Helical Extension Springs

S - Helical Extension Springs
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Compression, Extension, Garter and Torsion Springs

Helical Extension Springs
Introduction
Helical extension springs store energy and exert a pulling force. Usually, they are made from round wire and are close-wound with initial tension. Typical applications include tape cassette players, balance scales, toys, garage doors, automatic washing machines and various types of spring tensioning devices. Helical extension springs are stressed in torsion in the body. Design procedures for the body are similar to those discussed previously for compression springs with the following major exceptions. Most helical extension springs are coiled with initial tension, equal to the minimum force required to separate adjacent coils. Helical extension springs do not normally have set removed. Furthermore, unlike compression springs, extension springs do not have a solid stop to prevent overloading. For these reasons, design stress levels are generally lower for extension than for compression springs. A special type of extension spring, known as a drawbar spring (Figure S-23, below), has a solid stop. It is essentially a compression spring with special hooks.
Figure S-23. Drawbar Spring Provides a Solid Stop. The pulling force exerted by an extension spring body is transmitted to mating parts through hooks or loops. When stresses in the hooks are higher than in the spring body, the hooks limit spring performance.
Initial Tension
Initial tension in an extension spring is measured according to the procedure illustrated in Figure S-24, below. The linear portion of the load deflection curve is extrapolated to zero deflection. The point of intersection on the ordinate is initial tension P1. The amount of initial tension that can be put into a spring depends upon its index, material, method of manufacture and postcoiling stress relief treatment. Occasionally, in critical applications when stress is high, a high stress-relief temperature is required to minimize unfavorable residual stresses due to coiling or forming the hooks. High temperature stress relief reduces the amount of initial tension. Typical values of initial tension are shown in Figure S-25, page 31. High strength materials such as small diameter music wire are able to support higher levels of initial tension than low strength materials such as large diameter hard-drawn wire.
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Figure S-24. Load Deflection Curve for a Helical Extension Spring with Initial Tension.
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Figure S-25. Torsional Stress Due to Initial Tension as a Function of Index in Helical Extension Springs. Types of Ends
Extension springs require a method of attachment to other parts in an assembly. A wide variety of ends have been developed and used successfully for many years - for example, threaded inserts, swivel hooks, twist loops, side loops, cross-center loops and extended hooks. Loops are attachment ends that have small gaps (Figure S28, page 33), while hooks are loops with a large gap. In fact, the variety of ends is almost unlimited. The most common configurations are those that can be formed during the springmaking operation. Typical types include twist, cross center, side loops and extended hooks (Figure S-26, page 32). Many of these configurations are made by bending the last coils of an extension spring to form loops. Most special hooks are formed from straight sections of wire on the so-called "tangent ends" of an extension spring body.
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Figure S-26. Common End Configurations for Helical Extension Springs.

Guidelines for the lengths of common loops are presented in Figure S-26, page 32. Although other configurations and lengths are available, common loops of preferred lengths are generally the most economical. If possible, a spring should be designed with one or both loops at the preferred length. For example, if a design requires a total loop length equal to five times the I.D., a popular choice is one twist loop with a length equal to the I.D. and one extended loop with length equal to four times the I.D. Whenever possible for extended loops, the designer should allow for a straight section approximately three wire diameters long at the end of the wire (A, Figure S-26, above). Loops at each end can be made with a controlled angular relationship. Specifying an angular relationship may add to the cost; therefore, whenever an application permits, a random angular relationship should be allowed. Production of special end configurations may involve tool charges and generally results in increased costs. Stresses in loops are often higher than in the spring body. This limits spring performance, particularly in cyclic applications. Generous bend radii in loops and reduced end coil diameters are two methods frequently employed to reduce stresses. In a full twist loop, stress reaches a maximum at point A in bending and a maximum in torsion at point B (Figure S-27, page 33). Stress at these locations is complex, but can be estimated with reasonable accuracy by:
(S-19)
where
and
(S-20)
Recommended practice is to make C2 greater than four.
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Figure S-27. Location of Maximum Bending and Torsion Stresses in Twist Loops.
Extension Spring Dimensions

Free length of an extension spring is the distance between the inner surfaces of the ends (Figure S-28, below). It is equal to the spring body length plus ends, where spring body length is given by Lbody = d(N + 1) The gap, which is sometimes referred to as hook or loop opening, can be varied by the springmaker. Certain manufacturing processes require a minimum gap. The number of active coils in a spring is approximately equal to the number of coils in its body. For springs with threaded inserts or swivel hooks, the number of active coils is less than the total coils in the body. Hooks and loops add to the number of active coils. Allowances of 0.1 Na are occasionally made for one-half twist loops. Allowances as large as 0.5 Na can be made for some cross center, full twist and extended loops.
Figure S-28. Typical Extension Spring Dimensions. Design Equations

Design equations for extension spring are similar to compression springs. The rate is given by:
(S-21)
where P1 is initial tension. Stress is given by: (S-22)
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Dynamic considerations discussed previously in Section 5 are generally applicable to extension springs. Natural frequency when one end is fixed is given by:
(S-23)
Choice of Operating Stress - Static

Recommended maximum stresses for extension springs used in static applications (Table S-4, below) are similar to levels recommended for compression springs without set removal. For springs that cannot be adequately stress-relieved due to high initial tension requirements, the maximum recommended stress in the body should be reduced to that recommended for their ends. Maximum recommended stress in the ends is lower than in the body because the wire is often stretched, marked or distorted during loop-making. Percent of Tensile Strength In Torsion In Bending Body End End
Materials Patented, cold-drawn or hardened and tempered carbon 45 - 50 40 75 and low alloy steels Austenitic stainless steel and 35 30 55 nonferrous alloys This information is based on the following conditions: set not removed and low temperature heat treatment applied. For springs that require high initial tension, use the same percent of tensile strength as for end.
Table S-4. Maximum Allowable Stresses (KW1 Corrected) for Helical Extension Springs in Static Applications. Choice of Operating Stress - Cyclic
Maximum recommended stresses for extension springs used in cyclic applications are presented in Table S-5, page 35. These data are for stress-relieved springs with low levels of initial tension. Percent of Tensile Strength
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In Torsion Number of Cycles 105 106 Body 36 33 End 34 30
In Bending End 51 47
30 28 45 107 This information is based on the following conditions: not shot peened, no surging and ambient environment with a low temperature heat treatment applied. Stress ratio = 0.
Table S-5. Maximum Allowable Stresses for ASTM A228 and Type 302 Stainless Steel Helical Extension Springs in Cyclic Applications. Clearances
Extension springs, when deflected, do not require central arbors or holes to prevent buckling. When a spring is dynamically loaded or unloaded suddenly (as a cam drop-off), it may vibrate laterally, inducing additional stresses. If clearance is not allowed, this lateral vibration may be noisy and result in premature failure from abrasion of the spring or adjacent parts.
Tolerances
Since requesting close tolerances can increase manufacturing costs, only those characteristics which are critical to spring performance should have tolerances specified. Commercial free length, angular relationship of ends, and load tolerances are presented in Section TG. O.D. tolerances are the same as for compression springs. These tables should be used only as a guide since some manufacturing operations have different process capabilities which can cause variations in tolerance values.
How to Specify
For minimum cost, it is important to specify springs properly. The following checklist is presented as a guide. HELICAL EXTENSION SPRINGS SPECIFICATION CHECKLIST Suggested Design Data: (Fill in required data only.) Wire diameter___________________________ mm Material______________________________________ (in.) Outside diameter________________________ mm(in.) Working Conditions: Total number of Maximum outside diameter_________________ mm coils____________________________ (in.) Free length inside ends___________________ mm(in.) Initial tension_____________________________ N(lbf) Special Information: Load_______________ N(lbf), __________________ Finish_______________________________________ Maximum operating temperature______________ C( at_____________________________ length mm(in.) F) Load_______________ N(lbf), __________________ Operating environment__________________________ at_____________________________ length mm(in.) Frequency of Loading_______________________ Impact Loading____________________ m/sec (in./sec) hertz Required life_____________________________ Rate_______________________________ N/mm cycles (lbf/in) Maximum extended length in service__________ mm Required Reliability (see Section 4)______________ (in.) mm(in.) during installation Direction of coil: right____________ left_____________ optional___________________________________
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Type of ends__________________________________ Position of ends and tolerance____________________ Gap opening and tolerance_________________ mm (in.)
Extension Spring Design Example

A spring is to be incorporated into an overload circuit breaker. It is to be preloaded L1 = 25.00 mm (0.984") and must exert a load of 17.5N (3.93 Ibf), + 15%, when the circuit breaker is closed. If overload occurs, the circuit breaker is tripped and the spring is extended to a length L2 = 29.00 mm (1.142"). The load must be 30 N + 12%, to operate a lock, preventing accidental resetting before the malfunction is corrected. Either twist or extended loops with generous radii are satisfactory. Because of surrounding components the maximum O.D. is 7 mm (0.276"). Probability of overloads is small and breaker operation is expected only three or four times in a year. The spring will not be extended beyond L2 during service or installation. For static application, in an ambient environment, the material selected is ASTM A227. 1. Assume a clearance on O.D. of 10%: O.D. = (0.9) (7) = 6.3 mm 2. Assume S2 = 700 MPa uncorrected; let D = O.D. = 6.3 mm Calculate wire diameter d:
let d = 0.9 mm Tensile strength taken from Figure S-3, page 4, is 1790 MPa. 3. Calculate mean diameter D and coil index C: mm,
4. Calculate mean stress at the extended length:
5. Calculate rate k:
6. Calculate number of coils Na:
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7. Calculate free length Lf and deflections f1 and f2; assume full twist loops:
8. Calculate initial tension PI and uncorrected stress due to initial tension SI:
Referring to Figure S-25, page 31, it can be seen that this is in the preferred range for initial stress for an index of six. 9. Check stresses in the hooks: Bending Stress:
Torsional stress, where R2 = 2.70 mm:
Final Design Specifications

Free Length Lf: 21.78 mm (0.854") Reference Outside Diameter: 6.3 + 0.10 mm (0.248 0.004") Wire Diameter d: 0.9 mm (0.035") Reference Initial Tension Load Pi: 7.45 N (1.68 Ibf) Reference Extended Length L1: 25.00 mm (0.984") Extended Length L2: 29.00 mm (1.142) P1 Load at L1: 17.5 2.0 N (3.93 0.45 Ibf) P2 Load at L2: 30 2.5 N (6.74 0.55 Ibf) Final Design Stress S2: 708 MPa (103,000 psi) 40% TS Na: 13.2 Coils Refer to the load tolerances for helical extension springs (Table S-5, page 35). Tolerance on load for is P1 11%, which is less than the required 15%, and P2 is 8%, which is less than the required 12%.
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Related Topics:
Compression Springs Helical Extension Springs Garter Springs Torsion Springs
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Helical Extension Springs

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Helical Extension Springs

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S - Helical Extension Springs

Compression, Extension, Garter and Torsion Springs

S - Helical Extension Springs

S - Helical Extension Springs

S - Helical Extension Springs

Figure S-26. Common End Configurations for Helical Extension Springs.

Recommended practice is to make C2 greater than four.

S - Helical Extension Springs

Extension Spring Dimensions

Figure S-28. Typical Extension Spring Dimensions. Design Equations

where P1 is initial tension. Stress is given by: (S-22)

S - Helical Extension Springs

Choice of Operating Stress - Static

S - Helical Extension Springs

In Torsion Number of Cycles 105 106 Body 36 33 End 34 30

S - Helical Extension Springs

Extension Spring Design Example

4. Calculate mean stress at the extended length:

6. Calculate number of coils Na:

S - Helical Extension Springs

Torsional stress, where R2 = 2.70 mm:

Final Design Specifications

S - Helical Extension Springs

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