B.E. 3/4 II-Sem.

Machine Design Solutions

1. A bumper, consisting of two helical steel springs of circular section, brings to rest, a railway wagon of mass 1500 kg and moving at 1.2 m/s. While doing so, the springs are compressed by 150 mm. The mean dia of coils is 6 times the wire dia. The permissible shear stress is 400 MPa. Determine (a) max force on each spring (b) wire diameter of the spring (c) mean dia of coils, and (d) number of active coils. Take G = 0.84 x 10 5 MPa.

Prepared by : S.L.V. Prasad, Asst. Professor, MED

B.E. 3/4 II-Sem. Machine Design Solutions

2. A spring loaded safety valve for a boiler is required to blow off at a pressure of 1.5 N/mm2. The diameter of the valve is 60 mm. Design a suitable compression spring, assuming the spring index to be 6 and 25 mm initial compression. The maximum lift of the valve is 15 mm. The shear stress is limited to 450 MPa. Take G = 0.84 x 105 MPa.

Prepared by : S.L.V. Prasad, Asst. Professor, MED

B.E. 3/4 II-Sem. Machine Design Solutions

3. Design a concentric spring for an aircraft engine valve to exert a maximum force of 8000 N under a deflection a 40 mm. Both the spring have same free length. Solid length and are subjected to equal maximum shear stress of 850 N/mm2. The spring width for both spring is 6.

Prepared by : S.L.V. Prasad, Asst. Professor, MED

B.E. 3/4 II-Sem. Machine Design Solutions

4. A helical valve spring is subjected to an initial pre-load of 60 N and the expected maximum load during full spring of the valve is 180 N. Assuming a factor of safety of 1.5 and spring index of 6 design the spring. Take the wahl factor, K = 1.25 and K S the connection factor for shear as 1.08 for the spring wire. Sut = 1425 N/mm2.

Prepared by : S.L.V. Prasad, Asst. Professor, MED

B.E. 3/4 II-Sem. Machine Design Solutions

5. A helical spring is made from a wire of 6 mm diameter and has outside diameter of 75 mm. If the permeable shear stress is 350 N/mm2 and modulus of rigidity 84 kN/mm2 find the axial load which the spring can carry and the deflection per active turn. (a) Neglect the effect of curvature (b) Consider the effect of curvature.

Prepared by : S.L.V. Prasad, Asst. Professor, MED

B.E. 3/4 II-Sem. Machine Design Solutions

6. A car weighing 2500 Kg and moving at a velocity of 1.3 m/sec is brought to rest by a bumper consisting of 4 helical springs of circular cross section in which the mean diameter of the coil is 5 times the diameter of the spring wire. In bringing the car to rest the springs are to be compressed 160 mm. The maximum allowable stress in the spring is 400 MPa and the modulus of rigidity is 0.04 x 106 MPa. Determine the following: (a) maximum load on each spring (b) mean diameter of coil (c) no. of active coils.

Prepared by : S.L.V. Prasad, Asst. Professor, MED

B.E. 3/4 II-Sem. Machine Design Solutions

7. A weight of 800 N in to drop on the center of a plate from a height of 30 cms. The plate is supported on four identical helical springs. The deflection allowed for each spring is 6 cms. Assuming spring index as 5, maximum permissible stress as 400 MPa and G = 8 x 104 MPa, design the spring wire diameter, mean coil diameter and the active number of turns.

Prepared by : S.L.V. Prasad, Asst. Professor, MED

B.E. 3/4 II-Sem. Machine Design Solutions

8. A leaf-spring has an overall length of 1.1 m and carries a central load of 75 KN. It has 3 full length leaves and 15 graduated leaves with a central band of width 10 cms. All leaves are stressed to 400 MPa when fully loaded. The total spring depth to width ratio is 2. Calculate the width and thickness of each leaf.

Prepared by : S.L.V. Prasad, Asst. Professor, MED

B.E. 3/4 II-Sem. Machine Design Solutions

9. (a) Design a hot coiled compression spring required for a load of 50 KW at a deflection of 125 mm. The mean coil diameter is required to be 140 mm. (b) Why laminated spring are used in the vehicles.

Prepared by : S.L.V. Prasad, Asst. Professor, MED

B.E. 3/4 II-Sem. Machine Design Solutions

10. A load of 15 KN is supported by four leaf springs with the following data: Number of leaves = 10, span of each spring = 1 meter, Allowable deflection = 4 cm, E = 200 KN/m2, Permissible stress in the spring can be 600 to 700 N/mm2. Find the dimensions of the leaves.

Prepared by : S.L.V. Prasad, Asst. Professor, MED

B.E. 3/4 II-Sem. Machine Design Solutions

11. A coiled compression spring of oil tempered steel wire has seven active coils of 10 mm wire dia in a coil of 80 mm outside dia. It is used to produce an axial thrust on a clutch. Free length of the spring is 900 mm with the clutch engaged the length is 140 mm. Calculate (i) stress induced in the wire (ii) force existed by the spring on the clutch plate (iii) length of wire and (iv) power transmitted at 360 rpm by clutch if friction plate radia are 153 mm and 200 mm and = 0.1

Prepared by : S.L.V. Prasad, Asst. Professor, MED

B.E. 3/4 II-Sem. Machine Design Solutions

12. A truck spring has 10 full leaves of graduated length and 2 full length leaves. The spring supports are 110 cm apart and the central band is 9 cm wide. The central load is to be 6000 N with a permissible stress of 28 KN/cm2. Design the steel plates of the spring and find its deflection when loaded. Take the ratio of total depth of width of about 2.5. Also calculate the initial space to be provided between the full length and graduated leaves before the band is applied. What load is exerted on the bank after the spring is assembled?

Prepared by : S.L.V. Prasad, Asst. Professor, MED

B.E. 3/4 II-Sem. Machine Design Solutions

13. A helical spring used on an engine has following data: Length when valve is open and closed is 4.5 cm and 5.5 cm respectively and the corresponding spring load is 600 N and 200 N respectively. Maximum inside diameter of spring is 30 mm permissible shear stress is 40 MN/m2 and G: 8x 1010 N/m2 design the spring.

Prepared by : S.L.V. Prasad, Asst. Professor, MED

B.E. 3/4 II-Sem. Machine Design Solutions

14. A leaf spring has an overall length of 110 cm and carries a load of 80 KN at its center . The spring has 3 full length leaves and 15 graduated leaves with a central band 10 cm wide. All leaves are to be stressed to 42 KN/cm2 when fully loaded. Design the spring keeping the ratio of total depth to width of about 2.5.

Prepared by : S.L.V. Prasad, Asst. Professor, MED

B.E. 3/4 II-Sem. Machine Design Solutions

15. A semi-elliptic leaf spring consists two extra full-length leaves and six graduated length leaves, including the master leaf. The centre-to-centre distance between the two eyes of the spring is 1m. The total load is 10 KN on the spring and has a width of each leaf as 50 mm. The initial pre-load is adjusted such a way that under the maximum load the induced stresses in all waves are equal to 350 N/mm2. E for leaf material is 207000N/mm2. Design the thickness and calculate the maximum deflection.

Prepared by : S.L.V. Prasad, Asst. Professor, MED

B.E. 3/4 II-Sem. Machine Design Solutions

16. Design a valve spring for a petrol engine for the following operating conditions: spring load when valve is open = 400 N, spring load when valve is closed = 250 N, maximum inside diameter for the spring = 25 mm, length of spring when the valve is open = 40 mm, length of the spring when valve is closed = 50 mm, maximum permissible shear stress = 100 N/mm2.

Prepared by : S.L.V. Prasad, Asst. Professor, MED

B.E. 3/4 II-Sem. Machine Design Solutions

17. Design a helical compression spring for a maximum load of 1000 N for a deflection of 25 mm using the value of spring index as 5. The maximum permissible shear stress for spring wire is 420 MPa and modulus of rigidity is 64 KN/mm2. The ends of springs are squared and ground. Find wire dia, coil dia, number of coils, free length and pitch of the coil.

Prepared by : S.L.V. Prasad, Asst. Professor, MED