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Solution:
For oil tempered wire, Table AT 17
146
su 0.19 ksi , 0.032 Dw 0.5
Dw
solid stress = 0.6 s u
design stress, (average service)
ssd 0.324 su
0.324146 47.304
ssd
ksi
Dw0.19
Dw0.19
Dw Dm 7
F 2850 lb 2.85 kips
8FDm 47.304
3
Dw0.19
Dw
ss K
say K 1.3
8 2.85 7 Dw
47.304
ss 1.3
3
Dw
Dw0.19
Dw 1.062 in 0.5 in
use ssd
47.304
ksi 54 ksi
0.5 0.19
8 2.85 7 Dw
54
Dw3
ss 1.3
Dw 1.015 in
say Dw 1.0 in
8 2.85 Dm
ss 1.3
54
3
1
Dm 5.72 in
240
SECTION 4 - SPRINGS
say Dm 5.0 in
OD Dm Dw 5.0 1.0 6 in 7 in.
D
5.0
C m
5
Dw 1.0
= Free length Compressed length = 18 in 15 in = 3 in.
8 FC 3 N c
GDw
G 10,500 ksi , Dw
8 2.85 5 N c
10,5001
N c 11.05
3
in
8
say N c 11.5
8 2.85 5 11.5
3.12 in
10,5001
Free length = 15 + 3.12 = 18.12 in
3
At 2.85 kips
8FDm
ss K
3
Dw
C 5
4C 1 0.615 4 5 1 0.615
K
1.3105
4C 4
C
4 5 4
5
8 2.85 5
47.55 ksi
3
1
Permissible solid stress
0.6146
sso 0.6 su
ksi 99.93 ksi
0.5 0.19
F
k
using
or let T = Free length Solid height
47.55 99.93
3.12
T
T 6.56 in
T = Free length Solid height = P Dw N c
6.56 P 111.5
P 1.570 in
ss 1.3105
1
2
use P 1 in
241
SECTION 4 - SPRINGS
Pitch angle,
tan 1
1.5
P
tan 1
5.5 12 , o.k.
D
5
3.12 5.75
s so 87.63 ksi 99.93 ksi , ok
Summary of answer:
Dw = wire diameter = 1 in.
Dm = coil diameter = 5 in.
N c = no. of active coils = 11 1/2
P = pitch = 1 in.
= pitch angle = 5.5o
s so = solid stress = 87.63 ksi
272.
A coil spring is to be used for the front spring of a automobile. The spring is to
have a rate of 400 lb./in., an inside diameter of 4 3/64 in., and a free length of
14 1/8 in., with squared-and-ground ends. The material is to be oil-tempered
chrome vanadium steel. Decide upon the diameter of the wire and the number
of free coils for a design load of F 1500 lb . Be sure solid stress is all
right. How much is the pitch angle?
Solution:
Table AT 17 Cr-V steel
168
su 0.166 ksi , 0.032 Dw 0.437
Dw
average service
ssd 0.324 su
0.324168 54.432
ssd
0.166 ksi
Dw0.166
Dw
Max solid stress = 0.6 su
242
SECTION 4 - SPRINGS
3
in 4.046875 in
64
Dm Dw 4.046875 in
ID Dm Dw 4
8FDm
ssd
3
Dw
Assume K 1.3
F 1500 lb 1.5 kips
ss K
ssd
81.5 Dw 4.046875
54.432
1.3
0.166
Dw
Dw3
Dw 0.747 in 0.437 in
use
ssd
54.432
ksi 62.45ksi
0.437 0.166
81.5 Dw 4.046875
62.45
Dw3
ssd 1.3
Dw 0.724 in
use Dw
3
in
4
3
3
51
4 4 in
4
64
64
8FDm
ss K
3
Dw
4C 1 0.615
K
4C 4
C
51
4
Dm 64
C
6.4
Dw
3
4
4 6.4 1 0.615
K
1.235
4 6.4 4
6.4
51
81.5 4
64 53.64 ksi 62.45 ksi
ss 1.235
, (o.k.)
3
3
8 FC N c
GDw
Dm
243
SECTION 4 - SPRINGS
G 10,500 ksi , D w
3
in
8
F 1500
3.75 in
k
400
3
81.5 6.4 N c
3.75
10,500 3
4
N c 9.4
Table AT 16, Total coils = N c 2 9.4 2 11.4 for square and grounded end.
Summary of answer:
Dw = wire diameter = in.
No. of free coils = 11.4
To check for solid stress.
Permissible solid stress =
0.6168
115 .65 ksi
0.437 0.166
Free length = PN c 2 Dw
3
11.4 8.55 in
4
Solid height = Dw N c 2
14 8.55
8
79.74ksi 115
53.64
.65ksi (safe)
3.75
Solid stress =
Pitch:
1
PN c 2 Dw 14 in
8
1
3
P 9.4 2 14
8
4
11
P 1.343 in 1 in
32
Pitch angle,
11
1
P
32
tan 1
tan 1
D
4 51
64
273.
5.1 12 , o.k.
A coiled compression spring is to fit inside a cylinder 5/8 in. in diameter. For one
position of the piston, the spring is to exert a pressure on the piston equivalent
244
SECTION 4 - SPRINGS
to 5 psi of piston area, and in this position, the overall length of the spring
must not exceed (but may be less than) 2 in. A pressure of 46 psi on the piston
is to compress the spring in. from the position described above. Design a
spring for medium service. Specify the cheapest suitable material, number of
total and active coils for square-and-ground ends, and investigate the pitch
angle, and solid stress.
Solution:
8FDm
ss K
3
D
w
OD Dm Dw
Dm 1.5 Dw
F1 5
4
5
D
in w
8
2
5
in
8
2
5
8
F2 46 5
4
1.534 lb
5
8
15.647 lb
8FC 38.556
38,556
ksi 0.19 psi
2
0.19
Dw
Dw
Dw
ss K
815.647 C
38,556 Dw1.81
4C 4
C
K
245
SECTION 4 - SPRINGS
4C 1 0.615
0.625
39.845 C 38,556
C
4C 4
C 1.5
4C 1 0.615
1.81
C 1.5 C 413.3
C
4C 4
C 7.035
0.625
0.625
Dw
0.0732 in
C 1.5 7.035 1.5
Table AT 15, Dw 0.0720 in , W & M 15
Dm 7.035 0.0720 0.5065 in
For N c
2 1
1.81
8 F2 F1 C 3 N c
GDw
4
11.5 106 0.0720
N c 15.8
Table AT 16,
Total coils = N c 2 15.8 2 17.8
Solid height = N c 2 Dw 15.8 2 0.0720 1.28 in
Free length = PN c 2 Dw
Free length = 2 1
3
2 1
8 F1 C 3 N c
GDw
246
SECTION 4 - SPRINGS
su
146
ksi , 0.028 Dw 0.5
D w0.19
87.5
Max solid stress = D 0.19 ksi
w
146 47.304
Dw0.19
Dw0.19
ssd 0.324
8FC 47.304
47,304
ksi
psi
2
0.19
Dw
Dw0.19
Dw
ss K
815.647 C
47,304 Dw1.81
4C 4
C
4C 1 0.615
0.625
39.845 C 47,304
C
4C 4
C 1.5
4C 1 0.615
1.81
C 1.5 C 507.1
4
C
4
C
C 7.684
0.625
0.625
Dw
0.0680 in
C 1.5 7.684 1.5
Table AT 15, Dw 0.0625 in , W & M 16
Dm 7.684 0.0625 0.48025 in
K
say Dm
C
1.81
15
0.46875 in
32
Dm 0.46875
7.5
Dw
0.0625
8FC
D
w
1.1974
4C 4
C
4 7.5 4
7.5
ss K
815.647 7.5
91,600 psi 91.6 ksi
2
0.0625
ss 1.1974
For N c
2 1
8 F2 F1 C 3 N c
GDw
247
SECTION 4 - SPRINGS
G 11.5 106 psi
Free length = PN c 2 Dw
Free length = 2 1
8 F1 C 3 N c
1
GDw
P 0.1729 in
11
in
64
Pitch angle,
tan 1
0.1729
P
tan 1
6.7 12 , o.k.
0
.
46875
Solid stress
2 0.8325
sso 91.6
142.6 ksi
0.75
87.5
148.8 ksi 137.5 ksi , safe.
0.0625 0.19
Summary of answer:
Suitable material = Oil-Tempered Spring Wire
Total Coils = 13.32
Active Coils, N c 11.32
274.
A helical spring is to fit about a 11/16-in. rod with a free length of 2 in. or less.
A maximum load of 8 lb. is to produce a deflection of 1 in. The spring is
expected to be compressed less than 5000 times during its life, but is subjected
to relatively high temperatures and corrosive atmosphere. Select a material
and determine the necessary wire size, mean coil diameter, and number of
coils. Meet all conditions advised by Text.
Solution:
For 5000 cycles < 104 cycles, use light service
248
SECTION 4 - SPRINGS
Use stainless steel, type 302 (Cr-Ni), ASTM A313 for relative high temperature and
corrosive atmosphere, Table AT 17.
ssd 0.32 su (i)
170
ksi , 0.01 Dw 0.13
Dw0.14
97
su 0.41 ksi , 0.13 Dw 0.375
Dw
su
ss K
3
D
w
F 8 lb
11 D
Dm Dw w
16 2
Dm 1.5 Dw 0.6875 in
CDw 1.5Dw 0.6875
0.6875
Dw
C 1.5
4C 1 0.615
K
4C 4
C
170
assume su 0.14 ksi
Dw
0.32170 54.4
54,400
ssd
0.14 ksi
psi
0.14
Dw
Dw
Dw0.14
4C 1 0.615 8 8 C
54,400 D1w.86
C
4C 4
1.86
4C 1 0.615 64C
0.6875
54,400
C
4C 4
C 1.5
4C 1 0.615
1.86
C 1.5 C 1330
4
C
4
C
C 12.919
0.6875
Dw
0.0602 in
12.919 1.5
Use Table AT 15, Dw 0.0625 in , 16 W & M
Dm 12.919 0.0602 0.8074 in
say Dm
25
in 0.78125 in
32
11
16
0.78125 0.0625 0.6875
Dm Dw
249
SECTION 4 - SPRINGS
0.71875 0.6875
0.71875 0.6875 0.03125
C
Dw
, o.k.
2
Dm 0.71875
12.5
Dw
0.0625
su
170
ksi is o.k.
Dw0.14
8FC
2
Dw
412.5 1 0.615
K
1.1144
412.5 4 12.5
ss K
8 812.5
72,648 psi
2
0.0625
ss 1.1144
8 F C 3 N c
GDw
3
8 812.5 N c
1
4 10.6 106 0.0625
N c 9.3
To check for solid stress and pitch
Minimum solid height = Dw N c 0.0625 9.3 0.58125 in
72,648 2 3 0.58125
4
90,000 psi 90 ksi
Solid stress =
3
1
4
0.47 170 117 .8 ksi 90 ksi
Permissible solid stress =
, o.k.
0.0625 0.14
Free length = PN c , minimum
3
P 9.3 2
4
P 0.2957 in
Pitch angle,
3
tan 1
0.2957
P
tan 1
7.5 12 , o.k.
D
0.71825
Summary of answer
Material, Stainless Steel, Cr-Ni. ASTM A313
Dw 0.0625 in , 16 W & M
25
Dm
in
32
250
SECTION 4 - SPRINGS
N c 9.3
275.
Solution:
Use Music wire (The best material)
Table AT 17
190
su 0.154 ksi , 0.004 Dw 0.192
Dw
Maximum solid s so 0.5su
Light service, ssd 0.405su
0.405190 76.95
76,950
ssd
0.154 ksi 0.154 psi
0.154
Dw
Dw
Dw
8FC
2
Dw
F 3500 lb
OD Dm Dw 6 in
C 1 Dw 6
6
Dw
C 1
ss K
76,950
4C 1 0.615 8 3500 C
ss
C 6 6 0.154
4C 4
C 1 C 1
4C 1 0.615
1.846
235.9
C C 1
C
4C 4
C 5.635
6
Dw
0.9043 in 0.192 in
5.635 1
use ss
76.950
99,216 psi
0.192 0.154
4C 1 0.615 8 3500 C
99,216
ss
C 6
4C 4
C 1
251
SECTION 4 - SPRINGS
4C 1 0.615
2
C C 1 400.8
C
4C 4
C 6.205
6
Dw
0.8328 in
6.205 1
Say Dw
13
in 0.8125 in
16
1.2455
4 6.154 4 6.154
8FC
2
Dw
ss K
8 3500 6.154
103,481 psi 99,216 psi , not o.k.
2
0.8125
ss 1.2455
Use Dm 4.5 in
D
4.5
C m
5.5385
Dw 0.8125
4 5.5385 1 0.615
K
1.2763
45.5385 4 5.5385
8 3500 5.5385
ss 1.2763
95,435 psi 99,216 psi , o.k.
0.8125 2
1
95,435 190,870 psi 122,488 psi , not ok
0.5
Solid stress =
Use
0.5
ssd 122,488
61,244 psi
1
4C 1 0.615 8 3500 C
61,244
ss
C 6
4C 4
C 1
4C 1 0.615
2
C C 1 247.4
C
4C 4
C 5 .1
252
SECTION 4 - SPRINGS
Dw
6
0.9836 in
5.1 1
Say Dw 1.0 in
Dm 5.11.0 5.1 in
Say Dm 5 in
D
5
C m 5
Dw 1
8FC
2
Dw
4 5 1 0.615
K
1.3105
4 5 4
5
8 3500 5
ss 1.3105
58,400 psi 61,244 psi o.k.
2
1.0
Use Dw 1.0 in , Dm 5 in
ss K
1
58,400 116 ,800 psi 122,488 psi , o.k.
0 .5
Solid stress =
8 F C 3 N c
GDw
(Table AT 17)
G 12 106 psi
8 3500 5 N c
12 106 1.0
N c 1.7143
3
0.5
say N c 1.75
Free length Solid length = Solid Deflection
PN c Dw N c 1 in
P1.75 11.75 1
9
P 1.5714 in 1 in
16
Pitch angle,
tan
116
P
1
tan
5.68 12 ,
D
o.k.
Summary of answer.
F 3500
7000 lb in
0.5
Wire size, Dw 1.0 in
Scale, k
SECTION 4 - SPRINGS
Solid sress = 116,800 psi
Pitch of stress = P 1
9
in
16
The front spring of an automobile has a total of 9 coils, 7 3/8 active coils
(square-and-ground ends), an inside diameter of 4 3/64 in., and a free length
of 14 in. It is made of SAE 9255 steel wire, OQT 1000oF, with a diameter
of 43/64 in. Compute (a) the rate (scale) of the spring; (b) the solid stress
and compare with a permissible value (is a stop needed to prevent solid
compression?). (c) Can 95 % of the solid stress be repeated 105 times without
danger of failure? Would you advise shot peening of the spring?
Solution:
8 FC 3 N c
GDw
43
3
Dw
in in
64
8
6
G 10.5 10 psi
D
C m
Dw
Dm Dw ID
43
3
Dm
4 in
64
64
23
Dm 4 in
32
23
4
C 32 7.0233
43
64
3
Nc 7
8
(a)
10.5 10
6
k rate
F
GD
3w
8C N c
8 7.0233
43
64
345 lb in
3
7
8
254
SECTION 4 - SPRINGS
Solid deflection = Free length Solid height = 14 - 6.3828 = 7.8672 in.
Solid Force = Fso 7.8672 345 2714 lb
8 FsoC
2
Dw
4C 1 0.615
K
4C 4
C
4 7.0233 1 0.615
K
1.212
4 7.0233 4 7.0233
Solid Stress = K
8 2714 7.0233
ss 1.212
43
64
130,322 psi
An oil-tempered steel helical compression spring has a wire size of No. 3 W & M,
a spring index of 4.13, 30 active coils, a pitch of 0.317 in., ground-andsquared ends; medium service. (a) What maximum load is permitted if the
recommended stress is not exceeded (static approach)? Compute (b) the
corresponding deflection, (c) solid stress,. (d) pitch angle, (e) scale, (f) the
energy absorbed by the spring from a deflection of 0.25 in. to that of the
working load. (g) Is there any danger of this spring buckling? (h) What
maximum load could be used if the spring were shot peened?
Solution:
Table AT 17, oil-tempered
146
su 0.19 ksi , 0.032 Dw 0.5
Dw
87.5
Maximum solid sso 0.19 ksi
Dw
255
SECTION 4 - SPRINGS
ssd 0.324 su (medium service)
8 Fs C
2
Dw
4C 1 0.615
K
4C 4
C
4 4.13 1 0.615
K
1.3885
4 4.13 4 4.13
0.324146
ss ssd
61.858 ksi 61,858 psi
0.2437 0.19
8 F 4.13
ss 61,858 1.3885
2
0.2437
F 252 lb
8 FC 3 N c
GDw
(a) ss K
8 252 4.13 30
1.52 in
11.5 106 0.2437
3
87.5
87.5
ksi
ksi 114 .4 ksi 89.491 ksi , o.k. safe
0.19
Dw
0.2437 0.19
0.317
P
tan 1
5.76 12 , o.k.
F 252
166 lb in
(e) scale k
1.52
1
(d) tan
256
SECTION 4 - SPRINGS
(f) U s
1
k 22 12
2
k 166 lb in
1 0.25 in
2 1.52 in
1
2
2
U s 166 1.52 0.25 186.6 in lb
2
9.9974 4
Mean Diameter
1.0
There is a danger for spring buckling
(h) Shot peened, Table AT 17
ssd 61,8581.25 77,322 psi
8 F 4.13
2
0.2437
ss 77,322 1.3885
F 314 lb
280.
Solution:
Dw 1 in
3
Dm Dw 5 in
8
3
Dm 4 in
8
3
4
D
C m 8 4.375
Dw
1
(a)
8FC 3 N c
GDw
Assume N c 4.3
257
SECTION 4 - SPRINGS
G 10.5 10 6 psi , Dw
8F 4.375 4.3
10.5 10 6 1
F 3645 lb
1.0
No. of springs =
(b) F
3
in
8
W
47,300
13
F
3645
W 47,300
3638 lb
13
13
8 Fs C
2
Dw
4C 1 0.615
K
4C 4
C
4 4.375 1 0.615
K
1.3628
4 4.375 4 4.375
ss K
8 3638 4.375
55,235 psi
2
1.0
ss 1.3628
2
110,470 psi
1
A spring, subjected to a load varying from 100 lb. to 250 lb., is to be made of oiltempered, cold-wound wire. Determine the diameter of the wire and the mean
diameter of the coil for a design factor of 1.25 based on Wahls line. The spring
index is to be at least 5. Conform to good practice, showing checks for all
significant parameters. Let the free length be between 6 and 8.
Solution:
Fmax 250 lb
Fmin 100 lb
1
1
Fm Fmax Fmin 250 100 175 lb 0.175 kip
2
2
258
SECTION 4 - SPRINGS
1
Fmax Fmin 1 250 100 75 lb 0.075 kip
2
2
Wahls line
1 sms sas 2sas
N
s ys
sno
8 KFa Dm 8KFa C
sas
Dw3
Dw2
8 KFm Dm 8 KFmC
sms
K cDw3
K cDw2
C 5
4C 1 0.615
K
4C 4
C
4 5 1 0.615
K
1.31
4 5 4
5
Fig. AF 15, C 5
K c 1.19
For oil-tempered wire,
87.5
s ys 0.19
Dw , 0.032 Dw 0.5
Fa
47
Dw0.1 , 0.041 Dw 0.15
30
sno 0.34
Dw , 0.15 Dw 0.625
sno
N 1.25
81.31 0.075 5 1.251
sas
Dw2
Dw2
81.31 0.175 5 2.453
sms
1.19Dw2
Dw2
30
say sno 0.34 ksi
Dw
1 sms sas 2sas
N
s ys
sno
2.453 1.251
2
D
w
1.251
2
2
D
1
w
1.25
87.5
30
0.19
0.34
Dw
Dw
1
1
1
1.81
1.25 72.8 Dw
11.99 Dw1.66
259
SECTION 4 - SPRINGS
Dw 0.2857 in 0.15 in
Table AT 15, use No. 1, W & M
Dw 0.2830 in
Dm CDw 5 0.2830 1.415 in
say Dm 1
7
in
16
Free length = 4 Dm 4 1
7
5.75 in
16
Increase Dm
1
Dm 1 in
2
1
2
Summary of answer
Dw 0.2830 in
1
Dm 1 in
2
283.
A carbon-steel spring is to be subjected to a load that varies from 500 to 1200 lb.
The outside diameter should be between 3.5 and 4 in., the spring index between 5
to 10; approximate scale of 500 lb./in. Choose a steel and for a design factor of
1.4 by the Wahl line, find the wire diameter. Also determine the number of active
coils and the free length for squared-and-ground ends. Conform to the general
conditions specified in the Text.
Solution:
For carbon steel, Table AT 17
91
s ys 0.1 ksi , 0.093 Dw 0.25
Dw
49
sno 0.15 ksi , 0.093 Dw 0.25
Dw
Fmax 1200 lb
Fmin 500 lb
1
1
Fm Fmax Fmin 1200 500 850 lb 0.85 kip
2
2
1
1
Fa Fmax Fmin 1200 500 350 lb 0.35 kip
2
2
OD 3.5 ~ 4.0 in
C 5 ~ 10
260
SECTION 4 - SPRINGS
Wahls line
1 sms sas 2sas
N
s ys
sno
Figure AF 15, C 5 ~ 10
Assume K 1.2 , K c 1.125
8 KFa Dm
sas
Dw3
8 KFm Dm
sms
K cDw3
OD 3.75 in
Dm 3.75 Dw
81.2 0.35 3.75 Dw 1.0695 3.75 Dw
sas
Dw3
Dw3
81.2 0.85 3.75 Dw 2.3088 3.75 Dw
sms
1.125Dw3
Dw3
1
1.4
3.75 Dw
Dw3
2.3088 1.0695
91
0.1
Dw
1
3.75 Dw
3.75 Dw
2.9
1.4 73.4285 Dw
22.9079 Dw2.85
Dw 0.6171 in 0.25 in
Use
91
s ys
104.53 ksi
0.25 0.1
49
sno
60.33 ksi
0.25 0.15
3.75 Dw
Dw3
21.0695
49
0.15
Dw
3.75 Dw
3.75 Dw
21.0695
3
Dw
Dw3
1
1.4
104.53
60.33
1
3.75 Dw 3.75 Dw
2.3088 1.0695
261
SECTION 4 - SPRINGS
3
Dm Dw 3 in
4
19
3
Dm
3 in
32
4
5
Dm 3 in
32
5
3
Dm 32
C
5.316
Dw
19
32
. o.k.
Wire Diameter Dw
19
in , Carbon Steel
32
Number of coils:
8 FC 3 N c
GDw
G 10.5 10 6 psi 10,500 ksi , Dw
3
in
8
F
GD
k 3 w
8C N c
10.5 10
19
32
500
3
8 5.316 N c
N c 10.4
Table AT 16, square-and-ground ends
Free length = PN c 2 Dw
Solid height = Dw N c 2 Dw
Total Coils = N c 2
6
19
7.3625 in
32
F 1200
2.4 in
k
500
Min. Free length = 2.4 + 7.3625 in = 9.7625 in
Use Free length = 10 in
SECTION 4 - SPRINGS
tan
0.8474
5
3
32
4.885 12 ,
P
tan 1
Dm
o.k.
Solid stress:
T solid deflection 10 7.3625 2.6375 in
F k T 500 2.6375 1319 lb
4C 1 0.615
K
4C 4
C
4 5.316 1 0.615
K
1.29
4 5.316 4 5.316
5
81.29 1319 3
8 KFDm
32 23,033 psi 23.033 ksi s 104.53 ksi
ss
ys
3
3
Dw
19
32
284.
Solution:
Table AT 16,
For carbon steel,
182
su 0.1 ksi , 0.093 Dw 0.25
Dw
91
Max. solid s ys 0.1 ksi
Dw
49
sno 0.15 ksi , 0.093 Dw 0.25
Dw
Dm 2 in.
Fmax 300 lb
Fmin 100 lb
(a) F 300 lb 0.3 kip
severe service, ssd 0.263su
Dw0.1
263
SECTION 4 - SPRINGS
8 Fs C
2
Dw
4C 1 0.615
K
4C 4
C
D
C m
Dw
D
2
Dw m
C C
ss K
4C 1 0.615 8 0.3 2
ss
C 2 3
4C 4
C
4C 1 0.615 2.9
4C 4 C C 233.84
C 6.075
2
Dw
0.3292 in 0.25 in
6.075
Therefore use ssd
47.866
2
C
0.1
47.866
54.984 ksi
0.25 0.1
4C 1 0.615 8 0.3 2
ss
54.984
C 2 3
4C 4
C
4C 1 0.615 3
4C 4 C C 287.9
C 6.136
2
Dw
0.3259 in
6.136
say Dw
(b) s ys
21
in
64
91
104.53 ksi
0.25 0.1
49
60.33 ksi
0.25 0.15
1
1
Fm Fmax Fmin 300 100 200 lb 0.2 kip
2
2
1
1
Fa Fmax Fmin 300 100 100 lb 0.1 kip
2
2
sno
264
SECTION 4 - SPRINGS
Dm
2
6.095
Dw 21
64
Figure AF 15
K c 1.15
K 1.25
K 8 Fm Dm
sms
K c Dw3
C
sms
1.25 8 0.2 2
31.34 ksi
1.15 21 3
64
sas
8 KFa Dm
Dw3
sas 1.25
8 0.1 2
3
21
64
18.02 ksi
Wahls line
1 sms sas 2sas
N
s ys
sno
1 31.34 18.02 218.02
N
104.53
60.33
N 1.38
285.
A helical spring of hard-drawn wire with a mean diameter of 1 in. and squareand-ground ends is to be subjected to a maximum load of 325 lb. (a) Compute the
wire diameter for average service. (b) How many total coils are required if the
scale is 800 lb./in.? (c) For a minimum load of 100 lb., what is the factor of safety
according to Wahl line? Would it be safe for an indefinite life?
Solution:
Table AT 17,
Hard-drawn wire,
140
su 0.19 ksi , 0.028 Dw 0.625
Dw
265
SECTION 4 - SPRINGS
Maximum solid ss s ys
0.9 47 ksi
70
ksi
Dw0.19
, 0.041 Dw 0.15
Dw0.1
0.9 30 ksi
sno
, 0.15 Dw 0.625
Dw0.34
Average service
sno
0.2754140 38.556
ksi
Dw0.19
Dw0.19
Dm 1
1
in
2
8 FDm
3
Dw
ss K
4C 1 0.615
4C 4
C
1.5
Dw
C
0.615
4C 1
C
4C 4
8 0.3251.5
ss
1.5
38.556
1.5
4C 1 0.615 2.81
97.05
C
C
4C 4
C 4.586
1 .5
1.5
Dw
0.3271 in 0.625 in
C
4.586
21
Dw
in
64
(b)
Dm
1.5
4.57
Dw 21
64
4 4.57 1 0.615
1.345
4 4.57 4 4.57
8 FC 3 N c
GDw
F
GD
k 3 w
8C N c
k 800 lb in 0.8 kip in
266
0.19
SECTION 4 - SPRINGS
0.8
11,500
21
64
84.57 3 N c
N c 6.2
(c)
s ys
sno
70
0.19
21
64
0.9 30
86.5 ksi
39.44 ksi
0.19
, Dw 0.15 in
21
64
1
Fm 325 100 212.5 lb 0.2125 kip
2
1
Fa 325 100 112 .5 lb 0.1125 kip
2
K c 1.212 , Fig. AF 15
K 1.345
K 8 Fm Dm
1.345 8 0.21251.5
25.5 ksi
K c Dw3
1.212
21
64
8 Fm Dm
8 0.1125 1.5 16.36 ksi
K
1.345
3
3
21
Dw
64
s ms
sas
N
s ys
sno
86.5
39.44
A helical spring is to be subjected to a maximum load of 200 lb. (a) Determine the
wire size suitable for medium service if the material is carbon steel ASTM A230;
C 6 . Determine the factor of safety of this spring according to the Wahl line
(b) If the minimum force is 150 lb., (c) if the minimum force is 100 lb., (d) if the
minimum force is 25 lb.
Solution:
For carbon steel ASTM A230
Table AT 17
182
su 0.1 ksi , 0.093 Dw 0.25
Dw
267
SECTION 4 - SPRINGS
91
ksi , 0.093 Dw 0.25
Dw0.1
49
sno 0.15 ksi , 0.093 Dw 0.25
Dw
Medium Service
s ys
ssd 0.324 su
182 58.968
58,968
ksi
psi
(a) ssd 0.324 0.1
0.1
Dw
Dw0.1
Dw
8 FDm
ss K
3
Dw
4C 1 0.615
4C 4
C
4 6 1 0.615
K
1.2525
4 6 4
6
K
F 200 lb
8 200 6
58,968
2
Dw0.1
Dw
ss 1.2525
Dw 0.2371 in
1
200 150 175 lb 0.175 kip
2
1
200 150 25 lb 0.025 kip
2
Figure AF 15, K c 1.156
Fa
48.8 ksi
K c Dw2
1.156 0.2437 2
8 0.025 6
8 Fa C
sas K
1.2525
8.1 ksi
2
2
Dw
0.2437
sms
N
s ys
sno
268
SECTION 4 - SPRINGS
1
48.8 8.1 2 8.1
N
104.8
60.56
N 1.525
(b) Fm
1
200 100 150 lb 0.15 kip
2
1
200 100 50 lb 0.05 kip
2
Figure AF 15, K c 1.156
Fa
sms
K
Kc
8 Fm C 1.2525 8 0.15 6
41.8 ksi
2
1.156 0.2437 2
Dw
8 0.05 6
8 Fa C
1.2525
16.11 ksi
2
2
0
.
2437
sas K
N
s ys
sno
1
41.8 16.11 216.11
N
104.8
60.56
N 1.287
(c) Fm
1
200 25 112.5 lb 0.1125 kip
2
1
200 25 87.5 lb 0.0875 kip
2
Figure AF 15, K c 1.156
Fa
31.36 ksi
K c Dw2
1.156 0.2437 2
8 0.0875 6
8Fa C
sas K
1.2525
28.2 ksi
2
2
Dw
0.2437
sms
N
s ys
sno
N
104.8
60.56
N 1.04
CHECK PROBLEMS
A Diesel valve spring is made of 3/8-in. chrome-vanadium steel wire, shot-peened; inside
diameter is 3 in., 7 active coils, free length is 7 3/8 in., solid length is 4 1/8 in., length
with valve closed, 6 in., length when open, 5 1/8 in. (a) Compute the spring constant
and the factor of safety as defined by the Wahl criterion (see 6.13, Text). (b) Is there any
danger of damage to the spring if it is compressed solid? (c) What is the natural
269
SECTION 4 - SPRINGS
frequency? If this spring is used on a 4-stroke Diesel engine at 450 rpm, is there any
danger of surge? Compute the change of stored energy between working lengths.
Solution:
For chrome-vanadium steel wire, shot-peened, Table AT 17
1.25168 ksi
su
, 0.032 Dw 0.437
Dw0.166
1.25100 ksi
s ys
, 0.032 Dw 0.437
Dw0.166
1.25 49 ksi
sno
, 0.028 Dw 0.5
Dw0.15
3
in 0.375 in
8
1.25100 ksi 147.1 ksi
0.375 0.166
Dw
s ys
sno
1.25 49
0.375 0.15
(a)
8FC 3 N c
GDw
F
GD
k 3 w
8C N c
G 11 .5 10 6 psi
Nc 7
Dw 0.375 in
Dm Dw ID 3 in
Dm 3.375 in
Dm 3.375
9
Dw 0.375
k spring constant
GDw
11.5 106 0.375 105.64 lb in
3
8C 3 N c
8 9 7
3
1
1 7 4 3.25 in
8
8
F1 k1 105.64 3.25 343.33 lb
3
1
2 7 6 1.125 in
8
4
F2 k 2 105.64 1.125 118 .85 lb
270
SECTION 4 - SPRINGS
1
343.33 118 .85 231.09 lb 0.231 kip
2
1
Fa 343.33 118 .85 112 .24 lb 0.11224 kip
2
Fm
sms
K 8FmC
K c Dw2
4C 1 0.615
4C 4
C
4 9 1 0.615
K
1.162
4 9 4
9
Figure AF 15, K c 1.10
K
K 8 Fm C 1.162 8 0.231 9
39.8 ksi
K c Dw2
1.10 0.375 2
8 0.11224 9
8 Fa C
sas K
1
.
162
21.3 ksi
2
2
Dw
0.375
sms
N
s ys
sno
N
147.1
70.96
N 1.377
3
2.625 4.75 in.
8
8 0.5018 9
8 FC
1.162
95 ksi 147.1 ksi
2
2
Dw
0.375
There is no danger of damage
Solid stress = ss K
cps
N c Dm2
14,050
cps
N c C 2 Dw
14,050
cps 66 cps
7 9 2 0.375
271
SECTION 4 - SPRINGS
2
47 cps
60
66
1.4 12 , there is danger of surging.
47
(d) U s
289.
1
1
2
2
k 12 22 105.64 3.25 1.125 491 in lb
2
2
A helical spring is hot wound from 5/8-in. carbon-steel wire with an outside
diameter of 3 in. A force of 3060 lb. is required to compress the spring 1
in to the solid heigh. In service the spring is compressed so that its
deformation varies form in. to1 1/8 in. (a) What is the factor of safety by the
Wahl criterion? (b) Is the solid stress safe? Compute (c) the pitch angle, (d)
the change of stored energy between the working lengths, (e) the factor of
safety if the spring is peened?
Solution:
For hot-wound carbon steel wire
Dw
5
in
8
Table AT 17
91
s ys 0.1 ksi , 0.093 Dw 0.25
Dw
91
ksi 104.5 ksi , Dw 0.25 in.
0.25 0.1
49
0.15 ksi , 0.093 Dw 0.25
Dw
49
s ys
sno
sno
117
ksi , Dw 0.375 in. 6.3
Dw0.31
117
ksi 35.4 ksi
0.625 0.31
F 3060
1748.6 lb in
1.75
1
F1 k 1 1748.6 874.3 lb
2
1
F2 k 2 1748.6 1 1967.2 lb
8
(a) k
272
SECTION 4 - SPRINGS
1
1967.2 874.3 1420.7 lb 1.4207 kip
2
1
Fa 1967.2 874.3 546.4 lb 0.5464 kip
2
5
Dw in 0.625 in
8
1
Dm Dw 3 in
4
Dm 2.625 in
Fm
Dm 2.625
4.2
Dw 0.625
4C 1 0.615
4C 4
C
4 4.2 1 0.615
K
1.3808
4 4.2 4
4.2
K c 1.234
K
43.5 ksi
K c Dw2
1.234 0.625 2
8 0.5464 4.2
8 Fa C
sas K
1
.
3808
20.7 ksi
2
2
0
.
625
sms
N
s ys
sno
N
104.5
60.33
N 1.106
8 3.060 4.2
8 FC
1
.
3808
115 .7 ksi 135.4 ksi , safe
2
2
Dw
0.625
Solid stress, ss K
P Dw N c 1.75 in
3
in
4
8 FC 3 N c
GDw
G 10.5 10 6 psi , hot-wound
F
GD
3w
8C N c
273
SECTION 4 - SPRINGS
1748.6
10.5 10 0.625
6
8 4.2 N c
3
N c 6.332
P 0.625 6.332 1.75
P 0.9014 in
Pitch angle
tan
P
P
Dm CDw
tan 1
(d) U s
P
0.9014
tan 1
6.24
CDw
4.2 0.625
1
1
2
2
k 12 22 1748.6 1.125 0.5 888 in lb
2
2
N
130.6
75.4
N 1.38
ENERGY STORAGE
293.
A 10-lb. body falls 10 in. and then strikes a helical spring. Design a hard-drawn
carbon steel spring that will absorb this shock occasionally without permanent
damage. Determine appropriate values of wire diameter, coil diameter, pitch,
free length, closed length, and the maximum stress under the specified
conditions, and scale. Let C 7 .
Solution:
For hard-drawn carbon steel, Table AT 17
182
su 0.1 ksi , 0.093 Dw 0.25
Dw
91
Max. solid ss 0.1 ksi , 0.093 Dw 0.25
Dw
36.855
ssd 0.50 0.405 su
ksi
Dw0.1
Us
K
ss2V
4 K 2G
4C 1 0.615
4C 4
C
274
SECTION 4 - SPRINGS
K
4 7 1 0.615
1.213
4 7 4
7
Dw2
V
4
Dm N c
D Dm N c
4
2
2
w
Dm CDw
2CDw3 N c
4
3
8 FC N c
GDw
Us W h
8 FC
2
Dw
ss K
ssDw2
8 KC
s sDw2 8C 3 N c
8 KC GDw
s D C 2 N c
s w
KG
s 2 2CD 3 N c
s D C 2 N c
Us W h s w
KG
16 K 2G
Nc
Wh
s CD
ssDwC 2W
16 K 2G
KG
2
s
when ss
Nc
Nc
2
w
36.855
ksi
Dw0.1
36.855
Wh
CD
16 K 2G
2
2.8
w
36.855D 0w.9C 2W
0.01010
KG
Nc
2.8
w
0.3466 D
0.10
0.004067 D w0.9
combination of Dw and N c
Dw
Gage No. W & M
Nc
275
Dw N c
SECTION 4 - SPRINGS
12
11
10
9
8
7
6
5
4
3
0.1055
0.1205
0.1350
0.1483
0.1620
0.1770
0.1920
0.2070
0.2253
0.2437
991.2
312.1
166.1
108.0
75.2
53.7
40.2
31
23.4
18.1
105
37.6
22.4
16.0
12.2
9.5
7.7
6.4
5.3
4.4
45
in
64
0.9 2
0.9
2
ssDwC 2 N c 36.855D w C N c 36.855 0.2437 7 18.1
2.066 in
KG
KG
1.21311,500
36.855
42.44 ksi
0.2437 0.1
91
91
0. 1
104.8 ksi
Dw
0.2437 0.1
ss
sso
Solid deflection
104.8
2.066 5.1 in
42.44
P Dw N c 5.1
say P
17
0.53125 in
32
Summary of answer:
Dw 0.2437 in , No. 3 W & M
Dm 1
P
45
in
64
17
in
32
276
SECTION 4 - SPRINGS
Free length = 10.2 in
Closed length = 5 in
Maximum stress = 42.44 ksi
294.
Solution:
For hard-drawn steel wire, shock load, average service
140
su 0.19 ksi , 0.028 Dw 0.625
Dw
70
Max. solid ss 0.19 ksi , 0.028 Dw 0.625
Dw
140
0.19
Dw
Us
19.278
ksi
Dw0.19
sV
s D CN c
2
4K G
16 K G
2
s
2
s
3
w
2
C 6
4C 1 0.615
K
4C 4
C
4 6 1 0.615
K
1.2525
4 6 4
6
U s 75 in lb 0.075 in kip
19.278
2 Dw3 6 N c
2
0.19
Dw 161.2525 11,500
U s 0.075
0.9837 Dw2.62 N c
Table AT-15
W&M
9
8
7
6
5
Dw
Nc
Dw N c
0.1483
0.1620
0.1770
0.1920
0.207
146
116
92
74
61
21.65
18.79
16.28
14.21
12.63
277
SECTION 4 - SPRINGS
4
3
2
1
0
2-0
3-0
4-0
5-0
0.2253
0.2437
0.2625
0.2830
0.3065
0.3310
0.3625
0.3938
0.4305
49
40
32.7
26.9
21.8
17.8
14.0
11.3
8.95
11.04
9.75
8.58
7.61
6.68
5.89
5.075
4.45
3.85
Dm 6 0.4305 2.583 in 2
9
in
16
19.278
22.63 ksi
0.4305 0.19
ss
70
82.16 ksi
0.4305 0.19
0.6885 in
1.252511,500
KG
82.16
0.6885 2.5 in
Solid deflection
22.63
P Dw N c 2.5
2
P 0.4305 9 2.5
P 0.7083 in
say P
45
0.703125 in
64
7
8
45
P
64 5 12
tan 1
tan 1
Dm
2 9
16
Volume
0.4305 2 9
Dw2
3
Dm N c
V
2 9 10.55 in
16
278
SECTION 4 - SPRINGS
Summary of answer:
Dw 0.4305 in , No. 5-0 W & M
Dm 2
Nc 9
9
in
16
Free length = 6
21
in
64
Pitch Angle = 5
Solid Stress = 80.65 ksi
Volume of metal = 10.55 in3
Possibility of spring buckling
21
6
64 2.47 4
, no possibility
9
2
16
CONCENTRIC HELICAL SPRINGS
297.
Two concentric helical springs are to be subjected to a load that varies from a
maximum of 235 lb. to a maximum of 50 lb. They are to fit inside a 1 5/8 in.
cylinder. The maximum deflection is to be in., and the deflection when
compressed solid is to be approximately 1 in. Using the static approach for
severe service (maximum load), determine the wire diameter, mean coil
diameter, number of coils, solid length, and free length of both springs. (Start
with oil-tempered wire and assume a diametral clearance between the outer
D
spring and the cylinder of w , assume a similar clearance between springs.
2
Search for a suitable spring index and wire size.)
Solution:
For oil-tempered wire
Table AT 17
146
su 0.19 ksi , 0.032 Dw 0.5
Dw
87.5
Max. solid ss 0.19 ksi , 0.032 Dw 0.5
Dw
Severe service
0.263146 38.398
ssd 0.263su
ksi
Dw0.19
Dw0.19
F 235 lb 0.235 kip
o i
279
SECTION 4 - SPRINGS
8 Fo Co3 N co 8 Fi Ci3 N i
GDwo
GDwi
Assume, Co Ci
3GDwo
Fo
32C 3 N co
3GDwi
Fi
32C 3 N ci
8 Fo C
2
Dwo
sso K
8 Fi C
2
Dwi
D
D
C mo mi
Dwo Dwi
ssi K
4C 1 0.615
4C 4
C
Dmo Dwo
Dwi
Dmi Dwi
2
Dwo
Dmo Dwo
2
1.625
ksi
2
0.19
Dwo
Dwo
sso K
1.81
15.08 Dwo
Fo
KC
280
SECTION 4 - SPRINGS
8 Fi C
38.398
ksi
2
0.19
Dwi
Dwi
ssi K
Fi
1.81
15.08 Dwi
KC
Fo Fi F 0.235 kip
1.81
1.81
15.08 Dwo
15.08 Dwi
0.235
KC
KC
1.81
1.81
15.08Dwo
15.08 Dwi
0.235 KC
1.625
1.625 C 1
15.08
15.08
0.235KC
C 1.5
C 1.5
1.81
C
C 1.5 3.62
4C 4
C 1.5
C 5.328
1.625 5.328 1
Dwi
0.1509 in
5.328 1.5 2
1.625
Dwo
0.2380 in
5.328 1.5
Table AT 15, use Dwi 0.1620 in , No. 8 W & M and Dwo 0.2625 in , No. 2 W & M
13
Dmo CDwo 5.328 0.2625 1.3986 in 1
in
32
7
Dmi CDwi 5.328 0.1620 0.8631 in in
8
7
Dmi
8
Ci
5.401
Dwi 0.1620
1.81
1.81
Co
Dmo
Dwo
13
32
5.357
0.2625
1
1.81
15.08 Dwo
Fo
K o Co
4 5.357 1 0.615
Ko
1.287
4 5.357 1 5.357
15.08 0.2625
1.287 5.357
1.81
Fo
0.194 kip
1.81
15.08 Dwi
K i Ci
4 5.401 1 0.615
Ki
1.2843
4 5.401 1 5.401
Fi
281
SECTION 4 - SPRINGS
Fi
15.08 0.1620
0.081 kip
1.2843 5.401
3GDwo
32C 3 N co
311,500 0.2625
0.194
3
32 5.357 N co
Fo
N co 9.5
3GDwi
32C 3 N ci
311,500 0.1620
0.071
3
32 5.401 N ci
Fi
N ci 15.6
87.5
ksi ,
Dw0.19
87.5
112 .82 ksi
0.2625 0.19
87.5
123.65 ksi
0.1620 0.19
ssso
sssi
Stress
38.398
54.26 ksi
0.1620 0.19
38.398
49.51 ksi
0.2625 0.19
ssi
sso
Solid stress
1
sso 49.51
66.01 ksi 112 .82 ksi
0.75
1
ssi 54.26
72.35 ksi 123.65 ksi
0.75
Solid length
282
SECTION 4 - SPRINGS
Total coils = 9.5 + 1.93 = 11.43
Free Length = 3 in + 1 in = 4 in
Summary of answer:
Outside wire.
Solid length = 3 in
Free length = 4 in
Inside wire.
Solid length = 3 in
Free length = 4 in
298.
Two concentric, helical compression springs are used on a freight car. The larger
spring has an outside diameter of 7 in., a free length of 7 1/8 in., and is made
of a 1 in. steel bar. The smaller has an outside diameter of 4 1/8 in., a free
length of 6 13/16 in. , and is made of 7/8 in. steel bar. The solid height of each
spring is 5 in. and the forces required to compress them solid are 15,530 lb.
and 7,000 lb., respectively. The working load on the two springs is 11,350 lb.
Determine (a) the number of free coils in each spring, (b) the stress in each
spring when compressed solid, (c) the stresses induced by the working load.
Notice that the outer spring deflects 5/16 in. before the inner one takes a load.
(d) What energy is absorbed while changing deflection from that at the
working load to that when the springs are compressed solid?
Solution:
ODo 7 in
3
Dwo 1 in
8
1
FLo 7 in
8
1
ODi 4 in
8
7
Dwi in
8
283
SECTION 4 - SPRINGS
FLi 6
13
in
16
1
in
4
5.25
3.82
1.375
5.25
N Ti
6
0.875
N To
(b) Fo 15,530 lb
Fi 7000 lb
8 FC
2
Dw
3
Dmo 7 1 5.625 in
8
D
5.625
Co mo
4.091
Dwo 1.375
4 4.091 1 0.615
Ko
1.393
4 4.091 4 4.091
1 7
Dmi 4 3.25 in
8 8
D
3.25
Ci mi
3.714
Dwi 0.875
4 3.714 1 0.615
Ki
1.442
4 3.714 4 3.714
ss K
Solid stress
815,530 4.091
119 ,203 psi
1.375 2
sso 1.393
8 7000 3.714
124,689 psi
0.875 2
s si 1.442
ko
ko
15,530
8283 lb in
1
1
7 5
8
4
7000
4480 lb in
13
1
6 5
16
4
284
SECTION 4 - SPRINGS
5
0.3125 in
16
Fi ki i 4480 i
o i
Fo ko o 8283 0.3125 i
Fi Fo ko o 4480 i 8283 0.3125 i 11,350 lb
i 0.6865 in
o 0.3125 0.6865 0.9990 in
Fi 4480 0.6865 3076 lb
Fo 8283 0.9990 8275 lb
Stresses
8 8275 4.091
sso 1.393
63,516 psi
1.375 2
8 3076 3.714
ssi 1.442
54,792 psi
0.875 2
(d) Energy
1
k o o22 o21
2
1
1
o 2 7 5 1.875 in
8
4
o1 0.9990 in
1
2
2
U so 8283 1.875 0.999 10,427 in lb
2
1
U si ki i22 i21
2
13
1
i 2 6 5 1.5625 in
16
4
o1 0.6865 in
1
2
2
U si 4480 1.5625 0.6865 4,413 in lb
2
U so
TORSION-BAR SPRINGS
299.
SECTION 4 - SPRINGS
D d 3.
(c) The same as (b) except that the bar is shot-peened all over. What
other steps may be taken to improve the fatigue strength?
e 10 in
su 215 ksi
s ys 0.6 s y 115 .2 ksi 115,200 psi
16T
(a) ss d 3
T Fe 1.31500 10 19,500 in lb
115,200
1619,500
d3
d 0.95 in
use d 1 in
6.3
ss
117 117
117 ksi s ys
Dw0.3 1 0.3
Figure AF 12,
K t 1.45
r d 0.1 , D d 3
K f K t 1.45
1
1500 1200 1350 lb
2
Tm 135010 13,500 in lb 13.5 in kips
Fm
286
SECTION 4 - SPRINGS
sms
1613.5
68.8 ksi
3
1
1
1500 1200 150 lb
2
Ta 150 10 1500 in lb 1.5 in kips
Fa
161.5
7.64 ksi
3
1
1
68.8 1.45 7.64
N 115 .2
64.5
N 1.30
sas
(c) Shot-peened
N
144
80.6
N 1.625
300.
A solid steel torsion bar is loaded through a 10 in. arm as shown. The load F
perpendicular to the center-line of the arm varies from 500 to 1000 lb.,
200,000 cycles. The bar is d
7
in. in diameter and 30 in. long; let D d 3
8
; r d 0.1 ; (a) Determine the maximum stress in the bar, the angular
deflection, and the scale (lb./in.) where F is applied. The support is such that
bending of the bar is negligible. (b) Select a material and heat treatment for
this bar for a minimum N 1.2 , Soderberg criterion.
1
1000 500 750 lb
2
287
SECTION 4 - SPRINGS
1
1000 500 250 lb
2
Tm 750 10 7500 in lb 7.5 in kips
Fa
Kf
1.45
16T
ss
d3
16 7.5
sms
57 ksi
3
7
8
16 2.5
sas
19 ksi
3
7
8
JG d 4G
64 500 10 30
min
0.4533 rad
4
7
6
11.5 10
8
641000 10 30
max
0.9066 rad
4
7
6
11.5 10
8
F
1000
scale
110 .3 lb in
e 0.9066 10
(c)
sns
s ys
K f sas
1
s
ms
N s ys
sns
10 6
0.6 0.5 su
200,000
0.6 s y
0.085
0.344 su
1.3319
1
57
1.2 0.6 s y
0.344 su
su 220 ksi
N 1.24
288
SECTION 4 - SPRINGS
301.
Solution:
For oil-tempered wire,
146
su 0.19 , 0.032 Dw 0.5
Dw
Max. solid ss 0.6 su
(a) average service,
b Dw , t b
K FDm 3b 1.8t
2.4 FDm
ss q
Kq
2 2
2b t
b3
s sd 0.324 su , average service
Kq
2b 3
b 0.19
F 0.325 kip
Dm 1
1
in
2
K q 1.25
1.25
(assumed)
2.4 0.3251.5
0.324146
b
b 0.19
b 0.2902 in
2.45 FDm3 N c
2.45 FDm3 N c
(b) 3
Gt b 0.56t
0.44Gb 4
13 2.45 0.3251.5 N c
32 0.4411,500 0.313 4
3
N c 7.34
289
SECTION 4 - SPRINGS
Free length = PN c 2b
F 0.325 lb
2.4 0.3251.5
2.4 FDm
1
.
275
48.65 ksi
b
0.313 3
0.6146
109.2 ksi
solid stress =
0.313 0.19
ss Kq
solid deflection =
P b N c 0.91
109.2 13
0.91 in
48.65 32
use P
7
in
16
27
7
in
7.34 2 0.313 3.837 in 3
32
16
Free length = PN c 2b
7
P
16
tan
Dm 1.5
5.3 10
1 2 1
1
13
k F 0.325
0.066 in kip 66 in lb
2
2
2
32
66
Us
0.085 Btu
778
(d) U s
302.
A coil spring, of hard-drawn carbon steel, is to deflect 1 in. under a load of 100 lb.
The outside coil diameter is to be 1 in. Compute the number of active coils,
(a) if the wire is round, 5/32 in. in diameter, (b) if the wire is square, 5/32 in.
on the side, (c) if the wire is rectangular 1/8 x 3/16 in., long dimension parallel
to the axis, (d) If the wire is rectangular 3/16 x 1/8 in., short dimension
parallel to the axis. (e) What is the maximum stress in each of the above
springs under the 100-lb load? (f) What is the ratio of the approximate
volumes, square- or rectangular-wire to round wire spring?
Solution:
Dm Dw 1 in
5
in
(a) Dw
32
5
27
Dm 1
in
32 32
290
SECTION 4 - SPRINGS
27
Dm 32
C
5.4
Dw 5
32
8 FC 3 N c
GDw
8100 5.4 N c
1
5
11.5 106
32
3
N c 14.3
5
in
32
5
27
Dm 1
in
32 32
(b) Square, b
2.45 FD m3 N c
0.44Gb 4
27
2.45100
32
Nc
4
32
0.44 11.5 10 6
N c 20.5
3
1
in , t in
16
8
1 7
Dm 1 t 1 in
8 8
(c) b
2.45FD m3 N c
Gt 3 b 0.56t
3
7
2.45100 N c
8
1
3
1 3
1
11.5 10 6
0.56
8 16
8
N c 16.1
1
3
in , t
in
8
16
3 13
Dm 1 t 1
in
16 16
(d) b
2.45FD m3 N c
Gt 3 b 0.56t
291
SECTION 4 - SPRINGS
3
13
2.45100
Nc
16
1
3
3 1
3
6
11.5 10
0.56
16 8
16
N c 11.5
1.284
4 5.4 4
5.4
For (a) ss K
s s 1.284
8100 5.4
32
For (b) ss K q
72,320 psi
FD m 3b 1.8t
2.4 FD m
Kq
2 2
2b t
b3
27
Dm 32
C
5.4
b
5
32
K q 1.25
27
32 66,355 psi
3
32
2.4100
ss 1.25
For (c) ss K q
FD m 3b 1.8t
2b 2t 2
7
Dm 8
C
7
t
1
8
K q 1.1
7
100
8
ss 1.1
2
3 1
2
16 8
16
8
292
SECTION 4 - SPRINGS
For (d) ss K q
FD m 3b 1.8t
2b 2t 2
13
Dm 16
C
4.33
t
3
16
K q 1.2
100
ss 1.2
1
2
8
13
16
3
16
8
16
5
Va
4 32
27
3
14.3 0.727 in
32
5 27
3
20.5 1.327 in
32
32
Vb
Vc
7
3
8 16.1 1.037 in
Vd
Ratio of volume
Square to round wire
V
1.327
b
1.825
Va 0.727
Rectangular to round wire (long dimension parallel to the axis)
V
1.037
c
1.426
Va 0.727
Rectangular to round wire (short dimension parallel to the axis)
293
SECTION 4 - SPRINGS
Vd 0.688
0.946
Va 0.727
TENSION SPRINGS
305.
Design two tension springs for a spring balance with a capacity of 200 lb. Each
spring supports a maximum load of 100 lb. The outside diameter must not
exceed 1 in. and the total length including end loops must not exceed 9
in. Select a material and determine the dimension, including wire diameter,
number of coils, and free length.
Solution:
Table AT 17, assume oil tempered wire
146
su 0.19 ksi
Dw
87.5
s ys 0.19 ksi
Dw
0.8 87.5
70
ssd
0.19 ksi , 0.032 Dw 0.5
0.19
Dw
Dw
F Fi k
8 K cFDm
Dw3
2r
D
C m m
Dw Dw
ss
8 Fa C 3 N c
G Dw
G Dw
8C 3 N
G Dw
k
3
8C N
k
8Fa C 3 N c
Fa
GD
w
8 K cFi Dm 8 K cFa Dm
Dw3
Dw3
8 K cFa C
ss K csi
Dw2
ss
OD Dm Dw 1.25 in
294
SECTION 4 - SPRINGS
Dw
1.25
C 1
70
81.2 0.1 C
1.2 18
0.19
Dw
Dw2
70 C 1
1.25 0.19
0.19
67.1 C 1
67.1 C 1
21.6
0.19
0.19
81.2 0.1 C C 1
1.25 2
21.6 0.1956C C 1
0.1956C C 1 21.6
2
C 6.7
1.25
1.25
Dw
0.1623 in
C 1 6.7 1
Dm
1.0
6.17
Dw 0.1620
si 17.7 ksi
70
98.92 ksi 89.20 ksi , o.k.
0.1620 0.19
Total length = Dw N c 2 Dm Dw
9.5 0.162 N c 21.0 0.162
N c 44.3 coils
Two helical tension springs are to be used in scales for weighing milk. The
capacity of the scales is 30 lb., each spring carries 15 lb. with a deflection of 3
9/16 in. The springs are made of No. 14, W & M steel wire, outside diameter,
29/32 in. (a) how many coils should each spring have? (b) What is the
maximum stress in the wire? What material should be used?
295
SECTION 4 - SPRINGS
Solution:
k 15 lb
9
in
16
Dm OD Dw
29
0.0800 0.82625 in
32
Dm 0.82625
10.328
Dw
0.0800
8 k C 3 N c
GDw
9
81510.328 N c
3
16 11 .5 10 6 0.080
3
N c 24.8
(b) F Fi k
s D3
Fi i w
8 Dm
6.21, C 10.328
si 11,272 psi
Fi
11,272 0.08 3
2.743 lb
8 0.82625
F 2.743 15 17.743 lb
79,476 psi
3
Dw3
0.080
s
79,476
s ys s
99,345 psi 99.345 ksi
0.8
0.8
Table AT 17, use Hard drawn wire
70
70
s ys 0.19
113 ksi 99.345 ksi
Dw
0.080 0.19
307.
SECTION 4 - SPRINGS
maximum values), (c) the stress caused by the 5 -lb load, (d) the maximum
stress. What material should be used? (e) What energy is absorbed from the
point where the load is the initial tension until the springs length is 6 5/16 in.?
(Data courtesy Worthington Corporation.)
Solution:
Dw 0.078 in
Dm Dw 0.609 in
Dm 0.609 0.078 0.687 in
Dm 0.687
8.8
Dw 0.078
N c 55
8 FC 3 N c
GDw
1
lb
2
5
9
6 5
0.75 in
16
16
F 5
0.75
8 k 8.8 5
11.5 106 0.078
3
k 2.244 lb
12,000 psi
(b) si
2
Dw2
0.078
6.21, C 8.8
si 13,300 psi 12,000 psi , ok
(c) F 5.5 lb
8 K c FC
ss
Dw2
C 8.8
Figure AF 15
K c 1.1
ss
2.992 lb in
0.75
F k
297
SECTION 4 - SPRINGS
9
5
9
5
3.75 in
16
16
8 K c FC 81.114.476 8.8
58,651 psi
2
Dw2
0.078
Table AT 16
s
58,651
s ys s
73,300 psi 73.3 ksi
0 .8
0.8
Table AT 17, use Hard drawn wire
ss
s ys
70
70
(e) U s
1 2 1
2
k 2.992 0.75 0.8415 in lb
2
2
TORSION SPRINGS
308.
Solution:
T M Fa
F 55 lb
a 2 in
T M 55 2 110 in lb
Dm 2.5 in
Table AT 17, su
182
ksi , 0.093 Dw 0.25
Dw0.1
Average service
182
117 .936
117 ,936
sd 1.6 0.405 su 0.648
ksi
psi
0.1
0.1
Dw
Dw0.1
Dw
(a) ss
KMc
I
c
32
298
SECTION 4 - SPRINGS
ss
1.08110 32 117,936
Dw3
Dw0.1
Dw 0.2060 in 0.25 in
9.66 9 , ok
To check:
c Dw 0.2070
Table AT 18, K 1.08
1.08110 32 136,430 psi
ss
3
0.2070
117 ,936
138,054 psi 136,430 psi
0.2070 0.1
Therefore, use No. 5 W & M, Dw 0.2070 in
ssd
(b)
MDm N c
EI
E 30 106 psi
Dw4
64
180
64 MDm N c
EDw4
64110 2 N c
30 106 0.2070 4
N c 12.29
1
2
(c) U s T
312.
1
110 172.8 in lb
2
A pivoted roller follower is held in contact with the cam by a torsion spring. The
moment exerted by the spring varies from 20 lb-in to 50 lb-in. as the follower
oscillates through 30o. The spring is made of AISI 6152 steel, OQT 1000 oF.
What should be the value of Dw , Dm , and N c if the factor of safety is 1.75
based on the Soderberg line? Would this be a conservative or risky approach?
Solution:
AISI 6152, OQT 1000 oF
su 184 ksi
s y 173 ksi
sn 0.5su 92 ksi
1
M m 50 20 35 lb in
2
299
SECTION 4 - SPRINGS
1
50 20 15 lb in
2
assume K 1.08
Ma
32 KM m 321.08 35 385
3 psi
Dw3
Dw3
Dw
32 KM a 321.0815 165
sa
3 psi
Dw3
Dw3
Dw
sm
1 sm s a
N s y sn
1
385
165
3
1.75 173,000 Dw 92,000 Dw3
Dw 0.1916 in
1.75
173,000
92,000
K 1.0868
Table AT 18 K ci K 1.0868
r Dm
9.32 9 , ok
c Dw
MDm N c 64MDm N c
EI
EDw4
30 64 50 20 1.875 N c
180
30 106 0.1920 4
N c 5.93
Summary of answer:
Dw 0.1920 in , No. 6 W & M
7
in
8
N c 5.93 , N 1.4 , therefore conservative.
Dm 1
300
SECTION 4 - SPRINGS
315.
A cantilever flat spring of uniform strength, Fig. 6.20, Text, is to absorb an energy
impact of 500 ft-lb. Let the thickness of the steel, AISI 1095, OQT 900 oF, be
in. and let the maximum stress be half of the yield strength. (a) Find the
width b of the spring at the widest point in terms of the length L .
Determine values of b for lengths of 36 in., 48 in., 60 in., and 72 in. (b)
Determine the deflection of the spring for each set of values found in (a).
Solution.
Fig. 6/20
6 FL
bh 2
6 FL3
Ebh3
AISI 1095, OQT 900 oF, s y 104 ksi , Table AT 9
sB
Us
1
F
2
s B bh 2
6L
s bh 2 L3
s B L2
6 B
3
Eh
6 L Ebh
F
Us
1 sB bh 2
2 6 L
s B L2
1 s 2 bhL
E
Eh 12
U s 500 ft lb 6000 in lb
6000
1
12
52,000 2 b
bL 1598 in 2
1
L
2
30 10 6
1598 in 2
L
301
SECTION 4 - SPRINGS
L 36 in , b
1598 in 2
44.4 in
36 in
L 48 in , b
1598 in 2
33.3 in
48 in
L 60 in , b
1598 in 2
26.6 in
60 in
L 72 in , b
1598 in 2
22.2 in
72 in
(b)
s B L2
Eh
L 36 in ,
L 48 in ,
L 60 in ,
L 72 in ,
317.
52,000 36 2
30 10 12
4.4928 in
52,000 48 2
30 10 12
7.9872 in
52,000 60 2
30 10 12
12.48 in
52,000 72 2
30 10 12
17.9712 in
One of the carbon contacts on a circuit breaker is mounted on the free end of a
phosphor-bronze beam ( 0.35 ). This beam has the shape of the beam
shown in Fig. 6.24, Text, with b 1 in. , b
h
9
1
in. , L 4 in. , and
16
2
1
in. When the contacts are closed, the beam deflects in. Compute
16
bh 2
bh 2
K1 FL3 1 2
K1WL3 1 2
3EI
6 EI
9
b 16
0.5625
b
1
Figure 6.25, K1 1.14
302
SECTION 4 - SPRINGS
3EI
E 16 10 6 psi (phosphor bronze)
as a beam, I
bh 3
12
4 K1 FL3 1 2
Ebh 3
3
4
1
16 106 1 16
F 8 lb
(b)
318.
6 FL 6 8 4.5
55,296 psi
2
bh 2
1
1
16
A cantilever leaf spring 26 in. long is to support a load of 175 lb. The construction
is similar to that shown in Fig. 6.22 (a), Text. The leaves are to be 2 in. wide,
3/16 in. thick; SAE 9255 steel, OQT 1000 oF; 107 cycles ( 6.26). (a) How
many leaves should be used if the surfaces are left as rolled? (b) The same as
(a) except that the leaves are machined and the surfaces are not decarburized.
(c) The same as (b), except that the surface is peened all over. (d) Which of
these springs absorbs the most energy? Compute for each: (e) What are the
load and deflection of the spring in (b) when the maximum stress is the
standard-test yields strength?
Solution:
Figure 6.22 (a)
6 FL
sA
bh 2
6 FL3
A
Ebh 3
b N1b
F 175 lb
b 2 in
3
h
in
16
L 26 in
s y 160 ksi
303
SECTION 4 - SPRINGS
3
in 0.1875 in
16
sd 83.75 ksi
sA
6 FL
bh 2
6175 26
23,000
3
N 1 2
16
N1 16.88
say N1 17
sA
6 FL
bh 2
62,800
6175 26
3
N 1 2
16
N1 6.2
say N1 7
sA
6 FL
bh 2
78,500
6175 26
3
16
N 1 2
N1 4.95
say N1 5
(d) U s
1
F
2
F 175 lb
304
SECTION 4 - SPRINGS
6 FL3
EN1bh 3
For (a) N1 17
6175 26
2.745 in
3
3
30 10 17 2
16
1
U s 175 2.745 240 in lb
2
For (b) N1 7
6175 26
6.666 in
3
3
30 10 7 2
16
1
U s 175 6.666 583 in lb
2
For (c) N1 5
6175 26
9.332 in
3
3
30 10 5 2
16
1
U s 175 9.332 817 in lb
2
2
bh
N1bh 2
6 F 26
160,000
7 2 3
16
load F 505 lb
sd
319.
6 505 26
3
30 10 7 2
16
6
19.24 in
The rear spring of an automobile has 9 leaves, each with an average thickness of
0.242 in. and a width of 2 in.; material is SAE 9261, OQT 1000 oF. The
length of the spring is 56 in. and the total weight on the spring is 1300 lb.
Assume the spring to have the form shown in Fig. 6.22 (b), Text. Determine
(a) the rate of the spring, (b) the maximum stress caused by the dead weight.
(c) What approximate repeated maximum force (0 to Fmax ) would cause
impending fatigue in 105 cycles, the number of applications of the maximum
305
SECTION 4 - SPRINGS
load expected during the ordinary life of a car? (If the leaves are cold rolled
to induce a residual compressive stress on the surfaces, the endurance limit as
su 2 should be conservative.)
Solution:
Figure 6.22 (b)
3FL
sA
2bh 2
3FL3
A
8 Ebh 3
F 1300 lb
h 0.242 in
N1 9
b 2 in
L 56 in
(a) Rate , k
F
8 Ebh 3
A
3L3
8 EN1bh 3 8 30 10 6 9 2 0.242
116 .21lb in
3
3L3
3 56
3
3FL
31300 56
103,590 psi
2
2
2 N1bh
2 9 2 0.242
(c) SAE 9261. OQT 1000 oF
(b) s A
su 192 ksi
192
sn
96 ksi
2
sA
3FL
2 N1bh 2
96,000
3F 56
2
2 9 2 0.242
F 1200 lb
321.
The front spring of an automobile is made similar to Fig. 6.23, Text. The average
thickness for each of the 6 leaves, 0.213 in.; material is SAE 9255, OQT 1000
o
F. The load caused by the weight of the car is 775 lb. (a) What stress is
caused by a force of twice the dead weight? (b) What load would stress the
spring to the yield strength?
Solution:
Figure 6.23
6 FL 3WL
3WL
s
2
2
bh
bh
N1bh 2
306
SECTION 4 - SPRINGS
W 775 lb , N1 6 , b 2 in , h 0.213 in
36 in
18 in
2
6 FL 3WL
3WL
2
2
bh
bh
N1bh 2
3W 18
160,000
6 2 0.213 2
s
W 1613 lb
- end -
307