Outline

Spring

Functions & Types

Helical Springs
Compression
Extension
Torsional

The Function(s) of Springs

Most fundamentally: to STORE ENERGY

Many springs can also:

push
pull
twist

Some Review
linear springs: k=F/y

F
k

nonlinear springs: k

Series
1
ktotal

1 1
1

k1 k 2 k3

dF
dy

Parallel

ktotal=k1+k2+k3

Types of Springs
Helical:

Compression

Extension

Torsion

More Springs
Washer Springs:

Beams:

Power springs:

Helical Compression Springs

d
D
Lf
p
Nt

diameter of wire
mean coil diameter
free length
pitch
Total coils

may also need:

Do and Di

Length Terminology
minimum of 10-15%
clash allowance

Free Length

Lf

Assembled
Length

La

Max Working
Load

Lm

Bottomed
Out

Ls

End Conditions
Plain

Plain Ground

Na=
Active Coils
Square

Square Ground

Stresses in Helical Springs

F

Spring Index

2C 1
max K s
, where K s
2C
d 3
8 FD

F
F
T

C=D/d

Curvature Stress
Inner part of spring is a stress concentration
(see Chapter 4)

Kw includes both the direct shear factor and

the stress concentration factor

4C 1 0.615
max K w
, where K w

4C 4
C
d 3
8 FD

under static loading, local yielding eliminates stress

concentration, so use Ks

under dynamic loading, failure happens below Sy: use

Ks for mean, Kw for alternating

Spring Deflection

3
8 FD N
4
d G

Spring Rate
y

3
8 FD N
4
d G

k=F/y

d G
3

8D N a

Helical Springs
Compression

Nomenclature
Stress
Deflection and Spring Constant
Static Design
Fatigue Design
Extension
Torsion

Static Spring Design

Inherently

iterative

Some values must be set to calculate

stresses, deflections, etc.
Truly

Design

there is not one correct answer

must synthesize (a little bit) in addition to
analyze

Material Properties
Sut

ultimate tensile strength

Figure 13-3
Table 13-4 with Sut=Adb
Sys

torsional yield strength

Table 13-6 a function of Sut and set

Spring/Material Treatments

Setting
overstress material in same direction as applied
load
increase static load capacity 45-65%
increase energy storage by 100%

use Ks, not Kw (stress concentration relieved)

Load Reversal with Springs

Shot Peening

What type of failure would this be most effective

against?

What are You Designing?

Given

Find

F, y
k, y

k
F

d, C, D*, Lf*, Na*, clash

allowance ()**, material**

design variables

Such that:
Safety factor is > 1
Spring will not buckle
Spring will fit in hole, over pin, within vertical space
* - often can calculate from given
** - often given/defined

Static Spring Flow Chart

if GIVEN F,y, then find k; If GIVEN k, y, then find F
Na,
d, C
D, Ks, Kw
material strengths
material

STRESSES

DEFLECTION

Ns=Sys/

Lf, yshut, Fshut

for shut spring if possible

if not, for max working load

Three things to know:

effect of d
shortcut to finding d
how to check buckling

ITERATE?

CHECK
buckling, Nshut, Di, Do
Nshut=Sys/shut

Static Design: Wire Diameter

max K s

8 FD

8 FD 3 N a
d 4G

Based on Ns=Ssy/ and above equation for :

8 N s C 0.5 Fwork 1 Finitial

d

K m A

Three things to know:

effect of d
shortcut to finding d
how to check buckling

1 ( 2b )

use Table 13-2 to select standard d near

calculated d
Km=Sys/Sut
*maintain units (in. or mm) for A, b
**see Example 13-3A on MathCad CD

Buckling
S .R.

Lf

D
yinit y working
y
Lf

Three things to know:

effect of d
shortcut to finding d
how to check buckling

Helical Springs
Compression

Nomenclature
Stress
Deflection and Spring Constant
Static Design
Fatigue Design
Extension
Torsion

Material Properties

Sus

ultimate shear strength

Sus0.67 Sut

Sfw

torsional fatigue strength

Table 13-7 -- function of Sut, # of cycles

repeated, room temp, 50% reliability, no corrosion

Sew torsional endurance limit

for steel, d < 10mm
see page 816 (=45 ksi if unpeened, =67.5 ksi if
peened)
repeated, room temp., 50% reliability, no corrosion

Modified Goodman for Springs

a
Sfs
0.5 Sfw

Sfw, Sew are for torsional strengths, so von

Mises not used

ed
t
a
e
ep

S fs 0.5

S fw S us

0.5 Sfw

Sus

S us 0.5 S fw

Fatigue Safety Factor

a

Fi=Fmin
Fa=(Fmax-Fmin)/2

loa

Sa
N fs
a

dl
i ne

Sfs

Fm=(Fmax+Fmin)/2

0.5 Sfw

mload

Sa

mgood
0.5 Sfw

a,load = a,good at intersection

i m

Sus

S fs S us i
N fs
S fs m i Sus a
on page 828

What are you Designing?

Given

Find

Fmax,Fmin, y
k, y

k
F

d, C, D*, Lf*, Na*, clash

allowance ()**, material**

design variables

Such that:
Fatigue Safety Factor is > 1
Shut Static Safety Factor is > 1
Spring will not buckle
Spring is well below natural frequency
Spring will fit in hole, over pin, within vertical space
* - often can calculate from Given
** - often given/defined

Fatigue Spring Design Strategy

if GIVEN F,y, then find k; If GIVEN k, y, then find F
Na,
d, C
D, Ks, Kw
material strengths

STRESSES
S fs S us i
N fs
S fs m i Sus a

DEFLECTION
Lf, yshut, Fshut

material

Two things to know:

shortcut to finding d
how to check frequency

ITERATE?

CHECK
buckling, frequency,
Nshut, Di, Do
Nshut=Sys/shut

Fatigue Design:Wire Diameter

as before, you can iterate to find d, or you can use an equation
derived from relationships that we already know:

N fs 1

0.67A

N fs

8CN fs

K s Fm

1.34
1 K w Fa

S fw

1 ( 2b)

K s Fmin

Ad b

use Table 13-2 to select standard d near

calculated d
Two things to know:
shortcut to finding d
how to check frequency

*maintain units (in. or mm) for A, b

**see Example 13-4A on MathCad CD

Natural Frequency: Surge

Surge == longitudinal resonance
for fixed/fixed end conditions:

1 kg
fn
2 Wa

(Hz)

ideally, fn will be at least 13x more than fforcing

it should definitely be multiple times bigger

Two things to know:

shortcut to finding d
how to check frequency

see pages 814-815 for more

Review of Design Strategy

ITERATIVE

USING d EQUATION

Find Loading
Select C, d

Find Loading
Select C, safety factor

Find stresses
Determine material properties
Find safety factor

Solve for d, pick standard d

Find stresses
Determine material properties
Check safety factor

Strategy Review Continued

Find spring constant, Na, Nt

Find FSHUT (must find lengths and ys to do this)

Find static shut shear stress and safety factor

Check Buckling
Check Surge
Check Di, Do if pin to fit over, hole to fit in

Consider the Following:

Helical Springs
Compression

Nomenclature
Stress
Deflection and Spring Constant
Static Design
Fatigue Design
Extension
Torsion

Extension Springs
As before, 4 < C < 12

max K s

8 FD

, use K w for a
3
d

surge check is same as before

Lb=d(Na+1)

However, no peening, no setting,

no concern about buckling

Difference 1: Initial Force

force F
preloading
Fi

deflection y

F=Fi+ky

F Fi
d 4G
k

y
8D 3 N a

Difference 1a: Deflection

3
8( F Fi ) D N a
y
4

d G

Difference 2: Initial Stress

take initial stress as the average stress between these lines,

then find Fi

Difference 3: Ends!: Bending

a Kb

16 DF

Kb
C1
N fb
Se

3
d

4F
2
d

4C12 C1 1
4C1 (C1 1)

2 R1 2 D

C
d
2d

S e ( Sut min )
S e ( mean min ) S ut alt

S es
0.67

standard
end

Difference 3a: Ends: Torsion

4C 2 1
max K w2
, K w2
4C2 4
d 3
8 FD

C2=2R2/d

pick a value >4

Materials
Sut

Same

Sys,
Sys,

Sfw, Sew same for body

Sfw, Sew see Tables 13-10 and 1311 for ends

Strategy
similar to compression + end stresses - buckling

Helical Springs
Compression

Nomenclature
Stress
Deflection and Spring Constant
Static Design
Fatigue Design
Extension
Torsion

Torsion Springs
close-wound, always load to close

Deflection & Spring Rate

1 MLw
rev
,
2 EI

Lw length of wire DN a

rev ,roundwire 10.8

MDN a
d 4E

M
k
rev

Stresses
Compressive is Max Use for Static Inside of Coil

imax K bi

M max c
32 M max
K bi
I
d 3
4C 2 C 1
K bi
4C (C 1)

For Fatigue Slightly lower Outside Tensile Stress Outside of Coil

omax K bo

32 M max

d 3

omin K bo

4C 2 C 1
K bo
4C (C 1)

32 M min

d 3

Materials
see Tables 13-13 and 13-14, page 850
follow book on Sewb=Sew/0.577 for now

Strategy
Select C, d

fit over pin (if there is one)

dont exceed stresses

Helical Springs
Compression

Nomenclature
Stress
Deflection and Spring Constant
Static Design
Fatigue Design
Extension
Torsion