Helical Springs

Lecture 35 Engineering 473 Machine Design

Types of Helical Springs

Extension Springs oppose extension

Compression Springs oppose compression

Torsional Springs oppose rotational motion

Compression Spring Terminology

Spring Internal Forces

The cross section of a spring wire is exposed to a shear force and a torsion moment.
Shigley, Fig. 10-1

Stresses in Helical Springs

max Tr F = + J A
Tr = J

4 J = 2I = d 32
4 A= d 4

d r= 2
FD T= 2

Wire Diameter Pitch Diameter

F = A

Stresses In Helical Springs

(Continued)

Tr J

max

Tr F = + J A 8FD 4F = + 2 3 d d

F = A

max

4 J = 2I = d 32

2 A= d 4

d r= 2

FD T= 2

Stresses in Helical Springs

(Continued)

max

8FD 4F = + 2 3 d d 8FD 4F 2D d = + 2 3 d d 2D d 8FD 8DF d = + 3 3 d d 2D

max

8FD 8DF 1 = + 3 3 d d 2C 8FD 2C + 1 = 3 d 2C 8FD = Ks d 3

max

max

max

max

D Let C = , then d

2C + 1 Ks = 2C

Curvature Stress Concentration Factor

A stress concentration occurs on the inside of a helical spring due to the curvature of the wire. The formula for the stress concentration factor, Kc, is given by

2C(4C + 2) Kc = (4C 3)(2C + 1)

max

8FD = K cKs d3

Curvature Stress Concentration Factor

(Continued)

D C= d
Kc

C Note that for large C, Kc approaches 1. Kc is important for fatigue calculations.

Deflection/Stiffness
Strain Energy/Unit Volume Strain energy from a spring comes from two sources: 1) torsion, and 2) shear loading. Torsion Strain Energy

1 U T = dvol 2 vol

1 U = dvol 2 vol

Tr = ,= J G 1 Tr Tr UT = dvol 2 vol J JG

Deflection/Stiffness
(Continued) Torsion Strain Energy (Continued) Shear Load Strain Energy

1 Tr Tr UT = dvol 2 vol J JG 1 T2 2 r dA dL UT = 2 2 J G LA 1 T 2L UT = 2 JG

1 U T = dvol 2 vol F = ,= G A 1 F F UF = dvol 2 vol A AG 1 F2 L UF = 2 AG

Deflection/Stiffness
(Continued) Total Strain Energy Castiglianos Theorem

U = UT + U F 1 T 2 L 1 F2 L + U= 2 JG 2 AG T = F D 2 1FDL 1FL + U= 2 4JG 2 AG

2 2 2

U y= F FD2 L FL y= + 4JG AG
y => spring deflection due to load F

Deflection/Stiffness
(Continued)

FD L FL + y= 4JG AG

8FD N 1 y= 4 1 + 2 d G 2C 8FD3 N y 4 dG d 4G k= 3 8D N
Equation for stiffness of a spring.

4 J = 2I = d 32 2 A= d 4

D C= d

Extension Spring Ends

The end loop of an extension spring is weaker than the coils. A stress concentration factor of K=rm/ri is present in the loop.
Shigley, Figs 10.2 & 10.3

Compression Spring Ends

Shigley, Fig. 10.5

Compression Spring Ends

(Continued)

These formulas show how the type of ends effect the number of coils and length of the spring.

Spring Materials

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