FME461

Engineering Design II
Dr.Hussein Jama
Hussein.jama@uobi.ac.ke
Office 414

Lecture: Mon 8am -10am

Tutorial Tue 3pm - 5pm

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Spring design
 Types
 Factors in spring design
 Materials
 Torsional

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Types of Springs

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Types of spring cont.

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Types of springs cont.

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Types of springs cont.

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Spring Design
F  ky
kF/y

1 1 1 1
  
k series k1 k 2 k3
k parallel  k1  k 2  k3

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Factors in spring design
 High strength
 High yield
 Modulus may be low for energy storage
 Cost
 Environmental factors
 Temperature resistance (e.g. valve springs)
 Corrosion resistance

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Common materials for springs

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Influence of diameter on
ultimate stress

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 Influence of diameter on
ultimate stress cont.

Sut  Ad b
Sus  0.67Sut

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Design of helical compression
springs  Length nomenclature
 Free
 Assembled
 Solid or shut height
 Working deflection

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Stresses in Helical Spring

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Stresses in Helical springs
cont.
At the inside of the spring Substituting for

Gives

4<C<12
Defining the spring index

Therefore the stress is

Equation(1)

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Effect of curvature on Stress
 Equation (1) is based on the wire being
straight
 However the curvature increases the stress
on the inside of the wire
 For static stress the effect of curvature can
be neglected
 For fatigue the effect of curvature is important

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Effect of curvature cont.

Wahl factor

Bergstrasser
factor

The results of the two equations differ by less than 1%.

Bergstrasser factor is preferred due to simplicity

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Deflection
 The external work done on an elastic member
in deforming it is transformed into strain, or
potential, energy. If the member is deformed a
distance y, and if the force-deflection
relationship is linear, this energy is equal to
the product of the average force and the
deflection, or

 This equation is general in the sense that the

force F can also mean torque, or moment,
provided, that consistent units are used for k.
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Deflection cont..

 By substituting appropriate expressions for k,

strain-energy formulas for various simple
loadings may be obtained. For tension and
compression and for torsion,

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Deflection of a helical spring
 Using Castigliano’s theorem, strain energy is
equal to

 Substituting

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Deflection cont.
 Using the spring index

 Spring scale is

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Spring design – end treatment
 End details affect active coils
 Plain ends
 Squared ends
 Squared
 Ground

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Number of active coils

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Stability of a column

Euler Formula

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Stability of a spring
 We know a column will buckle when the load
is too large
 A compression coil spring will also buckle

 ycr is the deflection corresponding to onset of

instability

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Deflection cont.
Is called the effective slenderness ratio

Alpha = end condition constant

Lo is the spring length
D is the Coil diameter

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Instability cont.
 End constraint alpha given by

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Instability cont.
 For absolute stability

 For steels it turns out

 For square and ground ends

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Static design flow chart

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Flow chart cont.

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Recommended design
conditions

Figure of merit (fom)

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Materials for springs
 Yield strength for static loading
 Depends on set
 Before set removed use Wahl factor
 After set removed no stress concentration used

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Properties for 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

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Properties - 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

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 S-N and Modified Goodman

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Designing springs
Requirements Design Choices
 Functionality  Index C
 Stiffness  Material
 Lengths  Wire and coil
 Diameter diameter
 Forces
 Number of turns
 Reliable operation
 End treatment and
 Static factor of safety
constraint
 Fatigue factor of safety
 Buckling and surge  Set and shot peen
 Manufacturability Constraints (other)
• Bend radius
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Helical extension spring
 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-Fi )
 Spring hook is a source of
failure in bending and
torsion
 No set is used
 One coil not considered
active

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End stresses
Bending stress:
16 DF 4 F
 A  Kb  2
d 3
d
4C12  C1  1 2 R1
Kb  ; C1 
4C1 (C1  1) d

Torsional stress:

8DF
 B  K w2
d 3
4C2  1 2 R2
K w2  ; C2 
4C2  4 d
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Design for fatigue
 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

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Goodman curve

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A word about torsional springs
 The wire in a torsional spring is primarily in
bending
 Spring constant is rotary M=k
 Loading should act to wind up coil
 Design process resembles compression
springs

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Torsional

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Homework
 Read chapter 10 of Shigley

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