Debre Markos University Institute of Technology
Department of Mechanical and Industrial engineering
Machine Element I
(MEng_2112)
Chapter 5
Springs
5.1. Introduction
• Springs are the elastic machine element they undergo significant deformation when loaded and
store recoverable energy. It is a device that can also be defined as an elastic or resilient member,
whose main function is to deflect under the action of load and recovers it’s original shape when
the load is removed.
⚫ Mechanical Springs
◦ Exert Force
◦ Provide flexibility
◦ Store or absorb energy
Applications of Spring:
• Automobile suspension system.
• In clutch & brake, to exert force on these objects.
• In, door lock, and many other household accessories. 2
5.1. Introduction (Cont.…)
Advantages of Spring:
• To reduce the effect of shock or impact loading. Has good shock-absorbing ability.
• To apply forces and to control motions as in brakes and clutches
• It has high durability.
• Spring has the ability of stored energy inside it.
• It is easy to design and cheaper to produce.
• Spring is a maintenance-free device.
Disadvantages of Spring:
• Day by day its loose it shape and stability.
• Sometimes when the axial load of the spring is increased, it produce the buckling phenomena.
• If spring is broken then it is hard to repair.
3
5.2. Classification of springs
1. Wire springs:- it include helical springs of round or square wire, made to resist and deflect
under compressive, tensile, or torsional loads.
➢ Helical springs are made up of a wire coiled in the form of a helix and is primarily intended for
compressive, tensile and torsion loads. The cross-section of the wire from which the spring is
made may be circular, square or rectangular
4
5.2. Classification of springs (Cont.…)
2. Conical and volute springs:- are used in special
applications where a telescoping spring or spring with a
spring rate that increases with the load is desired.
▪ This characteristic is sometimes utilised in vibration
problems where springs are used to support a body that
has a varying mass.
3. Laminated or leaf springs
▪ Also known as flat spring or carriage spring
▪ It consists of a number of flat plates (known as leaves) of
varying lengths held together by means of clamps and bolts..
▪ Mostly used in automobiles
▪ The major stresses produced in leaf springs are tensile and compressive stresses 5
5.3. Terms used in helical spring
Outer diameter (Do)
Inner diameter (Di)
Mean coil diameter (D)
Wire diameter (d)
Coil pitch (P)
Helix angle (𝚿)
Free length (Lo)
Solid length (Ls)
Total number of coils (Nt)
Number of Inactive coils (end
coils (Ni) (0, 1 or 2)
Number of Active coils (Na)
6
5.3. Terms used in helical spring (Cont.…)
7
Total number of coils = 7
Number Active coils (Na) =5
Inactive coils (Ni) =2
Total number of coils = 6
Number Active coils (Na) =2
Inactive coils (Ni) =4 8
Most compression springs have closed
ends, creating inactive coils and do not
move under load
9
5.3. Terms used in helical spring (Cont.…)
10
5.3. Terms used in helical spring (Cont.…)
• Solid length (Ls):- The axial length of the spring, which is so compressed, and the adjacent coils
are touch each other. In this case the spring is completely compressed and no further compression
is possible. Ls = Nt × d since, Nt is Total number of coils
• Compressed length (δ):- It is the axial length of the spring that is subjected to maximum
compressive force with in elastic limit. In this case the spring is subjected to maximum
compressive length or deflection (δ).
• When the spring is subjected to maximum force, there should be some gap or clearance between
the adjacent coils. The gap is essential to prevent clashing of the coils. The clashing allowance or
the total axial gap is usually taken as 15% of the maximum deflection. Sometimes, an arbitrary
decision is taken and it is assumed that there is a gap of 1 or 2 mm between adjacent coils under
maximum load condition. In this case the total axial gap is given by,
Total gap = (Nt - 1)×Gap between adjacent coils 11
5.3. Terms used in helical spring (Cont.…)
✓ Inactive coils (Ni): - it is the springs in contact with the seat and does not contribute to spring
action. This coil does not support the load and do not deflect under the action of external force.
✓ Number Active coils (Na):- it is the coil in the spring, which contribute the spring action, support
the external force and free to deflect under the action of force. It determines as;
Total number of coil (Nt)- Inactive coils
✓ Total number of coils:- It is the sum of active and inactive coils in a spring body.
12
5.3. Terms used in helical spring (Cont.…)
• Free length:- It is the axial length of the spring in the free or unloaded condition. In this cases, no
external forces acts on the spring.
▪ It is an important dimension in spring design and manufacture. It is the length of the spring in
free condition prior to assembly
➢ Pitch of coil (P):- the axial distance between adjacent coils in uncompressed state of spring.
Free length of the spring L𝐹
Pitch of coil (P) = =
Total number of coil−1 Nt−1
13
5.3. Terms used in helical spring (Cont.…)
Spring index (C):- it is the ratio of mean diameter of coil to the wire diameter.
✓ It indicates the relative sharpness of the curvature of the coil.
✓ When the spring index is low (<3) the actual stress in the wire are excessive due to curvature effect
and difficult to manufacture. But when it maximum (>15) it is simply buckling. So, in real situation
the spring index is between in the range of 6 ≤ C ≤ 12.
D
Spring index (C) = Mean Diameter =
wire diameter d
Spring rate (Stiffness):- it is the load required per unit deflection of the spring.
𝑭
K= Where, k is stiffness of the spring, F, load and δ is deflection
𝜹
2 2 2
πd π d DN a
Volume of spring (V): - It is given by V = A× L = × πDN a =
4 4
14
5.4. End connection for compression helical spring
15
16
17
18
5.5. Stresses in helical Springs
• Two type of stress are developed in the spring due to applied load. Those are,
Torsional shear stress (𝝉𝒔), due to the effect of torque twisting moment (T).
From strength of material 𝜏𝑠 is given as,
16𝑇 𝐹𝐷 8𝐹𝐷
𝜏𝑠 = --------- T = by substitute 𝜏 𝑠 =
𝜋𝑑 3 2 𝜋𝑑 3
2
𝐹 4𝐹 𝜋𝑑
Direct shear stress(𝝉𝒕) on the wire. 𝜏𝑡 = = Since A =
𝐴 𝜋𝑑 2 4
• Resultant shear stress(𝜏) developed on the wire is,
𝜏 = 𝜏𝑠 + 𝜏𝑡 --------- 8𝐹𝐷3 + 4𝐹
𝜋𝑑 𝜋𝑑 2
8𝐹𝐷 𝑑 8𝐹𝐷 1 8𝐹𝐷 2𝐶+1 𝑑 1
𝜏= (1 + ) = (1 + )= ( 2𝐶 ) ---------Since, =
𝜋𝑑 3 2𝐷 𝜋𝑑 3 2𝐶 𝜋𝑑 3 𝐷 𝐶
8𝐹𝐷
∴ Maximum shear stress for helical spring 𝜏 = K𝑠 3
𝜋𝑑
1 2C +1
Ks = 1+ =
Where, 𝐾𝑠 = Shear Stress Correction Factor 2C 2C 19
5.6. Curvature Effect
• When the springs are subjected to static loads, the effect of wire curvature may be neglected,
because yielding of the material will relive the stresses.
• Can account for effect by replacing Ks with Wahl factor or Bergsträsser factor which account for
both direct, torsional and curvature shear stress effect.
• When the maximum shear stress (𝜏) developed in the wire is greater than the shear strength of the
spring material, the spring is fails due to shear effect.
5.7. Deflection of helical Springs
21
5.7. Deflection of helical Springs (Cont.…)
22
5.8. Critical Deflection for Stability
⚫ Buckling type of instability can occur in compression springs when the deflection
exceeds the critical deflection ycr
⚫ λeff is the effective slenderness ratio
⚫ is the end-condition constant, defined on the next slide
⚫ C'1 and C'2 are elastic constants
Shigley’s Mechanical Engineering Design
End-Condition Constant
⚫ The term is the end-condition constant.
⚫ It accounts for the way in which the ends of the spring are supported.
⚫ Values are given in Table 10–2.
Table 10–2
Shigley’s Mechanical Engineering Design
Absolute Stability
⚫ Absolute stability occurs when,
C 2 / e2f f 1
⚫ This results in the condition for absolute stability
⚫ For steels, this turns out to be
Shigley’s Mechanical Engineering Design
Strength of Spring Materials
⚫ With small wire diameters, strength is a function of diameter.
⚫ A graph of tensile strength vs. wire diameter is almost a straight line on log-log scale.
⚫ The equation of this line is
where A is the intercept and m is the slope.
⚫ Values of A and m for common spring steels are given in Table 10–4.
Shigley’s Mechanical Engineering Design
Constants for Estimating Tensile Strength
Table 10–4
Shigley’s Mechanical Engineering Design
Estimating Torsional Yield Strength
⚫ Since helical springs experience shear stress, shear yield strength is needed.
⚫ If actual data is not available, estimate from tensile strength
⚫ Assume yield strength is between 60-90% of tensile strength
0.6Sut Ssy 0.9Sut
⚫ Assume the distortion energy theory can be employed to relate the shear strength to the
normal strength.
Ssy = 0.577Sy
⚫ This results in
The relation between tensile strength and torsional yield strength of music wire and
hard-drawn steel spring are;
Mechanical Properties of Some Spring Wires (Table 10–5)
Shigley’s Mechanical Engineering Design
Maximum Allowable Torsional Stresses
Shigley’s Mechanical Engineering Design
Example 1
A helical compression spring is made of no.16 music wire with wire diameter 0.037in and
7
ultimate tensile strength of the wire is 324 kpsi. The outside coil diameter of the spring is in.
16
The ends are squared and there are 121 total turns.
2
Shigley’s Mechanical Engineering Design
Example 1
Example 1
Shigley’s Mechanical Engineering Design
This is all about Machine Element one
Thank You all !!!
34