Helical Spring Design
Introduction.... Nomenclature.... Spring Index .... Spring Rate.... Spring Stress Values.... Compression
Spring Formula....
Compression Spring End Designs .... Extension Springs.... Rectangular Section Springs.... Conical
Helical Springs....
INTRODUCTION
A helical spring is a spiral wound wire with a constant coil diameter and uniform pitch. The most
common form of helical spring is the compression spring but tension springs are also widely used.
. Helical springs are generally made from round wire... it is comparatively rare for springs to be
made from square or rectangular sections. The strength of the steel used is one of the most
important criteria to consider in designing springs. Most helical springs are mass produced by
specialists organisations. It is not recommended that springs are made specifically for
applications if off-the-shelf springs can be obtained to the job.
Tension Springs
Compression Springs
Nomenclature
C = Spring Index D/d
d = wire diameter (m)
D = Spring diameter (m)
Di = Spring inside diameter (m)
Dil = Spring inside diameter (loaded ) (m)
E = Young's Modulus (N/m2)
F = Axial Force (N)
G = Modulus of Rigidity (N/m2)
K d = Traverse Shear Factor = (C + 0,5)/C
K W = Wahl Factor = [(4C-1)/(4C+5)}]+ (0,615/C)
L = length (m)
L 0 = Free Length (m)
L s = Solid Length (m)
n t = Total number of coils
n = Number of active coils
p = pitch (m)
y = distance from neutral axis to outer fibre of wire (m)
τ = shear stress (N/m ) 2
τ = Max shear stress (N/m )
max
2
θ = Deflection (radians)
Note: metres (m) have been shown as the units of length in all of the variables above for
consistency. In most practical calculations milli-metres will be more convenient.
Spring Index
The spring index (C) for helical springs in a measure of coil curvature ..
For most helical springs C is between 3 and 12
Spring Rate
Generally springs are designed to have a deflection proportional to the applied load (or torque -for
torsion springs). The "Spring Rate" is the Load per unit deflection.... Rate (N/mm) = F(N) / d
e(deflection=mm)
Spring Stress Values
For General purpose springs a maximum stress value of 40% of the steel tensile stress may be
used. However the stress levels are related to the duty and material condition (ref to relevant
Code/standard). Reference Webpage Spring Materials
Compression Springs- Formulae
a) Stress
A typical compression spring is shown below
Consider a compression spring under an axial force F. If a section through a single wire is taken
it can be seen that, to maintain equilibrium of forces, the wire is transmits a pure shear load F and
also to a torque of Fr.
The stress in the wire due to the applied load =
This equation is simplified by using a traverse shear distribution factor K d = (C+0,5)/C.... The
above equation now becomes.
The curvature of the helical spring actually results in higher shear stresses on the inner surfaces
of the spring than indicated by the formula above. A curvature correction factor has been
determined ( attributed to A.M.Wahl). This (Wahl) factor D w is shown as follows.
This factor includes the traverse shear distribution factor K d.. The formula for maximum shear
stress now becomes.
b) Deflection
The spring axial deflection is obtained as follows.
The force deflection relationship is most conventiently obtained using Castigliano's
theorem. Which is stated as ... When forces act on elastic systems subject to small
displacements, the displacement corresponding to any force collinear with the force is equal to the
partial derivative to the total strain energy with respect to that force.
For the helical spring the strain energy includes that due to shear and that due to torsion.
Referring to notes on strain energy Strain Energy
Replacing T= FD/2, l = πDn, A = πd2 /4 The formula becomes.
Using Castiglianos theorem to find the total strain energy....
Substituting the spring index C for D/d The formula becomes....
In practice the term (1 + 0,5/C 2) which approximates to 1 can be ignored
c) Spring Rate
The spring rate = Axial Force /Axial deflection
In practice the term (C2 /(C2 + 0,5)) which approximates to 1 can be ignored
Compression Spring End Designs
The figure below shows various end designs with different handing. Each end design can be
associated with any end design. The plain ends are not desirable for springs which are highly
loaded or for precise duties.
The table below shows some equations affected by the end designs...
Note: The results from these equations is not necessarily integers and the equations are not
accurate. The springmaking process involves a degree of variation...
Plain and Closed and
Term Plain Closed
Ground Ground
End Coils (n e ) 0 1 2 2
Total Coils (n t ) n n+1 n+2 n+2
Free Length (L
pn+d p(n+1) pn +3d pn +2d
0 )
Solid Length (L s
d(n t +1) dn t d(n t +1 dn t
)
Pitch(p ) (L 0-d)/n L 0/(n +1) (L 0-3d)/n (L 0-2d)/n
Helical Extension Springs
The formulae provided for the compression springs generally also apply to extension springs.
An important design consideration for helical extensions springs is the shape of the ends which
transfers the load to the the spring body. These must be designed to transfer the load with
minimum local stress concentration values caused by sharp bends. The figures below show
some end designs.. The third design C) design has relatively low stress concentration factors.
Extension Spring Initial Tension
An Extension spring can have an initial tension which must be exceeded before any deflection can take place.
When the load exceeds the initial tension the spring behaves according the the formulae above.
The initial tension load can be calculated from the formula.... W i = π S i d 3/ ( 8 D)
Maximum value of Initial Stress (S i) for a spring related to the Spring Index (D/d)
D/d Initial Tension Stress
- (N/mm 2 )
3 172.25
4 155.03
5 137.80
6 124.02
7 111.62
8 99.91
9 89.57
10 79.92
11 73.03
12 66.14
13 60.63
14 54.43
15 48.23
Helical Springs (Rectangular Wire)
Spring Rate and Stress
Rate (N/mm) = K 2 G b t 3/ (N D 3) Stress (N/mm 2) = K 1 W D /( b t 2 )
b = largest section dimension(mm)
t = Smallest Section dimension(mm)
K 1 = Shape Factor (see table)
K 2 = Shape Factor (see table)
C = Spring Index = D/(radial dimension = b or t)
b/t 1.0 1.5 1.75 2.0 2.5 3.0 4.0 6.0
K1 2.41 2.16 2.09 2.04 1.94 1.87 1.77 1.67
K2 0.18 0.25 0.272 0.292 0.317 0.335 0.385 0.381
Conical Helical Compression Springs
These are helical springs with coils progressively change in diameter to give increasing stiffness
with increasing load. This type of spring has the advantage that its compressed height can be
relatively small. A major user of conical springs is the upholstery industry for beds and settees.
D1 = Smaller Diameter
D2 = Larger Diameter
Allowable Force on Spring...
Fa = allowable force (N)..τ = allowable shear stress (N/m2)
Stiffness of Spring...
