Muhannad Al_Waily_Machines Systems Design
Spring Design
Muhannad Al_Waily_Machines Systems Design
Types of Springs
Helical springs
Compression helical springs
Tension helical springs
Torsion helical springs
Leaf springs
Conical springs
Disk (Belleville) springs
Ring springs
Spiral springs
Torsion bear spring
Air springs
Liquid springs
Rubber springs
Muhannad Al_Waily_Machines Systems Design
applications in machinery
Springs are used to control forces due to impact or shock loading and to control vibration.
Springs are employed to control motions and to apply forces to members.
Springs are used for storing energy, in clocks, switch-throwing devices, and starters.
Springs are employed to measure forces, as in scales.
Spring Rate
F
k
y
For springs in series the spring rates add reciprocally
1 1 1 1 1
ktotal k1 k 2 k3 kn
The individual spring rates add directly
ktotal k1 k 2 k3 k n
Muhannad Al_Waily_Machines Systems Design
Spring Materials
Sut A.d b
Shear strength
S us 0.67 * S ut
Muhannad Al_Waily_Machines Systems Design
Muhannad Al_Waily_Machines Systems Design
Muhannad Al_Waily_Machines Systems Design
Muhannad Al_Waily_Machines Systems Design
Helical Spring
Helical Compression Springs
The force ' P ' applied at each end at a distance ' R ' from
the center of the wire produces a torsional moment
T P*R
Stresses in Helical Compression Spring Coils
Torsional shear stress Transverse Shear Stress
T * r T * d * 32 P 4* P
t ,max d , max
J 2 * * d 4 A *d2
16 * P * R 8 * P * D
*d3 *d3
max t , max d , max
8* P * D
4*P
8* P * D
.1
d 8* D * P C 0.5
3 2
max K d . Kd
*d *d *d3 2* D *d3 C
A curvature correction factor attributed to 'A.M'. Wahl results in the
following
8* D * P 4 * C 1 0.615 D
max K w . Kw C =3 and 12
3 4*C 4 C d
*d
Muhannad Al_Waily_Machines Systems Design
Muhannad Al_Waily_Machines Systems Design
Spring Rate
Deflection Castigliano's theorem
r * Deflection T 2 .l P 2 .l
z U
l Length 2.G.J 2. A.G
2
The deflection due to torsional loading P.D
. .D.N a
2 P 2 . .D.N a
U
D .d 4 .d 2
t R * . 2.G. 2.G.
2 32 4
4.P 2 .D 3 .N a 2.P 2 .D.N a
D T .L
t . G.d 4 G.d 2
2 G.J
D
t . 2
D .P. 2. . D .N
2 a
U 8.P.D 3 .N a 4.P.D.N a
P G.d 4 G.d 2
2 .d
4
G. 8.P.D 3 .N a d2
32 .
2.D 2
1
3 3
G.d 4
8.P.D .N a 8 * P * C * N a
8.P.C 3 .N a 0.5
G.d 4 G*d .1 2
G.d C
P G.d P G.d
kt k
0.5
t 8.C 3 .N a 8.C 3 .N a .1
C2
Muhannad Al_Waily_Machines Systems Design
End Conditions and
Spring Length
Muhannad Al_Waily_Machines Systems Design
l f ls s
The torsional strengths of spring wire vary depending on the
material
Muhannad Al_Waily_Machines Systems Design
Designing Helical Compression Springs
for Static and Fatigue Loading
The safety factor for static loading the dynamic safety factor
ys F
Fa max
Fmin
Ns 2
F Fmin
Fm max
2
S es . S us i
All spring-steel wire of ( > 10 mm) N fs
S es . m i S us * a
diameter exhibits a torsional endurance
limit for infinite life S ew * S us
S es 0.707 *
S ew 45.0 kpsi (310 Mpa) for un peened springs S us 0.707 * S ew
S ew 67.5 kpsi (465 Mpa) for peended springs
Muhannad Al_Waily_Machines Systems Design
Helical Extension Springs
F Fi d4 *G 8. F Fi .D 3 .N a
Nt N a 1 Lb d .N t k y
y 8 * D3 * N a d 4 .G
Muhannad Al_Waily_Machines Systems Design
Coil Preload in Extension
Springs
i 4.231 * C 3 181.5 * C 2 3387 * C 28640
i 2.987 * C 3 139.7 * C 2 3427 * C 38404
End Stresses in Extension Springs
The bending stress at point ' A '
16.D.F 4 .F 4.C12 C1 1 2.R1
A Kb . Kb C1
.d 3 .d 2 4.C1. C1 1 d
The torsional stress at point ' B '
8.D.F 4.C 2 1 2.R2
B K w2 . K w2 C2
.d 3 4.C2 4 d
' C2 ' should be greater than ' 4 '
Muhannad Al_Waily_Machines Systems Design
Helical Torsion Springs
L L2
equivalent number of coils Ne 1
3. .D
The number of active coils N a Nb Ne
' Nb ' is the number of coils in the spring body
Deflection of Torsion Springs
1 1 M .Lw
rev . rad .
2. 2. E.I
M .Lw 1 M . .D.N a 64 M .D.N a M .D.N a
rev . . 10.2 *
E .I 2. .d 4 2. d 4 .E d 4 .E
E.
64
The factor ' 10.2 ' is usually M .D.N a
increased to ' 10.8 ' to account for rev 10.8 *
the friction between coils d 4 .E
M d4 *E D.N b
k Dimin d Lmax d . N b 1
rev 10.8 * D * N a N b rev
Muhannad Al_Waily_Machines Systems Design
Coil Stresses in Torsion Springs
d
M max .
maximum compressive M .r 2 K . 32.M max 4.C 2 C 1
imax K bi . max K bi . K bi
bending stress at the inside 4 4.C. C 1
bi
I .d .d 3
coil diameter 64
32.M min o omin
omin K bo . omean max
the tensile bending stress .d 3 2 4.C 2 C 1
K bo
components at the outside
32.M max o omin 4.C. C 1
coil diameter omax K bo . oalt max
.d 3 2
Sy
Ny
imax
N fb
S e . Sut omin
S e . omean omin S ut . oalt
S ewb * Sut
S e 0.707 *
S ut 0.707 * S ewb
The torsional-endurance limit data for helical
compression springs be adapted for bending
by using the von Mises relationship between
torsion and tension loading
S ew
S ewb
0.577
for un peened springs
45.0
S ewb 78 kpsi (537 Mpa )
0.577
for peened springs
67.5
S ewb 117 kpsi (806 Mpa )
0.577
Muhannad Al_Waily_Machines Systems Design
Leaf Springs
M .c
I
6.M 6.P.x
b.t 2 b.t 2
The maximum moment occurs
at ' x = L'
6.P.l
max
b.l 2
6.P.l 3
E.n.b.t 3
P E * n * b * t3
k
6 * l3
Muhannad Al_Waily_Machines Systems Design
Belleville Spring Washers
Muhannad Al_Waily_Machines Systems Design
Stresses in Belleville Washers
4* E * y y
c
K1 * Do2 * 1 2
. K 2 * h
K3 * t
2
4* E * y y
ti
K1 * Do2 * 1 2
. K 2 * h K 3 * t
2
4* E * y y
to
2
K1 * Do * 1
2
. K 4 * h K5 * t
2
6 R 1 2 D
K1 . d and, Rd o
* ln Rd R 2 Di
d
6 R 1 D
K2 . d 1 , and, Rd o
* ln Rd ln Rd Di
6 R 1
K3 . d
* ln Rd 2
R * ln Rd Rd 1 Rd
K4 d *
ln Rd Rd 1
2
Rd
K5
2 * Rd 1
Muhannad Al_Waily_Machines Systems Design
Load-Deflection Function for Belleville Washers
4* E * y y
. h y . h .t t 3
F
K1 * Do2 * 1 2 2
The load at the flat
position ( y = h )
4 * E * h * t3
F flat
K1 * Do2 * 1 2
Designing Belleville Springs 1 F flat Do2
t . . in ( S .I . units)
10 4 132.4 h
t
