Wayne Book

ME3180
Norton: Machine Design

Spring Design

Basic Spring Behavior

Some Types of Springs

Some Types of Springs (2)

Some Types of Springs (3)

Some Types of Springs (4)

High strength
High yield
Modulus may be low for energy storage
Cost
Temperature resistance (e.g. valve springs)
Corrosion resistance

Spring Materials: Wires

Properties of interest

Common Materials (partial list for wires)

The Curious Behavior as Diameter

Decreases

Working deflection

Solid or shut height

Assembled

Free

Lengths

Helical Compression Springs

Ground

Squared

Ground

Plain

End details affect active coils

End Treatment

Torsion
Direct shear
Stress concentration Kc
or Wahl factor Kw

Active turns Na
Spring deflection
results from torsion
under load
Spring stress including

4<C<12

Spring index C

Spring Definitions and Calculations

Stress Distribution

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

A problem for long

skinny springs
Rod inside is
sometimes used to
eliminate, but wear
and friction result
Depends on ratio Lf /D
Surge is another
problem that occurs
with excitiation near
the natural frequency

Buckling and Surge

of Compression Springs

Depends on set
Before set removed use Wahl factor
After set removed no stress concentration used

Yield strength for static loading

Properties of Spring Materials--Yield

Torsion is relevant loading- could use von

Mises stress
Materials testing specific to helical
compression springs is available, however
Correct for temp., reliability, environment

Fatigue Strength

Properties of Spring Materials--Fatigue

Temperature may require compensation

Corrosion
Reliability

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

Endurance Strength (steels) unlimited cycles

Properties of Spring Materials-Endurance

S-N and Modified Goodman Diagram

Design Choices

Manufacturability

Bend radius

Index C
Stiffness
Material
Lengths
Wire and coil diameter
Diameter
Number of turns
Forces
End treatment and
Reliable operation
constraint
Static factor of safety
Set
and
shot
peen
Fatigue factor of safety
Constraints (other)
Buckling and surge

Functionality

Requirements

Designing 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-Fi )
Spring hook is a source of
failure in bending and
torsion
No set is used
One coil not considered
active

Helical Extension Springs

Torsional stress:

Bending stress:

End Hook Stresses

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

Torsional Springs

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

Static design also important but details left to

example
Data available for springs with loading from zero
to some compresion value

Compression Spring Design--Fatigue

Goodman Chart for Example 13-4

Due 11/28/01
In text: 13-1, 13-13 (Must see web page for
starting values in design and problem
statement corrections)

Homework 10