Mechanical Springs

BITS Pilani
Pilani Campus
VINAYAK KALLURI
BITS Pilani
Pilani Campus
BITS Pilani, Pilani Campus
Springs
A mechanical spring is an elastic member (generally
metal) whose primary function is to deflect under
load and then to recover its original shape and
position when the load is released.
Used for efficient storage and release of energy
Strength and flexibility are two essential
requirements of spring design.
1. Helical springs (Tension / Compression)
2. Torsion spring
3. Leaf springs
4. Spiral spring
5. Belleville Springs
Spring Types
Helical springs
Torsion spring
Spiral spring
Leaf spring
Belleville Spring
Stresses in Helical Springs
( )
2 3 2 3
max
4 8 4 2 / 16
2 /
d
F
d
FD
d
F
d
FD
A
F
J
Tr
FD T

+ = + = + =
=
inside
inside
Spring Index and shear stress correction factor
d
D
C = If we define the spring index to be as :
Then the expression for maximum shear stress can be expressed as:
(
+ =
(
+ = + =
C d
FD
D
d
d
FD
d
F
d
FD
2
1
1
8
2
1
8 4 8
3 3 2 3
max

Where K
s
is called as the shear stress correction factor and serves to
correct the shear stress estimated from the torsion alone for the direct
shear. Here K
s
is
C
C
K
s
2
1 2 +
=
For the standard springs, C ranges between 6 and 12.
3
max
8
d
FD
K
s
=
Curvature effect in fatigue loading
Only in fatigue loading, the curvature of the wire
introduces more shear stress than estimated above
Hence that expression for maximum shear stress needs
correction.
Many factors have been suggested for correction.
Prominent are Wahl factor (K
w
) and Bergstrasser factor
(K
B
).
These must replace K
s
when incorporated.
Curvature effect in fatigue loading:
Wahl factor and Bergstrasser factor
3 4
2 4 615 . 0
4 4
1 4
+
= +
=
C
C
K or
C C
C
K
B w
Static Loading, only effect of direct shear:
C
C
K
s
2
1 2 +
=
Fatigue Loading, effect of both direct shear and curvature:
Wahl factor (K
w
) or Bergstrasser factor (K
B
) is used
Fatigue Loading, effect of only curvature:
( )
( )( ) 1 2 3 4
2 4 2
+
+
= =
C C
C C
K
K
K
s
B
c
Deflection and Stiffness:
AG
l F
GJ
l T
U
2 2
2 2
+ =
The total strain energy for a helical spring is composed
of a torsional component and a shear component.
The strain energy
4
;
32
;
;
2
,
2
4
d
A
and
d
J
DN l
FD
T
where
a
=
=
=
=
2
2
4
3 2
2 4
Gd
DN F
Gd
N D F
U + =
Deflection and Stiffness:
a
a a a
a a
N D
Gd
y
F
k
Gd
N FC
Gd
N FD
C Gd
N FD
y
Gd
FDN
Gd
N FD
F
U
y
3
4
3
4
3
2 4
3
2 4
3
8
8 8
2
1
1
8
D/d, C index spring g Introducin
4 8
: theorem second s o' Castiglian
= =
=
|
\
|
+ =
=
+ =
=
Compression Springs
Manufacturing processing at the ends and effect on total coils
Compression Springs
Formulas for the Dimensional Characteristics of Compression-Springs
Table 101
If interested:
For a thorough discussion and development of these relations, refer
Cyril Samonov, Computer-Aided Design of Helical Compression Springs, ASME
paper No. 80-DET-69, 1980.
SPRING MATERIALS
Music wire, Oil-tempered wire, Hard drawn wire,
Chrome-vanadium wire and Chrome-silicon wire
Use Table 10-4 for A and m.
Table 104
m
ut
d
A
S = strength, tensile Minimum
SPRING MATERIALS
Table 105
Mechanical Properties of Some Spring Wires
Set removal or presetting
Is a process used in the manufacture of compression springs
to induce useful residual stresses
The spring is made to a longer free length than required and
then is compressed beyond the elastic limit by 30% of the
length
When the spring tries spring back, the plastic strain induced
opposes the same resulting in residual stress being set up that
are opposite in direction to the working stresses
Hence the springs behave stronger in service
Set removal must NOT be used for springs used in fatigue
loading
SPRING MATERIALS
Table 106
Maximum Allowable Torsional Stresses for Helical Compression Springs in Static
Applications
Check for stability:
A compression spring is stable if it does not buckle under the
load
(
(
|
|
\
|
=
2 / 1
2
'
2
'
1 0
1 1
eff
cr
C
C L y
D
L
eff
0
=
( ) G E
E
C
=
2
'
1
( )
E G
G E
C
+
=
2
2
2
'
2

( )
2 / 1
0
2
'
2
2
2
1
(
< >
E G
G E D
L
C
eff

For absolute stability and buckling not to occur,

Slenderness ratio
Elastic constants
End -condition constants () for helical compression springs
Table 102, page 522
A helical compression spring subjected to a force of 500
N, which causes the deflection of 20 mm. The spring
index is 6. The spring is made of music wire A228 (S
ut
=
2000 MPa, G = 81GPa, & E= 196 GPa) and has square
and ground ends. Calculate (i)wire diameter (d should be
round-up to next standard diameter), (ii) mean coil
diameter (D), (iii) active number of coils (N
a,
should be
round-up to the next integer), (iv) total number of coils
(N
t
) (v) Solid length and (vi) pitch of the coils (p). (v)
check for stability of the spring.
Problem:
) .......( .......... 56 . 6 ,
56 . 6
5 . 3 81000
21 500 8
20
8
) ...( .......... .......... 21
) ...( .......... .......... 5 . 3 032 . 3
6 500 8
083 . 1 900
8
083 . 1
12
13
2
1 2
900 2000 45 . 0 45 . 0
4
3
4
3
2 3
max
iii N coils of number Active
N
N
Gd
N FD
y
ii mm Cd D
i mm mm d
d d
FD
K
C
C
K
MPa S S
a
a
a a
s
s
ut sy
=
=

=
= =
=

= =
= =
+
=
= = =


( )
( )
76 . 105 96 . 49
196 81 2
81 196 2
5 . 0
21
96 . 49
2
2
) .......( .......... 55 . 6
56 . 6
7 96 . 49 2
,
96 . 49 ) ( ,
) .......( .......... 96 . 29 ,
) .......( .......... 56 . 8 2 56 . 6 ,
1 10
2 / 1
2 / 1
0
0
0
<
(
+

<
(
<
=
=
= + =
= =
= + =
E G
G E D
L
stability for Check
vi mm
N
d L
p Pitch
mm L y deflection L length Free
v mm dN L length Solid
iv N coils of number Total
table From
a
s
t s
t
A load of 2kN is dropped axially from a height of 250 mm
on a plain and ground helical compression spring of wire
diameter 20 mm. The active number of coils in spring is 20
and spring index is10. Determine the stiffness, the pitch
and the shear stress induced in the spring. Assume G =
84x103 MPa for spring material.
Problem:
A safety valve operated by a helical tension
spring through the lever mechanism is
schematically shown in Figure. The
diameter of the valve is 25mm. In normal
operating conditions, the maximum pressure
inside the chamber is 2MPa and the
corresponding lift of the valve is 24 mm.
The spring is made of cold drawn steel of
ultimate strength 1.5GPa and modulus of
rigidity of 81GPa. The spring index is 8.
Find the standard spring wire diameter,
stiffness and the active number of coils in
the spring.
Problem:
A safety valve operated by a helical tension spring
through the lever mechanism is schematically
shown in figure 4. The diameter of the valve is 50
mm. In normal operating conditions, the valve is
closed and the pressure inside the chamber is 0.5
MPa. The valve opens when the pressure inside the
chamber increases to 0.6 MPa. The maximum lift
of the valve is 5 mm. The spring is made of cold
drawn steel of ultimate strength 1200 MPa and
modulus of rigidity of 81370 N/mm2. Allowable
shear stress for the spring wire is 30% of the
ultimate tensile strength. The spring index is 8.
Find the spring wire diameter, stiffness and the
active number of turns in the spring.
Problem:
Springs are almost always subject to fatigue loading.
Automotive engine valves are supported by compression
springs that are subjected to millions of cycles of
operation without failure.
Shot peening is used to improve the fatigue strength of
dynamically loaded springs. Shot peening can increase
the torsional fatigue strength by 20 percent or more.
Springs are designed for infinite life based on
Zimmerlis data.
Design for Fatigue Load:
Zimmerlis Data: Shot Peening
A cold working process used to produce a compressive
residual stress layer and modify mechanical properties of
metals
Entails impacting a surface with shot (round metallic,
glass or ceramic particles of 1/64 inch diameter) with
force sufficient to create plastic deformation
Zimmerlis Data:
The best data on the torsional endurance limits of spring steels are
those reported by Zimmerli and discovered the surprising fact that
size, material, and tensile strength have no effect on the endurance
limits (infinite life only) of spring steels in sizes under 10 mm.
Unpeened springs were tested from a minimum torsional stress of
138 MPa to a maximum of 620 MPa and peened springs in the range
138 MPa to 930 MPa . The corresponding endurance strength
components for infinite life were found to be
ut sy ut ut su
sm sa
sm sa
S S S or S S
MPa S MPa S
Peened
MPa S MPa S
Unpeened
557 . 0 35 . 0 67 . 0
534 398
:
379 241
:
=
= =
= =
Design for Fatigue Loading Based on Zimmerlis Data
criterion. failure fatigue a apply then and
, , , , , , , ,
min max su sy e m a m a
S or S S F F find given F F
3 3
min max min max
8 8
2 2
d
D F
K and
d
D F
K
F F
F and
F F
F
m
W m
a
W a
m a
= =
+
=
=
Zimmerlis Data (Gerber criteria)
a
sa
f
S
n
= Safety, of Factor
m
a
m
a
ut
se
se
su
sa
su
sm
sa
se
su
sm
se
sa
F
F
r
rS
S
S
S r
S
line load given for cordinate tion Inter
S
S
-
S
S
S
S
S
S
= =
(
(
|
|
\
|
+ + =
|
|
\
|
= =
|
|
\
|
+
2
2 2
2
2
2
1 1
2
sec
1
1
limit endurance the find Then
Refer Table 6-7 ; page 307
S
sa
and S
sm
are
from Zimmerlis
data.
S
su
= 0.67S
ut
Zimmerlis Data (Goodman criteria)
a
sa
f
S
n
= Safety, of Factor
m
a
m
a
se su
su se
sa
su
sm
sa
se
su
sm
se
sa
F
F
r
S rS
S rS
S
S
S
-
S
S
S
S
S
S
= =
+
=
|
|
\
|
= =
|
|
\
|
+
sec
1
1
S
sa
and S
sm
are from
Zimmerlis data.
S
su
= 0.67S
ut
Zimmerlis Data (ASME- Elliptic criteria)
a
sa
f
S
n
= Safety, of Factor
m
a
m
a
sy se
sy se
sa
sy
sm
sa
se
sy
sm
se
sa
F
F
r
S r S
S S r
S
S
S
-
S
S
S
S
S
S
= =
(
(
+
=
|
|
\
|
= =
|
|
\
|
+
|
|
\
|
2 2 2
2 2 2
2
2
2
sec
1
1
S
sa
and S
sm
are from
Zimmerlis data.
ut sy ut
S S S 557 . 0 35 . 0
In an automotive plate clutch, six identical helical compression springs
(squared and ground end) arranged in between two parallel plates to provide
the axial thrust on the plate, which is varying from 600 N to 3000 N. The
minimum deflection of the springs corresponding to the maximum thrust
force is 20mm. The spring index is 6. The spring is made of cold drawn steel
(G= 81370 MPa) with ultimate strength of 1250 MPa and allowable shear
stress of 450 MPa. There should be a gap of 1 mm between adjacent turns
when the spring is subjected to maximum thrust force.
(i) Assuming the springs are subjected to static maximum thrust force, find
the standard spring wire diameter and free length.
(ii) By using the above spring wire diameter, determine the factor of safety
for fluctuating force based on Gerber criteria (unpeened) using Zimmerlis
data.
Problem
Tension/ Extension springs: end preparation
Combined axial tension and bending stress at A
Only torsion at B
Improved design
Side view
Tension /Extension springs:
Side view
Analysis of stresses in tension springs
( ) d
r
C
C C
C C
K
K
d d
D
K F
A
A
A A
1
1
1 1
1
2
1
2 3
2
,
1 4
1 4
by given curvature, for factor correction strss Bending
4 16
moment bending tension axial combined to due A at stress tensile maximum The
=

=
=
(
+ =

d
r
C
C
C
KB
K
d
FD
K
w
B
2
2
2
2
3
2
,
4 4
1 4
by given curvature, for factor correction strss Torsional
8
by given is B at stress shear torsional maximum The
=
=
=
=
B
Extension spring
Stress is to be computed at three locations
F
A
B
C
( ) d
r
C
C C
C C
K
d d
D
K F
A
A A
1
1
1 1
1
2
1
2 3
2
,
1 4
1 4
4 16
=

=
(
+ =

d
r
C
C
C
K
d
FD
K
B
B B
2
2
2
2
3
2
,
4 4
1 4
8
=
=
=
C
C
K
d
FD
K
s
s C
2
1 2
8
3
+
=
=

Initial tension in close-wound tension springs
When extension springs are made with coils in contact with one
another, they are said to be close-wound.
Spring manufacturers prefer some initial tension in close-wound
springs in order to hold the free length more accurately.
( ) ( ) ( )
E
G
N N coils of number Active
d N C d N d D L
ky F F
b a
b b o
i
+ =
+ = + + =
+ =
,
1 2 1 2 : length Free
No of body coils
INITIAL TENSION IN CLOSE-WOUND TENSION SPRINGS:
The initial tension in an extension spring is created in the
winding process by twisting the wire as it is wound onto
the mandrel.
( )
MPa
C
e
C
i
|
\
|

=
5 . 6
3
4 9 . 6
231
is, stress torsional d uncorrecte of range Preferred
105 . 0
When the spring is completed and

removed from the mandrel, the
initial tension is locked in because
the spring cannot get any shorter.
PROBLEM
A hard-drawn steel wire (G=79 GPa, E= 198GPa)
extension spring has a wire diameter of 0.9 mm, an
outside coil diameter of 6 mm, hook radii of r
1
=2.55
mm and r
2
= 2.1 mm, and an initial tension of 5 N and
subjected to a static load of 24 N. The number of body
turns is 12.17. From the given information:
(a) Determine the physical parameters of the spring
(b) Check the initial preload stress conditions
(c) Find the factors of safety under a static 24 N load.
Solution:
( )( )
( ) ( )
( ) ( ) ( ) ( )( )
mm y L L
mm
k
F F
y
mm d N d D L
mm N
N D
Gd
k
turns
E
G
N N
d D C
mm d OD D
o
i
b o
a
b a
14 . 25 89 . 4 25 . 20
89 . 4
885 . 3
5 24
25 . 20 9 . 0 1 17 . 12 9 . 0 1 . 5 2 1 2
/ 885 . 3
57 . 12 1 . 5 8
9 . 0 10 79
8
57 . 12
10 198
10 79
17 . 12
67 . 5 9 . 0 / 1 . 5 /
1 . 5 9 . 0 6
1 1
1
1
3
4
3
3
4
3
3
= + = + =
=
=
= + + = + + =
=
= =
=
+ = + =
= = =
= = =
( )
( )( )
( )
( )
| |
( ) . . 1 . 102 7 . 24 8 . 126
5 . 151 7 . 24 8 . 126
5 . 6
3 67 . 5
4 9 . 6
231
07 . 89
9 . 0
1 . 5 5 8 8
is stress initial d uncorrecte The
range preferred in the not is It
min
67 . 5 * 105 . 0 max
3 3
MPa
MPa
e
MPa
d
D F
i
i
i
uncorr
i
= =
= + =
|
\
|

+ =
= = =
( )( )
( )
( )
( )
737 . 1
3 . 465
55 . 818
S
55 . 818 1819 45 . 0 S 45 . 0 S
1819
9 . 0
1783
d
A
S
3 . 465
9 . 0
1 . 5 24 8
088 . 1
8

1
sy
ut sy
190 . 0 m
ut
3 3
1
1
= = =
= = =
= = =
= = =
s
s
n
MPa
MPa
MPa
d
D F
K
088 . 1
1 2
=
+
=
C
C
K
s
i)
( )
( )
( )
( )
( ) ( )
( )
( ) ( )
( )
( )
( )
( )
( )
( )
( )
( ) ( )
( )
( ) 595 . 1
513
55 . 818
, 513
9 . 0
1 . 5 24 20 . 1 8
2 . 1
4 66 . 4 4
1 66 . 4 4
4 4
1 4
66 . 4
9 . 0
9 . 0 1 . 5
d
2r
is B at hook - end in situation The
336 . 1
1021
25 . 1364
25 . 1364 1819 75 . 0 S 75 . 0 S
, 1021
9 . 0
4
9 . 0
1 . 5 16
15 . 1 24
15 . 1
1 67 . 5 67 . 5 * 4
1 67 . 5 67 . 5 4
1 4
1 4
67 . 5
d
D
d
2r
C
is A at bending hook end in the situation The
3
1
2
2
2
2
1
ut y
2 3
1
2
1 1
1
2
1
1
1
= = = =
=
=
=
= =
= = =
= = =
=
(
+ =
=

=
= = = =
B
y B
B
A
y
A
y
A
A
n MPa
C
C
K
d
d D
C
S
n
MPa
MPa
C C
C C
K
C
ii)
iii)
Close wound like helical coil
extension spring
Negligible initial tension
The ends connect a force at a
distance from coil axis to apply
a torque
Wound with a pitch that just
separates the body coils to avoid
intercoil friction.
The wire in the torsion
spring is in bending
TORSION SPRINGS:
Fixed End
Free
End
Free end
location angle
Back
angle
Angular rotation,
proportional to Fl
For all positions of the moving end + = = constant.
turns partial ; body turns
integer
360
integer
= =
+ = + =
p b
p
o
b
N N
N N

TORSION SPRING
Bending Stress :
The bending stress can be expressed as
3
3
2 2
32
,
32
) 1 ( 4
1 4
) 1 ( 4
1 4
' '
d
Fl
K is equation bending the
d
z
c
I
and Fl M ng Substituti
unity than less also and K than less always is K
C C
C C
K and
C C
C C
K
factor correction stress is K where
I
Mc
K
i
i o
o i
=
= = =
+
+
=

=
=
Torsional stiffness:
( )
radians
E d
Ml
radians
E d
Ml
d E
Fl
EI
Fl
l
y
e
e
4
4 4
2 2
3
64
3
64
64 / 3 3
: deflection End
=
= = = =
The angle subtended by the end deflection of a cantilever,
when viewed from the built-in ends, is y/l rad.
From Table A91,
E d
MDN
E d
FlDN
d I
EI
dx Fl
EI
dx l F
F F
U
l
b b
c
DN DN
c
b b
4 4
4
0
2
0
2 2
64 64
64 /
2
= =
=
|
|
\
|
=
|
|
\
|

The Force F will deflect through a distance l
Torsional stiffness
Strain energy in bending,

=
EI
dx M
U
2
2
The end deflection is bending of a cantilever beam whereas
the coils undergo bending action under M = Fl requiring
application of Castigliano theorem.
( ) ( )
a t e b a e
b
b
t
e e c t
N
E d
MD
N N N
D
l l
N
Defining
D
l l
N
E d
MD
E d
Ml
E d
Ml
E d
MDN
4
2 1
2 1
4 4
2
4
1
4
2 1
64
; ,
3
3
64
3
64
3
64 64
(rad), deflection angular total The
= + =
+
=
|
\
|
+
+ = + + =
+ + =

Torsional stiffness
Stiffness expressions in torque/radian units:
b c
c
DN
E d M
k
64
4
= =
( )
2 1
4
64
3
l l
E d M
k
e
e
+
= =

Stiffness values in torque/turn values (i.e 2 rad /turn) :

a t
s
DN
E d M
k
64
4
= =
2
64
4
'
'
= =
a t
s
DN
E d M
k
2
64
4
'
'
= =
b c
c
DN
E d M
k
( )

2
64
3
2 1
4
'
'
+
= =
l l
E d M
k
e
e
a t
s
DN
E d M
k
8 . 10
4
'
'
= =
b c
c
DN
E d M
k
8 . 10
4
'
'
= =
( )
2 1
4
'
'
8 . 10
3
l l
E d M
k
e
e
+
= =

Tests show that the effect of friction between the coils is such that the constant
10.186 (i.e 64/2) should be increased to 10.8
Torsional stiffness
Torsion spring supported on round bar or pin:
( ) ( ) | |
b
'
c b
c b
b
N D A N D' A
N
D N
D
= +
+
= n deformatio after and before balance volume from , '
'
( )
pin
pin c
b
pin
c b
b
pin pin i
D d D
D d
N
D d
N
D N
D d D D D

+ +
=

+
= = =
'
1
'
'

When the load is applied to a torsion spring, the spring winds up, causing
a decrease in the inside diameter of the coil body.
Ensure that the inside diameter of the coil never becomes equal to or less
than the diameter of the pin,
The helix diameter of the coil D becomes
The new inside diameter D
i
= D d makes the diametral clearance
between the body coil and the pin of diameter D
p
Table 106
Design of Torsion Springs for Strength:
Static strength
First column entries in Table 106 can be divided by 0.577 (from distortion-energy
theory) to give
m
ut
d
A
S =
Design of Torsion Springs for Strength:
Dynamic strength
The dynamic design can not be based on Zimmerlis data (which
was used for compression/tension springs) because the nature of
loading and stresses are due to bending rather than torsion.
We have to use the repeated bending stress data provided by
Associated Spring R=0 fatigue strength (S
r
)
Table 1010 (S
r
values for fatigue)
Maximum Recommended Bending Stresses (K
w
Corrected) for Helical
Torsion Springs in Cyclic Applications as Percent of S
ut
Design for dynamic (fatigue) strength:
2
2 /
1
2 /
|
|
\
|
=
ut
r
r
e
S
S
S
S
The value of S
r
from the table 10-10.
Gerber criterion:
1
2
=
|
|
\
|
+
|
|
\
|
ut
m
e
a
S S

a
a
f
ut
e
e
ut
a
m a
S
n
rS
S
S
S r
S
M M r
=
(
(
|
|
\
|
+ + =
=
2
2 2
2
1 1
2
/
The spring is formed by winding cold
drawn stainless steel wire A302 (E =
196 MPa) around a mandrel to obtain
2.5 body turns with torsion ends as
shown in figure. The wire clip is
arranged with initial torque/moment of
1200 N-mm.
A. Find the maximum static
torque/moment that can be applied,
if the factor of safety is 2.5
B. calculate the total angular deflection
of the spring corresponding to the
applied static torque/moment.
Problem
Solution
( )
MPa
n
S
C C
C C
K
d
D
C
mm d D D
MPa S S and MPa
d
A
S
A steel stainless drawn Cold
y
i
i
ut y
m
ut
2 . 446
5 . 2
5 . 1115
09 . 1
) 1 ( 4
1 4
9
36 4 32
5 . 1115 78 . 0 1430
4
2065
302
max
2
263 . 0
= = =
=

=
= =
= + = + =
= = = = =

rad
D
l l
N
E d
MD
mm N M M moment applied Maximum
mm N M
d
M
K
t
b t
initial
i
2 . 0
36 3
115 115
5 . 2
10 196 4
36 1372 64
3
64
1372
2572
09 . 1 32
4 2 . 446 32
3 4
2 1
4
max
3
max
3
max
max
=
|
\
|
+
+

=
|
\
|
+
+ =
= =
=

= =

PROBLEM :
Consider the twin torsional springs used in the bicycle
carrier. The spring material is oil quenched and tempered
(OQ & T) carbon steel (A229) having E = 198 GPa with a
spring index of 4. Each spring has lengths of the ends of
l
1
=100 mm and l
2
=200 mm. The number of body turns in
each spring is 5.3.
Find the required wire diameter (d) if the spring is to be
safe in bending as well as the maximum total angular
deflection be limited to 70
o
.
SOLUTION:
For OQ&T A229: From Table 10-4: m = 0.187 and A = 1855 MPa.
( ) { } 229 . 1 ) 1 ( 4 / 1 4
2
= = C C C C K
i
( )
( )
( )
( )
( )
(
+
+
)
`
=
(
+
+ =
(
= = = = =
=
= = =
Cd
Cd
d K
d
Ed D
l l
N
Ed
MD
d K
d
K
S d
M Fl
d
Fl
K S
n
d d
A
S S
i
b t
i i
yt
i yt
d
m
ut yt
3
200 100
3 . 5
1855
87 . 0
32
64
180
70
3
64
1855
87 . 0
32 32
32
1. Assume
;
1855
87 . 0 87 . 0 87 . 0
187 . 0
3
4
2 1
4
187 . 0
3
3
3
187 . 0
Simplifying the above equation, we obtain a non-linear equation.
( )
mm d
d d
387 . 2
327 . 1 88351 . 0 222 . 1
187 . 1
==
+ =
PROBLEM :
A stock spring is shown in Fig. It is made from 1.8 -mm-diameter
music wire and has 4 .25 body turns with straight torsion ends. It
works over a pin of 10 mm diameter. The coil outside diameter is 15
mm.
(a) Find the maximum operating torque
and corresponding rotation for static
loading.
(b) Estimate the inside coil diameter and
pin diametral clearance when the spring
is subjected to the torque in part (a).
(c) Estimate the fatigue factor of safety
n
f
if the applied moment varies between
M
min
= 0.1 to M
max
= 0.5 N-m.
For music wire, from Table 104 we find that A = 2211 MPa
mm
m
and m = 0.145.
( )
MPa n S S
MPa S S and MPa
d
A
S
y yt
ut y
m
ut
1318 /
1582 78 . 0 2029
8 . 1
2211
145 . 0
= =
= = = = =
( )
113 . 1
) 1 ( 4
1 4
2
=

=
C C
C C
K
i
The mean coil diameter is D = 15-1.8 = 13.2 mm. The spring index C = D/d = 7.33
( )
( )
( )
( )
mm N
K
S d
M Fl
d
Fl
K S
i
yt
i yt
. 3 . 678
113 . 1 32
1318 8 . 1
32
32
3
3
max max
3
max
max
= = = =
= =
Factor of safety is 1
Solution
( )( )( )
( ) ( )
0 0
4
'
4
'
4
'
'
72 ) 360 ( 2 . 0 2 . 0
196000 8 . 1
25 . 4 2 . 13 3 . 678 8 . 10
8 . 10
8 . 10
= = = =
= = =
turn
E d
MDN
DN
E d M
k
c
b
c
b c
c
( )
( )( )( )
( )
0 0
'
'
4
4
'
'
2 1
67 . 78 360 218 . 0 218 . 0
3104
3 . 678
. 3104
65 . 4 2 . 13 8 . 10
196000 8 . 1
8 . 10
65 . 4
) 2 . 13 ( 3
25 25
25 . 4
3
= = = = =
= = = =
=
+
+ =
+
+ =
turn
k
M
mm N
DN
E d M
k
spring complete of rate Spring
turns
D
l l
N N
s
t
a t
s
b a

( )
MPa
r
MPa
d
M
K
M
M
r
mm N
M M
M
mm N
M M
M
Fatigue c
mm D d D D D
mm
N
D N
D b
a
m
a
i a
m
a
m
a
pin pin i
c b
b
2 . 583
8 . 388
8 . 1
) 200 ( 32
113 . 1
32
667 . 0
. 300
2
100 500
2
. 200
2
100 500
2
) (
7 . 0 10 8 . 1 5 . 12 '
5 . 12
24 . 0 25 . 4
) 2 . 13 ( 25 . 4
' ) (
3 3
min max
min max
'
'
= =
= = =
= =
=
+
=
+
=
=
=
= = = =
=
+
=
+
=

From Table 1010, S
r
= 0.50S
ut
= 0.50(2029)=1014.5MPa
( ) ( )
( )
( )
22 . 1
8 . 388
4 . 474
4 . 474
) 2029 ( 667 . 0
541 2
1 1
541 2
2029 667 . 0
2
1 1
2
514
2029
2 / 5 . 1014
1
2 / 5 . 1014
2 /
1
2 /
2
2 2
2
2 2
2 2
= = =
=
(
(
|
|
\
|
+ + =
(
(
|
|
\
|
+ + =
=
|
\
|
=
|
|
\
|
=
a
a
f
ut
e
e
ut
a
ut
r
r
e
S
n
MPa
rS
S
S
S r
S
MPa
S
S
S
S

Leaf Springs:
Consists of a series of flat plates,
usually of semi-elliptical shape.
The leaves are held together by means
of two U-bolts and a centre bolt
Rebound clips are provided to keep
the leaves in alignment and prevent
lateral shifting of the plates during
operation
The master leaf (longest leaf) is bent
to form the spring eye
Leaf springs are capable of exerting
large forces within comparably small
spaces
(Reference: Mechanical Design by Peter R. N. Childs)
Leaf Springs:
L L
F F
2F
Without pre-stress
L L
F F
2F
Pre-stressed
Extra full length leaves are
provided to protect the ends.
They are not uniform strength
beams and hence 50% more
bending stress exists in them. To
protect them they are sometimes
pre-stressed during the
assembly.
The multi-leaf spring shown and the single triangular section beam both have the same stress
and deflection characteristics with the exceptions that the multi-leaf spring is subject to
additional damping due to friction between the leaves
Source: Mechanical Design by Peter R. N. Childs
The bending stress in the plate which is uniform throughout is given
by
Where n
g
is no. of graduated leaves including master leaf
The deflection at load point is given by (deflection of a triangular
plate)
The Spring rate is given by
( )
( )
2
3
6
) (
12
1
2 /
bh n
FL
h b n
h L F
I
Mc
g
g
b
= = =
( )
( )
3
3
3
3 3
6
) (
12
1
2
2 h b n E
FL
h b n E
L F
EI
L F
g
g
=
|
\
|
= =
3
3
6 L
bh En
F
k
g
= = =

Problem:
A truck spring has 6 no of leaves. The supports are 1.5 m
apart and maximum central load is to be 5.4 kN. The
permissible stress for spring material is 280 MPa.
Determine the thickness and width of the spring, if ratio of
total width to depth of the spring is 4. Also find the
deflection of the spring.
Solution:
( )( )
( )
( )( )
( )
mm
h b n E
FL
mm
b
t
mm b
b
b
b
b
bh n
FL
g
g
b
156 . 0
) 85 )( 7 . 56 ( 6 10 210
10 75 . 0 10 7 . 2 6 6
85
4
6
7 . 56 280
10 900
10 900
)
4
6
)( ( 6
10 75 . 0 10 7 . 2 6 6
3 3
3
3 3
3
3
2
3
2
3
2
3 3
2
=

= =
= =
= =
=

= =

Mechanical Springs

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For absolute stability and buckling not to occur,

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When the spring is completed and

Stiffness values in torque/turn values (i.e 2 rad /turn) :

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