9th edition

CHAPTER 10
Mechanical Springs

Prof. Dr. Necdet GEREN

University of Cukurova, Mech eng. Dep. Prof. Dr. Necdet GEREN 1

University of Cukurova, Mech eng. Dep.
Prof. Dr. Necdet GEREN 2
Various Mechanical Springs

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Prof. Dr. Necdet GEREN 3
Compressive Springs are very important part of any engine!
Cam mechanism

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Springs in valves of an engine

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Spring in presure relief or Spring in rifle
safety valve

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Prof. Dr. Necdet GEREN 6
University of Cukurova, Mech eng. Dep.
Prof. Dr. Necdet GEREN 7
University of Cukurova, Mech eng. Dep.
Prof. Dr. Necdet GEREN 8
 Mechanical Springs…..
Mechanical springs are used in machines

 to exert force,
 to provide flexibility and,
 to store or absorb energy

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Prof. Dr. Necdet GEREN 9
10–1 Stresses in Helical Springs
Fig. 10.1 (a) shows a round-wire helical compression spring loaded by
the axial force F. If we designate
D  As the mean diameter
d  As the wire diameter

Figure 10–1
(a) Axially loaded helical
spring;
(b) free-body diagram
showing that the wire is
subjected to a direct
shear and a torsional
shear

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Prof. Dr. Necdet GEREN 10
Nnow if we imagine that the spring is cut at the same point as shown in
Fig. 10.1 (b), the cut portion would exert a direct shear force F  and a
Torsion T .

Therefore, the maximum stress in the wire may be computed by

superposition of the forces and the result is

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Prof. Dr. Necdet GEREN 11
where,
Tr / J is the torsion formula and FA is the shear stress.

Replacing the terms by

T
FD
, rd , j
 d 4
 d2
, A ,
2 2 32 4

gives

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Prof. Dr. Necdet GEREN 12
 Now if we define the spring index, C (C range from 6 to 12)

With this relation, Eq. (10.1) can be rearranged to give

 
τ  8FD3 1  0.5  K s  2C  1  1  0.5
d  C  2C C
Ks is called a shear-stress correction or multiplication
factor

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Prof. Dr. Necdet GEREN 13
 Resultant
torsional shear
and direct
shear stress
diagram

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Prof. Dr. Necdet GEREN 14
 Equation (10-3) is quite general and applies
for
both static and dynamic loads.

Clutch Basket Spring failure in Clutch Basket

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Prof. Dr. Necdet GEREN 15
10–2 Curvature Effect

An effect very similar to stress concentration

occurs at the inside surface of a helical spring
due to curvature.

The curvature of the wire

increases the stress on the inside of the spring
but decreases it only slightly on the outside of the
wire.

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Prof. Dr. Necdet GEREN 16
 10–2 Curvature Effect
This curvature stress is primarily important in fatigue

This factor is given by either of the equations

Wahl factor,

the Bergsträsser factor 

The curvature correction factor is found to be

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Prof. Dr. Necdet GEREN 17
 we will use

τ = KB(8FD)/(πd3)

to predict the largest shear stress.

(a) Resultant torsional shear and (b) Resultant torsional shear, direct
direct shear stress diagram shear, and curvature shear stress
diagram

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Prof. Dr. Necdet GEREN 18
 10–3 Deflection of Helical Springs
If we use Castigliano’s theorem,
the deflection force relations are quite easily obtained.
Shear
Torsional component
component
T 2L F 2L  The total strain energy for a helical 
 
U   spring is composed of a torsional 
2GJ 2 AG  component and a shear component 

π d4
L  DN ,
Substituting
T
FD d 2
j ,
, A , 32
2 4

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Prof. Dr. Necdet GEREN 19
where
N = Na = number of active coils.

Then using Castigliano’s theorem, Eq. (4–20), to find total deflection y

gives
partial
derivative

Since C = D/d, Eq. (c) can be rearranged to yield

The spring rate (scale of the spring) is

k = F/y, and so

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Prof. Dr. Necdet GEREN 20
 10–4 Compression Springs
The four types of ends generally used for compression springs are
illustrated in Fig. 10–2.
Use for important
applications,
because a better
transfer of the
load is obtained.

Figure 10–2 Types of ends for compression

springs: (a) both ends plain; (b) both ends squared; (c) both ends squared
and ground; (d) both ends plain and ground.
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 10–4 Compression Springs
Showing Plain
Left-hand side ends

Closed and Showing

ground ends Righ-hand side

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 Table 10–1 shows how the type of end used affects the number
of coils and the spring length.

Table 10–1
Formulas for the Dimensional Characteristics of Compression-Springs.
(Na=Number of Active Coils)

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Prof. Dr. Necdet GEREN 23
 Set removal or presetting is a process
used in the manufacture of compression springs to induce useful
residual stresses.

It is done
by making the spring longer than needed
and then
compressing it to its solid height.

Before set removal

After set removal

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Prof. Dr. Necdet GEREN 24
 Set removal or presetting
is
useful
When the spring is used for energy-storage purposes.

spring-loaded energy storage

pneumatic clamp system

Set removal should not be used

when springs are subject to fatigue.

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Prof. Dr. Necdet GEREN 25
10–5 Stability
Compression coil springs may buckle
when the deflection becomes too large.

The critical deflection (ycr) is given by the equation

λeff: is the effective slenderness ratio

C′1 and C′2 are elastic constants defined by

α=end-condition constant.

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Prof. Dr. Necdet GEREN 26
 Table 10–2 gives values of “α” for usual end conditions.

Table 10–2 End-Condition Constants α for Helical Compression

Springs*

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 Absolute stability occurs when,
in Eq. (10–10), the term (C′2 /λ2eff >1) is greater than unity.

Buckled spring

Free-length

Solid-height
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 This means that the condition for absolute stability is that

For steels, this turns out to be

For squared and ground ends

Support spring if
buckling occurs!

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Prof. Dr. Necdet GEREN 29
10–6 Spring Materials
Springs are manufactured either by
hot- or cold-working processes,
depending upon
the size of the material,
the spring index, and
the properties desired.

In general, pre-hardened wire should not be used

if D/d < 4 or if d > 6mm.

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Prof. Dr. Necdet GEREN 30
Winding of the spring induces residual stresses
through bending,
but
these are normal to the direction of
the torsional working stresses in a coil spring.

They are relieved, after winding,

by a mild thermal treatment.

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Prof. Dr. Necdet GEREN 31
 A great variety of spring materials are available to the designer,
including plain carbon steels,
alloy steels,
and corrosion-resisting steels,
as well as
nonferrous materials such as
phosphor bronze,
spring brass,
beryllium copper, and
various nickel alloys.
Descriptions of the most commonly used steels will be found in Table 10–3

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Prof. Dr. Necdet GEREN 32
The UNS steels listed in Appendix A should be used in
designing
hot-worked, heavy-coil springs,
as well as flat springs, leaf springs, and torsion bars.

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Prof. Dr. Necdet GEREN 33
Table 10–3 High-Carbon and Alloy Spring Steels

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Table 10–3 High-Carbon and Alloy Spring Steels

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Table 10–3 High-Carbon and Alloy Spring Steels

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Prof. Dr. Necdet GEREN 36
 Tensile strength of spring materials vary so much with
wire size,
the material and its processing.

There is a relationship between the tensile strength and those

parameters, which is given by

See Table 10.4 for A and m values

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Prof. Dr. Necdet GEREN 37
 the distortion-energy theory
can be employed to obtain the torsional yield strength (Ssy = 0.577Sy).
This approach results in the range

For wires listed in Table 10–5,

the maximum allowable shear stress in a spring can be seen in column 3.

Use the maximum allowable torsional stress for static application

shown in Table 10–6.

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Prof. Dr. Necdet GEREN 38
Table 10–4 Constants A and m of Sut = A/dm for Estimating
Minimum Tensile Strength of Common Spring Wires

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Prof. Dr. Necdet GEREN 39
Table 10–5 Mechanical Properties of Some Spring Wires

%
Ssy = 0.45Sut

the maximum allowable shear stress

Ssy= (0.??). Sut !!!!!

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Prof. Dr. Necdet GEREN 40
Table 10–6 Maximum Allowable Torsional Stresses for Helical
Compression Springs in Static Applications
%

Ssy = 0.60Sut

Note: Music wire and hard (cold) -

drawn steel spring wire have a low end
of range Ssy = 0.45Sut .
Set removal increases the strength of the spring
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Prof. Dr. Necdet GEREN 41
 10–7 Helical Compression Spring Design for
Static Service
The first item of the design assessment is C
The preferred range of spring index is
more difficult to form May tangle
(surface cracking)
4 ≤ C ≤ 12

The recommended range of active turns is 3 ≤ Na ≤ 15.

the maximum operating force should be limited to Fmax ≤7/8 Fs

Defining the fractional overrun to closure as ξ, where

Solid force
it is recommended that ξ ≥ 0.15 (ξ :robust linearity)

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Prof. Dr. Necdet GEREN 42
we now have some recommended design conditions to follow,
namely:

where
ns : the factor of safety at closure (solid height).

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Prof. Dr. Necdet GEREN 43
 When designing a spring for high volume production,
the figure of merit (fom) can be
the cost of the wire from which the spring is wound.

The fom would be proportional to the relative

material cost,
weight density, and
volume
Omit this

25.43

Add 25.43

1 inch=25.4mm – 25.43 is used to normalize the fom for SI unit system

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Prof. Dr. Necdet GEREN 44
 Spring design is an open-ended process.
Today, the computer enables the designer to create programs.
One possible design approach is given here.

Design Strategy

 Make the a priori decisions, with hard-drawn steel wire the first
choice (relative material cost is 1.0).

 Choose a wire size d.

 With all decisions made, generate a column of parameters:

d, D, C, OD or ID, Na , Ls , L0, (L0)cr, ns , and fom.

 By incrementing wire sizes available, we can scan the table of

parameters and apply the design recommendations by inspection.

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Prof. Dr. Necdet GEREN 45
Design Strategy

 After wire sizes are eliminated, choose the spring design with the
highest figure of merit (FOM). This will give the optimal design.

 The column vector of information can be generated by using the

flowchart displayed in Fig. 10–3.

 In as-wound springs the controlling equation must be solved for

the spring index as follows. From Eq. (10–3)
with τ = Ssy/ns , C = D/d,
KB from Eq. (10–6), and Eq. (10–17),

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Prof. Dr. Necdet GEREN 46
Substituting Eqs. (b) and (c) into (a) and simplifying yields a quadratic
equation in C.
The larger of the two solutions will yield the spring index

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Prof. Dr. Necdet GEREN 47
Note: In fatigue replace

Ssy with Sse

ns with nf and

(1 + ξ )Fmax with Fa

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Figure 10–3 Helical coil compression spring design flowchart for static
loading.

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Figure 10–3……

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 Figure 10–3……

Print or display: d, D, C, OD, ID, Na, Nt,Ls, LO, (LO)cr, n

 Build a table, conduct design assessment by inspection
 Eliminate infeasible designs by showing active constraints
 Choose among satisfactory designs using the figure of
merit (FOM)

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Prof. Dr. Necdet GEREN 51
An example to the table

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Prof. Dr. Necdet GEREN 52
 STUDY EXAMPLE 10–2 and 10.3
in the book!

There are vendors who stock literally thousands of

music wire compression springs.
Browse their catalogs, you will usually find suitable one.
However,
test them before ordering.

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Prof. Dr. Necdet GEREN 53
10–8 Critical Frequency of Helical Springs

If a wave is created by a disturbance (i.e. Stone)

at one end of a swimming pool,
this wave will travel down the length of the pool,
be reflected back at the far end,
and
continue in this back-and-forth motion
until it is finally damped out.
.
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Prof. Dr. Necdet GEREN 54
The same effect occurs in helical springs,
and
it is called SPRING SURGE.
The spring surge results in failures

[Link]

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Prof. Dr. Necdet GEREN 55
Figure 10–5 is a photograph of a failure caused by such surging.

Figure 10–5
Valve-spring failure in an Overrevved
engine. Fracture is along the 45◦ line of
maximum principal stress associated
with pure torsional loading.

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Prof. Dr. Necdet GEREN 56
When helical springs are subjected to rapid reciprocating motion,
natural vibratory frequency must not be close to
the frequency of the applied force;
otherwise, resonance may occur, resulting in damaging stresses.

Natural vibratory frequency depends on

the physical dimensions of the spring

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Prof. Dr. Necdet GEREN 57
The governing equation for the translational vibration of a spring is
the wave equation

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Prof. Dr. Necdet GEREN 58
 The solution to this equation is harmonic and depends on the given
physical properties as well as the end conditions of the spring.

The harmonic, natural, frequencies for a spring placed between two

flat and parallel plates, in radians per second, are

where the fundamental

frequency is found for m = 1,
the second harmonic for m = 2,
and so on.

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Prof. Dr. Necdet GEREN 59
 We are usually interested in the frequency in cycles per second;
since ω = 2π f , we have, for the fundamental frequency in hertz
(1 hertz=1/s),

when one end is against a

flat plate and the other end is
driven with a sine-wave
motion, then use this

when the spring has one

end against a flat plate and
the other end free, then use
this

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Prof. Dr. Necdet GEREN 60
The weight of the active part of a helical spring is

where γ(Gamma); the specific weight.

in order to avoid resonance with the harmonics

f ≥ 15-20 fmotion
fmotion: the frequency of the force or motion of the spring
f: the fundamental critical frequency

If the frequency (f) is not high enough,

the spring should be redesigned to
increase k or decrease W

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Prof. Dr. Necdet GEREN 61
10–9 Fatigue Loading of Helical Compression
Springs
Springs are almost always subject to fatigue loading
Valve spring of an automotive engine
must sustain millions of cycles of operation without
failure; so
it must be designed for infinite life

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Prof. Dr. Necdet GEREN 62
 Shot peening
can increase the torsional fatigue strength by
20 percent or more

The best data on the torsional endurance limits of

spring steels are those reported by Zimmerli.

Based on Zimmerli;
size, material, and tensile strength
have no effect on the endurance limits of spring steels
in sizes under 10 mm

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Prof. Dr. Necdet GEREN 63
The corresponding endurance strengths
shot peening

For example, given an unpeened spring, the Gerber ordinate intercept

for shear, from Eq. (6–42),

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Prof. Dr. Necdet GEREN 64
Remember the fatigue failure criterions

Now we have SINES!

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Prof. Dr. Necdet GEREN 65
Sines failure criterion in torsional fatigue:
polished, notch-free, cylindrical specimens subjected
to torsional shear stress,
the maximum alternating stress that may be imposed without
causing failure is constant and independent of the mean stress.

Ssu :torsional modulus of rupture

Alternating shear stresses

Sse
Sines
Goodman

45

Ssu
Mean shear stresses

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Prof. Dr. Necdet GEREN 66
Sines failure criterion in torsional fatigue:
.
Note that: Then
Sse=Ssa nf=Ssa/τa
Alternating shear stresses

Ssu :torsional modulus of rupture

Sse

45

Ssu
Mean shear stresses

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Prof. Dr. Necdet GEREN 67
 Helical springs are never used as both
compression and extension springs.

In fact, they are usually assembled with a preload.

τ
τ

Then the shear stress amplitude and mean stresses are:

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Prof. Dr. Necdet GEREN 68
 In spring design
the Sines criterion will always be the most conservative
and
the Goodman the least.

The Goodman criterion

would be more conservative than the Gerber criterion

Then
Sines <Gerber< Goodman

More conservative for FS

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Prof. Dr. Necdet GEREN 69
10–10 Helical Compression Spring Design for
Fatigue Loading
EXAMPLE 10–5
A music wire helical compression spring with infinite life
is needed to resist a dynamic load that varies from 20 to
80 N at 5 Hz while the end deflection varies from 12 to
50 mm. Because of assembly considerations, the solid
height cannot exceed 25 mm and the free length cannot
be more than 100 mm. The springmaker has the following
wire sizes in stock: 1.7, 1.8, 2.0, 2.15, 2.3, 2.4, 2.6 and 2,8
mm.

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Prof. Dr. Necdet GEREN 70
Table 10–4 Constants A and m of Sut = A/dm for Estimating Minimum
Tensile Strength of Common Spring Wires

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Prof. Dr. Necdet GEREN 71
Table 10–5 Mechanical Properties of Some Spring Wires

for d=2.8 mm 1.6 mm = =3.1 mm

Ssy=0,[Link]

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Prof. Dr. Necdet GEREN 72
Solution From Table 10.4
The priori decisions are:
• Material and condition: for music wire,
A = 2211 Mpa mmm, m = 0.145, Relative cost: 2.6
G = 81 Gpa;
From Table 10.5
for d=2.8 mm
• Surface treatment: unpeened

• End treatment: squared and ground

Assumption!

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Prof. Dr. Necdet GEREN 73
• Robust linearity: ξ = 0.15

• Set: use in as-wound condition

• Fatigue-safe: nf = 1.5 using the Sines-Zimmerli fatigue-failure criterion

• Function:
Fmin = 20 N, Fmax = 80 N,
ymin = 12 mm, ymax = 50 mm, spring operates free (no rod or hole)

• Decision variable: wire size d

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Prof. Dr. Necdet GEREN 74
 Example 10-5……

The figure of merit will be the volume of wire to wind the

spring, Eq. (10–22). The design strategy will be to
1. set wire size d,
2. build a table,
3. inspect the table, and
4. choose the satisfactory spring with the highest figure of
merit (fom).

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Prof. Dr. Necdet GEREN 75
Set d = 2.8 mm Then

From Table 10.5

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Prof. Dr. Necdet GEREN 76
From Eq. (10-28), with the Sines criterion,
Sse=Ssa=241 Mpa.

Equation (10-23)

can be used to determine C with

Sse, nf, and Fa
in place of
Ssy ,ns and (1+ζ) Fmax, respectively.

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Prof. Dr. Necdet GEREN 77
Thus

Not
suitable

(6<C<12)

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 From Table 10.1
For squared and ground

(ID=D-d)

Free
L
(OD=D+d)

Solid
L

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Prof. Dr. Necdet GEREN 79
 Example 10-5……

Ɣ=82 KN/m3

when one end is

against a flat
plate
and
the other end is
driven with a
sine-wave
motion
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Prof. Dr. Necdet GEREN 80
Example 10-5……

Add 25.43

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Prof. Dr. Necdet GEREN 81
 Inspection of the results show that all conditions are
satisfied except for

4 ≤ C ≤ 12

Repeat the process using the other available wire sizes

and develop the following table

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Prof. Dr. Necdet GEREN 82
 12.73
24.3

The problem-specific inequality constraints: The general constraints:

Ls ≤ 25 mm, L0 ≤ 100 mm, fn ≥ 5(20) = 100 Hz 3 ≤ Na ≤ 15,
4 ≤ C ≤ 12, (L0)cr > L0
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Prof. Dr. Necdet GEREN 83
 The problem-specific inequality constraints are

Ls ≤ 25 mm, L0 ≤ 100 mm, fn ≥ 5(20) = 100 Hz

The general constraints are

3 ≤ Na ≤ 15, 4 ≤ C ≤ 12, (L0)cr > L0

None of the diameters satisfy the given constraints.

The 2.6 mm diameter wire is the closest to satisfy all.
The value of C =13.4 is not a serious deviation (acceptable).

If not, use the 2.8 mm diameter and accept a value C=15.3,

individually package the springs, and possibly reconsider supporting the
spring in service

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Prof. Dr. Necdet GEREN 84
10–11 Extension Springs
Extension springs carry tensile loads
and
the spring body is wound with an initial tension.
Figure 10–6 Types of ends used on extension springs.

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Prof. Dr. Necdet GEREN 85
 Homework Assigment
Solve Problem 10-28

Preloaed
spring

Preloaeding
spring

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Prof. Dr. Necdet GEREN 86
Stresses in the body of the extension
spring are handled
the same as compression springs.

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Prof. Dr. Necdet GEREN 87
 In designing a spring with a hook end,
bending and torsion in the hook must be included
in the analysis.

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Prof. Dr. Necdet GEREN 88
 In Fig. 10–7a and b a commonly used method of designing
the end is shown.

Figure 10–7
Ends for extension springs. (b) Side view of part a; stress is
(a) Usual design; stress at A is mostly torsion at B.
due to combined axial force
and bending moment.
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Prof. Dr. Necdet GEREN 89
 In Fig. 10–7c and d Improved design.

improved design due to a

reduced coil diameter

Figure 10–7
Ends for extension springs.
(d ) Side view of part c; stress
(c) Improved design; stress at A is
at B is mostly torsion.
due to combined axial force and
bending moment
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Prof. Dr. Necdet GEREN 90
 The maximum tensile stress at A,
due to bending and axial loading, is given by

Hook diameter (D=2r1)

where
(K)A : a bending stress correction factor for curvature, given by

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Prof. Dr. Necdet GEREN 91
The maximum torsional stress at point B is given by

The stress correction factor for curvature, (K)B, is

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Prof. Dr. Necdet GEREN 92
 Spring manufacturers prefer some initial tension in
close-wound springs
in order to hold the free length more accurately.

Fig. 10–8a shows load deflection

curve , where y is the extension and
Fi is the initial tension in the spring.

Initial tension

Figure 10–8
(a) Geometry of the force F and extension y curve of an extension spring;
University of Cukurova, Mech eng. Dep.
Prof. Dr. Necdet GEREN 93
Spring manufacturers prefer some initial tension in close-wound
springs in order to hold the free length more accurately.

Wire is pulled Fi
during
Spring production

University of Cukurova, Mech eng. Dep.

Prof. Dr. Necdet GEREN 94
 When extension springs are made with coils in
contact with one another,
they are said to be close-wound.

initial tension in
No-sagging!
close-wound
springs hold the free
length more accurately
University of Cukurova, Mech eng. Dep.
Prof. Dr. Necdet GEREN 95
 Figure 10–8
(c) torsional stresses due to
initial tension as a function of
spring index C in helical
extension springs.

The load-deflection relation is

where k is the spring rate

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Prof. Dr. Necdet GEREN 96
 The free length L0 of a spring measured inside the end
loops or hooks as shown in Fig. 10–8b

Figure 10–8;
(b) geometry of
the extension
spring;

can be expressed as

where
Nb : the number of body coils,
University of Cukurova, Mech eng. Dep.
Prof. Dr. Necdet GEREN 97
 in determining the spring rate k,
the equivalent number of
active helical turns Na for use in Eq. (10–9) is

where
G: the shear moduli of elasticity and
E: the tensile moduli of elasticity

University of Cukurova, Mech eng. Dep.

Prof. Dr. Necdet GEREN 98
 Initial tension for the uncorrected torsional stress

as

Guidelines for
the maximum allowable corrected stresses
for static applications of extension springs are given in Table 10–7.

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Prof. Dr. Necdet GEREN 99
Table 10–7 Maximum Allowable Stresses (KW or KB corrected) for Helical
Extension Springs in Static Applications

Ssy=0,[Link] Sy=0,[Link]

University of Cukurova, Mech eng. Dep.

Prof. Dr. Necdet GEREN 100
 The end hooks are usually the weakest part of
the extension springs.
Higher design factors
are used in extension-spring design than compression springs

we can estimate the endurance limit for the hook in bending

using the Zimmerli data.

Zimmerli data

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Prof. Dr. Necdet GEREN 101
 An alternative method is to use Table 10–8,
which is based on a stress-ratio of
R= See:
It means that =0 Fig. 6-26

For this case,

Label the strength values of Table 10–8 as

Sr for bending or Ssr for torsion.

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Prof. Dr. Necdet GEREN 102
Figure 6–26 Master fatigue diagram created for AISI 4340 steel
stress ratio amplitude ratio

Constant-Life line

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Prof. Dr. Necdet GEREN 103
 Then for torsion, for example,
Ssa = Ssm = Ssr /2
and the Gerber ordinate intercept,
given by Eq. (6–42) for shear, is

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Prof. Dr. Necdet GEREN 104
Table 10–8
Maximum Allowable Stresses for ASTM A228 and Type 302 Stainless
Steel Helical Extension Springs in Cyclic Applications

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Prof. Dr. Necdet GEREN 105
10–12 Helical Coil Torsion Springs

When a helical coil spring is subjected to end torsion,

it is called a torsion spring.

It is usually close-wound, but with negligible initial tension.

There are single-bodied and double-bodied types

(Fig. 10–9).

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Prof. Dr. Necdet GEREN 106
 single-bodied
Figure 10–9
Torsion springs.

It applies torque

subjected to
bending
double-bodied
usually used with a
rod

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Prof. Dr. Necdet GEREN 107
 .
As the applied torque
increases,
the inside diameter of the
coil decreases

Torsion springs are familiar in

clothespins, window shades, and animal trap

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Prof. Dr. Necdet GEREN 108
 For analysis purposes,
the nomenclature of Fig. 10–10 can be used.

Rotational coordinate θ
Figure 10–10
The free-end location angle is β.
The rotational coordinate θ is
proportional to the product Fl.
Its back angle is α. For all
positions of the moving end

Back angle
free-end
location
angle β

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Prof. Dr. Necdet GEREN 109
 The number of body turns Nb is the number of turns in the free
spring body by count.

The body-turn count is related to the initial position angle β by

Nb: number of body turns

Np :the number of partial turns.

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Prof. Dr. Necdet GEREN 110
 A torsion spring wire is subjected to bending.

The bending stress

where
K: a stress-correction factor.

for round wire,

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Prof. Dr. Necdet GEREN 111
 for round wire

For the inner fibers

When the bending moment is
M = Fr
and
the section modulus
I/c = d3/32

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Prof. Dr. Necdet GEREN 112
Deflection and Spring Rate

Spring Rate

Deflection

k′ :spring rate (units torque/turn)

Өt: total angular deflection in radians

l1, l2: each end of lengths

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Prof. Dr. Necdet GEREN 113
 F
Ensure that the inside diameter of the
coil never
becomes equal to
or
less than the diameter of the pin,
Diameter under torque
The helix diameter of the coil D′

: the angular deflection of the body of the coil in number of turns

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Prof. Dr. Necdet GEREN 114
The new inside diameter
Diameter under
torque

makes the diametral clearance

between the body coil and
the pin of diameter Dp equal to

Equation (10–55) solved for Nb is

Nb: number of body turns corresponding to a specified diametral

clearance of the arbor.

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Prof. Dr. Necdet GEREN 115
 Static Strength
First column entries in Table 10–6 can be divided by 0.577
(from distortion-energy theory) to give

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Prof. Dr. Necdet GEREN 116
 Fatigue Strength
Use the Gerber fatigue-failure criterion incorporating
the Associated Spring R = 0 fatigue strength Sr :

For this case,

Sr =[Link]

The value of Sr (and Se) has been corrected

for size, surface condition, and type of loading,
but not for temperature or miscellaneous effects.

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Prof. Dr. Necdet GEREN 117
The strength-amplitude component is given by

r = Ma/Mm (the slope of the load line)

The factor of safety guarding against fatigue failure is

Alternatively, we can find nf

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Prof. Dr. Necdet GEREN 118
10–13 Belleville Springs
Fig. 10–12 shows a coned-disk spring, called a Belleville spring.

Figure 10–12 Load-deflection curves for Belleville springs.

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Prof. Dr. Necdet GEREN 119
 The mathematical treatment is beyond the scope of this lecture.

However it has remarkable characteristics.

A) Only occupies a small space

B) Variation in the (height/thickness) ratio produce a wide variety of

load-deflection curve

C) ratio of 2.83 or larger gives an S curve which might be useful for

snap-acting mechanisms

D) ratio of 1.41 to 2.1 causes the central portion of the curve to

become horizontal

means that the load is constant over a

considerable deflection range
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Prof. Dr. Necdet GEREN 120
Use of Belleville Springs in Metal Seated Ball Valve

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Prof. Dr. Necdet GEREN 121
Use of Belleville Springs

in a Valve

A patented Belleville
spring mechanism
permits the CONSTANT
TORQUE clamp to
automatically adjust
diameter

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Prof. Dr. Necdet GEREN 122
10–14 Miscellaneous Springs
Figure 10–13 Constant-force spring.

Made of slightly curved strip steel, not flat.

so that the force required to uncoil it

remains constant;

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Prof. Dr. Necdet GEREN 123
Figure 10–14
(a) A volute spring; (b) a flat triangular spring.

A volute spring

As the deflection increases, A flat triangular spring

the number of active coils decreases.

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Prof. Dr. Necdet GEREN 124
 A volute spring

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Prof. Dr. Necdet GEREN 125
PROBLEM 10-3: (Similar)
A helical compression spring is wound using 3mm-
diameter music wire. The spring has an outside diameter
of 30 mm with plain ground ends, and 12 total coils.
(a) What should the free length be to ensure that when
the spring is compressed solid the torsional stress does
not exceed the yield strength, that is, that it is solid-
safe?
(b) What force is needed to compress this spring to
closure?
(c) Estimate the spring rate.
(d ) Is there a possibility that the spring might buckle in
service?
University of Cukurova, Mech eng. Dep.
Prof. Dr. Necdet GEREN 126
Solution
(a)- For plain and ground ends From Table 10.1
Nt=Na+1
Ls=[Link]
Nt=Na+1 Na=Nt-1=12-1=11 Coils
Ls=[Link]=3.(12)=36 mm
For music wire From Table 10.4
A=2211 MPa mmm
m=0,145

From Table 10.5 or Table 10.6

For music wire Ssy=0.45. Sut
“Before set removed” Ssy=0.45. (1885,4)=848,43 MPa
G=81 GPa 1,61<d<3 mm

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Prof. Dr. Necdet GEREN 127
 D=Do-d=30-3=27 mm Then

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Prof. Dr. Necdet GEREN 128
 k=3,7878 N/mm
Free Length L0=y+Ls
Deflection

L0=y+Ls=76,38+36=112,38 mm

University of Cukurova, Mech eng. Dep.

Prof. Dr. Necdet GEREN 129
 d)-Check buckling for steel wire material
Assumption: Spring supported between flat parallel surfaces
(𝝰=0.5 from Table 10.2)
(𝝰=0.5 from Table 10.2)

Hence, the spring will not buckle in service.

Will work
properley

University of Cukurova, Mech eng. Dep. 130

Prof. Dr. Necdet GEREN
PROBLEM 10–23 (Simiar)
A holding fixture for a workpiece 38 mm thick at clamp
locations is being designed. The detail of one of the
clamps is shown in the figure. A spring is required to
drive the clamp upward while removing or inserting a
workpiece. A clamping force of 45 N is satisfactory.
The base plate is 16 mm thick. The clamp screw has a
12 mm-20 UNF thread. It is useful to have the free
length L0 short enough so that the clamp screw can
compress the spring upon fixture reassembly during
inspection and service, say L0 ≤ 38+ 10 mm. The spring
cannot close solid at a length greater than 30 mm. The
safety factor when compressed solid should be ns ≥ 1.2,
and at service load nl ≥ 1.5. Design a suitable helical coil
compression spring for this fixture.
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Prof. Dr. Necdet GEREN 131
 PROBLEM 10–23………

Work piece

38 mm

Inner diameter
should be greater
than screw diameter!
University of Cukurova, Mech eng. Dep.
Prof. Dr. Necdet GEREN 132
 It is a Design problem!
Design boundaries are;
F=45 N
L0≤38+10 mm
LS≤30 mm
nS≥1,2
nl≥1,5
ID>12mm (due to 12 mm -20UNF screw)

ASSUMPTIONS for the design Ideal for

initial trial
Spring Ends: Squared and ground ends
Material: Hard-drawn (HD) wire (A227) steel for its low cost (CR=1)
Diameter: 1,61-3 mm

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Prof. Dr. Necdet GEREN 133
All selections are from 9th edition
For
From Table 10-4
“Hard-drawn (HD) wire (A227) steel”
CR=1.0,
A=1783 MPa mmm
m=0.190
Thickness of From Table 10-5
work-piece G=79,3 GPa (for d of 1,61-3 mm)
(Can also be solved for G=81.0 GPa)

L0≤38+10 mm means that

deflection “y” is 10 mm (y=10 mm) under F=45 N

Then

Let’s initiate TRIAL-and ERROR iteration

for sizing of the wire diameter

University of Cukurova, Mech eng. Dep.

Prof. Dr. Necdet GEREN 134
For reasonably From Table A-28 Can be
small force (45 N) Gauge size 14 –Ferrous wire, selected
Ferrous wire (A227 steel) standard wire dia. d=2,032 mm

We should provide clearance between the screw rod and the spring

For total clearance of 1,5 mm (Assumption)

(0,75 mm at each side)

ID=12+1,5 mm=13,5 mm
OD=ID+2d=13,5+2.(2,032)
OD=17,564 mm
D=OD-d=(17,564) – (2,032)=15,532 mm

ID: Inside diameter

OD: Outside diameter
University of Cukurova, Mech eng. Dep.
Prof. Dr. Necdet GEREN 135
 Now, total number of coils (Nt) can be found

For Squared and ground ends From Table 10.1

Ne=2
Nt=Na+2=10+2=12 coils
LS=[Link]=2,032.(12)=24,384 mm < 30 mm
L0=[Link]+2 (not useful in this problem)

LS < 30 mm then “LS” is acceptable.

University of Cukurova, Mech eng. Dep.

Prof. Dr. Necdet GEREN 136
 L0≤38+10048 mm given in the problem statement

Since L0=48 mm, then ys=L0-LS=(48)-(24,384)=23,616 mm

Deflection ys

24,384
48

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Prof. Dr. Necdet GEREN 137
 Fs=[Link]=(4,5). (23.616)= 106,27 N

For hard (cold) drawn wire, “A” and “m” are known.

For hard (cold) drawn wire: From Table 10.6

Ssy=0,45. (Sut) =0,45.(1558,28)=701,2 MPa

University of Cukurova, Mech eng. Dep.

Prof. Dr. Necdet GEREN 138
 ns < 1,2
!

nl > 1,5 then diameter is acceptable

(Dictated in the design statement)

However, we must go back and try again

until ns > 1,2

University of Cukurova, Mech eng. Dep.

Prof. Dr. Necdet GEREN 139
Second or more iterations are neded!

Please do (redesign it) it at home

Options are:
Reduce “D” or increase “d”
or change material or try other
sizes and/or materials

University of Cukurova, Mech eng. Dep.

Prof. Dr. Necdet GEREN 140
PROBLEM 10–30 -9th edition

A helical coil compression spring is needed for food

service machinery. The load varies from a minimum of
20 N to a maximum of 90 N. The spring rate k is to be
1660 N/m. The outside diameter of the spring cannot
exceed 62mm. The springmaker has available suitable
dies for drawing 2-, 2.3-, 2.6-, and 3-mm in-diameter
wire. Using a fatigue design factor nf of 1.5, and the
Gerber-Zimmerli fatigue-failure criterion, design a
suitable spring.

University of Cukurova, Mech eng. Dep.

Prof. Dr. Necdet GEREN 141
 It is a fatigue design problem.
For a food service From Table 10-3 and 10-4:
machinery application Select A313 Stainless wire
From Table 10-4: for sizes 0.3≤d≤2.5 mm
For A313 m=0.146
(302 Stainless wire A=1867 [Link]
CR=7.6-11
Spring is subjected fluctuating forces that results in fluctuating stresses

Fa
Fr
force

Fa
Fmax
Fm
Fmin

University of Cukurova, Mech eng. Dep.

Prof. Dr. Necdet GEREN 142
k=1660 N/m=1,66 N/mm

Let’s try the first diameter as d=2 mm

For d=2 mm

Ssu=[Link]=0,67.1687.3 =1130,5 MPa

For austenic From Table 10-6:

stainless steel wire Ssy=0,[Link]=0,35.1687,3 =590,56 MPa

University of Cukurova, Mech eng. Dep.

Prof. Dr. Necdet GEREN 143
For austenic From Table 10-6:
stainless steel wire Ssy=0,[Link]=0,35.1687,3 =590,56 MPa

Table 10–6 Maximum Allowable Torsional Stresses for Helical

Compression Springs in Static Applications

University of Cukurova, Mech eng. Dep.

Prof. Dr. Necdet GEREN 144
Let’s try unpeened Zimmerli’s endurance data
From Eq. 10-28
For unpeened
Ssa=241 Mpa
steel wire
Ssm=379 Mpa
Gerber ordinate intercept for the Zimmerli data

The amplitude component of strength Ssa ,

from Table 6–7,

Converted to shear !
University of Cukurova, Mech eng. Dep.
Prof. Dr. Necdet GEREN 145
 Ssa=240,99 MPa

Sse

Ssa

Ssm Ssu

Using Eq.(10–23)

University of Cukurova, Mech eng. Dep.

Prof. Dr. Necdet GEREN 146
For From Table 10-5:
A313 Stainless wire G=69.0 GPa

Na is not in recommended range 3 ≤ Na ≤ 15

University of Cukurova, Mech eng. Dep.

Prof. Dr. Necdet GEREN 147
 Assume «Squared and ground end» are used in spring
From Table 10.1
For
squared and ground ends
mm

Checking the stability of the spring for squared and ground ends (𝝰=0.5)

Spring buckles in service

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Prof. Dr. Necdet GEREN 148
 when one end is against a flat
plate and the other end is driven
with a sine-wave motion

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Prof. Dr. Necdet GEREN 149
 Do find the results for the remaning diameters of

d=2.3, 2.6, and 3 mm

The results for all the solutions are found and given in the next page

University of Cukurova, Mech eng. Dep.

Prof. Dr. Necdet GEREN 150
 d1 (mm) d2 (mm) d3 (mm) d4 (mm)
d 2.0 2.3 2.6 3.0
m 0.146 0.146 0.263 0.263
A 1867 1867 2065 2065
Sut 1687.3 1653.2 1606.13 1546.8
Ssu 1130.5 1107.67 1076 1036.36
Ssy 590.56 578.62 562.14 541.38
Sse 271,5 272,95 275.13 278.2
Ssa 240.99 241 241 241
α 160.66 160.66 160.66 160.66
β 22.28 16.848 13.184 9.903
C 5.774 8.159 10.843 14.90
D 11.548 18.766 28.19 44.72
KB 1.249 1.168 1.124 1.088
τa 160.66 160.56 160.67 160.61
nf 1.5 1.5 1.5 1.5
University of Cukurova, Mech eng. Dep.
Prof. Dr. Necdet GEREN 151
 Results for PROBLEM 10–30 continues….
d1 (mm) d2 (mm) d3 (mm) d4 (mm)
d 2.0 2.3 2.6 3.0
satisfactory
Na 53.98 22 10.59 4.7
Nt 55.98 24 12.99 6.7
Ls 111.96 55.2 33.8 20.1
ymax 54.216 54.216 54.216 54.216
Ys 62.34 62.34 62.34 62.34
L0 174.30 117.54 95.10 82.44
(L0)cr 60.74 98.709 148.28 235.22
τs 475 474.8 475.12 474.95
ns 1.24 1.218 1.183 1.139
f (Hz) 93.4 99 103.8 107.24

University of Cukurova, Mech eng. Dep.

Prof. Dr. Necdet GEREN 152
 The shaded areas depict conditions outside the
recommended design conditions.

Thus, one spring may be satisfactory although

n<1.2,
–A313 as wound, unpeened, squared and ground,
d = 2.6 mm, with
OD = 28.19+2.6 = 30.79 mm, Nt = 12.99 turns.
If this is found to be not satisfying due to low “n”.
Material may be replaced with a better one.

University of Cukurova, Mech eng. Dep.

Prof. Dr. Necdet GEREN 153
University of Cukurova, Mech eng. Dep.
Prof. Dr. Necdet GEREN 154