F T ra n sf o F T ra n sf o

PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

SPRINGS
A spring is de ned as an elastic machine element, which de ects under the action of the load and
returns to its original shape when the load is removed. It can take any shape and form depending
upon the application.
The important functions and applications of springs are as follows:
(i) Springs are used to absorb shocks and vibrations, e.g., vehicle suspension springs,
railway buffer springs, buffer springs in elevators and vibration mounts for
machinery.
(ii) Springs are used to store energy, e.g., springs used in clocks, toys, movie-cameras,
circuit breakers and starters.
(iii) Springs are used to measure force, e.g., springs used in weighing balances and scales.
(iv) Springs are used to apply force and control motion. There are a number of springs
used for this purpose. In the cam and follower mechanism, spring is used to maintain
contact between the two elements.

Types of Springs
Though there are many types of the springs, yet the following, according to their shape, are
important from the subject point of view.
1. Helical springs. The helical springs are made up of a wire coiled in the form of a helix and is
primarily intended for compressive or tensile loads. The cross-section of the wire from which the
spring is made may be circular, square or rectangular. The two forms of helical springs are
compression helical spring and tension helical spring.
A helical spring is said to be closely coiled spring, when the spring wire is coiled so close that
the plane containing each coil is almost at right angles to the axis of the helix. In other words, the
helix angle is very small. It is usually less than 10°. A helical spring is said to be open-coiled
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

spring, when the spring wire is coiled in such a way, that there is large gap between adjacent
coils. In other words, the helix angle is large. It is usually more than 10°
Helical springs, compression as well as extension, have the following advantages: (i) They are
easy to manufacture. (ii) They are cheaper than other types of springs. (iii) Their reliability is
high. (iv) The de ection of the spring is linearly proportional to the force acting on the spring.
Torsion springs.
The construction of this spring is similar to that of compression or extension 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, automobile starters and
door locks. The spiral type is also used where the load tends to increase the number of coils and
when made of flat strip are used in watches and clocks

Conical springs.
The conical springs, as shown in Fig. 23.2, are used in special applications where a telescoping
spring or a spring with a spring rate that increases with the load is desired. These springs tend to
reduce solid height and provide greater lateral stability that decreases the risk of buckling.
Conical spring design enables each coil to fit within the next coil, which is a major advantage in
applications where solid height is limited. Conical springs have variable force rate (as opposed to
the constant force rate of standard compression springs). Applications: They are frequently used
in various types of electrical contacts, such as push buttons and battery contacts. They also serve
as essential components in many automobile suspension systems. Some firearms manufacturers
use conical springs in the firing mechanism of the weapon. Other conical spring applications
include medical devices, major appliances, cell phones, large stamping presses and lawnmowers
etc.
4. Laminated or leaf springs.

SPRING MATERIALS
1. High-carbon hard-drawn spring steel.
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

It is often called ‘patented and cold-drawn’ steel wire. There are two important terms
related to patented and cold-drawn steel wires, namely, ‘patenting’ and ‘cold drawing’.
Patenting is de ned as heating the steel to above the critical range followed by rapid
cooling to transform at an elevated temperature from 455° to 465°C. This operation
produces a tough uniform structure that is suitable for severe cold drawing. After this
operation, the spring wire is produced from hot rolled rods by cold drawing through
carbide dies to obtain the required diameter. The patented and cold drawn steel wires are
made of high carbon steel and contain 0.85–0.95% carbon. It has high tensile strength,
high elastic limit and the ability to withstand high stresses under repeated loadings. The
patented and cold-drawn steel wires are the least expensive of all spring materials.
2. Unalloyed oil hardened and tempered spring steel wires and valve spring wire.
Oil-hardened and tempered spring steel wires contain 0.55–0.75% carbon. The wire is
cold drawn and then hardened and tempered. A valve spring wire contains 0.60–0.75%
carbon. It is the highest quality of oil-hardened and tempered steel wire. It has excellent
surface nish and considered to be most reliable for applications involving uctuating
forces. It is used for applications where the stresses are severe.
3. Chromium–vanadium steel and chromium–silicon steel.
Chromium–vanadium steel contains 0.48–0.53% carbon, 0.80–1.10% chromium and
0.15% vanadium. These wires are used for applications involving higher stresses and for
springs subjected to impact or shock loads, such as in pneumatic hammers. Chromium–
silicon spring steel is new compared with other spring steels and it was originally
developed for recoil springs in aircraft guns. Chromium–silicon steel contains 0.51–
0.59% carbon, 0.60–0.80% chromium and 1.2– 1.6% silicon. These wires are used for
applications involving highly stressed springs subjected to impact loading. Alloy steel
wires are superior to carbon steel wires. However, the cost is their limiting factor.
Stainless steel springs, which exhibit an excellent corrosion resistance, are ideal to work
in steam or other corrosive media.
The helical springs are either cold formed or hot formed depending upon the size of the wire.
Wires of small sizes (less than 10 mm diameter) are usually wound cold whereas larger size
wires are wound hot. The strength of the wires varies with size, smaller size wires have greater
strength and less ductility, due to the greater degree of cold working.
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

Terms used in Compression Springs

 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

In the design of helical springs, the designer should use good judgement in assuming the value of
the spring index C. The spring index indicates the relative sharpness of the curvature of the coil.
A low spring index means high sharpness of curvature. When the spring index is low (C < 3), the
actual stresses in the wire are excessive due to curvature effect. Such a spring is dif cult 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 large variation in the coil diameter. Such a spring is
prone to buckling and also tangles easily during handling. A spring index from 4 to 12 is
considered best from manufacturing considerations. Therefore, in practical applications, the
spring index usually varies from 4 to 12. However, a spring index in the range of 6 to 9 is still
preferred particularly for close tolerance springs and those subjected to cyclic loading. the spring
approaches solidity, small pitch differences between coils will lead to progressive coil- to- coil
contact rather than to sudden contact between all coils simultaneously. Any contact leads to
impact and surface deterioration, and to an increase in stiffness.
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

TYLES OF END
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

There are four common methods which are used in forming the ends of the helical compression
spring —plain ends, plain and ground ends, square ends and square and ground ends. The turns
at the two ends do not affect the de ection calculated by the load-de ection equation. Therefore,
while calculating the number of active turns, the end turns should be subtracted from the total
number of turns. It may be noted that part of the coil which is in contact with the seat does not
contribute to spring action and hence are termed as inactive coils. The turns which impart spring
action are known as active turns.
The end should be designed in such a way that the stress concentration at the bend is minimum.
Sometimes the effect of stress concentration in ends is so severe that the spring body becomes
stronger than the end and failure occurs in the end coils. For helical extension ends, all coils are
active coils. The number of active coils (N) is the same as the total number of coils (Nt). Baring
Surface : To improve squareness and reduce buckling during operation, a bearing surface of at
least 270º is required. Squared and ground springs are normally supplied with a bearing surface
of 270º to 330º.

STRESS AND DEFLECTION EQUATIONS

There are two basic equations for the design of helical springs, viz., load-stress equation and
load-deflection equation.
When the equivalent bar is bent in the form of helical coil, there are additional stresses on
account of following two factors: (i) There is direct or transverse shear stress in the spring wire.
(ii) When the bar is bent in the form of coil, the length of the inside bre is less than the length of
the outside bre. This results in stress concentration at the inside bre of the coil.
The resultant stress consists of superimposition of torsional shear stress, direct shear stress and
additional stresses due to the curvature of the coil. The stresses in the spring wire on account of
these factors are shown in Fig
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

The force P acting at the end of the bracket induces torsional shear stress in the bar. The torsional
moment Mt is given by,

Equation (a) does not take into consideration the effect of direct shear stress and stress
concentration due to curvature effect. It requires modi cation. We will assume the following
two factors to account for these effects: KS = factor to account for direct shear stress Kc = factor
to account for stress concentration due to curvature effect The combined effect of these two
factors is given by,
K = KS KC
where K is the factor to account for the combined effect of two factors.
The direct shear stress in the bar is given by,

Superimposing the two stresses of expressions (a) and (b), the resultant shear stress in the spring
wire is given by

The shear stress correction factor (Ks) is de ned as,

 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

So

AM Wahl derived the equation for resultant stress, which includes torsional shear stress, direct
shear stress and stress concentration due to curvature. This equation is given by

where K is called the stress factor or Wahl factor. The Wahl factor is given by,

where C is the spring index. The Wahl factor provides a simple method to nd out resultant
stresses in the spring. The resultant shear stress is maximum at the inside radius of the coil. In
normal applications, the spring is designed by using the Wahl factor.
The angle of twist for the equivalent bar, illustrated in Fig. 10.8(b), is given by,
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

When a helical spring is cut into two parts, the parameters G, d and D remain same and N
becomes (N/2). It is observed from Eq. (10.9), that the stiffness (k) will be double when N
becomes (N/2). The load-de ection curve for helical spring is shown in Fig. 10.11. The area
below the load-de ection line gives the strain energy stored in the spring. Assuming that the load
is gradually applied, the energy stored in the spring is given by,
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

Buckling in helical spring

A helical compression spring that is too long compared to the mean coil diameter, acts as a
exible column and may buckle at a comparatively low axial force. The spring should be
preferably designed as buckle-proof. Compression springs, which cannot be designed buckle-
proof, must be guided in a sleeve or over an arbor. However, provision of guide results in friction
between the spring and the guide and this may damage the spring in the long run. The thumb
rules for provision of guide are as follows:

SERIES AND PARALLEL CONNECTIONS

There are two types of spring connections—series and parallel. The objectives of series and
parallel combinations are as follows:
(i) To save the space;
(ii) (ii) to change the rate of the spring at a certain de ection; and
(iii) (iii) to provide a fail-safe system.
Figure 10.12 shows two springs, with spring rates k1 and k2, connected in series. For
series connection, (i) The force acting on each spring is same and equal to the
external force (ii) The total de ection of the spring combination is equal to the sum of
the de ections of individual springs
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

It is observed that de ections are additive in a series combination, while forces are additive in a
parallel combination. Using this principle, the individual springs can be designed.
Concentric or Composite Springs
A concentric or composite spring is used for one of the following purposes : 1. To obtain greater
spring force within a given space. 2. To insure the operation of a mechanism in the event of
failure of one of the springs.
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

The concentric springs for the above two purposes may have two or more springs and have the
same free lengths and are compressed equally. Such springs are used in automobile clutches,
valve springs in aircraft, heavy duty diesel engines and rail-road car suspension systems.

Factor of Safety
The factor of safety in the design of springs is usually 1.5 or less. The use of a relatively low
factor of safety is justi ed on the following grounds: (i) In most of the applications, springs
operate with well de ned de ections. Therefore, the forces acting on the spring and
corresponding stresses can be precisely calculated. It is not necessary to take higher factor of
safety to account for uncertainty in external forces acting on the spring. (ii) In case of helical
compression springs, an overload will simply close up the gaps between coils without a
dangerous increase in de ection and stresses. (iii) In case of helical extension springs, usually
overload stops are provided to prevent excessive de ection and stresses. (iv) The spring material
is carefully controlled at all stages of manufacturing. The thin and uniform wire cross-section
permits uniform heat treatment and cold working of the entire spring.
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

D-18: The spring loaded safety valve for a boiler is required to blow off at a pressure of 1.3
MPa. The diameter of the valve is 65 mm and the maximum lift of the valve is 17.5 mm.
Design a suitable compression spring for a valve assuming spring index to be 6 and
providing initial compression of 30 mm. Take allowable shear stress of 0.45 GPa and
modulus of rigidity as 84 GPa.

Given: p = 1.3N/mm2=1.3N/mm2,y2=17.5 mm, valve dia =65mm, = 450 MPa, initial

compression (y1) =30mm, C=D/d =6, K= (4C-1/4C-4) +0.615/C=1.25
1. Diameter of wire
=8KFmaxD/3.14*d 3 ------------------------------------------(1)
The load acting on the valve when it just begin to blow off,
F1=3.14/4*65 2*1.3 =4311.6 N (for deflection 30 mm)

Maximum compression of the spring

ymax= 30+17.5= 47.5 mm

Since a load of 4311.6 keeps the valve on its seat by providing initial compression of 30
mm, therefore the maximum load on the spring when the valve is open (i.e. for maximum
compression of 47.5 mm) is Fmax =(47.7/30)*F1=6826.7 N (spring rate is constant F1/y1
=F2/y2)

So d=17.04 mm say 18 mm is obtained from equation (1)

2. Mean diameter of spring
D=6d=108 mm
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

3. No. of active coil

ymax =8*i*FmaxC3/d*G
Given G=84kN/mm2
I=6.1 (active turns) and total no. of turns = i+2= 8.1
4. Pitch of the coil
Solid length of spring =it*d = 145.8 mm
Free length = solid length +y max+0.15*ymax = 200.4 mm
Pitch (p) = free length/ (it - 1) = 28.22 mm

D-17: Design a closed coiled helical compression spring for a service load ranging from
2250 N to 2750 N. The axial deflection of the spring for the load range is 6 mm. Assume a
spring index of 5. The permissible shear stress intensity is 420 MPa and modulus of rigidity
is 84 kN/mm2. Neglect the effect of stress concentration.
Given: F1= 2250 N , initial compression (y1) =x, F2 = 2750, y=6 mm,
Assume =420 MPa, G= 84kN/mm2, C=D/d =5, K= (4C-1/4C-4) +0.615/C=1.31
1. Diameter of wire
=8KFmaxD/3.14*d 3 ------------------------------------------(1)
Fmax =2750 N
So d=10.4 mm say 11 mm is obtained from equation (1)
2. Mean diameter of spring
D=5d=55 mm
3. No. of active coil
ymax =8*i*FmaxC3/d*G
500 N (F2- F1) load produce 6 mm deflection in the spring, so ymax is equal to 33 mm for
2750 N load (spring rate is constant F1/y1 = F2/y2)
i=11.1 (active turns) and total no. of turns = i+2= 13.1
4. Pitch of the coil
Solid length of spring =it*d = 144.1 mm
Free length = solid length +ymax+0.15*ymax = 182.05 mm
Pitch (p) = free length/ (it - 1) = 15.04 mm

D-15: A safety valve of 65 mm diameter is to blow off at a pressure of 1.5MPa. It is held on

its seat by a close coiled helical spring. The maximum lift of the valve is 12 mm. Designs a
suitable compression spring of spring index 5 and providing an initial compression of 38
mm. the maximum shear stress in the material of the wire is limited to 520 MPa. The
modulus of rigidity for the spring material is 85 kN/mm2. Calculate (a) diameter of spring
wire (b) mean coil diameter (c) number of active turns (d) pitch of spring.
Given: p = 1.5MN/m2=1.5N/mm2,y=12mm,valve dia =65mm.
Assume =52MPa, initial compression (y1) =38mm, C=D/d =5, K= (4C-1/4C-4)
+0.615/C=1.31
5. Diameter of wire
=8KFmaxD/3.14*d 3 ------------------------------------------(1)
The load acting on the valve when it just begin to blow off,
F1=3.14/4*65 2*1.5 =4974.9N (for deflection 38mm)
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y

Y
er

er
ABB

ABB
y

y
bu

bu
2.0

2.0
to

to
re

re
he

he
k

k
lic

lic
C

C
w om w om
w

w
w. w.
A B B Y Y.c A B B Y Y.c

Maximum compression of the spring

ymax=38+12= 50 mm
Since a load of 4974.9N keeps the valve on its seat by providing initial compression of 38
mm, therefore the maximum load on the spring when the valve is open (i.e. for maximum
compression of 50 mm) is F max =(50/38)*F1=6545.9 N (spring rate is constant F1/y1
=F2/y2)
So d=14.4mm say 15 mm is obtained from equation (1)
6. Mean diameter of spring
D=5d=75 mm
7. No. of active coil
ymax =8*i*FmaxC3/d*G
Given G=85kN/mm2
I=9.7 (active turns) and total no. of turns = i+2= 11.7
8. Pitch of the coil
Solid length of spring =it*d = 48.5 mm
Free length = solid length +y max+0.15*ymax = 106 mm
Pitch (p) = free length/ (it - 1) = 9.9 mm

Dec 2013:- A valve should blow at a pressure of 15 bar and should lift by 6 mm for 5%
increase in pressure. The diameter of the valve is 60 mm. Design the spring.
Given: p=15bar=15*105N/m2=1.5N/mm2,y=6mm,valve dia =60mm.
Assume =400MPa, C=D/d =5, K= (4C-1/4C-4) +0.615/C=1.31
1. Diameter of wire
=8KFmaxD/3.14*d 3 ------------------------------------------(1)
The load acting on the valve when it just begin to blow off,
F1=3.14/4*60 2*1.5 =4239N, for deflection x
The load acting on the valve when 5% increase in pressure Fmax=3.14/4*60 2*1.5*1.05
=4450.95N for deflection x+6
We know that F1/y1 =F2/y2 , so 4451/4239 = (x+6)/x or x = 120 mm,
and maximum deflection = x+6 = 126 mm
So d=14mm from equation (1)
2. Mean diameter of spring
D=5d=70mm
3. No. of active coil
ymax =8*i*FC3/d*G
Assume G=80kN/mm2
i=31.7 and total no. of turns = i+2= 33.7
4. Pitch of the coil
Solid length of spring =it*d = 471.8 mm
Free length = solid length +y max+0.15*ymax = 616.7 mm
Pitch (p) = free length/ (it - 1) = 18.85 mm

Dec 2012:- design a square helical spring to take 7kN load and permissible defection is
200mm.
Given F=7KN, y=200mm
1. Side of square cross-section of wire
 F T ra n sf o F T ra n sf o
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=2.4KFD/h3
Assume =400MPa, C=D/h or b=10, K=(4C-1/4C-4) +0.615/C=1.14
h2=2.4*7000*1.14*10/400
h=22mm, b=22mm
2. Mean diameter of coil
D=10h=220mm
3. No. of active coil
y=5.66*i*FD3/h4*G
Assume G=80kN/mm2
i=8.8 and total no. of turns = i+2= 10.8
4. Pitch of the coil
Solid length of spring =it*b = 237.6 mm
Free length = solid length +y max+0.15*ymax = 467.6 mm
Pitch (p) = free length/ (it - 1) = 47.7 mm
 F T ra n sf o F T ra n sf o
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A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
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A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
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 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
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A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
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A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
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A B B Y Y.c A B B Y Y.c

SURGE IN SPRING
When the natural frequency of vibrations of the spring coincides with the frequency of external
periodic force, which acts on it, resonance occurs. In this state, the spring is subjected to a wave
of successive compressions of coils that travels from one end to the other and back. This type of
vibratory motion is called ‘surge’ of spring. Surge is found in valve springs, which are subjected
to periodic force. Let us consider a helical compression spring, one end of which is held against a at
 F T ra n sf o F T ra n sf o
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A B B Y Y.c A B B Y Y.c

rigid surface and the other end is subjected to a periodic external force. It always takes some ‘time’ to
transmit this force from one end to the other. If the time required for the wave to travel from one
end to the other and back coincides with the time interval between successive load applications
of periodic external force, resonance occurs and very large de ections of the coils are produced
resulting in very high stresses. Many times, this stress in the coils is more than the endurance
limit stress of the spring and fatigue failure occurs.
Surge is the main cause of failure in valve springs. Surge in springs is avoided by the following
methods: (i) The spring is designed in such a way that the natural frequency of the spring is 15 to
20 times the frequency of excitation of the external force. This prevents the resonance condition
to occur. (ii) The spring is provided with friction dampers on central coils. This prevents
propagation of surge wave. (iii) A spring made of stranded wire reduces the surge. In this case,
the wire of the spring is made of three strands. The direction of winding of strands is opposite to
the direction of winding of the coils while forming the spring. In case of compression of the
coils, the spring tends to wind the individual wires closer together, which introduces friction.
This frictional damping reduces the possibility of surge. Surge is a serious problem in typical
vibrations like valve springs and guns. It is not a problem in other applications where the
external load is steady.
 F T ra n sf o F T ra n sf o
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2.0

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A B B Y Y.c A B B Y Y.c
 F T ra n sf o F T ra n sf o
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A B B Y Y.c A B B Y Y.c