1

ME 452: Machine Design II

Solution to Homework Set 10

Problem 1 (Problem 10-3 Page 561)
A helical compression spring is wound using 2.5 mm diameter music wire. The spring has an outside
diameter of 31 mm with plain ground ends, and 14 total coils.

(a) What should the free length be to ensure that when the spring is compressed solid the torsional stress
does not exceed the yield strength, that is, that it is solid-safe?

(b) What force is needed to compress this spring to closure?
(c) Estimate the spring rate.
(d) Is there a possibility that the spring might buckle in service?

SOLUTION:
(a) The helical compression spring has 14 total coils; i.e.,
N
t
= 14
The number of active coils for plain and ground ends, from Table 10-1, page 521, can be written as
1 =
a t
N N
Therefore, the number of active coils is
14 1 13
a
N = =
The solid length for plain and ground ends, from Table 10-1, page 521, can be written as

s t
L d N =
Therefore, the solid length of the compression spring is

s
L = 2.5 14 35 mm =
The ultimate tensile strength for a spring material, see Equation (10-14), page 523, can be written as

ut m
A
S
d
=
For music wire, the intercept and the exponent, see Table 10-4, page 525, are

m
2211 MPa.mm A = and 0.145 m =
Therefore, the ultimate tensile strength for the spring material is

0.145
2211
1936 MPa
(2.5)
ut
S = =
No setting operation was discussed in the problem statements, so we will assume none was performed
on the spring. Therefore, the torsional yield strength of the music wire, see Table 10-6, page 526 and
Example (10-1), page 527, can be written as
2
0.45 =
sy ut
S S
Therefore, the torsional yield strength of the music wire is
0.45 1936 871.2 MPa
sy
S = =
The mean coil diameter of the spring, see Figure 10-1a, page 518 and Example (10-1), page 527 can be
written as

o
D D d =
Therefore, the mean coil diameter of the spring is

D 31 2.5 28.5 mm = =
The spring index, see Equation (10-1), page 519, can be written as

D
C =
d

Therefore, the spring index is

28.5
C 11.4
2.5
= =
The Bergstrasser factor, see Equation (10-5), page 519, is

4 2
4 3
B
C
K
C
+
=

Therefore, the Bergstrasser factor is
(4 11.4) 2
1.117
(4 11.4) 3
B
K
+
= =


The spring force corresponding to the torsional yield stress, see Example (10-1), page 527 and Equation
(10-7), page 520, can be written as

3
sy
B
d S
F =
8 K D

Note that this equation gives the force that will just yield the spring. It is a matter of user preference
whether there should be a factor of safety used here (Using S
sy
/n
s
instead of S
sy
) or not. Since the
problem does not specifically call for a factor of safety, none will be used. However, the book does
suggest (see Equation (10-21), page 528) that as a rule of thumb, the factor of safety at the solid height
should be greater than or equal to 1.2. To illustrate this recommendation, see the solution to the next
problem in this homework set. So, the spring force corresponding to the torsional yield stress (with no
factor of safety) is
3
(2.5) 871.2
167.9 N
8 1.117 28.5
F

= =


The spring rate, see Equation (10-9), page 520, can be written as

4
3
a
d G
k =
8 D N

3
where N
a
is the number of active coils. The modulus of rigidity for music wire with diameter d = 2.5
mm (0.0984 in), see Table 10-5, page 526, is

81 GPa = 81,000 MPa G =
Therefore, the spring rate for the helical compression spring is

4
3
(2.5) 81, 000
1.314 N/mm
8 (28.5) 13
k

= =


The deflection caused by the above spring force, see Example (10-1), page 527, can be written as

F
y
k
=
Therefore, the deflection of the spring is

167.9
127.8 mm
1.314
y = =
The free length, see Example (10-1), page 527, can be written as

0 s
L y L = +
Therefore, the free length of the spring is
0
127.8 35 162.8 mm L = + =
(b) The force required to compress the spring to closure (i.e., the solid height or shut length) is the force
calculated in part (a). The force required to compress the spring to closure is
167.9 N F =
(c) The spring rate of the helical spring was obtained; in part (a); i.e., the spring rate is
1.314 N/mm k =
(d) The condition to avoid buckling, see Equation (10-13), page 523, can be written as

0
2.63
D
L

<
where the end-condition constant, see Table 10-2, page 522, assuming both ends are fixed, is
0.5 =
Therefore, the condition to avoid buckling is

0
28.5
2.63 149.9 mm
0.5
L < =
The free length of the spring obtained in part (a) is L
0
= 162.8 mm, which does not satisfy the above
condition. Therefore, this helical compression spring may buckle in service, depending on the
deflection amount. Equation (10-10), page 522 can be used to calculate the critical deflection at which
the spring buckles:

2
0 1 2
1 1
cr
eff
C
y L C

= (
(


Where
4

1
2( )
E
C
E G
=

2
2
2 ( )
2
E G
C
G E

=
+

and

0
eff
L
D

=
From Table (10-5), page 526, E = 196.5 GPa, and G = 81 GPa. Therefore

1
196.5
0.851
2(196.5 81)
C = =

2
2
2 (196.5 81)
6.359
2(81) 196.5
C

= =
+

0.5(162.8)
2.856
28.5
eff
= =

Therefore the critical buckling deflection is

2
6.359
(162.8)(0.851) 1 1 73.49 mm
2.856
cr
y
(
= =
(


The spring is predicted to buckle when the spring deflection reaches 73.49 mm of deflection, which
represents more than half of y, the deflection required to make the spring solid. Depending on the
application, this could be a problem with this spring design.

Problem 2 (Problem 10-26, page 563)
A compression spring is needed to fit over a 0.5 inch diameter rod. To allow for some clearance, the
inside diameter of the spring is to be 0.6 inches. To ensure a reasonable coil, use a spring index of 10.
The spring is to be used in a machine by compressing it (the spring, not the machine) from a free length
of 5 inches through a stroke of 3 inches to its solid length. The spring should have squared and ground
ends, should be unpeened, and is to be mad from cold-drawn wire.

(a) Determine a suitable wire diameter.
(b) Determine a suitable total number of coils.
(c) Determine the spring constant.
(d) Determine the yield factor of safety when compressed to solid length.
(e) Determine the fatigue factor of safety when repeatedly cycled from free length to solid length.

SOLUTION:

(a) The wire diameter can be determined from the given geometry information. From Figure (10-1),
page 518:
5

i
D D d = +
And from equation (10-1), page 219, the spring index is defined as:

D
C
d
=
Combining these two equations, eliminating D and solving for the wire diameter, d

0.6
0.06667 in
1 10 1
i
D
d
C
= = =


Then also, 10(0.06667) 0.6667 in D Cd = = =
(b) From Table (10-1), page 521, the solid length is
/ 2 / 0.06667 30 coils
t s
N L d = = =
(c) For squared and ground ends, from the same table,
2 30 2 28 coils
a t
N N = = =
Note that this spring design exceeds the recommended maximum number of coils (15) given by equation
(10-19), page 528.

Since Hard-Drawn means the same thing as Cold Drawn, then from table (10-5), page 526,

11.5 GPa G =
And from equation (10-9), page 520, the spring rate is


4 4 6
3 3
(0.06667) (11.5 10 )
3.423 lb/in
8 8(0.6667) (28)
a
d G
K
D N

= = =
(d) From Table (10-4), page 526, for hard-dawn (same as cold drawn) material:

140 kpsi in 0.190
m
A m = = i
So from Equation (10-14), page 523

0.190
140
234.2 kpsi
(0.06667)
ut m
A
S
d
= = =
Assuming the spring has not been set, then the shear yield strength can be calculated from parameters in
Table (10-6) on page 526. Note carefully the instructions in the table. Note that the words Before Set
Removed really mean the spring has not been set, and therefore the Percent Tensile Strength factor
should be 0.45 for Cold Drawn steel wire. Note also that the Bergstrasser factor, K
B
should be used in
calculating the shear stress. (If the spring were set, then the Percent Tensile Strength factor should be
0.65, and the direct shear factor K
S
should be used to calculate the shear stress.) Note also that
Samonovs approximation given by equation (10-16), page 525 is in between these more accurate values
given in Table (10-6). So the shear yield strength is:

0.45 0.45(234.2) 105.4 kpsi
sy ut
S S = = =
And the Bergstrasser factor, K
B
is
6

4 2 4(10) 2
1.135
4 3 4(10) 3
B
C
K
C
+ +
= = =


The maximum force on the spring, at the solid height, is

max max
3.423(3) 10.269 lb F Ky = = =
So the maximum shear stress is given by equation (10-7), page 520,


max
max 3 3
8 (8)(10.269)(0.6667)
1.135 66, 780 psi
(0.06667)
B
F D
K
d

= = =
Then the yield factor of safety, see Example (10-2), page 530, is


max
105, 400
1.58
66, 780
sy
y
S
n

= = =
(e) For the fatigue factor of safety, Zimmerlis data will be used. See section (10-9) beginning on page
539, and Example (10-4) on page 537. Since the material is not peened, the fatigue data is given in
equation (10-28):

35 kpsi 55 kpsi
sa sm
S S = =
From Equation (10-30), page 537,

0.67 0.67(234.2) 156.9 kpsi
su ut
S S = = =
Since our spring is to be cycles from its free length, where F
min
= 0, to its solid length, where F
max
=
10,269 lb, then from equation (10-31), page 537:


max
/ 2 10.269 / 2 5.135 lb
m a
F F F = = = =
Therefore

max
/ 2 66, 780 / 2 33, 390 psi
m a
= = = =
There are three commonly used fatigue failure theories for springs. All three use Zimmerlis failure
data, and extrapolate shear endurance limits for zero midrange from his data. The figure (next page)
show this idea. Shown in the figure is the Simmerli data point, and the failure theory lines generated
from it. Also shown is the data point corresponding to the spring design.


,
35 kpsi
se Sines sa
S S = =

,
35
53.89 kpsi
1 / 1 55 / 156.9
sa
se Goodman
sm su
S
S
S S
= = =


, 2 2
35
39.90 kpsi
1 ( / ) 1 (55 / 156.9)
sa
se Gerber
sm su
S
S
S S
= = =



So the fatigue factors of safety are

,
,
35
1.05
33.39
se Sines
f Sines
a
S
n

= = =
7

,
,
1 1
1.2
33.39 33.39
156.9 53.89
f Goodman
m a
su se Goodman
n
S S

= = =
+ +


2 2
,
,
,
2
1
1 1
2
m se Gerber
su a
y Gerber
m se Gerber su a
S
S
n
S S

(
| |
| | | |
(
= + +
|
| |
|
(
\ \
\


2
2
,
1 156.9 33.39 2(33.39)(39.9)
1 1 1.13
2 33.39 39.9 (156.9)(33.39)
y Gerber
n
(
| |
| | | |
(
= + + =
| | |
(
\ \
\



Notice that Sines model is the most conservative, at 1.05, Gerber is next at 1.13, and Goodman is leas
conservative at 1.2. These results are consistent with the observations of the respective plots in the
figure below.

Note also that although the S
se
values vary greatly on the plot, the factors of safety are all very similar.
Note also that this load line has a slope of 1, which is the steepest load line possible for helical
compression springs. All other spring designs are to the right of (or on) the load line shown below,
because the lowest F
min
possible for a compression spring is zero.




0
10
20
30
40
50
60
0 50 100 150 200
A
l
t
e
r
n
a
t
i
n
g

S
h
e
a
r

S
t
r
e
s
s
,

p
s
i
Midrange Shear Stress, psi
Comparison of Three Fatigue Failure Theories For Springs
Goodman
Gerber
Sines
LoadLine
DESIGN
Zimmerli's data
S
se,Goodman
S
se,Gerber
S
se,Sines
8
Problem 3 (Problem 10-30, page 564)
A helical coil compression spring is needed for food service machinery. The load varies from a
minimum of 4 lb to a maximum of 18 lb. The spring rate K is to be 9.5 lb/in. The outside diameter of
the spring cannot exceed 2.5 inches. The spring maker has available suitable dies for drawing wire in
the following diameters: 0.0800, 0.0915, 0.1005, and 0.1205 inches. Using a fatigue design factor of
1.5 and the Gerber-Simmerli fatigue failure criterion, design a suitable spring.

SOLUTION:

The problem does not specify a material for the spring. Because the application is food-services, it is
desirable to use a material that will not easily rust. Therefore, we will select A313 stainless steel as the
spring material. The modulus of rigidity for A313 Stainless steel wire, see Table 10-5, page 526, is

10 Mpsi G =
The ultimate tensile strength, see Equation (10-14), page 523, can be written as

ut m
A
S
d
=
Because wire diameter is unknown in the problem, we will need to iterate the solutions. We will show
the solution for one of the available wire diameters, then show the results when the other 3 wire sizes are
used. We will first solve the problem for a wire diameter of 0.080 in d = . The intercept and the
exponent, for A313 stainless steel wire with diameter 0.080 in d = , see Table 10-4, page 525, are


m
169 kpsi.in A = and 0.146 m =
Therefore, the ultimate tensile strength for the spring material is

0.146
169
244.4 kpsi
(0.080)
ut
S = =
The torsional modulus of rupture, see Equation (10-30), page 537, can be written as
0.67
su ut
S S =
Therefore, the torsional modulus of rupture is
0.67 244.4 163.7 kpsi
su
S = =
Assuming there is no setting operation for the spring, the torsional yield strength of A313 stainless steel
wire, see Table 10-6, page 526 can be written as
0.35 =
sy ut
S S
Therefore, the torsional yield strength of the A313 stainless steel wire is
0.35 244.4 85.5 kpsi
sy
S = =
The alternating component of the load, see Equation (10-31a), page 537, can be written as

max min
2
a
F F
F

=
Therefore, the alternating component of the load is
9
18 4
7 lb
2
a
F

= =
The mean (or mid-range) component of the load, see Equation (10-31b), page 537, can be written as

max min
2
m
F F
F
+
=
Therefore, the mean component of the load is

18 4
11 lb
2
m
F
+
= =
Assume that the spring is not peened. Then from Equation (10-28), page 536, the alternating component
of the torsional endurance strength is
35 kpsi
sa
S =
The mean component of the torsional endurance strength, see Equation (10-28), page 536, is
55 kpsi
sm
S =
Because of its accuracy, we will use the Gerber Fatigue Failure criteria on this problem. The torsional
endurance strength using the Gerber criterion, see Example (10-4), page 537 can be written as

2
1 ( / )
sa
se
sm su
S
S
S S
=

Therefore, the torsional endurance strength can be written as

2
35
39.5 kpsi
1 (55/163.7)
se
S = =

The Gerber fatigue-failure criteria is given by equation (6-47) page 306. Adapted here for shear stresses
is becomes:


2
1
f a f m
se su
n n
S S
| |
+ =
|
\


Where the shear stresses can be represented in terms of C and d as follows:


2 2
8 8 4 2 4 2
4 3 4 3
a m
a m
F C F C C C
C d C d


+ + | | | |
= =
| |

\ \


Combining these three equations and solving iteratively for C gives the solution C = 6.978.
Then the mean coil diameter, see Equation (10-1), page 519 can be written as
= D C d
Therefore, the mean coil diameter is
6.978 0.080 0.5582 in D = =
10
The Bergstrasser factor, see Equation (10-5), page 519 can be written as

4 2
4 3
B
C
K
C
+
=

Therefore, the Bergstrasser factor is
(4 6.97) 2
1.201
(4 6.97) 3
B
K
+
= =


The alternating component of the shear stress, see Equation (10-32), page 537, can be written as

3
8
a
a B
F D
K
d

=
Therefore, the alternating component of the shear stress is
3
8 7 0.558
1.201 23.3 kpsi
(0.080)
a

= =

The number of active coils, see Example (10-5), page 539 and Equation (10-9), page 520, is given by

4
3
8
a
d G
N
D k
=
Therefore, the number of active coils is given as

4 6
3
(0.080) (10 10 )
31.0
8 (0.558) 9.5
a
N

= =


Assuming squared and ground ends, the total number of coils from Table 10-1, page 521, is

2
t a
N N = +
Therefore, the total number of coils is
31.0 2 33.0
t
N = + =
The solid length of the spring, for squared and ground ends, see Table 10-1, page 521, can be written as

s t
L dN =
Therefore, the solid length of the spring is
0.080 33.0 2.638 in
s
L = =
We assume a robust linearity factor (fractional overrun to closure), 0.15 = (see page 528). Then the
spring deflection when the spring is compressed to its solid length, see Example (10-5), page 539, can be
written as

max max
(1 ) (1 )( / ) (1 0.15)(18 / 9.5) 2.179 in
s
y y F k = + = + = + =
The free length of the spring, see Example (10-5), page 539, can be written as

0 s s
L L y = +
Therefore, the free length of the spring is
11

0
2.638 2.179 4.817 in L = + =
The critical length to avoid buckling, see Example (10-5), page 539 and Equation (10-13), page 523, is

0
( ) 2.63
cr
D
L

=
The end-condition constant, see Table (10-2), page 522, assuming both ends of the spring are fixed, is
0.5 =
Therefore, the critical length to avoid buckling is
0
0.558
( ) 2.63 2.935 in
0.5
cr
L = =
Note that the chosen spring does has a free length of 5.561 in which is larger than the critical length.
Therefore, the chosen spring may buckle under service conditions. The shear stress when the spring is
compressed solid, see Example (10-5), page 539, can be written as

s
s a
a
F
F
=
The spring force required to compress the spring solid, see Example (10-5), page 539, can be written as

max
(1 )
s
F F = +
Therefore, the spring force required to compress the spring solid is
(1 0.15) 18 20.7 lb
s
F = + =
Therefore, the shear stress when the spring is compressed solid is

20.7
23.3 69.1 kpsi
7
s
= =
The factor of safety, see Example (10-5), page 539, can be written as

sy
s
s
S
n

=
Therefore, the factor of safety when the spring is compressed solid is

85.5
1.24
69.1
s
n = =
The fundamental frequency for fixed-fixed ends, see Equation (10-25), page 535 and Example (10-5),
page 539, can be written as

1
2
=
a
k g
f
W

The weight of the active part of the spring, see Equation (10-27), page 535, can be written as

2 2
4

=
a
a
d D N
W
For stainless steel, the specific weight, see Table A-5, page 1007 is
12

3
0.280 lb/in =
Therefore, the weight of the active part of the spring is
2 2
(0.080) 0.558 31.58 0.280
0.078 lb
4

= =
a
W
Therefore, the fundamental frequency is

1 9.333 386
107 Hz
2 0.078
f

= =
All the above steps which were carried out for a wire diameter of 0.080 in d = can be repeated for wire
diameters of 0.0915 in, 0.1055 in and 0.1205 in. This was accomplished with a simple spread sheet
calculation, using the goal-seek tool. The results are summarized in the Table below. Note that
different A and m parameters need to be used for the two larger wire sizes.


Wire Sizes available..
units 0.08 0.0915 0.1055 0.1205
d in 0.08 0.0915 0.1055 0.1205
m - 0.146 0.146 0.263 0.263
A kpsi 169 169 128 128
Sut kpsi 244.3631 239.6179 231.2568 223.3111
Ssu kpsi 163.7233 160.544 154.9421 149.6185
Ssy kpsi 85.52707 83.86626 80.93989 78.1589
C - 6.977244 9.613263 13.24391 17.70863
D in 0.55818 0.879614 1.397232 2.13389
KB - 1.200731 1.141032 1.100049 1.073709
Tau a kpsi 23.33394 23.35419 23.33252 23.34189
Tau m kpsi 36.66762 36.69944 36.66539 36.68011
n fatigue - 1.5 1.5 1.5 1.5
Na coils 30.99022 13.55174 5.975724 2.85508
Nt coils 32.99022 15.55174 7.975724 4.85508
Ls in 2.639218 1.422984 0.841439 0.585037
y solid in 2.178947 2.178947 2.178947 2.178947
Lo in 4.818165 3.601932 3.020386 2.763985
Lo crit in 2.936024 4.626767 7.349441 11.22426
Tau s kpsi 69.0018 69.06168 68.9976 69.0253
n solid - 1.239343 1.215267 1.173083 1.132323
freq hz 109.4807 115.3088 119.4937 122.4742

Table. Results for different wire diameters
The recommended design conditions, see Example (10-5), page 539, and Equations (10-18 to 10-21),
page 528, are
( )
0 0
4 12 , 3 15 , 1.2 ,
a s
cr
C N n L L
The bold blocks areas in the above table depict conditions outside the recommended design conditions.
Thus, only the spring with wire diameter 0.0915 in d = satisfies all design conditions.

13
Conclusion: An unpeened, stainless steel spring with squared and ground ends and a wire diameter of
0.0915 in d = will satisfy the given requirements. No setting operation is to be performed on the
spring.