Table Of Contents

• Introduction to Spring

Definition of Springs :
Different functions Of Springs :
Types of springs
1. Helical Springs
2. Conical and Volute Springs
3.Torsion Springs
4. Laminated Leaf Springs
5. Disc Springs or Belleville springs

• Spring Materials

• Spring Design

▪ Terminology of Helical Springs

▪ 1. Spring index (C):
▪ 2. Solid length:
▪ 3. Free length:
▪ 4. Spring Rate OR Spring Stiffness :
▪ 5. Pitch:

• Advantages Of Springs

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 INTRODUCTION TO SPRING

• Springs are elastic bodies (generally metal) that can be twisted, pulled, or
stretched by some force. They can return to their original shape when the
force is released. In other words it is also termed as a resilient member.
• It can take any shape and form depending upon the application

DEFINITION OF SPRINGS :

• Spring is defined as an elastic machine element that deflects under the

action of the load and returns to its original shape when the load is
removed.
• Spring is a resilient member capable of providing large elastic
deformation. Spring is defined as an elastic body whose function is to
distort when loaded and to recover its original shape when the load is
removed.

DIFFERENT FUNCTIONS OF SPRINGS :

1. To absorb shocks and vibrations. – Used in Vehicle suspension springs,

Railway buffer springs, Buffer springs in elevators, Vibration mounts for
machinery

2. To store energy – Used in Springs used in clocks, toys. Movie-cameras,

circuit breakers, and starters

3. To measure force – Used in Springs used in weighing balance and engine

indicators

4. To control Motion – Used in the cam and follower mechanism, spring is

used to maintain contact between two elements.

5. To apply force – Used in In engine valve mechanism, spring is used to

return the rocker arm to its normal position when the disturbing force is
removed. The spring used in the clutch provides the required force to
engage the clutch.

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TYPES OF SPRINGS
Following are important types of springs according to their shape:
1. Helical springs
2. Conical and volute springs
3. Torsion springs
4. Laminated or leaf springs
5. Disc or Belleville springs

1. HELICAL SPRINGS

• The helical spring is made from a wire, usually of circular cross-section,

that is bent in the form of a helix.
• There are two basic types of helical springs: compression spring and
tension spring.
• In helical compression spring, the external force tends to shorten the
spring. In other words, the spring is compressed.
• In helical tension spring, the external force tends to lengthen the spring.
In other words, the spring is elongated.

• It should be noted that although the spring is under compression, the wire
of helical compression spring is not subjected to compressive stress.
• Also, the wire of helical tension spring is not subjected to tensile stress
although the spring is under tension.
• In both cases, torsional shear stresses are induced in the spring wire.
• The words compression and tension are related to total spring and not the
stresses in spring wire.

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The helical springs have the following advantages:

• These are easy to manufacture.

• These are available in a wide range.
• These are reliable.
• These have a constant spring rate.
• Their performance can be predicted more accurately.
• Their characteristics can be varied by changing dimensions.
Application Of Helical Tension Spring :

1. Garage door assemblies

2. Vise-grip pilers
3. Carburetors

Application Of Helical Compression Spring :

Valve assemblies in engines, Brakes, Clutches.

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2. CONICAL AND VOLUTE SPRINGS

• The conical and volute springs are used in special applications where a
telescoping spring or a spring with a spring rate (load required per unit
deflection) that increases with the load is desired.

Conical spring and Volute casing

• The conical spring is wound with a uniform pitch whereas the volute
springs are wound in the form of a paraboloid with constant pitch and
lead angles.
• This characteristic is sometimes utilized in vibration problems where
springs are used to support a body that has a varying mass.

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3.TORSION SPRINGS

• The construction of this spring is similar to that of compression or tension

spring, except that the ends are formed in such a way, that the spring is
loaded by a torque, about the axis of the coils.
• Helical torsion spring is used to transmit torque to a particular component
in the machine or the mechanism.
• Helical torsion spring is used in door-hinges, brush-holders, starters, and
door locks.

Helical Torsion Spring

• For example, the spring transmits a torque of (P x r).

• The helical torsion resists the bending moment (P x r) that tends to wind
up the spring.
• The bending moment induces bending stresses in the spring wire.
• The term torsion spring is somewhat misleading because the wire is
subjected to bending stresses, unlike torsional shear stresses induced in
helical torsion or tension springs.

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Application Of Torsion Spring :

1. Mouse tracks
2. Rocker switches
3. Door hinges
4. Clipboards
5. Automobile starters
Spiral torsion spring:

• It is made of a band of steel wrapped around itself several times to create

a geometric shape as shown in the figure.
• Its inner end is attached to an arbor and the outer end is attached to a
retaining drum.
• It has a few rotations and also contains a thicker band of steel.
• It releases power when it unwinds.

Spiral Torsion Spring

Application of Spiral Spring :

• Alarm timepiece

• Watch

• Automotive seat recliners

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4. LAMINATED LEAF SPRINGS

• Multi-leaf spring is widely used for the suspension of trucks and railway
wagons.
• It consists of a series of flat plates, usually of semi-elliptical shape. The
flat plates are called leaves of the spring.
• The leaf at the top has a maximum length. The longest leaf at the top is
called a master leaf.
• The leaves have graduated lengths. The length gradually decreases from
the top leaf to the bottom leaf.
• It is bent at both ends to form the spring eye. Two bolts are inserted
through these eyes to fix the leaf spring to the automobile body.
• The leaves are held together utilizing two U-bolts and a center clip.

leaf spring

• Rebound clips are provided to keep the leaves in alignment and prevent
lateral shifting of the leaves during operation.
• At the center, the leaf spring is supported on the axle.
• Multi-leaf springs are provided with one or two extra full leaves in
addition to master leaf.
• The extra full-length leaves are stacked between the master leaf and the
graduated length leaves.

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 • The extra full-length leaves are provided to support the transverse shear
force.
Application of Leaf Spring :

• Mainly in automobiles suspension systems.

• Shock Absorber in railways
Advantages of Leaf Spring :

1. It can carry lateral loads.

2. It provides braking torque.
3. It takes driving torque and withstand the shocks provided by the vehicles.

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5. BELLEVILLE SPRINGS

• A Belleville spring consists of a coned disk, as shown in the above figure.

• It is called Belleville spring because it was invented by Julian Belleville,
who patented its design in France in 1867.
• Belleville spring has a typical load-deflection characteristic, as shown in
the above figure.
• The variation of (h/t) ratio provides a wide variety of load-deflection
curves.
• Belleville springs are used in plate clutches and brakes, relief valves, and
a wide variety of bolted connections.

Disc Or Belleville Spring

Belleville spring offers the following advantages:

Advantages of Belleville springs are as follows

1) It is simple in construction and easy to manufacture.

2) It is a compact spring unit.

3) It is especially useful where a very large force is desired for small deflection
of spring.

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4) It provides a wide range of spring constants making it versatile.
It can provide any linear or non-linear load-deflection characteristic.

5) The individual coned disks of a particular size and thickness can be stacked
in series, parallel or series-parallel combinations, as shown in
Figure. These combinations provide a variety of spring constants without
changing the design.

6) When two Belleville springs are arranged in series, double deflection is

obtained for the same force. On the other hand, when two Belleville springs
are in parallel, almost double force is obtained for a given deflection.

Disc Or Belleville Spring Combination

Special Purpose Springs :

These springs are all together made of different materials such as air and water.

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 SPRING MATERIALS

The material of the spring should have high fatigue strength, high ductility, high
resilience and it should be creep-resistant.

Selection of material for the spring wire depends upon the following
factors:

1. The load acting on the spring

2. The range of stress through which the spring operates
3. The limitations on mass and volume of spring
4. The expected fatigue life
5. The environmental conditions in which the spring will operate such as
temperature
6. The severity of deformation encountered while making the spring

The mainly used material for manufacturing the springs are as follows:
1. Hard drawn high carbon steel
2. Oil tempered high carbon steel
3. Stainless steel
4. Copper or nickel-based alloys
5. Phosphor bronze
6. Monel
7. Titanium
8. Chrome vanadium
9. Chrome silicon

Characteristics of some typical materials are explained below

1. Hard-drawn wire: This is cold drawn, cheapest spring steel. Normally used
for low stress and static load. The material is not suitable at subzero
temperatures or at temperatures above 120⁰ C.

2. Oil-tempered wire: It is a cold drawn, quenched, tempered, and general-

purpose spring steel. However, it is not suitable for fatigue or sudden loads, at
subzero temperatures, and at temperatures above 180⁰ C. When we go for highly
stressed conditions then alloy steels are useful.

3. Chrome Vanadium: This alloy spring steel is used for high-stress conditions
and at high temperature, up to 220⁰ C. It is good for fatigue resistance and long
endurance for shock and impact loads.

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4. Chrome Silicon: This material can be used for highly stressed springs. It
offers excellent service for long life, shock loading, and for temperature up to
250⁰ C.

5. Music wire: This spring material is most widely used for small springs. It is
the toughest and has the highest tensile strength and can withstand repeated
loading at high stresses. However, it cannot be used at subzero temperatures or
at temperatures above 120⁰ C. Normally when we talk about springs we will
find that the music wire is a common choice for springs.

6. Stainless steel: Widely used alloy spring materials.

7. Phosphor Bronze / Spring Brass: It has good corrosion resistance and

electrical conductivity. That is the reason it is commonly used for contacts in
electrical switches. Spring brass can be used at subzero temperatures.

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 SPRING DESIGN
Terminology of Helical Springs

Spring Design

The main dimensions of a helical spring subjected compressive force are as

follows:

d = wire diameter of spring

Di = inside diameter of the spring coil
Do = outside diameter of the spring coil
D = mean coil diameter
Therefore,

D= ( Di + Do ) / 2

1. Spring Index (C):

• The spring index is defined as the ratio of mean coil diameter to wire
diameter. It is denoted by letter C.

C = D/d

• The spring index indicates the relative sharpness of the curvature of the
coil.

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 • A low index means high sharpness of curvature.
• When the spring index is low (C < 3), the actual stresses in the wire are
excessive due to the curvature effect.
• Such a spring is difficult to manufacture and special care in coiling is
required to avoid cracking in some wires.
• When the spring index is high (C > 15), it results in a large variation in
coil diameter.
• Such a spring is prone to buckling and also tangles easily during
handling.
• Spring index from 4 to 12 is considered better from manufacturing
considerations. Therefore, in practical applications, the spring index
usually varies from 4 to 12.
• However, the spring index in the range of 6 to 9 is still preferred
particularly for close tolerance springs and those subjected to cyclic
loading.

2. Solid length:

• When the compression spring is compressed until the coils come in

contact with each other, then the spring is said to be solid.
• The solid length of a spring is the product of the total number of coils and
the diameter of the wire.
Mathematically, Solid length of the spring formula,

Ls = n’ * d

where,

n’ = Total number of coils, and

d = Diameter of the wire.

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3. Free length:
The free length of a compression spring is the length of the spring in the free or
unloaded condition.

It is equal to the solid length plus the maximum deflection or compression of

the spring and the clearance between the adjacent coils (when fully
compressed).

Mathematically, Free length of the spring formula,

Lf= Solid length + Maximum compression + Clearance between adjacent coils

Lf = n’d + δmax + 0.15 δmax

4. Spring Rate OR Spring Stiffness :

The spring rate (or stiffness or spring constant) is defined as the load required
per unit deflection of the spring.

Mathematically, Spring rate formula,

S=W/δ

where W = Load, and

δ = Deflection of the spring

5. Pitch:
It is defined as the axial distance between adjacent coils in an uncompressed
state.

Mathematically, spring pitch formula

p= Lf / ( n’- 1 )

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Advantages Of Springs :
Advantages of Springs are explained below :

• Springs are available in large variety and shapes hence application area is
large.
• Spring can minimize machine vibration. Springs can eliminate the
undesirable effects of vibrations.
• Springs are easy to manufacture.
• Springs are highly reliable.
• Mostly we use spring to avoid vibration because the sudden vibrations in
a car may affect the human and it causes vomiting
• It helps in storing energy as in the case of watches and toys.
• Normally Springs are maintenance-free
Disadvantages Of Springs :

• If the deflection of the spring exceeds some critical value than the spring
will buckle.
• It is difficult to replace the spring.
• Ones the spring is damaged it is difficult to repair.

Application Of Springs :
The following are some applications of springs.

1. To absorb or control energy in automobiles suspension springs,

vibration. dampers, railway buffers.
2. To apply forces in brakes, clutches, valves of IC engines.
3. To store the energy in watches and toys.
4. To measure forces in spring balances, gauges.
5. To provide clamping force in toolings like jigs and fixtures, etc.
6. To control motion by maintaining contact between two elements, as in
the case of cam and follower, etc.
7. To exert a force, as in spring-loaded safety valve
8. To support moving masses or to isolate vibration.
9. Tension springs are used in Industrial Robots, door locks.
10.Torsion springs are used in clothes pins, garage doors

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