Experiment 4: Design of Helical Spring
1. AIM OF THE EXPERIMENT: Design a helical spring based on given maximum force
and deflection to consider. Analyze the steps involved in designing the helical spring.
2. OBJECTIVE FOR THE DESIGN:
The spring should possess sufficient strength to withstand the external load.
It should have different load-deflection characteristic.
It should not buckle under the external load.
3. TYPES OF SPRINGS:
Helical Torsional
spring Conical or volute spring
Disc spring Laminated or leaf spring
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3.1. Two basic types of helical spring:
(i) Compression spring: shorten under the action of external load
(ii) Extension spring: elongate under the action of external load
Compression helical Extension helical
spring
4. HELICAL COMPRESSION SPRING DESIGN:
The main dimensions of a helical spring subjected to
compressive force are shown in the figure. They are:
d = wire diameter of the spring (mm)
Di = inner diameter of the spring (mm)
Do = inner diameter of the spring (mm)
D = mean diameter of the spring (mm)
D = (Di + Do) / 2
p = pitch of the spring (mm)
C = Spring index = D / d
For lower C values (C < 3): The actual stresses in the wire
are excessive due to curvature effect.
For higher C values (C > 15): Spring is prone to buckling and tangle easily during
handling.
A spring index from 4 to 12 is considered best from manufacturing conditions.
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5. TERMINOLOGIES USED IN HELICAL SPRINGS:
Solid Length: It is defined as the axial length of the spring, which when compressed, the
adjacent coils touch each other. No compression is possible beyond this point.
Solid length = Ntd, Nt = Total no. of coils.
Compressed Length: It is defined as the axial length of the spring, which is subjected to
maximum compressive force. In this case, the spring is subjected to a maximum deflection of
δ. Some gap is provided between the adjacent coils to prevent their clashing.
Clashing allowance = 15% of maximum deflection. Also, 1 - 2 mm gap between the adjacent coils
is provided as a thumb rule.
Total gap = (Nt - 1)xGap between adjacent coils.
Free Length: It is defined as the axial length of the unloaded spring. In this case, no external
force acts on the spring.
Free length = compressed length + δ
= solid length + total axial gap + δ
Pitch: It is defined as the axial distance between the adjacent coils in the uncompressed state.
p = free length/(Nt - 1)
Stiffness: k = P/ δ
P = Axial Spring Force
δ = Axial deflection of spring corresponding to force P.
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6. PROCEDURES FOR DESIGNING A HELICAL SPRING:
The basic procedure for the design of helical spring consists of following steps :
(i) For the given application, maximum spring force (P) and corresponding deflection (δ) are to be estimated.
In some cases, maximum spring force (P) and the stiffness (k) of the spring is specified.
(ii) A suitable spring material is to be selected and its ultimate tensile strength has to be ascertained. The
permissible shear stress for the spring wire is estimated by :
τ P = 0.3 - 0.5 σ UT
(iii) Depending on the application, appropriate spring index (C) has to be choosen. In general, a 'C' value of
8 is considered as a good value. However, 'C' value should not be less than 3.
(iv) The Wahl's factor is to be calculated using the following relationship :
4C - 1 0.615
KW = +
4C - 4 C
(v) The wire diameter (d) is evaluated using the following eqn,
8PD 8PC
τ = KW 3 = K W 2
πd πd
(vi) The mean diameter (D) of the coil is obatined using,
D = Cd
(vii) The number of active coils is determined using the following eqn,
3
8PD N
δ=
4
Gd
(viii) Depending upon the type of the ends for a spring, the no. of inactive coils are determined. Total no. of
coils (N t ) can be found out by adding no. of active and inactive coils.
(ix) The solid length of the spring = N t d
3
8PD N
(x) Actual deflection δ =
4
Gd
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(xi) Total axial gap between the coils = N t - 1 x gap between adjacent coils. In some cases, total gap is
taken as 15% of the maximum displacement.
(xii) Free length of the spring is to be determined using,
Free length = Solid length + total gap + δ
(xiii) Pitch (p) of the spring is found out as,
Free length
p=
N t - 1
(xiv) The stiffness (k) is calculated using,
4
Gd
k =
3
8D N
Experiment 5: Design of Leaf Spring
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