IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)

e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 11, Issue 6 Ver. III (Nov- Dec. 2014), PP 05-11
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Design, Analysis and Experimental Validation for Fatigue

Behavior of a Helical Compression Spring Used For a Two
Wheeler Horn
Mr. J. J. Pharne1, Dr. R.G.Todkar2, Dr.N.D.Sangle3
Lecturer, Dept. of Mechanical Engg., Nanasaheb Mahadik Polytechnic Institute, Peth, Sangli – India)
1(
2(
Prof. Dept. of Mechanical Engg. ,Annasaheb Dange College of Engineering and Technology, Ashta, Sangli
India)
3(
Prof. Dept. of Mathematics, Annasaheb Dange College of Engineering and Technology, Ashta, Sangli- India)

Abstract: Almost all two-wheelers are provided with a facility of a horn to be used to make aware of the
presence of the vehicle on road and to maintain a safe distance between two vehicles or to communicate for any
other safety reasons. The horn is a crucial element as it is directly related to safety of the vehicle and the person
using it. Thus the horn is most important element in the vehicle system and hence it is expected to function
properly for a longer time. Most problems of failure of two wheeler horns are due to fatigue failure of spring
element in warranty period. A finite element model for helical compression springs subjected to cyclic loads
(compression) is developed for fatigue stress analysis. In the design modification of this kind of spring both the
elastic characteristics and the fatigue strength have to be considered as significant aspects. A typical helical
compression spring used for two wheeler horn is chosen for study under fatigue loading condition. Fatigue
analysis is done in ANSYS 14.0 software. The results developed have been compared with the experimental
observations. A new design modification is done by introducing another spring coaxially.
Keywords: ANSYS 14.0, Finite Element Analysis, Helical compression spring, Fatigue life, Stress analysis.

I. Introduction
Springs are mainly used in many devices as members absorbing shock energy as well as for restoring
the initial position of a machine component upon displacement for obtaining a given function. Compression
springs or coil springs are those which resist compressive forces applied axially. Helical compression springs
are crucial components of in many devices including two-wheeler horn system where they are expected to work
for a longer life i.e. for more than 106 numbers of cycles. Almost all two-wheelers are provided with a facility of
a horn to be used to make aware of the presence of two wheeler on road and to maintain a safe distance between
two vehicles or to communicate for any other safety reasons. The horn is a crucial element as it is directly
related to safety of the vehicle and the person using it. Hence, fatigue failure analysis and life prediction of the
helical compression springs used for horns in two wheeler application plays important in order to verify the safe
working of horn system during its operational life. Many theoretical and experimental investigations for fatigue
failure of helical compression springs have been reported in recent literature. However there is a room for
fatigue failure analysis and life prediction of the helical compression springs used for horns in two wheeler
applications.
R.K. Luo et. al. [1] has presented a study on fatigue failure of anti-vibration springs, involving both
metal and rubber materials based on the actual fatigue loads using continuum mechanics method for the
analysis. The investigation, based on the actual fatigue loads, is carried out on these failed and modified
products using a method of continuum mechanics including simulation. It is shown that this approach can be
employed at a design stage for both metal and rubber fatigue evaluations on anti-vibration springs.
Sid Ali Kaoua et. al. [2] have reported a 3D geometric modeling of a twin helical spring and its finite
element analysis to study the spring mechanical behavior under tensile axial loading .A finite element analysis
of the mechanical behavior of the twin helical spring under uni-axial tensile load is presented for comparison
against those obtained from a theoretical approach based on a transformation of curvilinear coordinates. The is
values of von-Mises equivalent stresses have also been determine and compared with those obtained from a
theoretical approach based on a transformation of curvilinear coordinates It has been shown that numerical
normal stress evolution along the reference fibers (internal radial fibers and external ones) follows a sinusoidal
form, and matching those gathered through the theoretical alternative. The advantage of numerical approach
related to the ability to access nodal data (internally) so that stress fields (normal, principal and Von-Mises) can
be visualized.
C. Madan Mohan Reddy et al [3] have discussed modeling, analysis and testing of suspension spring
to replace the existed steel helical spring used in popular two wheeler vehicle for reduction in stress and

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 Design, Analysis and Experimental Validation for Fatigue Behavior of a Helical Compression …..

deflections of the helical using the new material. The comparative study is carried out between existed spring
and new material spring. Static analysis determines the stress and deflections of the helical compression spring
in finite element analysis. The testing proto type is used to test the spring under different loading conditions.
Results obtained using experimental investigation is compared with those obtained using FEA and analytical
procedure. It has been shown that i) the maximum shear stress of chrome vanadium steel spring has 13-17% less
with compare to hard drawn steel spring. ii) The deflection pattern of the chrome vanadium steel spring 10%less
at specified weight with compare to the hard drawn steel spring. iii) It is observed that 95% of the similarity in
deflection pattern and 97% similarity in shear stress pattern between experimental values to the analytical
values. iv) it is observed that 60%similarity in between theoretical values of deflection to the experimental
values and 85% similarity in maximum shear stress of spring.
V. K. Aher and P. M. Sonawane [4] presented fatigue analysis of a modified steel leaf spring of a light
commercial vehicle (LCV). The non-linear static analysis of 2D model of the leaf spring is performed using
NASTRAN solver and compared with analytical results. The fatigue life of the leaf spring is also predicted
using MSC Fatigue software. It is shown that the study will help to understand more the behavior of the spring
and give information for the manufacturer to improve the fatigue life of the spring using CAE tools. It can help
to reduce cost and times in research and development of new product.
Tausif M. Mulla et al [5] presented stress analysis of a helical coil compression spring, which is
employed in three wheeler’s auto-rickshaw belonging to the medium segment of the Indian automotive market.
The static stress analysis using finite element method has been presented.. The elastic behavior and the stress
analysis of springs employed in the TWV’s front automotive suspension have been presented and discussed in
this paper. The results obtained by a fully 3D FE analysis also highlighted the poor accuracy that can be
provided by the classical spring model when dealing with these spring geometries. Relative errors on maximum
shear stress ranging from 1.5 to 4 per cent, with reference to the applied loads, obtained when compared with
the values calculated by using simple analytical model which is found in textbooks. It shows that the shear stress
is having maximum value at the inner side of the every coil. The distribution of the stress is similar in every coil.
This shows that probability of failure of spring in every coil is same except end turns. In such case residual
stress in every coil may be important factor which influence the failure.
W.G. Jiang and J.L. Henshall [6] presented a general and accurate finite element model for helical
springs subject to axial loads (extension or/and torsion). Due to the establishment of precise boundary
conditions, only a slice of the wire cross-section needs to be modeled; hence, more accurate results can be
achieved. Due to the establishment of precise boundary conditions, only a slice of the wire cross-section needs
to be modeled; hence, more accurate results can be achieved In general, in has been shown that the FEM results
agree well with the analytical models for the tension and torsion springs as the helical angle and the ratio of wire
radius to coil radius tend to zero. On the contrary, as a and R/R. increase, the discrepancy between the FEM
results and analytical theory increase, probably due to neglecting the high-order terms in the series expansions.
The advantages of the present model incorporating helical boundary conditions are not only its accuracy and
conciseness, but also that it can be directly extended to model helical springs with arbitrary cross-sections, and
material nonlinearity and large deformation ejects can also be conveniently incorporated into the analysis by a
multi-step loading process.
The springs used in the bogie suspension of railway coaches are compression springs. They are made
of an elastic wire material formed into the shape of a helix. M. Sudhakar Reddy and B. Madhusudhan Reddy [7]
presented a study on springs used in the bogie suspension of railway coaches. It is observed that springs used in
railway coaches fail prematurely much before their intended service life. Before being put to service, the springs
are tested with extensive Non Destructive Testing Methods which are approved by ISO standards to make sure
that quality parts are used. However the springs still fail before their service life ends. To study the dynamic
behavior of the springs, 3D solid model of helical springs are modeled with PRO/E. Static and Dynamic stress
analysis are carried out using ANSYS to understand the Structural and Dynamic response of the springs. Spring
behavior has been observed under prescribed or expected loads. Based on the results design modifications has
been suggested for better life without failure in service.
Y. Prawoto a et al [8] presented a study on automotive suspension coil springs, their fundamental stress
distribution, materials characteristic, manufacturing and common failures. An in depth discussion on the
parameters influencing the quality of coil springs is also presented. Several case studies of suspension spring
failures ranging from the very basic including insufficient load carrying capacity, raw material defects such as
excessive inclusion levels, and manufacturing defects such as delayed quench cracking, to failures due to
complex stress usage and chemically induced failure have been discussed including FEA stress distributions
around typical failure initiation sites.

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II. Design Of A Helical Compression Spring Under Axial Load

The design of a compression spring under axial load involves the following considerations:
Space into which the spring must fit and operate, Values of working forces and corresponding
deflections, Operational 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 primary design constraints are that i) the wire size should be commercially available and that the stress at
the solid length be no longer greater than the torsional yield strength. ii) Functioning is expected to be stable.
The maximum shear stress at the inside of the coil given by,

τmax = Where, K = and is called as Wahl’s factor and used for

considering stress correction because of curvature effect and C = D/d is called as spring index. Stress obtained
by the imperial result can be cross checked by finite element method for better understanding of the stress
distribution. The deflection of spring end δ can be calculated as δ = (8PD3N/Gd4) where, P is the axially applied
load.

III. Finite Element Analysis

A primary reason to use FEA in coil design is to reduce the error caused by simplifications of the
equations. The most accurate FEA results can be obtained by creating 3-D parts of a coil spring, followed by
using finer meshing of the parts with 3-D solid element. For the FEA work a helical spring currently used in
modern two wheeler horn has been selected having the specifications shown in Table 1

Table 1. Spring specifications (stainless steel spring)

Outer diameter Do mm 4.8 Free length Lf mm 10.2
Inner diameter Di mm 3.9 Solid length Ls mm 2.7
Mean diameter D mm 4.35 Number of active turns N 4
Wire diameter d mm 0.450 Number of Total Turns 6
Spring index C 9.67 Pitch 2.04

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For this work the softwares used are PRO-E for solid modeling ( Fig. 1, Fig. 2 ) and ANSYS 14 for
analysis of shear stresses developed (Fig. 3,) , von-Mises stresses in single spring (Fig. 4) and total
deformation (Fig. 5) when single spring is used and life of spring in number of cycles needed for failure (Fig. 6
). It is seen that the life of single spring is observed to be in between 115 cycles to 6492 cycles. The criterion for
acceptance of the spring was it should sustain minimum 3 lakh cycles.

IV. Design Modification

The experimental investigations and customers report show that the spring under investigation has high
response to fatigue and failure chances are more. The modification in fatigue life can be based on i) change of
material and ii) change of the geometrical shape. The first case is not recommended because of availability of
space for the spring in the final assembly. Hence a design modification with co-axial spring has been done in the
design of single compression spring. Keeping the coil outer diameter and free length of the spring same, an
inner spring mean with coil diameter is 2.17 mm has been added without changing the wire diameter and
number of active coils.

Table 2: Modified Spring specifications (stainless steel spring)

Parameter Outer Inner Parameter Outer Inner
Spring Spring Spring Spring
Outer diameter Do mm 4.8 2.62 Solid length Ls mm 2.7 2.7
Inner diameter Di mm 3.9 1.72 Number of active turns N 4 4
Mean diameter D mm 4.35 2.17 Number of total turns 6 6
Wire diameter d mm 0.45 0.45 Pitch p mm 2.04 2.04
Spring Index C 9.67 9.67 Spring rate N/mm 1.26 0.39

4.1 Finite Element Modeling of Modified Compression Spring

For this work the softwares used are PRO-E for solid modeling (Fig. 7, Fig. 8) and ANSYS 14 for
analysis of shear stresses developed (Fig 9), von-Mises stresses in single spring (Fig 10) and total deformation
when single spring is used (Fig. 11) and life of spring in number of cycles needed for failure (Fig. 12). Cut
section of the modified new design is shown in Fig. 13. It is seen that the life of modified spring is observed to
be upto 106 cycles which is more than expected.

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V. Experimental Investigation
The experimental study was carried out by using “Special Purpose Fatigue Testing Machine” for design
validation. The fatigue testing machine has following specifications.

Table 3: Specifications of Fatigue Testing Machine

Operation Fully automatic
Maximum load kg 200
Minimum load kg 0.3
Stroke length mm 1.5 to 200
Max speed cycles/hr 12000
Machine weight kg 700

Note: The springs having mean coil diameter ranging from 2 mm to 250 mm can be tested for fatigue failure
using the test rig.
A random sample consisting five springs selected from a lot of 100 springs was taken for experimental
investigation under following testing conditions.
a. Working temperature: Room temperature.
b. Stroke: 5 mm deformation
c. Frequency: 1 cycle/sec
d. Cycle to be completed: 3 lakh cycle

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VI. Observations
At the end of 3 lakh cycles, no cracks or breakages were found in any of the five modified springs under
experimental investigation. Table 3 shows the results of experimental investigation in detail.

Table 4: Result comparisons between original and modified spring

Sr. SINGLE SPRING MODIFIED SPRING
Parameters
No. Min Max Min Max
1 Shear stress MPa 74 661 42 306
2 Deformation after test mm 0 4.42 0 0.96
3 von-Mises stress MPa 0 1333.7 0 609
4 Life (cycles) 115 6492 862 106

VII. Discussions Of Results And Conclusion

Initially a single spring (spring rate of 1.26 N/mm) was modeled for dynamic analysis and prediction
regarding shear stress disturbance, von-Mises stresses, deformation and fatigue life using ANSIS 14.0. The
results show that there was a permanent deformation of the spring by 4.425 mm and the maximum fatigue life
was 6492 cycles.
As these predictions are not acceptable , the spring assembly was modified by adding one more spring
in series maintaining the assembly configurations ( outer spring rate of 1.26 N/mm in series with inner spring
rate of 0.39 N/mm). The results show that there was a permanent deformation of the modified spring by 0.74
mm and the maximum fatigue life was upto 106 cycles. These theoretical predictions are found to be acceptable.
The modified spring was manufactured and tested as described. The experimental results show that at
the end of 3 lakh cycles, no cracks or breakages were found in any of the five modified springs under
experimental investigation.

VIII. Future Scope

The low cost consideration can be achieved by changing the spring material as composite material with different
compositions.

Acknowledgments
The authors would like to thank The Management of Annasaheb Dange College of Engineering and
Technology, ASHTA, for providing us necessary technological and laboratory facilities as and when needed.
The efforts taken by M/s. Able technologies (I) Pvt. Ltd. Pune, to provide the research project, entire
experimental setup and technical knowhow during experimental investigation including man power are highly
appreciated.

References
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[2]. Sid Ali Kaoua a, Kamel Taibi a, Nacera Benghanem a, Krimo Azouaoui b, Mohammed Azzaz “ a Numerical modelling of twin
helical spring under tensile loading.” Applied Mathematical Modelling, 35 (2011) 1378–1387.

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 Design, Analysis and Experimental Validation for Fatigue Behavior of a Helical Compression …..
[3]. C. Madan Mohan Reddy1, D.Ravindra Naik2, Dr M.Lakshmi Kantha Reddy3, “Analysis and Testing of Two Wheeler Suspension
Helical Compression Spring” IOSR Journal of Engineering (IOSRJEN) ISSN (e): 2250-3021, ISSN (p): 2278-8719 Vol. 04, Issue
06 (June. 2014), ||V1|| PP 55-60.
[4]. Mr. V. K. Aher, Mr. P. M. Sonawane, “Static And Fatigue Analysis Of Multi Leaf Spring Used In The Suspension System Of
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[5]. Tausif M. Mulla1, Sunil J. Kadam2, Vaibhav S. Kengar3, “Finite Element Analysis Of Helical Coil Compression Spring For Three
Wheeler Automotive Front Suspension” International Journal of Mechanical and Industrial Engineering (IJMIE) ISSN No. 2231 –
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[6]. W.G. Jiang a, J.L. Henshall b, “A novel finite element model for helical springs”, Finite Elements in Analysis and Design 35 (2000)
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[7]. M.Sudhakar Reddy1, B.Madhusudhan Reddy2, “The Study of Premature Failure of Springs Used In Railway Coaches” IOSR
Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 8, Issue 5 (Sep. -
Oct. 2013), PP 19-28
[8]. Y. Prawoto a, M. Ikeda a, S.K. Manville a, A. Nishikawa a,b “Design and failure modes of automotive suspension springs”
Engineering Failure Analysis 15 (2008) 1155–1174
[9]. V.B. Bhandari, Design of Machine Elements (New Delhi, Tata McGraw-Hills,2009).

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