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INTRODUCTION
A spring is an elastic object used to store mechanical energy.
Springs are elastic bodies (generally metal) that can be twisted,
pulled, or stretched by some force.
They can return to their original shape when the force is released.
In other words it is also termed as a resilient member.
A spring is a flexible element used to exert a force or a torque and,
at the same time, to store energy.
The force can be a linear push or pull, or it can be radial, acting
similarly to a rubber band around a roll of drawings.
The torque can be used to cause a rotation, for example, to close a
door on a cabinet or to provide a counterbalance force for a
machine element pivoting on a hinge.
TYPES OF SPRINGS
Springs can be classified according to the direction and the nature
of the force exerted by the spring when it is deflected.
Uses
Types of Springs
Push
Pull
Radial
torque
TYPES OF SPRINGS
TYPES OF SPRINGS
TYPES OF SPRINGS
HELICAL SPRING
It is made of wire coiled in the form of helix having circular, square
or rectangular cross section.
HELICAL SPRING
The flexing of a helical spring creates torsion in
the wire and the force applied induces a direct
stress. The maximum stress in the wire may be
computed by super position.
Stress and deformation analysis of a closely
coiled helical spring are derived directly from
the corresponding equations for the torsion of a
round bar.
NOMENCLATURE
C = Spring index
d = Wire diameter of spring (mm)
Di = Inside diameter of spring
coil (mm)
Do = Outside diameter of spring
coil (mm)
D = Mean coil diameter (mm)
N = Number of coils
Di Do
D
Therefore,
2
SPRING INDEX
D
C
d
There are three terms - free length, compressed length and solid
length that are illustrated in the figure. These terms are related to
helical compression spring. These lengths are determined by
following way.
Solid length: solid length is defined
as the axial length of the spring which is
so compressed, that the adjacent coils
touch each other.
Solid length = Nd , where N = no. of
coil
Compressed length: Compressed
length is defined as the axial length of
the spring that is subjected to maximum
compressive force.
Total gap = (N-1) x gap between
adjacent coils
Free length: Free length is defined as
the axial length of an unloaded helical
compression spring. In this case, no
external force acts on the spring.
freelength
p
N 1
p
k
The broken arrows show the shear stresses (T) arising due to the torsion
T and solid arrows show the shear stresses (F) due to the force F.
Maximum shear stress (T + F) always occurs at the inner side of the
spring. Hence, failure of the spring, in the form of crake, is always
initiated from the inner radius of the spring.
The radius of the spring is given by D/2.
D Note that D is the mean
.is
Fx on the spring
diameter of the spring. The torque T
T acting
2
(1)
d 4
Ip
32
The shear stress in the spring wire due to torsion is
D d
F
Tr
2 2
T
d 4
Ip
32
.
(2)
F
4F
d 2 d 2
4
.
(3)
8 FD 4 F
T F
2
3
d
d
Or,
max
8FD
1
1
3
2D
d
or
max
8 FD
1
3
d
2C
Ks
max
8 FD
Ks
3
d
Ks 1
2
C
.
(4)
CURVATURE EFFECT
For springs where the wire diameter is comparable with the coil
diameter, in a given segment of the spring, the inside length of the
spring segment is relatively shorter than the outside length. Hence, for
a given magnitude of torsion, shearing strain is more in the inner
segment than the outer segment. This unequal shearing strain is called
the curvature effect. Curvature effect decreases with the increase in
spring index.
To take care of the curvature effect, the earlier equation for maximum
8FD
shear stress
in the
k spring wire is modified as,
max
d 3
Where, KW is Wahl
4C correction
1 0.165 factor, which takes care of both curvature
effect andkshear
stresscorrection factor and is expressed as,
w
4C 4
The spring rate, also called the scale of the spring, is k = F /y, and
so
8FDk
d 3
4c 1 0.615
4c 4
c
D
c
d
Spring index:
8 FD 3i
y ,
Axial deflection
Gd 4
Where i = number of active turns or coils
4. Free length
lo t n d y a
y = Maximum deflection
Clearance a = 25% of max
deflection
Assumed squared and ground end,
Number of additional coil, n = 2
F
Fo
y
6. Pitch
lo 2 d
t
Problem 1
A helical spring of wire diameter 6mm and spring
index 6 is acted by an initial load of 800N. After
compressing it further by 10mm the stress in the
wire is 500MPa. Find the number of active coils. G =
84000MPa.
Problem 2
Design a helical compression spring to support an
axial load of 3000 N. The deflection under load is
limited to 60mm. The spring index is 6.The spring is
made of chrome vanadium steel and factor of safety
is equal to 2
SPRING MATERIALS
Springs are manufactured either by hot- or cold-working processes.
Winding of the spring induces residual stresses through bending,
but, Quite frequently, they are relieved by a mild thermal
treatment.
The graph of tensile strength versus wire diameter is almost a
straight line for some materials when plotted on log-log paper with
SPRING MATERIALS