Unit VI DME I Springs

DME I Unit 6 Springs
Prof.Sachin P Dhavane(Sinhgad
Mechanical)
Syllabus
Mechanical)
Mechanical springs
Mechanical)
About Spring
A spring is defined as an elastic
body, whose function is to distort
when loaded and to recover its
original shape, when the load is
removed.
Applications:
Springs in clutches, brakes, spring
loaded valves, toys, clocks, vehicle
suspension systems.
Mechanical)
Types Of Springs
Mechanical)
Mechanical)
Mechanical)
HELICAL SPRINGS
The helical springs are made up of a wire coiled in
the form of a helix and is primarily intended for
compressive or tensile loads.
The cross-section of the wire from which the
spring is made may be circular, square or
rectangular. The two forms of helical springs are
compression helical spring as shown in Fig. (a)
and tension helical spring as shown in Fig.(b).
Mechanical)
Mechanical)
The helical springs have the following

advantages
1) Easy to manufacture.
2) Available in wide range.
3) Reliable.
4) Constant spring rate.
5) Performance can be predicted more
accurately.
Mechanical)
CONICAL AND VOLUTE SPRINGS

1. The conical spring, is wound with a uniform pitch.
2. The volute springs, are wound in the form of
paraboloid with constant pitch and lead angles.

3. Used in special applications where a telescoping
spring or a spring with a spring rate that increases

with the load is desired.
4. The major stresses produced in conical and volute
springs are also shear stresses due to twisting
Mechanical)
Conical and volute springs
Mechanical)
TYPES OF SPRINGS-TORSION SPRINGS
The
helical
type
may
be
used
only
in
applications where the load tends to wind up the

spring
and
are
used
in
various
electrical
mechanisms.
The spiral type is also used where the load
tends to increase the number of coils and when
made of flat strip are used in watches and
clocks.
The major stresses produced in torsion springs
are tensile and compressive
due to bending.
Mechanical)
Helical and Spiral torsion springs
Mechanical)
LAMINATED OR LEAF SPRINGS
The laminated or leaf spring (also known as

flat spring or carriage spring) consists of
a number of flat plates (known as leaves) of
varying lengths held together by means of
clamps and bolts.
These are mostly used in automobiles.
The major stresses produced in leaf springs
are tensile and compressive stresses
Mechanical)
Laminated Or Leaf
Springs
Mechanical)
DISC OR BELLEVILE SPRINGS

These springs consist of a number of conical
discs held together against slipping by a central

bolt or tube.
These springs are used in applications where
high spring rates and compact spring units are

required.
The major stresses produced in disc or bellevile
springs are tensile and compressive stresses.

Mechanical)
Disc Or Bellevile Springs
Mechanical)
TERMS USED IN COMPRESSION

SPRINGS
1.Solid Length (Ls):

When the spring is compressed until the coils touch
each other.
Mechanical)
2. Free Length (Lf)
A free length is the length when spring is in

uncompressed condition.
3. Active Coils : Which contributes to the spring

action
4. Inactive Coils : When the ends coils which are in
contact with seat do
not contribute spring action
Mechanical)
5. Spring index. The spring index is defined as the ratio of

the mean diameter of the coil to the diameter of the wire.
Mathematically,
C=D/d
Where
D = Mean diameter of the
coil, and
d = Diameter of the wire.
6. Spring rate :The spring rate (or stiffness or spring
constant) is defined as the load required per unit deflection
of the spring. Mathematically,
k=W/
where W = Load
= Deflection of the spring.
Mechanical)
7.Pitch: The pitch of the coil is defined as the axial

distance between adjacent coils in uncompressed state.
Mathematically,
Pitch of the coil, p = Free length / n 1
The pitch of the coil may also be obtained by using
the following relation, i.e.
where Lf = Free length of the spring,

LS = Solid length of the spring,
n' = Total number of coils, and
d = Diameter of the wire.
Mechanical)
Types Of Ends of Helical Compression

Springs
Mechanical)
Types Of Ends of Helical Compression

Springs
Let, n = Total no of coils or turns
n = no of active coils or turns p = pitch , mm d =
wire diameter.
Mechanical)
Material For Helical Springs

1. The springs are mostly made from oil-tempered
carbon steel wires containing 0.60 to 0.70 per cent
carbon and 0.60 to 1.0 per cent manganese.
2. Music wire is used for small springs. Non-ferrous
materials like phosphor bronze, beryllium copper,
monel metal, brass etc., may be used in special
cases to increase fatigue resistance, temperature
resistance and corrosion resistance.
3. The helical springs are either cold formed or hot
formed depending upon the size of the wire.
4. Wires of small sizes (less than 10 mm diameter) are
usually wound cold whereas larger size wires are
wound hot.
5. The strength of the wires varies with size, smaller
P Dhavane(Sinhgad
size wires have Prof.Sachin
greater
strength and less ductility,
Mechanical)
Material Properties For Helical Springs
A. The material of the spring should have high

fatigue
strength,
high
ductility,
high
resilience and it should be creep resistant. It

largely depends upon the service for which they are
used i.e. severe service, average service or light
service.
. Severe service
. Average service
. Light service
Mechanical)
Material Properties For Helical Springs

A. Severe
loading
service
where
means
the
ratio
rapid
of
continuous
minimum
to
maximum load (or stress) is one-half or less, as

in automotive valve springs.
B. Average service includes the same stress
range as in severe service but with only
intermittent operation, as in engine governor
springs
and
automobile
suspension
springs.
P Dhavane(Sinhgad
C. Light serviceProf.Sachin
includes
subjected to
Mechanical) springs
Material For Helical Springs

The values of allowable shear stress, modulus of rigidity and
modulus of elasticity for various materials used for springs.
Mechanical)
STRESSES IN HELICAL SPRINGS OF

CIRCULAR WIRE
Consider a helical compression spring made of circular
wire and subjected to an axial load W.
Let D = Mean diameter of the spring coil,
d = Diameter of the spring wire,
n = Number of active coils,
G = Modulus of rigidity for the spring material,
F = Axial force on the spring
= Maximum shear stress induced in the wire,
C = Spring index = D/d,
p = Pitch of the coils, and
= Deflection of the spring, as a result of an axial load

F.
Mechanical)
STRESSES IN HELICAL SPRINGS OF CIRCULAR

WIRE
Mechanical)
STRESSES IN HELICAL SPRINGS OF CIRCULAR

WIRE
Mechanical)
Stresses Induced In Spring Wire:

1)Torsional Shear Stress:
Torsional Shear Stress induced in a spring
wire due to torsional moment T=FD/2
D
16F
16T
8FD
2
t 3
3
d
d
d 3
2) Direct Shear Stress: Due to the direct shear

force F
Mechanical)
Stresses In Spring Wire
Mechanical)
Stresses Induced In Spring Wire:

3) Resultant Shear Stresses
8FD
4F
t s
3
2
d
d
8FD
d
[1
]
3
d
2D
8FD
0.5
[1
]
3
d
C
8FD
8FC
Ks Ks
3
d
d 2
Where
Ks shear stress correction factor
0.5
[1
]
C
Mechanical)
Stresses In Spring Wire
Mechanical)
4. Result Shear Stress with Curvature Effect :

Curvature of wires increases the shear stress on
inner surface of spring and decreases it slightly on
outer surface.
1. Wahl shear stress factor is used to consider effects of
direct shear stress and curvature effect stresses in
addition to torsional shear stress.
The maximum shear stress induced in a spring

wire is
Mechanical)
Mechanical)
Deflection Of Helical Springs

Spring Stiffness is given by K = F /
where F = Load
= Deflection of the
According
spring
to castiglianos theorem
8FC n
Gd
where n number of active coils
G modulus of rigidity
d wire diameter
Mechanical)
Spring Stiffness is given by K = F /
F
k
F
k
3
8FC n
Gd
Gd
k
3
8C n
Mechanical)
Mechanical)
Mechanical)
Problem
1.
Design
close
coiled
helical
compression spring with following data:

Service load range = 2250 N to 2750 N
Axial deflection of spring for load range= 6 mm
Spring Index = 5
Permissible shear stress for spring=420 N/mm2
Modulus of rigidity for spring material = 84 KN/mm2
Neglect the effect of stress concentration.( Assume
Square and Ground ends) Draw a dimensional sketch
of spring.
Given Data: Fmin= 2250 N Fmax=2750 N G=84
KN/mm2 C=5
Mechanical)
Problem 1
Solution:
Wire diam. d= 9.58 mm
Ls= ( n+2 )
d=112.32 mm
Mean coil diam. D=48 mm
Max.
Deflection=33 mm
Spring stiffness K=83.33N/mm
Lf=Ls + Max Defle. +
0.15 Max Defle

No of turns n=9.7 turns
=150.27
mm
Total no of turns n= n+2 =11.7 turns
Mechanical)
Lf= pn +2d
p= 13.5
Problem 2. A safety valve of 60mm diameter is to

blow off at a pressure of 1.2 Mpa. It is held on its seat
by closed coil helical spring. The maximum lift of the
valve is 10 mm. Design a suitable compression spring
of spring index 5 and providing an initial compression
of 35 mm. The maximum shear stress in the material
of the wire is limited to 500 N/mm2 while the modulus
of rigidity of spring material is 80000 N/mm2.Calculate
1) diameter of spring wire.
2) mean coil diameter 3)
no of active turns 4) pitch of coil. Assume Square and

Ground ends.
Given Data: dv=60 mmMechanical)

Pmax= 1.2 N/mm2
Springs In Series
Consider two springs connected in series as shown
in Fig.
W = Load carried by the springs,
1 = Deflection of spring 1,
2 = Deflection of spring 2,
k1 = Stiffness of spring 1 = W / 1, and
k2 = Stiffness of spring 2 = W / 2
A little consideration will show that when the
springs are connected in series, then the total

deflection produced by the springs is equal to the
sum of the deflections of

the individual springs.
Mechanical)
Springs In Series
Mechanical)
Springs In Parallel
Consider two springs connected in parallel as shown
in Fig
Let W = Load carried by the springs,
W1 = Load shared by
spring 1,
W2 = Load shared by
spring 2,
k1 = Stiffness of spring
1, and
Mechanical)
Springs In Parallel
A little consideration will show that
when the springs are connected in
parallel,
then
the
total
deflection
produced by the springs is same as the

deflection of the individual springs.
We know that W = W1 + W2
or .k = .k1 + .k2
k = k1 + k2
where k = Combined stiffness of the
springs, and
Mechanical)
= Deflection produced.
Concentric Or Composite Springs

1. To obtain greater spring force within a given space.
2.
To insure the operation of a mechanism in the

event of failure of one of the springs.
3. The concentric springs for the above two purposes

may have two or more springs and have the same
free lengths as and are compressed equally.
4. Such springs are used in automobile clutches,
valve springs in aircraft, heavy duty diesel engines
and rail-road car suspension systems.
Mechanical)

4. Sometimes concentric springs are used to
obtain a spring force which does not
increase
in
direct
relation
to
the
deflection but increases faster.

5.
Such
springs
are
made
of
different
lengths .The shorter spring begins to act

only after the longer spring is compressed
to a certain amount.
6.These springsProf.Sachin
are P Dhavane(Sinhgad
used in governors of
Mechanical)
A Carriage Suspension System Showing The Use Of

P Dhavane(Sinhgad
Concentric Springs Prof.Sachin
Mechanical)
Mechanical)
Mechanical)

Consider a concentric spring as .
W = Axial load,
W 1 = Load shared by outer spring
W2 = Load shared by inner spring
d1 = Diameter of outer spring,
d2 = Diameter of inner spring,
D1 = Mean diameter of outer spring,
D2 = Mean diameter of inner spring
1 = Deflection of outer spring,
2 = Deflection of inner spring,
n1 = Number of active turns of outer spring
n2 = Number of active turns of
inner spring.
Mechanical)
Problem 3: A concentric spring consists of two helical

compression springs one inside the other. The free
length of the outer spring is 15 mm greater than the
inner spring. The wire diameter and mean coil diameter
of inner spring are 5 mm and 30 mm respectively,
while wire diameter and mean coil diameter of outer
spring are 8 mm and 52 mm resp. Assume same
material for two spring and modulus of rigidity of spring
is 81370 N/mm2. If the composite spring is subjected to
maximum axial force of 1000 N. The inner spring and
outer spring has 8 and 10 active coils. calculate
i. The compression of each spring
ii. The force transmitted
Mechanical) by each spring; and
Problem 4: Two helical springs are arranged in a

concentric manner with one inside each other. Both
the springs have same free length and carry a total
load of 2000 N. The outer spring has 8 active coils
with mean coil diam. Of 80 mm and wire diam. Of 10
mm. The inner spring has 12 active coils with mean
coil diam. Of 64 mm and wire diam of 8mm
.G=81370 N/mm2. determine
i)
Max. load carried by each spring.
ii) Total deflection of each spring.

iii) Max. deflection in each spring.
Mechanical)
Solution: i)F1= 1304.3 N F2=695.7 N ii)def.=52.33
Leaf Springs
Leaf springs (also known as flat springs)
are made out of flat plates.
The advantage of leaf spring over helical

spring is that the ends of the spring may
be guided along a definite path as it
deflects to act as a structural member in
addition to energy absorbing device.
Thus the leaf springs may carry lateral

loads, brake torque,
driving torque etc., in
Mechanical)
Leaf Springs
Mechanical)
Nipping of Leaf Springs
Nipping: Process of pre stressing by giving

different
radii
of
curvature
before
assembly .
The Gap C between the full length leaf and
the graduated leaf before assembly is
called Nip.
Nip is adjusted so that under maximum
load condition the stresses in all leaves are
equal.
Mechanical)
Nipping Of Leaf Springs
Mechanical)
Surge In Springs
When one end of a helical spring is resting on a
rigid support and the other end is loaded suddenly,
then all the coils of the spring will not suddenly
deflect equally, because some time is required for
the propagation of stress along the spring wire.
A
little
consideration
will
show
that
in
the
beginning, the end coils of the spring in contact

with the applied load takes up whole of the
deflection and then it transmits a large part of its
deflection to the adjacent coils.
In this way, a Prof.Sachin
wave P of
compression propagates
Dhavane(Sinhgad
Mechanical)
Surge In Springs
This wave of compression travels along the spring
indefinitely.
If the applied load is of fluctuating
type as in the case of valve spring in internal

combustion engines and if the time interval between
the load applications is equal to the time required for
the wave to travel from one end to the other end,
then resonance will occur.
This results in very large deflections of the coils and
correspondingly very
high stresses. Under these
conditions, it is just possible that the spring may fail.

This phenomenon is
called
surge.
Mechanical)
Failure Of Valve Spring Due To Surge In Springs
Mechanical)
Shot Peening
Under fatigue loading of springs the poor
surface
finish
reduces
the
endurance
strength.
So spring surface becomes irregular which
acts as source for stress concentration. The
fatigue cracks begins at such points and
propogates leading to failure of springs.
In order to reduce the chances of failure due
to surface cracks , a residual compressive
Mechanical)
stress is induced in the surface of spring wire .
Shot Peening In Springs
Mechanical)
Shot Peening In Springs
Mechanical)
Shot Peening
Shot peening is used for inducing the residual
compressive stress.
The surface is bombarded with high velocity
iron or steel shots (balls) discharged from a
rotating wheel or pneumatic nozzle.
It increases the area of exposed surface which
creates a layer of residual compressive stress
on the surface.
Shot peening improves the fatigue strength.
Mechanical)
InSem QP Backlog 2015
Mechanical)
InSem QP Backlog 2015
Mechanical)

Unit VI DME I Springs

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Unit VI DME I Springs

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DME I Unit 6 Springs

The helical springs have the following

CONICAL AND VOLUTE SPRINGS

paraboloid with constant pitch and lead angles.

spring or a spring with a spring rate that increases

springs are also shear stresses due to twisting

Conical and volute springs

TYPES OF SPRINGS-TORSION SPRINGS

applications where the load tends to wind up the

Helical and Spiral torsion springs

LAMINATED OR LEAF SPRINGS

The laminated or leaf spring (also known as

DISC OR BELLEVILE SPRINGS

discs held together against slipping by a central

high spring rates and compact spring units are

springs are tensile and compressive stresses.

Disc Or Bellevile Springs

TERMS USED IN COMPRESSION

1.Solid Length (Ls):

2. Free Length (Lf)

A free length is the length when spring is in

3. Active Coils : Which contributes to the spring

5. Spring index. The spring index is defined as the ratio of

7.Pitch: The pitch of the coil is defined as the axial

the following relation, i.e.

where Lf = Free length of the spring,

Types Of Ends of Helical Compression

Types Of Ends of Helical Compression

Material For Helical Springs

Material Properties For Helical Springs

A. The material of the spring should have high

resilience and it should be creep resistant. It

Material Properties For Helical Springs

maximum load (or stress) is one-half or less, as

Material For Helical Springs

STRESSES IN HELICAL SPRINGS OF

p = Pitch of the coils, and

= Deflection of the spring, as a result of an axial load

STRESSES IN HELICAL SPRINGS OF CIRCULAR

STRESSES IN HELICAL SPRINGS OF CIRCULAR

Stresses Induced In Spring Wire:

2) Direct Shear Stress: Due to the direct shear

Stresses In Spring Wire

Stresses Induced In Spring Wire:

Stresses In Spring Wire

4. Result Shear Stress with Curvature Effect :

The maximum shear stress induced in a spring

Deflection Of Helical Springs

Spring Stiffness is given by K = F /

compression spring with following data:

Lf=Ls + Max Defle. +

0.15 Max Defle

Problem 2. A safety valve of 60mm diameter is to

2) mean coil diameter 3)

no of active turns 4) pitch of coil. Assume Square and

Given Data: dv=60 mmMechanical)

A little consideration will show that when the

springs are connected in series, then the total

sum of the deflections of

produced by the springs is same as the

Concentric Or Composite Springs

To insure the operation of a mechanism in the

3. The concentric springs for the above two purposes

Concentric Or Composite Springs