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:
