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Sheet No. 4 Helical Spring Design 1

The document discusses helical spring design, including estimating spring rates, forces required to compress springs to solid lengths, determining free lengths, and verifying design conditions and factors of safety. It provides examples of calculating properties for springs made of different materials and under different loading conditions. Equations for spring rate and stress are examined for dimensional consistency between U.S. customary and SI units.

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Mohamed Said
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97 views

Sheet No. 4 Helical Spring Design 1

The document discusses helical spring design, including estimating spring rates, forces required to compress springs to solid lengths, determining free lengths, and verifying design conditions and factors of safety. It provides examples of calculating properties for springs made of different materials and under different loading conditions. Equations for spring rate and stress are examined for dimensional consistency between U.S. customary and SI units.

Uploaded by

Mohamed Said
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Mechanical Engineering

Subject: Engineering Design (II)


Sheet No. 4: Helical Spring Design

1) A helical compression spring is wound using 2.5-mm-diameter music wire. The spring has an
outside diameter of 31 mm with plain ground ends, and 14 total coils.
a) Estimate the spring rate.
b) What force is needed to compress this spring to closure?
c) What should the free length be to ensure that when the spring is compressed solid the
torsional stress does not exceed the yield strength?
d) Is there a possibility that the spring might buckle in service?

2) A helical compression spring is made with oil-tempered wire with wire diameter of 0.2 in, mean
coil diameter of 2 in, a total of 12 coils, a free length of 5 in, with squared ends.
a) Find the solid length.
b) Find the force necessary to deflect the spring to its solid length.
c) Find the factor of safety guarding against yielding when the spring is compressed to its solid
length.

3) A helical compression spring is to be made of oil-tempered wire of 4-mm diameter with a spring
index of C = 10. The spring is to operate inside a hole, so buckling is not a problem and the ends
can be left plain. The free length of the spring should be 80 mm. A force of 50 N should deflect
the spring 15 mm.
a) Determine the spring rate.
b) Determine the minimum hole diameter for the spring to operate in.
c) Determine the total number of coils needed.
d) Determine the solid length.
e) Determine a static factor of safety based on the yielding of the spring if it is compressed to its
solid length.

4) A helical compression spring is made of hard-drawn spring steel wire 0.080-in in diameter and
has an outside diameter of 0.880 in. The ends are plain and ground, and there are 8 total coils.
a) The spring is wound to a free length, which is the largest possible with a solid-safe property.
Find this free length.
b) What is the pitch of this spring?
c) What force is needed to compress the spring to its solid length?
d) Estimate the spring rate.
e) Will the spring buckle in service?
5) Consider the steel spring in the Figure below, find:
a) the pitch, solid height, and number of active turns.
b) the spring rate for A227 HD steel spring material.
c) the force Fs required to close the spring solid.
d) the shear stress in the spring due to the force Fs.

6) The spring in Problem (1) is to be used with a static load of 130 N. Verify the next recommended
design conditions if the spring is closed to solid height.

7) The spring in Problem (4) is to be used with a static load of 130 N. Verify the next recommended
design conditions if the spring is closed to solid height.

8) It is instructive to examine the question of the units of the parameter A of Equation:

a) Show that for U.S. customary units the units for Auscu are kpsi . inm and for SI units are MPa .
mmm for ASI. which make the dimensions of both Auscu and ASI different for every material to
which this Equation applies.
b) Also show that the conversion from Auscu to ASI is given by:
ASI = 5 6.895 (25.40)m Auscu

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