Object: To Study and Design of Helical Spring.

Learning Objective:
1. To study Uses of springs 2. To study Nomenclature of a typical helical spring 3. To design of helical compression spring

Theory (A) Functions of a spring

1. Cushioning , absorbing , or controlling of energy due to shock and vibration. Car springs or railway buffers To control energy, springs-supports and vibration dampers. 2. Control of motion Maintaining contact between two elements (cam and its follower) Creation of the necessary pressure in a friction device (a brake or a clutch) Restoration of a machine part to its normal position when the applied force is withdrawn (a governor or valve) 3. Measuring forces Spring balances, gages 4. Storing of energy In clocks or starters The clock has spiral type of spring which is wound to coil and then the stored energy helps gradual recoil of the spring when in operation. Nowadays we do not find much use of the winding clocks.

(B) Commonly used spring materials

Hard-drawn wire: This is cold drawn, cheapest spring steel. Normally used for low stress and static load. The material is not suitable at subzero temperatures or at temperatures above 1200C. Oil-tempered wire: It is a cold drawn, quenched, tempered, and general purpose spring steel. However, it is not suitable for fatigue or sudden loads, at subzero temperatures and at temperatures above 1800C. When we go for highly stressed conditions then alloy steels are useful. Chrome Vanadium: This alloy spring steel is used for high stress conditions and at high temperature up to 2200C. It is good for fatigue resistance and long endurance for shock and impact loads. Chrome Silicon: This material can be used for highly stressed springs. It offers excellent service for long life, shock loading and for temperature up to 2500C. Music wire: This spring material is most widely used for small springs. It is the toughest and has highest tensile strength and can withstand repeated loading at high stresses. However, it can not be used at subzero temperatures or at temperatures above 1200C.

Normally when we talk about springs we will find that the music wire is a common choice for springs. Stainless steel: Widely used alloy spring materials. Phosphor Bronze / Spring Brass:

(C) Terms used in Compression Springs

1. Solid length. When the compression spring is compressed until the coils come in contact with each other, then the spring is said to be solid. The solid length of a spring is the product of total number of coils and the diameter of the wire. Mathematically, Solid length of the spring, LS = n'.d where n' = Total number of coils, and d = Diameter of the wire. 2. Free length. The free length of a compression spring, as shown in Fig. 23.6, is the length of the spring in the free or unloaded condition. It is equal to the solid length plus the maximum deflection or compression of the spring and the clearance between the adjacent coils (when fully compressed). Mathematically, Free length of the spring, LF = Solid length + Maximum compression + *Clearance between adjacent coils (or clash allowance) = n'.d + max + 0.15 max The following relation may also be used to find the free length of the spring, i.e. LF = n'.d + max + (n' 1) 1 mm In this expression, the clearance between the two adjacent coils is taken as 1 mm. 3. Spring index. The spring index is defined as the ratio of the mean diameter of the coil to the diameter of the wire. Mathematically, Spring index, C = D / d where D = Mean diameter of the coil, and

d = Diameter of the wire. 4. Spring rate. The spring rate (or stiffness or spring constant) is defined as the load required per unit deflection of the spring. Mathematically, Spring rate, k = W / where W = Load, and

= Deflection of the spring.

5. 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

Figure 1

(D) Stresses in Helical Springs of Circular Wire

Consider a helical compression spring made of circular wire and subjected to an axial load W, as shown in Fig. 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, W = Axial load 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 W.

Figure 2

Problems to Solve 1. In an automotive plate clutch, six helical compression springs arranged in parrale, provide the axial thrust of 15000N.The springs are compressed by 10mm to provide this thrust force. the spring are identical and spring index is 6.the springs are made of cold-drawn steel wires with ultimate tensile strength of 1200N/mm2.the permissible shear stress for the spring wire can be taken as 50% of the ultimate tensile strength(G=81370 N/mm2).Springs have square and ground ends. There should be a gap of 1mm between adjacent coils when springs are subjected to the maximum force. Design the springs and calculate : i) wire diameter; ii) mean coil diameter; iii) number of active coils; iv) total number of coils; v) solid length vi) free length vii) required spring rate; and viii) actual spring rate. A direct spring balance consists of a helical tension spring that is attached to a rigid support at one end and carries weights at the other free end. The pointer attached to the free end moves on the

2.

scale and indicates weight. the length of the scale is 75mm.The maximum capacity of the balance is to measure the weight of 50N.the spring index is 6.The spring is made of oil-hardened and tempered steel wire with ultimate tensile strength of 1400 N/mm2.The permissible shear stress for spring wire can be taken as 50% of the ultimate tensile strength(G=81370 N/mm 2).Design the spring and calculate: a. wire diameter; b. mean coil diameter; c. number of active coils; d. required spring rate; and e. actual spring rate. [Ans. i) 3.7 or 4mm ii) 24 mm iii) 29 iv) 6.67 N/mm v) 6.5 N/mm 3. It is required to design a helical compression spring for a valve mechanism. The force acting on the spring is 300 N when the valve is open and 150 N when the valve is closed. The length of the spring is 30 mm when the valve is open and 35 mm when the valve is closed. The spring is made of valve spring wire and ultimate tensile strength is 1370 N/mm2. The permissible shear stress for spring wire can be taken as 30 % of the ultimate tensile strength. The modulus of rigidity is 81370 N/mm2. The spring is to be fitted over a valve rod and the minimum inside diameter of the spring should be 20 mm. Design the spring (i) wire diameter (ii) mean coil diameter (iii) number of active turns (iv) free length of the spring. Assume clash allowance is 15 % of the deflection under the maximum load.