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Design Consideration
The primary consideration in the design of the coil springs are that the induced stresses
are below the permissible limits while subjected to or exerting the external force F
capable of providing the needed deflection or maintaining the spring rate desired.
D
2
t max = +
Tr F
+
J A
d
F
T=
FD
d
d 4
d 4
,r = ,J =
and A=
2
2
32
4
Figure 4.10
Machine Design II
And re-arranging,
= Ks
8FD
8FC
or = Ks
d3
d 2
Ks =
2C + 1
2C
Figure 4.11
Machine Design II
Curvature Effect
The curvature of the wire increases the
stress on the inside of the spring, an
effect
very
similar
to
stress
Kw =
4C 1 0.615
+
4C 4
C
Machine Design II
u=
T 2 l F2 l
+
2G J 2A G
U=
4 F 2 D 3 N F 2D N
+
4
G. d
Gd2
Machine Design II
Where N is the number of active coils. The deflection in the spring, using
Castiglianos theorem
y=
U 8FD 3 N 4FDN
=
+
4
F
Gd
Gd 2
y=
8 F D 3N
1
1 +
Gd 4 2C 2
For normal range of C, the term within bracket (contribution of direct shear) is so
negligible we can write
y=
8FD3 N
Gd 4
or
8FC3 N
Gd
F
G.d
Gd 4
k= =
=
y 8C3 N 8D3 N
The spring stiffness or springs rate,
k=
F
G.d
Gd 4
=
=
y 8C3 N 8D3 N
Using the equation the number of active coils needed to maintain the desired
deflection or spring stiffness will be determined. In order to maintain proper
contact and align the force along the spring axis the ends are to be properly
shaped.
Machine Design II
End Construction
Coil compression springs generally use four different types of ends. These are
illustrated in Fig. 4.13. and Table shows how the type of end used affects the
number of coils and the spring length. Foe important applications the ends of
springs should always be of both squared and ground, because a better or even
transfer of the load is obtained.
Na= Nt -2
Na = Nt
(a) plain ends
Na = Nt -1
(b) plain-ground ends
Na= Nt -2
(d) squared-ground ends Fi
Figure 4.13
Machine Design II
preload
no load
maximum
working
load
initial
indefinite
load
La
Lm
assembled length
free length
Ls
Figure 4.14
load, F
yield limit
Fs
hi
F
k
lo
definition,
working
range
solid
length
Ls
clash
allowance
free length L0
Figure 4.15
Animate
shut height