SECTION 4 - SPRINGS

Page 1 of 70
HELICAL COMPRESSION SPRINGS

DESIGN LIGHT, MEDIUM SERVICE

271. A solenoid brake (Fig. 18.2, Text) is to be actuated by a helical compression
spring. The spring should have a free length of approximately 18 in. and is to
exert a maximum force of 2850 lb. when compressed to a length of 15 in. The
outside diameter must not exceed 7 in. Using oil-tempered wire, design a
spring for this brake, (wire diameter, coil diameter, number of active coils,
pitch, pitch angle, solid stress). General Electric used a spring made of 1 in.
wire, with an outside diameter of 6 in., and 11 free coils for a similar
application.

Solution:
For oil tempered wire, Table AT 17
ksi
D
s
w
u
19 . 0
146
= , [ ] 5 . 0 032 . 0 < <
w
D
solid stress =
u
s 6 . 0
design stress, (average service)
u sd
s s 324 . 0 =

( )
ksi
D D
s
w w
sd 19 . 0 19 . 0
304 . 47 146 324 . 0
= =

7 +
m w
D D

kips lb F 85 . 2 2850 = =


19 . 0 3
304 . 47 8
w w
m
s
D D
FD
K s =
|
|

\
|
=

say 3 . 1 = K
( )( )
19 . 0 3
304 . 47 7 85 . 2 8
3 . 1
w w
w
s
D D
D
s =
(

in in D
w
5 . 0 062 . 1 > =

use
( )
ksi ksi s
sd
54
5 . 0
304 . 47
19 . 0
= =
( )( )
54
7 85 . 2 8
3 . 1
3
=
(

=
w
w
s
D
D
s

in D
w
015 . 1 =

say in D
w
0 . 1 =
( )
( )
54
1
85 . 2 8
3 . 1
3
=
(

m
s
D
s

in D
m
72 . 5 =

SECTION 4 - SPRINGS
Page 2 of 70
say in D
m
0 . 5 =
. 7 6 0 . 1 0 . 5 in in D D OD
w m
< = + = + =

5
0 . 1
0 . 5
= = =
w
m
D
D
C

= Free length Compressed length = 18 in 15 in = 3 in.

w
c
GD
N FC
3
8
=

ksi G 500 , 10 = , in D
w
8
3
>
( )( )
( )( ) 1 500 , 10
5 85 . 2 8
3
3
c
N
= =

05 . 11 =
c
N

say 5 . 11 =
c
N
( )( ) ( )
( )( )
in 12 . 3
1 500 , 10
5 . 11 5 85 . 2 8
3
= =

Free length = 15 + 3.12 = 18.12 in

At 2.85 kips
|
|

\
|
=
3
8
w
m
s
D
FD
K s

5 = C

( )
( )
3105 . 1
5
615 . 0
4 5 4
1 5 4 615 . 0
4 4
1 4
= +

= +

=
C C
C
K

( )( )
( )
ksi s
s
55 . 47
1
5 85 . 2 8
3105 . 1
3
=
(

Permissible solid stress
( )
( )
ksi ksi s s
u so
93 . 99
5 . 0
146 6 . 0
6 . 0
19 . 0
= = =

using

F
k =

or let
T
= Free length Solid height
T

93 . 99
12 . 3
55 . 47
=

in
T
56 . 6 =

T
= Free length Solid height = ( )
c w
N D P
( )( ) 5 . 11 1 56 . 6 = P

in P 570 . 1 =

SECTION 4 - SPRINGS
Page 3 of 70
use in P
2
1
1 =
Pitch angle,
( )
o o
12 5 . 5
5
5 . 1
tan tan
1 1
< =
(

= =

D
P
, o.k.

For actual solid stress
( )( ) . 75 . 5 5 . 11 1 5 . 1 in
T
= =

75 . 5 12 . 3
55 . 47
so
s
=

ksi ksi s
so
93 . 99 63 . 87 < = , ok

Summary of answer:
w
D = wire diameter = 1 in.
m
D = coil diameter = 5 in.
c
N = no. of active coils = 11 1/2
P = pitch = 1 in.
= pitch angle = 5.5
o

so
s = solid stress = 87.63 ksi

272. A coil spring is to be used for the front spring of a automobile. The spring is
to have a rate of 400 lb./in., an inside diameter of 4 3/64 in., and a free length
of 14 1/8 in., with squared-and-ground ends. The material is to be oil-
tempered chrome vanadium steel. Decide upon the diameter of the wire and
the number of free coils for a design load of lb F 1500 = . Be sure solid
stress is all right. How much is the pitch angle?

Solution:
Table AT 17 Cr-V steel
ksi
D
s
w
u
166 . 0
168
= , [ ] 437 . 0 032 . 0
w
D <
average service
u sd
s s 324 . 0 =

( )
ksi
D D
s
w w
sd 166 . 0 166 . 0
432 . 54 168 324 . 0
= =

Max solid stress =
u
s 6 . 0
SECTION 4 - SPRINGS
Page 4 of 70
in in D D ID
w m
046875 . 4
64
3
4 = = =

in D D
w m
046875 . 4 + =


sd
w
m
s
s
D
FD
K s =
|
|

\
|
=
3
8

Assume 3 . 1 = K
kips lb F 5 . 1 1500 = =

( )( )
(

+
= =
3 166 . 0
046875 . 4 5 . 1 8
3 . 1
432 . 54
w
w
w
sd
D
D
D
s

in in D
w
437 . 0 747 . 0 > =

use
( )
ksi ksi s
sd
45 . 62
437 . 0
432 . 54
19 . 0
= =

( )( )
45 . 62
046875 . 4 5 . 1 8
3 . 1
3
=
(

+
=
w
w
sd
D
D
s

in D
w
724 . 0 =

use in D
w
4
3
=
in D
m
64
51
4
64
3
4
4
3
= + =

|
|

\
|
=
3
8
w
m
s
D
FD
K s

C C
C
K
615 . 0
4 4
1 4
+

=

4 . 6
4
3
64
51
4

\
|
|

\
|
= =
w
m
D
D
C

( )
( )
235 . 1
4 . 6
615 . 0
4 4 . 6 4
1 4 . 6 4
= +

= K

( )
ksi ksi s
s
45 . 62 64 . 53
4
3
64
51
4 5 . 1 8
235 . 1
3
< =
(
(
(
(

\
|
|

\
|
=

, (o.k.)
w
c
GD
N FC
3
8
=

SECTION 4 - SPRINGS
Page 5 of 70
ksi G 500 , 10 = , in D
w
8
3
>
in
k
F
75 . 3
400
1500
= = =

( )( )
( )
|

\
|
= =
4
3
500 , 10
4 . 6 5 . 1 8
75 . 3
3
c
N

4 . 9 =
c
N

Table AT 16, Total coils = 4 . 11 2 4 . 9 2 = + = +
c
N for square and grounded end.

Summary of answer:
w
D = wire diameter = in.
No. of free coils = 11.4

To check for solid stress.

Permissible solid stress =
( )
( )
ksi 65 . 115
437 . 0
168 6 . 0
166 . 0
=
Free length =
w c
D PN 2 +
Solid height = ( ) ( ) in N D
c w
55 . 8 4 . 11
4
3
2 = |

\
|
= +
Solid stress = ( ) ksi ksi 65 . 115 74 . 78
75 . 3
55 . 8
8
1
14
64 . 53 < =
|
|
|
|

\
|

(safe)

Pitch:
in D PN
w c
8
1
14 2 = +

( )
8
1
14
4
3
2 4 . 9 = |

\
|
+ P

in in P
32
11
1 343 . 1 = =

Pitch angle,
o o
12 1 . 5
64
51
4
32
11
1
tan tan
1 1
< =
(
(
(
(

\
|
= =

D
P
, o.k.



SECTION 4 - SPRINGS
Page 6 of 70
273. A coiled compression spring is to fit inside a cylinder 5/8 in. in diameter. For
one position of the piston, the spring is to exert a pressure on the piston
equivalent to 5 psi of piston area, and in this position, the overall length of the
spring must not exceed (but may be less than) 2 in. A pressure of 46 psi on the
piston is to compress the spring in. from the position described above.
Design a spring for medium service. Specify the cheapest suitable material,
number of total and active coils for square-and-ground ends, and investigate
the pitch angle, and solid stress.

Solution:
|
|

\
|
=
3
8
w
m
s
D
FD
K s

2 8
5
w
w m
D
in D D OD = + =

in D D
w m
8
5
5 . 1 = +

( ) lb F 534 . 1
8
5
4
5
2
1
=
|

\
|
|

\
|
=


( ) lb F 647 . 15
8
5
4
5 46
2
2
=
|

\
|
|

\
|
+ =



Using hard-drawn spring wire, Cost Index = 1
( ) 85 . 0 324 . 0
u sd
s s =

ksi
D
s
w
u 19 . 0
140
=
,
[ ] 625 . 0 028 . 0 < <
w
D

Max solid stress = ksi
D
w
19 . 0
70

( )
19 . 0 19 . 0
556 . 38 140
85 . 0 324 . 0
w w
sd
D D
s = =

psi
D
ksi
D D
FC
K s
w w w
s 19 . 0 19 . 0 2
556 , 38 556 . 38 8
= =
|
|

\
|
=

( )
81 . 1
556 , 38
647 . 15 8
w
D
C
K =
(

( )
81 . 1
556 , 38 845 . 39
w
D C K =

625 . 0 5 . 1 = +
w m
D D

625 . 0 5 . 1 = +
w w
D CD

5 . 1
625 . 0
+
=
C
D
w

SECTION 4 - SPRINGS
Page 7 of 70
C C
C
K
615 . 0
4 4
1 4
+

=

( )
81 . 1
5 . 1
625 . 0
556 , 38 845 . 39
615 . 0
4 4
1 4
|

\
|
+
=
|

\
|
+

C
C
C C
C

( ) 3 . 413 5 . 1
615 . 0
4 4
1 4
81 . 1
= + |

\
|
+

C C
C C
C

035 . 7 = C

in
C
D
w
0732 . 0
5 . 1 035 . 7
625 . 0
5 . 1
625 . 0
=
+
=
+
=

Table AT 15, in D
w
0720 . 0 = , W & M 15
( ) in D
m
5065 . 0 0720 . 0 035 . 7 = =

For
c
N
( )
w
c
GD
N C F F
3
1 2
1 2
8
=

psi G
6
10 5 . 11 =

( )( )
( )( ) 0720 . 0 10 5 . 11
035 . 7 534 . 1 647 . 15 8
4
3
6
3
1 2

= =
c
N


8 . 15 =
c
N

Table AT 16,
Total coils = 8 . 17 2 8 . 15 2 = + = +
c
N
Solid height = ( ) ( )( ) in D N
w c
28 . 1 0720 . 0 2 8 . 15 2 = + = +
Free length =
w c
D PN 2 +
Free length =
1
2 +
( )
w
c
GD
N C F
3
1
1
8
=

( )( ) ( )
( )( )
. 082 . 0
0720 . 0 10 5 . 11
8 . 15 035 . 7 534 . 1 8
6
3
1
in =

=

Free length = in 082 . 2 082 . 0 2 = +
( )
w
c
GD
N C F
3
2
2
8
=

( )( ) ( )
( )( )
. 832 . 0
0720 . 0 10 5 . 11
8 . 15 035 . 7 647 . 15 8
6
3
2
in =

=

Solid Height

Free Length -
2

Solid Height

in 832 . 0 082 . 2
Solid Height

in 25 . 1
But Solid Height > 1.25 in.

Therefore change material to Oil-tempered spring wire, Cost Index = 1.5
SECTION 4 - SPRINGS
Page 8 of 70

Table AT 17
ksi
D
s
w
u
19 . 0
146
= , 5 . 0 028 . 0 < <
w
D
Max solid stress = ksi
D
w
19 . 0
5 . 87

19 . 0 19 . 0
304 . 47 146
324 . 0
w w
sd
D D
s = =

psi
D
ksi
D D
FC
K s
w w w
s 19 . 0 19 . 0 2
304 , 47 304 . 47 8
= =
|
|

\
|
=

( )
81 . 1
304 , 47
647 . 15 8
w
D
C
K =
(

( )
81 . 1
304 , 47 845 . 39
w
D C K =

5 . 1
625 . 0
+
=
C
D
w

C C
C
K
615 . 0
4 4
1 4
+

=

( )
81 . 1
5 . 1
625 . 0
304 , 47 845 . 39
615 . 0
4 4
1 4
|

\
|
+
=
|

\
|
+

C
C
C C
C

( ) 1 . 507 5 . 1
615 . 0
4 4
1 4
81 . 1
= + |

\
|
+

C C
C C
C

684 . 7 = C

in
C
D
w
0680 . 0
5 . 1 684 . 7
625 . 0
5 . 1
625 . 0
=
+
=
+
=

Table AT 15, in D
w
0625 . 0 = , W & M 16
( ) in D
m
48025 . 0 0625 . 0 684 . 7 = =

say in D
m
46875 . 0
32
15
= =
5 . 7
0625 . 0
46875 . 0
= = =
w
m
D
D
C

|
|

\
|
=
2
8
w
s
D
FC
K s

( )
( )
1974 . 1
5 . 7
615 . 0
4 5 . 7 4
1 5 . 7 4 615 . 0
4 4
1 4
= +

= +

=
C C
C
K

( )( )
( )
ksi psi s
s
6 . 91 600 , 91
0625 . 0
5 . 7 647 . 15 8
1974 . 1
2
= =
(

For
c
N
SECTION 4 - SPRINGS
Page 9 of 70
( )
w
c
GD
N C F F
3
1 2
1 2
8
=

psi G
6
10 5 . 11 =

( )( )
( )( ) 0625 . 0 10 5 . 11
5 . 7 534 . 1 647 . 15 8
4
3
6
3
1 2

= =
c
N


32 . 11 =
c
N

Table AT 16, squared and ground ends
Total coils = 32 . 13 2 32 . 11 2 = + = +
c
N
Solid height = ( ) ( )( ) in D N
w c
8325 . 0 0625 . 0 2 32 . 11 2 = + = +
Free length =
w c
D PN 2 +
Free length =
1
2 +
( )
w
c
GD
N C F
3
1
1
8
=

( )( ) ( )
( )( )
. 082 . 0
0625 . 0 10 5 . 11
32 . 11 5 . 7 534 . 1 8
6
3
1
in =

=

Free length =
( ) ( ) 0625 . 0 2 32 . 11 082 . 2 082 . 0 2 + = = + P in

in in P
64
11
1729 . 0 =

Pitch angle,
( )
o o
12 7 . 6
46875 . 0
1729 . 0
tan tan
1 1
< =
(

= =

D
P
, o.k.

Solid stress
( ) ksi s
so
6 . 142
75 . 0
8325 . 0 2
6 . 91 = |

\
|
=

Permissible solid stress =
( )
ksi ksi 5 . 137 8 . 148
0625 . 0
5 . 87
19 . 0
> = , safe.

Summary of answer:
Suitable material = Oil-Tempered Spring Wire
Total Coils = 13.32
Active Coils, 32 . 11 =
c
N

274. A helical spring is to fit about a 11/16-in. rod with a free length of 2 in. or
less. A maximum load of 8 lb. is to produce a deflection of 1 in. The spring
is expected to be compressed less than 5000 times during its life, but is
subjected to relatively high temperatures and corrosive atmosphere. Select a
material and determine the necessary wire size, mean coil diameter, and
number of coils. Meet all conditions advised by Text.

SECTION 4 - SPRINGS
Page 10 of 70
Solution:
For 5000 cycles < 104 cycles, use light service
Use stainless steel, type 302 (Cr-Ni), ASTM A313 for relative high temperature and
corrosive atmosphere, Table AT 17.
u sd
s s 32 . 0 =
(i)
ksi
D
s
w
u 14 . 0
170
= , [ ] 13 . 0 01 . 0 < <
w
D
ksi
D
s
w
u 41 . 0
97
= , [ ] 375 . 0 13 . 0 < <
w
D
Maximum solid
u o
s s 47 . 0 =
|
|

\
|
=
3
8
w
m
s
D
FD
K s

lb F 8 =

2 16
11
w
w m
D
D D + =

in D D
w m
6875 . 0 5 . 1 =

6875 . 0 5 . 1 =
w w
D CD

5 . 1
6875 . 0

=
C
D
w

C C
C
K
615 . 0
4 4
1 4
+

=

assume ksi
D
s
w
u 14 . 0
170
=
( )
psi
D
ksi
D D
s
w w w
sd 14 . 0 14 . 0 14 . 0
400 , 54 4 . 54 170 32 . 0
= = =

( )
86 . 1
400 , 54
8 8 615 . 0
4 4
1 4
w
D
C
C C
C
=
(

\
|
+

86 . 1
5 . 1
6875 . 0
400 , 54
64 615 . 0
4 4
1 4
|

\
|

=
|

\
|
|

\
|
+

C
C
C C
C

( ) 1330 5 . 1
615 . 0
4 4
1 4
86 . 1
= |

\
|
+

C C
C C
C

919 . 12 = C

in D
w
0602 . 0
5 . 1 919 . 12
6875 . 0
=

=

Use Table AT 15, in D
w
0625 . 0 = , 16 W & M
( ) in D
m
8074 . 0 0602 . 0 919 . 12 = =

say in in D
m
78125 . 0
32
25
= =
SECTION 4 - SPRINGS
Page 11 of 70
16
11
>
w m
D D

6875 . 0 0625 . 0 78125 . 0 >

6875 . 0 71875 . 0 >

2
03125 . 0 6875 . 0 71875 . 0
w
D
= = , o.k.
5 . 12
0625 . 0
71875 . 0
= = =
w
m
D
D
C

[ ] 13 . 0 0625 . 0 <
, therefore, ksi
D
s
w
u 14 . 0
170
= is o.k.
|
|

\
|
=
2
8
w
s
D
FC
K s

( )
( )
1144 . 1
5 . 12
615 . 0
4 5 . 12 4
1 5 . 12 4
= +

= K

( )( )
( )
psi s
s
648 , 72
0625 . 0
5 . 12 8 8
1144 . 1
2
=
(

( )
w
c
GD
N C F
3
8
=

psi G
6
10 6 . 10 =

( )( )
( )( ) 0625 . 0 10 6 . 10
5 . 12 8 8
4
3
1
6
3

= =
c
N

3 . 9 =
c
N

To check for solid stress and pitch
Minimum solid height = ( )( ) in N D
c w
58125 . 0 3 . 9 0625 . 0 = =
Solid stress =
( )
ksi psi 90 000 , 90
4
3
1
58125 . 0
4
3
2 648 , 72
= =
|

\
|


Permissible solid stress =
( )( )
( )
ksi ksi 90 8 . 117
0625 . 0
170 47 . 0
14 . 0
> = , o.k.
Free length =
c
PN , minimum
( )
4
3
2 3 . 9 = P

in P 2957 . 0 =

Pitch angle,
( )
o o
12 5 . 7
71825 . 0
2957 . 0
tan tan
1 1
< =
(

= =

D
P
, o.k.
Summary of answer
Material, Stainless Steel, Cr-Ni. ASTM A313
SECTION 4 - SPRINGS
Page 12 of 70
in D
w
0625 . 0 = , 16 W & M
in D
m
32
25
=

3 . 9 =
c
N


275. In order to isolate vibrations, helical compression springs are used to support a
machine. The static load on each spring is 3500 lb., under which the deflection
should be about 0.5 in. The solid deflection should be about 1 in. and the
outside coil diameter should not exceed 6 in. Recommend a spring for this
application; include scale, wire size, static stress, material, number of coils,
solid stress, and pitch of coils.

Solution:
Use Music wire (The best material)
Table AT 17
ksi
D
s
w
u 154 . 0
190
= , [ ] 192 . 0 004 . 0 < <
w
D
Maximum solid
u so
s s 5 . 0 =
Light service,
u sd
s s 405 . 0 =
( )
psi
D
ksi
D D
s
w w w
sd 154 . 0 154 . 0 154 . 0
950 , 76 95 . 76 190 405 . 0
= = =
|
|

\
|
=
2
8
w
s
D
FC
K s

lb F 3500 =

in D D OD
w m
6 = + =

( ) 6 1 = +
w
D C

1
6
+
=
C
D
w

( )
154 . 0
1
6
950 , 76
1
6
3500 8 615 . 0
4 4
1 4
|

\
|
+
=
(
(
(
(

\
|
+
|

\
|
+

=
C
C
C
C C
C
s
s

( ) [ ] 9 . 235 1
615 . 0
4 4
1 4
846 . 1
= + |

\
|
+

C C
C C
C

635 . 5 = C

in in D
w
192 . 0 9043 . 0
1 635 . 5
6
> =
+
=

use
( )
psi s
s
216 , 99
192 . 0
950 . 76
154 . 0
= =
SECTION 4 - SPRINGS
Page 13 of 70
( )
216 , 99
1
6
3500 8 615 . 0
4 4
1 4
=
(
(
(
(

\
|
+
|

\
|
+

=
C
C
C C
C
s
s

( ) 8 . 400 1
615 . 0
4 4
1 4
2
= + |

\
|
+

C C
C C
C

205 . 6 = C

in D
w
8328 . 0
1 205 . 6
6
=
+
=

Say in in D
w
8125 . 0
16
13
= =
( )( ) in D
m
042 . 5 8125 . 0 205 . 6 = =

Say in D
m
5 =
154 . 6
8125 . 0
5
= = =
w
m
D
D
C

( )
( )
2455 . 1
154 . 6
615 . 0
4 154 . 6 4
1 154 . 6 4
= +

= K

|
|

\
|
=
2
8
w
s
D
FC
K s

( )( )
( )
psi psi s
s
216 , 99 481 , 103
8125 . 0
154 . 6 3500 8
2455 . 1
2
> =
(

, not o.k.
Use in D
m
5 . 4 =
5385 . 5
8125 . 0
5 . 4
= = =
w
m
D
D
C

( )
2763 . 1
5385 . 5
615 . 0
4 5385 . 45
1 5385 . 5 4
= +

= K

( )( )
( )
psi psi s
s
216 , 99 435 , 95
8125 . 0
5385 . 5 3500 8
2763 . 1
2
> =
(

, o.k.
To check for solid stress
Permissible solid stress =
( )( )
( )
psi ksi 488 , 122 488 . 122
192 . 0
190 5 . 0
154 . 0
= =
Solid stress = ( ) psi psi 488 , 122 870 , 190 435 , 95
5 . 0
1
> = |

\
|
, not ok
Use
.
psi s
sd
244 , 61
1
5 . 0
488 , 122 = |

\
|
=

SECTION 4 - SPRINGS
Page 14 of 70
( )
244 , 61
1
6
3500 8 615 . 0
4 4
1 4
=
(
(
(
(

\
|
+
|

\
|
+

=
C
C
C C
C
s
s

( ) 4 . 247 1
615 . 0
4 4
1 4
2
= + |

\
|
+

C C
C C
C

1 . 5 = C

in D
w
9836 . 0
1 1 . 5
6
=
+
=

Say in D
w
0 . 1 =
( )( ) in D
m
1 . 5 0 . 1 1 . 5 = =

Say in D
m
5 =
5
1
5
= = =
w
m
D
D
C

|
|

\
|
=
2
8
w
s
D
FC
K s

( )
( )
3105 . 1
5
615 . 0
4 5 4
1 5 4
= +

= K

( )( )
( )
psi psi s
s
244 , 61 400 , 58
0 . 1
5 3500 8
3105 . 1
2
> =
(

o.k.
Use in D
w
0 . 1 = , in D
m
5 =
Solid stress = ( ) psi psi 488 , 122 800 , 116 400 , 58
5 . 0
1
< = |

\
|
, o.k.
( )
w
c
GD
N C F
3
8
=

(Table AT 17)
psi G
6
10 12 =

( )( )
( )( ) 0 . 1 10 12
5 3500 8
5 . 0
6
3

= =
c
N

7143 . 1 =
c
N

say 75 . 1 =
c
N
Free length Solid length = Solid Deflection
in N D PN
c w c
1 =

( ) ( )( ) 1 75 . 1 1 75 . 1 = P

in in P
16
9
1 5714 . 1 =

Pitch angle,
SECTION 4 - SPRINGS
Page 15 of 70
( )
o o
12 68 . 5
5
16
9
1
tan tan
1 1
< =
(
(
(

= =

D
P
, o.k.

Summary of answer.
Scale, in lb
F
k 7000
5 . 0
3500
= = =

Wire size, in D
w
0 . 1 =
Material = Music Wire
Solid sress = 116,800 psi
Pitch of stress = in P
16
9
1 =

CHECK PROBLEMS LIGHT, MEDIUM SERVICE

276. The front spring of an automobile has a total of 9 coils, 7 3/8 active coils
(square-and-ground ends), an inside diameter of 4 3/64 in., and a free length
of 14 in. It is made of SAE 9255 steel wire, OQT 1000oF, with a diameter
of 43/64 in. Compute (a) the rate (scale) of the spring; (b) the solid stress
and compare with a permissible value (is a stop needed to prevent solid
compression?). (c) Can 95 % of the solid stress be repeated 105 times without
danger of failure? Would you advise shot peening of the spring?

Solution:

(a)
w
c
GD
N FC
3
8
=
in in D
w
8
3
64
43
> =

psi G
6
10 5 . 10 =

w
m
D
D
C =

ID D D
w m
=

in D
m
64
3
4
64
43
=

in D
m
32
23
4 =

0233 . 7
64
43
32
23
4
= = C

SECTION 4 - SPRINGS
Page 16 of 70
8
3
7 =
c
N

( )
( )
in lb
N C
GD F
rate k
c
w
345
8
3
7 0233 . 7 8
64
43
10 5 . 10
8 3
6
3
=
|

\
|
|

\
|

= = = =

(b) Solid Stress
Solid height = ( )( ) in Coils Total D N
w c
3828 . 6
2
1
9
64
43
= |

\
|
|

\
|
= =
Solid deflection = Free length Solid height = 14 - 6.3828 = 7.8672 in.

Solid Force = ( ) lb F
so
2714 345 8672 . 7 = =
Solid Stress =
(

2
8
w
so
D
C F
K

C C
C
K
615 . 0
4 4
1 4
+

=

( )
( )
212 . 1
0233 . 7
615 . 0
4 0233 . 7 4
1 0233 . 7 4
= +

= K

( )( )
psi s
s
322 , 130
64
43
0233 . 7 2714 8
212 . 1
2
=
(
(
(
(

\
|
=

Permissible value,
sy ys s
s s 6 . 0 = = , [ ] in D
w
5 . 0 >
SAE 9255, OQT 1000 oF
ksi s
y
160 =
,
ksi s
u
180 =

( ) psi psi ksi s
ys
322 , 130 000 , 96 96 160 6 . 0 < = = =

Therefore a stop is needed to prevent solid compression.

(c)
u sd
s s 324 . 0 = (105 cycles)
( ) ksi s
sd
32 . 58 180 324 . 0 = =

( ) ksi ksi psi s
so
32 . 58 8 . 123 800 , 123 322 , 130 95 . 0 95 . 0 > = = =

There is a danger of failure, shot peening is advisable
( )
so ys
s psi s 95 . 0 000 , 120 000 , 96 25 . 1 = =


277. An oil-tempered steel helical compression spring has a wire size of No. 3 W
& M, a spring index of 4.13, 30 active coils, a pitch of 0.317 in., ground-and-
squared ends; medium service. (a) What maximum load is permitted if the
recommended stress is not exceeded (static approach)? Compute (b) the
SECTION 4 - SPRINGS
Page 17 of 70
corresponding deflection, (c) solid stress,. (d) pitch angle, (e) scale, (f) the
energy absorbed by the spring from a deflection of 0.25 in. to that of the
working load. (g) Is there any danger of this spring buckling? (h) What
maximum load could be used if the spring were shot peened?

Solution:
Table AT 17, oil-tempered
ksi
D
s
w
u 19 . 0
146
= , [ ] 5 . 0 032 . 0 < <
w
D
Maximum solid ksi
D
s
w
so 19 . 0
5 . 87
=
u sd
s s 324 . 0 = (medium service)

Table AT 15, No. 3 W & M
in D
w
2437 . 0 =

13 . 4 = C

( ) in CD D
w m
0 . 1 2437 . 0 13 . 4 = = =


(a)
(

=
2
8
w
s
s
D
C F
K s

C C
C
K
615 . 0
4 4
1 4
+

=

( )
( )
3885 . 1
13 . 4
615 . 0
4 13 . 4 4
1 13 . 4 4
= +

= K

( )
( )
psi ksi s s
sd s
858 , 61 858 . 61
2437 . 0
146 324 . 0
19 . 0
= = = =

( )( )
( )
(

= =
2
2437 . 0
13 . 4 8
3885 . 1 858 , 61

F
s
s

lb F 252 =

w
c
GD
N FC
3
8
=

psi G
6
10 5 . 11 =

30 =
c
N

( )( ) ( )
( )( )
in 52 . 1
2437 . 0 10 5 . 11
30 13 . 4 252 8
6
3
=

=


(c) For solid stress . Square-and-ground end)

Free length = ( )( ) ( ) in D PN
w c
9974 . 9 2437 . 0 2 30 317 . 0 2 = + = +
SECTION 4 - SPRINGS
Page 18 of 70
Solid height = ( )( ) in D N D
w c w
7984 . 7 2437 . 0 2 30 2 = + = +
Solid deflection = 9.9974 7.7984 = 2.199 in.
Solid stress = ( ) psi 491 , 89
52 . 1
199 . 2
858 , 61 = |

\
|


Maximum solid
( )
ksi ksi ksi ksi
D
s
w
so
491 . 89 4 . 114
2437 . 0
5 . 87 5 . 87
19 . 0 19 . 0
> = = = , o.k. safe

(d)
( )
o o
12 76 . 5
1
317 . 0
tan tan
1 1
< =
(

= =

D
P
, o.k.
(e) in lb
F
k scale 166
52 . 1
252
= = = =

(f) ( )
2
1
2
2
2
1
= k U
s

in lb k 166 =

in 25 . 0
1
=

in 52 . 1
2
=

( ) ( ) ( ) [ ] lb in U
s
= = 6 . 186 25 . 0 52 . 1 166
2
1
2 2


(g) i 6.18 Free length = 9.9974 in
Mean Diameter = in D
m
0 . 1 =
4 9974 . 9
0 . 1
9974 . 9
> = =
Diameter Mean
length Free

There is a danger for spring buckling

(h) Shot peened, Table AT 17
( )( ) psi s
sd
322 , 77 25 . 1 858 , 61 = =

( )( )
( )
(

= =
2
2437 . 0
13 . 4 8
3885 . 1 322 , 77

F
s
s

lb F 314 =


280. It is desired to isolate a furnace, weighing 47,300 lb., from the surroundings
by mounting it on helical springs. Under the weight, the springs should deflect
approximately 1 in., and at least 2 in. before becoming solid. It has been
decided to use springs having a wire diameter of 1 in., an outside diameter of
5 3/8 in., 4.3 free coils. Determine (a) the number of springs to be used, (b)
the stress caused by the weight, (c) the solid stress. (d) What steel should be
used?

Solution:
SECTION 4 - SPRINGS
Page 19 of 70
in D
w
1 =

in D D
w m
8
3
5 = +

in D
m
8
3
4 =

375 . 4
1
8
3
4
= = =
w
m
D
D
C



(a)
w
c
GD
N FC
3
8
=
Assume 3 . 4 =
c
N
psi G
6
10 5 . 10 = , in D
w
8
3
>
( ) ( )
( )( ) 1 10 5 . 10
3 . 4 375 . 4 8
0 . 1
6
3

= =
F

lb F 3645 =

No. of springs = 13
3645
300 , 47
= =
F
W


(b) lb
W
F 3638
13
300 , 47
13
= = =
(

=
2
8
w
s
s
D
C F
K s

C C
C
K
615 . 0
4 4
1 4
+

=

( )
( )
3628 . 1
375 . 4
615 . 0
4 375 . 4 4
1 375 . 4 4
= +

= K

( )( )
( )
psi s
s
235 , 55
0 . 1
375 . 4 3638 8
3628 . 1
2
=
(

(c) Solid Stress = psi s
s
470 , 110
1
2
235 , 55 = |

\
|
=
(d) psi s
ys
470 , 110
ksi psi
s
s
ys
y
117 . 184 117 , 184
6 . 0
470 , 110
6 . 0
= = = =

From Table AT 7,
Use AISI 8760, OQT 800 oF, ksi s
y
200 =
SECTION 4 - SPRINGS
Page 20 of 70

VARYING STRESS APPROACH

DESIGN PROBLEMS

282. A spring, subjected to a load varying from 100 lb. to 250 lb., is to be made of oil-
tempered, cold-wound wire. Determine the diameter of the wire and the mean
diameter of the coil for a design factor of 1.25 based on Wahls line. The spring
index is to be at least 5. Conform to good practice, showing checks for all
significant parameters. Let the free length be between 6 and 8.

Solution:
lb F 250
max
=

lb F 100
min
=

( ) ( ) kip lb F F F
m
175 . 0 175 100 250
2
1
2
1
min max
= = + = + =

( ) ( ) kip lb F F F
a
075 . 0 75 100 250
2
1
2
1
min max
= = = =

Wahls line
no
as
ys
as ms
s
s
s
s s
N
2 1
+

=

2 3
8 8
w
a
w
m a
as
D
C KF
D
D KF
s

= =

2 3
8 8
w c
m
w c
m m
ms
D K
C KF
D K
D KF
s

= =

5 = C

C C
C
K
615 . 0
4 4
1 4
+

=

( )
( )
31 . 1
5
615 . 0
4 5 4
1 5 4
= +

= K

Fig. AF 15,
5 = C

19 . 1 =
c
K

For oil-tempered wire,
19 . 0
5 . 87
w
ys
D
s =
,
[ ] 5 . 0 032 . 0 < <
w
D

1 . 0
47
w
no
D
s =
,
[ ] 15 . 0 041 . 0 < <
w
D

34 . 0
30
w
no
D
s =
,
[ ] 625 . 0 15 . 0 < <
w
D

25 . 1 = N

SECTION 4 - SPRINGS
Page 21 of 70

( )( )( )
2 2
251 . 1 5 075 . 0 31 . 1 8
w w
as
D D
s = =

( )( )( )
( )
2 2
453 . 2
19 . 1
5 175 . 0 31 . 1 8
w w
ms
D D
s = =

say ksi
D
s
w
no 34 . 0
30
=
no
as
ys
as ms
s
s
s
s s
N
2 1
+

=

|
|

\
|
|
|

\
|
+
|
|

\
|
|
|

\
|
=
34 . 0
2
19 . 0
2
30
251 . 1
2
5 . 87
251 . 1 453 . 2
25 . 1
1
w
w
w
w
D
D
D
D

66 . 1 81 . 1
99 . 11
1
8 . 72
1
25 . 1
1
w w
D D
+ =

in in D
w
15 . 0 2857 . 0 > =

Table AT 15, use No. 1, W & M
in D
w
2830 . 0 =


( ) in CD D
w m
415 . 1 2830 . 0 5 = = =

say in D
m
16
7
1 =
Check for Free length
6 in < Free length < 8 in
Free length = in D
m
75 . 5
16
7
1 4 4 = |

\
|
=
Increase
m
D
in D
m
2
1
1 =

Free length = in D
m
6
2
1
1 4 4 = |

\
|
= , o.k.

Summary of answer
in D
w
2830 . 0 =

in D
m
2
1
1 =


283. A carbon-steel spring is to be subjected to a load that varies from 500 to 1200 lb.
The outside diameter should be between 3.5 and 4 in., the spring index between 5
to 10; approximate scale of 500 lb./in. Choose a steel and for a design factor of
1.4 by the Wahl line, find the wire diameter. Also determine the number of active
SECTION 4 - SPRINGS
Page 22 of 70
coils and the free length for squared-and-ground ends. Conform to the general
conditions specified in the Text.
Solution:
For carbon steel, Table AT 17
ksi
D
s
w
ys 1 . 0
91
= , [ ] 25 . 0 093 . 0 < <
w
D
ksi
D
s
w
no 15 . 0
49
= , [ ] 25 . 0 093 . 0 < <
w
D
lb F 1200
max
=

lb F 500
min
=

( ) ( ) kip lb F F F
m
85 . 0 850 500 1200
2
1
2
1
min max
= = + = + =

( ) ( ) kip lb F F F
a
35 . 0 350 500 1200
2
1
2
1
min max
= = = =

in OD 0 . 4 ~ 5 . 3 =

10 ~ 5 = C

Wahls line
no
as
ys
as ms
s
s
s
s s
N
2 1
+

=

Figure AF 15, 10 ~ 5 = C
Assume 2 . 1 = K , 125 . 1 =
c
K
3
8
w
m a
as
D
D KF
s

=

3
8
w c
m m
ms
D K
D KF
s

=

in OD 75 . 3

w m
D D = 75 . 3

( )( )( ) ( )
3 3
75 . 3 0695 . 1 75 . 3 35 . 0 2 . 1 8
w
w
w
w
as
D
D
D
D
s

=

( )( )( )
( )
( )
3 3
75 . 3 3088 . 2
125 . 1
75 . 3 85 . 0 2 . 1 8
w
w
w
w
ms
D
D
D
D
s

=

( ) ( )
|
|

\
|
|
|

\
|
+
|
|

\
|
|
|

\
|

=
15 . 0
3
1 . 0
3
49
75 . 3
0695 . 1 2
91
75 . 3
0695 . 1 3088 . 2
4 . 1
1
w
w
w
w
w
w
D
D
D
D
D
D


85 . 2 9 . 2
9079 . 22
75 . 3
4285 . 73
75 . 3
4 . 1
1
w
w
w
w
D
D
D
D
+

=

in in D
w
25 . 0 6171 . 0 > =

Use
SECTION 4 - SPRINGS
Page 23 of 70
( )
ksi s
ys
53 . 104
25 . 0
91
1 . 0
= =

( )
ksi s
no
33 . 60
25 . 0
49
15 . 0
= =

( ) ( )
33 . 60
75 . 3
0695 . 1 2
53 . 104
75 . 3
0695 . 1 3088 . 2
4 . 1
1
3 3 |
|

\
|
+
|
|

\
|

=
w
w
w
w
D
D
D
D

3 3
205 . 28
75 . 3
346 . 84
75 . 3
4 . 1
1
w
w
w
w
D
D
D
D
+

=

3
137 . 21
75 . 3
4 . 1
1
w
w
D
D
=

in D
w
5935 . 0 =

use
in D
w
32
19
=

in D D
w m
4
3
3 +

in D
m
4
3
3
32
19
= +

in D
m
32
5
3 =

316 . 5
32
19
32
5
3
=
|

\
|
|

\
|
= =
w
m
D
D
C
. o.k.
Wire Diameter in D
w
32
19
= , Carbon Steel
Number of coils:
w
c
GD
N FC
3
8
=

ksi psi G 500 , 10 10 5 . 10
6
= = , in D
w
8
3
>
c
w
N C
GD
k
F
3
8
= =

( )
( )
c
N
3
6
316 . 5 8
32
19
10 5 . 10
500
|

\
|

=

4 . 10 =
c
N

Table AT 16, square-and-ground ends
SECTION 4 - SPRINGS
Page 24 of 70
Free length =
w c
D PN 2 +
Solid height =
w c w
D N D 2 +
Total Coils = 2 +
c
N

Solid height = ( ) in D N D
w c w
3625 . 7
32
19
2 4 . 10 2 = |

\
|
+ = +
in
k
F
4 . 2
500
1200
= = =

Min. Free length = 2.4 + 7.3625 in = 9.7625 in
Use Free length = 10 in

To check for pitch angle.
Free length =
w c
D PN 2 +
( ) 10
32
19
2 4 . 10 = |

\
|
+ P

in P 8474 . 0 =

o o
12 885 . 4
32
5
3
8474 . 0
tan tan
1 1
< =
(
(
(
(

\
|
= =

m
D
P
, o.k.

Solid stress:
in deflection solid
T
6375 . 2 3625 . 7 10 = = =

( )( ) lb k F
T
1319 6375 . 2 500 = = =

C C
C
K
615 . 0
4 4
1 4
+

=

( )
( )
29 . 1
316 . 5
615 . 0
4 316 . 5 4
1 316 . 5 4
= +

= K

( )( )
( ) ksi s ksi psi
D
KFD
s
ys
w
m
s
53 . 104 033 . 23 033 , 23
32
19
32
5
3 1319 29 . 1 8
8
3 3
= < = =
|

\
|
|

\
|
= =

284. A helical compression spring, made of oil-tempered, cold-wound carbon steel, is
to be subjected to a working load varying from 100 to 300 lb. for an indefinite
time (severe). A mean coil diameter of 2 in. should be satisfactory. (a) Using the
static approach, compute a wire diameter. (b) For this wire size, compute the
factor of safety as given by the Wahl line.

Solution:

SECTION 4 - SPRINGS
Page 25 of 70
Table AT 16,
For carbon steel,
ksi
D
s
w
u 1 . 0
182
= , [ ] 25 . 0 093 . 0 < <
w
D
Max. solid ksi
D
s
w
ys 1 . 0
91
=
ksi
D
s
w
ys 1 . 0
91
=

ksi
D
s
w
no 15 . 0
49
= , [ ] 25 . 0 093 . 0 < <
w
D
. 2 in D
m
=

lb F 300
max
=

lb F 100
min
=


(a) kip lb F 3 . 0 300 = =
severe service,
( )( )
ksi
D D
s s
w w
u sd 1 . 0 1 . 0
866 . 47 182 263 . 0
263 . 0 = = =

(

=
2
8
w
s
s
D
C F
K s

C C
C
K
615 . 0
4 4
1 4
+

=

w
m
D
D
C =

C C
D
D
m
w
2
= =

( )( )
1 . 0 3
2
866 . 47
2
2 3 . 0 8 615 . 0
4 4
1 4
|

\
|
=
(
(
(
(

\
|
(

=
C C
C C
C
s
s

84 . 233
615 . 0
4 4
1 4
9 . 2
=
(

C
C C
C

075 . 6 = C

in in D
w
25 . 0 3292 . 0
075 . 6
2
> = =

Therefore use
( )
ksi s
sd
984 . 54
25 . 0
866 . 47
1 . 0
= =
SECTION 4 - SPRINGS
Page 26 of 70
( )( )
984 . 54
2
2 3 . 0 8 615 . 0
4 4
1 4
3
=
(
(
(
(

\
|
(

=
C
C C
C
s
s

9 . 287
615 . 0
4 4
1 4
3
=
(

C
C C
C

136 . 6 = C

in D
w
3259 . 0
136 . 6
2
= =

say in D
w
64
21
=

(b)
( )
ksi s
ys
53 . 104
25 . 0
91
1 . 0
= =
( )
ksi s
no
33 . 60
25 . 0
49
15 . 0
= =

( ) ( ) kip lb F F F
m
2 . 0 200 100 300
2
1
2
1
min max
= = + = + =

( ) ( ) kip lb F F F
a
1 . 0 100 100 300
2
1
2
1
min max
= = = =

095 . 6
64
21
2
=
|

\
|
= =
w
m
D
D
C

Figure AF 15
15 . 1 =
c
K

25 . 1 = K

(

=
3
8
w
m m
c
ms
D
D F
K
K
s

( )( )
ksi s
ms
34 . 31
64
21
2 2 . 0 8
15 . 1
25 . 1
3
=
(
(
(
(

\
|
=

3
8
w
m a
as
D
D KF
s

=

SECTION 4 - SPRINGS
Page 27 of 70
( )( )
ksi s
as
02 . 18
64
21
2 1 . 0 8
25 . 1
3
=
(
(
(
(

\
|
=

Wahls line
no
as
ys
as ms
s
s
s
s s
N
2 1
+

=

( )
33 . 60
02 . 18 2
53 . 104
02 . 18 34 . 31 1
+

=
N

38 . 1 = N


285. A helical spring of hard-drawn wire with a mean diameter of 1 in. and square-
and-ground ends is to be subjected to a maximum load of 325 lb. (a) Compute the
wire diameter for average service. (b) How many total coils are required if the
scale is 800 lb./in.? (c) For a minimum load of 100 lb., what is the factor of safety
according to Wahl line? Would it be safe for an indefinite life?


Solution:

Table AT 17,
Hard-drawn wire,
ksi
D
s
w
u 19 . 0
140
= , [ ] 625 . 0 028 . 0 < <
w
D
Maximum solid ksi
D
s s
w
ys s 19 . 0
70
= =
( )( )
ksi
D
s
w
no 1 . 0
47 9 . 0
= , [ ] 15 . 0 041 . 0 < <
w
D
( )( )
ksi
D
s
w
no 34 . 0
30 9 . 0
= , [ ] 625 . 0 15 . 0 < <
w
D
Average service

(a) ( )
( )
ksi
D D
s s s
w w
u u sd 19 . 0 19 . 0
556 . 38 140 2754 . 0
2754 . 0 324 . 0 85 . 0 = = = =
kip lb F 325 . 0 325 = =
in D
m
2
1
1 =
(

=
3
8
w
m
s
D
FD
K s

SECTION 4 - SPRINGS
Page 28 of 70
C C
C
K
615 . 0
4 4
1 4
+

=
C
D
w
5 . 1
=
( )( )
19 . 0 3
5 . 1
556 . 38
5 . 1
5 . 1 325 . 0 8 615 . 0
4 4
1 4
|

\
|
=
(
(
(
(

\
|
|

\
|
+

=
C C
C C
C
s
s

05 . 97
615 . 0
4 4
1 4
81 . 2
= |

\
|
+

C
C C
C

586 . 4 = C
in in
C
D
w
625 . 0 3271 . 0
586 . 4
5 . 1 5 . 1
< = = =
in D
w
64
21
=

(b) 57 . 4
64
21
5 . 1
=
|

\
|
= =
w
m
D
D
C
( )
( )
345 . 1
57 . 4
615 . 0
4 57 . 4 4
1 57 . 4 4
= +

= K
w
c
GD
N FC
3
8
=
c
w
N C
GD
k
F
3
8
= =

in kip in lb k 8 . 0 800 = =
( )
c
N
3
57 . 84
64
21
500 , 11
8 . 0
|

\
|
=
2 . 6 =
c
N

(c) ksi s
ys
5 . 86
64
21
70
19 . 0
=
|

\
|
=
( )( )
ksi s
no
44 . 39
64
21
30 9 . 0
19 . 0
=
|

\
|
= , in D
w
15 . 0 >
( ) kip lb F
m
2125 . 0 5 . 212 100 325
2
1
= = + =
SECTION 4 - SPRINGS
Page 29 of 70
( ) kip lb F
a
1125 . 0 5 . 112 100 325
2
1
= = =
212 . 1 =
c
K , Fig. AF 15
345 . 1 = K
( )( )
ksi
D
D F
K
K
s
w
m m
c
ms
5 . 25
64
21
5 . 1 2125 . 0 8
212 . 1
345 . 1 8
3 3
=
(
(
(
(

\
|
=
(

( )( )
ksi
D
D F
K s
w
m m
as
36 . 16
64
21
5 . 1 1125 . 0 8
345 . 1
8
3 3
=
(
(
(
(

\
|
=
(

( )
44 . 39
36 . 16 2
5 . 86
36 . 16 5 . 25 2 1
+

= +

=
no
as
ys
as ms
s
s
s
s s
N

[ ]
min
15 . 1 07 . 1 N N < =
Not safe for indefinite life.

286. A helical spring is to be subjected to a maximum load of 200 lb. (a) Determine
the wire size suitable for medium service if the material is carbon steel ASTM
A230; 6 = C . Determine the factor of safety of this spring according to the Wahl
line (b) If the minimum force is 150 lb., (c) if the minimum force is 100 lb., (d) if
the minimum force is 25 lb.

Solution:

For carbon steel ASTM A230
Table AT 17
ksi
D
s
w
u 1 . 0
182
= , [ ] 25 . 0 093 . 0 < <
w
D
ksi
D
s
w
ys 1 . 0
91
= , [ ] 25 . 0 093 . 0 < <
w
D
ksi
D
s
w
no 15 . 0
49
= , [ ] 25 . 0 093 . 0 < <
w
D
Medium Service
u sd
s s 324 . 0 =

(a) psi
D
ksi
D D
s
w w w
sd 1 . 0 1 . 0 1 . 0
968 , 58 968 . 58 182
324 . 0 = =
|
|

\
|
=
SECTION 4 - SPRINGS
Page 30 of 70
(

=
3
8
w
m
s
D
FD
K s

C C
C
K
615 . 0
4 4
1 4
+

=
( )
( )
2525 . 1
6
615 . 0
4 6 4
1 6 4
= +

= K
lb F 200 =
( )( )
1 . 0 2
968 , 58 6 200 8
2525 . 1
w w
s
D D
s =
(

in D
w
2371 . 0 =

Table At 15, use in D
w
2437 . 0 = , No. 3 W & M
in in D
w
25 . 0 2437 . 0 < = , o.k.

Factor of safety.
( )
ksi ksi ksi
D
s
w
ys
8 . 104
2437 . 0
91 91
1 . 0 1 . 0
= = =
( )
ksi ksi ksi
D
s
w
no
56 . 60
2437 . 0
49 49
15 . 0
= = =

(a) ( ) kip lb F
m
175 . 0 175 150 200
2
1
= = + =
( ) kip lb F
a
025 . 0 25 150 200
2
1
= = =
Figure AF 15, 156 . 1 =
c
K
( )( )
( )
ksi
D
C F
K
K
s
w
m
c
ms
8 . 48
2437 . 0
6 175 . 0 8
156 . 1
2525 . 1 8
2 2
=
(

=
(

=


( )( )
( )
ksi
D
C F
K s
w
a
as
1 . 8
2437 . 0
6 025 . 0 8
2525 . 1
8
2 2
=
(

=
(

=


no
as
ys
as ms
s
s
s
s s
N
2 1
+

=
( )
56 . 60
1 . 8 2
8 . 104
1 . 8 8 . 48 1
+

=
N

525 . 1 = N

(b) ( ) kip lb F
m
15 . 0 150 100 200
2
1
= = + =
( ) kip lb F
a
05 . 0 50 100 200
2
1
= = =
SECTION 4 - SPRINGS
Page 31 of 70
Figure AF 15, 156 . 1 =
c
K
( )( )
( )
ksi
D
C F
K
K
s
w
m
c
ms
8 . 41
2437 . 0
6 15 . 0 8
156 . 1
2525 . 1 8
2 2
=
(

=
(

=


( )( )
( )
ksi
D
C F
K s
w
a
as
11 . 16
2437 . 0
6 05 . 0 8
2525 . 1
8
2 2
=
(

=
(

=


no
as
ys
as ms
s
s
s
s s
N
2 1
+

=
( )
56 . 60
11 . 16 2
8 . 104
11 . 16 8 . 41 1
+

=
N

287 . 1 = N

(c) ( ) kip lb F
m
1125 . 0 5 . 112 25 200
2
1
= = + =
( ) kip lb F
a
0875 . 0 5 . 87 25 200
2
1
= = =
Figure AF 15, 156 . 1 =
c
K
( )( )
( )
ksi
D
C F
K
K
s
w
m
c
ms
36 . 31
2437 . 0
6 1125 . 0 8
156 . 1
2525 . 1 8
2 2
=
(

=
(

=


( )( )
( )
ksi
D
C F
K s
w
a
as
2 . 28
2437 . 0
6 0875 . 0 8
2525 . 1
8
2 2
=
(

=
(

=


no
as
ys
as ms
s
s
s
s s
N
2 1
+

=
( )
56 . 60
20 . 28 2
8 . 104
20 . 28 36 . 31 1
+

=
N

04 . 1 = N

CHECK PROBLEMS

A Diesel valve spring is made of 3/8-in. chrome-vanadium steel wire, shot-peened; inside
diameter is 3 in., 7 active coils, free length is 7 3/8 in., solid length is 4 1/8 in., length
with valve closed, 6 in., length when open, 5 1/8 in. (a) Compute the spring constant
and the factor of safety as defined by the Wahl criterion (see 6.13, Text). (b) Is there
any danger of damage to the spring if it is compressed solid? (c) What is the natural
frequency? If this spring is used on a 4-stroke Diesel engine at 450 rpm, is there any
danger of surge? Compute the change of stored energy between working lengths.



Solution:

For chrome-vanadium steel wire, shot-peened, Table AT 17
SECTION 4 - SPRINGS
Page 32 of 70
( )( )
ksi
D
s
w
u 166 . 0
168 25 . 1
= , [ ] 437 . 0 032 . 0 < <
w
D
( )( )
ksi
D
s
w
ys 166 . 0
100 25 . 1
= , [ ] 437 . 0 032 . 0 < <
w
D
( )( )
ksi
D
s
w
no 15 . 0
49 25 . 1
= , [ ] 5 . 0 028 . 0 < <
w
D
in in D
w
375 . 0
8
3
= =
( )( )
( )
ksi ksi s
ys
1 . 147
375 . 0
100 25 . 1
166 . 0
= =
( )( )
( )
ksi ksi s
no
96 . 70
375 . 0
49 25 . 1
15 . 0
= =
(a)
w
c
GD
N FC
3
8
=
c
w
N C
GD
k
F
3
8
= =

psi G
6
10 5 . 11 =
7 =
c
N
in D
w
375 . 0 =
in ID D D
w m
3 = =
in D
m
375 . 3 =
9
375 . 0
375 . 3
= = =
w
m
D
D
C
nstant co spring k =
( )( )
( ) ( )
in lb
N C
GD
k
c
w
64 . 105
7 9 8
375 . 0 10 5 . 11
8
3
6
3
=

= =
in 25 . 3
8
1
4
8
3
7
1
= =
( )( ) lb k F 33 . 343 25 . 3 64 . 105
1 1
= = =
in 125 . 1
4
1
6
8
3
7
2
= =
( )( ) lb k F 85 . 118 125 . 1 64 . 105
2 2
= = =
( ) kip lb F
m
231 . 0 09 . 231 85 . 118 33 . 343
2
1
= = + =
( ) kip lb F
a
11224 . 0 24 . 112 85 . 118 33 . 343
2
1
= = =
(

=
2
8
w
m
c
ms
D
C F
K
K
s

SECTION 4 - SPRINGS
Page 33 of 70
C C
C
K
615 . 0
4 4
1 4
+

=
( )
( )
162 . 1
9
615 . 0
4 9 4
1 9 4
= +

= K
Figure AF 15, 10 . 1 =
c
K
( )( )
( )
ksi
D
C F
K
K
s
w
m
c
ms
8 . 39
375 . 0
9 231 . 0 8
10 . 1
162 . 1 8
2 2
=
(

=
(

=


( )( )
( )
ksi
D
C F
K s
w
a
as
3 . 21
375 . 0
9 11224 . 0 8
162 . 1
8
2 2
=
(

=
(

=


no
as
ys
as ms
s
s
s
s s
N
2 1
+

=
( )
96 . 70
3 . 21 2
1 . 147
3 . 21 8 . 39 1
+

=
N

377 . 1 = N

(b) max. solid ksi s s
ys s
1 . 147 = =

Min. Solid Height = ( )( ) in N D
c w
625 . 2 7 375 . 0 = =
Solid deflection = . 75 . 4 625 . 2
8
3
7 in =
( )( ) kip lb k F 5018 . 0 8 . 501 75 . 4 64 . 105 = = = =
Solid stress =
( )( )
( )
ksi ksi
D
FC
K s
w
s
1 . 147 95
375 . 0
9 5018 . 0 8
162 . 1
8
2 2
< =
(

=
(

=


There is no danger of damage

(c) Natural frequency

For steel
cps
D N
D
m c
w
2
050 , 14
=
cps
D C N
w c
2
050 , 14
=
( )( ) ( )
cps cps 66
375 . 0 9 7
050 , 14
2
= =
For 450 rpm, cps 47
60
2
450 = |

\
|
=


12 4 . 1
47
66
< = , there is danger of surging.

SECTION 4 - SPRINGS
Page 34 of 70
(d) ( ) ( ) ( ) ( ) [ ] lb in k U
s
= = = 491 125 . 1 25 . 3 64 . 105
2
1
2
1
2 2 2
2
2
1


289. A helical spring is hot wound from 5/8-in. carbon-steel wire with an outside
diameter of 3 in. A force of 3060 lb. is required to compress the spring 1
in to the solid heigh. In service the spring is compressed so that its
deformation varies form in. to1 1/8 in. (a) What is the factor of safety by
the Wahl criterion? (b) Is the solid stress safe? Compute (c) the pitch angle,
(d) the change of stored energy between the working lengths, (e) the factor of
safety if the spring is peened?

Solution:

For hot-wound carbon steel wire
in D
w
8
5
=
Table AT 17
ksi
D
s
w
ys 1 . 0
91
= , [ ] 25 . 0 093 . 0 < <
w
D
( )
ksi ksi s
ys
5 . 104
25 . 0
91
1 . 0
= = , . 25 . 0 in D
w
>
ksi
D
s
w
no 15 . 0
49
= , [ ] 25 . 0 093 . 0 < <
w
D
( )
ksi ksi s
no
33 . 60
25 . 0
49
15 . 0
= = , . 25 . 0 in D
w
>

Permissible solid stress = ksi
D
s
w
s 31 . 0
117
= , [ ] . 375 . 0 in D
w
> 6.3
( )
ksi ksi s
s
4 . 35
625 . 0
117
31 . 0
= =

(a) in lb
F
k 6 . 1748
75 . 1
3060
= = =

( ) lb k F 3 . 874
2
1
6 . 1748
1 1
= |

\
|
= =
( ) lb k F 2 . 1967
8
1
1 6 . 1748
2 2
= |

\
|
= =
( ) kip lb F
m
4207 . 1 7 . 1420 3 . 874 2 . 1967
2
1
= = + =
( ) kip lb F
a
5464 . 0 4 . 546 3 . 874 2 . 1967
2
1
= = =
SECTION 4 - SPRINGS
Page 35 of 70
in in D
w
625 . 0
8
5
= =
in D D
w m
4
1
3 = +
in D
m
625 . 2 =
2 . 4
625 . 0
625 . 2
= = =
w
m
D
D
C
C C
C
K
615 . 0
4 4
1 4
+

=
( )
( )
3808 . 1
2 . 4
615 . 0
4 2 . 4 4
1 2 . 4 4
= +

= K
234 . 1 =
c
K
( )( )
( )
ksi
D
C F
K
K
s
w
m
c
ms
5 . 43
625 . 0
2 . 4 4207 . 1 8
234 . 1
3808 . 1 8
2 2
=
(

=
(

=


( )( )
( )
ksi
D
C F
K s
w
a
as
7 . 20
625 . 0
2 . 4 5464 . 0 8
3808 . 1
8
2 2
=
(

=
(

=


no
as
ys
as ms
s
s
s
s s
N
2 1
+

=
( )
33 . 60
7 . 20 2
5 . 104
7 . 20 5 . 43 1
+

=
N

106 . 1 = N

(b) Permissible solid stress = 135.4 ksi

kip F 060 . 3 =

Solid stress,
( )( )
( )
ksi ksi
D
FC
K s
w
s
4 . 135 7 . 115
625 . 0
2 . 4 060 . 3 8
3808 . 1
8
2 2
< =
(

=
(

=

, safe

(c) Solid deflection = in
4
3
1
( ) in N D P
c w
75 . 1 =
w
c
GD
N FC
3
8
=
psi G
6
10 5 . 10 = , hot-wound
c
w
N C
GD F
k
3
8
= =

SECTION 4 - SPRINGS
Page 36 of 70
( )( )
( )
c
N
3
6
2 . 4 8
625 . 0 10 5 . 10
6 . 1748

=
332 . 6 =
c
N
( )( ) 75 . 1 332 . 6 625 . 0 = P
in P 9014 . 0 =
Pitch angle
w m
CD
P
D
P

= = tan
( )( )
o
24 . 6
625 . 0 2 . 4
9014 . 0
tan tan
1 1
=
(

= =

w
CD
P


(d) ( ) ( ) ( ) ( ) [ ] lb in k U
s
= = = 888 5 . 0 125 . 1 6 . 1748
2
1
2
1
2 2 2
2
2
1

(e) When peened
( ) ksi s
ys
6 . 130 5 . 104 5 . 12 = =
( ) ksi s
no
4 . 75 33 . 60 25 . 1 = =
( )
4 . 75
7 . 20 2
6 . 130
7 . 20 5 . 43 1
+

=
N

38 . 1 = N


ENERGY STORAGE

293. A 10-lb. body falls 10 in. and then strikes a helical spring. Design a hard-
drawn carbon steel spring that will absorb this shock occasionally without
permanent damage. Determine appropriate values of wire diameter, coil
diameter, pitch, free length, closed length, and the maximum stress under the
specified conditions, and scale. Let 7 = C .

Solution:

For hard-drawn carbon steel, Table AT 17
ksi
D
s
w
u 1 . 0
182
= , [ ] 25 . 0 093 . 0 < <
w
D
Max. solid ksi
D
s
w
s 1 . 0
91
= , [ ] 25 . 0 093 . 0 < <
w
D
( )( ) ksi
D
s s
w
u sd 1 . 0
855 . 36
405 . 0 50 . 0 = =
G K
V s
U
s
s 2
2
4
=
SECTION 4 - SPRINGS
Page 37 of 70
C C
C
K
615 . 0
4 4
1 4
+

=
( )
( )
213 . 1
7
615 . 0
4 7 4
1 7 4
= +

= K
( )
c m
w
N D
D
V

|
|

\
|

4
2

4
2 2
c m w
N D D
V

=
w m
CD D =
4
3 2
c w
N CD
V

=
w
c
GD
N FC
3
8
=
( ) + = h W U
s

(

=
2
8
w
s
D
FC
K s

KC
D s
F
w s
8
2

=
(

=
w
c w s
GD
N C
KC
D s
3 2
8
8

KG
N C D s
c w s
2

=
G K
N CD s
KG
N C D s
h W U
c
c w s
s
w s
2
3 2 2
2
16

=
(

+ =
KG
W C D s
G K
CD s
Wh
N
w s w s
c 2
2
2 2 2
16

=
when ksi
D
s
w
s 1 . 0
855 . 36
=
( )
KG
W C D
G K
CD
Wh
N
w w
c 2 9 . 0
2
8 . 2 2 2
855 . 36
16
855 . 36

=
( )( )
( ) ( )
( ) ( )
( ) ( )
( )( ) 500 , 11 213 . 1
010 . 0 7 855 . 36
500 , 11 213 . 1 16
7 855 . 36
10 010 . 0
2 9 . 0
2
8 . 2 2 2
w
D
D
N
w
c

=
9 . 0 8 . 2
004067 . 0 3466 . 0
10 . 0
w
D D
N
w
c

=
SECTION 4 - SPRINGS
Page 38 of 70
combination of
w
D and
c
N
Gage No. W & M
w
D
c
N
c w
N D
12 0.1055 991.2 105
11 0.1205 312.1 37.6
10 0.1350 166.1 22.4
9 0.1483 108.0 16.0
8 0.1620 75.2 12.2
7 0.1770 53.7 9.5
6 0.1920 40.2 7.7
5 0.2070 31 6.4
4 0.2253 23.4 5.3
3 0.2437 18.1 4.4

Use in in D
w
25 . 0 2437 . 0 < = , 1 . 18 =
c
N
( ) in in D D
w m
64
45
1 7059 . 1 2437 . 0 7 7 = = = =

( ) ( ) ( )
( )( )
in
KG
N C D
KG
N C D s
c
c w s w
066 . 2
500 , 11 213 . 1
1 . 18 7 2437 . 0 855 . 36
855 . 36
2 9 . 0 2 9 . 0
2
= = = =

( )
ksi s
s
44 . 42
2437 . 0
855 . 36
1 . 0
= =
( )
ksi
D
s
w
so
8 . 104
2437 . 0
91 91
1 . 0 1 . 0
= = =
Solid deflection
( ) in 1 . 5 066 . 2
44 . 42
8 . 104
= |

\
|
=
( ) 1 . 5 =
c w
N D P
( )( ) 1 . 5 1 . 18 2437 . 0 = P
in P 5255 . 0 =
say in P 53125 . 0
32
17
= =
Minimum Solid Height = ( )( ) in N D
c w
41 . 4 1 . 18 2437 . 0 = =
Assume squared and ground end
Solid height = ( )( ) ( ) in D N D
w c w
0 . 5 2437 . 0 2 1 . 18 2437 . 0 2 = + = +
Solid deflection = ( )( ) in 2 . 5 1 . 18 2437 . 0 53125 . 0 =
Free length = 5.0 in + 5.2 in = 10.2in



Summary of answer:
in D
w
2437 . 0 = , No. 3 W & M
SECTION 4 - SPRINGS
Page 39 of 70
in D
m
64
45
1 =
in P
32
17
=
Free length = 10.2 in
Closed length = 5 in
Maximum stress = 42.44 ksi

294. A helical spring, of hard-drawn steel wire, is to absorb 75 in-lb of energy
without being stressed beyond the recommended value of average service. Let
6 = C . Decide upon satisfactory dimensions;
w
D ,
m
D ,
c
N , free length, pitch
angle, solid stress, volume of metal, possibility of spring buckling.

Solution:

For hard-drawn steel wire, shock load, average service
ksi
D
s
w
u 19 . 0
140
= , [ ] 625 . 0 028 . 0 < <
w
D
Max. solid ksi
D
s
w
s 19 . 0
70
= , [ ] 625 . 0 028 . 0 < <
w
D
( )( )( ) ( )( )( ) ksi
D D
s s
w w
u sd 19 . 0 19 . 0
278 . 19 140
324 . 0 85 . 0 50 . 0 324 . 0 85 . 0 50 . 0 =
|
|

\
|
= =
G K
CN D s
G K
V s
U
c w s s
s 2
3 2 2
2
2
16 4

= =
6 = C
C C
C
K
615 . 0
4 4
1 4
+

=
( )
( )
2525 . 1
6
615 . 0
4 6 4
1 6 4
= +

= K
kip in lb in U
s
= = 075 . 0 75
( )
( ) ( ) 500 , 11 2525 . 1 16
6 278 . 19
075 . 0
2
3 2
19 . 0
c w
w
s
N D
D
U

(

= =
c w
N D
62 . 2
9837 . 0 =






Table AT-15
W & M
w
D
c
N
c w
N D
SECTION 4 - SPRINGS
Page 40 of 70
9 0.1483 146 21.65
8 0.1620 116 18.79
7 0.1770 92 16.28
6 0.1920 74 14.21
5 0.207 61 12.63
4 0.2253 49 11.04
3 0.2437 40 9.75
2 0.2625 32.7 8.58
1 0.2830 26.9 7.61
0 0.3065 21.8 6.68
2-0 0.3310 17.8 5.89
3-0 0.3625 14.0 5.075
4-0 0.3938 11.3 4.45
5-0 0.4305 8.95 3.85

Use in D
w
4305 . 0 = , 5-0 W & M
9
c
N
( ) in in D
m
16
9
2 583 . 2 4305 . 0 6 = =
( )
ksi s
s
63 . 22
4305 . 0
278 . 19
19 . 0
= =
Max. Solid Stress =
( )
ksi s
so
16 . 82
4305 . 0
70
19 . 0
= =
( )( )( )( ) ( )
( )( )
in
KG
N C D s
c w s
6885 . 0
500 , 11 2525 . 1
9 6 4305 . 0 63 . 22
2 2
= = =


Solid deflection ( ) in 5 . 2 6885 . 0
63 . 22
16 . 82
= |

\
|
=
( ) 5 . 2 =
c w
N D P
( )( ) 5 . 2 9 4305 . 0 = P
in P 7083 . 0 =
say in P 703125 . 0
64
45
= =
Solid deflection = ( )( ) in 453625 . 2 9 4305 . 0 703125 . 0 =
Solid stress ksi 65 . 80
6885 . 0
453625 . 2
63 . 22 = |

\
|
=
Minimum Solid Height = ( )( ) in in N D
c w
8
7
3 8745 . 3 9 4305 . 0 = =
Minimum Free Length = ( ) in in PN
c
64
21
6 328125 . 6 9
64
45
= |

\
|
=
Pitch Angle
SECTION 4 - SPRINGS
Page 41 of 70
o o
12 5
16
9
2
64
45
tan tan
1 1
< =
(
(
(
(

\
|
= =

m
D
P

Volume
( )
( )
( )
3
2 2
55 . 10 9
16
9
2
4
4305 . 0
4
in N D
D
V
c m
w
=
(

\
|
(

=
|
|

\
|

Summary of answer:
in D
w
4305 . 0 = , No. 5-0 W & M
in D
m
16
9
2 =
9 =
c
N
Free length = in
64
21
6
Pitch Angle =
o
5 =
Solid Stress = 80.65 ksi
Volume of metal = 10.55 in
3


Possibility of spring buckling
4 47 . 2
16
9
2
64
21
6
< = , no possibility

CONCENTRIC HELICAL SPRINGS

297. Two concentric helical springs are to be subjected to a load that varies from a
maximum of 235 lb. to a maximum of 50 lb. They are to fit inside a 1 5/8 in.
cylinder. The maximum deflection is to be in., and the deflection when
compressed solid is to be approximately 1 in. Using the static approach for
severe service (maximum load), determine the wire diameter, mean coil
diameter, number of coils, solid length, and free length of both springs. (Start
with oil-tempered wire and assume a diametral clearance between the outer
spring and the cylinder of
2
w
D
, assume a similar clearance between springs.
Search for a suitable spring index and wire size.)

Solution:

For oil-tempered wire
Table AT 17
SECTION 4 - SPRINGS
Page 42 of 70
ksi
D
s
w
u
19 . 0
146
= , [ ] 5 . 0 032 . 0 < <
w
D
Max. solid ksi
D
s
w
s 19 . 0
5 . 87
= , [ ] 5 . 0 032 . 0 < <
w
D
Severe service
( )
ksi
D D
s s
w w
u sd 19 . 0 19 . 0
398 . 38 146 263 . 0
263 . 0 = = =
kip lb F 235 . 0 235 = =
i o
=
wi
i i i
wo
co o o
GD
N C F
GD
N C F
3 3
8 8
=
Assume,
i o
C C =
co
wo
o
N C
GD
F
3
32
3
=
ci
wi
i
N C
GD
F
3
32
3
=
(

=
2
8
wo
o
so
D
C F
K s

=
2
8
wi
i
si
D
C F
K s

wi
mi
wo
mo
D
D
D
D
C = =
C C
C
K
615 . 0
4 4
1 4
+

=
wi mi
wi
wo mo
D D
D
D D + =
2

wi wo mi mo
D D D D 5 . 1 + =
wo mo
wo
D D
D
+ =
2
625 . 1
625 . 1 5 . 1 = +
wo mo
D D
625 . 1 5 . 1 = +
wo wo
D CD
5 . 1
625 . 1
+
=
C
D
wo

5 . 1
625 . 1
+
=
C
C
D
mo

wi wo wi wo
D D CD CD 5 . 1 + =

( ) ( )
wi wo
D C D C 5 . 1 1 + =
SECTION 4 - SPRINGS
Page 43 of 70
( )
( )
2
5 . 1
1 625 . 1
+

=
C
C
D
wi

( )
( )
2
5 . 1
1 625 . 1
+

=
C
C C
D
mi

ksi
D D
C F
K s
wo wo
o
so 19 . 0 2
398 . 38 8
=
(

KC
D
F
wo
o
81 . 1
08 . 15
=
ksi
D D
C F
K s
wi wi
i
si 19 . 0 2
398 . 38 8
=
(

KC
D
F
wi
i
81 . 1
08 . 15
=
kip F F F
i o
235 . 0 = = +
235 . 0
08 . 15 08 . 15
81 . 1 81 . 1
= +
KC
D
KC
D
wi wo

KC D D
wi wo
235 . 0 08 . 15 08 . 15
81 . 1 81 . 1
= +
( )
KC
C
C
C
235 . 0
5 . 1
1 625 . 1
08 . 15
5 . 1
625 . 1
08 . 15
81 . 1 81 . 1
=
(

+
|

\
|
+

( )
( )
( )
C
C C
C
C
C
C
|

\
|
+

=
(

+
+
615 . 0
4 4
1 4
235 . 0
5 . 1
1
5 . 1
1
52 . 154
62 . 3
81 . 1
81 . 1

328 . 5 = C
( )
( )
in D
wi
1509 . 0
5 . 1 328 . 5
1 328 . 5 625 . 1
2
=
+

=
in D
wo
2380 . 0
5 . 1 328 . 5
625 . 1
=
+
=
Table AT 15, use in D
wi
1620 . 0 = , No. 8 W & M and in D
wo
2625 . 0 = , No. 2 W & M
( )( ) in in CD D
wo mo
32
13
1 3986 . 1 2625 . 0 328 . 5 = = =
( )( ) in in CD D
wi mi
8
7
8631 . 0 1620 . 0 328 . 5 = = =
401 . 5
1620 . 0
8
7
=
|

\
|
= =
wi
mi
i
D
D
C
357 . 5
2625 . 0
32
13
1
=
|

\
|
= =
wo
mo
o
D
D
C
SECTION 4 - SPRINGS
Page 44 of 70
o o
wo
o
C K
D
F
81 . 1
08 . 15
=
( )
( )
287 . 1
357 . 5
615 . 0
1 357 . 5 4
1 357 . 5 4
= +

=
o
K
( )
( )( )
kip F
o
194 . 0
357 . 5 287 . 1
2625 . 0 08 . 15
81 . 1
= =
i i
wi
i
C K
D
F
81 . 1
08 . 15
=
( )
( )
2843 . 1
401 . 5
615 . 0
1 401 . 5 4
1 401 . 5 4
= +

=
i
K
( )
( )( )
kip F
i
081 . 0
401 . 5 2843 . 1
1620 . 0 08 . 15
= =
kip kip F F
i o
235 . 0 275 . 0 071 . 0 194 . 0 > = + = + , ok
co
wo
o
N C
GD
F
3
32
3
=
( )( )
( )
co
N
3
357 . 5 32
2625 . 0 500 , 11 3
194 . 0 =
5 . 9 =
co
N
ci
wi
i
N C
GD
F
3
32
3
=
( )( )
( )
ci
N
3
401 . 5 32
1620 . 0 500 , 11 3
071 . 0 =
6 . 15 =
ci
N
Max. solid stress, ksi
D
s
w
ss 19 . 0
5 . 87
= ,
( )
ksi s
sso
82 . 112
2625 . 0
5 . 87
19 . 0
= =
( )
ksi s
ssi
65 . 123
1620 . 0
5 . 87
19 . 0
= =
Stress
( )
ksi s
si
26 . 54
1620 . 0
398 . 38
19 . 0
= =
( )
ksi s
so
51 . 49
2625 . 0
398 . 38
19 . 0
= =

Solid stress
ksi ksi s
so
82 . 112 01 . 66
75 . 0
1
51 . 49 < = |

\
|
=
SECTION 4 - SPRINGS
Page 45 of 70
ksi ksi s
si
65 . 123 35 . 72
75 . 0
1
26 . 54 < = |

\
|
=
Solid length
( )( ) in N D
co wo
5 . 2 5 . 9 2625 . 0 = =
( )( ) in N D
ci wi
53 . 2 6 . 15 1620 . 0 = =

assume solid length = 3 in
( ) ( )( ) in x x N D
i i ci wi
3 6 . 15 1620 . 0 = + = +
92 . 2 =
i
x
Total coils = 15.6 + 2.92 = 18.52
( ) ( )( ) in x x N D
o o co wo
3 5 . 9 2625 . 0 = + = +
93 . 1 =
o
x
Total coils = 9.5 + 1.93 = 11.43

Free Length = 3 in + 1 in = 4 in

Summary of answer:

Outside wire.
in D
wo
2625 . 0 = , No. 2 W & M
in D
mo
32
13
1 =
43 . 11 =
to
N
Solid length = 3 in
Free length = 4 in

Inside wire.
in D
wi
1620 . 0 = , No. 8 W & M
in D
mi
8
7
=
52 . 18 =
ti
N
Solid length = 3 in
Free length = 4 in

298. Two concentric, helical compression springs are used on a freight car. The
larger spring has an outside diameter of 7 in., a free length of 7 1/8 in., and is
made of a 1 in. steel bar. The smaller has an outside diameter of 4 1/8 in., a
free length of 6 13/16 in. , and is made of 7/8 in. steel bar. The solid height of
each spring is 5 in. and the forces required to compress them solid are
15,530 lb. and 7,000 lb., respectively. The working load on the two springs is
11,350 lb. Determine (a) the number of free coils in each spring, (b) the stress
in each spring when compressed solid, (c) the stresses induced by the working
SECTION 4 - SPRINGS
Page 46 of 70
load. Notice that the outer spring deflects 5/16 in. before the inner one takes a
load. (d) What energy is absorbed while changing deflection from that at the
working load to that when the springs are compressed solid?

Solution:
in OD
o
7 =
in D
wo
8
3
1 =
in FL
o
8
1
7 =
in OD
i
8
1
4 =
in D
wi
8
7
=
in FL
i
16
13
6 =

(a) Solid height = in N D
T w
4
1
5 =
82 . 3
375 . 1
25 . 5
= =
To
N
6
875 . 0
25 . 5
= =
Ti
N

(b) lb F
o
530 , 15 =
lb F
i
7000 =
(

=
2
8
w
s
D
FC
K s

in D
mo
625 . 5
8
3
1 7 = =
091 . 4
375 . 1
625 . 5
= = =
wo
mo
o
D
D
C
( )
( )
393 . 1
091 . 4
615 . 0
4 091 . 4 4
1 091 . 4 4
= +

=
o
K
in D
mi
25 . 3
8
7
8
1
4 = =
714 . 3
875 . 0
25 . 3
= = =
wi
mi
i
D
D
C
( )
( )
442 . 1
714 . 3
615 . 0
4 714 . 3 4
1 714 . 3 4
= +

=
i
K

SECTION 4 - SPRINGS
Page 47 of 70
Solid stress
( )( )
( )
psi s
so
203 , 119
375 . 1
091 . 4 530 , 15 8
393 . 1
2
=
(

( )( )
( )
psi s
si
689 , 124
875 . 0
714 . 3 7000 8
442 . 1
2
=
(

(b) Stresses induced by working load

lb F F
o i
350 , 11 = +
in lb k
o
8283
4
1
5
8
1
7
530 , 15
=
|

\
|

=
in lb k
o
4480
4
1
5
16
13
6
7000
=
|

\
|

=
in
i o
3125 . 0
16
5
= =
i i i i
k F 4480 = =
( )
i o o o
k F + = = 3125 . 0 8283
( ) lb k F F
i i o o o i
350 , 11 3125 . 0 8283 4480 = + + = = +
in
i
6865 . 0 =
in
o
9990 . 0 6865 . 0 3125 . 0 = + =
( )( ) lb F
i
3076 6865 . 0 4480 = =
( )( ) lb F
o
8275 9990 . 0 8283 = =
Stresses
( )( )
( )
psi s
so
516 , 63
375 . 1
091 . 4 8275 8
393 . 1
2
=
(

( )( )
( )
psi s
si
792 , 54
875 . 0
714 . 3 3076 8
442 . 1
2
=
(

(d) Energy
( )
2
1
2
2
2
1
o o o so
k U =
in
o
875 . 1
4
1
5
8
1
7
2
= =
in
o
9990 . 0
1
=
( ) ( ) ( ) [ ] lb in U
so
= = 427 , 10 999 . 0 875 . 1 8283
2
1
2 2

SECTION 4 - SPRINGS
Page 48 of 70
( )
2
1
2
2
2
1
i i i si
k U =
in
i
5625 . 1
4
1
5
16
13
6
2
= =
in
o
6865 . 0
1
=
( ) ( ) ( ) [ ] lb in U
si
= = 413 , 4 6865 . 0 5625 . 1 4480
2
1
2 2


TORSION-BAR SPRINGS

299. A torsion-bar similar to that shown is to be used for the front spring of an
automobile. Its rate should be 400 lb./in. of deflection of the end of the arm
which is . 10 in e = long. It is made of AISI 9261,OQT 900
o
F, and the
maximum repeated load is 1500 lb. perpendicular to the centerline of the arm.
The support is such that bending of the bar is negligible. (a) Determine its
diameter and length so that no permanent set occurs due to a 30 % overload
(limited by a stop). Use
y ys
s s 6 . 0 = , but check with equation (c) 6.3, Text, if
appropriate. (b) Determine the factor of safety according to the Soderberg
criterion if the load varies from 1200 lb. to 1500 lb.; minimum 1 . 0 = d r ,
3 = d D . (c) The same as (b) except that the bar is shot-peened all over. What
other steps may be taken to improve the fatigue strength?



Problem 299, 300

Solution:
in e 10 =
For AISI 9261, OQT 900
o
F
ksi s
y
192 =
ksi s
u
215 =
psi ksi s s
y ys
200 , 115 2 . 115 6 . 0 = = =

SECTION 4 - SPRINGS
Page 49 of 70
(a)
3
16
d
T
s
s

=
( )( )( ) lb in Fe T = = = 500 , 19 10 1500 3 . 1
( )
3
500 , 19 16
200 , 115
d
=
in d 95 . 0 =
use in d 1 =
6.3
( )
ys
w
s
s ksi
D
s = = = 117
1
117 117
3 . 0 3 . 0


(b) Soderberg Criterion
ns
as f
ys
ms
s
s K
s
s
N
+ =
1

( )( )( ) ksi s
ns
5 . 64 215 5 . 0 6 . 0 = =
Figure AF 12, 1 . 0 = d r , 3 = d D
45 . 1 =
t
K
45 . 1 =
t f
K K

( ) lb F
m
1350 1200 1500
2
1
= + =
( )( ) kips in lb in T
m
= = = 5 . 13 500 , 13 10 1350
( )
( )
ksi s
ms
8 . 68
1
5 . 13 16
3
= =

( ) lb F
a
150 1200 1500
2
1
= =
( )( ) kips in lb in T
a
= = = 5 . 1 1500 10 150
( )
( )
ksi s
as
64 . 7
1
5 . 1 16
3
= =

( )( )
5 . 64
64 . 7 45 . 1
2 . 115
8 . 68 1
+ =
N

30 . 1 = N

(c) Shot-peened
( ) ksi s
ys
144 2 . 115 25 . 1 = =
( ) ksi s
ns
6 . 80 5 . 64 25 . 1 = =
( )( )
6 . 80
64 . 7 45 . 1
144
8 . 68 1
+ =
N

625 . 1 = N
SECTION 4 - SPRINGS
Page 50 of 70



300. A solid steel torsion bar is loaded through a 10 in. arm as shown. The load F
perpendicular to the center-line of the arm varies from 500 to 1000 lb.,
200,000 cycles. The bar is .
8
7
in d = in diameter and 30 in. long; let 3 = d D ;
1 . 0 = d r ; (a) Determine the maximum stress in the bar, the angular
deflection, and the scale (lb./in.) where F is applied. The support is such that
bending of the bar is negligible. (b) Select a material and heat treatment for
this bar for a minimum 2 . 1 = N , Soderberg criterion.

Problem 299, 300
Solution:
Fig. AF 12, 45 . 1 =
f
K
( ) lb F
m
750 500 1000
2
1
= + =
( ) lb F
a
250 500 1000
2
1
= =
( )( ) kips in lb in T
m
= = = 5 . 7 7500 10 750
( )( ) kips in lb in T
a
= = = 5 . 2 2500 10 250
( )
( )
( )
33 . 1
45 . 1
000 , 200
3 45 . 1 log 3 log
= =
f
K
fl
K
n
K
f

3
16
d
T
s
s

=
( )
ksi s
ms
57
8
7
5 . 7 16
3
=
|

\
|
=

( )
ksi s
as
19
8
7
5 . 2 16
3
=
|

\
|
=

(a) ( )( ) ksi s K s s
as fl ms
27 . 82 19 33 . 1 57
max
= + = + =
SECTION 4 - SPRINGS
Page 51 of 70
G d
TL
JG
TL
4
64

= =
( )( )( )
( )
rad 4533 . 0
10 5 . 11
8
7
30 10 500 64
min
6
4
=

\
|
=

( )( )( )
( )
rad 9066 . 0
10 5 . 11
8
7
30 10 1000 64
max
6
4
=

\
|
=

( )( )
in lb
e
F
scale 3 . 110
10 9066 . 0
1000
= = =

(c)
ns
as f
ys
ms
s
s K
s
s
N
+ =
1

( )( )
u u ns
s s s 344 . 0
000 , 200
10
5 . 0 6 . 0
085 . 0
6
=
|
|

\
|
=
y ys
s s 6 . 0 =
( )( )
u y
s s 344 . 0
19 33 . 1
6 . 0
57
2 . 1
1
+ =
Use AISI 8760, OQT 800
o
F
ksi s
y
200 =
ksi s
u
220 =
24 . 1 = N

HELICAL SPRINGS NON CIRCULAR SECTION

301. A spring is to be designed of square oil-tempered steel wire and subjected to a
repeated maximum load of 325 lb.; mean coil diameter, 1 in.; deflection,
13/32 in. Determine (a) the wire size for average service, (b) the required
number of active coils, (c) the solid height, free length, and pitch (the ends are
squared and ground, the solid stress must be satisfactory, and the pitch angle
not excessive). (d) What amount of energy is stored when the load is 325 lb.?
Express in in-lb. and Btu.

Solution:

For oil-tempered wire,
19 . 0
146
w
u
D
s = , [ ] 5 . 0 032 . 0 < <
w
D
Max. solid
u s
s s 6 . 0 =

SECTION 4 - SPRINGS
Page 52 of 70
(a) average service,
w
D b = , b t =
( )
3 2 2
4 . 2
2
8 . 1 3
b
FD
K
t b
t b FD K
s
m
q
m q
s
=
+
=
u sd
s s 324 . 0 = , average service
( )
19 . 0 3
146 324 . 0
2
4 . 2
b b
FD
K
m
q
=
kip F 325 . 0 =
in D
m
2
1
1 =
25 . 1 =
q
K (assumed)
( )( ) ( )
19 . 0 3
146 324 . 0 5 . 1 325 . 0 4 . 2
25 . 1
b b
=
(

in b 2902 . 0 =
Table AT 15, use in b 313 . 0 = , # 1 wire size
8 . 4
313 . 0
5 . 1
= = =
b
D
C
m

Figure AF 15, 275 . 1 =
q
K

(b)
( )
4
3
3
3
44 . 0
45 . 2
56 . 0
45 . 2
Gb
N FD
t b Gt
N FD
c m c m
=

=
( )( )
( )( )
4
3
313 . 0 500 , 11 44 . 0
5 . 1 325 . 0 45 . 2
32
13
c
N
=
34 . 7 =
c
N

(c) Solid height = ( ) ( ) in N b
c
92 . 2 2 34 . 7 313 . 0 2 = + = +

Free length = b PN
c
2 +
lb F 325 . 0 =
( )( )
( )
ksi
b
FD
K s
m
q s
65 . 48
313 . 0
5 . 1 325 . 0 4 . 2
275 . 1
4 . 2
3 3
=
(

=
(

=
solid stress =
( )
( )
ksi 2 . 109
313 . 0
146 6 . 0
19 . 0
= =
solid deflection = in 91 . 0
32
13
65 . 48
2 . 109
= |

\
|
=
( ) 91 . 0 =
c
N b P
( )( ) 91 . 0 34 . 7 313 . 0 = P
in P 437 . 0 =
SECTION 4 - SPRINGS
Page 53 of 70
use in P
16
7
=
Free length = ( ) ( ) in in b PN
c
32
27
3 837 . 3 313 . 0 2 34 . 7
16
7
2 = + |

\
|
= +

( ) 5 . 1
16
7
tan

\
|
= =
m
D
P

o o
10 3 . 5 < =

(d) ( ) lb in kip in F k U
s
= = |

\
|
= = = 66 066 . 0
32
13
325 . 0
2
1
2
1
2
1
2

Btu U
s
085 . 0
778
66
= =

302. A coil spring, of hard-drawn carbon steel, is to deflect 1 in. under a load of
100 lb. The outside coil diameter is to be 1 in. Compute the number of active
coils, (a) if the wire is round, 5/32 in. in diameter, (b) if the wire is square,
5/32 in. on the side, (c) if the wire is rectangular 1/8 x 3/16 in., long
dimension parallel to the axis, (d) If the wire is rectangular 3/16 x 1/8 in.,
short dimension parallel to the axis. (e) What is the maximum stress in each of
the above springs under the 100-lb load? (f) What is the ratio of the
approximate volumes, square- or rectangular-wire to round wire spring?

Solution:

in D D
w m
1 = +
(a) in D
w
32
5
=
in D
m
32
27
32
5
1 = =
4 . 5
32
5
32
27
=
|

\
|
|

\
|
= =
w
m
D
D
C
w
c
GD
N FC
3
8
=
( )( )
( )
|

\
|

=
32
5
10 5 . 11
4 . 5 100 8
1
6
3
c
N

3 . 14 =
c
N
SECTION 4 - SPRINGS
Page 54 of 70
(b) Square, in b
32
5
=
in D
m
32
27
32
5
1 = =
4
3
44 . 0
45 . 2
Gb
N FD
c
m
=
( )
( )
4
6
3
32
5
10 5 . 11 44 . 0
32
27
100 45 . 2
1
|

\
|

\
|
=
c
N

5 . 20 =
c
N

(c) in b
16
3
= , in t
8
1
=
in t D
m
8
7
8
1
1 1 = = =
( ) t b Gt
N FD
c
m
56 . 0
45 . 2
3
3

=
( )
( )
(

\
|

\
|

\
|
=
8
1
56 . 0
16
3
8
1
10 5 . 11
8
7
100 45 . 2
1
3
6
3
c
N

1 . 16 =
c
N

(d) in b
8
1
= , in t
16
3
=
in t D
m
16
13
16
3
1 1 = = =
( ) t b Gt
N FD
c
m
56 . 0
45 . 2
3
3

=
( )
( )
(

\
|

\
|

\
|
=
16
3
56 . 0
8
1
16
3
10 5 . 11
16
13
100 45 . 2
1
3
6
3
c
N

5 . 11 =
c
N

(e) Maximum Stress

SECTION 4 - SPRINGS
Page 55 of 70
For (a)
3
8
w
s
D
FC
K s

=
( )
( )
284 . 1
4 . 5
615 . 0
4 4 . 5 4
1 4 . 5 4
= +

= K
( )( )
psi s
s
320 , 72
32
5
4 . 5 100 8
284 . 1
3
=
(
(
(
(

\
|
=

For (b)
( )
3 2 2
4 . 2
2
8 . 1 3
b
FD
K
t b
t b FD
K s
m
q
m
q s
=
+
=
4 . 5
32
5
32
27
=
|

\
|
|

\
|
= =
b
D
C
m

25 . 1 =
q
K
( )
psi s
s
355 , 66
32
5
32
27
100 4 . 2
25 . 1
3
=
(
(
(
(

\
|
|

\
|
=
For (c)
( )
2 2
2
8 . 1 3
t b
t b FD
K s
m
q s
+
=
7
8
1
8
7
=
|

\
|
|

\
|
= =
t
D
C
m

1 . 1 =
q
K
( )
psi s
s
992 , 68
8
1
8 . 1
16
3
3
8
1
16
3
2
8
7
100
1 . 1
2 2
=
(

\
|
+ |

\
|
(
(
(
(

\
|
|

\
|
|

\
|
=
For (d)
( )
2 2
2
8 . 1 3
t b
t b FD
K s
m
q s
+
=
33 . 4
16
3
16
13
=
|

\
|
|

\
|
= =
t
D
C
m

SECTION 4 - SPRINGS
Page 56 of 70
2 . 1 =
q
K
( )
psi s
s
232 , 63
16
3
8 . 1
8
1
3
16
3
8
1
2
16
13
100
2 . 1
2 2
=
(

\
|
+ |

\
|
(
(
(
(

\
|
|

\
|
|

\
|
=

(e) Ratio of the approximate volumes

For (a) Round wire
( )
c m w a
N D D V

\
|
=
2
4

( )
3
2
727 . 0 3 . 14
32
27
32
5
4
in V
a
=
(

\
|
(
(

\
|
=

For (b) Square wire
( )
c m b
N D b V
2
=
( )
3
2
327 . 1 5 . 20
32
27
32
5
in V
b
=
(

\
|
|

\
|
=
For (c) rectangular wire
( )
c m c
N D bt V =
( )
3
037 . 1 1 . 16
8
7
8
1
16
3
in V
c
=
(

\
|
|

\
|
|

\
|
=
For (d) rectangular wire
( )
c m d
N D bt V =
( )
3
688 . 0 5 . 11
16
13
16
3
8
1
in V
d
=
(

\
|
|

\
|
|

\
|
=

Ratio of volume
Square to round wire
825 . 1
727 . 0
327 . 1
= = =
a
b
V
V

Rectangular to round wire (long dimension parallel to the axis)
426 . 1
727 . 0
037 . 1
= = =
a
c
V
V

Rectangular to round wire (short dimension parallel to the axis)
946 . 0
727 . 0
688 . 0
= = =
a
d
V
V




SECTION 4 - SPRINGS
Page 57 of 70
TENSION SPRINGS

305. Design two tension springs for a spring balance with a capacity of 200 lb.
Each spring supports a maximum load of 100 lb. The outside diameter must
not exceed 1 in. and the total length including end loops must not exceed 9
in. Select a material and determine the dimension, including wire diameter,
number of coils, and free length.

Solution:
Table AT 17, assume oil tempered wire
ksi
D
s
w
u
19 . 0
146
=
ksi
D
s
w
ys 19 . 0
5 . 87
=
( )
ksi
D D
s
w w
sd 19 . 0 19 . 0
70 5 . 87 8 . 0
= = , [ ] 5 . 0 032 . 0 < <
w
D
k F F
i
+ =
3
8
w
m c
s
D
FD K
s

=
w
m
w
m
D
D
D
r
C = =
2

w
c a
D G
N C F
3
8
=
N C
D G
k
w
3
8
=
a
w
c a w
F
GD
N C F
N C
D G
k =
|
|

\
|
|

\
|
=
3
3
8
8

kip lb F
a
10 . 0 100 = =
Figure AF 15, assume 2 . 1 =
c
K
3 3
8 8
w
m a c
w
m i c
s
D
D F K
D
D F K
s

+ =
2
8
w
a c
i c s
D
C F K
s K s

+ =
in D D OD
w m
25 . 1 = + =
1
25 . 1
+
=
C
D
w

6.21, assume ksi s
i
18 =
s sd
s s =
SECTION 4 - SPRINGS
Page 58 of 70
( )( )
( )( )
2 19 . 0
1 . 0 2 . 1 8
18 2 . 1
70
w w
D
C
D
+ =
( )
( )
( )( ) ( )
( )
2
2
19 . 0
19 . 0
25 . 1
1 1 . 0 2 . 1 8
6 . 21
25 . 1
1 70

+
+ =
+ C C C

( ) ( )
2 19 . 0
1 1956 . 0 6 . 21 1 1 . 67 + + = + C C C
( ) ( ) 6 . 21 1 1956 . 0 1 1 . 67
2 19 . 0
= + + C C C
7 . 6 = C
in
C
D
w
1623 . 0
1 7 . 6
25 . 1
1
25 . 1
=
+
=
+
=
Table AT 15, use in D
w
1620 . 0 = , 8 W & M
( )( ) in CD D
w m
085 . 1 1620 . 0 7 . 6 = = =
say in D
m
0 . 1 =
17 . 6
1620 . 0
0 . 1
= = =
w
m
D
D
C
ksi s
i
7 . 17 =
To check, Fig. AF 15, 15 . 1 =
c
K
( )
( )( )( )
( )
ksi s
s
20 . 89
1620 . 0
17 . 6 10 . 0 15 . 1 8
7 . 17 15 . 1
2
= + =

( )
ksi ksi s
sd
20 . 89 92 . 98
1620 . 0
70
19 . 0
> = = , o.k.

Total length = ( )
w m c w
D D N D + + 2
( ) ( ) 162 . 0 0 . 1 2 162 . 0 5 . 9 + + =
c
N
coils N
c
3 . 44 =

Free length = ( )( ) in N D
c w
18 . 7 3 . 44 1620 . 0 = =

Summary of answer:
Material, oil-tempered wire
in D
w
1620 . 0 = , 8 W & M
coils N
c
3 . 44 =
Free length = 7.18 in.

306. Two helical tension springs are to be used in scales for weighing milk. The
capacity of the scales is 30 lb., each spring carries 15 lb. with a deflection of 3
9/16 in. The springs are made of No. 14, W & M steel wire, outside diameter,
29/32 in. (a) how many coils should each spring have? (b) What is the
maximum stress in the wire? What material should be used?


SECTION 4 - SPRINGS
Page 59 of 70
Solution:

lb k 15 =
in
16
9
3 =
(a) Table AT 15, No. 14 W &M

in D
w
0800 . 0 =
in D OD D
w m
82625 . 0 0800 . 0
32
29
= = =
328 . 10
0800 . 0
82625 . 0
= = =
w
m
D
D
C
( )
w
c
GD
N C k
3
8
=
( )( )
( )( ) 080 . 0 10 5 . 11
328 . 10 15 8
16
9
3
6
3

=
c
N

8 . 24 =
c
N

(b) k F F
i
+ =
m
w i
i
D
D s
F
8
3

=
6.21, 328 . 10 = C
psi s
i
272 , 11 =
( )( )
( )
lb F
i
743 . 2
82625 . 0 8
08 . 0 272 , 11
3
= =


lb F 743 . 17 15 743 . 2 = + =
Figure AF 15, 09 . 1 =
c
K
( )( )( )
( )
psi
D
FD K
s
w
m c
s
476 , 79
080 . 0
82625 . 0 743 . 17 09 . 1 8 8
3 3
= = =


ksi psi
s
s
s
ys
345 . 99 345 , 99
8 . 0
476 , 79
8 . 0
= = =
Table AT 17, use Hard drawn wire
( )
ksi ksi
D
s
w
ys
345 . 99 113
080 . 0
70 70
19 . 0 19 . 0
> = = =

307. A tension spring for a gas-control lever is made of in D
w
078 . 0 = steel wire;
inside diameter, 0.609 in.; number of coils, 55; free length including end
loops, 5 9/16 in. When the spring is extended to a length of 6 5/16 in., it must
exert a force 5 lb.; it must extend to (a) the initial tension, (b) the stress in
the spring caused by the initial tension (compare with the recommended
SECTION 4 - SPRINGS
Page 60 of 70
maximum values), (c) the stress caused by the 5 -lb load, (d) the maximum
stress. What material should be used? (e) What energy is absorbed from the
point where the load is the initial tension until the springs length is 6 5/16 in.?
(Data courtesy Worthington Corporation.)

Solution:
in D
w
078 . 0 =
in D D
w m
609 . 0 =
in D
m
687 . 0 078 . 0 609 . 0 = + =
8 . 8
078 . 0
687 . 0
= = =
w
m
D
D
C
55 =
c
N
w
c
GD
N FC
3
8
=
lb F
2
1
5 =
in 75 . 0
16
9
5
16
5
6 = =
( )( ) ( )
( )( ) 078 . 0 10 5 . 11
5 8 . 8 8
75 . 0
6
3

= =

k

lb k 244 . 2 =

(a) lb k F F
i
256 . 3 244 . 2 5 . 5 = = =
(b)
( )( )
( )
psi
D
C F
s
w
i
i
000 , 12
078 . 0
8 . 8 256 . 3 8 8
2 2
= = =


6.21, 8 . 8 = C
psi psi s
i
000 , 12 300 , 13 > = , ok

(c) lb F 5 . 5 =
2
8
w
c
s
D
FC K
s

=
8 . 8 = C
Figure AF 15
1 . 1 =
c
K
( )( )( )
( )
psi s
s
284 , 22
078 . 0
8 . 8 5 . 5 1 . 1 8
2
= =

(d) maximum stress
in lb
k
k 992 . 2
75 . 0
244 . 2
= = =

SECTION 4 - SPRINGS
Page 61 of 70
= k F
in 75 . 3
16
9
5
16
5
9 = =
( )( ) lb k F F
i
476 . 14 75 . 3 992 . 2 256 . 3 = + = + =
( )( )( )
( )
psi
D
FC K
s
w
c
s
651 , 58
078 . 0
8 . 8 476 . 14 1 . 1 8 8
2 2
= = =


Table AT 16
ksi psi
s
s
s
ys
3 . 73 300 , 73
8 . 0
651 , 58
8 . 0
= = =
Table AT 17, use Hard drawn wire
( )
ksi ksi
D
s
w
ys
3 . 73 658 . 113
078 . 0
70 70
19 . 0 19 . 0
> = = =

(e) ( )( ) lb in k U
s
= = = 8415 . 0 75 . 0 992 . 2
2
1
2
1
2 2


TORSION SPRINGS

308. A carbon-steel (ASTM A230) torsion spring is to resist a force of 55 lb. at a
radius of 2 in.; the mean diameter is to be 2 in. Compute (a) the diameter of
the wire for average service, (b) the number of coils for a deflection of 180
o

under the given torque, (c) the energy the spring has absorbed when the force
is 55 lb.

Solution:
Fa M T = =
lb F 55 =
in a 2 =
( )( ) lb in M T = = = 110 2 55
in D
m
5 . 2 =
Table AT 17, ksi
D
s
w
u 1 . 0
182
= , [ ] 25 . 0 093 . 0 < <
w
D
Average service
( )( ) psi
D
ksi
D D
s s
w w w
u d 1 . 0 1 . 0 1 . 0
936 , 117 936 . 117 182
648 . 0 405 . 0 6 . 1 = =
|
|

\
|
= =

(a)
I
KMc
s
s
=
For round wire, assume 08 . 1 = =
ci c
K K , Table AT 18
2
w
D
c =
SECTION 4 - SPRINGS
Page 62 of 70
32
3
w
D
c
I
=
( )( )( )
1 . 0 3
936 , 117 32 110 08 . 1
w w
s
D D
s = =

in in D
w
25 . 0 2060 . 0 < =
Table AT 15, use in D
w
2070 . 0 = , No. 5 W & M
To check: 9 66 . 9
2070 . 0
2
> = = =
w
m
D
D
c
r
, ok
Table AT 18, 08 . 1 = K
( )( )( )
( )
psi s
s
430 , 136
2070 . 0
32 110 08 . 1
3
= =

( )
psi psi s
sd
430 , 136 054 , 138
2070 . 0
936 , 117
1 . 0
> = =
Therefore, use No. 5 W & M, in D
w
2070 . 0 =

(b)
EI
N D M
c m

=
psi E
6
10 30 =
64
4
w
D
I

=
= =
o
180
4
64
w
c m
ED
N MD
=
( )( )
( )( )
4 6
2070 . 0 10 30
2 110 64

=
c
N

29 . 12 =
c
N

(c) ( )( ) lb in T U
s
= = = 8 . 172 110
2
1
2
1


312. A pivoted roller follower is held in contact with the cam by a torsion spring.
The moment exerted by the spring varies from 20 lb-in to 50 lb-in. as the
follower oscillates through 30
o
. The spring is made of AISI 6152 steel, OQT
1000
o
F. What should be the value of
w
D ,
m
D , and
c
N if the factor of safety
is 1.75 based on the Soderberg line? Would this be a conservative or risky
approach?

Solution:
AISI 6152, OQT 1000
o
F
ksi s
u
184 =
SECTION 4 - SPRINGS
Page 63 of 70
ksi s
y
173 =
ksi s s
u n
92 5 . 0 = =
( ) in lb M
m
= + = 35 20 50
2
1

( ) in lb M
a
= = 15 20 50
2
1

assume 08 . 1 = K
( )( )
psi
D D D
KM
s
w w w
m
m 3 3 3
385 35 08 . 1 32 32
= = =


( )( )
psi
D D D
KM
s
w w w
a
a 3 3 3
165 15 08 . 1 32 32
= = =


n
a
y
m
s
s
s
s
N
+ =
1

3 3
000 , 92
165
000 , 173
385
75 . 1
1
w w
D D
+ =
in D
w
1916 . 0 =
Table AT 15, use in D
w
1920 . 0 = , No. 6 W & M
To solve for K
( )
( )
psi K
K
s
m
369 , 50
1920 . 0
35 32
3
= =

( )
( )
psi K
K
s
a
587 , 21
1920 . 0
15 32
3
= =

000 , 92
587 , 20
000 , 173
369 , 50
75 . 1
1 K K
+ =
0868 . 1 = K
Table AT 18 0868 . 1 = = K K
ci

9 32 . 9 > = =
w
m
D
D
c
r
, ok
( ) in D
m
7894 . 1 1920 . 0 32 . 9 = =
use in in D
m
875 . 1
8
7
1 = =
4
64
w
c m c m
ED
N MD
EI
N D M
=

=


( )( )
( )( )
4 6
1920 . 0 10 30
875 . 1 20 50 64
180
30

=
c
N

93 . 5 =
c
N
Summary of answer:
in D
w
1920 . 0 = , No. 6 W & M
SECTION 4 - SPRINGS
Page 64 of 70
in D
m
8
7
1 =
93 . 5 =
c
N , 4 . 1 > N , therefore conservative.

FLAT AND LEAF SPRINGS

315. A cantilever flat spring of uniform strength, Fig. 6.20, Text, is to absorb an
energy impact of 500 ft-lb. Let the thickness of the steel, AISI 1095, OQT 900
o
F, be in. and let the maximum stress be half of the yield strength. (a) Find
the width b of the spring at the widest point in terms of the length L .
Determine values of b for lengths of 36 in., 48 in., 60 in., and 72 in. (b)
Determine the deflection of the spring for each set of values found in (a).

Solution.
Fig. 6/20

2
6
bh
FL
s
B
=
3
3
6
Ebh
FL
=
AISI 1095, OQT 900
o
F, ksi s
y
104 = , Table AT 9
( ) psi ksi s s
y B
000 , 52 52 104 5 . 0 5 . 0 = = = =
F U
s
2
1
=
L
bh s
F
B
6
2
=
Eh
L s
Ebh
L
L
bh s
B B
2
3
3 2
6
6 =
|
|

\
|
=
|
|

\
|
=
|
|

\
|
|
|

\
|
=
E
bhL s
Eh
L s
L
bh s
U
B B B
s
2 2 2
12
1
6 2
1

lb in lb ft U
s
= = 6000 500
SECTION 4 - SPRINGS
Page 65 of 70
( )
6
2
10 30
2
1
000 , 52
12
1
6000

\
|
=
L b

2
1598 in bL =
L
in
b
2
1598
=

in L 36 = , in
in
in
b 4 . 44
36
1598
2
= =
in L 48 = , in
in
in
b 3 . 33
48
1598
2
= =
in L 60 = , in
in
in
b 6 . 26
60
1598
2
= =
in L 72 = , in
in
in
b 2 . 22
72
1598
2
= =

(b)
Eh
L s
B
2
=
in L 36 = ,
( )( )
( )
in 4928 . 4
2
1
10 30
36 000 , 52
6
2
=
|

\
|

=
in L 48 = ,
( )( )
( )
in 9872 . 7
2
1
10 30
48 000 , 52
6
2
=
|

\
|

=
in L 60 = ,
( )( )
( )
in 48 . 12
2
1
10 30
60 000 , 52
6
2
=
|

\
|

=
in L 72 = ,
( )( )
( )
in 9712 . 17
2
1
10 30
72 000 , 52
6
2
=
|

\
|

=

317. One of the carbon contacts on a circuit breaker is mounted on the free end of
a phosphor-bronze beam ( 35 . 0 = ). This beam has the shape of the beam
shown in Fig. 6.24, Text, with . 1in b = , .
16
9
in b = , .
2
1
4 in L = , and .
16
1
in h =
When the contacts are closed, the beam deflects in. Compute (a) the force
on the contacts, (b) the maximum stress.

Solution:
SECTION 4 - SPRINGS
Page 66 of 70
Figure 6.24
2 2
3 6
bh
WL
bh
FL
s = =
( ) ( )
EI
WL K
EI
FL K
6
1
3
1
2 3
1
2 3
1

=
5625 . 0
1
16
9
=
|

\
|
=

b
b

Figure 6.25, 14 . 1
1
= K

(a) Force on contacts = F
( )
EI
FL K
3
1
2 3
1

=
psi E
6
10 16 = (phosphor bronze)
as a beam,
12
3
bh
I =
( )
3
2 3
1
1 4
Ebh
FL K

=
( ) ( ) ( ) [ ]
( )( )
3
6
2 3
16
1
1 10 16
35 . 0 1 5 . 4 14 . 1 4
4
3
|

\
|

=
F

lb F 8 =

(b)
( )( )
( )
psi
bh
FL
s 296 , 55
16
1
1
5 . 4 8 6 6
2 2
=
|

\
|
= =

318. A cantilever leaf spring 26 in. long is to support a load of 175 lb. The
construction is similar to that shown in Fig. 6.22 (a), Text. The leaves are to
be 2 in. wide, 3/16 in. thick; SAE 9255 steel, OQT 1000
o
F; 107 cycles (
6.26). (a) How many leaves should be used if the surfaces are left as rolled?
(b) The same as (a) except that the leaves are machined and the surfaces are
not decarburized. (c) The same as (b), except that the surface is peened all
over. (d) Which of these springs absorbs the most energy? Compute for each:
(e) What are the load and deflection of the spring in (b) when the maximum
stress is the standard-test yields strength?

Solution:
Figure 6.22 (a)
2
6
bh
FL
s
A
=
SECTION 4 - SPRINGS
Page 67 of 70
3
3
6
Ebh
FL
A
=
b N b =
1

lb F 175 =
in b 2 =
in h
16
3
=
in L 26 =
6.26, SAE 9255, OQT 1000
o
F
ksi s
u
180 =
ksi s
y
160 =
in in t 1875 . 0
16
3
= =
ksi s
d
75 . 83 =

(a) As rolled, Figure AF 5

Surface factor = 0.275
( ) psi ksi s
d
000 , 23 23 75 . 83 275 . 0 = = =
2
6
bh
FL
s
A
=
( )( )
( )
2
1
16
3
2
26 175 6
000 , 23
|

\
|
=
N

88 . 16
1
= N
say 17
1
= N

(b) Machined, Figure AF 5
Surface factor = 0.75
( ) psi ksi s
d
800 , 62 8 . 62 75 . 83 75 . 0 = = =
2
6
bh
FL
s
A
=
( )( )
( )
2
1
16
3
2
26 175 6
800 , 62
|

\
|
=
N

2 . 6
1
= N
say 7
1
= N

(c) Peened surface, (b)

SECTION 4 - SPRINGS
Page 68 of 70

( ) psi ksi s
d
500 , 78 5 . 78 8 . 62 25 . 1 = = =
2
6
bh
FL
s
A
=
( )( )
( )
2
1
16
3
2
26 175 6
500 , 78
|

\
|
=
N

95 . 4
1
= N
say 5
1
= N

(d) F U
s
2
1
=
lb F 175 =
3
1
3
6
h b EN
FL

=
For (a) 17
1
= N
( )( )
( )( )( )
in 745 . 2
16
3
2 17 10 30
26 175 6
3
6
3
=
|

\
|

=
( )( ) lb in U
s
= = 240 745 . 2 175
2
1

For (b) 7
1
= N
( )( )
( )( )( )
in 666 . 6
16
3
2 7 10 30
26 175 6
3
6
3
=
|

\
|

=
( )( ) lb in U
s
= = 583 666 . 6 175
2
1

For (c) 5
1
= N
( )( )
( )( )( )
in 332 . 9
16
3
2 5 10 30
26 175 6
3
6
3
=
|

\
|

=
( )( ) lb in U
s
= = 817 332 . 9 175
2
1


answer spring (c)

(e) ksi s s
y d
160 = = , 7
1
= N (b)

SECTION 4 - SPRINGS
Page 69 of 70
2
1
2
6 6
h b N
FL
bh
FL
s
d

= =
( )
( )( )
2
16
3
2 7
26 6
000 , 160
|

\
|
=
F

load lb F 505 =
( )( )
( )( )( )
in 24 . 19
16
3
2 7 10 30
26 505 6
3
6
3
=
|

\
|

=

319. The rear spring of an automobile has 9 leaves, each with an average thickness
of 0.242 in. and a width of 2 in.; material is SAE 9261, OQT 1000
o
F. The
length of the spring is 56 in. and the total weight on the spring is 1300 lb.
Assume the spring to have the form shown in Fig. 6.22 (b), Text. Determine
(a) the rate of the spring, (b) the maximum stress caused by the dead weight.
(c) What approximate repeated maximum force (0 to
max
F ) would cause
impending fatigue in 10
5
cycles, the number of applications of the maximum
load expected during the ordinary life of a car? (If the leaves are cold rolled
to induce a residual compressive stress on the surfaces, the endurance limit as
2
u
s should be conservative.)

Solution:
Figure 6.22 (b)
2
2
3
bh
FL
s
A
=
3
3
8
3
Ebh
FL
A
=
lb F 1300 =
in h 242 . 0 =
9
1
= N
in b 2 =
in L 56 =

(a) Rate ,
3
3
3
8
L
Ebh F
k
A
= =

( )( )( )( )
( )
in lb
L
h b EN
k 21 . 116
56 3
242 . 0 2 9 10 30 8
3
8
3
3 6
3
3
1
=

=

(b)
( )( )
( )( )( )
psi
h b N
FL
s
A
590 , 103
242 . 0 2 9 2
56 1300 3
2
3
2 2
1
= =

=
SECTION 4 - SPRINGS
Page 70 of 70
(c) SAE 9261. OQT 1000
o
F
ksi s
u
192 =
ksi s
n
96
2
192
= =
2
1
2
3
h b N
FL
s
A

=
( )
( )( )( )
2
242 . 0 2 9 2
56 3
000 , 96
F
=
lb F 1200 =

321. The front spring of an automobile is made similar to Fig. 6.23, Text. The
average thickness for each of the 6 leaves, 0.213 in.; material is SAE 9255,
OQT 1000
o
F. The load caused by the weight of the car is 775 lb. (a) What
stress is caused by a force of twice the dead weight? (b) What load would
stress the spring to the yield strength?

Solution:
Figure 6.23
2
1
2 2
3 3 6
h b N
WL
bh
WL
bh
FL
s

= = =
lb W 775 = , 6
1
= N , in b 2 = , in h 213 . 0 =
in
in
L 18
2
36
= =
(a) ( ) lb W 1550 775 2 = =
( )( )
( )( )( )
psi s 740 , 153
213 . 0 2 6
18 1550 3
2
= =

(b) SAE 9255, OQT 1000
o
F
ksi s
y
160 =
2
1
2 2
3 3 6
h b N
WL
bh
WL
bh
FL
s

= = =
( )
( )( )( )
2
213 . 0 2 6
18 3
000 , 160
W
=
lb W 1613 =

- end -