Definition of spring

 A spring is an elastic object used to store mechanical energy.

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.
 A spring is a flexible element used to exert a force or a torque
and, at the same time, to store energy.
 The force can be a linear push or pull, or it can be radial,
acting similarly to a rubber band around
a roll of drawings.
 Objectives of Spring
1. Absorbing , cushioning, or controlling of energy due to shock and vibration.
Car springs or railway buffers . To control energy, springs-supports and
vibration dampers.
2. Control of motion
 Maintaining contact between two elements (cam and its follower) In a cam
and a follower arrangement, widely used in numerous applications, a spring
maintains contact between the two elements. It primarily controls the
motion.
 Creation of the necessary pressure in a friction device (a brake or a clutch)
A person driving a car uses a brake or a clutch for controlling the car motion. A
spring system keep the brake in disengaged position until applied to stop the
car. The clutch has also got a spring system (single springs or multiple springs)
which engages and disengages the engine with the transmission system.
 Restoration of a machine part to its normal position when the applied force
is withdrawn (a governor or valve)
3. Measuring forces
Spring balances, gages
4. Storing of energy
In clocks or starters
The clock has spiral type of spring which is wound to coil and then the stored
energy helps gradual recoil of the spring when in operation. Nowadays we do
not find much use of the winding clocks.
 spring materials
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 1200C.
Oil-tempered wire
It is a cold drawn, quenched, tempered, and general purpose spring steel. It is not suitable for fatigue or
sudden loads, at subzero temperatures and at temperatures above 1800C.
Chrome Vanadium
This alloy spring steel is used for high stress conditions and at high temperature up to 2200C. It is good
for fatigue resistance and long endurance for shock and impact loads.
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 2500C.
Music wire
This spring material is most widely used for small springs. It is the toughest and has highest tensile
strength and can withstand repeated loading at high stresses. It cannot be used at subzero
temperatures or at temperatures above 12000 C.
Stainless steel:
Widely used alloy spring materials.
Phosphor Bronze / Spring Brass:
It has good corrosion resistance and electrical conductivity. it is commonly used for contacts in electrical
switches. Spring brass can be used at subzero temperatures
 Types of springs

uses Types of springs

Push Helical compression spring, Belleville spring, Torsion spring, force acting at
the end of torque arm. flat spring, such as a cantilever spring or leaf spring
Pull Helical extension spring, Torsion spring, force acting at the end of torque
arm. Flat spring, such as a cantilever spring or leaf spring, Draw bar spring
(special case of the compression spring) constant – force spring.
Radial Garter spring, elastomeric band, spring clamp, Torsion spring, Power spring
torque
 Helical spring
It is made of wire coiled in the form of helix having circular, square or rectangular
cross.
Terms used in Compression Springs

Spring index indicates the relative sharpness of curvature

If C low value: Stresses excessive due to curvature effect
If C high: Prone to buckling
C: 6-9 is preferred

• D = Mean diameter of the spring coil,

• d = Diameter of the spring wire,
• N = Number of active coils,
• G = Modulus of rigidity for the spring material,
• F = Axial load on the spring,
• τ = Maximum shear stress induced in the wire,
• C = Spring index = D/d,
• p = Pitch of the coils, and
• δ = Deflection of the spring, as a result of an
axial load F.
1. 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 total number of coils and the diameter of the wire.
S.L. = 𝑁𝑡 𝑑 𝑁𝑡 = total no. of coil

2. Free length : The free length of a compression spring, as shown in Fig, 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).
Free length of the spring,
FL = Compressed length + 𝛿 = Solid length + Maximum compression +Clearance
3 . Compressed length: The axial length of the spring which is subjected to maximum
compressive force .
4. Pitch. The pitch of the coil is defined as the axial distance between
adjacent coils in uncompressed state.
𝑭𝑳
p=
𝑵𝒕 −𝟏
Stiffness of the spring of Spring rate or spring constant (k): The spring rate is
defined as the load required per unit deflection of the spring. Mathematically,
Spring rate, k = F / δ
where W = Load, and
δ = Deflection of the spring.
Active (N) and inactive coils: Active coils are the coils in the spring which
contribute to spring action, support the external force and deflect under the
action of force.
End coils which do not contribute to spring action are called inactive coils.
inactive coils = 𝑵𝒕 − 𝑵 N = No. of active coils
End Connections for Compression Helical Springs

End Style No. of Active turns N

Plain ends 𝑵𝒕
Plain and Ground ends 𝑵𝒕 − 𝟏/𝟐
Ground ends 𝑵𝒕
Squared ends 𝑵𝒕 − 𝟐
Squared and ground ends 𝑵𝒕 − 𝟐
 STRESS AND DEFLECTION EQUATIONS

There are two basic equations for the design of helical springs viz.
load-stress equation and load deflection equation.
Stresses in spring wire
The force P acting at the end of the bracket induces torsional shear stress in the bar.
The torsional
𝑀𝑡 = 𝐹𝐷 /2
The torsional shear stress in the bar is given by,
16𝑀𝑡 16 𝐹𝐷/2
𝜏1 = 3 =
𝜋𝑑 𝜋𝑑3
8𝐹𝐷
𝜏1 =
𝜋𝑑 3
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 a direct or transverse shear stress in the spring wire.
(i) When the bar is bent in the form of coil, the length of the inside fiber is
less than the length of outside fiber. This results in stress concentration at the
inside fiber of the coil.
the direct shear stress in the bar is given by,

𝐹 8𝐹𝐷 0.5𝐷
𝜏2 = 𝜋 =
𝑑 2 𝜋𝑑 3 𝑑
4

8𝐹𝐷 0.5𝐷
𝜏 = 𝜏1 +𝜏2 = 𝜋𝑑3 1 + 𝑑

0.5𝑑
𝐾𝑠 = 1 + 𝐾𝑠 = shear stress correction factor
𝐷
0.5
𝐾𝑠 = 1 + 𝐶

𝟖𝑭𝑫
𝝉 = 𝑲𝒔 𝟑
𝝅𝒅
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

𝐾𝑤 = 𝐾𝑠 𝐾𝑐 where 𝐾𝑤 is called stress factor or Wahl factor is given by,
4𝐶 − 1 0.615
𝐾𝑤 = +
4𝐶 − 4 𝐶
In normal applications, the spring is designed by using Wahl factor.
When the spring is subjected to fluctuating stresses, two factors 𝐾𝑠 , and 𝐾𝑐 are
separately used.
 Load-Deflection Equation

𝑭
𝑭

𝑭
 Helical Spring: Design Procedure

 Estimate spring force (F) and required deflection (y), In some cases it will be
specified
 Select suitable material, Obtain permissible shear stress, 𝜏=0.5𝑆𝑢𝑡
 Assume spring index value C
 Calculate Wahl factor,
 Determine wire diameter from load-stress equation, d
 Determine coil diameter, D
 Determine number of active coils, by load deflection equation
 Determine total number of coils, it,
 Determine solid length of the spring,
 Find actual deflection, y by load-deflection equation and also free length
(Assuming suitable gaps)
 Obtain pitch of the coil, p
 Determine actual spring rate, k