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DESIGN OF SPRINGS

Definition of spring
A spring is an elastic object used to store mechanical energy. Springs are elastic bodies
(generally metal) that can be twisted, pulled, or stretched by some force. They can return to their
original shape when the force is released. In other words it is also termed as a resilient member.
A spring is a flexible element used to exert a force or a torque and, at the same time, to store
energy.

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force on the spring

DESIGN OF MACHINE ELEMENTS DESIGN OF SPRINGS BY SAM JOSHY ,SSET

1. A spring loaded safety valve has to blow off at a pressure of 1.5N/mm2. Dia of valve seat = 60mm.
assume spring index C =6.initial compression of spring = 25 mm. Max lift of valve = 15 mm. design a
suitable compression spring. Take shear stress for spring material as 450 MPa and G = 0.84x105 MPa.
Given:
Blow off pressure =
Diameter of valve seat =
Initial compression of spring =
Shear stress =
Modulus of rigidity G =
Ans:
Find the maximum load on the spring
Initial load on the valve F1 =
Initial deflection y1 =
Final deflection y2 =
Total load F2 (Max load at the opening of valve) =

(Eq 20.31)

Design of spring
Diameter of spring wire d (Eq 20.22)

Wahls stress factor K (E 20.23)


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K=
DESIGN OF MACHINE ELEMENTS DESIGN OF SPRINGS BY SAM JOSHY ,SSET

dia of wire d =
axial deflection of the whole spring y (E 20.29)
where y is the deflection corresponding to maximum force (IMPORTANT)
y=

active number of turns i =


length of spring wire l (E20.28a)

l=
minimum freelength of the spring

lf (E 20.53)

lf =
assume ends are ground ,n=2,
take clearance = 25% of maximum deflection

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lf =
DESIGN OF MACHINE ELEMENTS DESIGN OF SPRINGS BY SAM JOSHY ,SSET

outside dia of coil Do (E 20.53a)


Do =
solid length of spring ls (E20.53 b)

ls =

where t = total number of coils T20.14

it=

pitch of spring p (E20.53 c)


p=

where ys=lf -ls (refer fig20.7 d)

maximum working length lmax (E20.53 e)


lmax =

minimum working length lmin (E20.53 f)


lmin =

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dimensions of the spring are

DESIGN OF MACHINE ELEMENTS DESIGN OF SPRINGS BY SAM JOSHY ,SSET

2. Design a helical spring for a spring loaded safety valve so as to meet the following requirements
dia of valve seat =70mm.
operating pressure (when valve remain closed) = 0.7 N/mm2
maximum pressure (when valve blows off freely) =0.75 N/mm2
lift of valve during the change of pressure = 4 mm
permissible shear stress = 560 MPa
G =0.84 x1011 N/m2
assume spring index.

Given:
operating pressure p1 =
maximum pressure p2 =
operating force =

Maximum force =

change in force =
deflection of spring during the change in force =

Design of spring
Diameter of spring wire d (Eq 20.22) (ALWAYS DESIGN FOR TAKING THE MAXIMUM FORCE

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d=

DESIGN OF MACHINE ELEMENTS DESIGN OF SPRINGS BY SAM JOSHY ,SSET

Wahls stress factor k (E 20.23)


k=
dia of wire d =
axial deflection of the whole spring y (E 20.29)
y=

active number of turns i =


length of spring wire l (E20.28a)

l=

minimum freelength of the spring lf (E 20.53)

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assume ends are ground ,n=2,

lf =

take clearance =
DESIGN OF MACHINE ELEMENTS DESIGN OF SPRINGS BY SAM JOSHY ,SSET

lf =
outside dia of coil Do (E 20.53a)
Do =
solid length of spring ls (E20.53 b)

ls =

where t = total number of coils T20.14

it=

pitch of spring p (E20.53 c)


p=

where ys=lf -ls (refer fig20.7 d)

maximum working length lmax (E20.53 e)


lmax =

minimum working length lmin (E20.53 f)

DESIGN OF MACHINE ELEMENTS DESIGN OF SPRINGS BY SAM JOSHY ,SSET

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dimensions of the spring are

lmin =

3. A load of 1 kN is dropped from a height of 250mm on a helical spring. spring have 20 active number of
coils. dia of spring wire =20mm.spring index =8. Determine the deflection and stress in the spring
Ans:
given:
dia of spring wire=
spring index=
No of active coils =
weight of body dropped =
deflection of spring = ?
stress in spring =?
Ans:

when a body is dropped on a spring PE of body PE stored in spring

deflection of spring (when body id dropped) = y


PE of body =

..1

PE stored in spring = (1/2) force * deflection = (1/2)Fy

..2

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Eq 1 = Eq 2

DESIGN OF MACHINE ELEMENTS DESIGN OF SPRINGS BY SAM JOSHY ,SSET

F=
shear stress =

4. A spring is subjected to a variable load varying from 500N to 900N. determine dia of spring and mean
coil diameter. take FOS =1.5. assume spring index C=6, y =750 MPa,en =350 MPa.
mean load Fm=
alternating load Fa =

mean shear stress m =

alternating shear stress a =

use soderberg eqn

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d=
DESIGN OF MACHINE ELEMENTS DESIGN OF SPRINGS BY SAM JOSHY ,SSET

5.

2 concentric springs of same length are placed one inside the other. total axial load =3000 N,
deflection =25mm, shear stress =150MPa. spring indices are 5 and 9.dia of wire is same for both
springs. find the ratio of actual number of coils for both springs

Given:

inner spring -1
outer spring -2
F1+F2 =3000N
1 = 2

d1=
d2=

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D1=
D2=
DESIGN OF MACHINE ELEMENTS DESIGN OF SPRINGS BY SAM JOSHY ,SSET

since both springs have equal deflections, y1=y2


i1/i2 =

7.design a helical spring for an engine valve.


length of spring when valve is opened =45mm.
length of spring when valve is closed =55 mm.
load on spring when valve is opened =450 N
load on spring when valve is closed =300 N
maximum int. dia of spring =30mm.
permissible shear stress = 560 MPa

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G =0.84 x1011 N/m2

DESIGN OF MACHINE ELEMENTS DESIGN OF SPRINGS BY SAM JOSHY ,SSET

8.a railway wagon of mass 20000kg moving with a velocity 2m/s is brought to rest by 2 buffers of spring
dia 300 mm. the maximum deflection of spring is 200mm. permissible shear stress is 600Mpa. design
the spring
ans:
given: velocity of wagon =
mass of wagon =
KE of wagon =

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PE stored in spring when wagon is brought to rest =

DESIGN OF MACHINE ELEMENTS DESIGN OF SPRINGS BY SAM JOSHY ,SSET

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