Helical Spring Design - Static Load

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

effect of d
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

effect of d
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:

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:
*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:

see pages 814-815 for more
Consider the Following:

Helical Spring Design - Static Load

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What are the different types of springs discussed?

What are the different types of springs discussed?

What are the key parameters used to characterize helical compression springs?

What are the key parameters used to characterize helical compression springs?

Design of Helical Compression

Springs Under Static And Fatigue

Helical Compression Springs

may also need:

Stresses in Helical Springs

Kw includes both the direct shear factor and

under static loading, local yielding eliminates stress

under dynamic loading, failure happens below Sy: use

Static Spring Design

Some values must be set to calculate

there is not one correct answer

=ultimate tensile strength

=torsional yield strength

a function of Sut and set

What are You Designing?

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

Static Spring Flow Chart

Lf, yshut, Fshut

for shut spring if possible

Three things to know:

Static Design: Wire Diameter

Based on Ns=Ssy/ and above equation for :

8 N s C 0.5 Fwork 1 Finitial

Three things to know:

use Table 13-2 to select standard d near

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

Three things to know:

Modified Goodman for Springs

Sfw, Sew are for torsional strengths, so von

Fatigue Safety Factor

a,load = a,good at intersection

What are you Designing?

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

Fatigue Spring Design Strategy

Two things to know:

Fatigue Design:Wire Diameter

use Table 13-2 to select standard d near

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

Natural Frequency: Surge

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

Two things to know:

see pages 814-815 for more

Consider the Following:

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

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