Springs 437

l = 750 mm sb= 100 N/mm2 maximum length. The length gradually decreases
E = 106 000 N/mm2 from the top leaf to the bottom leaf. The longest
leaf at the top is called master leaf. It is bent at
Step I Thickness of strip
both ends to from the spring eyes. Two bolts are
M = Pr = 5 (75) = 375 N-mm
inserted through these eyes to fix the leaf spring to
From Eq. (10.32),
the automobile body. The leaves are held together
12 M 12(375) by means of two U-bolts and a centre clip. Rebound
sb = or 100 =
bt 2
12.5t 2 clips are provided to keep the leaves in alignment
\ t = 1.897 or 2 mm (i) and prevent lateral shifting of the leaves during
operation. At the centre, the leaf spring is supported
Step II Degrees of rotation on the axle. Multi-leaf springs are provided with
From Eq. (10.33), one or two extra full length leaves in addition to
12 Ml 12(375)(750) master leaf. The extra full-length leaves are stacked
q= = radians
Ebt 3
(106 000)(12.5)(2)3 between the master leaf and the graduated length
leaves. The extra full-length leaves are provided to
12(375)(750) Ê 180 ˆ support the transverse shear force.
or q= Á ˜ degrees
(106 000)(12.5)(2) Ë p ¯
3 For the purpose of analysis, the leaves are
divided into two groups namely, master leaf along
q = 18.24° (ii)
with graduated-length leaves forming one group
and extra full-length leaves forming the other. The
10.16 MULTI-LEAF SPRING
following notations are used in the analysis:
Multi-leaf springs are widely used for the suspension nf = number of extra full-length leaves
of cars, trucks and railway wagons. A multi-leaf ng = number of graduated-length leaves
spring consists of a series of flat plates, usually of including master leaf
semi-elliptical shape, as shown in Fig. 10.31. The n = total number of leaves
flat plates are called leaves of the spring. The leaves b = width of each leaf (mm)
have graduated lengths. The leaf at the top has t = thickness of each leaf (mm)

Fig. 10.31 Semi-elliptic Leaf Spring

L = length of the cantilever or half the length Pg = portion of P taken by the graduated-length
of semi-elliptic spring (mm) leaves (N)
P = force applied at the end of the spring (N) The group of graduated-length leaves along with
Pf = portion of P taken by the extra full-length the master leaf can be treated as a triangular plate,
leaves (N) as shown in Fig. 10.32. In this case, it is assumed
438 Design of Machine Elements

that the individual leaves are separated and the master

6 Pf L
leaf placed at the centre. Then the second leaf is cut (s b ) f =
or n f bt 2 (c)
longitudinally into two halves, each of width (b/2)
and placed on each side of the master leaf. A similar
procedure is repeated for the other leaves. The resultant
shape is approximately a triangular plate of thickness
t and a maximum width at the support as (ng b). The
bending stress in the plate at the support is given by,
Mb y ( Pg L) (t / 2)
(s b ) g = =
I È1 3 ˘
ÍÎ12 (ng b) (t ) ˙˚

6 Pg L
or, (s b ) g = (a)
ng bt 2

Fig. 10.33 Extra full-length leaves as

rectangular plate

The deflection at the load point is given by,

Pf L3 Pf L3
df =
3EI È1 ˘
3E Í (n f b)(t 3 ) ˙
Î12 ˚

4 Pf L3
or df = (d)
En f bt 3
Fig. 10.32 Graduated-length Leaves as
Triangular Plate Since the deflection of full-length leaves is equal
to the deflection of graduated- length leaves,
It can be proved that the deflection (dg) at the dg = df
load point of the triangular plate is given by,
3
6 Pg L 4 Pf L3
Pg L3 Pg L3 =
dg = = Eng bt 3 En f bt 3
2 EI max. È1 ˘
2 E Í (ng b) (t 3 ) ˙
Î12 ˚ Pg 2 ng
3 or = (e)
6 Pg L Pf 3n f
or, dg = (b)
Eng bt 3 also, Pg + Pf = P (f)
Similarly, the extra full-length leaves can be
From Eqs (e) and (f),
treated as a rectangular plate of thickness t and
uniform width (nf b), as shown in Fig. 10.33. The 3n f P
bending stress at the support is given by, Pf = (g)
(3n f + 2ng )
M y ( Pf L)(t / 2)
(s b ) f = b = 2 ng P
I È1 3 ˘ Pg = (h)
ÍÎ12 (n f b)(t ) ˙˚ (3 n f + 2ng )
 Springs 439

Substituting the above values in Eqs. (a) and (c), achieved by a difference in radii of curvature,
12 PL is known as ‘nipping’. Nipping is common in
(s b ) g = (10.36) automobile suspension springs.
(3n f + 2ng ) bt 2
18 PL
(s b ) f = (10.37)
(3n f + 2ng ) bt 2
It is seen from the above equations that bending
stresses in full-length leaves are 50% more than
those in graduated-length leaves. The deflection at
the end of the spring is determined from Eqs. (b) and
(h). It is given by,
12 PL3
d = (10.38) Fig. 10.34 Nipping of Leaf Spring
Ebt 3 (3n f + 2ng )
Multi-leaf springs are designed using load- Rewriting Eqs (a) and (c) of the previous section,
stress and load-deflection equations. The standard 6 Pg L
(s b ) g = (a)
dimensions for the width and thickness of the leaf n bt 2
g
section are as follows:6 6 Pf L
Nominal thickness (mm): 3.2, 4.5, 5, 6, 6.5, (s b ) f = (b)
7, 7.5, 8, 9, 10, 11, 12, 14, and 16 n f bt 2
Nominal width (mm): 32, 40, 45, 50, 55, 60, 65, Assuming that pre-stressing results in stress-
70, 75, 80, 90, 100 and 125 equalisation,
The leaves are usually made of steels, 55Si2Mn90, (sb)g = (sb)f
50Cr1 or 50CrlV23. The plates are hardened
From (a) and (c),
and tempered. The factor of safety based on the
yield strength is from 2 to 2.5 for the automobile Pg ng
= (i)
suspension. Pf nf
Also, Pg + Pf = P (ii)
10.17 NIPPING OF LEAF SPRINGS
Solving Eqs (i) and (ii),
As discussed in the previous section, the stresses ng P
in extra full-length leaves are 50% more than the Pg = (iii)
stresses in graduated-length leaves. One of the n
methods of equalising the stresses in different nf P
Pf = (iv)
leaves is to pre-stress the spring. The pre-stressing n
is achieved by bending the leaves to different radii where n = ng + nf
of curvature, before they are assembled with the
centre clip. As shown in Fig. 10.34, the full-length Rewriting Eqs (b) and (d) of the previous section,
leaf is given a greater radius of curvature than the 6 Pg L3
adjacent leaf. The radius of curvature decreases with dg = (c)
Eng bt 3
shorter leaves. The initial gap C between the extra
full-length leaf and the graduated-length leaf before 4 Pf L3
the assembly, is called a ‘nip’. Such pre-stressing, df = (d)
En f bt 3

6 IS 1135–1966: Specifications for leaf-springs for automobile suspension.

440 Design of Machine Elements

Under the maximum force P, the deflection of Example 10.24 A semi-elliptic leaf spring used
graduated-length leaves will exceed the deflection for automobile suspension consists of three extra
of extra full-length leaves by an amount equal to the full-length leaves and 15 graduated-length leaves,
initial nip C. including the master leaf. The centre-to-centre
Therefore, distance between two eyes of the spring is 1 m. The
6 Pg L3 4 Pf L3 maximum force that can act on the spring is 75 kN.
C= - For each leaf, the ratio of width to thickness is 9:1.
Eng bt 3 En f bt 3
The modulus of elasticity of the leaf material is
Substituting Eqs (iii) and (iv) in the above 207 000 N/mm2. The leaves are pre-stressed in such
expression, a way that when the force is maximum, the stresses
2 PL3 induced in all leaves are same and equal to 450
C= (10.39) N/mm2. Determine
Enbt 3 (i) the width and thickness of the leaves;
The initial pre-load Pi required to close the gap C (ii) the initial nip; and
between the extra full-length leaves and graduated- (iii) the initial pre-load required to close the
length leaves is determined by considering the initial gap C between extra full-length leaves and
deflection of leaves. graduated-length leaves.
Under the action of pre-load Pi,
C = (dg)i + (df)i Solution
Given 2P = 75 kN 2L = 1 m b = 9t nf = 3
2 PL3 6( Pi / 2) L3 4( Pi / 2) L3 ng = 15 E = 207 000 N/mm2 sb = 450 N/mm2
= +
Enbt 3 Eng bt 3 En f bt 3 Step I Width and thickness of the leaves
2P = 75 kN or P = 37 500 N
2ng n f P
or Pi = (10.40) 2L = 1 m or L = 500 mm
n(3n f + 2ng ) b = 9t n = nf + ng = 3 + 15 = 18
The resultant stress in the extra full-length leaves From Eq. (10.41),
is obtained by superimposing the stresses due to 6 PL 6(37 500)(500)
sb = or (450) =
initial pre-load (Pi) and the external force (P). From nbt 2 (15 + 3)(9t )t 2
Eq. (b),
6 L( Pf - 0.5 Pi ) \ t = 11.56 or 12 mm
(s b ) f =
n f bt 2 b = 9 t = 9 (12) = 108 mm (i)
Substituting Eq. (g) of the previous section and Step II Initial nip
Eq. (10.40) in the above expression, From Eq. (10.39),

(s b ) f =
6 PL 2 PL3 2(37 500)(500)3
C= =
nbt 2 Enbt 3 (207 000)(18)(108)(12)3
Since the stresses are equal in all leaves, the = 13.48 mm (ii)
above expression is written as
Step III Initial pre-load
6 PL
sb = (10.41) From Eq. (10.40),
nbt 2
2ng n f P 2(15)(3)(37 500)
The deflection of the multi-leaf spring due Pi = =
to the external force P is the same as given by n(3n f + 2ng ) 18(3 ¥ 3 + 2 ¥ 15)
Eq. (10.38). = 4807.69 N (iii)
 Springs 441

Example 10.25 A semi-elliptic multi-leaf spring without a bottom. This type of spring is also called
is used for the suspension of the rear axle of a ‘coned disk’ spring. It is called Belleville spring
truck. It consists of two extra full-length leaves and because it was invented by Julian Belleville, who
ten graduated-length leaves including the master patented its design in France in 1867. The Belleville
leaf. The centre-to-centre distance between the
spring eyes is 1.2 m. The leaves are made of steel
55Si2Mo90 (Syt = 1500 N/mm2 and E = 207 000
N/mm2) and the factor of safety is 2.5. The spring is
to be designed for a maximum force of 30 kN. The
leaves are pre-stressed so as to equalize stresses in
all leaves. Determine
(i) the cross-section of leaves; and
(ii) the deflection at the end of the spring.
Solution
Given 2 P = 30 kN 2 L = 1.2 m nf = 2 ng = 10
E = 207 000 N/mm2 Syt = 1500 N/mm2 (fs) = 2.5
Step I Cross-section of the leaves
2 P = 30 kN or P = 15 000 N
2 L = 1.2 m or L = 600 mm Fig. 10.35 Belleville Spring
S yt 1500
sb = = = 600 N/mm 2 spring has typical load-deflection characteristics
( fs ) 2.5
as shown in Fig. 10.36. The variation of (h/t) ratio
From Eq. (10.41), produces a wide variety of load deflection curves.
6 PL 6(15 000)(600) For example, when (h/t) ratio is 3.5, an S-curve is
sb = or (600) =
nbt 2 (2 + 10)bt 2 obtained which is useful in applications involving
snap acting mechanism. When (h/t) is reduced
bt2 = 7500 mm3 to 2.1, the central portion of the curve becomes
Assuming a standard width of 60 mm, horizontal, which means that the load is constant for
7500
t2 = or t = 11.18 or 12 mm
60
Cross-section of the leaves = 60 ¥ 12 mm (i)
Step II Deflection at the end of the spring
From Eq. (10.38),
12 PL3
d =
Ebt 3 (3n f + 2ng )
12(15 000)(600)3
=
(207 000)(60)(12)3 (3 ¥ 2 + 2 ¥ 10)
Fig. 10.36 Load Deflection Curves for Belleville
= 69.68 mm (ii) Springs

10.18 BELLEVILLE SPRING this range of deflection. This portion of the curve is
useful for engaging or disengaging the clutch, when
A Belleville spring consists of a coned disk as the Belleville spring is used as a clutch spring. The
shown in Fig. 10.35. It resembles a dinner plate Belleville spring offers the following advantages: