ME-PC 321

MACHINE
DESIGN 1
ENGR. LOUIE A. LARIOSA

FACULTY – ME DEPARTMENT

CTU – MAIN CAMPUS

2. Tolerance and Allowances

3. Variable Stress analysis

4. Shaft design

5. Keys and coupling Design

6. Design of Threaded Member and Power Screws

7. Design of Mechanical Springs

9. Gears
ME-PC 321

MACHINE
DESIGN 1

DESIGN OF MECHANICAL
SPRINGS
 DESIGN OF MECHANICAL SPRINGS
Spring is an elastic body (generally metal) that can be twisted, pulled, or
stretched by some force.
It deflects when loaded (i.e., applied force ) and returns to its original
shape when the load is removed.
It is also termed as a resilient member, which stores energy once
deflected and release the same as it recovers to its original shape.
Materials for Springs: Oil-tempered spring wire, music wire, hard-drawn
spring wire, carbon steel, chrome-vanadium steel, chrome-silicon steel,
stainless steel.
Uses of Springs
1. To absorb energy or shock loads, as in automobile shock absorbers
2. To maintain contact between machine members, as in valves and
clutches
3. To act as source of energy, as in clocks
4. To serve as measuring device, as in springs scales
TYPES OF SPRINGS
TYPES OF ENDS OF COIL SPRINGS

Actual
Solid Free
number of
Length Length
coils
Plain n (n+1)d np+d
Plain & Ground n nd np
Squared n+2 (n+3)d np+3d
Square & Ground n+2 (n+2)d np+2d

Where:
𝑛 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑒𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑐𝑜𝑖𝑙𝑠
𝑝 = 𝑝𝑖𝑡𝑐ℎ
𝑑 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
 𝒄𝒐𝒊𝒍 𝒎𝒆𝒂𝒏 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓 𝑫𝒎
,𝑪 = =
𝒘𝒊𝒓𝒆 𝒅𝒊𝒂𝒎𝒆𝒕𝒆𝒓 𝒅
𝑭𝒐𝒓𝒄𝒆 𝑭
,𝒌 = =
𝒅𝒆𝒇𝒍𝒆𝒄𝒕𝒊𝒐𝒏 𝒚
SPRING RATE/SPRING SCALE

DEFLECTION,𝑦
F 𝑦 = 𝑦1 + 𝑦2 + 𝑦3 …(Series)
𝑦 = 𝑦1 = 𝑦2 = 𝑦3 + ⋯ (Parallel)

FORCE,𝐹
F 𝐹 = 𝐹1 = 𝐹2 = 𝐹3 … (Series)
𝐹 = 𝐹1 + 𝐹2 + 𝐹3 … (Parallel)
EXAMPLE 1: (𝑀𝐸 𝐵𝑑 𝑂𝑐𝑡 1997, 𝑂𝑐𝑡 2006)
𝐴 𝑡ℎ𝑟𝑒𝑒 𝑒𝑥𝑡𝑒𝑛𝑠𝑖𝑜𝑛 𝑐𝑜𝑖𝑙 𝑠𝑝𝑟𝑖𝑛𝑔𝑠 𝑎𝑟𝑒 ℎ𝑜𝑜𝑘𝑒𝑑 𝑖𝑛 𝑎 𝑠𝑒𝑟𝑖𝑒𝑠 𝑡ℎ𝑎𝑡 𝑠𝑢𝑝𝑝𝑜𝑟𝑡 𝑎 𝑠𝑖𝑛𝑔𝑙𝑒
𝑘𝑔
𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 100 𝑘𝑔𝑠. 𝑇ℎ𝑒 𝑓𝑖𝑟𝑠𝑡 𝑠𝑝𝑟𝑖𝑛𝑔 𝑖𝑠 𝑟𝑎𝑡𝑒𝑑 𝑎𝑡 0.400 𝑎𝑛𝑑 𝑡ℎ𝑒 𝑜𝑡ℎ𝑒𝑟 𝑡𝑤𝑜
𝑚𝑚
𝑘𝑔
𝑙𝑜𝑤𝑒𝑟 𝑖𝑠 𝑟𝑎𝑡𝑒𝑑 𝑎𝑡 0.64 . 𝐶𝑜𝑚𝑝𝑢𝑡𝑒 𝑡ℎ𝑒 𝑡𝑜𝑡𝑎𝑙 𝑑𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛 𝑖𝑛 𝑚𝑚.
𝑚𝑚

GIVEN: SOLUTION:
𝐹 = 𝐹1 = 𝐹2 = 𝐹3 = 100 𝑘𝑔 𝑦 = 𝑦1 + 𝑦2 + 𝑦3
𝑘𝑔
𝑘1 = 0.400
𝑚𝑚 Where:
𝑘𝑔 𝐹
𝑘2 = 𝑘3 = 0.64 𝑦=
𝑚𝑚 𝑘
REQUIRED: Thus,
𝑡𝑜𝑡𝑎𝑙 𝑑𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛, 𝑦 =? 𝐹 𝐹 𝐹
𝑦= + +
𝑘1 𝑘2 𝑘3
100 𝑘𝑔 100 𝑘𝑔 100 𝑘𝑔
𝑦= + +
𝑘𝑔 𝑘𝑔 𝑘𝑔
0.40 𝑚𝑚 0.64 𝑚𝑚 0.64 𝑚𝑚

𝒚 = 𝟓𝟔𝟐. 𝟓 𝒎𝒎
EXAMPLE 2: (𝑀𝐸 𝐵𝑑 𝑂𝑐𝑡 1998)
𝐴𝑙𝑙 𝑓𝑜𝑢𝑟 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛 𝑐𝑜𝑖𝑙 𝑠𝑝𝑟𝑖𝑛𝑔𝑠 𝑠𝑢𝑝𝑝𝑜𝑟𝑡 𝑜𝑛𝑒 𝑙𝑜𝑎𝑑 𝑜𝑓 400 𝑘𝑔. 𝐴𝑙𝑙 𝑓𝑜𝑢𝑟 𝑠𝑝𝑟𝑖𝑛𝑔𝑠
𝑘𝑔
𝑎𝑟𝑒 𝑎𝑟𝑟𝑎𝑛𝑔𝑒𝑑 𝑖𝑛 𝑝𝑎𝑟𝑎𝑙𝑙𝑒𝑙 𝑎𝑛𝑑 𝑟𝑎𝑡𝑒𝑑 𝑠𝑎𝑚𝑒 𝑎𝑡 0.709 .
𝑚𝑚
𝐶𝑜𝑚𝑝𝑢𝑡𝑒 𝑡ℎ𝑒 𝑡𝑜𝑡𝑎𝑙 𝑑𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛 𝑖𝑛 𝑚𝑚.

SOLUTION:
GIVEN:
𝑦 = 𝑦1 = 𝑦2 = 𝑦3 = 𝑦4
𝐹 = 400 𝑘𝑔
𝐹 400 𝑘𝑔
𝐹1 = 𝐹2 = 𝐹3 = 𝐹4 = = = 100 𝑘𝑔 Where:
4 4 𝐹
𝑘𝑔 𝑦=
𝑘1 = 𝑘2 = 𝑘3 = 𝑘4 = 0.709 𝑘
𝑚𝑚
Thus,
𝐹
𝑦=
REQUIRED: 𝑘1
𝑡𝑜𝑡𝑎𝑙 𝑑𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛, 𝑦 =? 100 𝑘𝑔
𝑦=
𝑘𝑔
0.709
𝑚𝑚

𝒚 = 𝟏𝟒𝟏. 𝟎𝟒 𝒎𝒎
 STRESSES AND DEFLECTION
OF COIL SPRING
TORSIONAL SHEAR STRESS IN THE WIRE,𝑆𝑠
8𝐾𝐹𝐷𝑚
𝑆𝑠 =
𝜋𝑑 3
Spring Factor,𝐾 IMPACT LOAD ON SPRING (FREE FALL), 𝑾

0.615 𝐹𝑦
𝐾 = 𝑊𝑓 + 𝑊(ℎ + 𝑦) = 𝒚
𝐶 Where:
2
Where: 𝑾
4𝐶 − 1 𝐹 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑓𝑜𝑟𝑐𝑒/𝑙𝑜𝑎𝑑 𝑜𝑛 𝑠𝑝𝑟𝑖𝑛𝑔
𝑊𝑎ℎ𝑙 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑊𝑓 = 𝐷𝑚 = 𝑠𝑝𝑟𝑖𝑛𝑔 𝑚𝑒𝑎𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
4𝐶 − 4
𝐷𝑜 + 𝐷𝑖
𝐷𝑚 = = 𝐷𝑜 − 𝑑 = 𝐷𝑖 + 𝑑
SPRING DEFLECTION,𝑦 2
𝑑 = 𝑠𝑝𝑟𝑖𝑛𝑔 𝑤𝑖𝑟𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟
8𝐹𝐶 3 𝑛 𝑛 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑎𝑐𝑡𝑖𝑣𝑒 𝑐𝑜𝑖𝑙𝑠
𝑦= 𝐺 = 𝑠ℎ𝑒𝑎𝑟 𝑚𝑜𝑑𝑢𝑙𝑢𝑠 𝑜𝑓 𝑒𝑙𝑎𝑠𝑡𝑖𝑐𝑖𝑡𝑦
𝐺𝑑
ℎ = ℎ𝑒𝑖𝑔ℎ𝑡
EXAMPLE 3: (𝑀𝐸 𝐵𝑜𝑎𝑟𝑑 𝑂𝑐𝑡𝑜𝑏𝑒𝑟 1997)
𝐴 ℎ𝑖𝑔ℎ 𝑎𝑙𝑙𝑜𝑦 16 − 𝑐𝑜𝑖𝑙 𝑠𝑝𝑟𝑖𝑛𝑔 ℎ𝑎𝑣𝑖𝑛𝑔 𝑠𝑞𝑢𝑎𝑟𝑒𝑑 𝑎𝑛𝑑 𝑔𝑟𝑜𝑢𝑛𝑑 𝑒𝑛𝑑𝑠 ℎ𝑎𝑠 𝑎 𝑚𝑜𝑑𝑢𝑙𝑢𝑠
𝑜𝑓 𝑒𝑙𝑎𝑠𝑡𝑖𝑐𝑖𝑡𝑦 𝑖𝑛 𝑠ℎ𝑒𝑎𝑟 𝑜𝑓 85 𝐺𝑃𝑎. 𝑇ℎ𝑒 𝑠𝑝𝑟𝑖𝑛𝑔 𝑜𝑢𝑡𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑖𝑠 9.66 𝑐𝑚 𝑎𝑛𝑑
𝑤𝑖𝑟𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑖𝑠 0.65 𝑐𝑚. 𝐶𝑜𝑚𝑝𝑢𝑡𝑒 𝑡ℎ𝑒 𝑊𝑎ℎ𝑙 𝑎𝑛𝑑 𝑠𝑝𝑟𝑖𝑛𝑔 𝑓𝑎𝑐𝑡𝑜𝑟.

GIVEN: SOLUTION:
Squared and ground ends 4𝐶 − 1
𝑊𝑓 =
𝑁 = 16 4𝐶 − 4 4𝐶 − 1 0.615 0.615
𝐺 = 84 𝐺𝑃𝑎 Where: 𝐾= + = 𝑊𝑓 +
4𝐶 − 4 𝐶 𝐶
𝐷𝑜 = 9.66 𝑚𝑚 𝐷𝑚 𝐷𝑜 − 𝑑 9.66 − 0.65
𝐶= = = = 13.86
𝑑 = 0.65 𝑚𝑚 𝑑 𝑑 0.65 0.615
𝐾 = 1.06 +
13.86
Thus,
REQUIRED: 4(13.86) − 1
𝑊𝑓 = 𝑲 = 𝟏. 𝟏𝟎
𝑊𝑎ℎ𝑙 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑊𝑓 =? 4(13.86) − 4
𝑆𝑝𝑟𝑖𝑛𝑔 𝑓𝑎𝑐𝑡𝑜𝑟, 𝐾 =?
𝑾𝒇 = 𝟏. 𝟎𝟔
EXAMPLE 4: (𝑀𝐸 𝐵𝑜𝑎𝑟𝑑 𝑂𝑐𝑡𝑜𝑏𝑒𝑟 1997)
𝐶𝑜𝑚𝑝𝑢𝑡𝑒 𝑡ℎ𝑒 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑑𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛 𝑖𝑛 𝑚𝑚 𝑜𝑓 𝑎 20 𝑐𝑜𝑖𝑙𝑠 ℎ𝑒𝑙𝑖𝑐𝑎𝑙 𝑠𝑝𝑟𝑖𝑛𝑔 ℎ𝑎𝑣𝑖𝑛𝑔 𝑎
𝑙𝑜𝑎𝑑 𝑜𝑓 75 𝑘𝑖𝑙𝑜𝑔𝑟𝑎𝑚𝑠. 𝑇ℎ𝑒 𝑠𝑝𝑟𝑖𝑛𝑔 𝑖𝑠 𝑎 𝑠𝑞𝑢𝑎𝑟𝑒𝑑 𝑎𝑛𝑑 𝑔𝑟𝑜𝑢𝑛𝑑 𝑒𝑛𝑑𝑠 𝑤𝑖𝑡ℎ 𝑚𝑜𝑑𝑢𝑙𝑢𝑠
𝑜𝑓 𝑒𝑙𝑎𝑠𝑡𝑖𝑐𝑖𝑡𝑦 𝑖𝑛 𝑠ℎ𝑒𝑎𝑟 𝑜𝑓 79.84 𝐺𝑃𝑎, 𝑜𝑢𝑡𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 101.6 𝑚𝑚 𝑎𝑛𝑑 𝑤𝑖𝑟𝑒
𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 9.525 𝑚𝑚.

GIVEN: SOLUTION:
Squared and ground ends 8𝐹𝐶 3 𝑛
𝑁 = 20 𝑦=
𝐺𝑑
𝐹 = 75 𝑘𝑔 = 735.75 𝑁 Where:
𝐺 = 79.84 𝐺𝑃𝑎 = 79,840 𝑀𝑃𝑎 𝐷𝑚 𝐷𝑜 − 𝑑 101.6 − 9.525
𝐶= = = = 9.67
𝐷𝑜 = 101.6 𝑚𝑚 𝑑 𝑑 9.525
𝑑 = 9.525 𝑚𝑚 𝑛 = 𝑁 − 2 = 20 − 2 = 18 (for square and ground ends)

REQUIRED: Thus,
𝑑𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛, 𝑦 =? 8 735.7 𝑁 9.67 3 (18)
𝑦=
𝑁
79,840 (9.525 𝑚𝑚)
𝑚𝑚2

𝒚 = 𝟏𝟐𝟓. 𝟗𝟕 𝒎𝒎
EXAMPLE 5: (𝑀𝐸 𝐵𝑜𝑎𝑟𝑑 𝑂𝑐𝑡𝑜𝑏𝑒𝑟 1998)
𝑙𝑏𝑠
𝐴 ℎ𝑒𝑙𝑖𝑐𝑎𝑙 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑜𝑛 𝑠𝑝𝑟𝑖𝑛𝑔 ℎ𝑎𝑠 𝑎 𝑠𝑐𝑎𝑙𝑒 𝑜𝑓 400 , 𝑎𝑛 𝑖𝑛𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 2.5 𝑖𝑛𝑐ℎ𝑒𝑠, 𝑎 𝑓𝑟𝑒𝑒 𝑙𝑒𝑛𝑔𝑡ℎ
𝑖𝑛𝑐ℎ
𝑜𝑓 8 𝑖𝑛𝑐ℎ𝑒𝑠 𝑎𝑛𝑑 𝑤𝑖𝑡ℎ 𝑠𝑞𝑢𝑎𝑟𝑒𝑑 𝑎𝑛𝑑 𝑔𝑟𝑜𝑢𝑛𝑑 𝑒𝑛𝑑𝑠. 𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑖𝑠 𝑡𝑜 𝑏𝑒 𝑐ℎ𝑟𝑜𝑚𝑒 𝑣𝑎𝑛𝑎𝑑𝑖𝑢𝑚 𝑠𝑡𝑒𝑒𝑙 . 𝐹𝑜𝑟 𝑎 𝑙𝑜𝑎𝑑 𝑜𝑓
𝐹 = 750 𝑙𝑏𝑠, 𝑠𝑝𝑟𝑖𝑛𝑔 𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 1.25, 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠 𝑜𝑓 57,296 𝑝𝑠𝑖 𝑎𝑛𝑑 𝐺 = 10,800 𝑘𝑠𝑖 , 𝑑𝑒𝑡𝑒𝑟𝑚𝑖𝑛𝑒:
𝑎. 𝑊𝑖𝑟𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑖𝑛 𝑖𝑛𝑐ℎ𝑒𝑠
𝑏 . 𝐴𝑐𝑡𝑢𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑜𝑖𝑙𝑠
𝑐 . 𝑆𝑜𝑙𝑖𝑑 ℎ𝑒𝑖𝑔ℎ𝑡 𝑖𝑛 𝑖𝑛𝑐ℎ𝑒𝑠
𝑑 . 𝑆𝑡𝑟𝑒𝑠𝑠 𝑎𝑡 𝑠𝑜𝑙𝑖𝑑 ℎ𝑒𝑖𝑔ℎ𝑡 𝑖𝑛 𝑝𝑠𝑖
SOLUTION: From:
GIVEN: From, 𝑆𝐿 = 𝑛 + 2 𝑑 = 7.8125 𝑖𝑛 + 2 0.5 𝑖𝑛
Squared and ground ends 8𝐾𝐹𝐷𝑚 8𝐾𝐹(𝐷𝑖 + 𝑑) 𝑺𝑳 = 𝟒. 𝟗𝟏 𝒊𝒏
𝑙𝑏𝑠 𝑆𝑠 = =
𝜋𝑑 3 𝜋𝑑 3 From:
𝑘 = 400 𝑙𝑏𝑠 8(1.25)(750 𝑙𝑏𝑠)(2.5 𝑖𝑛 + 𝑑) 8𝐾𝐹𝐷𝑚
𝑖𝑛𝑐ℎ 57,296 2 =
𝑖𝑛 𝜋𝑑 3 𝑆𝑠 =
𝐷𝑖 = 2.5 𝑖𝑛𝑐ℎ𝑒𝑠 𝒅 = 𝟎. 𝟓𝟎 𝒊𝒏 𝜋𝑑3
Where,
𝐹𝐿 = 8 𝑖𝑛𝑐ℎ𝑒𝑠 From:
𝐹𝑆𝐿 = 𝑘𝑦𝑚𝑎𝑥
𝐹 = 750 𝑙𝑏𝑠 8𝐹𝐶 3 𝑛
𝑦= Also,
𝐾 = 1.25 𝐺𝑑
Where: 𝑦𝑚𝑎𝑥 = 𝐹𝐿 − 𝑆𝐿 = 8 𝑖𝑛 − 4.91 𝑖𝑛
𝑆𝑠 = 57,296 𝑝𝑠𝑖 (𝑎𝑡 𝑙𝑜𝑎𝑑 𝐹 = 750 𝑙𝑏𝑠) 𝐹 750 𝑙𝑏𝑠 𝑦𝑚𝑎𝑥 = 3.09 𝑖𝑛
𝑦= = = 1.875 𝑖𝑛 Thus,
𝐺 = 10,800 𝑘𝑠𝑖 𝑘 400 𝑙𝑏𝑠Τ𝑖𝑛
𝐷𝑚 𝐷𝑖 + 𝑑 2.5 + 0.5 𝑙𝑏𝑠
𝐶= = = =6 𝐹𝑆𝐿 = 400 3.09 𝑖𝑛
REQUIRED: 𝑑 𝑑 0.5 𝑖𝑛
𝑎. 𝑊𝑖𝑟𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑 𝑖𝑛 𝑖𝑛𝑐ℎ𝑒𝑠 Thus, 𝐹𝑆𝐿 = 1,237.5 𝑙𝑏𝑠
𝑏. 𝐴𝑐𝑡𝑢𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑜𝑖𝑙𝑠, 𝑁 8 750 𝑙𝑏𝑠 63 𝑛 Therefore:
1.875 𝑖𝑛 = 8(1.25)(1,237.5 𝑙𝑏𝑠)(3 𝑖𝑛)
𝑐. 𝑆𝑜𝑙𝑖𝑑 ℎ𝑒𝑖𝑔ℎ𝑡 𝑖𝑛 𝑖𝑛𝑐ℎ𝑒𝑠, 𝑆𝐿 (10,800,000 𝑙𝑏𝑠Τ𝑖𝑛2 )(0.5 𝑖𝑛)
𝑑. 𝑆𝑡𝑟𝑒𝑠𝑠 𝑎𝑡 𝑠𝑜𝑙𝑖𝑑 ℎ𝑒𝑖𝑔ℎ𝑡 𝑖𝑛 𝑝𝑠𝑖, 𝑆𝑤
𝑆𝑠 =
𝑛 = 7.8125 𝜋(0.5 𝑖𝑛)3
𝑁 = 𝑛 + 2 = 7.8125 + 2 = 9.81 𝑺𝒔 = 𝟗𝟒, 𝟓𝟑𝟖. 𝟎𝟒 𝒑𝒔𝒊
𝑵 = 𝟗. 𝟖𝟏 𝒄𝒐𝒊𝒍𝒔
EXAMPLE 6:
𝐴 𝑑𝑢𝑚𝑏𝑤𝑎𝑖𝑡𝑒𝑟 𝑑𝑒𝑠𝑖𝑔𝑛𝑒𝑑 𝑡𝑜 𝑡𝑟𝑎𝑣𝑒𝑙 𝑎 ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 3 𝑚𝑒𝑡𝑒𝑟𝑠 𝑤ℎ𝑒𝑛 𝑙𝑜𝑎𝑑𝑒𝑑 𝑤𝑖𝑙𝑙 ℎ𝑎𝑣𝑒 𝑎 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑔𝑟𝑜𝑠𝑠 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 100 𝑘𝑔 .
𝐴 𝑐𝑜𝑖𝑙 𝑠𝑝𝑟𝑖𝑛𝑔 𝑖𝑠 𝑝𝑟𝑜𝑣𝑖𝑑𝑒𝑑 𝑏𝑒𝑙𝑜𝑤 𝑡𝑜 𝑎𝑏𝑠𝑜𝑟𝑏 𝑠ℎ𝑜𝑐𝑘 𝑖𝑛 𝑡ℎ𝑒 𝑒𝑣𝑒𝑛𝑡 𝑡ℎ𝑎𝑡 𝑡ℎ𝑒 𝑑𝑢𝑚𝑏𝑤𝑎𝑖𝑡𝑒𝑟 𝑠ℎ𝑜𝑢𝑙𝑑 𝑓𝑎𝑙𝑙 𝑓𝑟𝑒𝑒𝑙𝑦 𝑏𝑒𝑐𝑎𝑢𝑠𝑒 𝑜𝑓
𝑠𝑢𝑑𝑑𝑒𝑛 𝑏𝑟𝑒𝑎𝑘𝑎𝑔𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 𝑟𝑜𝑝𝑒 𝑐𝑎𝑟𝑟𝑦𝑖𝑛𝑔 𝑖𝑡 . 𝑇ℎ𝑒 𝑐𝑜𝑖𝑙 𝑠𝑝𝑟𝑖𝑛𝑔 𝑤𝑖𝑙𝑙 𝑏𝑒 𝑑𝑒𝑓𝑙𝑒𝑐𝑡𝑒𝑑 𝑡𝑜 30.48 𝑐𝑚 𝑖𝑓 𝑡ℎ𝑒 𝑑𝑢𝑚𝑏𝑤𝑎𝑖𝑡𝑒𝑟
𝑠ℎ𝑜𝑢𝑙𝑑 𝑎𝑐𝑐𝑖𝑑𝑒𝑛𝑡𝑎𝑙𝑙𝑦 𝑓𝑎𝑙𝑙 𝑎𝑛𝑑 𝑖𝑡 ℎ𝑖𝑡 𝑡ℎ𝑒 𝑠𝑝𝑟𝑖𝑛𝑔 𝑓𝑟𝑜𝑚 𝑖𝑡𝑠 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑡𝑟𝑎𝑣𝑒𝑙 . 𝑆𝑝𝑟𝑖𝑛𝑔 𝑖𝑛𝑑𝑒𝑥 𝑖𝑠 8, 𝑚𝑎𝑥𝑖𝑚𝑢𝑚
𝑖𝑛𝑑𝑢𝑐𝑒𝑑 𝑠𝑡𝑟𝑒𝑠𝑠 𝑖𝑠 3,868 𝑘𝑔 Τ𝑐 𝑚 2 𝑎𝑛𝑑 𝐺 𝑖𝑠 808,720 𝑘𝑔 Τ𝑐 𝑚 2 .
𝐷𝑒𝑡𝑒𝑟𝑚𝑖𝑛𝑒 :
𝑎 . 𝑊𝑖𝑟𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑖𝑛 𝑐𝑚
𝑏 . 𝑀𝑒𝑎𝑛 𝑐𝑜𝑖𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑖𝑛 𝑐𝑚
𝑐 . 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑎𝑐𝑡𝑖𝑣𝑒 𝑐𝑜𝑖𝑙𝑠
SOLUTION: From:
GIVEN: From, 𝐷𝑚 = 8𝑑 = 8 3.67 𝑐𝑚
ℎ = 3 𝑚 = 300 𝑐𝑚 8𝐾𝐹𝐷𝑚 𝑫𝒎 = 𝟐𝟗. 𝟑𝟕 𝒄𝒎
𝑆𝑠 =
𝑊 = 100 𝑘𝑔 𝜋𝑑 3 From:
Where:
𝑦 = 30.48 𝑐𝑚 𝐷𝑚 8𝐹𝐶 3 𝑛
𝐶=8 𝐶= 𝑦=
𝑑 𝐺𝑑
𝑘𝑔
8=
𝐷𝑚
; 𝐷𝑚 = 8𝑑
8(2,168.50 𝑘𝑔)(8)3 𝑛
𝑆𝑠 = 3,868 𝑑 30.48 𝑐𝑚 =
𝑐𝑚2 4𝐶 − 1 0.615 4(8) − 1 0.615
𝑘𝑔
𝑘𝑔 808,720 (3.67 𝑐𝑚)
𝐾= + = + = 1.18 𝑐𝑚2
𝐺 = 808,720 4𝐶 − 4 𝐶 4(8) − 4 8
𝒏 = 𝟏𝟎. 𝟏𝟗 𝒄𝒐𝒊𝒍𝒔
𝑐𝑚2 𝐹𝑦
𝑊 ℎ+𝑦 =
2
𝐹 30.48 𝑐𝑚
REQUIRED: 100 𝑘𝑔 300 + 30.48 𝑐𝑚 =
2
𝑎. 𝑊𝑖𝑟𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑖𝑛 𝑐𝑚 𝐹 = 2,168.50 𝑘𝑔
𝑏. 𝑀𝑒𝑎𝑛 𝑐𝑜𝑖𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑖𝑛 𝑐𝑚 Thus,
𝑐. 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑎𝑐𝑡𝑖𝑣𝑒 𝑐𝑜𝑖𝑙𝑠 8 1.18 2,168.50 𝑘𝑔 (8𝑑)
3,868 𝑘𝑔/𝑐𝑚2 =
𝜋𝑑 3
𝒅 = 𝟑. 𝟔𝟕 𝒄𝒎
The leaf spring is used mainly for vehicle
suspension and in one form consists of a stack of
slightly curved narrow plates of equal width and
varying length clamped together, with the shorter
plates in the centre to form a semielliptical shape.
 STRESSES AND DEFLECTION
OF LEAF SPRING
SIMPLE CANTILEVER (QUARTER ELLIPTICAL LEAF SPRING)
6𝐹𝐿
𝐵𝑒𝑛𝑑𝑖𝑛𝑔 𝑆𝑡𝑟𝑒𝑠𝑠, 𝑆𝑏 = Where:
𝑛𝑏𝑡 2 𝐹 = 𝑡𝑜𝑡𝑎𝑙 𝑙𝑜𝑎𝑑 𝑜𝑛 𝑠𝑝𝑟𝑖𝑛𝑔
6𝐹𝐿3 𝑆𝑏 𝐿2 𝐿 = 𝑠𝑝𝑟𝑖𝑛𝑔 𝑙𝑒𝑛𝑔𝑡ℎ
𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛, 𝑦 = =
𝑛𝑏𝑡 3 𝐸 𝐸𝑡 𝑛 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑙𝑒𝑎𝑣𝑒𝑠
𝑛′ = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑒𝑥𝑡𝑟𝑎 𝑓𝑢𝑙𝑙 − 𝑙𝑒𝑛𝑔𝑡ℎ 𝑙𝑒𝑎𝑣𝑒𝑠
SEMI-ELLIPTICAL LEAF SPRING 𝐸 = 𝑠ℎ𝑒𝑎𝑟 𝑚𝑜𝑑𝑢𝑙𝑢𝑠 𝑜𝑓 𝑒𝑙𝑎𝑠𝑡𝑖𝑐𝑖𝑡𝑦
3𝐹𝐿 𝑏 = 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑒𝑎𝑐ℎ 𝑙𝑒𝑎𝑓
𝐵𝑒𝑛𝑑𝑖𝑛𝑔 𝑆𝑡𝑟𝑒𝑠𝑠, 𝑆𝑏 = 𝑡 = 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑒𝑎𝑐ℎ 𝑙𝑒𝑎𝑓
2𝑛𝑏𝑡 2
3𝐹𝐿3 𝑆𝑏 𝐿2
𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛, 𝑦 = 3 = (without extra full length leaf)
8𝑛𝑏𝑡 𝐸 4𝐸𝑡
3𝐹𝐿3 𝑆𝑏 𝐿2
𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛, 𝑦 = 𝑛′
= 𝑛′
(with extra full length leaf)
4(2+ 𝑛 )𝑏𝑡 3 𝐸 2 2+ 𝑛 𝐸𝑡
EXAMPLE 7:
𝐴 𝑐𝑎𝑛𝑡𝑖𝑙𝑒𝑣𝑒𝑟 𝑠𝑝𝑟𝑖𝑛𝑔 𝑖𝑠 𝑐𝑜𝑚𝑝𝑜𝑠𝑒𝑑 𝑜𝑓 𝑠𝑖𝑥 𝑔𝑟𝑎𝑑𝑢𝑎𝑡𝑒𝑑 𝑙𝑒𝑎𝑣𝑒𝑠 𝑒𝑎𝑐ℎ 60 𝑚𝑚 𝑤𝑖𝑑𝑒 𝑎𝑛𝑑 12 𝑚𝑚 𝑡ℎ𝑖𝑐𝑘.
𝑇ℎ𝑒 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑠𝑝𝑟𝑖𝑛𝑔 𝑖𝑠 700 𝑚𝑚 𝑎𝑛𝑑 𝑙𝑜𝑎𝑑 𝑖𝑠 8,000 𝑁 𝑎𝑡 𝑡ℎ𝑒 𝑡𝑖𝑝. 𝑈𝑠𝑒 𝐸 = 200 𝐺𝑃𝑎. 𝐹𝑖𝑛𝑑:
𝑎. 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑖𝑛𝑑𝑢𝑐𝑒𝑑 𝑠𝑡𝑟𝑒𝑠𝑠 𝑖𝑛 𝑀𝑃𝑎.
𝑏. 𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛 𝑖𝑛 𝑚𝑚

GIVEN: SOLUTION:
𝑐𝑎𝑛𝑡𝑖𝑙𝑒𝑣𝑒𝑟 𝑠𝑝𝑟𝑖𝑛𝑔 For simple cantilever spring
𝑛=6 6𝐹𝐿
𝑏 = 60 𝑚𝑚 𝑆𝑏 =
𝑛𝑏𝑡 2
𝑡 = 12 𝑚𝑚 6(8,000 𝑁)(700 𝑚𝑚)
𝐿 = 700 𝑚𝑚 𝑆𝑏 =
6(60 𝑚𝑚)(12 𝑚𝑚)2
𝐹 = 8,000 𝑁
𝑺𝒃 = 𝟔𝟒𝟖. 𝟏𝟓 𝑴𝑷𝒂
𝐸 = 200 𝐺𝑃𝑎 = 200,000 𝑀𝑝𝑎
From,
6𝐹𝐿3
𝑦=
REQUIRED: 𝑛𝑏𝑡 3 𝐸
𝑎. 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑖𝑛𝑑𝑢𝑐𝑒𝑑 𝑠𝑡𝑟𝑒𝑠𝑠 𝑖𝑛 𝑀𝑃𝑎. 6(8,000 𝑁)(700 𝑚𝑚)3
𝑏. 𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛 𝑖𝑛 𝑚𝑚 𝑦=
𝑁
6(60 𝑚𝑚) 12 𝑚𝑚 3 200,000
𝑚𝑚2
𝒚 = 𝟏𝟑𝟐. 𝟑𝟑 𝒎𝒎
EXAMPLE 8:
𝑆𝑒𝑚𝑖 − 𝑒𝑙𝑙𝑖𝑝𝑡𝑖𝑐𝑎𝑙 𝑠𝑝𝑟𝑖𝑛𝑔𝑠 𝑠𝑢𝑝𝑝𝑜𝑟𝑡 𝑎 𝑐𝑎𝑟 𝑤𝑒𝑖𝑔ℎ𝑖𝑛𝑔 20 𝑘𝑁.
𝑇ℎ𝑒𝑟𝑒 𝑎𝑟𝑒 4 𝑠𝑝𝑟𝑖𝑛𝑔𝑠 𝑎𝑛𝑑 𝑡ℎ𝑒 𝑙𝑜𝑎𝑑 𝑖𝑠 𝑎𝑠𝑠𝑢𝑚𝑒𝑑 𝑡𝑜 𝑏𝑒 𝑒𝑞𝑢𝑎𝑙𝑙𝑦 𝑑𝑖𝑠𝑡𝑟𝑖𝑏𝑢𝑡𝑒𝑑 𝑡𝑜 𝑒𝑎𝑐ℎ.
𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑠𝑝𝑟𝑖𝑛𝑔 𝑖𝑠 1.225 𝑚 𝑙𝑜𝑛𝑔 𝑎𝑛𝑑 55 𝑚𝑚 𝑤𝑖𝑑𝑒. 𝐷𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛 𝑎𝑡 𝑟𝑒𝑠𝑡 𝑖𝑠 90 𝑚𝑚 𝑎𝑛𝑑
𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑖𝑠 360𝑀𝑃𝑎. 𝑈𝑠𝑒 𝐸 = 200 𝐺𝑃𝑎. 𝐹𝑖𝑛𝑑:
𝑎. 𝐿𝑒𝑎𝑓 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑖𝑛 𝑚𝑚
𝑏. 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑙𝑒𝑎𝑣𝑒𝑠

GIVEN: SOLUTION:
𝑆𝑒𝑚𝑖 − 𝑒𝑙𝑙𝑖𝑝𝑡𝑖𝑐𝑎𝑙 𝑠𝑝𝑟𝑖𝑛𝑔𝑠 For semi-elliptical spring
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑝𝑟𝑖𝑛𝑔𝑠 = 4 Deflection of a spring without extra full length leaf
𝑏 = 55 𝑚𝑚 3𝐹𝐿3 𝑆𝑏 𝐿2
𝐿 = 1.225 𝑚 = 1,225 𝑚𝑚 𝑦= =
8𝑛𝑏𝑡 2 𝐸 4𝐸𝑡
𝐹 = 20 𝑘𝑁 = 20,000 𝑁 𝑆𝑏 𝐿2 360𝑀𝑃𝑎 (1,225 𝑚𝑚)2
𝐸 = 200 𝐺𝑃𝑎 = 200,000 𝑀𝑝𝑎 𝑡= =
𝑆𝑏 = 360 𝑀𝑃𝑎 4𝐸𝑦 4(200,000 𝑀𝑃𝑎)(90 𝑚𝑚)
𝑦 = 90 𝑚𝑚 𝒕 = 𝟕. 𝟓𝟎 𝒎𝒎
From,
REQUIRED: 3𝐹𝐿3 𝐹 20 𝑘𝑁
𝑦= 𝐹 = 𝑓𝑜𝑟𝑐𝑒 𝑝𝑒𝑟 𝑙𝑒𝑎𝑓𝑠𝑝𝑟𝑖𝑛𝑔 = =
Where: = 5 𝑘𝑁 = 5,000 𝑁
𝑎. 𝐿𝑒𝑎𝑓 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑖𝑛 𝑚𝑚 8𝑛𝑏𝑡 3 𝐸 𝑛 4
3
𝑏. 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑙𝑒𝑎𝑣𝑒𝑠 3𝐹𝐿 3(5,000 𝑁)(1,225 𝑚𝑚)3
𝑛= =
8𝑏𝑡 𝐸𝑦 8(55 𝑚𝑚) 7.50 𝑚𝑚 3 200,000 𝑁 (90 𝑚𝑚)
3
𝑚𝑚2
𝒏 = 𝟖. 𝟐𝟓 𝒍𝒆𝒂𝒗𝒆𝒔
EXAMPLE 9:
𝐴 𝑠𝑒𝑚𝑖 − 𝑒𝑙𝑙𝑖𝑝𝑡𝑖𝑐𝑎𝑙 𝑎𝑢𝑡𝑜𝑚𝑜𝑏𝑖𝑙𝑒 𝑠𝑝𝑟𝑖𝑛𝑔 1.5 𝑚 𝑙𝑜𝑛𝑔 𝑖𝑠 𝑚𝑎𝑑𝑒 𝑜𝑓 𝑡𝑒𝑛 𝑙𝑒𝑎𝑣𝑒𝑠, 𝑡𝑤𝑜 𝑜𝑓 𝑤ℎ𝑖𝑐ℎ 𝑎𝑟𝑒
𝑓𝑢𝑙𝑙 − 𝑙𝑒𝑛𝑔𝑡ℎ𝑠, 60 𝑚𝑚 𝑤𝑖𝑑𝑒 𝑒𝑎𝑐ℎ. 𝐼𝑡 𝑐𝑎𝑟𝑟𝑖𝑒𝑠 𝑎 𝑙𝑜𝑎𝑑 𝑜𝑓 8,000 𝑁 𝑤𝑖𝑡ℎ 𝑎 𝑑𝑒𝑓𝑙𝑒𝑐𝑡𝑖𝑜𝑛
𝑜𝑓 70 𝑚𝑚. 𝑈𝑠𝑒 𝐸 = 200 𝐺𝑃𝑎. 𝐹𝑖𝑛𝑑:
𝑎. 𝐿𝑒𝑎𝑓 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑖𝑛 𝑚𝑚
𝑏. 𝐼𝑛𝑑𝑢𝑐𝑒𝑑 𝑠𝑡𝑟𝑒𝑠𝑠 𝑖𝑛 𝑀𝑃𝑎.

GIVEN: SOLUTION:
𝑆𝑒𝑚𝑖 − 𝑒𝑙𝑙𝑖𝑝𝑡𝑖𝑐𝑎𝑙 𝑠𝑝𝑟𝑖𝑛𝑔𝑠 For semi-elliptical spring with extra full-length leaves
𝑛 = 10 3𝐹𝐿3 𝑆𝑏 𝐿2
𝑦= =
𝑛′ 𝑛′
𝑛′ = 1 4 2+ 3
𝑛𝑏𝑡 𝐸 2 2 + 𝐸𝑡
𝑛 𝑛
𝑏 = 60 𝑚𝑚
𝑦 = 70 𝑚𝑚 3 3𝐹𝐿3 3 3(8,000 𝑁)(1,500 𝑚𝑚)3
𝑡= =
𝐿 = 1.5 𝑚 = 1,500 𝑚𝑚 𝑛′ 1 𝑁
4 2+ 𝑛𝑏𝐸𝑦 4 2+ 10 60 𝑚𝑚 200,000 (70 𝑚𝑚)
𝑛 10 𝑚𝑚2
𝐹 = 8,000 𝑁
𝐸 = 200 𝐺𝑃𝑎 = 200,000 𝑀𝑝𝑎 𝒕 = 𝟏𝟎. 𝟒𝟕 𝒎𝒎
From,
𝑆𝑏 𝐿2
REQUIRED: 𝑦=
𝑎. 𝐿𝑒𝑎𝑓 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑖𝑛 𝑚𝑚 𝑛′
2 2+ 𝐸𝑡
𝑏. 𝐼𝑛𝑑𝑢𝑐𝑒𝑑 𝑠𝑡𝑟𝑒𝑠𝑠 𝑖𝑛 𝑀𝑃𝑎. 𝑛
𝑛′
2 2+ 𝐸𝑡𝑦 2 2 + 0.1 200,000𝑀𝑃𝑎 (10.47 𝑚𝑚)(70 𝑚𝑚)
𝑛
𝑆𝑏 = =
𝐿2 1,500 𝑚𝑚 2
𝑺𝒃 = 𝟐𝟕𝟑. 𝟔𝟐 𝑴𝑷𝒂