Problem 1

Design a helical compression spring to support an

axial load of 3000 N, the deflection under the load
being limited to 60 mm. The spring index is 6. The
spring is to be made of chrome-vanadium steel & a
factor of safety is 2.
Data: F=3000N, y=60 mm, C=(D/d)=6, FOS=2
t=(te/FOS) where te is elastic limit in torsion for
chrome-vanadium steel.
 From Table 11.5, page 191, for chrome vanadium steel,
(Column. No 9 & 10)
Elastic limit in torsion te =690 Mpa
Rigidity modulus G=78450 Mpa
Applying Factor of safety of 2, the allowable shear stress
t=(690/2)=345 Mpa (N/mm2).
1. Diameter of the wire:

8FDK 8FCK D
Shear stress t = = (as C = )
d 3
πd 2
d
where K = Wahl' s stress factor
4C - 1 0.615
K= + = 1.2525
4C - 4 C
8  3000  6  K
345 =  d = 12.89mm  13mm
πd 2
2. Mean diameter of the coil :
D = Cd = 6 13 = 78 mm
Inside dia of coil Di = ( D − d ) = (78 − 13) = 65mm
Outside dia of coil D o = ( D + d ) = (78 + 13) = 91mm
3.Number of active turns(coils) :
8FD3i 8  3000  783  i
Deflection y =  60 =  i = 11.8  12 turns
Gd 4
78450 13 4

4.Free length of the spring : For squared & ground ends, free length
lo  (i + 2)d + y + a 11.20a Page 142
where a = clearance between wo rking coils under maximum load
Take a = 25% of maximum deflection = 25% of 60 = 15 mm
lo  (12 + 2)13 + 60 + 15 = 257 mm
 Table 11.4 Page 189
Different types of spring coil ends

Plain end Ground Square end Square & Ground

 lo − 2d 257 − 2 13
5. Pitch : p = = = 19.25mmT 11.2(d ) P152
i 12
6.Stiffnes s or Spring rate :
F 3000
Fo = = = 50 N/mm
y 60
Specifications :
(i) Material : Chrome - Vanadium steel
(ii) Wire diameter d = 13 mm
(iii) Mean coil diameter D = 78mm
(iv) Free length lo = 257 mm
(v) Total number of turns i ' = 14
(vi) style of ends : - Squared & ground
(vii) Pitch p = 19.25 mm
(viii) Spring rate Fo = 50 N/mm
 Problem 2
Design a helical compression spring for a safety valve.
The valve must blow off at a pressure of 1.2 Mpa &
should lift by 3 mm for 5% increase in pressure. The
valve diameter is 60 mm. The maximum allowable
shear stress is 400 MN/m2 & the modulus of rigidity
is 82.7 GPa. Take spring index as 8.
Data: p1= 1.2 Mpa, p2=1.05p1=1.26 Mpa,
valve dia Dv=60 mm , C=(D/d)=8, G=82.7x103Mpa
t=400 Mpa
 Dv 2   60 2
Initialload on the spring F1 =  p1 = 1.2
4 4
F1 = 3392 .92 N
Dv 2
  60 2
Maximumload on the springF2 =  p2 = 1.26
4 4
F2 = 3562 .57 N
F2 F2 − F1
From fig 11.2a, page 156, = '
where y' is the compression
y2 y
of the spring as force changes from F1 to F2 . Here y' = 3 mm
F2 y ' 3562 .57  3
 y2 = = = 63mm
F2 − F1 (3562 .57 − 3392 .92)
Now, for design, maximum load & corresponding deflection
have to be considered. Hence F = 3562.57 N, y = 63 mm.
1.Diameter of the wire :
8FDK
Shear stress t = where K = Wahl' s stress factor
d 3

4C - 1 0.615 4  8 - 1 0.615
K= + = + = 1.184
4C - 4 C 48 - 4 8
8  3562 .57  8d 1.184
 400 =  d = 14.66  15mm
d 3

2.Mean Diameter of the coil :

Mean coil dia D = 8  d = 8 15 = 120 mm
Inside dia of coil Di = ( D − d ) = (120 − 15) = 105 mm
Outside dia of coil D o = ( D + d ) = (120 + 15) = 135 mm
3.Number of active coils :
8FD3i 8  3562 .57 120 3  i
y =  63 =  i = 5.35  6 turns
Gd 4
82.7 10 15
3 4
4.Free length of the spring :
lo  (i + 2)d + y + a = (6 + 2)15 + 63 + 0.25(63)
lo = 198 .75mm
( clearance = 25% of maximum deflection )
5.Pitch of the coil :
lo − 2d 198 .75 − 2 15
p= = = 28.125 mm
i 6
6.Stiffnes s or spring rate :
F 3562 .57
Fo = = = 56.55 N/mm
y 63
 Problem 3
A railway wagon weighing 40 KN and moving
with a speed of 10 Kmph has to be stopped by
four buffer springs in which the maximum
compression allowed is 200 mm. Find the
number of turns in each spring of mean diameter
150 mm. The diameter of the spring wire is 25
mm. Take G=82.7 Gpa.
Velocity of wagon v :
1000 5
v = 10 kmph = 10  = 10  = 2.778 m/sec
3600 18
1 W 2 40 10 3  2.778 2
Kinetic energy =   v = = 15733 Nm
2 g 2  9.81
K .E = 15733 10 3 Nmm
1 
Equating K.E & Resilience of the springs ' U' =   F  y n
2 
where n = number of springs (in parallel)
1 
15733 10 =   F  200   4
3

2 
Load on each spring F = 39333 N
1.Number of active turns :
8FD3i 8  39333 150 3  i
y =  200 =
Gd 4
82.7 10 3  25 4
 i = 6.08  6 turns
2.Free length of the spring :
(Assume sqaured & ground ends)
lo = (i + 2)d + y + a = (6 + 2)25 + 200 + 0.25(200 ) = 450 mm
3.Pitch of the coils :
lo − 2d 450 − 2  25
p= = = 66.67 mm
i 6
F 39333
4.Stiffnes s : Fo = = = 196.66 N/mm
y 200
 Problem 4
Design a spring for an elevator shaft at the
bottom of which 8 identical springs are set in
parallel to absorb the shock of the elevator in
case of failure. The weight of elevator is 60 KN &
the counter weight is 20 KN. The elevator has a
free fall of 1.5 m from rest. The spring is made of
25 mm diameter rod.
Determine the maximum stress in each spring, if
the spring index is 6 & each spring has 15 active
turns. Take G=84 Gpa.
Weight of falling body :
W = Weight of elevator - counter weight = (60 - 20) = 40 KN
D
Spring index C =  Mean coil dia D = Cd = 6  25 = 150 mm.
d
Potential energy = W (h + y ) = 40 10 3 (1500 + y )
1 
Energy absorbed by the 8 springs =   F  y   8
2 
EquatingP. E & Resilience of the springs
1 
40 10 (1500 + y ) =   F  y   8
3

2 
F  y =15 10 6 +10 4 y  (i)
Deflection of spring :
8FD3i 8  F 150 3 15
y= = = 0.01234 F
Gd 4
84 10  25
3 4

Substituti ng for y in (i), we get

F(0.01234F) = 15 10 6 + 10 4 (0.01234F)
F2 = 1215 .56 10 6 + 10 4 F  F 2 − 10 4 F − 1215 .56 10 6 = 0
Solving, load on each spring F = 40217.4 N
Deflection y = 0.01234F = 0.01234  40217.4
y = 496.4mm
Shear stress induced in the spring
8FDK 8  40217 .4 150 1.2525
t= = = 1231 .4 N/mm 2

d 3
  25 3
 Problem 5
The spring used in an automobile engine has to exert
500N when the valve is closed and 600 N when the
valve is opened. The displacement of the valve is
5mm. The engine crankshaft rotates at 8000 rpm.
Design the spring for permissible shear stress of 300
Mpa. The spring index is 6, the density of spring
material 7.35N/mm3 & rigidity modulus is 80 Gpa. The
ends are square & ground.
Inspect the suitability of the spring for this engine. At
what speed of the engine does the spring resonate?
Note:
1. After complete design, Suitability of spring is
checked w.r.t buckling or Crippling load Fcr given
by equation Fcr=Fo Kl lo----11.21a Page 143,
where load factor Kl is obtained from fig 11.3
page 157. For safe design, Fcr > F.
2. As the cam shaft speed which controls the
valves is half the engine speed, the engine
speed for resonance=2xNatural frequency of
valve springs.
Data: F1=500 N, F2=600N, y’=5 mm, C=6, t=300 Mpa
Specific weight or weight density=7.35x10-5 N/mm3
End styles: square & ground.
Solution: The spring must be designed for maximum
load i.e. F2, & deflection y2.
F2 y ' 600  5
y2 = = = 30 mm.
F2 − F1 600 − 500
1. Diameter of the wire :
8FDK 8  600  6d 1.2525
Shear stress t =  300 =
d 3
d 3

d = 6.186 mm  6.3mm (Standard size)

2. Mean diameter of the coil :
D = Cd = 6  6.3 = 37.8 mm
Inside dia of coil D i = ( D − d ) = (37.8 − 6.3) = 31.5mm
Outside dia of coil D o = ( D + d ) = (37.8 + 6.3) = 44.1mm
3.Number of active turns(coils) :
8 FD3i 8  600  37.83  i
Deflection y =  30 =
Gd 4
80 10 3  6.34
 i = 14.58  15 turns
4.Free length of the spring : For squared & ground ends,
free length lo  (i + 2)d + y + a 11.20 a Page 142
where a = clearance between wo rking coils under maximum load
Take a = 25% of maximum deflection = 25% of 30 = 7.5 mm
lo  (15 + 2)6.3 + 30 + 0.25(30) = 144 .6mm
 lo − 2d 144 .6 − 2  6.3
5. Pitch : p = =
i 15
p = 8.8mmT 11.2(d ) P152
6.Stiffnes s or Spring rate :
F 600
Fo = = = 20 N/mm
y 30
Check for buckling :
lo 144 .6
Fcr = Fo kl lo where load factor kl for = = 3.83
D 37.8
and for built in ends (fig. 11.3, page 157), is = 0.63
 Fcr = 20  0.63 144 .6 = 1822 N  600 N (max load)
Hence the design is safe.
The natural frequency of the spring when both ends are fixed :
12 Fo g F
f = = 1.41 o Hz
 W W
where W = weight of spring = Weight density  volume
d 2 6.3 2
Volume of spring = Di   V =  2  37.8 15  = 55527 mm3
4 4
W = 7.35 10 −5  55527 = 4.08 N
Spring rate Fo = 20 N/mm = 20000N/m
Hence natural frequency of springs(camshaft)
20000
f = 1.41 = 98.7Hz  Critical speed = 98.7  60
4.08
Critical speed of cam shaft = 5922 .3 rpm.
 Critical speed of engine at which the springs surge
= 2  critical speed of camshaft = 11844.6 rpm.
As the engine speed = 8000 rpm, (far away from 11844.6 rpm), the
springs are safe for operation
 Problem 6
Two helical springs, nested one inside the other,
support a load of 2 KN. Both the springs are of the
same material & the modulus of rigidity is 79.3 Gpa.
The dimensions of each spring are as follows;
Particulars Outer spring Inner spring
Mean diameter 120 mm 75 mm
Wire diameter 18 mm 10 mm
Active turns 20 15
Free length 350 mm 350 mm

Determine (a) Deflection (b) Load carried by each spring

(c) Max shear stress in each spring
(d) Energy stored by the spring system
Data: F=2000KN, G=79.3 Gpa, D1=120 mm, D2=75 mm,
d1=18 mm, d2=10 mm, i1=20, i2=15, lo1=lo2=350 mm.

Solution:
D1 120 D2 75
Spring index C1 = = = 6.67; C 2 = = = 7.5
d1 18 d 2 10
4C1 − 1 0.615
Wahl' s stress factor K1 = + = 1.224, K 2 = 1.197
4C1 − 4 C1
As the two springs have same free length, their deflection s are equal.
8  F1 120 3  20 8  F2  753 15
3 3
8F1D1 i1 8F2 D 2 i2
i.e =  4 = 4
4
d1 G
4
d2 G 18  79 .3  10 3
10  79 .3  10 3

Simplifyin g, we get F1 = 1.922 F2 . But F1 + F2 = 2000

 F1 = 1315 .6 N , F2 = 684 .4 N .
 8 1315 .6 120 3  20
Hence deflection y1 = y 2 = = 43.69 mm
18  79.3 10
4 3

Shear stress induced in the outer spring;

8F1 D1 K1 8 1315 .6 120 1.224
t1 = = = 84 .37 MPa (N/mm 2
)
d13
 18 3

Shear stress induced in the inner spring;

8F2 D2 K 2 8  684 .4  75 1.197
t2 = = = 156 .47 MPa (N/mm 2
)
d 2 3
 10 3

Energy stored by the spring system :

1 1
U = Fy =  2000  43.69 = 43,690 Nmm.
2 2
 Problem 7
Two helical springs, nested one inside the other,
support a load of 500N. Both the springs are of the
same material & the modulus of rigidity is 82.7 Gpa.
The dimensions of each spring are as follows;
Particulars Outer spring Inner spring
Mean diameter 40 mm 28 mm
Wire diameter 5 mm 4 mm
Active turns 10 8
Free length 90 mm 78 mm

Determine (a) Deflection of each spring

(b) Load carried by each spring
(c) Max shear stress in each spring
 Solution:
D1 40 D
Spring index C1 = = = 8; C 2 = 2 = 4 = 7
d1 5 d2
4C1 − 1 0.615
Wahl' s stress factor K1 = + = 1.184, K 2 = 1.213
4C1 − 4 C1
As the outer spring(1) has more free length, their deflection s are related as,
y1 = y 2 + (90 − 78)  y1 = y 2 + 12
8  F1  40 3 10 8  F2  283  8
3 3
8F1D1 i1 8F2 D 2 i2
i.e = + 12  4 = 4 + 12
4
d1 G
4
d2 G 5  82.7 10 3
4  82.7 10 3

Simplifyin g, we get 0.099F1 = 0.0664 F2 + 12

 F1 − 0.67F2 = 121 .21 (i ) But F1 + F2 = 500 . Solving, we get
 F1 = 273 .18 N , F2 = 226 .82 N .
i.e. the force carried by outer spring F1 = 273 .18 N
the force carried by inner spring F 2 = 226 .82 N
Deflection of outer spring :
y1 = 0.099 F1 = 0.099  273 .18 = 27.04mm
Deflection of inner spring :
y2 = 0.0664 F2 = 0.0664  226.82 = 15.06mm
Shear stress induced in the outer spring :
8F1 D1 K1 8  273.18  40 1.184
τ1 = = = 263 .57 Mpa
d1 3
 5 3

Shear stress induced in the inner spring :

8F2 D2 K 2 8  226 .82  28 1.213
τ2 = = = 306 .52 Mpa
d 2 3
 4 3
 Problem 8
Design a concentric spring for an aircraft engine
valve to exert a maximum force of 5000N under a
deflection of 40 mm. Both the springs have same
free length, same spring index of 6, and are
subjected to equal shear stress of 0.85 Gpa.
Assume rigidity modulus G=80 Gpa and the
diametral clearance to be equal to the difference
between the wire diameters.
 NOTE :
The clearance between th e inner & outer coils will be
diametral clearance = ( D1 − D2 ) − (d1 + d 2 )
As a standard,the above value is taken as(d 1 −d2 )
Also for same spring index, C, D1 = Cd1 & D2 = Cd 2
 (d1 − d 2 ) = C (d1 − d 2 ) − (d1 + d 2 )
 C (d1 − d 2 ) = 2d1  d1 (C − 2) = Cd 2
d1 C
 = where C = spring index (i)
d2 C - 2
Solution:
As it is stated that both the springs are stressed equally, t 1 = t 2
8F1 D1 K1 8F2 D2 K 2
i.e. =
d13
d 2 3
3
F1  D2  d1   K1 
 =      As spring index is stated to be same,
F2  D1  d 2   K 2 
D1 = Cd1 & D2 = Cd 2 and also K1 = K 2 . Substituti ng, we get
2
F1  d1  d1 C 6
=   From the equation (i) = = = 1.5
F2  d 2  d2 C − 2 6 − 2
2
F1  d1 
 =   = 1.52  F1 = 2.25F2
F2  d 2 
Also the total load = sum of loads shared by each spring
i.e.F1 + F2 = 5000 N  2.25 F2 + F2 = 5000 OR F 2 =1538.5N
and F1 = (5000 −1538.5) = 3461.5N
Design of outer spring(1)
1.Diameter of the wire :
8F1 D1 K1
Shear stress t 1 = where K1 = Wahl' s stress factor
d13

4C - 1 0.615 4  6 - 1 0.615
K1 = + = + = 1.2525
4C - 4 C 46 - 4 6
8  3461 .5  6d1 1.2525
 850 =  d1 = 8.82  9mm
d1 3

 Mean coil dia D1 = 6  d1 = 6  9 = 54 mm

2.Number of active coils :
8  3461 .5  54 3  i1
3
8F1 D1 i1
y1 =  40 =  i1 = 4.815  5 turns
Gd1
4
80 10  9
3 4
Design of inner spring(2)
1.Diameter of the wire :
8F2 D2 K 2
Shear stress t 2 = where K 2 = Wahl' s stress factor
d 2 3

4C - 1 0.615 4  6 - 1 0.615
K2 = + = + = 1.2525
4C - 4 C 4 6 - 4 6
8 1538 .5  6d 2 1.2525
 850 =  d 2 = 5.885  6mm
d 2 3

 Mean coil dia D 2 = 6  d 2 = 6  6 = 36 mm

2.Number of active coils :
8 1538 .5  36 3  i2
3
8F2 D2 i2
y2 =  40 =  i1 = 7.22  8 turns
Gd2
4
80 10  6
3 4
• For rectangular cross section refer equations 11.14,
11.14a & 11.14b page 140 & 141.
• For square cross section springs, refer equations, 11.16
& 11.17 page 141.
Problem 9
A diesel engine weighs 800 KN is mounted on 16
springs in order to prevent vibration of the
building. The section of the spring is rectangular
with side ratio=1.8 & the longer side is parallel
to its axis. Each spring has 4 active coils & spring
index is 6. Determine (i) the cross section (ii)
Deflection of spring (iii) Maximum coil dia. Take
G=80 Gpa & t=300 Mpa.
 800 10 3
Load on each spring F = (as there are 16 springs) = 50000N
16
1.Diameter of the wire :
KFD(1.5h + 0.9b)
Shear stress t ' = 2 2
where K = Wahl' s stress factor
bh
4C - 1 0.615 D b
K= + where C = as  1 (given h = 1.8b);
4C - 4 C b h
4  6 - 1 0.615
K = + = 1.2525
4 6 - 4 6
1.2525  50000  6b(1.5 1.8b + 0.9b)
 300 = 2 2
 b = 37.5mm
b (1.8b)
 Mean coil dia D = 6  b = 6  37.5 = 225 mm
Height of cross section h = 1.8b = 67.5 mm.
2.Deflection under load :
2.83iFD3 (b 2 + h 2 ) 2.83  4  50000  225 3 (37.52 + 67.52 )
y = =
3 3
bhG 37.53  67.53  80 10 3
 y = 29.63mm
3.Inside & outside (maximum) dia of coil
Di = ( D − b) = (225 − 37.5) = 187 .5mm
Do = ( D + b) = (225 + 37.5) = 262 .5mm (Max dia of coil)
Note :
Shear stress induced if shorter side is parallel to axis;
put h = 37.5mm & b = 67.5 mm (i.e.inter change the values)
in the equation of shear stress.
1.2525  50000  225(1.5  37.5 + 0.9  67.5)
t ' =
67.52  37.52
t ' = 257 .3Mpa
 Problem 10
A railway car weighing 18 KN and moving at a speed
of 72m/min is brought to rest by a buffer consisting
of 2 helical springs of square cross section. In
bringing the car to rest, the spring undergoes a
deflection of 0.25m. The allowable shear stress for
the steel wire is 0.3 Gpa. Spring index=6. Rigidity
modulus G=84 Gpa. Design the spring and show the
dimensioned sketch of the spring section.
Load on each spring :
Given W = 18KN = 18 10 3 N, Velocity of rail car V = 72m / min
72
V = = 1.2m / sec . Deflection y = 0.25 m = 250 mm
60
1  W  2 1  18 10 3 
K.E of rail car =     V =    1.2 2 = 1321 .1Nm
2 g 2  9.81 
 K.E of rail car = 1321 .110 3 Nmm
1 
Resilience or Energy stored by springs U =  Fy   n
2 
1 
where n = number of springs. Here n = 2, U =   F  250   2 = 250 F Nmm
2 
Equating the K.E of rail car to energy stored by the springs,
1321.1 10 3 = 250 F  Load on each spring F = 5284.4N
1.Cross section of the spring :
2.4 KFD
Shear stress t ' = 3
 Eq.11.16, page 141
h
where K = Wahl' s stress factor
4C - 1 0.615 D D
K= + where C = or (as b = h for square section);
4C - 4 C b h
4  6 - 1 0.615
K = + = 1.2525
4 6 - 4 6
2.4 1.2525  5284 .4  6h
 300 = 3
 h = b = 17.82 mm  18 mm
h
 Mean coil dia D = 6  h = 6 18 = 108 mm
2.Number of active coils :
5.66iFD 3
5 .66  i  5284 .4  108 3
y' =  250 =
4
hG 18 4  84 10 3
 Number of active turns i = 58.51  59 turns
3.Free length of the spring :
lo  (i + 2)h + y + a (Assuming square & ground ends)
lo = (59 + 2)18 + 250 + 0.25(250 ) = 1410 .5mm
4.Pitch of the spring :
lo − 2h 1410 .5 − 2 18
p= = = 23.3mm
i 59
5. Spring rate or Stiffness :
F 5284 .4
Fo = = = 21.14 N/mm
y 250
 Problem 11
The load on a steel helical compression spring
varies from 500 N to 1200 N. The spring index is
6 & the desired design factor of safety is 1.3.
Determine the required wire size by taking the
yield shear stress as 690 MN/m2 & the
endurance limit stress as 300 MN/m2.
Data: Fmin=500 N, Fmax =1200 N, C=6, n=1.3,
ten=300 Mpa, ty=690 Mpa.
1.Mean stress & stress amplitude :
8D  Fmax + Fmin 
Mean shear stress t m = Kt 3  
d  2 
 1   0.5 
where Kt = Shear stress factor = 1 +  = 1 +  = 1.0833
 2C   C 
8  6d  1200 + 500  14068 .86
t m = 1.0833  3  =
d  2  d2
8D  Fmax − Fmin 
Amplitudeof shear stress t a = K 3  
d  2 
4C - 1 0.615 4  6 - 1 0.615
K= + = + = 1.2525
4C - 4 C 4 6 - 4 6
8  6d  1200 − 500  6697 .87
 t a = 1.2525  3  =
d  2  d 2
Soderberg equation :
1 t m − t a 2t a
= +
F .S ty t en
1 14068 .86 − 6697 .87 2  6697 .87
 = +
1.3 d  690
2
d  300
2

1 55.335
 = 2
1.3 d
 wire diameter d = 8.48mm  8.5mm
Mean coil diameter D = 6d = 6  8.5 = 51 mm.
 Problem 12
A helical compression spring is made of 6 mm dia
stainless steel wire & carries a fluctuating load.
The spring index is 6 & the factor of safety is 1.5.
If the average (mean) load on the spring is 500N,
find the permissible values of the maximum &
minimum loads. The tensile strength of the wire
is 1350 N/mm2. Take shear strength at yield as
0.5 sut & the shear endurance limit as 0.22 sut.
Data:
wire dia d=6 mm
Spring index C=6 i.e. D=6d=6x6=36 mm
Factor of safety F.S=1.5
Average or Mean load=(Fmax+Fmin)/2=500 N
Given ten=0.22sut=0.22(1350)=297 Mpa
ty=0.5sut=0.5(1350)=675 Mpa
To find: Fmax & Fmin
1.Mean stress & stress amplitude :
8 D  Fmax + Fmin 
Mean shear stress t m = Kt 3  
d  2 
 1   0.5 
where Kt = Shear stress factor = 1 +  = 1 +  = 1.0833
 2C   6 
8  36
t m = 1.0833  (500 ) = 229.883Mpa
 6 3

8D  Fmax − Fmin 
Amplitudeof shear stress t a = K 3  
d  2 
4C - 1 0.615 4  6 - 1 0.615
K= + = + = 1.2525
4C - 4 C 4 6 - 4 6
8  36  Fmax − Fmin 
 t a = 1.2525  (Fa ) = 0.532 Fa where Fa =  
 6 3
 2 
Modified Soderberg equation for helical springs :
1 t m − t a 2t a
= +
F .S ty t en
1 229 .883 − 0.532 Fa 2  0.532 Fa
 = +
1.5 675 297
1
 = 0.3406 + 2.794 10 −3 Fa
1.5
Fmax − Fmin
 Amplitude of force Fa = 116 .69 N  = 116 .69 N
2
i.e.( Fmax − Fmin ) = 233 .38 N But by data Fmax + Fmin = 1000 N ,
Solving, Fmax = 616 .69 N & Fmin = 383 .31N .
 Problem 13
Design a cantilever spring of length 0.6 m to
absorb 800 Nm of energy with a deflection of
0.1m. The permissible stress in the leaves is 600
Mpa. E=206.8 Gpa. Take total number of leaves
as 10.
Data: Energy absorbed U=800 Nm
l=0.6m=600 mm, y=0.1m=100 mm, s =600 Mpa
E=206.8 Gpa=206.8x103 Mpa, no of leaves i=10.
width of plate b=ib’=10b’ where b’=width of each
leaf.
 Fy F  0.1
Energy stored by the spring U =  800 =
2 2
Force at the end of cantilever F =16000 N .
C1 Fl
Maximum stress s = 2
where C1 = 6 from Table 11.1, P 149
ib' h
(For cantilever type a in fig 11.6, page 157C)
6 16000  600
 600 =  b' h 2
= 9600mm 3
(1)
10  b'h 2

C 2 Fl 3 4 16000  600 3
Deflection y =  100 =
Eib' h 3
206 .8 10 3 10  b' h 3
 b' h 3 = 66.847 10 3 mm4 (2)
Dividing eq (2) by eq (1), we get h = 6.963 mm  7 mm.
i.e thickness of leaves h = 7 mm.
9600
Widthof the leaves b' = 2 =195.18mm 196mm.
7
 F

h Front view

2l

b Top view

Fig 11.6(d) P 157 C (Simply supported beam spring)

Consider a simply supported beam of length 2l with a central load ' F'.
F
The maximum bending moment M =  l
2
I
bh3(12 = bh 2 )
 Bending stress s =
M
Section modulus Z = =
c h
2
( )6 Z
F l
3Fl
s = 2 = 2  Eq11.31 page 144 A
 bh  bh
2
 
 6 
where C1 = 3 from T 11.1 P149
The maximum deflection for a simply supported beam with concentrated load
F at the centre is given by
F (2l )
3
Fl 3 2 Fl 3
y= =
48 EI 48  E  bh3( 12
) =
Ebh 3
 Eq11.32 P144 A

where C 2 = 2 from T 11.1 P149

Determine the width & thickness of a flat spring
carrying a central load of 3500 N. The deflection is
limited to 30 mm. The spring is supported at both
ends at a distance of 650 mm. The allowable stress
is 345 N/mm2 & modulus of elasticity 207 Gpa. The
spring is of constant thickness & varying width.

h
2l

b
Data : F = 3500N, 2l = 650  l = 325 mm, s = 345 Mpa, y = 30mm
Maximumstress in the spring
C1 Fl
s = 2  Eq11.31 page 144 A where C1 = 3 from T 11.1 P149
bh
(for type (e) beam, page 157C)
3  3500  325
 345 = 2
 bh 2
= 9.8913  10 3
 (i )
bh
The maximumdeflection' y ' is
C2 Fl 3
y= 3
 Eq11.32 P144 A where C 2 = 3 from T 11.1 P149
Ebh
3  3500  3253
 30 =  bh 3
= 5.8043  10 4
 (ii )
207 10  bh
3 3

5.8043 10 4
(ii )  (i ) gives h = = 5.868 mm  6mm.
9.8913 10 3

9.8913 10 3
 Width of plate (at the center) b = 2
= 275 mm
6
 A truck spring has 12 number of leaves , two of
which are full length leaves. The springs are 1m apart
and the central band is 70 mm wide. The central load
is to be 6KN with a permissible stress of 200 Mpa.
Determine the thickness, width & deflection of the
steel spring leaves if the ratio of total depth to width
of the spring is 3. E=206 Gpa.
Data: F=6KN=6000 N
Number of full length leaves if=2
Total number of leaves i=12,
Ratio of total depth to width =(ih/b’)=(12xh)/b’=3
Or b’=4h
Hence number of graduated leaves ig=12-2=10
Effective length l=(1000-70)/2=465 mm,
Max stress s=200 Mpa, E=206x103 N/mm2
Since the leaves are not pre stressed, maximumstress
occurs in the full length leaves; Hence s f = 200Mpa
9 Fl 9  6000  465
 200 = =
b' h (2ig + 3i f ) 4h  h 2 (2 10 + 3  2)
2

 h = 10.65  11mm
 Thickness of the leaves h = 11 mm,
width b' = 4h = 4 11 = 44 mm.
Deflection of the spring
6 Fl 3 6  6000  465 3
y= =
b' h E (2ig + 3i f ) 44 113  206 10 3 (2 10 + 3  2)
3

y = 11.54mm
 A locomotive spring has an over all length of 1100 mm and
sustain a load of 75 KN at its centre. The spring has 3 full
length leaves and 15 graduated leaves with a central band
100 mm wide. All the leaves are to be stressed to 0.4 Gpa
when fully loaded. The ratio of total spring depth to width
is 2. Determine (i) Width & thickness of leaves (ii) nip or
clearance to be provided (iii) Load exerted on the band by
the clip bolt after assembly. Take E=206.8 Gpa
Data: F=75KN=75000 N
Number of full length leaves if=3
Number of graduated leaves ig=15
Total number of leaves i=(15+3)=18
Ratio of total depth to width =(ih/b’)=(18xh)/b’=2
Or b’=9h
Effective length l=(1100-100)/2=500 mm,
Equalized stress s=0.4 Gpa=400 Mpa,
E=206.8x103 N/mm2
 3Fl 3  75000  500
Equalized stress s =  400 =
ib' h 2
18  9h  h 2
 Thickness of the leaves h = 12mm
Hence width of leaves b' = 9h = 9 12 = 108 mm.
Initial gap or nip' c'
Fl 3
75000  500 3
c= = = 13.5mm
ib' h E 18 108 12  206.8 10
3 3 3

Load on the band F b

ig i f F 15  3  75000
Fb = = = 4807 .7 N
i (2ig + 3i f ) 18(2 15 + 3  3)
 A multi leaf spring with camber is fitted to the chassis of an
automobile over a span of 1.2 m to absorb shocks due to a
maximum load of 20 KN. The spring material can sustain a
maximum stress of 0.4 Gpa. The spring has 2 full length
leaves out of 8 leaves. The leaves are assembled with bolts
with a central band of width 150 mm. Design the spring
for a maximum deflection of 50 mm. Take E=206.92 Gpa.
Data: F=20KN=20000 N
Number of full length leaves if=2
Total number of leaves i=8
Number of graduated leaves ig=8-2=6
Deflection y=50 mm
Effective length l=(1200-150)/2=525 mm,
Equalized stress s=0.4 Gpa=400 Mpa,
E=206.92x103 N/mm2
 3Fl 3  20000  525
Equalized stress s =  400 =
ib' h 2
8  b'h 2
 b' h 2 = 9843 .75mm3  (i )
6Fl 3
Deflection y =
b' h 3 E(2i g + 3i f )
6  20000  525 3
i.e. 50 =
b'h3  206 .92 10 3 ( 2  6 + 3  2 )
 b' h 3 = 93242 .56 mm 4  (ii )
9843.75
(ii )  (i ) gives h = 9.5 mm, Hence width b' = 2
= 109 mm
9.5
Initial gap or nip' c'
Fl 3 20000  525 3
c= = = 18.7mm
ib' h E 8 109  9.5  206 .92 10
3 3 3

Load on the band F b

ig i f F 6  2  20000
Fb = = = 1666 .67 N
i (2ig + 3i f ) 8(2  6 + 3  2)