03 2.54 3 . 1 8 r0.500) ( 0.021) (0.030) (0.040) (0.062) (0.0E0)(0.100) (0.12s)

8(33.2)3 Qz.s)

6.4

L, : 8.4 x 4.8 : 40.3mm Lz-L.:50-40.3:9.7mm f, = 72.2- 40.3 - 31.9mm (Lz - L,) : 9.7 > 0.15f, = 4.8 mm = P, : (31.9)(22.5) 718N

rawt=(4x6.9)-4-et= s , - @ : 6 7 t (4.8)' Mpa S. : 671MPaot ffi

(+X6.e)_l*#:r.zz

x loo - 48vo rS of

Assos$tf;g& wB ffi*ffirys

Helical CompressionSprings
CHECKLIST SPECIFICATION SPRING COMPR,ESSION (Fill in requireddoto only)
Moteriol: Wo*ing Conditions: To work in To work over m(in.) diometer hole m(in. dismeter shoft Frequency of looding Required life Required reliobility (see Section 4) Speciol Informotion: Porollelism Squoreness Finish Moximum operoting fem Peroture Operoting environment Electricol/ mognetic Design Dofo (Reference): Wire diometer Outside diom lnside diometer Free length Totol number of coils

cYcles'

Lood

* (1b0,

tl (lb0

:c("F)

x (tbO
(lbf/in.) (lbf/in.), t -N/mm Rote -N/mm qnd -mm(in.) between -rnm(in.) mm(in.) Moximum solid height Direction of coil (right-hond, left-hond or opfionol) Type of ends Alfowobfe reloxotion -o/o lmpoct looding Hours/doys mm/sec (in./sec)

mm(in.)

of Tablc 54. Load Tolerances Helical CompressionSprings.

X.*ugth Tskrarr* ::mm {in.}

r"*,l""*' *qb."r1yrd..y{,*t pry|,]:i Tl.e.ry

, .:I

,,to',.[ , mm {in.) fien f,romfre*,,I '19*,1 "28*, t*.1 fO;il,.,'l?6 ,,.1, "V,67, 10.2 'l;3;7' ?.54 3,*r. 5"S0 ,,f,$$ .i,ltrEl ,,:1 ,: 1:,7 ,' (0.400,1{ 0 } {s-.?50} (s.s3o) {r;tr} (r (2'ffi1 {,s,;} {*$1 {6iffi} {0,ltr} {0,1$6} {0"m,}{0,2sJ t0.300)

, l.Y'H.bl,f:

(0.00s) ,: 0.13 (0.010) 0.25 (0.020) 0.51 0.76(0.030) 1.0 (0.040) r.3 (0.050)
1 . 5 (0.060) 1 . 8 (0.070) 2 .0 (0.080)

7. t2. 22.

6. 8.5 15.5

5. 7. t2. 17. 22.

6.5 10.

l.s

8.s

5. 7.

6. 8 l0 12 l4 l6 l8 6. 7.5 9. 5 6 7 8 9 10 s 5.5

T4 ))

r8

9.5 t2. 1 5 . 5 12. 14.5 19. 22. 25.

17. 19.5 22.

10. 11. 12.5

14. 15.5

6. 6.5 7.5

5. ).) 6.
5. 5.5 8.5

2.3 (0.0e0) 2.s (0.100) 5.1 (0.200) 7.6 (0.300) 10.2 (0.400) 12.7 (0.500) deflectron. of Firstloadtestat not lessthanl5Vo available deflection. Finalload test at not morethan85%of available Fis.5-22. Tansled Helical CompressionSprings (Left) and-Spring Flow P ackaging.

20. :

1l t2 22

6 8. 8.5 7 1 5 . 5 t2

7.

17 2l 25

9.5 7 . t2. 8.5 1 5 . t2. 18.5 14.5 10.5

Again referring to Table 5-2, page35, it is clear that the spring can be made without presetting. Tolerances are obtaineOfrom Tables 54, 5-5 and 5-5. The final design becomes: Final Design Specifications: Material: ASTM A229 Wire Diameter d: 4.8 mm (0.189) Reference + O.D.: 38.0 -r 0.4 mm (1.500 0.050) (2.843') Reference Free Length I-r: 72.2 mm Test Height Lr: 60 mm (2.362') Test Height Lz: 50 mm (1.96Y) Pr Load at Lr: 275 N (61.8 lbO = ll.0% Pz Load at L2: 500 N (112 lbO =7Vo Final Design StressS,: 671 MPa (97,300psi) or 48%TS N,: 8.4

Helical Extension 7 ngs I Spri

o"tF'!fi349*nrrs !t

HelicalExtensionSprings Introduction Helical extension springs store energy and exert a pulling force. Usually, they are made from round wire and are close-wound with initial tension. Typical applications players,balancescales,toys, garage includetape cassette doors, auiomatic waJhing machines and various types of spring tensioning devices Helical extension springs are stressed in torsion in the body. Design proceduresfor the body are similar to those pleviously for compressionsprings(Section5) discussed with the following major exceptions. Most helical extension springs are coiled with initial tension, equal to the minimum force required to separateadjacent coils. Helical extension springs do not normally have set removed. Furthermore, untit<e compression springs, extension springs do not have a solid stop to prevent overloading. For thesereasons,designstresslevels are generally lower for extension than for compression springs. A special type of extension spring, known as a drawbar spring (figurl 7-1), has a solid stop. It is essentiallya compression spring with special hooks. Fig.7-1. Drawbar Spring Provides a Solid Stop. The pulling force exerted by an extension spring body is tranimitted to mating parts througfi hooks or loops. When stressesin the hooks are higher than in the spring body, the hooks limit spring performance. Alsociated Spring includes hundreds of different extension spring designs with full twist loops in its SPEC line of stbck iprings. These extension springs are made from.either music wire or stainless steel and are preengineeredto meet a wide range of applications. Initiat Tension Initial tension in an extension spring is rneasured according to the procedure illustrated in Figure 7-2. T\e linear portion of the load deflection curve is extrapolatgf to zero deflection. The point of intersection on the ordinate is initial tension Pr. The amount of initial tension that can be put into a spring depends upon its index, material, method of manufacture and postcoiling stressrelief treatment. Occasionally, in critical applications is when stress is high, a high stress-relief'temperature required to minimize unfavorable residual stresses due to Loiling or forming the hooks. High temperature stress relief reduces the amount of initial tension. Typical values of initial tension are shown in Figure 7-3. High strength materials such as small diameter music wire are able io support higher levels of initial tension than low strength materials such as large diameter hard-drawn wire. Types of Ends -Extension springs require a method of attachment to other parts in an assembly. A wide variety of ends has Fig.7-3. Torsional StressDue to Initial Tension as a Function of Index in Helical Extension Springs.
300

Fie. 74. Load Deflection Curvefor a Helical Extension Spring with Initial Tension.

t
Lood (P)

275

t
|
t v

250

22s 30
t
A O

P1

=3 2oo
U =
9 c

: 8.
to " c
o o -

gg t7s
o . 9
U|.=

2s E.g 9 c
5 P 20;E g s
.n
; 6

j f rso
Deflection(f)

3s tn
;tg

125

.E roo T I t
7s
50 25 l0 lndex--+ 12
I4

rs.ET
p 6
l0
I t

l6

HelicalExtensionSprings been developed and used successfullyfor many years for example,threadedinserts, swivel hooks, twisi loops, side loops, cross-center loops and extended hooks. l-oops are attachment ends that have small gaps (Figure -{). while hooks.are loops with a large gap. In fact, the 'ariet-v-of ends is almost unlimited. The most common configurations are those that can be formed during the springmaking operation. Typical types include twist, crosscenter, side loops and extendedhooks (Figure 74). Man), of these configurations are made by bending the last coils of an extension spring to form loops. Most special hooks are formed from straight sectioni of wire on the so-called "tangent ends" of an extension spring body. Guidelines for the lengths of common loops are presented in Figure 74. Alrhough other configuiations and lengths are available, common loops of preferred lengths are generally the most eccnomical. If possible, a spring should be designed with one or both loops at the prefered length. For example, if a design requires a-total loop length equal to five times the I.D., a popular choice is one twist loop with a length equal to the I.D. and one extended loop with length equal to four times the I.D. Wheneverpossiblefor extendedloops, the designer should allow for a straight section approximately three wire diameters long at the end of the wire (A, Figure 74). Loops at each end can be made with a controlled angular relationship. Specifying an angular relationship may add to the cost; therefore, whenever an application permits, a random angular relationship should be allowed. Production of special end configurirtions may involve tool charges and generally resufts in increasedcosts. Stressesin loops are often higher than in the spring body. This limits spring performance, particularly in cyclic applications. Generous bend radii in loops and reduced end coil diameters are two methods frequently employed to reduce stresses.In a full twist loop, stress reachesa maximum at point A in bending and a maximum in torsion at point B (Figure 7-5). Stress at these locations is complex, but can be estimatedwith reasonable accuracy by:

se: S*,

#bending
lRr

t-rt

w h e r e K t - 4 Ct 2 f C a t d c r : ? ? : + tf - i t-n

8DP/4C,-l\ 2R, A Ss: andCz: torsion e4t A \4ffi) ? practice is to make C2geater than four. Recommended Fig.7-5. r,ocation of Maximum Bending and Torsion Stresses Twist Loops. in
P

rl
,-r;lF(--=r:f--

\ ltl
)

Torsion Slress otB

Fig. 74. common End configurations for Helical Extension Springs.

hceCImm*ndd,,Lrn#h* Min"-t\{sx, I 0 . 5 - 1 . 7. D .

?ypr
Twist Loop or Hook

-W J m
t

::'--::i"T_
A\UZ
-Tr-rr-7r-

#@

Cross Center Loop or Hook

Side Loop or Hook Extended Hook
I

-TrnF

rmA
- 7r
I

/A

ullv/

\Jlz

I.D.

-uNz rz
A A
vvvvvvv -ffi

v pQ
I

I.D. 0.9-1.0
l . l I . D .a n du p as requiredby design

Special Ends

'

<
I

@-F
t
'

a )i L v l

6i lZl Y \
l g

' length is distancefrom last body coil to inside of end. I.D. is inside diameter of adjacentcoil in spring body.

As requiredby design

A'"oEFIf;g &wwyvW

Helical ExtensionSprings Extension Spring Dimensions Free length of an extension spring is the distance between the inner surfaces of the ends (Figure 7-6). It is equal to the spring body length plus ends, where spring body length is given by Lur, = d(N + 1). The gap, which is sometimes referred to as hook or loop opening, can be varied by the springmaker. Certain manufacturing processes require a minimum gap and the designer should consult Associated Spring engineersif a gap must be less than one-half wire diameter. The number of active coils in a spring is approximately equal to the number of coils in its body. For springs with threaded inserts or swivel hooks, the number of active coils is less than the total coils in the body. Hooks and loops add to the number of active coils. Allowances of 0.1 N" are occasionally made for one-half twist loops. Allowances as large as 0.5 N" can be made for some cross center, full twist and extended loops. Desigp Equations Design equations for extension spring are similar to compressionsprings. The rate is given by:
16:

Choice of Operating Shess - Static Recommended maximum stresses for extension springs used in static applications (Table 7-1) are similar to levels recommendedfor compression springs without set removal. For springs that cannot be adequately stress-relieved due to high initial tension requirements, the ma,rimum recommendedstress in the body should be reduced to that recommended for their ends. Maximum recommended stress in the ends is lower than in the body because the wire is often stretched, marked or distorted during loop-making. Choice of Operating Stress - Cyclic Maximum recommended stresses for extension springs used in cyclic applications are presentedin Table 7-2. These data are for stress-relieved springs with low levels of initial tension. ('Kn,Corrected) Tabte7-1. Maximum Allowable Stresses Helical Extension Springs in Static Applifor cations.
Pcrst of Twih Sftng{h

P-Pr

:m

Gd4

(7-3)

fi4rnniak
Patented, cold-drawn or hardened and tempered carbon and low alloy steels Austenitic stainlesssteel and nonferrous alloys

InT Ddf
45-50 35

n
affd 40 30

In End
75 55

wherePr is initial tension.Stressis given by:

5 =

8PD---liTKw

(74)

Dynamic considerations discussed previously in Section 5 are generally applicable to extension springs. Natural frequency when one end is fixed is given by:

5.6 x ldd n:5;;V7

EE

metnc
metn( metric

(7-s)

This information is based on the following conditions: set not removed and low temperanrre heat treatment applied. For springs that require high initial tension, use the same percent of tensile strength as for end.

t76xlffd forsteeln=j::+W-

Tobb 7-2. Maximum Allowable Stresses ASTM A228 for and Tvpe 302 StainlessSteel Helical Extension Sirings in Cyclic Applications.
Scrwt-of ,.,ill ff,'ffd6 ld 106 107 .. In tordffi Epdl, 36 33 30 Tadk @$

n: ofu.',tr English
Tooog fcr r s t e e l n : N F English
Fig. 74. Typical Extension Spring Dimensions.

In Ucntrry
ffiil
34 30 28

trffi
51 47 45

This inforrration is based on the following conditions: not shotpeened, no surging and ambient environment with a low temperature heat treatment applied. Stress ratio : 0.

EA""Th!8$M

Helical Extension Springs Clearances Extension springs,when deflected,do not require central arbors or holes to prevent buckling. When a spring is dynamically loaded or unloaded suddenly (as a cam drop-off), it may vibrate laterally, inducing additional If stresses. clearanceis not allowed, this lateral vibration may be noisy and result in premature failure from abrasion of the ppring or adjacent parts. Tolerances Since requestingclose tolerancescan increasemanufacturing costs, only those characteristics which are critTable 7-3. Commercial Free Lensth Tblerances Helifor cal Extension Springs Wtttt Initial Tdnsion. $pring Sreelxngttu tirsidn koolrri rnm fin-) (0.500) Up to 12.7 to over 12.7 25.4(0.500 1.00) to Over25.4to 50.8(1.00 2.00) to (2.00 4.00) Over50.8to 102 to Over 102to 203(4.00to 8.00) Over 203to 406(8.00to 16.0) Over406to 610(16.0 24.0) to
Tohrsscs * nrm {in.}

ical to spring performance should have tolerances specified. Commercial free length, angular relationship of ends,and load tolerances presented Thbles7-3, are in 7-4, and 7-5 respectively.O.D. tolerancesare the same as for compression springs (Table5-5, page43). These tables should be used only as a guide since some manufacturing operations have different process capabilities which can cause variations in tolerancevalues. For special applicationsrequiring closer tolerances,consult Associated Springengineers. How to Specify For minimum cost, it is important to specify springs properly. The following checklist is presented a guide. as Table74. Toleranceson Angular Relationshipof Extension Spring Ends.
Arryular Tohranm ptr Coih I Deperx Index 6 7 5 E l0 t2 9 0.9
l.l

0.51(0.020) 0.76(0.030) r.0 (0.040) 1.5 (0.060) 2.4 (0.093) 4.0 (0.155) 5.5 (0.2r8)

4 0.75

t4 2. 6

l6
J

1.3

1.5

t.7

1.9

2.3

For example, tolerance for a lGcoil spring with an index of 8 l0x+1.5=tl5o. If angulartolerance is greater than * 45o,or if closer tolerancesthan indicatedmust be held, consult with AssociatedSpring.

;ff

H E L I C AE X T E N S I O N P R I N G S P E C I F I C A T I O N E C K L I S T L S S CH (Fill in requireddoto only.)

Moteriol Working Conditions: Moximum outside diometer mm(in.)

Suggested Design Doto:

Wire diometer mm(in.)

Outsidedio
Totol number of coils Free length inside ends Speciol Informotion: mm(in.)

I n i t i o ltens ion Lood

of

N (l b 0 N(lbf), +
length mm(in.)

Fi ni sh
Moximum operoting temperoture Operoting environment Frequency of Looding Required life Required Reliobility (see Section 4)

Lood
ot lmpoct Looding

N(lbf), +
length mm(in.) sec (in. /sec) N/mm(lbf/in) mm(in.)

hertz

Rote Moximum extended length in service Direction of coil: right optionol Typ" of ends Posifion of ends ond toleronce Gop opening ond toleronce

) during instollotion left

mm(in.)

Associatgd

SPring

iwffii ..*,,, ':': ';;:ffi "'"' :':ri' :r:;,,r:,.,xff: "M:'6'" "':;";: '

Helical Extension SPrings Table7-5. Load Tolerances Helical Extension Springs. for

i
k&x d
J

a i
I i

Sodg I"e.qgth 1 Uirldcd ,bf Ildlecth*r

Tokrrm*r: * Pstcnt of:,$hgroilld ld qpcl {Cb*rr tohnnct* nry rt@ll dlt*ud Whc Dfiril#cr: *JS t0..CIls) 20.0 18.5 r6.8 15.0 13.1 0;56 (0.f22) 18.5 17.5 16.1 t4.7 LZ.4 9.9 5.4 16.5 15.7 14.8 l3.l 1l.3 9.3 5.4 15.5 t4.7 14.0 12.4 10.8 9.0 5.5

"}

)
3.t {0"r2ft
15.0 14.0 t2.7 11.5 9.1 7.0 4.0 . :, :,'1,!l; {0;lft} 14.3 13.2 11.8
, ::g;l['::.,

*p r r2
8 6 4.5 2.5 1.5 0.5

*s1 {0;03?} t0;0*tl

17.6 16.7 15.5 14.l 16.9 15.8 t4.7 13.5 l1.8 8.9 4.6

,,,,.,f;{

tr"f (0.ffiat
16.2 15.0 13.8 12.6 10.6 8.0 4.3

,,3 f0,0e!) 15.5 14.5 13.2 12.0 10.0 7.5 4.1

t4.l 13.0 11.8 10.5 9.0 7.7 4.2

',:,1'8 {off,f,}

ta;ffSt
13.8 t2.5 tl.2 9.7 8.0 6.1 3.6 12.3 8.8
1 <

t1.l @8n,

r3.0
11.5 9.9 8.4 6.E 5.3 3.3

r0.3
8.5 6.5 3.8
l2.E

r2.r
9 .3 4 .t

r0.2 6.2
l7.E l6.E 15.8 14.2 12.3 10.0 6.2 17.0 16.2 t5.2 13.7 11.9 9.9 6.3 15.8

t2.6 11.0 9.4 7. 9 6.2 4. 8 3.2

I1.5 l0.l 8.7 7.4

t2 E 6 4. 5

? s 1.5 0.5

t5.7 t4.9 13.8 t7.3 1 0 .8 E.9 4 .9

14.6 13.9 12.9 11.5 10.2 8.3 4.9

15.5 t4.3 13.2 tl.7 10.0 E.4 4 .6

t4.I 13.4 t2.3 11.0 9.8 7.7 4.7

14.8 13.5 12.3

1l.l 9.6 8.0 4.4 13.5 12.6 I1.6 10.5 9.4 7.3 4.5

13.5 12.5 tl.4 10.2 8.7 7.2 4.1

12.7 tL.7 10.7 9.6 E.5 6.7 4.1 I1.5 10.6 9.7 E.7 7.7 6.5 4.2 10.5 9.7 8.9 8.1
t.5

tr.7
10.7 9.6 E.l 6.5 3.9

rt.z r0.0
6.2 3.7 11.5 10.5 9.4 E .3 7.2 6.0 3.7

12.0 10.6 9.3 8.0 6.5 5.0 3.4 tt.2 10.0 8.8 7.6 6.2 4.9 3.5 10.0 9.0 8.1 7.2 6.1 4.9 3.6 9.2 8.3 7.6 6.8 5.9 5.0 3.E 8.2 7.5 6.9 6.3 5.6 4.E 4.0
1' '

6.r
4.5 3.3

12 8 6 4. 5 2. 5 1.5 0. 5 t2 8 6 4.5
? s

l3.l 12.2 10.9 10.0 9.0 7.0 4.3 12.0 11.0 r0.0 9.0 7.9 6.7 4.4
10.9

12.0 11.0 10.0 9.0 7.9 6.4 4.0

10.7 9.5 8. 3 7.1 6.0 4.7 3. 4 9. 5 E. 5 7. 6 5.6 5. 6 4. 5 3.5 E. 8 8. 0 7. 2 6.4 5.5 4.6 3. 7 7. 9 7. 2 6.4 5. E <) 4. 5 3.3 7. 0 6.4 5.9 5.4 5. 0 4.5 4.0
6.1 5.7 5.4 5.1 4.7 4.4 4.1

r5.0 t4.2
12.8 tt.2 9.5 6.3

1.5 0. 5 t2 8 6 4. 5 2. 5 1.5 0. 5
t2 8 6 4.5 ) < 1.5 0.5

t4.3 13.7 1 3 .0 rt.7 10.2 8 .6 5 .6 13.3 12.E 12.l 10.8 9.6 8 .3 5 .7

12.3 11.8

13.1 12.5

rr.7

1.0.7 9 .5 7 .8 5 .0 1 2 .0 1r.6 1 0 .E r0.0 9.0 7 .5 5.1

1l.l 10.7 10.2 9.4 8.5 7.2 5.3

1 3 .0 12.l rt.2 l0.l 8 .8 7.1 4 .8

11.9

t2.l

r0.8
l 0.l 9.3 8.3 7.4 6.2 4.1 9.9 9.2 E.6 7.E 7.0 6.0 4.2 9.0 E.4 7.9 7.2 6.6 5.7 4.3
8.1 7.6 7.2 6.7 6.2 5.5 4.4

r0.2
9.4 E .6 7.E 5.9 5.E 3.9 9.3 8.6 8.0 7.3 6.5 5.6 4:0 E .5 7.9 7.4 6.E 5.1 5.4 4.2
7.6
1' '

rr.4
10.6 9.7 8.3 6.9 4.5

r0

14.8 14.2 t3.4 t2.3 10. 8 9.2 6.4

14.0 13.2 12.6

rr.2

10.5 9.5 E.4 6.9 4.9 10.8

1l.l 10.5 9.8 9.0 8.0 6.7 4.7 10.1 9.6 9.0 E.4 7,E 6.5 4.9 9.1 8.7 8.3 7.8 7.1 6.3 5.0
8.1 7.8 7.5 7.2 6.7 6.0 5.1

r0.2 9.3 8.5 7.7 6.5 4.5 9.E 9.3 8.5 E .0 7.4 6.3 4.7
8.8 8.3 7.7
1 J

6.3 4.3 9.5 8.9 8.2 7.6 7.0 6.1 4.5 8.4 8.0 7.5 7.0 6.5 5.8 4.6
7.4 7.2 6.9 6.5 6.1 5.6 4.8

L2

rr.7
10.5 8.9 6.5
13.1 t2.4 11.8 ll.l 10.1 8.6 6.6

rr.2

r0.2
9 .7 9.0 E .0 6 .E 5.1 9 .7 9 .2 8 .8 8 .2 7 .6 6.7 \) 8.6 8 .3 8 .0 7.5 7 .0 6 .2 5.3

1 0 .2 9.2 8 .0 5.8
l1.3 10.9 10.4 9.7 8.8 7.7 5.9 10.3 10.0 9.6 9.1 8.4 7.4 5.9

l4

T2 E 6 4. 5 2. 5 1.5 0.5
t2 8 6 4.5 2.5 1.5 0.5

r0.2
9.8 9.3 8.7 8.1 7.0 5.4 9.2 8.9 8.5 8.i 7.6 6.6 5.5

6.7 6.0 4.8

1 1

6.8 6.3 5.7

< t

4.3
6.8 6.5 6.2 5.8 5.4 5.1 4.5

5.8 6.3 5.8 <) 4.7 4.2 6.3 6.0 5.7 5.3 4.9 4.6 4.3

12 .3

rr.7

l6

11.0 10.5 9.7 8.3 6.7

7.4 7.1 6.8 6.3 5.8 5.0

7.2 6.E 6.5 6.2 >.t 5.3 4.6

Helical ExtensionSPrings r-rtrrdon Spring Desi$ Example -{ spring is to be incorporated into an overload circuit rreaker. It is to be preloadedat length Lr :25.00 mm 0.84-l and must exerta load of 17.5N(3.93lbf), + IsVo, sten the circuit breaker is closed. If overload occurs, Cre circuit breaker is tripped and the spring is extended u a lengrh Lz : 29.00mm (1.142').The load must be 30 \ - ll%. to operatea lock, preventing accidentalresetnng before the malfunction is corrected. Either twist or ertended loops with generousradii are satisfactory.Because of surroundingcomponentsthe maximum O.D. is nrm (0.276'). Probability of overloads is small and t'reaker operation is expected only three or four times rn a )'ear. The spring will not be extended beyond Li during service or installation. For static application, in an ambient environment, the material selected is ASTM A227. l. Assume a clearance O.D. of lWo: on O . D . - ( 0 . 9 )( 7 ) : 6 . 3 m m l. Assume Sz : 700 MPa uncorrected; let D = O.D. :6.3 mm Calculate wire diameter d:
o:

7 . Calculate free length I+ and deflections fr and fz;

assumefull twist loops: I-r : 2(ID) + (N" + l)d : (2)(4.5) (13.2+ 1X0.9) + : 21.78 m m f, = L, - I4 : 25.00- 21.78= 3.22 mm fz: Lz - Lr :29.00 - 21.78: 7.22mm 8 . Calculate initial tension P1 and uncorrected stress due to initial tension 51: N Pr : Pr - kf' : 17.5- (3.13)(3.22):7.42
d sr=--F 2.55 PrD

(2.ss)(7 .42)(s.4) : 140MPa (0.e0)'

Referring to Figure 7-3,it can be seenthat this is in the preferred range for initial stress for an index of 6. 9. Check stressesin the hooks: Bending Stress: 4P f, A :fff' Se l6PD.. - # tKr= 4Cr2 ffi - C- I , ; letCr:C

/zffi \r::
Y J

' i(2.ssx30)(6.3)

Kr:
vA So:

4(.6)2-6-r : 1.142 4(6X6- l) (16)(30X5.i1)9.142) * 1^3%,: LJ 'v Mpa or 1340 '

z(0'90)3 z(0'90)z

700

: 0.88 mm

letd:0.9mm Tensile strength taken from Figure 3-3, page 19, is 1790MPa. D Calculate mean diameter. and coil index C: D = O . D . - d = 6 . 3- 0 . 9 : 5 . 4 m m .

74.9%o TS Torsional stress, where Rz : 2.70 mm: 8P c r =;ArD 1 4 C 2 - 1 \ ^ DB t,: \rc= ) 6 _ (8)(30)(s.4) t4(6) ss: =1ffi (Affi Final Desig Specifications: Free Length l-t 21.78 mm (0.854') Reference Outside Diameter: 6.3 + 0.10 mm (0.248f 0.004'J Wire Diameter d: 0.9 mm (0.035t Reference Initial Tension Load Pi: 7.45 N (1.68lbf) Reference Extended Length L1: 25.00 mm (0.9&4') Extended Length Lz: 29.00mm (1.142') P1Load at L1: 17.5+2.0 N (3.93*0.45 lbO PzLoad atLz:30 +2.5 N (6.74+0.55lbO Final Design Stress Sz: 708 MPa (103,000psi) 40"76 TS N": 13.2Coils Refer to the load tolerances for helical extension springs (Table 7-5). Tolerance on load for P1is -r llVo, which is less than the required + lsVo, and Pz is = 8Vo,which is less than the required + lTVo. - l\ 2Rz

C:Drdi;:6
4 . Calculate mean stressat the extended length:

7 4

):6sr

MPa 36vo or rs

Lz = 29.00DD, Pz = 30 N 2.55PzD., )=: -a3-n*t t w r_ 4 C K :N Su: 1 - 0 . 6 1 5 _ 4 ( 6 ) - I _ -0 . 6 1 _ 1 5 46)----:1.25 c

(2.55X30X5.4)(1.2s)

(0.eOf

: 708 MPa or 4Vo TS

Calculate rate k:

g =,Pt P' : 39^-Y;t :3.13 N/mm r'Le Lz-L, 29-25

6 . Calculate number of coils N": Gd4 N " : d m : fQ.g31 3 . 2 f i : x 104)(0.90)4 rY

AssoS&!fi$,'eP*sqre ffi

Torsion Helical ngs Spri

C C C C C C C C
-

C C

g----''-';

'' "

ff

&

Lff

Helical TorsionSprings lntroduction Helical springs used to apply a torque or store rotadonal energy' are commonly referred to as torsion springs. The two most common types are single and double-bodiedsprings (Figure 9-l). Torsion springs are found in clothes pins, window shades, counterbalance ratchetsand various types of machine commechanisms, ponents. They are also used as couplings between concentric shafts such as in a motor and pump assembly. Torsion springsare generally mounted around a shaft or arbor. and must be supported at three or more points. Yarious kinds of ends are available to facilitate mounting. Torsion springs are stressedin bending. Rectangular uire is more efficient in bending than round wire, but due to the premium cost of rectangular wire, round wire is preferred. If possible, a torsion spring should always be loaded in a direction that causesits body diameter to decrease.The residual forming stressesare favorable in this direction, but unfavorable when the spring is loaded in a direction which increases body diameter. Unless there are unfavorableresidual stressesin the end bends, springmakers normally heat-treat these springs at a low temperatureto stabilize the end positions rather than to fulll' stressrelieve them. If the direction of loading tends to increase body diameter, the springmaker should be advised to stress relieve the springs. The Associated Spring SPEC line contains many torsion spring designsusing stainlesssteel and music wire, either left or right-hand wound. These springs have tangent ends and are available for immediate delivery. \umber of Turns The number of active turns in a helical torsion spring is equal to the number of body turns, plus a contribution from the ends. For straight torsion ends, this contribution is equal to one-third of the moment arms and is usually expressed as an equivalent number of turns: shaft or tube and spring at all times to prevent binding. The ideal shaft size is equal to, or slightly less than,90Vo of the I.D. when the spring is fully deflected (minimum diameter). Shafts significantly smaller than 907a should be avoidedto prevent buckling during large deflections. Length Most torsion springs Ere close-wound, with body length equal to the wire diameter multiplied by the number of turns plus one. When a spring is deflected in the direction that will reduce the coil diameter, body length increasesaccording to: L = d ( N o + 1 + 0 )
(9-4)

For applications that require minimum hysteresis, springsshould be designedwith space between adjacent coils to reduce frictional losses. Spring Rate Spring rate for helical round wire torsion springs is given by: ,
t : - _

l0.8DN"

(e-s)

The 10.8factor is greater than the theoretical factor of 10.2 to allow for friction between adjacent spring coils and between the spring body and the arbor. This factor is basedon experienceand has been found to be satisfactory. Loads for torsion springs should be specified at a fixed angular position and not at a fixed deflection from the free position (Figure 9-1). Presenfly, there is no standard way to test loadsfor torsion springs. Consequently, in critical applications,it is advisableto contact Associated Spring engrneersto establish a test method during prototype work. Fig. 9-1. Specifiing Load and Deflection Requirements for Torsion Springs.
l-L

N":t#

(e-t)

Lr : length of the moment arm of the first end. Lz: length of the moment arm of the second end. (e-2) N":Ns*N. Nu : number of body turns. Mean Dinmeter Mean diameter is equal to I.D. plus O.D. divided by tu'o. When the direction of loading tends to reduce the bodl' diameter,the mean diameter changeswith deflection accordineto:

D - -

D,N,

(9-3)

N o + 0

E n d si n Free Position Specify: c = P= L= 0 =

E n d si n Free Position

*here D, is initial mean diameter and d is deflection in revolutions. Clearancemust be maintained between the

Angle between ends Lood on ends ol a Moment orm Angulor Deflection from Frce Posiiion

AssogFifiS&ff*nfn$ @

Helical Torsion Springs Stress Stress in torsion springs is due to bending, and for round wire is given by: n : 32M, (e-6t d n: ,ffiV7; f"

forsteel: ffi
i-

8040dF-^,:-,English

and with both ends fixed:

ff*,

During elastic deflection of a curved beam, the neutral axis shifts toward the center of curvature, causinghigher stress at the inner surface than the outer. Wahl (Reference 3, page 102) has calculated the stress correction factor at the I.D. of a round wire torsion spring as: rc16 _ t) A convenient approximation for engineeringcalculations is:
4C-l f, llBrD:4C_4
f7

n:
n:

2.5 x ld,

ffid

VT ; forsteel: ffi
rfor steel :

4 x tfd _--^--: metricQ-II.

d E A",tFi.I" !-

lE8od English tr-I\a

ABrD:

4C2 -

C -

(e-7)

(e-8) (e-e)

l(gop:4C+4

4C+1

At low indexes, stress is significantly higtrer on the inner surface than the outer. These factors are useful to determine the stress range for cyclic applications and the set point for fully stress-relievedsprings in static applications. A stress correction factor of 1 is recommended to determine the set point of springs that have favorable residual stresses induced by yielding during forming. Yielding results in a more uniform stress distribution over the round cross section. Therefore, the actual stress correction factor approaches the recommended value of l. End Configurations Some of the more common end configurations available are shown in Figure 9-2. Special configurations are available on request. In designing ends, it is important to recall that bends, loaded to decrease their radius of curvature, have favorable residual stresses. They can operate at higher applied stress levels than bends that increasethe radius by loading. Frequently, spring performance is limited because the sharply bent ends have greater stress than the body. Equation 9-6 is generally employed to determine maximum bending stress in the ends. Torsion springs are subject to surging and resonance phenomena. The natural frequency n for a torsion spring with one end fixed is:

To avoid or minimize resonancephenomena,the natural frequency must be much greater than the operating frequency and/or the spring should contain initial tension. Choig of Operating Stress - Static Recommendedmaximum operating stressesfor static applications are given as a percentages of tensile strength in Table 9-1. For spring bodies or ends loaded in a direction that increases the radius of curvature, "stress-relieved" column are most stress levels in the appropriate. These stresses should be calculated using tfie appropriateKB stresscorrection factor (Equation 9-8 or 9-9). When the outer surface is in tension, springs with a low index usually yield at the inner surface, while those with a higfr index may yield at the outer surface. For springs not stress-relievedand loaded in a direction that decreasesthe radius of curvature, the stress levels recommended for springs with favorable residual stress are appropriate. No stress correction factor is used since the spring has yielded. Fig.9-2. Com.monHelical Torsion Spring End Config' uratrcns. O-O /
A

*s
I

,',,}t

ENDS SPECIAT

t( )) ililll I'UU \r/

HOOK ENDS SHORT

ftfif l lil ltl

/6\ ]iltl (( )) [m \r/ tulj

HINGE ENDS

n:

t.26xldd r

ffi

: 2 x t d d meric9-Ioi VT ; forsteet ffi

bm N
STRAIGHT OFFSET

( n5liltr v/ tuu
I t \ l r I I I

/-\\

-^.

illt

DOU

T ORSION

TORSION STR.AIGHT

Associatec'

sprindl&**firys

Helical TorsionSprings CLoi- of Operating Stress - Cyclic \tarimum allowed operating stressesfor cyclic appli;arions are presentedin Table 9-2 as percentagesof tenare assumedto be calculated sile suength. All stresses rrith the appropriate Ks correction factor. This infortnaion can be used to estimatefatigue lives at other stress previously (Section4). Frerangesb1'methodsdiscussed quentll'. bending stresses higher in the ends than in are the bodl'. In this situation, bear in mind that during forrr.ng of sharp bends, the wire may be stretched or rrarked. resulting in stress concentrations that reduce design stresslevels below those recommended.Because of friction, the point of contact between torsion end and arbor is often the highest stressed area. DouHe Torsion Springs Double-bodied torsion springs are designedusing the sarnemethods as for single-bodiedtorsion springs. The rate for a double-bodied torsion spring is equal to the sum of the rates for eachcomponent. For the samewire diameter, coil diameter and wire length, double-bodied torsion springs have rates four times those of singlebodied types. Double-bodiedtorsion springs should be designed so they are coiled out from the center rather than in from the ends (Figure 9-3). Rectangular Wire Rectangular wire torsion springs have higher energy storage capacities than similar round wire springs. The general comments on round wire torsion springs apply to springs with rectangular wire. In producing springs Tablc 9-1. Maximum RecommendedBending .Stresses for Helical Torsion Springs in Static Applica' tions.
Fr,*mi nf :Tcrdle,Slrqfh M.lrtrid

from rectangular wire, the wire cross-section distorts and becomes "keystoned" (Figure 94).The wire axial dimension br can be estimated from:

br:bF#)

(9-r2)

wire can When axial length is critical, keystone-shaped be purchased. This wire will have a near rectangular shape after coiling. The rate equation is:

k:M/0=6*K
and the stressequation is:

(e-I3)

t:#*"
4C 4Cl 4C 4C+3

(9-r4)

These equations are for springs wound either on edge or on flat (Figure 94).Stress correction factor Ks is slie[tly lower than for round wire and can approximated by:
Kgro : Ksoo =

(e-r5) (9-r6)

Sharp corners on rectangular wire cause stress concentrations and should be avoided, while generous corner radii of rolled wire reduce the wire cross sections sufficienfly to lower the rate. Table9-2. Maximum Recommended Bending Stresses (Kp Corrected) for Helical Torsion Springs in Cyclic Applications.
fucml of Tnnr*lelitrugth

Patented and Cold Drawn

$trr*r'&trcv ,{,tr} *eeied SrcrF {2} l , {lio Corrac'thnFrctori {XrCo r00 EO

85

lf,frl:f*v,otl&,,

ASTeilA23t rild TIF t&l $trtudwscel

lJf" fi$kl
105 106

A"5TlilA?*rO he3,2, sd
L$oe:. 8*

Hardened and Tempered Carbon and Low Alloy Steels Austenitic Stainless Steelsand NonFerrous Alloys

100

Noil Sbo{M 53 50

I l snot-n t*O.

'

Sbqt-ften*d*

62 60

55 53

& 62

60

80

This information is based on the following conditions: no surging, springs are in the "as-stress-relieved" condition *Not always possible.

t l) Also for springs without residual stresses. i2) Springs that have not beenstress-relievedand which have bodies and ends loaded in a direction that decreasesthe radius of curvature.

Fig. 94. KeystonedCross Sectionsof SpringsWoundon Edge and Flat

Wound On Edge Wound On Flot

Fig. 9-3. Preferred Windingfor Double-Bodied Torsion Springs.

l-br

-lbr

_i_ _l_

F'-l
Spring Axis

-l ' l--

A"TFtfi8Arynffis

BellevilteSPringWashers Fig. I1-2. Load Deflection Curves BeIIeviIIeWashers for with Various h lt Ratios.
hh = 0.4

Fig. 11-5. Comparison of S7 and Sn for Various Deflections, h lt Ratios and Diameter Ratios (R Values) of Belleville Washers.

hh = o.7 h/r = L4l

l Srz Hi g h e r t l I

Tl-T.c

L r
bd* 9-':

#W{ffi
/,

-cil

t1\

h/t = 2'83

- 0.6
a

4eij
Srr Higher
. l l

zt

Fig. 11-3. Mounting a Belleville Washerfor Deflection Past the FIat Position.

Fig. 11-6. Compressive Stress Constantsfor Belleville Washers.

2.5 6 " t = , ' l n R fl R - r l 2 )

=,
o
(J
d

1.5

Fig.114. Highest Stessed Regions in Washers.

Belleville

o ;
o (J

1.0

777777V,
Spring Axis

6 l=;"e-l( R- l ) ' l *r-1

Assogb?ifi8,r,.fuffi ffi

Belleville Spring Washers Fig. 11J. Tensile Jtress Washers.

3.0

Constants fo,

Belleville

)' 2.O

"=--r.F;t1n-1y

RlnR-(R-l)

+ ' R - r
E o (J . l.) l t

_. l

0.5R

I |
l

Determining an optimum solution to a belleville washer design problem is a trial and error process which may have to be repeated many times. A simple approach, designed to minimize the number of repetitions, is presentedbelow. All of the graphs are basedon belleville washer designswith a ratio of O.D. to I.D. of 2 (R : Z). Designs that have R approximately equal to 2 have muu(imum energy storage capacity. The first step is to select an appropriate h/t ratio based on the load, outside diameter and stress constraints given. For example, (referring to Figure l lJ), assumethe desired load at flat is 1125 and outside diameter is 76 N mm. A washer with an h/t equal to 1.41 would have a maximum stress S. of 1500MPa. Loads at intermediate deflection can readily be computed with the aid of Figure ll-9. Material thickness is then determined from:

t=*Vmmetric
) Before finalizing a design based on these graphs, it is best to check results using the equations, making final adjustmentsas required. For cyclic applications, stress levels Srr and Sp mustbe determinedin order to estimate belleville washer life.

r : l /\@ E n g r i s h tg.z x to?(h/t

0.5
1

T z : I l r r r 3 R

Fig. 11-8. Inads and CompressiveStresses Srfor SteelBelleville Washers with VariousOutsideDiameters and h/t Ratios.
A

o.

o !o
F\

=
q,

o o ra)
c v,

o o
r

=
Lood At Flot - (lbf) 60 80 r00 200 400 When R = 2 6008001000 2000
o

o o o o

e e'E
6 ;

O (n

q 4000 60008000

U)

tt)

i
I I

.tt

I
I
I

g E Fi E.

8 f r

r 0I l 81
100 80 60 2 160 1 2 0 60 l-30 o 80 40 120 60 3 0 F 1 5

6l
I

sJ
41

''rl 21
r.l
I I

3J

r0.
8 6' o 5. E 4.o
J. o

I I .5.{ l" l2 '

40 2 0 F r o 30 r 5 F7.s 20
Metric Units

Il ).s.1
I

751 r I

2.

37J0. 1 . 5 ).

I( 2s1
,4ffi
6
I

1.0

.-- r ,4b- 1F,'

Y

to-\/ t 32A (h/r) 8

19.2xlo? (h4)

I I
I

Metric E n g l l s h1 0 0

200

4 6 t l 400 600800I 000

LoodAtFlot

6000 r
( H ) W h e n R= 2

ffiAssogb?lfi F$ 3;"fu$.*ff

Bellevitle SPring Washers diagram (Figure 11-10) illustrates fatigue strength for various thicknesses of carbon and alloy steel washersat HRC 47 to 49. (Use of this diagram is discussedon page 27.) Shot peening increasesfatigue strength while burrs, edge cracks and surface imperfections reduce it. Stacks of Belleville Washers To increasedeflection or loads, belleville washerscan be used in series, parallel or a combination of seriesand parallel (Figure 1l-11). Deflection for a series stack of identical belleville washers is equal to the number of washers multiplied by the deflection of one, while the load is equal to the load of one washer. When belleville washers with an h/t ratio greater than 1.3 are used in a stack, the load deflection curve will be erratic as some washerswill snap through the flat position. To avoid this problem, the h/t ratio for each washer in a seriesstack should not exceed 1.3.

Ch)ic! of Sress Level - Static For static applications,stressat the convex inner cor:er S. us,uellvcontrols the spring set point. Carbon steel 3g{lrrlle u-asherswill start to set when stress (S") reachEs l,l[Fr of tensile strength (Table 1l-1). Set is removed :r nilostbellevillewashers,and in this case stress(S.)can :each T56c of tensile strength before additional set ocJ.rrs. These calculated stressesEueconsiderably higher :hen actual stressesdue to yielding. If washers are to be piarcd or operated at elevated temperatures,these values must be reduced. Cbob of Stress Level - Cyclic For cy'clic applications, it is necessary to consider both the stress level and stress range at the concave conrcrs Srr and Sr2.Minimum and maximum stress must be evaluatedat both Srr and Srzusing a modified Goodman diagam. The location with the more severe condiions u'ill control washer life. The modified Goodman

Fig. 114. Load Deflection Characteristics BellevilleWashers. for

tf ur ootl .{lo o/o uolpolreo

+ ,
o

0 o CL

:, . E r
o oE ! l

= s o
o o o-

o
o o

t 2.
o
3

s :
J

o o

o a plv

90

too
4 I

Deflecionino/o f' lf OO ol f

o o3
B

.:
o

lf a *'asher is supported and loaded at its edges so that it is deflected :c1'ond the flat position, then the greatest possible deflection can be :ru-lizcd.Since the load/deflection curve beyond the horizontal position :s slmmetrical with the first part of the curve, this chart has been

labeled at the right and top to be read upside down for deflections beyond horizontal. Dotted lines extending beyond the chart indicate continuation of curves beyond flat.

AssogFlf;S&H*ffirns ffi

Belleville Spring Washers Load on a parallel stack of identical belleville washers is equal to the load of one multiplied by the number of washers, while deflection is equal to the deflection of one washer. The load deflection curve for both series and parallel stacks has a hysteresis due to friction. Hysteresis (Figure 1l-I2) is greater for parallel than series stacks and can be minimized by lubrication. The energy absorbed by this hysteresishelpsto dampen vibrations. By careful selection, stacks can be designed with increasing, approximately linear or decreasingrates. Stacked belleville washers must be guided either over a pin or in a tube. Hardness of the guides should be at least HRC 50 to minimize wear. Clearancebetween washer holes and pin of or tube should be about 1,.5Vo the relevant diameter. Fig. 11-10. Modtfted Goodman Diagram for Fatigue and Strength of Belleville Washers. Carbon
Alloy Steel at HRC 47-49 with Set Removed but Not Shot-Peened.
Lower Tensile Stress (103 psi)

Tolerances To ensure proper clearance, it is good practice to specify outside diameter with a minus-only tolerance and inside diameter with a plus-only tolerance. Recortmended tolerancesare shown in Table ll-2. Load tolerances should be specified at a test height. For belleville washers with h/t < 0.25, reqommendedload tolerances zue =, l1Vo. For washerswith h/t > 0.25, use + lVo. The recommendedtolerance for washers made of nonferrous materials generally is + lsVo. Closer diameter and load tolerances are available. How to Specify A checklistto aid the springdesignerin specifyingbelleis ville spring washers shownon the next page. For washthat it ers with critical load requirements, is recommended a test fixture be developed. Fig. 11-11. Stacksof Belleville Washers.

C C C C C C

C C C 3

50

r00

I 50

200

250

ffiRR:
Deflection (in.)

Combinolion of Series ond Porollel

Belleville Washers. in Fig. 11-12. Hysteresis Stacked

A

=
o

o. o
o v, o o
F

aA o o F o o I

o o

C C C C C

z
o

xxx
Lower Tensile Stress (MPo)

Colculotcd uwe C Ten in Series

--Tcst -

Test Five in Porollcl

Figurc| l - 10 maybereadas follols: A bclleville washer 106 0.8mm (0.030") thick maybe expected havea life of approximately cycles to whenstrcssed between either psi) 0-820MPa (0-I 17,000 or 350-990 psi) MPa (50,000-141.000 or 700-l 170MPa (100.000-167,000 psi) andmaybe expccted harre lifc of approximarely cycleswhens!rcssed to a l0: bctwcen either psi) 0-740MPa (0-105.000 psi) or 3 15-890 MPa (45.000127,000 or 630-1050 psi) MPa (90,000150.000

Dcflcction

(mm)

Table 11-1. Maximum RecommendedStressLevels S, for Belleville Washers in Static Applications.

Table11-2. Belleville WasherDiameter Tolerances.

D*rrn*tcr, mnn{in.} Lll, m,(h-l *0.ffi

Carbon or Alloy Steel Nonferrous and Austenitic Stainless Steel

up to 5 (0.197) s-10(0.1924.3%) tL25 (0.3,94-0.984) 2s-s0(0.98f 1.%9) 5L100(r.%9-3.937)

-0.20(-0.00E) -0.2s(-0.0r0) -0.30(-0.012) -0.40(-0.016) -0.50(-0.020)

+0.20(+0.00E) (+0.0r0) +0.25 (+0.012) +0.30 (+0.016) +0.40 +0.50(+0.020)

Based on R = 2, increased tolerances are required for lower R ratios.

ffiAssoget#Affieffiffis

Belleville Spring Washers B.{leritle Spring VYasberDesign Example ln a clutch. a minimum pressureof 900 N (202 lbfl is rcquired. This pressuremust be held as nearly constant as possible*'hile the clutch facing wears down 0.80 mm r0.031-r.The washer O.D. is 76 mm (2.99). Material sclected for this application is carbon steel HRC 47-50. l. Base the load on a value l0Vo above minimum load, or 900+ lVo :990 N. Assume O.D./I.D. = 2. From Figure 1l-9, select a load deflection curve *'hich gives approximately constant load between 50 and l$Vo of deflection to flat. Choose the hlt : l.4t curve. 2. From Figure 1l-9, the percent load at 50Vo deflection to flat is 88%. 3. Flat load is Pr:990/0.88 : 1125N (follow line A-B from 1125N to 4. Using Figure ll{ h/t = 1.41, and line B-C to approximately 76 mm O.D.), estimatedstress is 1500MPa. 5. From Table11-1, maximum staticstresswithout setremovedis 120% of tensile strength. From Table l9-1, page 103, tensile strengthat HRC 48 will be approximately 1650 MPa. Yield point without residual stress will be 1650 x L.20 = 1980 MPa. Therefore,stress of 1500MPa is lessthan maximumstress 1980MPa. ' I /-qDF 6. Stock thickne; s SS ' : r 8 . Referring to Figure 11-9, the load of 990 N will be reached at fr = 5Wo of maximum available deflection. fr : 0.50 x 1.93:0.97 mm deflection, or the load of 990 N will be reached at Hr : fl - fr = 3.30 - 0.97 : 2.33 mm height at load. To allow for wear, the spring should be preloaded at Hz : Hr - Af (wear) :2.33 - 0.80: 1.53mm height. This preloadcorrespondsto a deflection fz : H - Hz : 3.30 - 1.53: : 1.77 mm. Then fzlh : 1.7711.93 0.92or 92%. 9 . Because 92Voof h exceeds the recommended85Vo (the load-deflection cunre is not reliable beyond 85Vo deflection when a washer is compressedbetweenflat surfaces), increase the deflection range to 4Vo to 85%. From Figure ll-9, the percent load at 40Vodeflection is78.5Voand Pr : 990 + 0.785 = l26L N. Repeat previous procedures4, 5, 6, 7 and 8, and find that fz + h x 100: SlVo of h.

mv 132-4hh

Final Desrgn Specifications: Material: AISI 1074, 1075 O.D.: 76 +0.00,-0.5 mm (2.99 +0.00,-0.020) I . D . : 3 8 + 0 . 0 4 0 , - 0 . 0 0m m ( 1 . 5 0 + 0 . 0 1 6 , - 0 . 0 0 ) Thickness t: 1.40 mm (0.055') Reference Height h: 1.97 mm (0.078') Reference Load: 990 N (223 lbf) + lVo at h1 : 1.18 mm (0.046') Compressive S.: 1216MPa (185,000psi) at fz ESVo h of Tensile Stress Srr: -203 MPa (-29,500 psi) at f2 85Vo ofh Tensile Stress Srz: +710 MPa (103,000psi) at fz 85% ofh

7 . h = 1 . 4 1 = l . 4 l x 1 . 3 7: 1 . 9 3m m t = H : h * t = 1.93 L.37 3.30 mm +

BELLEVILLE WASHER SPECIFICATION SPR,ING CHECKLIST (Fillin requireddoto only.) Moteriol Working Conditions:
To work in To work over mm(in.) diometer hole diometer pin Speciol Informotion: Moximum operoting temperoture * Operoting environment

"c("F)

To be used in o stock (type)

Reference Doto: Thickness mm(in.)

Lood Testheight
Reloxotion

I N (1b0, -N(lb0
mm(in.)
o/o

Outside Dio
Inside Diomefer

Requiredlife
Required reliobility (see Section 4)

Free height

m(in.)

h/r

Assog&r#&H*ffitr$ ffi

ruffi

Special ng Spri Washers

"@

SpecialSpring Washers Introductiron Special spring washersexert a thrust load and absorb rrbration. reduce end play or apply pressure. The state of stress is primarily bending, and most of the general desienconsiderationsfor flat springs(Section 12) apply. Spnng u'ashers are used in seals,bearings, motors and o$er rotating mechanisms, and because of the trend tosard miniaturization and compactness, demand for tbem is increasing. The Associated Spring SPEC product line contains rnanv precision engineered wave, curved and finger spring washers. These washersare made to close tolerancesand are available for immediate delivery. Selecting SPEC washer designs savesdesigntime, avoids tooling costs and is generally more cost-effective than specifying parts. custom-designed Cured Washers Curved washers exert a relatively light thrust load and are often used to absorb axial end play. Designersmust provide space for diametral expansionin a direction perpendicular to the A dimension (Figure l3-1). Bearing surfaces should be hard to prevent washer corners from scraping or digging in. The spring rate is approximately linear up to 80Voof available deflection. Beyond 80Vothe rate increasesand is considerablyhigher than calculated. Design equations for spring waJhers are similar to those for simple beams, discussedin Section 12, except for an empirical correction factor K. The equation for load is: Wave Washers Wave spring washers,Figure 13-3,are especiallyuseful to apply moderate thrust loads when radial space is limited. The rate is linear between 20 and 8Vo of available deflection. During forming, the washer is often stretched at the crest and trough of the waves. Washers that are round in the free position go out-of-round when deflected. Generally, a ratio of D/b = 8 is a good balance betweenflexibility and load-carrying ability. When the ratio of D/b is substantiallylower than 8, a belleville washeris preferred. The number of wavesN" can be equal to 3 or more and is usually selectedon the basis of desired spring rate, since spring rate is proportional to the number of wavesraised to the fourth power, as:

ft=Plf=r/ot-,

Ebt3N.oD"

(13-s)

This formula is basedon the equations for a simple beam with correction factors based on experience to improve accuracy. Stress is given by: 3zrPD s (t 3-4) " 4bttN.' The outside diameterof the washer changesupon deflection and at flat is given by: (I 3-s) Do is outside diameter in the free position. The above equations for load, stress and diametral change are not exact solutions, but do provide useful engineeringestimates for design purposes. Fig. 13-2. Empirical Stess Correction Factor K for Curved Spring Washers.
4.0

o=@ ^ (oD)'K

(r3-r )

O.D. is outside diameter in the flat position and the equation for stress is:

r:T*

(13-2)

Correctionfactor K is shown in Figure l3-2. Theseequations are approximate and yield satisfactory solutions of only for deflections up to 80Vo h where f is less than li 3 of O.D. Associated Spring engineersshould be consultedwhen clearancesare critical or more exact designs required. Fig. 13-1. Typical Curved Spring Washer.

3.0
Y o o e .9 o o e,

2.5

\ \ \

2.0

2.O

2.5

3.0

3.5

4.0

Rofio At O.D./1.D. Flor

*Long

oxis of the wosher

in free position

Assog&'lfi3&ffi*ffiF$ @

SpecialSpring Washers Finger Washers Finger washers,Figure 134, combine the flexibility of curved washers and the distributed loading points of wave washers. Load, deflection and stressare approximated by assuming that the fingers are cantilever springs; then samplesare made and tested to prove the design. Finger washers are used in static applications such as applying an axial load to ball bearing races to reduce vibration and noise. Choice of Operating Stress - Static Operating stressesrecommended for special spring for washersare similar to stresslevels recommended flat springs and are shown in Table l3-l as a percent of tensile strength. Finger washers are generally produced in the stress-relievedcondition. If favorable residual stresses required, consult AssociatedSpring. are Choice of Operating Stress - Cyclic Maximum recommended operating stressesfor cyclic conditions are shown in Table l3-2 for curved and wave washers. Finger washersare not recommendedfor cyclic applications. Tolerances Dimensional tolerances are similar to those on flat springs. Load tolerancesdepend primarily on strip thickness tolerances and are listed in Table l3-3. All load tolerances should be specified at a test heigttt and only those dimensions critical to spring function should have tolerances. Special tolerances are available for demanding applications. Fig. 134. Typical Wave Spring Washer. How to Specify The specification checklist on the next pageis provided as a guide to all critical aspects of special spring washers. Special Spring lVasher Design Example A wave washer is needed to go into a 80 mm (3.15') bore and over a 60 mm (2.362') shaft, to support a load of approximately 500 to 550 N (112 to 124 lb) with 1.8 mm (0.071')deflection. The applicationrequires a steady load and is therefore a static application. The washer will operate in an ambient environment. AISI 1075 is the preferred material. Since deflection is comparatively large for a spring of this type, select the most flexible design - a three wave configuration. Assumea 75 mm (2.953") outside diameter and a 64 mm (2.520") inside diameter to fit the given conditions. This would make the mean diameter (D) 69.5 mm (2.736"). 1. Substituting these values in the load-deflection equation, solve for thickness: ,: \

Y(207,000) (5.t (3r0t (1.s)

= l . 3 0m m

&
P,=

D,

= 530N

2.4 D3 Fig. 134. Typical Finger Spring Washer.

'-ll'-

+:+.:+b ,*il.h = H - t

h\-

Table13-1. Maximum Recommended Operating S/ress Levels for Special Spring Washersin Static Applications.

Table13-2. Maximum RecommendedOperating Stress Levels for Steel Curved and Wave Washers in Cyclic Applications.
Pcreent of T,mih Strerylh

Finger washers are not generally supplied with favorable residual stresses.

This information is based on the following conditions: ambient environment, free from sharp bends, burrs, and other stress concentrations. AISI 1075

Assos&tfi8 H# /fu H#,ffirp$

SpecialSpring Washers l. Set the maximum stress at solid at 8Vo of tensile suenglh. Steel with a hardnessof HRC 49 has a tenpsi) (Table l3-1 and MPa (250,000 sile strength of 1725 Figure 3-6, page 2l). \Vo of 1725MPa is 1380MPa. Solve for deflection at that stress. Using the equation: Deflection to load of 1.8 mm is 75% of deflectionto solid, which is satisfactory. Diameter in the deflected position:

Do'=ffi:
Do': 75.1 mm There is adequate clearance.

pPsD _ f r_ fe.6 r = fimm f, = 2.39

(9.6x69.t'(1380x64)

finat Dexf,gnSpecifications: Tablc13-3. Load Tolerancesfor Special Spring Washers. Material: AISI 1075 + O.D.: 75 *,0.2 mm (2.953 0.008) + 0.2 mm (2.520<- 0.008) I.D.: S,!, Thickness t: 1.30 mm (0.055'r 0.002) H: 3.69 mm (0.145') Reference Load P1: 530 N + lTVo(119 lbf + l7Vo) H,: 1.89 mm (0.074')

0.r-1.0 (0.0044.03e)
0.1-0.25(0.004{.010) 0.2il.30 (0.0104.012) 0.H.5 (0.0124.020) 0.5-1.0 (0.020{.039). 1.G2.0 (0.039-0.079) 33 25 20 15 t2

SPECIAL SPRINGWASHER SPECIFICATION CHECKLIST (Fill in required doto only.) Type of Wosher: Curved wove
finger designer recommendotion Speciol Mqximum operoting temperoture Operoting environmeni Reference Thickness mm(in.) diometer hole diometer pin Outside diometer Inside diom mm(in.)

,"c('F)

Moteriol: Working Conditions:

To work in To work over rm(in.)

I Lood
Describeone cycle

N(lb0+ -N(lbo
mm(in.)

i Test height Required reliobility (see Section 4)

Assog&'ifi8/&,H*ffis ffi