Haroon Rashidi

02/12/2015

Lab No. 1-Compression of Helical Spring

CET 3135-(001)
Mechanics of Materials with Laboratory
Spring 2015
Laboratory Report
Lab 1 Compression of a Helical Spring

Submitted by: Haroon Rashidi, James Pettus, Marquis Smith

Laboratory Date: 02/05/2015
Date of Submission: 02/12/2015
Submitted to: Dr. Runing Zhang
Team Members: Haroon Rashidi, James Pettus, Marquis Smith

CET 3135-001

Haroon Rashidi
02/12/2015

Lab No. 1-Compression of Helical Spring

CET 3135-001

TABLE OF CONTENTS
ABSTRACT........................................................................................................................
THEORECTICAL BACKGROUND.................................................................................
LIST OF EQUIPMENT......................................................................................................
LIST OF MATERIALS......................................................................................................
PROCEDURES..................................................................................................................
SUMMARY OF DATA......................................................................................................
RESULTS...........................................................................................................................
CONCLUSIONS................................................................................................................
SAFETY.............................................................................................................................
REFERENCES..................................................................................................................
SIGNATURE PAGE.........................................................................................................
APPENDIX A Test Data & Computed Material Properties..........................................
APPENDIX B Sample Calculations..............................................................................
APPENDIX C Raw Data Sheets....................................................................................

Haroon Rashidi
02/12/2015

Lab No. 1-Compression of Helical Spring

CET 3135-001

ABSTRACT
The purpose of this lab was to find the spring constant K of the helical spring, the work
W required to compress the spring and the modulus of rigidity G. By comparing the
spring displacement y with the load P, it is possible to understand and calculate the spring
constant K. The goals of studying this experiment were determining the spring constant
90240 and modulus of rigidity 9540812.203. After calculating and studying the
collected data Spring Constant, 90240; Rotation of the Spring, 0.465116279 [rad];
shear stress, c; 48863.60827; shear strain, 0.005121535; and Modulus of Rigidity,
9540812.203 were each calculated using their respective formulas. Hooke's Law, also
known as the Theory of Elasticity, is the law explaining the relationship between the
spring constant, the displacement and the load, and . The original experiment performed
by Hooke described the linear variation of tension with the extension of an elastic spring.
In our experiment, the spring was compressed instead of extended, though the law was
proven all the same.

THEORETICAL BACKGROUND:
The principles used in the lab include material properties, calculations and laws used, and
procedures introduced.

Material properties: There are a few characteristics based on the nature of the
material:
A Linear behavior: The deformation and the internal stress of metal [in] due a
certain load [psi].
B Elastic behavior: the permanent repositioning to the original shape after
removing the load [psi], though no changes in the material's mechanical
properties.
C Stress alignment: the increase of stiffness due to the internal alignment of the
particles when is subjected to load field. Alignment of particle will increase
the resistance of displacement.
D Hysteresis: The reliance of the strain of a material not only on the
instantaneous value of the stress but also on the previous history of the stress.

Calculations and laws used:

A Stiffness Law: K*y=P; K is the spring constant, can be determined by the
slope of stress versus strain plot. Y is strain [in] and P is stress [psi].
B Work done W=1/2Py where P=load and y=displacement
C Work done by statically applied torque: W=1/2T() where T=torque

Haroon Rashidi
02/12/2015

Lab No. 1-Compression of Helical Spring

CET 3135-001

D Maximum shear stress (tc)=[(T)(c)/J] where T=torque; c=radius of coiled

material and J is the Polar Moment of Inertia.
E Polar Moment of Inertia J=(c^4)/2
F Shear strain =c/L
G Modulus of Rigidity G=t/ or G=KN where K is the Spring Constant and N is
the following equation
H N=[(4R^3n)/c^4]
I Lead angle ()=tan^-1[p/(2pi) where p=lead or pitch and R=spring radius

Procedures Introduced:
Instron machine: device with axial loading capability (vertical loading/
tension or compression)
Experimental design: achievement of experiment best results with least error
and most efficiency.

LIST OF EQUIPMENT:
1.
2.
3.
4.
5.
6.

Instron 5569 Load Frame (50 kilo Newton 11,250 lb. force capacity)
Microcomputer with BlueHill Software
Two (2) compression plates for Instron 5569 Load Frame
Minimum 0.2 inch thick Steel Plate
Spherical Block
12 inch Caliper

All of the equipment was essential for the success and safety of the experiment. The
Instron Load Frame was the equipment applying and taking away the load to the Spring.
The BlueHill Software was what controlled the Instron, and thereby the compressive load
applied to the spring. BlueHill also collected all the data in the experiment, such as the
amount of load applied and the deflection of the spring. Both the platens provided a flat
surface and a constant force between with the spring was compressed. The steel plate
ensured an even load application. The spherical block acted as a ball and socket joint
between the steel plate and top compression platen to ensure that a downward axial load
is being applied to the spring, without which the spring could jump out under any uneven
load.

Haroon Rashidi
02/12/2015

Lab No. 1-Compression of Helical Spring

CET 3135-001

LIST OF MATERIALS
The specimen in the experiment was a closed end, squared & ground, train boxcar spring.
The ends of the spring were squared and flattened to be capable of being placed on and
support a flat surface. It had a cylindrical, helix shape.

PROCEDURES
1. Start the computer with the BlueHill software.
2. Turn on Instron 5569 Load Frame. (this is where specimen will be placed)
3. Install compression platens on Instron Load Frame. (used for general
compression testing)
4. Initiate BlueHill software on microcomputer.
5. Open the pre-programmed spring compression test from BlueHill software menu.
6. Measure Spring dimensions including:
1. diameter of the spring (outside and/or inside diameter),
2. number of active coils,
3. number of inactive coils,
4. space (gap height) between active coils,
5. diameter of spring coil (size of material),
6. spring height (free length),
7. the active compression height, h (height of active coils).
7. Determine/compute maximum spring compression (point at which active coils
touch).
8. Place spring onto lower compression platen on Instron 5569 Load Frame.
9. Place 0.2-inch thick steel plate on top of the spring, centered as much as possible.
This is to ensure an even load.
10. Place spherical block on top of steel plate. Use concentric circles on the top platen
to center the block.
11. Make to load zero-out by pressing No. 1 button on Intron load frame control
panel, or by inputting the command into the program.
12. Lower the upper compression platen of Instron 5569 Load Frame using the JogDown button on the load frame control panel. Do so until the platen is to the top
of the spherical block.
13. Use Fine Position dial on Intron load frame control panel to apply seating load
of approximately 50 pounds force, or by inputting the command into the program.

Haroon Rashidi
02/12/2015

Lab No. 1-Compression of Helical Spring

CET 3135-001

14. Zero-out displacement using Reset Gauge Length on Intron Load Frame control
panel, or by inputting command into the program.
15. Activate BlueHill software to the start point of test to activate data acquisition
component of the software. The software is pre-programmed to compress spring
to a maximum deflection of 1.0 inch and then unload the spring to a load of
approximately 0 pounds force. 1.0 in. was under the maximum amount of
displacement allowed, and so insures no damage to the spring material. Data
acquisition is set-up to read load and displacement data approximately every 9
seconds during the load and unload cycle.
16. Perform one (1) run of this test to seat the spring. (Done by lab coordinator)
17. Each group of students tests the spring and collects only their data.
18. Each group should input the group number of their student group prior to testing,
and save their data at the completion of their respective test run.

SUMMARY OF DATA
Criteria

Quantity

Units

Number of active coils

Coil

Number of inactive coils

Coil

Coil diameter

1.19

Inch

Spring diameter

4.3

Inch

Spring height

6.46

Inch

Total spring height

8.03

Inch

Active Coil Gaps:

0.39

Inch

0.37

Inch

0.40

Inch

0.44

Inch

Average gap between active 0.4

coils

Inch

Estimate max. compression 1.6

Inch

Average Pitch

Inch

1.6

Figure 1 Lab 1 Compression of Helical Spring Specifications of the Spring

Specimen

Haroon Rashidi
02/12/2015

Lab No. 1-Compression of Helical Spring

CET 3135-001

RESULTS
The results of the laboratory experiment of the compression test of the spring were as
expected. We calculated the spring could be compressed a maximum of 1.6 inches before
the active coils would touch each other. When the coils of the spring are touching, the
resistance is no longer correlated with the spring constant, but the Normal force of the
steel itself. Because of this, we only compressed the spring 1 inch. Attached is a copy of
the graph generated by the Instron machine. The graph shows the compression up to 1
inch and a max of 7520 lbs of compressive force. This compression took 120 seconds.
The graph also shows the decompression of the spring. Mostly, the decompression
followed the track of the compression, save for the fatter part that can be observed in the
middle. The fatter part is the graphical representation of hysteresis. Hysteresis is the
phenomenon that is defined as the work required to load and unload a spring, or the heat
energy released by internal friction during loading (lab Manual, David Mcallum).

Figure 2 Lab 1 Compression of Helical Spring Calculated results

Haroon Rashidi
02/12/2015

Lab No. 1-Compression of Helical Spring

CET 3135-001

W = work, P = force, y = displacement, = angle between coils, T = torque, R = radius

of the spring
W=Py
W = T therefore,
Py=T
and T = P R so
= y/R

c = T c/J
c = coil radius, J = moment of inertia, which for a spring is c4/2

c = c /L
c = shear strain, G = Modulus of Rigidity = 11,000 ksi, L = length = 2Rn
G = c/c = K N
K = spring constant, N = 4R3n/c4
R Radius of spring [in]=
y total distance compressed [in] =
Maximum compression possible [in]
Spring height [in]
Total spring height [in]
active coils
inactive coils
Gap between active coils [in]
d(coil)[in]=
P max compresive force [lbs]=
[rad]= y/R=
n [loops]=
work[ Joules]= (1/2) Py=
Torque [ftlbs]= (work*2)/
c radius of coil [in]= d/2
J Polar Moment = (c^4)/2
[Shear Stress] =(Torque*c)/J
L Length of active coils [in]=2R*n
[Shear Strain] =(c*)/L
G[ Modulus of Rigidity= /
K spring constant [lbs]ft]= p*12

2.15
1
1.6
6.46
8.03
4
2
0.4
1.19
7520
0.465116279
4
3760
16168
0.595
0.196873713
48863.60827
54.03539364
0.005121535
9540812.203
90240

Haroon Rashidi
02/12/2015

Lab No. 1-Compression of Helical Spring

CET 3135-001

SAFETY
Safety was a very important aspect of the experiment. The cylindrical block and the
plates of steel were both for safety, to insure that the spring would not jump out under so
much pressure. The spring was accumulating a large amount of potential energy, that
could be very dangerous if released uncontrolled. The Instron machine could be
potentially dangerous due to the amount of force that is was exerting. For both of these
aspects we also had an emergency stop button. We also were a safe distance away from
the experiment as it took place.

CONCLUSIONS:
In this experiment it was possible to calculate the real Rigidity Modulus from the Shear
Stress and Strain basic calculations. After we calculate the modulus from the data taken
in the lab we found that the numbers are different. This difference in numbers came from
the usage of the spring during the certain period of time that made it loose some of its
initial properties. This will explain the hysteresis loss of energy due to loading and
unloading the spring. As an engineer's this experiment we were able to determine the
stiffness of the spring and what is the limit that the spring can be compressed to before
deforming.
Recommendations for Improvements: to reduce human errors digital caliper might be
used in addition to a better spring surface finish.
A caliper is prone to error; a source of error is introduced anytime the reference line of a
measuring system doesnt lie along the same line as the dimension being measured. On a

Haroon Rashidi
02/12/2015

Lab No. 1-Compression of Helical Spring

CET 3135-001

caliper, the scales or gears are not in line with the measuring faces or contacts. As a
result, the caliper shifts and wiggles.
-The error can be minimized by measuring as close to rail as possible, meaning as close
to height of spring, diameter in coil and spring, active coil gaps, etc.
-A caliper is the additive nature of the error amounts that are permitted by the
instruments calibration. To pass calibration, a dial caliper with 0.001-inch resolution
must be accurate within 0.001 inch for length measurements and allow no more than
0.001 inch for parallelism error

REFERENCES
1) Edward Steinhauser. Example Lab Report 01. Denver, CO: Metropolitan State
University Denver, 2013. Print.
2) Edward Steinhauser. Laboratory Notes - Compression of a Helical Spring.
Denver, CO: Metropolitan State University Denver, 2014.
3) R. C. Hibbler. Mechanics of Materials. Upper Saddle River, NJ: Pearson Prentice
Hall, 2014

Haroon Rashidi
02/12/2015

Lab No. 1-Compression of Helical Spring

SIGNATURE PAGE
Mechanics of Materials Testing Laboratory CET 3135 Section 001
Laboratory No. 1 Compression of a Helical Spring
Group No. 3 Haroon Rashidi, James Pettus, Marquis Smith

Haroon Rashidi

James Pettus

Marquis Smith

CET 3135-001

Haroon Rashidi
02/12/2015

Lab No. 1-Compression of Helical Spring

CET 3135-001

APPENDIX:
Sample Calculations
= 1.0in/2.15in = 0.465 rad

c = T c/J = P R c/J = (7524.1 lbf)(2.15 in)(0.595 in)/[(0.595 in)

c = c /L = (0.595 in)(0.465 rad)/[2(2.15 in)(4)] = 5.12*10

-3

/2] = 48.89 ksi

rad

K = G/N = (11,000 ksi)/[4(2.15 in)3 (4)/(0.595 in)4] = 8670 lbf/in