Unit IV Energy Storing Elements and Engine Components

ENERGY STORING ELEMENTS
AND
ENGINE COMPONENTS
Types of springs,
springs design of helical and
concentric springs–surge in springs, Design
of laminated springs - Flywheels considering
stresses in rims and arms for engines and
presses - Solid and Rimmed flywheels
Types of Springs
1. Helical springs
2. Conical and volute springs.

3. Torsion springs.
4. Laminated or leaf springs.
5. Disc or bellevile springs

Terms used in Compression Springs
End Connections for Compression
Helical Springs
End Connections for Tension Helical Springs
End connection for tension

Compression spring for
carrying tensile load.
Stresses in Helical Springs of
Circular Wire
Deflection of Helical Springs of
Circular Wire
A helical spring is made from a wire of 6 mm diameter and has outside diameter of 75
mm. If the permissible shear stress is 350 MPa and modulus of rigidity 84 kN/mm 2, find
the axial load which the spring can carry and the deflection per active turn.
7.100
7.100
7.100
7.100
7.100
7.100
Design a helical spring for a spring loaded safety valve (Ramsbottom safety valve) for the
following conditions :
Diameter of valve seat = 65 mm ; Operating pressure = 0.7 N/mm 2;
Maximum pressure when the valve blows off freely = 0.75 N/mm 2;
Maximum lift of the valve when the pressure rises from 0.7 to 0.75 N/mm 2 = 3.5 mm ;
Maximum allowable stress = 550 MPa ;
Modulus of rigidity = 84 kN/mm2;
Spring index = 6.
Draw a neat sketch of the free spring showing the main dimensions.
13.1
Concentric or Composite Springs
A concentric spring for an aircraft engine valve is to exert a maximum force of 5000 N under
an axial deflection of 40 mm. Both the springs have same free length, same solid length and
are subjected to equal maximum shear stress of 850 MPa. If the spring index for both the
springs is 6, find (a) the load shared by each spring, (b) the main dimensions of both the
springs, and (c) the number of active coils in each spring.
Assume G = 80 kN/mm2 and diametral clearance to be equal to the difference between the
wire diameters.
AND
ENGINE COMPONENTS
Types of springs, design of helical and

concentric springs–surge in springs,
springs Design
of laminated springs - Flywheels considering
stresses in rims and arms for engines and
presses - Solid and Rimmed flywheels
Surge in Springs
• When one end of a helical spring is resting on a rigid support and the other end is
loaded suddenly, then all the coils of the spring will not suddenly deflect equally,
because some time is required for the propagation of stress along the spring wire.
• A little consideration will show that in the beginning, the end coils of the spring in
contact with the applied load takes up whole of the deflection and then it transmits a
large part of its deflection to the adjacent coils. In this way, a wave of compression
propagates through the coils to the supported end from where it is reflected back to
the deflected end.
• This wave of compression travels along the spring indefinitely. If the applied load is of
fluctuating type as in the case of valve spring in internal combustion engines and if the
time interval between the load applications is equal to the time required for the wave
to travel from one end to the other end, then resonance will occur.
• This results in very large deflections of the coils and correspondingly very high stresses.
Under these conditions, it is just possible that the spring may fail. This phenomenon is
called surge.
Leaf Springs
Leaf springs (also known as flat springs) are made

out of flat plates.
The advantage of leaf spring over helical spring is
that the ends of the spring may be guided along a
definite path as it deflects to act as a structural
member in addition to energy absorbing device.
Thus the leaf springs may carry lateral loads,
brake torque, driving torque etc., in addition to
shocks.
Design a leaf spring for the following specifications :
Total load = 140 kN ; Number of springs supporting the load = 4 ; Maximum number of
leaves = 10; Span of the spring = 1000 mm ; Permissible deflection = 80 mm.
Take Young’s modulus, E = 200 kN/mm2 and allowable stress in spring material as 600 MPa.
7.104
7.104
AND
ENGINE COMPONENTS
Types of springs, design of helical and

concentric springs–surge in springs, Design
of laminated springs - Flywheels
considering stresses in rims and arms for
engines and presses - Solid and Rimmed
flywheels
Stresses in a Flywheel Rim
1. Tensile stress due to centrifugal force,
2. Tensile bending stress caused by the restraint of
the arms, and
3. The shrinkage stresses due to unequal rate of
cooling of casting. These stresses may be very
high but there is no easy method of determining.
This stress is taken care of by a factor of safety.
1.Tensile stress due to the centrifugal force
A multi-cylinder engine is to run at a constant load at a speed of 600 r.p.m. On drawing the
crank effort diagram to a scale of 1 m = 250 N-m and 1 mm = 3º, the areas in sq mm above
and below the mean torque line are as follows:
+ 160, – 172, + 168, – 191, + 197, – 162 sq mm. The speed is to be kept within ± 1% of the
mean speed of the engine. Calculate the necessary moment of inertia of the flywheel.
Determine suitable dimensions for cast iron flywheel with a rim whose breadth is twice its
radial thickness. The density of cast iron is 7250 kg / m 3, and its working stress in tension is
6 MPa. Assume that the rim contributes 92% of the flywheel effect.
Stresses in Flywheel Arms
The following stresses are induced in the arms of a
flywheel.
1. Tensile stress due to centrifugal force acting on the
rim.
2. Bending stress due to the torque transmitted from
the rim to the shaft or from the shaft to the rim.
3. Shrinkage stresses due to unequal rate of cooling of
casting. These stresses are difficult to determine.
Design and draw a cast iron flywheel used for a four stroke I.C engine developing 180 kW
at 240 r.p.m. The hoop or centrifugal stress developed in the flywheel is 5.2 MPa, the total
fluctuation of speed is to be limited to 3% of the mean speed. The work done during the
power stroke is 1/3 more than the average work done during the whole cycle. The
maximum torque on the shaft is twice the mean torque. The density of cast iron is 7220
kg/m3.
5.16

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ENERGY STORING ELEMENTS

2. Conical and volute springs.

4. Laminated or leaf springs.

5. Disc or bellevile springs

End connection for tension

Types of springs, design of helical and

Leaf springs (also known as flat springs) are made

Types of springs, design of helical and

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