SPRINGS –DATA BOOK
SOURCE
J A L A L U D D IN – C H A P T E R 1 3
1 3 . 1 , 2, 3 , 4 , 5 , 6 , 7 , 8 , 9 , 1 0 , 1 1 , 1 2 , 1 3 1 4
, 1 7 , 1 8 , 1 9 2 0,
L EA F S PR I N G - 1 3 . 22 , 2 3, 2 4 , 25 ,
Springs
It is defined as an elastic element, which deflects under the
action of the load and returns to its original shape when the
load is removed.
Shape of the spring depends on the application.
Spring usage & applications:To absorb shocks and
vibration such as vehicle suspension springs,railway buffer
springs and vibration mounts for machinery.
-to store energy such as clocks , toys,movie cameras, circuit
breakers and starters.
-to measure force eg..weighing balances and scales.
-springs are used to apply force and control motion.eg..cam
and follower mechanism.
Factors to be considered for the design of
prings
Spring design based on its deflection criteria.
Material strength properties.
Service environment.
Desired life.
Manufacturing cost
Spring applications
Helical springs-Brake lever, Spring
balance,Automobiles,Toys.
LEAF SPRINGS-heavy vehicles like
buses,lorry,tractor
TORSIONAL SPRINGS-Toys,watches,Clips and
Clocks.
DISC SPRINGS- Clutches,Pressure relief
valve,Shock absorbers,Buffer springs etc
Terminology of Spring
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.
Ls=n.d
Where n=total no of coils ls
d=diameter of wire
Free length: Length of Spring in un loaded condition.
Lf=solid length+ max compression+ clearence between adjacent coil s.
Lf=n.d+ max+0.15 max
Terminology
Spring Index: Ratio of mean dia of coil to the dia of
the wire.- C=
Spring rate: Load required per unit deflection of
Spring-K =
Pitch: The axial distance between adjacent coils in
un-compressed state.-p=
A.M WAHL factor: k
K= +
Helical spring
Helical spring-made up of wire coiled in the form of
helix.
Primarily intended for compressive or tensile tests.
Cross-section -Circular, Square, Rectangular
Desirable properties & Material for
Helical Spring
Should have high fatigue strength
High ductility
High resilience& Creep resistance
Oil tempered Carbon wires(.6-.7 % C &.6-1% Mn)
Non –ferrous material like Phosphor bronze, Be Cu,
Monel metal, Brass ,.etc
Manufacturing either Cold formed &Hot formed
(depend upon the size of wires).
Small size<10 mm dia---Cold formed
>10 mm dia---Hot formed.
Material for Helical Spring
Should have high fatigue strength
High ductility.
High Resilience& Creep resistance
Oil tempered Carbon wires(0.6-0.7% C & 0.6-1%Mn)
Non –ferrous material like Phosphor Bronze ,Be Cu, Monel metal, Brass e..t.c
Manufacturing either cold formed hot formed(depend upon the size of wires)
Small size<10 mm diameter---cold formed
>10 mm diameter ---Hot formed.
Helical torsion Springs
Maximum shear stress induced in the wire =
= kx =kx ( since C= )
Where k=
Angle of deflection of Helical Spring of Circular wire
=
=
Deflection
=
Stiffness of the Spring = k =
= =
Leaf Spring Design procedure
From the available data ,note the loads to be supported, no of
springs required, space available and other working
conditions.
Choose the suitable material for the leaf spring and assume
its design yield stress in bending. Usually silicon steel& cr –
manganese steel& allowable stress is 400-600 N/
Adopt prestressing method if required, this method(nipping)
is preferable to make all the leaves to be equally stressed.
Adopt at least two leaves include master leaf as full length
leaves & consider other leaves as graduated leaves.
LEAF SPRINGS
Also called as flat springs, laminated springs
Mainly used in automobiles like car, bus etc,,.
Made of flat rolled steel plates& they are arranged in laminated structure.
Their lengths are gradually reduced from first plate to last plate.
All plates are held together to act as a single spring by means of central
band, containing two u-clips and bolted at the centre.
Rebound clips are provided to keep the leaves in alignment & prevent
lateral shifting of the plates during the operation.
These springs are formed into a semi-elliptical shape by providing initial
curvature(known as camber) which is nothing but pre- deflection & this
can be straightened during operation under the applied load.
Leaf spring characteristics
Leaf spring Design procedure
Determine the stress induced in the corresponding
leaves& also find out the deflection produced using
proper equations. Similarly evaluate the width &
thickness of leaves.
Then find out the length of leaves, camber, clipping
load, the radious of curvature etc..,using proper
relations.
Draw the neat sketch of a leaf spring.
NIP& its prominence in in leaf spring
design
Nip is the initial gap which is provided in between
the full length leaves and graduated leaves of the leaf
spring.
If all these leaves are joined by the bolt, then the nip
can be vanished.
With this set up, when the leaf spring is subjected to
load ,all the leaves are equally stressed by the load
and hence may have equal life.
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