Outline

 Spring Functions & Types

 Helical Springs
Compression
Extension
Torsional
 The Function(s) of Springs
Most fundamentally: to STORE ENERGY

Many springs can also: push

pull
twist
Some Review
F linear springs: k=F/y
dF
k nonlinear springs: k 
dy

y Parallel
Series
1 1 1 1
  
ktotal k1 k 2 k3 ktotal=k1+k2+k3
 Types of Springs
Helical:

Compression

Extension
Torsion
 More Springs
Washer Springs:

Power springs:
Beams:
Helical Compression Springs

d diameter of wire
D mean coil diameter
Lf free length
p pitch
Nt Total coils

may also need:

Do and Di
 Length Terminology
minimum of 10-15%
clash allowance

Free Length Assembled Max Working Bottomed

Length Load Out

Lf L L L
a m s
 End Conditions
Plain Plain Ground

Na=
Active Coils

Square Square Ground

 Stresses in Helical Springs
F
Spring Index C=D/d

8FD 2C  1
 max  K s , where K s 
T d 3 2C
F
F
T

F
 Curvature Stress
Inner part of spring is a stress concentration
(see Chapter 4)

Kw includes both the direct shear factor and

the stress concentration factor

8FD 4C  1 0.615
 max  K w , where K w  
d 3 4C  4 C
 under static loading, local yielding eliminates stress
concentration, so use Ks
 under dynamic loading, failure happens below Sy:
use Ks for mean, Kw for alternating
Spring Deflection

3
8 FD N
y a
4
d G
 Spring Rate
3
8 FD N
y a
4
d G
k=F/y

4
d G
k
3
8D N a
 Helical Springs
 Compression
Nomenclature
Stress
Deflection and Spring Constant
Static Design
Fatigue Design
 Extension
 Torsion
 Static Spring Design
 Inherently iterative
Some values must be set to calculate
stresses, deflections, etc.
 Truly Design
there is not one “correct” answer
must synthesize (a little bit) in addition to
analyze
 Material Properties
 Sut ultimate tensile strength
Figure 13-3
Table 13-4 with Sut=Adb

 Sys torsional yield strength

Table 13-6 – a function of Sut and set
 Spring/Material Treatments
 Setting
 overstress material in same direction as applied
load
» increase static load capacity 45-65%
» increase energy storage by 100%
 use Ks, not Kw (stress concentration relieved)
 Load Reversal with Springs
 Shot Peening
 What type of failure would this be most effective
against?
 What are You Designing?
Given Find
F, y k d, C, D*, Lf*, Na*, clash
k, y F + allowance ()**, material**

design variables
Such that:
Safety factor is > 1
Spring will not buckle
Spring will fit in hole, over pin, within vertical space

* - often can calculate from given

** - often given/defined
 Static Spring Flow Chart
if GIVEN F,y, then find k; If GIVEN k, y, then find F

N a, 
d, C
STRESSES DEFLECTION
D, Ks, Kw
Ns=Sys/ Lf, yshut, Fshut
material strengths
for shut spring if possible
material if not, for max working load

CHECK
Three things to know: ITERATE?
• effect of d buckling, Nshut, Di, Do
• shortcut to finding d
• how to check buckling Nshut=Sys/shut
 Static Design: Wire Diameter
 max  K s
8FD 8 FD 3 N a
y
d 3 d 4G

Based on Ns=Ssy/ and above equation for :

1 ( 2 b )
8 N s C  0.5Fwork 1     Finitial  
d  
 K m A 
Three things to know: use Table 13-2 to select standard d near
• effect of d calculated d Km=Sys/Sut
• shortcut to finding d
*maintain units (in. or mm) for A, b
• how to check buckling
**see Example 13-3A on MathCad CD
 Buckling

Lf
S .R. 
D
yinit  y working
y 
Lf

Three things to know:

• effect of d
• shortcut to finding d
• how to check buckling
 Helical Springs
 Compression
Nomenclature
Stress
Deflection and Spring Constant
Static Design
Fatigue Design
 Extension
 Torsion
 Material Properties
 Sus ultimate shear strength
 Sus0.67 Sut
 Sfw´ torsional fatigue strength
 Table 13-7 -- function of Sut, # of cycles
 repeated, room temp, 50% reliability, no corrosion
 Sew´ torsional endurance limit
 for steel, d < 10mm
 see page 816 (=45 ksi if unpeened, =67.5 ksi if
peened)
 repeated, room temp., 50% reliability, no corrosion
 Modified Goodman for Springs
 Sfw, Sew are for torsional strengths, so von
Mises not used
a

C S fwSus
S fs  0.5
 
Sfs
Sus  0.5 S fw
B
0.5 Sfw

0.5 Sfw m
Sus
 Fatigue Safety Factor
a Fi=Fmin
Fa=(Fmax-Fmin)/2
Fm=(Fmax+Fmin)/2
Sfs
0.5 Sfw mload
Sa
N fs  Sa
a a mgood
0.5 Sfw i m m
Sus
S fs Sus   i 
a,load = a,good at intersection N fs 
S fs  m   i   Sus a
…on page 828
 What are you Designing?
Given Find
Fmax,Fmin, y k d, C, D*, Lf*, Na*, clash
k,  y F + allowance ()**, material**

design variables
Such that:
Fatigue Safety Factor is > 1
Shut Static Safety Factor is > 1
Spring will not buckle
Spring is well below natural frequency
Spring will fit in hole, over pin, within vertical space
* - often can calculate from Given
** - often given/defined
 Fatigue Spring Design Strategy
if GIVEN F,y, then find k; If GIVEN k, y, then find F

N a, 
d, C
STRESSES DEFLECTION
D, Ks, Kw
S fs Sus   i 
N fs 
material strengths S fs  m   i   Sus a Lf, yshut, Fshut

material

CHECK
ITERATE? buckling, frequency,
Two things to know:
Nshut, Di, Do
• shortcut to finding d
• how to check frequency Nshut=Sys/shut
 Fatigue Design:Wire Diameter
as before, you can iterate to find d, or you can use an equation
derived from relationships that we already know:

1 ( 2b )
 8CN fs  N fs  1  Ad b   
d   K s Fm  K s Fmin  1.34  1 K w Fa  
 0.67A  N fs  S fw   


use Table 13-2 to select standard d near

calculated d

Two things to know:

• shortcut to finding d
• how to check frequency *maintain units (in. or mm) for A, b
**see Example 13-4A on MathCad CD
 Natural Frequency: Surge
Surge == longitudinal resonance

for fixed/fixed end conditions:

1 kg
fn  (Hz)
2 Wa

ideally, fn will be at least 13x more than fforcing…

it should definitely be multiple times bigger

Two things to know:

• shortcut to finding d
• how to check frequency …see pages 814-815 for more
 Review of Design Strategy
ITERATIVE USING d EQUATION

Find Loading Find Loading

Select C, d Select C, safety factor

Find stresses Solve for d, pick standard d

Determine material properties Find stresses
Find safety factor Determine material properties
Check safety factor
Strategy Review Continued
Find spring constant, Na, Nt

Find FSHUT (must find lengths and y’s to do this)

Find static shut shear stress and safety factor

Check Buckling

Check Surge

Check Di, Do if pin to fit over, hole to fit in

Consider the Following:
 Helical Springs
 Compression
Nomenclature
Stress
Deflection and Spring Constant
Static Design
Fatigue Design
 Extension
 Torsion
 Extension Springs
As before, 4 < C < 12

8FD
 max  K s , use K w for a
d 3
surge check is same as before

However, no peening, no setting,

Lb=d(Na+1)
no concern about buckling
 Difference 1: Initial Force

force F
“preloading”

Fi

deflection y

F  Fi d 4G
F=Fi+ky k 
y 8D 3 N a
Difference 1a: Deflection

3
8( F  Fi ) D N a
y
4
d G
 Difference 2: Initial Stress

take initial stress as the average stress between these lines,

then find Fi
Difference 3: Ends!: Bending
16DF 4F
 a  Kb 
d 3 d 2

4C12  C1  1
Kb  standard
4C1 (C1  1) end
2 R1 2 D
C1   C
d 2d

S e ( Sut   min )
N fb 
S e ( mean   min )  Sut  alt
S es
Se 
0.67
Difference 3a: Ends: Torsion

8FD 4C2  1
 max  K w2 , K w2 
d 3 4C2  4

C2=2R2/d

pick a value >4

 Materials

 Sut – Same
 Sys, Sfw, Sew – same for body
 Sys, Sfw, Sew – see Tables 13-10 and 13-
11 for ends
Strategy
similar to compression + end stresses - buckling
 Helical Springs
 Compression
Nomenclature
Stress
Deflection and Spring Constant
Static Design
Fatigue Design
 Extension
 Torsion
Torsion Springs
• close-wound, always load to close

Deflection & Spring Rate

1 MLw
 rev  , Lw  lengthof wire  DN a
2 EI
MDN a
 rev,roundwire  10.8
d 4E

M
k
 rev
 Stresses
Compressive is Max – Use for Static – Inside of Coil

M max c 32M max

 imax  K bi  K bi
I d 3

4C 2  C  1
K bi 
4C (C  1)
For Fatigue – Slightly lower Outside Tensile Stress – Outside of Coil
32M max 32M min
 omax  K bo  omin  K bo
d 3 d 3

4C 2  C  1
K bo 
4C (C  1)
Materials
see Tables 13-13 and 13-14, page 850

follow book on Sewb=Sew/0.577… for now

 Strategy

Select C, d
• fit over pin (if there is one)
M K • don’t exceed stresses
 Helical Springs
 Compression
Nomenclature
Stress
Deflection and Spring Constant
Static Design
Fatigue Design
 Extension
 Torsion