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Steps To Design Helical Springs Under Static Load

The document outlines the design steps for helical springs under static loading, starting with estimating maximum spring force and deflection. It includes material selection, calculations for wire diameter, mean coil diameter, number of active coils, and determining spring length and stiffness. Additionally, it provides guidelines for ensuring the spring's structural integrity and preventing buckling based on its dimensions.

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XCALIBUR 11216
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63 views6 pages

Steps To Design Helical Springs Under Static Load

The document outlines the design steps for helical springs under static loading, starting with estimating maximum spring force and deflection. It includes material selection, calculations for wire diameter, mean coil diameter, number of active coils, and determining spring length and stiffness. Additionally, it provides guidelines for ensuring the spring's structural integrity and preventing buckling based on its dimensions.

Uploaded by

XCALIBUR 11216
Copyright
© © All Rights Reserved
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

Design step of helical springs for static loading:

Step1: For the given application, estimate the maximum spring force (F) and the
corresponding required deflection (𝛿) of the spring. In some cases, maximum spring
force (F) and stiffness (k), which is (F/ 𝛿), are specified.
Step2: Select a suitable spring material and find out ultimate tensile strength (Sut) from
the data. Calculate the permissible shear stress for the spring wire by following
relationship: 𝛕 = 0.30 Sut or 0.50 Sut
Step3: Assume a suitable value for the spring index (C).
For industrial applications, the spring index varies from 8 to 10. A spring index of 8 is
considered as a good value.
The spring index for springs in valves and clutches is 5. The spring index should never
be less than 3

11-09-2024 School of Mechanical Engineering 1


Design step of helical springs continued:
Step4: Calculate the Wahl factor (K) by the following equation:

𝟒𝐂−𝟏 𝟎⋅𝟔𝟏𝟓
𝒌= +
𝟒𝐂−𝟒 𝑪

Step5: Determine wire diameter (d)

𝟖𝑭𝑫 𝟖𝑭𝑪
𝝉=𝒌 ( )= 𝒌( )
𝝅𝒅𝟑 𝝅𝒅𝟐

Step6:Determine mean coil diameter (D)


𝑫 = 𝑪𝒅

11-09-2024 School of Mechanical Engineering 2


Design step of helical springs continued:

Step7: Determine the number of active coils (N)


𝟖𝑭𝑫𝟑 𝑵
𝜹=
𝑮𝒅𝟒

Step8: Decide the style of ends for the spring depending upon the configuration of the
application.
Determine the number of inactive coils. Find total number of coils (𝑁𝑡 )
𝑵𝒕 = Active +Inactive

Step9: Determine the solid length of the spring by the following relationship:
Solid length = 𝑵𝒕 d (plain and ground)

11-09-2024 School of Mechanical Engineering 3


Design step of helical springs continued:
Step10:Determine the actual deflection of the spring (𝜹 )

𝟖𝑭𝑫𝟑 𝑵
𝜹=
𝑮𝒅𝟒

Step11: When the spring is under the action of maximum load. The total axial gap
between coils is given by
Total gap = (𝑵𝒕 – 1) × gap between two adjacent coils

(gap between adjacent coils of 0.5 to 2 mm )


Total gap =15% deflection

11-09-2024 School of Mechanical Engineering 4


Design step of helical springs continued:
Step12:Determine the free length of the spring

Free length = solid length + total gap + 𝜹

Step13: Determine the pitch of the coil (p)

𝑭𝒓𝒆𝒆 𝒍𝒆𝒏𝒈𝒕𝒉
𝒑=
𝑵𝒕 − 𝟏

Step14: Determine the rate of spring/ spring constant/ stiffness of spring


𝑮 ⅆ𝟒
𝒌=
𝟖𝑫𝟑 𝑵

11-09-2024 School of Mechanical Engineering 5


Design step of helical springs continued:

Step15: A helical compression spring that is too long compared to the mean coil
diameter, acts as a flexible column and may buckle at a comparatively low axial force.
𝑭𝒓𝒆𝒆 𝒍𝒆𝒏𝒈𝒕𝒉
≤ 𝟐 ⋅ 𝟔 (Guide not required)
𝑴𝒆𝒂𝒏 𝒄𝒐𝒊𝒍 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓

𝑭𝒓𝒆𝒆 𝒍𝒆𝒏𝒈𝒕𝒉
> 𝟐 ⋅ 𝟔 (Guide required)
𝑴𝒆𝒂𝒏 𝒄𝒐𝒊𝒍 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓

11-09-2024 School of Mechanical Engineering 6

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