Springs V8.

xmcd [Pg 1 / 7]

Mechanical Spring pg 500

Pegas Mekanikal

Objective
Selection of spring by load and stress
analysis.
Application
Vehicle suspension, weighing system, energy
storage system, door system etc

Kinds of Springs
Helical spring, Spiral spring, Leaf spring,
Torsional spring

Important topics
Helical Tension & Compression spring (Pg )

For Helical springs

The basic specs

D - diameter of wire
d - mean diameter of spring
OD - outside diameter of spring, OD = D + d
ID - inside diameter , ID = D − d
Nt - number of coils
Na - number of active coils
Lf - free length
Lo - operating length of string
Li - installed length
Ls - solid length
p - pitch
Springs [Link] [Pg 2 / 7]

Stresses and Deflection in Helical Springs

Loads that cause failure in spring

1. torsional load
2. direct shear load
3. bending load
4. buckling load
5. variable load and fatigue (not in
scope)

Shear stress is caused by transverse

shear loads and torsional shear loads.

2
F πd
Transverse Shear Stress τp = where A=
A 4
4
Tr πd FD d
Torsional Load τs = where J= & T= & r =
J 32 2 2

Tr F 8F D 4F
Therefore, overall shear stress in spring : τ= + = +
J A 3 2
πd πd
D
Spring Index, C =
d
2C + 1
Correction factor for Shear stress, KS =
2C
4C−1 0.615
Wahl factor, KW = +
4C−4 C
4C+2
Bergstrassor factor, KB =
4C−3
KB
Therefore the curvature correction factor, KC = which handle curvature effect only
KS

The Wahl and Bergstrasser factors consider the effect of both curvature of wire and
shear stress. Their values differ only by 1%. Shigley recommends using KB .

8F D
Hence Torsional and direct shear stress τ = KB
3
πd
Springs [Link] [Pg 3 / 7]

Deflection of Helical Spring

TL
Torsional deflection, θ=
GJ

Force, F = k y
k - spring constant
4
d G
k= or G - modulus of rigidity
3
8D Na
Na - number of active coils
3 3
8F D Na 8F C Na
y= = [10-8] y - linear deflection
4 dG
d G

See Table 10-5 to get value of Modulus of material.

Compression Spring
STANDARD Compression spring

Types of Ends Refer to Figure 10-2, pg 503

Number of active coils

(a) Na = Nt

(b) or (c), Na = Nt − 2

(d) Na = Nt − 1

Non-STANDARD spring design

The Table 10-1 and Figures 10-2 cannot be used when designing non-standard spring.
Manual evalution based on observation and measurement is used to obtained the
specifications for the spring.
Springs [Link] [Pg 4 / 7]

Buckling - Stability of Compression Spring

The spring will buckle if the force is too large and the deflection is higher than the
critical deflection. See pg 745, Topic Buckling

Stability of Compression Spring

The spring will buckle if the force is too large and the deflection is higher than the critical
deflection. This can be determined by End Condition Constants, α (refer to Table 10-2,
pg 504.)
πD 2( E − G)
For absolute stability : Lo < ⋅
α 2G + E
D
For all steel, the spring is stable (no buckling) if Lo < 2.63
α

For stability of square and ground ends steel spring ==> α = 0.5 and Lo < 5.26D

Spring material Pg 505

A
Tensile strength : Sut =
m
d

Get A & m from Table-10-4. unit: d [mm, inch] , A [[Link]]

Shear yield strength of spring in torsion : from Table 10-6

⎛ 0.45 Sut ⎞ - cold drawn carbon steel, hard drawn steel

⎜ ⎟
Ssy = ⎜ 0.50 Sut ⎟ - hardened & tempered carbon and alloy steel
⎜ ⎟
⎝ 0.35 S ut ⎠ - austenitic stainless steel and non-ferrous alloy

SEE Sample 1: EXAMPLE 10-1 pg 509 : Analyzing standard spring

SEE Sample 2: Example - Analyzing Non-standard spring

SOLVE Sample 3: QUESTION 10-4 pg 543 : Analyzing standard spring

SOLVE Sample 4: QUESTION 10-18 pg 544 : Analyzing non-standard spring

Springs [Link] [Pg 5 / 7]
Helical compression spring design for static service

Spring deflect non-linearly when compressed to solid length. To avoid the non-linear
7
behaviour, the maximum operating load should be limited to Fmax ≤ Fs
8
where the shear force at solid length Fs = ( 1 + ξ )Fmax and deflection ys = ( 1 + ξ )ymax

Based on the above factor, the following design condition is recommended :

4 ≤ C ≤ 12
3 ≤ Na ≤ 15
ξ ≥ 0.15
ns ≥ 1.2 (Safety factor at solid length)

As-wound : D = C ⋅d
Ssy 8 ( 1 + ξ )Fmax
where α= , β=
ns 2
πd
2
2α − β ⎛ 2α − β ⎞ 3α
and C= + ⎜ ⎟ −
4β ⎝ 4β ⎠ 4β
Over-a-rod : D = drod + d + allowance

In-a-hole : D = dhole − d − allowance

SEE Sample 5: EXAMPLE 10-2 pg 512 : Analyzing standard spring for static loading

Critical Frequency of Helical Springs

When the spring is loaded and suddenly released, a certain vibration-like action occurs
until it is damped out. This is called Spring-surge. Unfavored reaction to this surge is the
spring may actually jump out of contact with its support-plate causing extensive damage to
the plate and spring. To avoid this, designer must ensure that the natural frequency of the
spring is not closed to the frequency of the applied force to avoid resonance.

1 kg
For spring with both end in contact with the plates, the natural freq f =
2 W

1 kg
For spring with one end free, the natural freq f =
4 W
2 2
π d D Na γ where γ is the
The weight of the active part of the spring is W = specific weight.
4
Springs [Link] [Pg 6 / 7]
Zimmerli Endurance Strength Components for Helical
compression spring under fatigue loading
According to Zimmerli, size, material and tensile strength have no effect on the
endurance limits (infinite life only) of spring steels in sizes under 10mm.
Shot peening can be used to improve fatigue strength of dynamically loaded springs
by 20% or more. Base on test for peened and unpeened spring, the following value is
obtained and applied in spring fatigue analysis. For spring steel, the corresponding
endurance strength components for infinite life is

1. Unpeened Ssa = 241MPa , Ssm = 379MPa

Peened Ssa = 398MPa , Ssm = 534MPa

A
Based on Eqn 6-53 pg 309, Ssu = 0.67Sut where Sut =
m
d

Ssa
Gerber's fatigue criterion Sse =
2
⎛ Ssm ⎞
1−⎜ ⎟
⎝ Ssu ⎠
2
η τa ⎛ η τm ⎞
+⎜ ⎟ =1
Sse S
⎝ su ⎠
Ssa
Modified Goodman fatigue criterion Sse =
Ssm
1−
Ssu

τa τm 1
+ =
Sse Ssu η

See Sample 6: Example 10-4 pg 519 - Analyzing STANDARD spring with fatigue loading.

Sine Failure Criterion

Unlike rotating shaft which support both tensile and compression loads
continuously, springs are usually designed for either compression or tension load.
With preload the load curve is as Fig 6-23d on pg 293. This criterion shall assume
that the midrange stresses can be ignored in the fatigue analysis (like
reverse-loading).
Hence Ssm = 0 and τm = 0 and hence Sse = Ssa
Springs [Link] [Pg 7 / 7]

Helical compression spring under fatigue Loads

Fmax − Fmin
Alternating load, Fa =
2 For pre-loaded spring:
Fmin = F ( preload )
Fmax + Fmin
Mean load, Fm =
2

For torsional and shear stress

8Fa D
τa = K B KB - Bergstrasser factor
3
πd

8Fm D
τm = K B
3
πd

Spring Marin Factors