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(1)
Where:
P = load
D = mean coil diameter
n = Number of active coils
d = bar diameter
G = rigidity
The total deflection of a slotted cylinder spring is reported by Wilhem A. Schneider, 1963 [7] as follows:
(2)
Where
P = total compression load
E = Yongs modulus of elasticity
L
s
= length of slot
n
ss
= number of slot section
n
s
= number of slots per section
b = wall thickness
h = height of horizontal path
Total deflection
270 International Journal of Engineering & Technology
3. Finite element method
In this study, the finite element analysis (FEA) was performed using ANSYS11. Finite element analysis was applied to
determine the stiffness, natural frequencies, mode shapes and transient responses of the springs. This method is based
on the solution of differential equations with imposed boundary conditions. The system under investigation is an
assembly of nodes that serve to connect elements together. All elements used in ANSYS11 have two defined sets of
property tables; material and physical tables. The finite element method is an approximate technique used to obtain a
solution to a specific problem. The following procedure was used in obtaining the finite element solution:
a) Generate a solid model of the springs.
b) Create a grid of nodes connected by elements.
c) Apply boundary conditions.
d) Solving of static and dynamic models.
e) Model updating.
f) Display and interpreting of results.
The geometry for the helical coil compression spring was modeled in the AutoCAd14 software and export as a SAT file,
then imported the SAT file in ANSYS11 code. While the geometry of slotted cylinder spring plotted section by section
according to the each cases size. Element selected for this analysis is SOLID45. SHELL element is used for meshing
the cross section of helical spring then dragged by solid45. SOLID92 is a pyramid element that increases time of
calculations and it has error in nonlinear complex models. Therefore, a cubic SOLID45 element has been used in the
stress analysis for both helical spring and slotted cylinder spring. This element is defined by eight nodes having three
degrees of freedom at each node: translations in nodal x, y and z directions. For the design of the slotted cylinder spring,
the design in Fig.(1-A) is fail under static and dynamic load, so the slots in the section is design as a verse versa, as
shown in Fig.(1-B) similar to Ref.[7]. The finite element method is an approximate numerical technique for solving
structural problems. It must also be remembered that inaccuracy may arise from the fact that the finite element model is
rarely an exact representation of the physical structure. The element mesh may not exactly fit the structures geometry.
In addition, the actual distribution of the load and possibly elastic properties may be approximated by simple
interpolation functions. Boundary conditions simulating the rigid base may also be approximated.
A B
Fig. 1: Slotted Cylinder Spring (A) Worst Design (B) Good Design
Case A Case B Case C Case D Case E
Helical Coil Compression Spring
Case A Case B Case C Case D Case E
Slotted Cylinder Spring With Three Slots Per Section
Case A
Case B
Case C
Case D
Case E
Fig. 2: Shows the Meshes of the Helical and Slotted Cylinder Spring with three Slots and Four Slots Per Section for the Cases Studied.
Slotted cylinder spring with four slots per section
International Journal of Engineering & Technology 271
4. Static analysis
In the static modeling of the system, three dimension solid elements were used to represent the helical coil compression
spring and slotted cylinder spring. These elements mathematically modeled the overall deflection of the spring. At the
base of the model, the nodes representing the inactive coil were completely restrained. This condition created the fixed
base associated with the real system. The applied load was considered to be concentrated at the centerline of the spring.
The elements of the stiffness matrix were determined based upon the linear load deformation relationship
P = [K] (3)
Where [K] is the stiffness matrix of the spring. As the spring is deformed, the spring exerts a force that is proportional
to the displacement, the resulting stiffness of spring was determined. Tables(1) to (5) indicated deflection of the helical
and slotted cylinder springs with 3-slots and 4-slots for cases A,B,C,D and E. Fig.(3) explained the ANSYS and
theoretical stiffness of springs (Helical and slotted cylinder spring with 3-slots and 4-slots).
Table 1: Deflection [M] of the Springs: Case-A-
Load
[N]
Helical Spring Slotted cylinder spring
ANSYS
Theory
Eq.(1)
ANSYS
(3-slots)
ANSYS
(4-slots)
Theory
(3-slots)
Eq.(2)
Theory
(4-slots)
Eq.(2)
10 0.431e-3 9.9e-4 0.119e-6 0.572e-7 3.44472e-8 1.08993e-8
20 0.862e-3 1.98e-3 0.293e-6 0.114e-6 6.88944e-8 2.17986e-8
30 0.001336 2.97e-3 0.358e-6 0.171e-6 1.03342e-7 3.26979e-8
40 0.00188 3.96e-3 0.477e-6 0.229e-6 1.37789e-7 4.35972e-8
50 0.002425 4.95e-3 0.597e-6 0.286e-6 1.72236e-7 5.44965e-8
60 0.002975 5.94e-3 0.716e-6 0.343e-6 2.06683e-7 6.53958e-8
70 0.003525 6.93e-3 0.836e-6 0.4e-6 2.4113e-7 7.62951e-8
80 0.004076 7.92e-3 0.955e-6 0.457e-6 2.75577e-7 8.71944e-8
90 0.004627 8.91e-3 0.107e-5 0.514e-6 3.10025e-7 9.80937e-8
100 0.005178 9.9e-3 0.119e-5 0.572e-6 3.44472e-7 1.08993e-7
Table 2: Deflection [M] of the Springs: Case-B
Load
[N]
Helical Spring Slotted cylinder spring
ANSYS
Theory
Eq.(1)
ANSYS
(3-slots)
ANSYS
(4-slots)
Theory
(3-slots)
Eq.(2)
Theory
(4-slots)
Eq.(2)
10 0.896e-3 1.17e-3 0.537e-6 0.205e-6 4.6368e-7 1.46711e-7
20 0.001793 2.34e-3 0.107e-5 0.409e-6 9.27361e-7 2.9342e-7
30 0.002689 3.51e-3 0.161e-5 0.614e-6 1.39104e-6 4.40134e-7
40 0.003586 4.68e-3 0.215e-5 0.818e-6 1.85472e-6 5.86846e-7
50 0.004638 5.85e-3 0.268e-5 0.102e-5 2.3184e-6 7.3355e-7
60 0.005773 7.02e-3 0.322e-5 0.123e-5 2.78208e-6 8.80268e-7
70 0.00691 8.19e-3 0.376e-5 0.143e-5 3.24576e-6 1.02698e-6
80 0.008051 9.36e-3 0.430e-5 0.164e-5 3.70944e-6 1.17369e-6
90 0.009196 1.05e-2 0.483e-5 0.184e-5 4.17312e-6 1.3204e-6
100 0.0010344 1.17e-2 0.537e-5 0.205e-5 4.6368e-6 1.46711e-6
Table 3: Deflection [M] of the Springs: Case-C
Load
[N]
Helical Spring Slotted cylinder spring
ANSYS
Theory
Eq.(1)
ANSYS
(3-slots)
ANSYS
(4-slots)
Theory
(3-slots)
Eq.(2)
Theory
(4-slots)
Eq.(2)
10 0.001392 1.2e-3 0.543e-6 0.180e-6 6.94611e-7 2.19779e-7
20 0.002784 2.4e-3 0.109e-5 0.36e-6 1.38922e-6 4.39558e-7
30 0.004176 3.6e-3 0.163e-5 0.541e-6 2.08383e-6 6.59338e-7
40 0.005568 4.8e-3 0.217e-5 0.721e-6 2.77844e-6 8.79117e-7
50 0.007129 6e-3 0.272e-5 0.901e-6 3.47305e-6 1.0989e-6
60 0.008894 7.2e-3 0.326e-5 0.108e-5 4.16767e-6 1.31868e-6
70 0.010662 8.4e-3 0.380e-5 0.126e-5 4.86228e-6 1.53845e-6
80 0.102432 9.6e-3 0.435e-5 0.144e-5 5.55689e-6 1.75823e-6
90 0.014204 1.08e-2 0.489e-5 0.162e-5 6.2515e-6 1.97801e-6
100 0.015983 1.2e-2 0.543e-5 0.18e-5 6.94611e-6 2.19779e-6
272 International Journal of Engineering & Technology
Table 4: Deflection [M] of the Springs: Case-D
Load
[N]
Helical Spring Slotted cylinder spring
ANSYS
Theory
Eq.(1)
ANSYS
(3-slots)
ANSYS
(4-slots)
Theory
(3-slots)
Eq.(2)
Theory
(4-slots)
Eq.(2)
10 0.662e-3 8.66e-4 0.503e-6 0.164e-6 7.51568e-7 2.37801e-7
20 0.001324 1.73e-3 0.101e-5 0.328e-6 1.50314e-6 4.75602e-7
30 0.001986 2.6e-3 0.151e-5 0.492e-6 2.2547e-6 7.16402e-7
40 0.002648 3.46e-3 0.201e-5 0.656e-6 3.00627e-6 9.51203e-7
50 0.00331 4.33e-3 0.251e-5 0.82e-5 3.75784e-6 1.189e-6
60 0.003972 5.2e-3 0.302e-5 0.984e-5 4.50941e-6 1.4268e-6
70 0.004634 6.06e-3 0.352e-5 0.115e-5 5.26098e-6 1.66461e-6
80 0.005296 6.93e-3 0.402e-5 0.131e-5 6.01254e-6 1.90241e-6
90 0.005958 7.79e-3 0.452e-5 0.148e-5 6.76411e-6 2.14021e-6
100 0.00662 8.66e-4 0.503e-5 0.164e-5 7.51568e-6 2.37801e-6
Table 5: Deflection [M] of the Springs: Case-E
Load
[N]
Helical Spring Slotted cylinder spring
ANSYS
Theory
Eq.(1)
ANSYS
(3-slots)
ANSYS
(4-slots)
Theory
(3-slots)
Eq.(2)
Theory
(4-slots)
Eq.(2)
10 0.003588 1.87e-2 0.493e-5 0.157e-5 1.39996e-5 4.42957e-6
20 0.007175 3.75e-2 0.987e-5 0.314e-5 2.79993e-5 8.85915e-6
30 0.010763 5.62e-2 0.148e-4 0.471e-5 4.19989e-5 1.32887e-5
40 0.015007 7.49e-2 0.197e-4 0.627e-5 5.59986e-5 1.77183e-5
50 0.019573 9.37e-2 0.247e-4 0.784e-5 6.99982e-5 2.21479e-5
60 0.024145 1.12e-1 0.296e-4 0.941e-5 8.39978e-5 2.65774e-5
70 0.028728 1.31e-1 0.345e-4 0.11e-4 9.79975e-5 3.1007e-5
80 0.033321 1.5e-1 0.395e-4 0.125e-4 0.000111997 3.54366e-5
90 0.037915 1.69e-1 0.444e-4 0.141e-4 0.000125997 3.98662e-5
100 0.042511 1.87e-1 0.493e-4 0.157e-4 0.000139996 4.42957e-5
International Journal of Engineering & Technology 273
Fig. 3: ANSYS and Theoretical Stiffness of Springs ( Helical and Slotted Cylinder Spring with 3-Slots and 4-Slots)
Case-A- Helical Case-A- 3slots Case-A-4slots
274 International Journal of Engineering & Technology
Case-B- Helical Case-B- 3slots Case-B-4slots
Case-C- Helical Case-C- 3slots Case-C-4slots
Case-D- Helical Case-D- 3slots Case-D-4slots
Case-E- Helical Case-E- 3slots Case-E-4slots
Fig. 4: Equivalent Stresses for Helical and Slotted Cylinder Spring with 3-Slots and 4-Slots
Numerical analysis provides details such as spring stiffness, static stresses for helical spring and slotted cylinder spring
under compression. All these results are available in design of helical and slotted cylinder springs.
5. Dynamics analysis
In this system, energy is transformed from kinetic energy to potential energy and back again. This results in a vibrating
system. A vibrating system dissipates energy in the form of damping and the governing equation of motion representing
this system is written in matrix form as:
(4)
Where
F = a vector force on each DOF in the system
[M] = mass matrix
[K] = stiffness matrix
International Journal of Engineering & Technology 275