Spring Design Ii: Prepared and Presented by

SPRING DESIGN II
PREPARED AND PRESENTED BY:

MANOJ ADHIKARI
HELICAL COMPRESSION SPRING DESIGN
FOR STATIC SERVICE
◦ Preffered range of spring index is 4 ≤ 𝐶 ≤ 12
◦ Recommended range of active turns is 3 ≤ 𝑁𝑎 ≤ 15
◦ The spring force is not reproducible for very small deflections, and near closure non linear behavior
begins as number of active turns diminishes as coil begins to touch designer confines the spring’s
operating point to the central 75 % of the curve between no load 𝐹 = 0 and closure 𝐹 = 𝐹𝑠 .
◦ The maximum operating force is limited to 𝐹𝑚𝑎𝑥 ≤ 7Τ8 𝐹𝑠 .
◦ Defining the fractional overrun to closure as 𝜉, where 𝐹𝑠 = (1 + 𝜉)𝐹𝑚𝑎𝑥
◦ It is recommended that 𝜉 ≥ 0.15
◦ Factor of safety 𝑛𝑠 ≥ 1.2
◦ Figure of merit, 𝑓𝑜𝑚 = 𝑟𝑒𝑙𝑎𝑡𝑖𝑣𝑒 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑐𝑜𝑠𝑡 ∗ 𝑚𝑎𝑠𝑠
4 ≤ 𝐶 ≤ 12 3 ≤ 𝑁𝑎 ≤ 15 𝑛𝑠 ≥ 1.2 buckling
𝑆𝑠𝑦
𝑛𝑠 =
𝜏𝑠 8𝐷𝐹𝑠
𝜏𝑠 = 𝐾𝐵
𝑆𝑠𝑦 = 0.35𝑆𝑢𝑡 𝜋𝑑 3 𝐹𝑠 = 𝑘𝑦𝑠
𝐴 4𝐶 + 2
𝑆𝑢𝑡 = 𝐹
𝑑𝑚 𝐾𝐵 = 𝑘=
4𝐶 − 3 𝑦
Since, our diameter restriction goes from 0.2 to 3.2 mm we will need two sets of values
CRITICAL FRQUENCY OF HELICAL
SPRING 𝐹=
1
4
𝑘𝑔
𝑊
One end against flat
plate and other free
Weight of active part of helical spring
◦ If one end of a helical compression spring is held against a
flat surface and the other end is disturbed, a compression
wave is created that travels back and forth from one end 𝛾 is specific weight
to the other. It is called spring surge.
◦ When helical springs are used in applications requiring a
rapid reciprocating motion, the designer must be certain
that the physical dimension of the spring are not such as to
create a natural vibratory frequency close to the applied
force. Otherwise, resonance may occur, resulting in
damaging stresses, since the internal damping of the
material is quite low.
◦ Natural frequency depends on material properties and
how you support the spring The fundamental critical frequency
should be greater than 15 to 20 times
1 𝑘𝑔 the frequency of the force or motion
𝐹= 2 𝑊 of the spring in order to avoid resonance
Spring supports between flat parallel plates with the harmonics. Fracture is along the 450 line of maximum principal stress
associated with pure torsional loading
FATIGUE LOADING OF HELICAL
COMPRESSION SPRINGS
In some cases the number of cycles of required life may be small whereas in some cases the spring
must sustain millions of cycles of operation without failure; so it must be designed for infinite life.
COMPRESSION SPRINGS
◦ In case of shafts and many other machine members, fatigue loading in the form of completely reversed
stresses is quite ordinary.
◦ Helical spring, on the other hand, are never used as both compression and extension springs.
◦ In fact they are usually assembled with a preload so that the working load is additional. Thus the stress-
time diagram of figure express the usual condition for helical springs.
◦ Now we define
𝐹𝑚𝑎𝑥 −𝐹𝑚𝑖𝑛 𝐹𝑚𝑎𝑥 +𝐹𝑚𝑖𝑛
𝐹𝑎 = 𝐹𝑚 =
2 2
Also the shear stress amplitude and mid range stress is,
8𝐹𝑎 𝐷 8𝐹𝑚 𝐷
𝜏𝑎 = 𝐾𝐵 𝜏𝑚 = 𝐾𝐵
𝜋𝑑 3 𝜋𝑑 3
Where 𝐾𝐵 is a Bergstrasser factor , and corrects for both direct shear and
The curvature effect.
COMPRESSION SPRINGS
◦ The best data on torsional endurance limits of spring steels are those reported by Zimmerli. He discovered
the surprising fact that size, material, and tensile strength have no effect on the endurance limits (infinite
life only) of spring steels in sizes under 10 mm (3/8 in). zimmerli suggests that it must be because the
original surfaces are alike or because plastic flow during testing makes them the same.
◦ To improve fatigue strength of dynamically loaded springs, shot peening can be used. It can increase
the torsional fatigue strength by 20 percent or more.
◦ Unpeened springs were tested from a minimum torsional stress of 20 kpsi to a maximum of 90 kpsi and
peened springs in the range 20 kpsi to 135 kpsi. The corresponding endurance strength components for
infinite life are found to be
COMPRESSION SPRINGS
In constructing certain failure criteria on the

designers’ torsional fatigue diagram, the torsional
modulus of rupture 𝑆𝑠𝑢 is needed
𝑆𝑠𝑢 = 0.67𝑆𝑢𝑡
COMPRESSION SPRINGS
◦ An extended study of available literature regarding torsional fatigue found that for polished, notch free,
cylindrical specimens subjected to torsional shear stress, the maximum alternating stress that may be
imposed without causing failure is constant and independent of the mean stress in the cycle provided
that the maximum stress range does not equal or exceed the torsional yield strength of the metal.
◦ With notches and abrupt section changes this consistency is not found. Springs are free of notches and
surfaces are often very smooth.
◦ This failure criterion is known as the Sines failure criterion in torsional fatigue.
𝐷 4𝐶 + 2
𝐷 = 𝐷0 − 𝑑 𝐶= 𝐾𝐵 =
𝑑 4𝐶 − 3

Spring Design Ii: Prepared and Presented by

Uploaded by

Copyright:

Available Formats

Spring Design Ii: Prepared and Presented by

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Spring Design Ii: Prepared and Presented by

Uploaded by

Copyright:

Available Formats

SPRING DESIGN II

PREPARED AND PRESENTED BY:

In constructing certain failure criteria on the

You might also like