Spring Design

Wayne Book
ME3180
Norton: Machine Design
Basic Spring Behavior
y F k
ky F
/ =
=
3 2 1
3 2 1
1 1 1 1
k k k k
k k k k
parallel
series
+ + =
+ + =
Some Types of Springs
Some Types of Springs (2)
Some Types of Springs (3)
Some Types of Springs (4)
Spring Materials: Wires
Properties of interest
High strength
High yield
Modulus may be low for energy storage
Cost
Temperature resistance (e.g. valve springs)
Corrosion resistance
Common Materials (partial list for wires)
The Curious Behavior as Diameter
Decreases
ut us
b
ut
S S
Ad S
67 . 0 ~
=
Helical Compression Springs
Lengths
Free
Assembled
Solid or shut height
Working deflection
End Treatment
End details affect active coils
Plain
Ground
Squared
Ground

Spring Definitions and Calculations
Spring index C
4<C<12
Active turns N
a

Spring deflection
results from torsion
under load
Spring stress including
Torsion
Direct shear
Stress concentration K
c

or Wahl factor K
w

F
k
F
G d
N D
y
a
1 8
4
3
= =
d
D
C =
s
K
d
FD
C d
FD
d
F
d
FD
3 3
2 3
max
8
2
1
1
8
4 8
t t
t t
t
=
|
.
|

\
|
+ =
+ =
s c w
w
K K
C C
C
K
d
FD
K
= +

=
=
615 . 0
4 4
1 4
8
3
max
t
t
Stress Distribution
The thing about residual stresses
Setting, also called removing the set
consists of compressing the spring past
yield as part of manufacture
The residual stresses remain in the inner
surface of the wire
This reduces static stress during following
cycles
Should not be used in tension
Shot peening can also be used primarily
for fatigue strength
Buckling and Surge
of Compression Springs
A problem for long
skinny springs
Rod inside is
sometimes used to
eliminate, but wear
and friction result
Depends on ratio L
f
/D
Surge is another
problem that occurs
with excitiation near
the natural frequency
Properties of Spring Materials--Yield
Yield strength for static loading
Depends on set
Before set removed use Wahl factor
After set removed no stress concentration used
Properties of Spring Materials--Fatigue
Fatigue Strength
Torsion is relevant loading- could use von
Mises stress
Materials testing specific to helical
compression springs is available, however
Correct for temp., reliability, environment

Properties of Spring Materials--
Endurance
Endurance Strength (steels) unlimited cycles
For high ultimate strengths, endurance limits max
out at 45 kpsi (unpeened) and 67.5 kpsi (peened)
Small wires have high ultimate strength
Tests have been done specific to spring wire
Temperature may require compensation
Corrosion
Reliability

S-N and Modified Goodman Diagram
Designing Springs
Functionality
Stiffness
Lengths
Diameter
Forces
Reliable operation
Static factor of safety
Fatigue factor of safety
Buckling and surge
Manufacturability
Index C
Material
Wire and coil diameter
Number of turns
End treatment and
constraint
Set and shot peen
Requirements Design Choices
Constraints (other)
Bend radius
Helical Extension Springs
Similar in most ways to
compression springs
Usually wound to be closed
coil at zero force
Thus a preload is required to
stretch any, i.e. y=k(F-F
i
)
Spring hook is a source of
failure in bending and
torsion
No set is used
One coil not considered
active
End Hook Stresses
d
R
C
C C
C C
K
d
F
d
DF
K
b
b A
1
1
1 1
1
2
1
2 3
2
;
) 1 ( 4
1 4
4 16
=

=
+ =
t t
o
Bending stress:
d
R
C
C
C
K
d
DF
K
w
w B
2
2
2
2
2
3
2
2
;
4 4
1 4
8
=

=
=
t
t
Torsional stress:
Torsional Springs
The wire in a torsional spring is primarily
in bending
Spring constant is rotary M=ku
Loading should act to wind up coil
Design process resembles compression
springs
Compression Spring Design--Fatigue
Static design also important but details left to
example
Data available for springs with loading from zero
to some compresion value
Application often has preload how to use?
First construct (or find) S-N curve
Next construct Mod-Goodman chart
Apply load line for given preload and design stress
Find factor of safety to failure point
Details discussed via MathCad solution
Goodman Chart for Example 13-4
Homework 10
Due 11/28/01
In text: 13-1, 13-13 (Must see web page for
starting values in design and problem
statement corrections)