SECTION 4 - SPRINGS

HELICAL COMPRESSION SPRINGS

DESIGN LIGHT, MEDIUM SERVICE
271.

A solenoid brake (Fig. 18.2, Text) is to be actuated by a helical compression

spring. The spring should have a free length of approximately 18 in. and is to
exert a maximum force of 2850 lb. when compressed to a length of 15 in. The
outside diameter must not exceed 7 in. Using oil-tempered wire, design a
spring for this brake, (wire diameter, coil diameter, number of active coils,
pitch, pitch angle, solid stress). General Electric used a spring made of 1 in.
wire, with an outside diameter of 6 in., and 11 free coils for a similar
application.

Solution:
For oil tempered wire, Table AT 17
146
su 0.19 ksi , 0.032 Dw 0.5
Dw
solid stress = 0.6 s u
design stress, (average service)
ssd 0.324 su
0.324146 47.304
ssd

ksi
Dw0.19
Dw0.19
Dw Dm 7
F 2850 lb 2.85 kips
8FDm 47.304

3
Dw0.19
Dw

ss K

say K 1.3
8 2.85 7 Dw
47.304
ss 1.3

3
Dw
Dw0.19

Dw 1.062 in 0.5 in

use ssd

47.304
ksi 54 ksi
0.5 0.19

8 2.85 7 Dw
54
Dw3

ss 1.3

Dw 1.015 in

say Dw 1.0 in
8 2.85 Dm
ss 1.3
54
3
1

Dm 5.72 in
240

SECTION 4 - SPRINGS
say Dm 5.0 in
OD Dm Dw 5.0 1.0 6 in 7 in.
D
5.0
C m
5
Dw 1.0
= Free length Compressed length = 18 in 15 in = 3 in.

8 FC 3 N c
GDw

G 10,500 ksi , Dw

8 2.85 5 N c
10,5001
N c 11.05

3
in
8

say N c 11.5

8 2.85 5 11.5

3.12 in
10,5001
Free length = 15 + 3.12 = 18.12 in
3

At 2.85 kips
8FDm

ss K
3
Dw
C 5
4C 1 0.615 4 5 1 0.615
K

1.3105
4C 4
C
4 5 4
5
8 2.85 5
47.55 ksi
3
1
Permissible solid stress
0.6146
sso 0.6 su
ksi 99.93 ksi
0.5 0.19
F
k

using
or let T = Free length Solid height
47.55 99.93

3.12
T
T 6.56 in
T = Free length Solid height = P Dw N c
6.56 P 111.5
P 1.570 in
ss 1.3105

1
2

use P 1 in
241

SECTION 4 - SPRINGS
Pitch angle,
tan 1

1.5
P

tan 1
5.5 12 , o.k.
D
5

For actual solid stress

T 1.5 111.5 5.75 in.
47.55 sso

3.12 5.75
s so 87.63 ksi 99.93 ksi , ok
Summary of answer:
Dw = wire diameter = 1 in.
Dm = coil diameter = 5 in.
N c = no. of active coils = 11 1/2
P = pitch = 1 in.
= pitch angle = 5.5o
s so = solid stress = 87.63 ksi
272.

A coil spring is to be used for the front spring of a automobile. The spring is to
have a rate of 400 lb./in., an inside diameter of 4 3/64 in., and a free length of
14 1/8 in., with squared-and-ground ends. The material is to be oil-tempered
chrome vanadium steel. Decide upon the diameter of the wire and the number
of free coils for a design load of F 1500 lb . Be sure solid stress is all
right. How much is the pitch angle?

Solution:
Table AT 17 Cr-V steel
168
su 0.166 ksi , 0.032 Dw 0.437
Dw
average service
ssd 0.324 su
0.324168 54.432
ssd
0.166 ksi
Dw0.166
Dw
Max solid stress = 0.6 su

242

SECTION 4 - SPRINGS
3
in 4.046875 in
64
Dm Dw 4.046875 in
ID Dm Dw 4

8FDm
ssd
3
Dw
Assume K 1.3
F 1500 lb 1.5 kips
ss K

ssd

81.5 Dw 4.046875
54.432
1.3

0.166
Dw
Dw3

Dw 0.747 in 0.437 in
use
ssd

54.432
ksi 62.45ksi
0.437 0.166

81.5 Dw 4.046875
62.45
Dw3

ssd 1.3

Dw 0.724 in
use Dw

3
in
4

3
3
51
4 4 in
4
64
64
8FDm

ss K
3
Dw
4C 1 0.615
K

4C 4
C
51
4
Dm 64
C

6.4
Dw
3

4
4 6.4 1 0.615
K

1.235
4 6.4 4
6.4

51
81.5 4
64 53.64 ksi 62.45 ksi
ss 1.235
, (o.k.)
3

3
8 FC N c

GDw
Dm

243

SECTION 4 - SPRINGS
G 10,500 ksi , D w

3
in
8

F 1500

3.75 in
k
400
3
81.5 6.4 N c
3.75
10,500 3
4
N c 9.4

Table AT 16, Total coils = N c 2 9.4 2 11.4 for square and grounded end.
Summary of answer:
Dw = wire diameter = in.
No. of free coils = 11.4
To check for solid stress.
Permissible solid stress =

0.6168
115 .65 ksi
0.437 0.166

Free length = PN c 2 Dw
3
11.4 8.55 in
4

Solid height = Dw N c 2

14 8.55
8
79.74ksi 115
53.64
.65ksi (safe)
3.75

Solid stress =

Pitch:
1
PN c 2 Dw 14 in
8
1
3
P 9.4 2 14
8
4
11
P 1.343 in 1 in
32
Pitch angle,

11
1
P
32
tan 1
tan 1
D

4 51
64

273.

5.1 12 , o.k.

A coiled compression spring is to fit inside a cylinder 5/8 in. in diameter. For one
position of the piston, the spring is to exert a pressure on the piston equivalent
244

SECTION 4 - SPRINGS
to 5 psi of piston area, and in this position, the overall length of the spring
must not exceed (but may be less than) 2 in. A pressure of 46 psi on the piston
is to compress the spring in. from the position described above. Design a
spring for medium service. Specify the cheapest suitable material, number of
total and active coils for square-and-ground ends, and investigate the pitch
angle, and solid stress.
Solution:
8FDm

ss K
3

D
w

OD Dm Dw
Dm 1.5 Dw

F1 5
4

5
D
in w
8
2

5
in
8
2

5

8

F2 46 5
4

1.534 lb
5

8

15.647 lb

Using hard-drawn spring wire, Cost Index = 1

ssd 0.324 su 0.85
140
su 0.19 ksi
Dw
, 0.028 Dw 0.625
70
ksi
Dw0.19
140 38.556
ssd 0.324 0.85 0.19
Dw
Dw0.19

Max solid stress =

8FC 38.556
38,556

ksi 0.19 psi
2
0.19
Dw
Dw
Dw

ss K

815.647 C
38,556 Dw1.81

K 39.845 C 38,556 Dw1.81

Dm 1.5 Dw 0.625
CDw 1.5 Dw 0.625
0.625
Dw
C 1.5
4C 1 0.615
K

4C 4
C
K

245

SECTION 4 - SPRINGS
4C 1 0.615
0.625

39.845 C 38,556

C
4C 4
C 1.5
4C 1 0.615
1.81

C 1.5 C 413.3
C
4C 4
C 7.035
0.625
0.625
Dw

0.0732 in
C 1.5 7.035 1.5
Table AT 15, Dw 0.0720 in , W & M 15
Dm 7.035 0.0720 0.5065 in
For N c

2 1

1.81

8 F2 F1 C 3 N c
GDw

G 11.5 106 psi

3 815.647 1.534 7.035 N c

4
11.5 106 0.0720
N c 15.8
Table AT 16,
Total coils = N c 2 15.8 2 17.8
Solid height = N c 2 Dw 15.8 2 0.0720 1.28 in
Free length = PN c 2 Dw
Free length = 2 1
3

2 1

8 F1 C 3 N c
GDw

81.534 7.035 15.8

0.082 in.
11.5 10 6 0.0720
Free length = 2 0.082 2.082 in
8 F2 C 3 N c
2
GDw

815.647 7.035 15.8

2
0.832 in.
11.5 10 6 0.0720
Solid Height Free Length - 2
Solid Height 2.082 0.832 in
Solid Height 1.25 in
But Solid Height > 1.25 in.
3

Therefore change material to Oil-tempered spring wire, Cost Index = 1.5

Table AT 17

246

SECTION 4 - SPRINGS
su

146
ksi , 0.028 Dw 0.5
D w0.19

87.5
Max solid stress = D 0.19 ksi
w

146 47.304

Dw0.19
Dw0.19

ssd 0.324

8FC 47.304
47,304

ksi
psi
2
0.19
Dw
Dw0.19
Dw

ss K

815.647 C
47,304 Dw1.81

K 39.845 C 47,304 Dw1.81

0.625
Dw
C 1.5
4C 1 0.615
K

4C 4
C
4C 1 0.615
0.625

39.845 C 47,304

C
4C 4
C 1.5
4C 1 0.615
1.81

C 1.5 C 507.1
4
C

4
C

C 7.684
0.625
0.625
Dw

0.0680 in
C 1.5 7.684 1.5
Table AT 15, Dw 0.0625 in , W & M 16
Dm 7.684 0.0625 0.48025 in
K

say Dm
C

1.81

15
0.46875 in
32

Dm 0.46875

7.5
Dw
0.0625

8FC

D
w

4C 1 0.615 4 7.5 1 0.615

K

1.1974
4C 4
C
4 7.5 4
7.5

ss K

815.647 7.5
91,600 psi 91.6 ksi
2
0.0625

ss 1.1974
For N c

2 1

8 F2 F1 C 3 N c
GDw
247

SECTION 4 - SPRINGS
G 11.5 106 psi

3 815.647 1.534 7.5 N c

2 1
4
11.5 106 0.0625
N c 11.32
Table AT 16, squared and ground ends
Total coils = N c 2 11.32 2 13.32
Solid height = N c 2 Dw 11.32 2 0.0625 0.8325 in
3

Free length = PN c 2 Dw
Free length = 2 1
8 F1 C 3 N c
1
GDw

81.534 7.5 11.32

1
0.082 in.
11.5 10 6 0.0625
Free length = 2 0.082 2.082 in P 11.32 2 0.0625
3

P 0.1729 in

11
in
64

Pitch angle,
tan 1

0.1729
P

tan 1
6.7 12 , o.k.

0
.
46875

Solid stress
2 0.8325
sso 91.6
142.6 ksi
0.75

Permissible solid stress =

87.5
148.8 ksi 137.5 ksi , safe.
0.0625 0.19

Summary of answer:
Suitable material = Oil-Tempered Spring Wire
Total Coils = 13.32
Active Coils, N c 11.32
274.

A helical spring is to fit about a 11/16-in. rod with a free length of 2 in. or less.
A maximum load of 8 lb. is to produce a deflection of 1 in. The spring is
expected to be compressed less than 5000 times during its life, but is subjected
to relatively high temperatures and corrosive atmosphere. Select a material
and determine the necessary wire size, mean coil diameter, and number of
coils. Meet all conditions advised by Text.

Solution:
For 5000 cycles < 104 cycles, use light service

248

SECTION 4 - SPRINGS
Use stainless steel, type 302 (Cr-Ni), ASTM A313 for relative high temperature and
corrosive atmosphere, Table AT 17.
ssd 0.32 su (i)
170
ksi , 0.01 Dw 0.13
Dw0.14
97
su 0.41 ksi , 0.13 Dw 0.375
Dw
su

Maximum solid so 0.47 su

8FDm

ss K
3

D
w

F 8 lb
11 D
Dm Dw w
16 2
Dm 1.5 Dw 0.6875 in
CDw 1.5Dw 0.6875
0.6875
Dw
C 1.5
4C 1 0.615
K

4C 4
C
170
assume su 0.14 ksi
Dw
0.32170 54.4
54,400
ssd
0.14 ksi
psi
0.14
Dw
Dw
Dw0.14
4C 1 0.615 8 8 C

54,400 D1w.86

C
4C 4
1.86

4C 1 0.615 64C
0.6875

54,400

C
4C 4
C 1.5
4C 1 0.615
1.86

C 1.5 C 1330
4
C

4
C

C 12.919
0.6875
Dw
0.0602 in
12.919 1.5
Use Table AT 15, Dw 0.0625 in , 16 W & M
Dm 12.919 0.0602 0.8074 in
say Dm

25
in 0.78125 in
32

11
16
0.78125 0.0625 0.6875
Dm Dw

249

SECTION 4 - SPRINGS
0.71875 0.6875
0.71875 0.6875 0.03125
C

Dw
, o.k.
2

Dm 0.71875

12.5
Dw
0.0625

0.0625 0.13 , therefore,

su

170
ksi is o.k.
Dw0.14

8FC

2
Dw
412.5 1 0.615
K

1.1144
412.5 4 12.5

ss K

8 812.5
72,648 psi
2
0.0625

ss 1.1144

8 F C 3 N c
GDw

G 10.6 106 psi

3
8 812.5 N c
1
4 10.6 106 0.0625
N c 9.3
To check for solid stress and pitch
Minimum solid height = Dw N c 0.0625 9.3 0.58125 in
72,648 2 3 0.58125
4
90,000 psi 90 ksi
Solid stress =
3
1
4
0.47 170 117 .8 ksi 90 ksi
Permissible solid stress =
, o.k.
0.0625 0.14
Free length = PN c , minimum
3
P 9.3 2
4
P 0.2957 in
Pitch angle,
3

tan 1

0.2957
P

tan 1
7.5 12 , o.k.
D
0.71825

Summary of answer
Material, Stainless Steel, Cr-Ni. ASTM A313
Dw 0.0625 in , 16 W & M
25
Dm
in
32
250

SECTION 4 - SPRINGS
N c 9.3
275.

In order to isolate vibrations, helical compression springs are used to support a

machine. The static load on each spring is 3500 lb., under which the deflection
should be about 0.5 in. The solid deflection should be about 1 in. and the
outside coil diameter should not exceed 6 in. Recommend a spring for this
application; include scale, wire size, static stress, material, number of coils,
solid stress, and pitch of coils.

Solution:
Use Music wire (The best material)
Table AT 17
190
su 0.154 ksi , 0.004 Dw 0.192
Dw
Maximum solid s so 0.5su
Light service, ssd 0.405su
0.405190 76.95
76,950
ssd
0.154 ksi 0.154 psi
0.154
Dw
Dw
Dw
8FC

2
Dw
F 3500 lb
OD Dm Dw 6 in
C 1 Dw 6
6
Dw
C 1
ss K

76,950
4C 1 0.615 8 3500 C

ss

C 6 6 0.154
4C 4

C 1 C 1

4C 1 0.615
1.846

235.9

C C 1
C
4C 4
C 5.635
6
Dw
0.9043 in 0.192 in
5.635 1

use ss

76.950
99,216 psi
0.192 0.154

4C 1 0.615 8 3500 C
99,216
ss

C 6
4C 4

C 1
251

SECTION 4 - SPRINGS
4C 1 0.615
2

C C 1 400.8
C
4C 4
C 6.205
6
Dw
0.8328 in
6.205 1
Say Dw

13
in 0.8125 in
16

Dm 6.205 0.8125 5.042 in

Say Dm 5 in
D
5
C m
6.154
Dw 0.8125
4 6.154 1 0.615
K

1.2455
4 6.154 4 6.154
8FC

2
Dw

ss K

8 3500 6.154
103,481 psi 99,216 psi , not o.k.
2
0.8125

ss 1.2455

Use Dm 4.5 in
D
4.5
C m
5.5385
Dw 0.8125
4 5.5385 1 0.615
K

1.2763
45.5385 4 5.5385
8 3500 5.5385
ss 1.2763
95,435 psi 99,216 psi , o.k.
0.8125 2

To check for solid stress

0.5190 122.488 ksi 122,488 psi
Permissible solid stress =
0.192 0.154

1
95,435 190,870 psi 122,488 psi , not ok
0.5

Solid stress =
Use

0.5
ssd 122,488
61,244 psi
1

4C 1 0.615 8 3500 C
61,244
ss

C 6
4C 4

C 1
4C 1 0.615
2

C C 1 247.4
C
4C 4
C 5 .1
252

SECTION 4 - SPRINGS
Dw

6
0.9836 in
5.1 1

Say Dw 1.0 in
Dm 5.11.0 5.1 in
Say Dm 5 in
D
5
C m 5
Dw 1

8FC

2
Dw
4 5 1 0.615
K

1.3105
4 5 4
5
8 3500 5
ss 1.3105
58,400 psi 61,244 psi o.k.
2
1.0
Use Dw 1.0 in , Dm 5 in
ss K

1
58,400 116 ,800 psi 122,488 psi , o.k.
0 .5

Solid stress =

8 F C 3 N c
GDw
(Table AT 17)
G 12 106 psi

8 3500 5 N c
12 106 1.0
N c 1.7143
3

0.5

say N c 1.75
Free length Solid length = Solid Deflection
PN c Dw N c 1 in
P1.75 11.75 1
9
P 1.5714 in 1 in
16
Pitch angle,
tan

116
P
1

tan
5.68 12 ,
D

o.k.

Summary of answer.
F 3500

7000 lb in

0.5
Wire size, Dw 1.0 in

Scale, k

Material = Music Wire

253

SECTION 4 - SPRINGS
Solid sress = 116,800 psi
Pitch of stress = P 1

9
in
16

CHECK PROBLEMS LIGHT, MEDIUM SERVICE

276.

The front spring of an automobile has a total of 9 coils, 7 3/8 active coils
(square-and-ground ends), an inside diameter of 4 3/64 in., and a free length
of 14 in. It is made of SAE 9255 steel wire, OQT 1000oF, with a diameter
of 43/64 in. Compute (a) the rate (scale) of the spring; (b) the solid stress
and compare with a permissible value (is a stop needed to prevent solid
compression?). (c) Can 95 % of the solid stress be repeated 105 times without
danger of failure? Would you advise shot peening of the spring?

Solution:
8 FC 3 N c
GDw
43
3
Dw
in in
64
8
6
G 10.5 10 psi
D
C m
Dw
Dm Dw ID
43
3
Dm
4 in
64
64
23
Dm 4 in
32
23
4
C 32 7.0233
43
64
3
Nc 7
8

(a)

10.5 10
6

k rate

F
GD
3w
8C N c

8 7.0233

43

64
345 lb in
3
7
8

(b) Solid Stress

43 1
9 6.3828 in
64 2

Solid height = N c Dw Total Coils

254

SECTION 4 - SPRINGS
Solid deflection = Free length Solid height = 14 - 6.3828 = 7.8672 in.
Solid Force = Fso 7.8672 345 2714 lb

8 FsoC
2
Dw
4C 1 0.615
K

4C 4
C
4 7.0233 1 0.615
K

1.212
4 7.0233 4 7.0233

Solid Stress = K

8 2714 7.0233

ss 1.212

43

64

130,322 psi

Permissible value, ss s ys 0.6 sy , Dw 0.5 in

SAE 9255, OQT 1000 oF
s y 160 ksi su 180 ksi
,
s ys 0.6160 96 ksi 96,000 psi 130,322 psi

Therefore a stop is needed to prevent solid compression.

(c) ssd 0.324 su (105 cycles)
ssd 0.324180 58.32 ksi
0.95sso 0.95130,322 123,800 psi 123.8 ksi 58.32 ksi
There is a danger of failure, shot peening is advisable
s ys 1.25 96,000 120,000 psi 0.95sso
277.

An oil-tempered steel helical compression spring has a wire size of No. 3 W & M,
a spring index of 4.13, 30 active coils, a pitch of 0.317 in., ground-andsquared ends; medium service. (a) What maximum load is permitted if the
recommended stress is not exceeded (static approach)? Compute (b) the
corresponding deflection, (c) solid stress,. (d) pitch angle, (e) scale, (f) the
energy absorbed by the spring from a deflection of 0.25 in. to that of the
working load. (g) Is there any danger of this spring buckling? (h) What
maximum load could be used if the spring were shot peened?

Solution:
Table AT 17, oil-tempered
146
su 0.19 ksi , 0.032 Dw 0.5
Dw
87.5
Maximum solid sso 0.19 ksi
Dw
255

SECTION 4 - SPRINGS
ssd 0.324 su (medium service)

Table AT 15, No. 3 W & M

Dw 0.2437 in
C 4.13
Dm CDw 4.13 0.2437 1.0 in

8 Fs C
2
Dw
4C 1 0.615
K

4C 4
C
4 4.13 1 0.615
K

1.3885
4 4.13 4 4.13
0.324146
ss ssd
61.858 ksi 61,858 psi
0.2437 0.19
8 F 4.13
ss 61,858 1.3885
2
0.2437
F 252 lb
8 FC 3 N c

GDw

(a) ss K

G 11.5 106 psi

N c 30

8 252 4.13 30

1.52 in
11.5 106 0.2437
3

(c) For solid stress . Square-and-ground end)

Free length = PN c 2 Dw 0.317 30 2 0.2437 9.9974 in
Solid height = Dw N c 2 Dw 30 2 0.2437 7.7984 in
Solid deflection = 9.9974 7.7984 = 2.199 in.
2.199
89,491 psi
1.52

Solid stress = 61,858

Maximum solid sso

87.5
87.5
ksi
ksi 114 .4 ksi 89.491 ksi , o.k. safe
0.19
Dw
0.2437 0.19

0.317
P

tan 1
5.76 12 , o.k.

F 252
166 lb in
(e) scale k
1.52
1
(d) tan

256

SECTION 4 - SPRINGS
(f) U s

1
k 22 12
2

k 166 lb in
1 0.25 in
2 1.52 in
1
2
2
U s 166 1.52 0.25 186.6 in lb
2

(g) i 6.18 Free length = 9.9974 in

Mean Diameter = Dm 1.0 in
Free length
9.9974

9.9974 4
Mean Diameter
1.0
There is a danger for spring buckling
(h) Shot peened, Table AT 17
ssd 61,8581.25 77,322 psi

8 F 4.13
2
0.2437

ss 77,322 1.3885
F 314 lb
280.

It is desired to isolate a furnace, weighing 47,300 lb., from the surroundings by

mounting it on helical springs. Under the weight, the springs should deflect
approximately 1 in., and at least 2 in. before becoming solid. It has been
decided to use springs having a wire diameter of 1 in., an outside diameter of
5 3/8 in., 4.3 free coils. Determine (a) the number of springs to be used, (b)
the stress caused by the weight, (c) the solid stress. (d) What steel should be
used?

Solution:
Dw 1 in
3
Dm Dw 5 in
8
3
Dm 4 in
8
3
4
D
C m 8 4.375
Dw
1

(a)

8FC 3 N c
GDw

Assume N c 4.3
257

SECTION 4 - SPRINGS
G 10.5 10 6 psi , Dw

8F 4.375 4.3
10.5 10 6 1
F 3645 lb

1.0

No. of springs =
(b) F

3
in
8

W
47,300

13
F
3645

W 47,300

3638 lb
13
13

8 Fs C
2
Dw
4C 1 0.615
K

4C 4
C
4 4.375 1 0.615
K

1.3628
4 4.375 4 4.375

ss K

8 3638 4.375
55,235 psi
2
1.0

ss 1.3628

2
110,470 psi
1

(c) Solid Stress = ss 55,235

(d) s ys 110,470 psi

s
110,470
s y ys
184,117 psi 184.117 ksi
0.6
0.6
From Table AT 7,
Use AISI 8760, OQT 800 oF, s y 200 ksi
VARYING STRESS APPROACH
DESIGN PROBLEMS
282.

A spring, subjected to a load varying from 100 lb. to 250 lb., is to be made of oiltempered, cold-wound wire. Determine the diameter of the wire and the mean
diameter of the coil for a design factor of 1.25 based on Wahls line. The spring
index is to be at least 5. Conform to good practice, showing checks for all
significant parameters. Let the free length be between 6 and 8.

Solution:
Fmax 250 lb
Fmin 100 lb
1
1
Fm Fmax Fmin 250 100 175 lb 0.175 kip
2
2
258

SECTION 4 - SPRINGS
1
Fmax Fmin 1 250 100 75 lb 0.075 kip
2
2
Wahls line
1 sms sas 2sas

N
s ys
sno
8 KFa Dm 8KFa C
sas

Dw3
Dw2
8 KFm Dm 8 KFmC
sms

K cDw3
K cDw2
C 5
4C 1 0.615
K

4C 4
C
4 5 1 0.615
K

1.31
4 5 4
5
Fig. AF 15, C 5
K c 1.19
For oil-tempered wire,
87.5
s ys 0.19
Dw , 0.032 Dw 0.5
Fa

47
Dw0.1 , 0.041 Dw 0.15
30
sno 0.34
Dw , 0.15 Dw 0.625
sno

N 1.25
81.31 0.075 5 1.251
sas

Dw2
Dw2
81.31 0.175 5 2.453
sms

1.19Dw2
Dw2
30
say sno 0.34 ksi
Dw
1 sms sas 2sas

N
s ys
sno
2.453 1.251

2
D
w

1.251

2
2
D
1
w

1.25
87.5
30
0.19
0.34
Dw
Dw
1
1
1

1.81
1.25 72.8 Dw
11.99 Dw1.66
259

SECTION 4 - SPRINGS
Dw 0.2857 in 0.15 in
Table AT 15, use No. 1, W & M
Dw 0.2830 in
Dm CDw 5 0.2830 1.415 in
say Dm 1

7
in
16

Check for Free length

6 in < Free length < 8 in

Free length = 4 Dm 4 1

7
5.75 in
16

Increase Dm
1
Dm 1 in
2

1
2

Free length = 4 Dm 4 1 6 in , o.k.

Summary of answer
Dw 0.2830 in
1
Dm 1 in
2
283.

A carbon-steel spring is to be subjected to a load that varies from 500 to 1200 lb.
The outside diameter should be between 3.5 and 4 in., the spring index between 5
to 10; approximate scale of 500 lb./in. Choose a steel and for a design factor of
1.4 by the Wahl line, find the wire diameter. Also determine the number of active
coils and the free length for squared-and-ground ends. Conform to the general
conditions specified in the Text.
Solution:
For carbon steel, Table AT 17
91
s ys 0.1 ksi , 0.093 Dw 0.25
Dw
49
sno 0.15 ksi , 0.093 Dw 0.25
Dw
Fmax 1200 lb
Fmin 500 lb
1
1
Fm Fmax Fmin 1200 500 850 lb 0.85 kip
2
2
1
1
Fa Fmax Fmin 1200 500 350 lb 0.35 kip
2
2
OD 3.5 ~ 4.0 in
C 5 ~ 10
260

SECTION 4 - SPRINGS
Wahls line
1 sms sas 2sas

N
s ys
sno
Figure AF 15, C 5 ~ 10
Assume K 1.2 , K c 1.125
8 KFa Dm
sas
Dw3
8 KFm Dm
sms
K cDw3
OD 3.75 in
Dm 3.75 Dw
81.2 0.35 3.75 Dw 1.0695 3.75 Dw
sas

Dw3
Dw3
81.2 0.85 3.75 Dw 2.3088 3.75 Dw
sms

1.125Dw3
Dw3
1

1.4

3.75 Dw

Dw3

2.3088 1.0695

91
0.1
Dw

1
3.75 Dw
3.75 Dw

2.9
1.4 73.4285 Dw
22.9079 Dw2.85
Dw 0.6171 in 0.25 in
Use
91
s ys
104.53 ksi
0.25 0.1
49
sno
60.33 ksi
0.25 0.15

3.75 Dw

Dw3

21.0695

49

0.15
Dw

3.75 Dw
3.75 Dw
21.0695

3
Dw
Dw3
1

1.4
104.53
60.33
1
3.75 Dw 3.75 Dw

1.4 84.346 Dw3 28.205Dw3

1
3.75 Dw

1.4 21.137 Dw3

Dw 0.5935 in
use
19
Dw
in
32

2.3088 1.0695

261

SECTION 4 - SPRINGS
3
Dm Dw 3 in
4
19
3
Dm
3 in
32
4
5
Dm 3 in
32
5
3
Dm 32
C

5.316
Dw
19

32
. o.k.
Wire Diameter Dw

19
in , Carbon Steel
32

Number of coils:
8 FC 3 N c

GDw
G 10.5 10 6 psi 10,500 ksi , Dw

3
in
8

F
GD
k 3 w

8C N c

10.5 10

19

32

500
3
8 5.316 N c
N c 10.4
Table AT 16, square-and-ground ends
Free length = PN c 2 Dw
Solid height = Dw N c 2 Dw
Total Coils = N c 2
6

19
7.3625 in
32

Solid height = Dw N c 2 Dw 10.4 2

F 1200

2.4 in
k
500
Min. Free length = 2.4 + 7.3625 in = 9.7625 in
Use Free length = 10 in

To check for pitch angle.

Free length = PN c 2 Dw
19
P10.4 2
10
32
P 0.8474 in
262

SECTION 4 - SPRINGS

tan

0.8474
5

3
32

4.885 12 ,

P
tan 1
Dm

o.k.

Solid stress:
T solid deflection 10 7.3625 2.6375 in
F k T 500 2.6375 1319 lb
4C 1 0.615
K

4C 4
C
4 5.316 1 0.615
K

1.29
4 5.316 4 5.316
5
81.29 1319 3
8 KFDm
32 23,033 psi 23.033 ksi s 104.53 ksi
ss

ys
3
3
Dw
19

32
284.

A helical compression spring, made of oil-tempered, cold-wound carbon steel, is

to be subjected to a working load varying from 100 to 300 lb. for an indefinite
time (severe). A mean coil diameter of 2 in. should be satisfactory. (a) Using the
static approach, compute a wire diameter. (b) For this wire size, compute the
factor of safety as given by the Wahl line.

Solution:
Table AT 16,
For carbon steel,
182
su 0.1 ksi , 0.093 Dw 0.25
Dw
91
Max. solid s ys 0.1 ksi
Dw
49
sno 0.15 ksi , 0.093 Dw 0.25
Dw
Dm 2 in.
Fmax 300 lb
Fmin 100 lb
(a) F 300 lb 0.3 kip
severe service, ssd 0.263su

0.263182 47.866 ksi

Dw0.1

Dw0.1

263

SECTION 4 - SPRINGS
8 Fs C
2
Dw
4C 1 0.615
K

4C 4
C
D
C m
Dw
D
2
Dw m
C C
ss K

4C 1 0.615 8 0.3 2
ss

C 2 3
4C 4

C
4C 1 0.615 2.9
4C 4 C C 233.84
C 6.075
2
Dw
0.3292 in 0.25 in
6.075
Therefore use ssd

47.866
2

C

0.1

47.866
54.984 ksi
0.25 0.1

4C 1 0.615 8 0.3 2
ss

54.984
C 2 3
4C 4

C
4C 1 0.615 3
4C 4 C C 287.9
C 6.136
2
Dw
0.3259 in
6.136
say Dw
(b) s ys

21
in
64

91
104.53 ksi
0.25 0.1

49
60.33 ksi
0.25 0.15
1
1
Fm Fmax Fmin 300 100 200 lb 0.2 kip
2
2
1
1
Fa Fmax Fmin 300 100 100 lb 0.1 kip
2
2

sno

264

SECTION 4 - SPRINGS
Dm
2

6.095
Dw 21

64
Figure AF 15
K c 1.15
K 1.25
K 8 Fm Dm
sms

K c Dw3
C

sms

1.25 8 0.2 2

31.34 ksi
1.15 21 3


64

sas

8 KFa Dm
Dw3

sas 1.25

8 0.1 2

3
21


64

18.02 ksi

Wahls line
1 sms sas 2sas

N
s ys
sno
1 31.34 18.02 218.02

N
104.53
60.33
N 1.38
285.

A helical spring of hard-drawn wire with a mean diameter of 1 in. and squareand-ground ends is to be subjected to a maximum load of 325 lb. (a) Compute the
wire diameter for average service. (b) How many total coils are required if the
scale is 800 lb./in.? (c) For a minimum load of 100 lb., what is the factor of safety
according to Wahl line? Would it be safe for an indefinite life?

Solution:
Table AT 17,
Hard-drawn wire,
140
su 0.19 ksi , 0.028 Dw 0.625
Dw
265

SECTION 4 - SPRINGS
Maximum solid ss s ys

0.9 47 ksi

70
ksi
Dw0.19

, 0.041 Dw 0.15
Dw0.1
0.9 30 ksi
sno
, 0.15 Dw 0.625
Dw0.34
Average service

sno

0.2754140 38.556

ksi
Dw0.19
Dw0.19

(a) ssd 0.85 0.324 su 0.2754su

F 325 lb 0.325 kip

Dm 1

1
in
2

8 FDm
3
Dw

ss K

4C 1 0.615

4C 4
C
1.5
Dw
C

0.615
4C 1

C
4C 4

8 0.3251.5

ss

1.5

38.556
1.5

4C 1 0.615 2.81

97.05

C
C
4C 4
C 4.586
1 .5
1.5
Dw

0.3271 in 0.625 in
C
4.586
21
Dw
in
64

(b)

Dm
1.5

4.57
Dw 21

64

4 4.57 1 0.615

1.345
4 4.57 4 4.57

8 FC 3 N c
GDw

F
GD
k 3 w

8C N c
k 800 lb in 0.8 kip in

266

0.19

SECTION 4 - SPRINGS

0.8

11,500

21

64
84.57 3 N c

N c 6.2

(c)

s ys

sno

70
0.19

21

64
0.9 30

86.5 ksi

39.44 ksi
0.19
, Dw 0.15 in
21

64
1
Fm 325 100 212.5 lb 0.2125 kip
2
1
Fa 325 100 112 .5 lb 0.1125 kip
2
K c 1.212 , Fig. AF 15
K 1.345

K 8 Fm Dm
1.345 8 0.21251.5

25.5 ksi

K c Dw3
1.212
21

64

8 Fm Dm
8 0.1125 1.5 16.36 ksi
K
1.345
3
3

21
Dw

64

s ms

sas

1 sms sas 2 sas 25.5 16.36 216.36

N
s ys
sno
86.5
39.44

N 1.07 1.15 N min

Not safe for indefinite life.
286.

A helical spring is to be subjected to a maximum load of 200 lb. (a) Determine the
wire size suitable for medium service if the material is carbon steel ASTM A230;
C 6 . Determine the factor of safety of this spring according to the Wahl line
(b) If the minimum force is 150 lb., (c) if the minimum force is 100 lb., (d) if the
minimum force is 25 lb.

Solution:
For carbon steel ASTM A230
Table AT 17
182
su 0.1 ksi , 0.093 Dw 0.25
Dw

267

SECTION 4 - SPRINGS
91
ksi , 0.093 Dw 0.25
Dw0.1
49
sno 0.15 ksi , 0.093 Dw 0.25
Dw
Medium Service
s ys

ssd 0.324 su

182 58.968
58,968
ksi
psi
(a) ssd 0.324 0.1
0.1
Dw
Dw0.1
Dw
8 FDm
ss K
3
Dw
4C 1 0.615

4C 4
C
4 6 1 0.615
K

1.2525
4 6 4
6
K

F 200 lb

8 200 6
58,968

2
Dw0.1
Dw

ss 1.2525

Dw 0.2371 in

Table At 15, use Dw 0.2437 in , No. 3 W & M

Dw 0.2437 in 0.25 in , o.k.
Factor of safety.
91
91
s ys 0.1 ksi
ksi 104.8 ksi
Dw
0.2437 0.1
49
49
sno 0.15 ksi
ksi 60.56 ksi
0.2437
Dw
(a) Fm

1
200 150 175 lb 0.175 kip
2

1
200 150 25 lb 0.025 kip
2
Figure AF 15, K c 1.156
Fa

K 8FmC 1.2525 8 0.175 6

48.8 ksi

K c Dw2
1.156 0.2437 2
8 0.025 6
8 Fa C
sas K
1.2525
8.1 ksi
2
2
Dw
0.2437
sms

1 sms sas 2 sas

N
s ys
sno

268

SECTION 4 - SPRINGS
1
48.8 8.1 2 8.1

N
104.8
60.56
N 1.525

(b) Fm

1
200 100 150 lb 0.15 kip
2

1
200 100 50 lb 0.05 kip
2
Figure AF 15, K c 1.156
Fa

sms

K
Kc

8 Fm C 1.2525 8 0.15 6

41.8 ksi

2
1.156 0.2437 2
Dw

8 0.05 6
8 Fa C
1.2525
16.11 ksi
2
2

0
.
2437

sas K

1 sms sas 2 sas

N
s ys
sno

1
41.8 16.11 216.11

N
104.8
60.56
N 1.287

(c) Fm

1
200 25 112.5 lb 0.1125 kip
2

1
200 25 87.5 lb 0.0875 kip
2
Figure AF 15, K c 1.156
Fa

K 8FmC 1.2525 8 0.1125 6

31.36 ksi

K c Dw2
1.156 0.2437 2
8 0.0875 6
8Fa C
sas K
1.2525
28.2 ksi
2
2
Dw
0.2437
sms

1 sms sas 2 sas

N
s ys
sno

1 31.36 28.20 2 28.20

N
104.8
60.56
N 1.04

CHECK PROBLEMS
A Diesel valve spring is made of 3/8-in. chrome-vanadium steel wire, shot-peened; inside
diameter is 3 in., 7 active coils, free length is 7 3/8 in., solid length is 4 1/8 in., length
with valve closed, 6 in., length when open, 5 1/8 in. (a) Compute the spring constant
and the factor of safety as defined by the Wahl criterion (see 6.13, Text). (b) Is there any
danger of damage to the spring if it is compressed solid? (c) What is the natural
269

SECTION 4 - SPRINGS
frequency? If this spring is used on a 4-stroke Diesel engine at 450 rpm, is there any
danger of surge? Compute the change of stored energy between working lengths.

Solution:
For chrome-vanadium steel wire, shot-peened, Table AT 17
1.25168 ksi
su
, 0.032 Dw 0.437
Dw0.166
1.25100 ksi
s ys
, 0.032 Dw 0.437
Dw0.166
1.25 49 ksi
sno
, 0.028 Dw 0.5
Dw0.15
3
in 0.375 in
8
1.25100 ksi 147.1 ksi

0.375 0.166

Dw

s ys

sno

1.25 49
0.375 0.15

(a)

ksi 70.96 ksi

8FC 3 N c
GDw

F
GD
k 3 w

8C N c
G 11 .5 10 6 psi
Nc 7

Dw 0.375 in
Dm Dw ID 3 in
Dm 3.375 in

Dm 3.375

9
Dw 0.375

k spring constant

GDw
11.5 106 0.375 105.64 lb in

3
8C 3 N c
8 9 7

3
1
1 7 4 3.25 in
8
8
F1 k1 105.64 3.25 343.33 lb
3
1
2 7 6 1.125 in
8
4
F2 k 2 105.64 1.125 118 .85 lb

270

SECTION 4 - SPRINGS
1
343.33 118 .85 231.09 lb 0.231 kip
2
1
Fa 343.33 118 .85 112 .24 lb 0.11224 kip
2
Fm

sms

K 8FmC

K c Dw2

4C 1 0.615

4C 4
C
4 9 1 0.615
K

1.162
4 9 4
9
Figure AF 15, K c 1.10
K

K 8 Fm C 1.162 8 0.231 9

39.8 ksi

K c Dw2
1.10 0.375 2
8 0.11224 9
8 Fa C
sas K

1
.
162

21.3 ksi

2
2
Dw
0.375
sms

1 sms sas 2 sas

N
s ys
sno

1 39.8 21.3 2 21.3

N
147.1
70.96
N 1.377

(b) max. solid ss s ys 147.1 ksi

Min. Solid Height = Dw N c 0.375 7 2.625 in
Solid deflection = 7

3
2.625 4.75 in.
8

F k 105.64 4.75 501.8 lb 0.5018 kip

8 0.5018 9
8 FC
1.162
95 ksi 147.1 ksi
2
2
Dw
0.375
There is no danger of damage

Solid stress = ss K

(c) Natural frequency

For steel
14,050 Dw

cps
N c Dm2
14,050

cps
N c C 2 Dw

14,050
cps 66 cps
7 9 2 0.375

271

SECTION 4 - SPRINGS
2
47 cps
60

For 450 rpm, 450

66
1.4 12 , there is danger of surging.
47

(d) U s
289.

1
1
2
2
k 12 22 105.64 3.25 1.125 491 in lb
2
2

A helical spring is hot wound from 5/8-in. carbon-steel wire with an outside
diameter of 3 in. A force of 3060 lb. is required to compress the spring 1
in to the solid heigh. In service the spring is compressed so that its
deformation varies form in. to1 1/8 in. (a) What is the factor of safety by the
Wahl criterion? (b) Is the solid stress safe? Compute (c) the pitch angle, (d)
the change of stored energy between the working lengths, (e) the factor of
safety if the spring is peened?

Solution:
For hot-wound carbon steel wire
Dw

5
in
8

Table AT 17
91
s ys 0.1 ksi , 0.093 Dw 0.25
Dw
91
ksi 104.5 ksi , Dw 0.25 in.
0.25 0.1
49
0.15 ksi , 0.093 Dw 0.25
Dw
49

ksi 60.33 ksi , Dw 0.25 in.

0.25 0.15

s ys

sno
sno

Permissible solid stress = ss

ss

117
ksi , Dw 0.375 in. 6.3
Dw0.31

117
ksi 35.4 ksi
0.625 0.31

F 3060

1748.6 lb in

1.75
1
F1 k 1 1748.6 874.3 lb
2
1
F2 k 2 1748.6 1 1967.2 lb
8

(a) k

272

SECTION 4 - SPRINGS
1
1967.2 874.3 1420.7 lb 1.4207 kip
2
1
Fa 1967.2 874.3 546.4 lb 0.5464 kip
2
5
Dw in 0.625 in
8
1
Dm Dw 3 in
4
Dm 2.625 in
Fm

Dm 2.625

4.2
Dw 0.625

4C 1 0.615

4C 4
C
4 4.2 1 0.615
K

1.3808
4 4.2 4
4.2
K c 1.234
K

K 8 FmC 1.3808 81.4207 4.2

43.5 ksi

K c Dw2
1.234 0.625 2
8 0.5464 4.2
8 Fa C
sas K

1
.
3808

20.7 ksi

2
2

0
.
625

sms

1 sms sas 2 sas

N
s ys
sno

1 43.5 20.7 2 20.7

N
104.5
60.33
N 1.106

(b) Permissible solid stress = 135.4 ksi

F 3.060 kip

8 3.060 4.2
8 FC

1
.
3808
115 .7 ksi 135.4 ksi , safe

2
2
Dw
0.625

Solid stress, ss K

(c) Solid deflection = 1

P Dw N c 1.75 in

3
in
4

8 FC 3 N c

GDw
G 10.5 10 6 psi , hot-wound

F
GD
3w
8C N c
273

SECTION 4 - SPRINGS

1748.6

10.5 10 0.625
6

8 4.2 N c
3

N c 6.332
P 0.625 6.332 1.75
P 0.9014 in

Pitch angle
tan

P
P

Dm CDw

tan 1

(d) U s

P
0.9014

tan 1
6.24
CDw
4.2 0.625

1
1
2
2
k 12 22 1748.6 1.125 0.5 888 in lb
2
2

(e) When peened

s ys 12.5104.5 130.6 ksi

sno 1.25 60.33 75.4 ksi

1 43.5 20.7 2 20.7

N
130.6
75.4
N 1.38

ENERGY STORAGE
293.

A 10-lb. body falls 10 in. and then strikes a helical spring. Design a hard-drawn
carbon steel spring that will absorb this shock occasionally without permanent
damage. Determine appropriate values of wire diameter, coil diameter, pitch,
free length, closed length, and the maximum stress under the specified
conditions, and scale. Let C 7 .

Solution:
For hard-drawn carbon steel, Table AT 17
182
su 0.1 ksi , 0.093 Dw 0.25
Dw
91
Max. solid ss 0.1 ksi , 0.093 Dw 0.25
Dw
36.855
ssd 0.50 0.405 su
ksi
Dw0.1

Us
K

ss2V
4 K 2G

4C 1 0.615

4C 4
C

274

SECTION 4 - SPRINGS
K

4 7 1 0.615

1.213
4 7 4
7

Dw2
V
4

Dm N c

D Dm N c
4
2

2
w

Dm CDw

2CDw3 N c
4
3
8 FC N c

GDw

Us W h

8 FC
2
Dw

ss K

ssDw2
8 KC
s sDw2 8C 3 N c

8 KC GDw
s D C 2 N c
s w
KG
s 2 2CD 3 N c

s D C 2 N c
Us W h s w

KG
16 K 2G

Nc

Wh
s CD
ssDwC 2W

16 K 2G
KG
2
s

when ss

Nc

Nc

2
w

36.855
ksi
Dw0.1

36.855

Wh

CD
16 K 2G
2

2.8
w

36.855D 0w.9C 2W

0.01010

KG

36.855 7 Dw2.8 36.855D 0.9 7 2 0.010

2
1.21311,500
161.213 11,500
2

Nc

2.8
w

0.3466 D

0.10
0.004067 D w0.9

combination of Dw and N c
Dw
Gage No. W & M

Nc

275

Dw N c

SECTION 4 - SPRINGS
12
11
10
9
8
7
6
5
4
3

0.1055
0.1205
0.1350
0.1483
0.1620
0.1770
0.1920
0.2070
0.2253
0.2437

991.2
312.1
166.1
108.0
75.2
53.7
40.2
31
23.4
18.1

105
37.6
22.4
16.0
12.2
9.5
7.7
6.4
5.3
4.4

Use Dw 0.2437 in 0.25 in , N c 18.1

Dm 7 Dw 7 0.2437 1.7059 in 1

45
in
64

0.9 2
0.9
2
ssDwC 2 N c 36.855D w C N c 36.855 0.2437 7 18.1

2.066 in
KG
KG
1.21311,500

36.855
42.44 ksi
0.2437 0.1
91
91
0. 1
104.8 ksi
Dw
0.2437 0.1

ss

sso

Solid deflection
104.8
2.066 5.1 in
42.44

P Dw N c 5.1

P 0.2437 18.1 5.1

P 0.5255 in

say P

17
0.53125 in
32

Minimum Solid Height = Dw N c 0.2437 18.1 4.41 in

Assume squared and ground end
Solid height = Dw N c 2 Dw 0.2437 18.1 2 0.2437 5.0 in
Solid deflection = 0.53125 0.2437 18.1 5.2 in
Free length = 5.0 in + 5.2 in = 10.2in

Summary of answer:
Dw 0.2437 in , No. 3 W & M
Dm 1
P

45
in
64

17
in
32

276

SECTION 4 - SPRINGS
Free length = 10.2 in
Closed length = 5 in
Maximum stress = 42.44 ksi
294.

A helical spring, of hard-drawn steel wire, is to absorb 75 in-lb of energy without

being stressed beyond the recommended value of average service. Let C 6 .
Decide upon satisfactory dimensions; Dw , Dm , N c , free length, pitch
angle, solid stress, volume of metal, possibility of spring buckling.

Solution:
For hard-drawn steel wire, shock load, average service
140
su 0.19 ksi , 0.028 Dw 0.625
Dw
70
Max. solid ss 0.19 ksi , 0.028 Dw 0.625
Dw
140
0.19
Dw

s sd 0.50 0.85 0.324 su 0.50 0.85 0.324

Us

19.278
ksi
Dw0.19

sV
s D CN c

2
4K G
16 K G
2
s

2
s

3
w
2

C 6
4C 1 0.615
K

4C 4
C
4 6 1 0.615
K

1.2525
4 6 4
6

U s 75 in lb 0.075 in kip

19.278
2 Dw3 6 N c
2
0.19
Dw 161.2525 11,500

U s 0.075

0.9837 Dw2.62 N c

Table AT-15
W&M
9
8
7
6
5

Dw

Nc

Dw N c

0.1483
0.1620
0.1770
0.1920
0.207

146
116
92
74
61

21.65
18.79
16.28
14.21
12.63

277

SECTION 4 - SPRINGS
4
3
2
1
0
2-0
3-0
4-0
5-0

0.2253
0.2437
0.2625
0.2830
0.3065
0.3310
0.3625
0.3938
0.4305

49
40
32.7
26.9
21.8
17.8
14.0
11.3
8.95

11.04
9.75
8.58
7.61
6.68
5.89
5.075
4.45
3.85

Use Dw 0.4305 in , 5-0 W & M

Nc 9

Dm 6 0.4305 2.583 in 2

9
in
16

19.278
22.63 ksi
0.4305 0.19

ss

Max. Solid Stress = s so

70
82.16 ksi
0.4305 0.19

ssDwC 2 N c 22.63 0.4305 6 9

0.6885 in
1.252511,500
KG
82.16
0.6885 2.5 in
Solid deflection
22.63
P Dw N c 2.5
2

P 0.4305 9 2.5
P 0.7083 in

say P

45
0.703125 in
64

Solid deflection = 0.703125 0.4305 9 2.453625 in

2.453625
80.65 ksi
0.6885

Solid stress 22.63

7
8

Minimum Solid Height = Dw N c 0.4305 9 3.8745 in 3 in

21
45
in
9 6.328125 in 6
64
64

Minimum Free Length = PN c

Pitch Angle

45

P
64 5 12
tan 1
tan 1
Dm
2 9
16
Volume
0.4305 2 9
Dw2
3
Dm N c
V
2 9 10.55 in

16

278

SECTION 4 - SPRINGS
Summary of answer:
Dw 0.4305 in , No. 5-0 W & M
Dm 2
Nc 9

9
in
16

Free length = 6

21
in
64

Pitch Angle = 5
Solid Stress = 80.65 ksi
Volume of metal = 10.55 in3
Possibility of spring buckling
21
6
64 2.47 4
, no possibility
9
2
16
CONCENTRIC HELICAL SPRINGS
297.

Two concentric helical springs are to be subjected to a load that varies from a
maximum of 235 lb. to a maximum of 50 lb. They are to fit inside a 1 5/8 in.
cylinder. The maximum deflection is to be in., and the deflection when
compressed solid is to be approximately 1 in. Using the static approach for
severe service (maximum load), determine the wire diameter, mean coil
diameter, number of coils, solid length, and free length of both springs. (Start
with oil-tempered wire and assume a diametral clearance between the outer
D
spring and the cylinder of w , assume a similar clearance between springs.
2
Search for a suitable spring index and wire size.)

Solution:
For oil-tempered wire
Table AT 17
146
su 0.19 ksi , 0.032 Dw 0.5
Dw
87.5
Max. solid ss 0.19 ksi , 0.032 Dw 0.5
Dw
Severe service
0.263146 38.398
ssd 0.263su

ksi
Dw0.19
Dw0.19
F 235 lb 0.235 kip

o i

279

SECTION 4 - SPRINGS
8 Fo Co3 N co 8 Fi Ci3 N i

GDwo
GDwi

Assume, Co Ci
3GDwo
Fo
32C 3 N co
3GDwi
Fi
32C 3 N ci

8 Fo C
2
Dwo

sso K

8 Fi C
2
Dwi
D
D
C mo mi
Dwo Dwi
ssi K

4C 1 0.615

4C 4
C

Dmo Dwo

Dwi
Dmi Dwi
2

Dmo Dmi Dwo 1.5 Dwi

Dwo
Dmo Dwo
2

1.625

Dmo 1.5 Dwo 1.625

CDwo 1.5 Dwo 1.625

1.625
Dwo
C 1.5
1.625C
Dmo
C 1.5
CDwo CDwi Dwo 1.5 Dwi

C 1 Dwo C 1.5 Dwi

1.625 C 1
Dwi
C 1 .5 2
1.625C C 1
Dmi
C 1 .5 2
8 FoC
38.398

ksi
2
0.19
Dwo
Dwo

sso K

1.81
15.08 Dwo
Fo
KC

280

SECTION 4 - SPRINGS

8 Fi C
38.398

ksi
2
0.19
Dwi
Dwi

ssi K
Fi

1.81
15.08 Dwi
KC

Fo Fi F 0.235 kip
1.81
1.81
15.08 Dwo
15.08 Dwi

0.235
KC
KC
1.81
1.81
15.08Dwo
15.08 Dwi
0.235 KC

1.625
1.625 C 1
15.08
15.08
0.235KC

C 1.5
C 1.5

C 11.81 0.235 4C 1 0.615 C

1
154.52

1.81
C
C 1.5 3.62
4C 4
C 1.5
C 5.328
1.625 5.328 1
Dwi
0.1509 in
5.328 1.5 2
1.625
Dwo
0.2380 in
5.328 1.5
Table AT 15, use Dwi 0.1620 in , No. 8 W & M and Dwo 0.2625 in , No. 2 W & M
13
Dmo CDwo 5.328 0.2625 1.3986 in 1
in
32
7
Dmi CDwi 5.328 0.1620 0.8631 in in
8
7

Dmi
8
Ci
5.401
Dwi 0.1620
1.81

1.81

Co

Dmo
Dwo

13

32

5.357
0.2625
1

1.81
15.08 Dwo
Fo
K o Co
4 5.357 1 0.615
Ko

1.287
4 5.357 1 5.357

15.08 0.2625
1.287 5.357

1.81

Fo

0.194 kip

1.81
15.08 Dwi
K i Ci
4 5.401 1 0.615
Ki

1.2843
4 5.401 1 5.401

Fi

281

SECTION 4 - SPRINGS
Fi

15.08 0.1620
0.081 kip
1.2843 5.401

Fo Fi 0.194 0.071 0.275 kip 0.235 kip , ok

3GDwo
32C 3 N co
311,500 0.2625
0.194
3
32 5.357 N co
Fo

N co 9.5

3GDwi
32C 3 N ci
311,500 0.1620
0.071
3
32 5.401 N ci
Fi

N ci 15.6

Max. solid stress, sss

87.5
ksi ,
Dw0.19

87.5
112 .82 ksi
0.2625 0.19
87.5

123.65 ksi
0.1620 0.19

ssso
sssi

Stress
38.398
54.26 ksi
0.1620 0.19
38.398

49.51 ksi
0.2625 0.19

ssi
sso

Solid stress
1
sso 49.51
66.01 ksi 112 .82 ksi
0.75
1
ssi 54.26
72.35 ksi 123.65 ksi
0.75

Solid length

Dwo N co 0.2625 9.5 2.5 in

Dwi N ci 0.1620 15.6 2.53 in

assume solid length = 3 in

Dwi N ci xi 0.1620 15.6 xi 3 in
xi 2.92

Total coils = 15.6 + 2.92 = 18.52

Dwo N co xo 0.2625 9.5 xo 3 in
xo 1.93

282

SECTION 4 - SPRINGS
Total coils = 9.5 + 1.93 = 11.43
Free Length = 3 in + 1 in = 4 in
Summary of answer:
Outside wire.

Dwo 0.2625 in , No. 2 W & M

13
Dmo 1
in
32
N to 11.43

Solid length = 3 in
Free length = 4 in
Inside wire.

Dwi 0.1620 in , No. 8 W & M

7
Dmi in
8
N ti 18.52

Solid length = 3 in
Free length = 4 in
298.

Two concentric, helical compression springs are used on a freight car. The larger
spring has an outside diameter of 7 in., a free length of 7 1/8 in., and is made
of a 1 in. steel bar. The smaller has an outside diameter of 4 1/8 in., a free
length of 6 13/16 in. , and is made of 7/8 in. steel bar. The solid height of each
spring is 5 in. and the forces required to compress them solid are 15,530 lb.
and 7,000 lb., respectively. The working load on the two springs is 11,350 lb.
Determine (a) the number of free coils in each spring, (b) the stress in each
spring when compressed solid, (c) the stresses induced by the working load.
Notice that the outer spring deflects 5/16 in. before the inner one takes a load.
(d) What energy is absorbed while changing deflection from that at the
working load to that when the springs are compressed solid?

Solution:

ODo 7 in
3
Dwo 1 in
8
1
FLo 7 in
8
1
ODi 4 in
8
7
Dwi in
8

283

SECTION 4 - SPRINGS
FLi 6

13
in
16

(a) Solid height = Dw N T 5

1
in
4

5.25
3.82
1.375
5.25
N Ti
6
0.875
N To

(b) Fo 15,530 lb
Fi 7000 lb

8 FC
2
Dw
3
Dmo 7 1 5.625 in
8
D
5.625
Co mo
4.091
Dwo 1.375
4 4.091 1 0.615
Ko

1.393
4 4.091 4 4.091
1 7
Dmi 4 3.25 in
8 8
D
3.25
Ci mi
3.714
Dwi 0.875
4 3.714 1 0.615
Ki

1.442
4 3.714 4 3.714
ss K

Solid stress

815,530 4.091
119 ,203 psi
1.375 2

sso 1.393

8 7000 3.714
124,689 psi
0.875 2

s si 1.442

(b) Stresses induced by working load

Fi Fo 11,350 lb

ko

ko

15,530
8283 lb in
1
1
7 5
8
4
7000
4480 lb in
13
1
6 5
16
4

284

SECTION 4 - SPRINGS
5
0.3125 in
16
Fi ki i 4480 i

o i

Fo ko o 8283 0.3125 i
Fi Fo ko o 4480 i 8283 0.3125 i 11,350 lb
i 0.6865 in
o 0.3125 0.6865 0.9990 in
Fi 4480 0.6865 3076 lb
Fo 8283 0.9990 8275 lb

Stresses

8 8275 4.091
sso 1.393
63,516 psi
1.375 2

8 3076 3.714
ssi 1.442
54,792 psi
0.875 2

(d) Energy

1
k o o22 o21
2
1
1
o 2 7 5 1.875 in
8
4
o1 0.9990 in
1
2
2
U so 8283 1.875 0.999 10,427 in lb
2
1
U si ki i22 i21
2
13
1
i 2 6 5 1.5625 in
16
4
o1 0.6865 in
1
2
2
U si 4480 1.5625 0.6865 4,413 in lb
2
U so

TORSION-BAR SPRINGS
299.

A torsion-bar similar to that shown is to be used for the front spring of an

automobile. Its rate should be 400 lb./in. of deflection of the end of the arm
which is e 10 in. long. It is made of AISI 9261,OQT 900 oF, and the
maximum repeated load is 1500 lb. perpendicular to the centerline of the arm.
The support is such that bending of the bar is negligible. (a) Determine its
diameter and length so that no permanent set occurs due to a 30 % overload
(limited by a stop). Use s ys 0.6 s y , but check with equation (c) 6.3, Text,
if appropriate. (b) Determine the factor of safety according to the Soderberg
criterion if the load varies from 1200 lb. to 1500 lb.; minimum r d 0.1 ,
285

SECTION 4 - SPRINGS
D d 3.

(c) The same as (b) except that the bar is shot-peened all over. What
other steps may be taken to improve the fatigue strength?

Problem 299, 300

Solution:

e 10 in

For AISI 9261, OQT 900 oF

s y 192 ksi

su 215 ksi
s ys 0.6 s y 115 .2 ksi 115,200 psi
16T

(a) ss d 3

T Fe 1.31500 10 19,500 in lb

115,200

1619,500
d3

d 0.95 in
use d 1 in

6.3

ss

117 117

117 ksi s ys
Dw0.3 1 0.3

(b) Soderberg Criterion

K f sas
1
s
ms
N
s ys
sns

sns 0.6 0.5 215 64.5 ksi

Figure AF 12,
K t 1.45

r d 0.1 , D d 3

K f K t 1.45

1
1500 1200 1350 lb
2
Tm 135010 13,500 in lb 13.5 in kips
Fm

286

SECTION 4 - SPRINGS
sms

1613.5
68.8 ksi
3
1

1
1500 1200 150 lb
2
Ta 150 10 1500 in lb 1.5 in kips
Fa

161.5
7.64 ksi
3
1
1
68.8 1.45 7.64

N 115 .2
64.5
N 1.30

sas

(c) Shot-peened

s ys 1.25115 .2 144 ksi

sns 1.25 64.5 80.6 ksi

1 68.8 1.45 7.64

N
144
80.6
N 1.625

300.

A solid steel torsion bar is loaded through a 10 in. arm as shown. The load F
perpendicular to the center-line of the arm varies from 500 to 1000 lb.,
200,000 cycles. The bar is d

7
in. in diameter and 30 in. long; let D d 3
8

; r d 0.1 ; (a) Determine the maximum stress in the bar, the angular
deflection, and the scale (lb./in.) where F is applied. The support is such that
bending of the bar is negligible. (b) Select a material and heat treatment for
this bar for a minimum N 1.2 , Soderberg criterion.

Problem 299, 300

Solution:
Fig. AF 12, K f 1.45
Fm

1
1000 500 750 lb
2

287

SECTION 4 - SPRINGS
1
1000 500 250 lb
2
Tm 750 10 7500 in lb 7.5 in kips
Fa

Ta 250 10 2500 in lb 2.5 in kips

log K f 3
n
200,000 log1.45 3 1.33
K fl

Kf
1.45
16T
ss
d3
16 7.5
sms
57 ksi
3
7

8
16 2.5
sas
19 ksi
3
7

8

(a) smax sms K fl sas 57 1.3319 82.27 ksi

TL
64TL

JG d 4G
64 500 10 30
min
0.4533 rad
4
7
6
11.5 10
8
641000 10 30
max
0.9066 rad
4
7
6
11.5 10
8
F
1000
scale

110 .3 lb in
e 0.9066 10

(c)
sns

s ys

K f sas
1
s
ms
N s ys
sns

10 6

0.6 0.5 su
200,000
0.6 s y

0.085

0.344 su

1.3319
1
57

1.2 0.6 s y
0.344 su

Use AISI 8760, OQT 800 oF

s y 200 ksi

su 220 ksi

N 1.24

HELICAL SPRINGS NON CIRCULAR SECTION

288

SECTION 4 - SPRINGS
301.

A spring is to be designed of square oil-tempered steel wire and subjected to a

repeated maximum load of 325 lb.; mean coil diameter, 1 in.; deflection,
13/32 in. Determine (a) the wire size for average service, (b) the required
number of active coils, (c) the solid height, free length, and pitch (the ends are
squared and ground, the solid stress must be satisfactory, and the pitch angle
not excessive). (d) What amount of energy is stored when the load is 325 lb.?
Express in in-lb. and Btu.

Solution:
For oil-tempered wire,
146
su 0.19 , 0.032 Dw 0.5
Dw
Max. solid ss 0.6 su
(a) average service,
b Dw , t b
K FDm 3b 1.8t
2.4 FDm
ss q
Kq
2 2
2b t
b3
s sd 0.324 su , average service

Kq

2.4 FDm 0.324146

2b 3
b 0.19

F 0.325 kip

Dm 1

1
in
2

K q 1.25

1.25

(assumed)
2.4 0.3251.5
0.324146

b
b 0.19

b 0.2902 in

Table AT 15, use b 0.313 in , # 1 wire size

D
1.5
C m
4.8
b
0.313
Figure AF 15, K q 1.275

2.45 FDm3 N c
2.45 FDm3 N c

(b) 3
Gt b 0.56t
0.44Gb 4
13 2.45 0.3251.5 N c

32 0.4411,500 0.313 4
3

N c 7.34

(c) Solid height = b N c 2 0.313 7.34 2 2.92 in

289

SECTION 4 - SPRINGS
Free length = PN c 2b
F 0.325 lb

2.4 0.3251.5
2.4 FDm

1
.
275
48.65 ksi

b
0.313 3

0.6146
109.2 ksi
solid stress =
0.313 0.19
ss Kq

solid deflection =

P b N c 0.91

109.2 13

0.91 in
48.65 32

P 0.313 7.34 0.91

P 0.437 in

use P

7
in
16
27
7
in
7.34 2 0.313 3.837 in 3
32
16

Free length = PN c 2b
7

P
16
tan

Dm 1.5
5.3 10

1 2 1
1
13
k F 0.325
0.066 in kip 66 in lb
2
2
2
32
66
Us
0.085 Btu
778

(d) U s

302.

A coil spring, of hard-drawn carbon steel, is to deflect 1 in. under a load of 100 lb.
The outside coil diameter is to be 1 in. Compute the number of active coils,
(a) if the wire is round, 5/32 in. in diameter, (b) if the wire is square, 5/32 in.
on the side, (c) if the wire is rectangular 1/8 x 3/16 in., long dimension parallel
to the axis, (d) If the wire is rectangular 3/16 x 1/8 in., short dimension
parallel to the axis. (e) What is the maximum stress in each of the above
springs under the 100-lb load? (f) What is the ratio of the approximate
volumes, square- or rectangular-wire to round wire spring?

Solution:
Dm Dw 1 in
5
in
(a) Dw
32
5
27
Dm 1

in
32 32

290

SECTION 4 - SPRINGS
27

Dm 32
C

5.4
Dw 5

32
8 FC 3 N c

GDw

8100 5.4 N c
1
5
11.5 106

32
3

N c 14.3

5
in
32
5
27
Dm 1

in
32 32

(b) Square, b

2.45 FD m3 N c

0.44Gb 4
27
2.45100

32

Nc
4

32

0.44 11.5 10 6
N c 20.5

3
1
in , t in
16
8
1 7
Dm 1 t 1 in
8 8

(c) b

2.45FD m3 N c

Gt 3 b 0.56t
3

7
2.45100 N c
8
1
3
1 3
1
11.5 10 6
0.56
8 16
8
N c 16.1

1
3
in , t
in
8
16
3 13
Dm 1 t 1

in
16 16

(d) b

2.45FD m3 N c

Gt 3 b 0.56t
291

SECTION 4 - SPRINGS
3

13
2.45100
Nc
16

1
3
3 1
3
6
11.5 10
0.56

16 8
16
N c 11.5

(e) Maximum Stress

8FC
Dw3
4 5.4 1 0.615
K

1.284
4 5.4 4
5.4

For (a) ss K

s s 1.284

8100 5.4

32

For (b) ss K q

72,320 psi

FD m 3b 1.8t
2.4 FD m
Kq
2 2
2b t
b3

27

Dm 32
C

5.4
b
5

32
K q 1.25

27

32 66,355 psi
3

32

2.4100

ss 1.25

For (c) ss K q

FD m 3b 1.8t
2b 2t 2

7

Dm 8
C

7
t
1

8
K q 1.1

7
100
8
ss 1.1
2
3 1

2
16 8

3 3 1.8 1 68,992 psi

16
8

292

SECTION 4 - SPRINGS
For (d) ss K q

FD m 3b 1.8t
2b 2t 2

13

Dm 16
C

4.33
t
3

16
K q 1.2

100

ss 1.2

1
2
8

13

16
3

16

3 1 1.8 3 63,232 psi

8
16

(e) Ratio of the approximate volumes

For (a) Round wire
2
Va
Dw Dm N c
4

5
Va

4 32

27
3
14.3 0.727 in

32

For (b) Square wire

Vb b 2 Dm N c
2

5 27
3

20.5 1.327 in
32
32

Vb

For (c) rectangular wire

Vc bt Dm N c
3 1

16 8

Vc

7
3
8 16.1 1.037 in

For (d) rectangular wire

Vd bt Dm N c
1 3 13
3


11.5 0.688 in
8 16 16

Vd

Ratio of volume
Square to round wire
V
1.327
b
1.825
Va 0.727
Rectangular to round wire (long dimension parallel to the axis)
V
1.037
c
1.426
Va 0.727
Rectangular to round wire (short dimension parallel to the axis)
293

SECTION 4 - SPRINGS

Vd 0.688

0.946
Va 0.727

TENSION SPRINGS
305.

Design two tension springs for a spring balance with a capacity of 200 lb. Each
spring supports a maximum load of 100 lb. The outside diameter must not
exceed 1 in. and the total length including end loops must not exceed 9
in. Select a material and determine the dimension, including wire diameter,
number of coils, and free length.

Solution:
Table AT 17, assume oil tempered wire
146
su 0.19 ksi
Dw
87.5
s ys 0.19 ksi
Dw
0.8 87.5
70
ssd
0.19 ksi , 0.032 Dw 0.5
0.19
Dw
Dw
F Fi k

8 K cFDm
Dw3
2r
D
C m m
Dw Dw
ss

8 Fa C 3 N c
G Dw

G Dw
8C 3 N
G Dw
k

3
8C N
k

8Fa C 3 N c

Fa
GD
w

Fa 100 lb 0.10 kip

Figure AF 15, assume K c 1.2

8 K cFi Dm 8 K cFa Dm

Dw3
Dw3
8 K cFa C
ss K csi
Dw2
ss

OD Dm Dw 1.25 in

294

SECTION 4 - SPRINGS
Dw

1.25
C 1

6.21, assume si 18 ksi

ssd ss

70
81.2 0.1 C
1.2 18
0.19
Dw
Dw2

70 C 1
1.25 0.19

0.19

67.1 C 1

67.1 C 1

21.6
0.19
0.19

81.2 0.1 C C 1
1.25 2

21.6 0.1956C C 1

0.1956C C 1 21.6
2

C 6.7
1.25
1.25
Dw

0.1623 in
C 1 6.7 1

Table AT 15, use Dw 0.1620 in , 8 W & M

Dm CDw 6.7 0.1620 1.085 in
say Dm 1.0 in

Dm
1.0

6.17
Dw 0.1620

si 17.7 ksi

To check, Fig. AF 15, K c 1.15

81.15 0.10 6.17
ss 1.1517.7
89.20 ksi
2
0.1620
ssd

70
98.92 ksi 89.20 ksi , o.k.
0.1620 0.19

Total length = Dw N c 2 Dm Dw
9.5 0.162 N c 21.0 0.162
N c 44.3 coils

Free length = Dw N c 0.1620 44.3 7.18 in

Summary of answer:
Material, oil-tempered wire
Dw 0.1620 in , 8 W & M
N c 44.3 coils

Free length = 7.18 in.

306.

Two helical tension springs are to be used in scales for weighing milk. The
capacity of the scales is 30 lb., each spring carries 15 lb. with a deflection of 3
9/16 in. The springs are made of No. 14, W & M steel wire, outside diameter,
29/32 in. (a) how many coils should each spring have? (b) What is the
maximum stress in the wire? What material should be used?
295

SECTION 4 - SPRINGS

Solution:
k 15 lb

9
in
16

(a) Table AT 15, No. 14 W &M

Dw 0.0800 in

Dm OD Dw

29
0.0800 0.82625 in
32

Dm 0.82625

10.328
Dw
0.0800

8 k C 3 N c
GDw

9
81510.328 N c
3
16 11 .5 10 6 0.080
3

N c 24.8

(b) F Fi k
s D3
Fi i w
8 Dm
6.21, C 10.328
si 11,272 psi

Fi

11,272 0.08 3
2.743 lb
8 0.82625

F 2.743 15 17.743 lb

Figure AF 15, K c 1.09

8K c FDm 81.09 17.743 0.82625
ss

79,476 psi
3
Dw3
0.080
s
79,476
s ys s
99,345 psi 99.345 ksi
0.8
0.8
Table AT 17, use Hard drawn wire
70
70
s ys 0.19
113 ksi 99.345 ksi
Dw
0.080 0.19
307.

A tension spring for a gas-control lever is made of Dw 0.078 in steel wire;

inside diameter, 0.609 in.; number of coils, 55; free length including end
loops, 5 9/16 in. When the spring is extended to a length of 6 5/16 in., it must
exert a force 5 lb.; it must extend to (a) the initial tension, (b) the stress in
the spring caused by the initial tension (compare with the recommended
296

SECTION 4 - SPRINGS
maximum values), (c) the stress caused by the 5 -lb load, (d) the maximum
stress. What material should be used? (e) What energy is absorbed from the
point where the load is the initial tension until the springs length is 6 5/16 in.?
(Data courtesy Worthington Corporation.)
Solution:

Dw 0.078 in
Dm Dw 0.609 in
Dm 0.609 0.078 0.687 in

Dm 0.687

8.8
Dw 0.078

N c 55

8 FC 3 N c
GDw

1
lb
2
5
9
6 5
0.75 in
16
16
F 5

0.75

8 k 8.8 5
11.5 106 0.078
3

k 2.244 lb

(a) Fi F k 5.5 2.244 3.256 lb

8 Fi C 8 3.256 8.8

12,000 psi
(b) si
2
Dw2
0.078
6.21, C 8.8
si 13,300 psi 12,000 psi , ok
(c) F 5.5 lb
8 K c FC
ss
Dw2
C 8.8
Figure AF 15
K c 1.1

ss

81.1 5.5 8.8

22,284 psi
0.078 2

(d) maximum stress

k 2.244
k

2.992 lb in

0.75

F k

297

SECTION 4 - SPRINGS
9

5
9
5
3.75 in
16
16

F Fi k 3.256 2.992 3.75 14.476 lb

8 K c FC 81.114.476 8.8

58,651 psi
2
Dw2
0.078
Table AT 16
s
58,651
s ys s
73,300 psi 73.3 ksi
0 .8
0.8
Table AT 17, use Hard drawn wire
ss

s ys

70
70

113 .658 ksi 73.3 ksi

0.19
Dw
0.078 0.19

(e) U s

1 2 1
2
k 2.992 0.75 0.8415 in lb
2
2

TORSION SPRINGS
308.

A carbon-steel (ASTM A230) torsion spring is to resist a force of 55 lb. at a radius

of 2 in.; the mean diameter is to be 2 in. Compute (a) the diameter of the
wire for average service, (b) the number of coils for a deflection of 180 o under
the given torque, (c) the energy the spring has absorbed when the force is 55
lb.

Solution:
T M Fa

F 55 lb
a 2 in
T M 55 2 110 in lb

Dm 2.5 in

Table AT 17, su

182
ksi , 0.093 Dw 0.25
Dw0.1

Average service
182
117 .936
117 ,936

sd 1.6 0.405 su 0.648
ksi
psi
0.1
0.1
Dw
Dw0.1
Dw

(a) ss

KMc
I

For round wire, assume K c K ci 1.08 , Table AT 18

D
c w
2
I Dw3

c
32
298

SECTION 4 - SPRINGS

ss

1.08110 32 117,936
Dw3

Dw0.1

Dw 0.2060 in 0.25 in

Table AT 15, use Dw 0.2070 in , No. 5 W & M

r Dm
2

9.66 9 , ok
To check:
c Dw 0.2070
Table AT 18, K 1.08
1.08110 32 136,430 psi
ss
3
0.2070
117 ,936
138,054 psi 136,430 psi
0.2070 0.1
Therefore, use No. 5 W & M, Dw 0.2070 in
ssd

(b)

MDm N c
EI

E 30 106 psi

Dw4
64

180

64 MDm N c
EDw4
64110 2 N c

30 106 0.2070 4

N c 12.29

1
2

(c) U s T
312.

1
110 172.8 in lb
2

A pivoted roller follower is held in contact with the cam by a torsion spring. The
moment exerted by the spring varies from 20 lb-in to 50 lb-in. as the follower
oscillates through 30o. The spring is made of AISI 6152 steel, OQT 1000 oF.
What should be the value of Dw , Dm , and N c if the factor of safety is 1.75
based on the Soderberg line? Would this be a conservative or risky approach?

Solution:
AISI 6152, OQT 1000 oF
su 184 ksi
s y 173 ksi

sn 0.5su 92 ksi
1
M m 50 20 35 lb in
2

299

SECTION 4 - SPRINGS
1
50 20 15 lb in
2
assume K 1.08
Ma

32 KM m 321.08 35 385

3 psi
Dw3
Dw3
Dw
32 KM a 321.0815 165
sa

3 psi
Dw3
Dw3
Dw
sm

1 sm s a

N s y sn

1
385
165

3
1.75 173,000 Dw 92,000 Dw3
Dw 0.1916 in

Table AT 15, use Dw 0.1920 in , No. 6 W & M

To solve for K
32 35 K
sm
50,369 K psi
3
0.1920
3215 K
sa
21,587 K psi
3
0.1920
1
50,369 K 20,587 K

1.75
173,000
92,000

K 1.0868

Table AT 18 K ci K 1.0868
r Dm

9.32 9 , ok
c Dw

Dm 9.32 0.1920 1.7894 in

7
use Dm 1 in 1.875 in
8

MDm N c 64MDm N c

EI
EDw4
30 64 50 20 1.875 N c

180
30 106 0.1920 4

N c 5.93

Summary of answer:
Dw 0.1920 in , No. 6 W & M
7
in
8
N c 5.93 , N 1.4 , therefore conservative.

Dm 1

FLAT AND LEAF SPRINGS

300

SECTION 4 - SPRINGS
315.

A cantilever flat spring of uniform strength, Fig. 6.20, Text, is to absorb an energy
impact of 500 ft-lb. Let the thickness of the steel, AISI 1095, OQT 900 oF, be
in. and let the maximum stress be half of the yield strength. (a) Find the
width b of the spring at the widest point in terms of the length L .
Determine values of b for lengths of 36 in., 48 in., 60 in., and 72 in. (b)
Determine the deflection of the spring for each set of values found in (a).

Solution.
Fig. 6/20

6 FL
bh 2
6 FL3

Ebh3
AISI 1095, OQT 900 oF, s y 104 ksi , Table AT 9
sB

s B 0.5s y 0.5104 52 ksi 52,000 psi

Us

1
F
2

s B bh 2
6L
s bh 2 L3
s B L2

6 B

3
Eh
6 L Ebh
F

Us

1 sB bh 2

2 6 L

s B L2
1 s 2 bhL

E
Eh 12

U s 500 ft lb 6000 in lb

6000

1
12

52,000 2 b

bL 1598 in 2

1
L
2
30 10 6

1598 in 2
L

301

SECTION 4 - SPRINGS
L 36 in , b

1598 in 2
44.4 in
36 in

L 48 in , b

1598 in 2
33.3 in
48 in

L 60 in , b

1598 in 2
26.6 in
60 in

L 72 in , b

1598 in 2
22.2 in
72 in

(b)

s B L2
Eh

L 36 in ,

L 48 in ,

L 60 in ,

L 72 in ,

317.

52,000 36 2

30 10 12

4.4928 in

52,000 48 2

30 10 12

7.9872 in

52,000 60 2

30 10 12

12.48 in

52,000 72 2

30 10 12

17.9712 in

One of the carbon contacts on a circuit breaker is mounted on the free end of a
phosphor-bronze beam ( 0.35 ). This beam has the shape of the beam
shown in Fig. 6.24, Text, with b 1 in. , b
h

9
1
in. , L 4 in. , and
16
2

1
in. When the contacts are closed, the beam deflects in. Compute
16

(a) the force on the contacts, (b) the maximum stress.

Solution:
Figure 6.24
6 FL 3WL
s

bh 2
bh 2
K1 FL3 1 2
K1WL3 1 2

3EI
6 EI
9

b 16

0.5625
b
1
Figure 6.25, K1 1.14

302

SECTION 4 - SPRINGS

(a) Force on contacts = F

K1 FL3 1 2

3EI
E 16 10 6 psi (phosphor bronze)

as a beam, I

bh 3
12

4 K1 FL3 1 2

Ebh 3

3 41.14 F 4.5 1 0.35

3
4
1
16 106 1 16

F 8 lb

(b)

318.

6 FL 6 8 4.5

55,296 psi
2
bh 2
1
1
16

A cantilever leaf spring 26 in. long is to support a load of 175 lb. The construction
is similar to that shown in Fig. 6.22 (a), Text. The leaves are to be 2 in. wide,
3/16 in. thick; SAE 9255 steel, OQT 1000 oF; 107 cycles ( 6.26). (a) How
many leaves should be used if the surfaces are left as rolled? (b) The same as
(a) except that the leaves are machined and the surfaces are not decarburized.
(c) The same as (b), except that the surface is peened all over. (d) Which of
these springs absorbs the most energy? Compute for each: (e) What are the
load and deflection of the spring in (b) when the maximum stress is the
standard-test yields strength?

Solution:
Figure 6.22 (a)
6 FL
sA
bh 2
6 FL3
A
Ebh 3
b N1b
F 175 lb

b 2 in
3
h
in
16
L 26 in

6.26, SAE 9255, OQT 1000 oF

su 180 ksi

s y 160 ksi

303

SECTION 4 - SPRINGS
3
in 0.1875 in
16
sd 83.75 ksi

(a) As rolled, Figure AF 5

Surface factor = 0.275

sd 0.275 83.75 23 ksi 23,000 psi

sA

6 FL
bh 2

6175 26

23,000

3
N 1 2

16
N1 16.88
say N1 17

(b) Machined, Figure AF 5

Surface factor = 0.75

sd 0.75 83.75 62.8 ksi 62,800 psi

sA

6 FL
bh 2

62,800

6175 26

3
N 1 2

16

N1 6.2
say N1 7

(c) Peened surface, (b)

sd 1.25 62.8 78.5 ksi 78,500 psi

sA

6 FL
bh 2

78,500

6175 26
3

16

N 1 2

N1 4.95
say N1 5

(d) U s

1
F
2

F 175 lb

304

SECTION 4 - SPRINGS
6 FL3

EN1bh 3
For (a) N1 17

6175 26

2.745 in
3
3
30 10 17 2

16
1
U s 175 2.745 240 in lb
2
For (b) N1 7

6175 26

6.666 in
3
3
30 10 7 2

16
1
U s 175 6.666 583 in lb
2
For (c) N1 5

6175 26

9.332 in
3
3
30 10 5 2

16
1
U s 175 9.332 817 in lb
2

answer spring (c)

(e) sd s y 160 ksi , N1 7 (b)
6 FL
6 FL

2
bh
N1bh 2
6 F 26
160,000
7 2 3
16
load F 505 lb
sd

319.

6 505 26

3
30 10 7 2

16
6

19.24 in

The rear spring of an automobile has 9 leaves, each with an average thickness of
0.242 in. and a width of 2 in.; material is SAE 9261, OQT 1000 oF. The
length of the spring is 56 in. and the total weight on the spring is 1300 lb.
Assume the spring to have the form shown in Fig. 6.22 (b), Text. Determine
(a) the rate of the spring, (b) the maximum stress caused by the dead weight.
(c) What approximate repeated maximum force (0 to Fmax ) would cause
impending fatigue in 105 cycles, the number of applications of the maximum
305

SECTION 4 - SPRINGS
load expected during the ordinary life of a car? (If the leaves are cold rolled
to induce a residual compressive stress on the surfaces, the endurance limit as
su 2 should be conservative.)
Solution:
Figure 6.22 (b)
3FL
sA
2bh 2
3FL3
A
8 Ebh 3
F 1300 lb
h 0.242 in

N1 9
b 2 in
L 56 in

(a) Rate , k

F
8 Ebh 3

A
3L3

8 EN1bh 3 8 30 10 6 9 2 0.242

116 .21lb in
3
3L3
3 56
3

3FL
31300 56

103,590 psi
2
2
2 N1bh
2 9 2 0.242
(c) SAE 9261. OQT 1000 oF
(b) s A

su 192 ksi
192
sn
96 ksi
2

sA

3FL
2 N1bh 2

96,000

3F 56
2
2 9 2 0.242

F 1200 lb

321.

The front spring of an automobile is made similar to Fig. 6.23, Text. The average
thickness for each of the 6 leaves, 0.213 in.; material is SAE 9255, OQT 1000
o
F. The load caused by the weight of the car is 775 lb. (a) What stress is
caused by a force of twice the dead weight? (b) What load would stress the
spring to the yield strength?

Solution:
Figure 6.23
6 FL 3WL
3WL
s

2
2
bh
bh
N1bh 2
306

SECTION 4 - SPRINGS
W 775 lb , N1 6 , b 2 in , h 0.213 in

36 in
18 in
2

(a) W 2 775 1550 lb

31550 18
s
153,740 psi
6 2 0.213 2
(b) SAE 9255, OQT 1000 oF
s y 160 ksi

6 FL 3WL
3WL

2
2
bh
bh
N1bh 2
3W 18
160,000
6 2 0.213 2
s

W 1613 lb

- end -

307