Design of Helical Compression

Springs Under Static And Fatigue

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Group Members :
Chandra Prakash
Ajeet Kumar Meena
Pavan Kumar

Types of Springs
Helical:

Compression

Extension

Torsion

Some Review
linear springs: k=F/y

F
k

nonlinear springs: k

Series
1
ktotal

1 1
1

k1 k 2 k3

dF
dy

Parallel

ktotal=k1+k2+k3

Helical Compression Springs

d
D
Lf
p
Nt

diameter of wire
mean coil diameter
free length
pitch
Total coils

may also need:

Do and Di

End Conditions
Plain

Plain Ground

Na=
Active Coils
Square

Square Ground

Stresses in Helical Springs

F

Spring Index

2C 1
max K s
, where K s
2C
d 3
8 FD

F
F
T

C=D/d

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

4C 1 0.615
max K w
, where K w

4C 4
C
d 3
8 FD

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

8 FD N a
y
4
d G

Spring Rate
3

8 FD N a
y
4
d G
k=F/y

4
d G
3
8D N

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

Sut=Adb
Sys

=torsional yield strength

a function of Sut and set

What are You Designing?

Given

Find

F, y
k, y

k
F

d, C, D*, Lf*, Na*, clash

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
Na,
d, C
D, Ks, Kw
material strengths
material

STRESSES

DEFLECTION

Ns=Sys/

Lf, yshut, Fshut

for shut spring if possible

if not, for max working load

Three things to know:

effect of d
shortcut to finding d
how to check buckling

ITERATE?

CHECK
buckling, Nshut, Di, Do
Nshut=Sys/shut

Static Design: Wire Diameter

max K s

8 FD

8 FD 3 N a
d 4G

Based on Ns=Ssy/ and above equation for :

8 N s C 0.5 Fwork 1 Finitial

d

K m A

Three things to know:

effect of d
shortcut to finding d
how to check buckling

1 ( 2b )

use Table 13-2 to select standard d near

calculated d
K =S /S
m

*maintain units (in. or mm) for A, b

ys

ut

Buckling
BucklingDe pendson

Lf
D

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

Modified Goodman for Springs

a
Sfs
0.5 Sfw

Sfw, Sew are for torsional strengths, so von

Mises not used

ed
t
a
e
ep

S fs 0.5

S fwSus

0.5 Sfw

Sus

Sus 0.5 S fw

Fatigue Safety Factor

a

Fi=Fmin
Fa=(Fmax-Fmin)/2

loa

Sa
N fs
a

dl
i ne

Sfs

Fm=(Fmax+Fmin)/2

0.5 Sfw

mload

Sa

mgood
0.5 Sfw

a,load = a,good at intersection

i m

Sus

S fs S us i
N fs
S fs m i S us a
on page 828

What are you Designing?

Given

Find

Fmax,Fmin, y
k, y

k
F

d, C, D*, Lf*, Na*, clash

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
Na,
d, C
D, Ks, Kw
material strengths

STRESSES
S fs Sus i
N fs
S fs m i S us a

DEFLECTION
Lf, yshut, Fshut

material

Two things to know:

shortcut to finding d
how to check frequency

ITERATE?

CHECK
buckling, frequency,
Nshut, Di, Do
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:

N fs 1

0.67A

N fs

8CN fs

K s Fm

1.34
1 K w Fa
S fw

1 ( 2 b )

K s Fmin

Ad b

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
2 Wa

(Hz)

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

Consider the Following: