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Helical Spring Design and Analysis Guide

This document summarizes the governing equations and design considerations for different types of springs, including helical compression springs, extension springs, and torsion springs. It provides equations for calculating spring rate, stress, deflection, fatigue life, and stress concentration factors. Key aspects covered include the stress distribution in different spring types, end conditions, critical buckling deflection, and design for finite versus infinite fatigue life.

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Rajumhaveri Haveri
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60 views1 page

Helical Spring Design and Analysis Guide

This document summarizes the governing equations and design considerations for different types of springs, including helical compression springs, extension springs, and torsion springs. It provides equations for calculating spring rate, stress, deflection, fatigue life, and stress concentration factors. Key aspects covered include the stress distribution in different spring types, end conditions, critical buckling deflection, and design for finite versus infinite fatigue life.

Uploaded by

Rajumhaveri Haveri
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

SPRINGS

Designed by: Shaun Scott, Vaughn Schiweck, Nathan Cropper


All Equations and Figures From: Shigley & Mischke. Mechanical Engineering Design. Fifth Edition, 2002.

Helical Springs

Compression Springs
Note: compression produces shear stress in the spring

Compression

Torsion

Extension

Extension Springs
Note: Loading the Extension Spring creates a shear stress in the spring.

Governing equation: F=k*y


y= 8 F D d
4 3

1+

1 2 C
2

; eqn. 10-8

Extension Springs: These must have a way of transferring load from a support to the body of the spring. Using Springs with a hooked end, stress concentration must be considered. This is shown below. The lower spring has a decreased stress concentration because the moment arm is smaller.

Spring Rate k:
K= d
4 3

G N

; eqn. 10-9

8 D

Torsion Springs
Note: Twisting the Torsion Spring creates a normal stress in the spring.

End Conditions:

Helical Torsion Springs: Helical torsion springs are wound in the same manner as extension and compression springs. For torsion springs, the ends are designed to transmit torque.

Critical Deflection:
Critical deflection in a compression spring: This is when the deflection becomes too large and the spring buckles. The equation is shown below.
1 2

Stress Concentration Factor:


; eqn. 10-11
K= r_m ; eqn. 10-10 r_i

ycr = Lo C1

1- 1-

C2 eff
2

The effective slenderness ratio is given by:


; eff = *L/D; eqn. 10-12

Stress Concentration Factor on inside of the Spring Ki:


Ki = 4 4 C -C-1 ; eqn. 10-32 C (C - 1)
2

The chart below describes , which is the end condition constant.

Bending stress for a round wire torsion spring:


= Ki 32 d F
3

Fatigue Loading
Spring Fatigue Loading: Some springs are subjected to fatigue loading. It must be determined whether the spring will need to have infinite life or finite life. Helical springs are never designed to be used in both compression and tension. Alternating stress Fa:
Fa = F_max - F_min ; eqn. 10-26 2

; eqn.10-33

C1 =

E 2 (E - G )

eqn. 10-13

C2 =

Displacement in torsion springs is described in radians.


(E - G ) ; eqn. 10-14

2 G+E

64

F d
4

D E

; 10-34
Fm =

Mean stress Fm:


F_max + F_min ; eqn. 10-27 2

<

The spring rate, taking into account the curvature of the wire:
k` = d 10.8
4

E ; 10-37 D N

This is the free length of the spring.

Stress Amplitude a: Kb 8 Fm D ; eqn. 10-28 3 d Mean Stress m: Ks 8 Fm D m = ; eqn. 10-29 3 d


a =

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