EPORTERS:

LIZAR LUENGAS
EXIE JOHN LUGATIMAN
AY MACABENTA
EINA ANN MACABUDBUD
OHN MICHAEL MACALINAO

SPRING

WHAT IS SPRING

A spring is an elastic object used to store mechanical

energy. Springs are usually made out of spring steel. Small
springs can be wound from pre-hardened stock, while larger
ones are made from annealed steel and hardened after
fabrication. Some non-ferrous metals are also used including
phosphor bronze and titanium for parts requiring corrosion
resistance and beryllium copper for springs carrying electrical
current (because of its low electrical resistance).

USES OF SPRINGS
To absorb energy or shock loads,( as in
automobile chassis springs and rail road
bumper springs)
To act as a source of energy, (as in clocks)
To produce a pressure of force,(as in
maintaining pressure between the friction
surfaces of clutches and as in keeping calm
follower in contact with the cam)
To absorb vibrations

SPRING EXAMPLES

Helical or coil springs designed for tension

Compression springs store energy when

compressed

The English longbow a simple but very powerful spring

made of yew, measuring 2m (6ft 6in) long, with a 470
N (105lbf) draw force

A volute spring. Under compression the

coils slide over each other, so affording
longer travel.

Leaf spring on a truck

NOMENCLATURE OF HELICAL
SPRING

C = Spring Index
/
= wire diameter (m)
D = Spring diameter (m)
Di = Spring inside diameter (m)
= Spring inside diameter (loaded ) (m)
E = Young's Modulus (N/m)
F = Axial Force (N)
G = Modulus of Rigidity (N/m)
K W = Wahl Factor = [(4C-1)/(4C+5)}]+ (0,615/C)
L = Free Length (m)
SH= Solid Height (m)
= Total number of coils
= Number of active coils
P = pitch (m)
y = distance from neutral axis to outer fiber of wire (m)
= shear stress (N/m2)
= Max shear stress (N/m)
= Deflection (radians)

SPRING SYSTEM
F = F1 = F2 = F3
= 1 + 2 + 3
PARALLEL
SYSTEM

F = F1 = F2 = F3
= 1 + 2 + 3

Before Impact
After
Impact
By conservation of energy:
P.E. = E. absorbed by the spring
W (h + ) =

Where:
K= wahls factor
Dm= mean coil diameter
Dw= wire size
F= axial load on the
spring

Wahls factor

C=Dm/ Dw

called the spring

index

EFFECT OF END TREATMENT.

THE MODULE CALCULATES THE FOLLOWING

DESIGN PARAMETERS:

1. Outer Diameter (Do)

5. Maximum load

2. Spring Index (C)

6. Corrected maximum stress

index range is 4 to 12
3. Slenderness ratio

7. Uncorrect maximum stress

4. Spring rate (k)

8. Wahl correction factor

9. Maximum deflection

12. Shear stress

10. Spring mass

13. uncorrected
Shear stress

11. Wire length

14. Natural frequency

SOLID HEIGHT AND FREE

LENGTH.
The solid height of a coil is the over-all length of
the springs when it is compressed until all adjacent
coils touch.
The free length is the length of a coil spring
under no load.

DESIGN OF HELICAL SPRINGS.

A helical spring is a spiral wound wire with a constant coil
diameter and uniform pitch. The most common form of helical
spring is the compression spring but tension springs are also
widely used. Helical springs are generally made from round
wire. It is comparatively rare for springs to be made from
square or rectangular sections. The strength of the steel used
is one of the most important criteria to consider in designing
springs. Most helical springs are mass produced by specialists
organizations. It is not recommended that springs are made
specifically for applications if off-the-shelf springs can be
obtained to the job.

The design of a new spring involves the following

considerations:
Space into which the spring must fit and operate.
Values of working forces and deflections.
Accuracy and reliability needed.
Tolerances and permissible variations in specifications.
Environmental conditions such as temperature, presence of a
corrosive atmosphere.
Cost and qualities needed.

The designers use these factors to select a material and

specify suitable values for the wire size, the number of turns,
the coil diameter and the free length, type of ends and the
spring rate needed to satisfy working force deflection
requirements. The primary design constraints are that the
wire size should be commercially available and that the stress
at the solid length be no longer greater than the tensional
yield strength. Further functioning of the spring should be
stable.

AVERAGE
SERVICE
Design a helical spring with squared-and-ground ends to

withstand a maximum force of F=250 lb with a deflection of

1.5 in. The maximum number of applications of F is expected to
be about 10;say average service. The spring is to operate over
a 1 in . rod, with a free length of 7 in if possible. Use hard
drawn wire.

NOTE: FROM Fig. AF 15, Assume

k=1.3; and Try
;
FROM Table 17 Use,

from design stress of Light Load, Use 0.85 times constant. So,

EQUATE SHEARING STRESS AND DESIGN STRESS to

get the Wire Dia Dw,

ROM TABLE AT 15, the nearest W & M is Gage No. 2-0 =

in.
Dm-Dw) = 2-0.331 = 1.669 in.

INDEFINITE SERVICE
The load on a compression spring varies from 158 to 516
lb. The mean diameter of the coil is Dm=1 in., and the design
factor is to be 1.3 based on the wahl line. If the material is
oil-tempered carbon steel, what size wire should be used?

SOLUTION
FROM TABLE AT 17, Assume value of K & Ks
AND ERROR: From Fig AF 15 we assume k=1.48; c=3.5; kc=1.29

Fm =
Fu
=
Sms=

Sus
=

FROM TABLE AT 17

ps
=
i
= ps
i

FROM FORMULA:

Find the Clearance (bet. Spring & the in. rod) = 1.669= 0.044 in
; k=1.25 From Fig AF 15
(Round Wire)

The Spring Index is

omputed INDUCED STRESS: FROM,

ompared to the DESIGN STRESS;

We find that Design Stress > Induced Stress, the Wire Size found is
strength.
;
ND:satisfactory
N (No. of for
Coils)=
c

G=11.5x

Nc =

TABLE AT 16, SH = Dm(Nc+2) = 0.331(13+2) = 4.97 in

FOR A SPRING SCALE
of k =
Fc = k(L-SH) = 167(7-4.97) = 339.01 lb.
;
we need Equate
To find
so,
S=F;
To find the
Pitch =

Find Pitch Angle:

Therefore, Do = Dm + Dw =
2.331 in

=
4.5

MATERIALS USED FOR

COIL SPRINGS
Hard-drawn spring wire (ASTM A227) is a low cost material;
sizes, o.o28 to about 9/16 in.; suitable where service is not
severe and dimensional precision is not needed; wound cold;
0.45 to 0.75%C; not used for indefinite life. The quality of the
surface is lower (with, say,hairline seams) than for the other
grades ( 6.13).
Music Wire (ASTM A228) is hard drawn also (80%reduction),
but it is made of high-grade steel; excellent surface,
comparable to valve-spring quality, 0.7 to 1.0%C; wound cold;
sizes, 0.004 to 0.156 in. It is the best materials available in
sizes below about in.

Oil-tempered springs wire (ASTM A229) is cold drawn to

sizes(reduction 50-70%) and then hardened and tempered
(pretempered; 0.55-0.75%C; usually wound cold and stress
relieved at low temperature, say 450F ; sizes 0.225 to 0.5.
Its surface is noty the best but it is significantly better than
hard-drawn wire.
Valve-spring-quality (VSQ) carbon steel (ASTM 230) is
the highest quality oil-tempered wire; 0.60-0.75%C. Since it
has an excellent surface, valve-spring quality is the most
reliable (with music wire) for fatigue and is thus used for the
most severe service; size 0.093 to 0.375 in.

Chromium-canadium steel (ASTM 231) is oil tempered; 0.45

to 0.55%C;sizes, 0.28 to 0.375 in. The alloy steels are
superiorto carbon steels of the same quality above about
250F .Valve-spring-quality Cr-V (ASTM 232) has the best
commercial surface;sizes 0.032 to 0.437 in.
Chromium-silicon (ASTM 401), good quality for impact loads
and moderately high temperature (perhaps to 450F ,
depending on the permissible amnt of relaxation).
Steenless Steel, type 302 (Chromium-nickel, ASTM A313) is
corrosions resistant and readily available; sizes 0.009 to 0.375
in. It is cold drawn and its relaxation at higher temperatures
is much less than the grades described above.Steenless steel
wire with strengths comparable to or better than music wire is
available.

FACTORS AFFECTING FATIGUE

STRENGTH OF COIL SPRINGS

If the number of cycles of loading is small (light service

), the computed stress in the wire may be relatively high, and
normal surface defects may not be significant. When fatigue
is involved, the surface condition is primary. Any slight flaw
such as seams, pits, die marks, hardening cracks, inclusions, or
an accidental scratched spot, may result in fatigue failure.
For unpeened springs of high-quality carbon steel, some
engineers let the maximum stress be 90 ksi with a range of 70
ksi; if peened, the max stress may be 110 ksi.

RELAXATION OF SPRING
MATERIALS
The relaxation is sometimes measured by the amount of
the loss of force exerted by the spring at a particular
deflection, sometimes by the change of deflection for a
particular load.
Springs may be preset at a temperature and stress above
operating values, which removes the set.

 EXAMPLE:
The load loss of carbon valve spring steel at a stress of 80
ksi is about 3% at 250 F, 5% at 300 F, 6% at 350 F, 7.5% at
400 F. Normal limiting temperature of operation are: 400 F of
carbon steel, 550F for 18-8 stainless steel, 700F for Inconel,
500F for Monel, 200F for phosphor bronze. Note that springs
rate is significantly lower at high temperatures ( via decrease
of G,E)

SPRING MATERIAL

When selecting a spring material, many factors come into

play. Cost is usually a factor, as well as, tensile strength,
quality, operating temperature, and corrosion resistance.
The most common spring materials are listed below:

Type
Wire

Usage

Hard
Draw
n
ASTM
A227

Usually the least expensive material. Hard Drawn is

used for lower cost, lower stress springs, not subject
to shock, high temperature, or cyclic loading

Oil
Temp
ered
ASTM
A 229

General purpose spring wire. Cold drawn,

thenquenched and tempered after drawing, in order
to get the required tensile strength. The heat
treatment process allows higher tensile strength than
Hard Drawn in the larger wire sizes. The quench and
temper also has the advantage of creating a very
straight material

Usage
Wire
Type

Music
Wire
ASTM
A 228
Chro
me
Silico
n
ASTM
A 401

Cold drawn to create the tensile strength. High

tensile and very high quality and consistency.
Suitable for cyclic applications
An alloy spring steel, heat treated after
drawing to generate tensile strength. Very
straight like Oil Tempered. High tensile
strength and high quality material suitable for
cyclic applications and higher temperatures
and higher shock than Music Wire. Not suitable
for any type of electroplating or acid cleaning
due to a high susceptibility to hydrogen
embrittlement. Valve quality grade is available
special order providing even

TOLERANCES
In a particular application, the designer use close
tolerances only where such tolerances are significant. The
significant dimension might be the outside coil diameter , the
inside coil diameter , or the free length.
The minimum tolerance on force for hot coiled as rolled rod
should be about 10% and for small wire, say under about 0.32
in., the tolerance may need to be larger for economic reasons,
because the percentage variation of Dw will be larger.

SURGE IN SPRINGS
When there are impact loads on the springs, the stress
propagates along the spring wire. The end coil 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. This wave of compression travels along the
spring indefinitely. Resonance will occur depending upon time
traveled. This results in very large deflections and
correspondingly very high stresses. Under these conditions, it
is just possible that the spring may fail. This phenomenon is
called surge.

The lowest natural frequency (first harmonic) of a spring is

given by:

cycles per unit time.

Where:
k- spring scale
m- mass of the active coils
k and m in consistent units

The mass of active coil is:

m=lb
Where is in lb/cu. in and the other dimensions
in inches. Using the value of k from the
equation(6.2), the equation for becomes

m=

cps

COMPRESSION COILED
SPRINGS WITH RECTANGULAR
WIRE
Wahl gives the following formula for the maximum
shearing stress in a spring of rectangular wire when the
dimension b of the rectangle is parallel to the axis of
the spring (and b/t < 3 if b is the larger dimension):

For a small pitch angle (<10),approximately

For a spring of square wire (b=t).

EXTENSION SPRINGS
Are generally wound with the coils pressing
against each other.

TORSION SPRINGS
is one that resist a moment tending to wind up the spring.
the torque is T= F a =M
the flexural stress is
for round wire

for rectangular wire

The angular deflection of a torsion spring

subjected to opposing moments T = radians
radians,
where the length of active coils
;I is
the rectangular moment of inertia of the
section of the wire taken as a beam.

For torsion springs hot-wound from rods,

the equations

s=
[SAE 1080 ]

and

s=

[6150 AND 9260]

Agarter springis acoil springtied end-to-end to provide

a even force around an object. They are often used to
maintain the function ofradial shaft sealsby keeping
theelastomericsealstight against the shaft as it
moves and the seal is worn away.

Motor springs are locked to a shaft with a catch, and to a

pin or housing edge. This design can give 10-20 turns of
spring force.

A fine coiled spring that regulates the movement of the

balance wheel in a watch or clock.

AVolute springis a compressionspringin the form of a

cone (aVolute). Under compression, the coils slide past
each other, thus enabling the spring to be compressed
to a very short length in comparison to what would be
possible with a more conventionalhelixspring.

Conicalspiralspringis always used for sofa cushion and

so on . we can design and customize springs for your
special needs..

Belleville springorcupped spring washer, is a type of

springshaped like awasher. It has afrustoconicolshape which gives the washer a spring
characteristic.

LEAF SPRINGS
If the flat spring of uniform strength just describe are
divided and assembled , the same stress and deflection
formulas apply, friction between the leaves neglected.
(Note: Friction results in the computations being inherently
less accurate than those for coil spring.)
The result obtained is a leaf spring with all leaves of the same
thickness:
formula: b = Nb
Where:
b sum of the width of the leaves
N number of leaves
b width of the leaves

FORMULAS:
from fig. 6.20 :

from fig. 6.21:

A Camber is frequently made such that the

main leaf is nearly straight under load.
An approximation of actual semielliptic springs
which can be presented easily is the trapezoidal
spring.
For which:

an
d

FATIGUE OF LEAF SPRING

Leaf springs often have holes or notches that are points
of stress concentration, and the principles of CHAPTER 4
apply. Even though the clamping action of the center bolt and
U-clips reduces the bending stresses at the action of the bolt
hole, it would be on the safe side to check this section in
accordance with fatigue procedures when the load is repeated.
Rubbing of the leaves is conducive to fretting corrosion.

Materials used:
For leaf springs;
SAE 1080, 1095, 5155-60, 6150-60 & 9250-60
For flat springs;
bronze, beryllium, copper, stainless steel, inconel, clad
stainless & carbon steels
Maximum design stresses for 10 cycles SAE 1095
flat
& leaf springs, as function of thickness are:
155 ksi for t = 0.005 in.
140 ksi for t= 0.010 in.
130 ksi for t= 0.020 in.

125 ksi for t= 0.030 in.

120 ksi for t= 0.040 in.
105 ksi for t= 0.060 in.
100 ksi for t= 0.090 in.

GENERAL REMARKS ON LEAF

SPRINGS
A common practice is to bend the leaves to different radii
of curvature, the radius decreasing on the shorter leaves, the
leaves are said to be nipped or to have nip.
(Note: That when the leaves are pulled tightly together ( by
the center bolt), the main leaf is bent opposite to the
direction that the working load will bend it).

Another idea for improving the load capacity of the main

leaf is to make it thinner than the others. Using the elastic
curve equation of a straight beam
M= EI/r and stress equation M= sI/c, we get s= Ec/r,
where r is directly proportional to the thickness of the leaf
(2c).

SAMPLE PROBLEM

271. A solenoid brake (Fig. 18.2, Text) is to be actuated by a helical

compression spring. The spring should have a free length of
approximately 18 in. and is to exert a maximum force of 2850 lb. when
compressed to a length of 15 in. The outside diameter must not exceed 7
in. Using oil-tempered wire, design a spring for this brake, (wire diameter,
coil diameter, number of active coils, pitch, pitch angle, solid stress).
General Electric used a spring made of 1 in. wire, with an outside
diameter of 6 in., and 11 free coils for a similar
application.

Solution:
Mean Diameter, Dm
For oil- tempered wire (TABLE AT 16)
(0.002<<0.5)
SOLID STRESS = 0.6SU

DESIGN STRESS [average service] (TABLE AT 17)

Ssd =0.324SU

Ssd

kips

DW + D m 7
F = 2850 lb = 2.85 kips
(say k = 1.3)

DW 7 - D m
Dm = 5.96 in. in.
Do = 6 + 0.5 = 6.5 7

Finding DW of the given problem to find the spring index (C) : D W

DW = 1.015 in.
Therefore:

C = 5.87
So: from (figure AF 15) we find k = 1.28

Dm = 5.99 in.

ans.

b.) Nc (number of coils)

= 18 in. 15 in. = 3 in.

And (we used Dw = 7-Dm= 7-5.99 = 1.01)
for oil tempered wire from TABLE AT 17 & G = 11500 ksi

NC = 8
c.) Permissible Solid Stress
Sso = 0.6 SU =
Sso = 31.49 ksi

d.) Pitch
= (P 1) Nc
3 = (P 1) 8
P = 1.375 in.
e.) Pitch angle ()
tan =
= 4.17

Fin (^_^)