Brief instructions for using the new fatigue strength diagrams for cold-formed helical

compression springs
As a result of the research project IGF 19693 BR, new fatigue strength diagrams (Goodman diagrams)
analogous to DIN EN 13906-1 for cold-formed helical compression springs are available. In the last
few years, the representation of the fatigue strength according to Haigh has become established in
strength theory. Therefore, the results are presented as both Goodman and Haigh plots.
By using the available and further developed methods for the mathematical proof of strength for
springs, the fatigue strength characteristics were determined on the basis of fatigue tests. For this
purpose, several thousand current spring breaks were statistically evaluated. The new graphs are
based on modern materials and manufacturing processes. The geometries of the reference springs
and their manufacture are documented. The statistical evaluation was carried out for a confidence
level of 95% and a survival probability of 99.9%. The diagrams are therefore designed to be
conservative and safe for standard applications.
For special applications, a fatigue strength transfer method is available for deviating spring
properties (tensile strength, heat treatment, d, w, Rz, residual stresses from shot peening), number of
cycles and survival probabilities.
24 diagrams were developed for reference springs for 106 or 107 load cycles (Goodman diagrams and
additional Haigh diagrams). The approach to determining the permissible stresses is the same as
previously in the standard DIN EN 13906-1. A diagram is described below as an example.
Goodman diagram for compression springs Parameters of the characteristic lines
Wire and shot peening DH | patent drawn wire | shot peened
d w n R m,W K R,τ ∆τ ES
information
1.200 #1 [mm] - - [MPa] - [MPa]
1 #1 1,0 6,0 6,5 2.344 0,92 180
Goodman diagram #2

1.000 2 #3
#2 2,0 6,0 6,5 2.085 0,92 180
3
#4
#3 3,0 6,0 6,5 1.935 0,92 180
New fatigue strength 5
#4 5,0 6,0 6,5 1.746 0,92 180
τkO in N/mm²

800 #5
lines 10
8 #6
#5 8,0 6,0 6,5 1.571 0,92 180
600 #6 10,0 6,0 6,5 1.486 0,92 180
Guide lines for static
load capacity 400 Safety concept Static load guidelines
Confidence level τ permissible,static =
Fatigue strength lines 200 C = 95% 0,51 ⋅ R m
from DIN EN 13906-1 Partial safety factor [MPa]
N = 10^6
0 j C = 1,15 #1 1.196
0 200 400 600 800 1.000 1.200
Parameters for the new τkU in N/mm² Diagram 8 Failure probability P A #2 1.063
Haigh diagram for compression springs
fatigue strength lines DH | patent drawn wire | shot peened
P A = 0,10% #3 987
500 Safety factor #4 890
R = -1 R=0 N = 10^6
j S = 1,25 #5 801
Load cycles N
Overall safety factor #6 758
400
#1
j ges = 1,43
Information for safety #2
#3
1 Equations for characteristic lines
aspects #4 2
straight line equation f(x) = m x + n
τkA in N/mm²

300 #5 3
#6
5
8
Goodman-diagram Haigh-diagram
Values of the static load 10
m n m n
capacity 200
- [MPa] - [MPa]
#1 0,645 758,1 -0,216 460,8
Haigh diagram 100
#2 0,686 739,7 -0,186 438,8
#3 0,710 712,8 -0,17 416,8
#4 0,742 653,9 -0,148 375,4
Equations for
0 #5 0,772 603,0 -0,128 340,2
calculating values 0 200 400 600 800 1.000 1.200
τkm in N/mm² Diagram 8 #6 0,788 579,5 -0,119 324,2

www.tu-ilmenau.de/maschinenelemente
Prof. Dr.-Ing. Ulf Kletzin | [email protected] | (+49) 3677 / 69-2471
Page 1 of 2 M. Sc. Martin Petrich | [email protected] | (+49) 3677 / 69-1865
Use of the transfer method for springs with different properties
To further increase the design quality of springs that deviate from the parameters of the reference
springs in the diagrams, the desired number of cycles or the safety requirements, a transfer method
was derived. With the help of the calculation formulas, the permissible stresses can be determined
on the basis of the diagrams presented above to convert the desired requirements.
In principle, the procedure is as follows:
1. Determine the strength value of the reference spring from the diagram at N = 106 for the spring
that comes closest to the spring to be considered
2. Determine the transfer factors and calculate the new permissible stress range at N = 106
3. Transfer the fatigue strength + safety factors to the required load cycles 𝑁i / stresses 𝜏i
The transfer formula from a fatigue strength 𝜏kH1 from a Goodman diagram (index 1) to a similar
spring 𝜏kH2 (index 2) is composed according to equation (1). When working with the amplitude in
the Haigh diagram, equation (2) should be used. These equations relate two individual calculations
to each other. The spring with index 1 contains the parameters that are listed next to the diagrams.
Various transmission factors K are defined for the transfer method. Influences of geometry, surface
roughness, tensile strength, shot peening and medium stress can be taken into account.
𝜏kH1
𝜏kH2 = 2 ⋅ (𝐾GF ⋅ 𝐾OF ⋅ 𝐾ZF ⋅ ⋅ 𝑗ges + 𝐾KS + 𝐾MS ) (Goodman diagram) (1)
2
𝜏kA2 = 𝐾GF ⋅ 𝐾OF ⋅ 𝐾ZF ⋅ 𝜏kA1 ⋅ 𝑗ges + 𝐾KS + 𝐾MS (Haigh diagram) (2)
𝑛
Geometry factor 𝐾GF = 𝑛2 (3)
1

Surface roughness 𝐾OF =

𝐾Rτ,2
(4)
𝐾Rτ,1
factor
Tensile strength 𝐾ZF =
𝑅m,2
(5)
𝑅m,1
factor
Shot peening factor 𝐾KS = 𝜎ES,2 ⋅ 𝑀τ,2 − 𝜎ES,1 ⋅ 𝑀τ,1 (6)
Medium stress 𝐾MS = 𝜏km,1 ⋅
𝑀τ,1
− 𝜏km,2 ⋅
𝑀τ,2
(not shot peened) (7)
3 3
factor
𝐾MS = 𝜏km,1 ⋅ 𝑀τ,1 − 𝜏km,2 ⋅ 𝑀τ,2 (shot peened) (8)
• jges : safety factor
• n : support number for influence of size
• KR : Surface roughness facor
• Rm : Tensile strength (for 𝑅m > 2000 MPa follows 𝑅m = 2000 MPa)
• ES : existing residual stresses
• km : existing medium stress
• M : medium stress sensitivity

The formulas are valid for a transfer of the fatigue strength at N = 106. Users can therefore select the
characteristic curve of a reference spring that comes closest to the geometry of the desired spring
from the respective diagram for N = 106 and use the above formulas to determine the necessary
transmission factors. The stress range can then be converted to any Ni or τi. The calculation formulas
are contained in the final report of IGF 18495. An application example is described in detail in the
final report of IGF 19693.

www.tu-ilmenau.de/maschinenelemente
Prof. Dr.-Ing. Ulf Kletzin | [email protected] | (+49) 3677 / 69-2471
Page 2 of 2 M. Sc. Martin Petrich | [email protected] | (+49) 3677 / 69-1865