Compression Spring Ends
An Overview of Different Types and
Their Effects
Spring terminology
• Wire Diameter (d)
− Thickness of the wire.
• Outer Diameter (Dₒ)
− Total outer width of the spring.
• Inner Diameter (Dᵢ)
− Inner width of the spring.
• Mean Coil Diameter (D)
− Average diameter of the coil.
• Spring Index (C)
− Ratio of mean coil diameter to wire diameter.
• Pitch
− The axial distance b/w two adjacent coils
• Helix Angle (α)
− Angle of the coil with the horizontal axis.
Spring terminology
• Active Coils (Nₐ)
− Coils contributing to deflection.
• Total Coils (Nₜ)
− Includes all coils.
• Free Length (L₀)
− The length when no force is applied.
• Solid Length (Lₛ)
− The fully compressed length when all
coils touch.
Types of Compression Spring Ends
[Link] ends plain
[Link] ends squared
[Link] ends squared and ground
[Link] ends plain and ground
Both ends plain
• A spring with plain ends has a noninterrupted helicoid; the ends are the same as if
a long spring had been cut into sections.
• Easier to manufacture and cost-effective.
• Suitable for non-critical applications.
• Provides minimal axial stability.
• No. of inactive coils = 0
• No. of active coils = Na
• Total coils (Nt)= Na
• Free Length (L0) = Na*p + d
• Solid Length (Ls) = d*(Nt+1)
Both ends squared
• A spring with plain ends that are squared or closed is obtained by deforming
the ends to a zero-degree helix angle.
• Moderate stability with lower cost.
• Effective for general-purpose applications.
• No. of inactive coils = 2
• No. of active coils = Na
• Total coils (Nt)= Na +2
• Free Length (L0) = Na*p + 3d
• Solid Length (Ls) = d*(Nt+1)
Both ends squared and ground
• Tightly wound coils with a flat, ground surface.
• Provides better load distribution and stability.
• Reduces buckling and increases effective coil count.
• Suitable for precision applications.
• No. of inactive coils = 2
• No. of active coils = Na
• Total coils (Nt)= Na +2
• Free Length (L0) = Na*p + 2*d
• Solid Length (Ls) = d*Nt
Both ends plain and ground
• Noninterrupted helicoid with flat surface.
• Provides enhanced stability and load-bearing capacity.
• Reduces potential for misalignment.
• Ideal for high-load applications.
• No. of inactive coils = 1
• No. of active coils = Na
• Total coils (Nt)= Na +1
• Free Length (L0) = p*(Na+1)
• Solid Length (Ls) = d*Nt
Data book
• Formulas for the Dimensional Characteristics of Compression-
Springs
Spring Materials
Data book
• Constants A and m of Sut = A/dm for Estimating Minimum
Tensile Strength of Common Spring Wires
Data book
• Mechanical Properties of Some Spring Wires
Data book
• Maximum Allowable Torsional Stresses for Helical
Compression Springs in Static Applications
Stability
Example
It is required to design a helical compression spring subjected to a maximum force of
1250 N. The deflection of the spring corresponding to the maximum force should be
approximately 30 mm. The spring index can be taken as 6. The spring is made of
patented and cold-drawn steel wire. The ultimate tensile strength and modulus of rigidity
of the spring material are 1090 and 81370 N/mm2 respectively. The permissible shear
stress for the spring wire should be taken as 50% of the ultimate tensile strength. Design
the spring and calculate:
(i) wire diameter;
(ii) mean coil diameter;
(iii) number of active coils;
(iv) total number of coils;