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Design of Helical Springs By Prof S S Chauhan, IEC College of Enginee...

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Design of Helical Springs

common form of helical spring is the compression spring but tension springs are also widely used.

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Helical springs are generally made from round wire. It is comparatively rare for springs to be made

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from square or rectangular sections. The strength of the steel used is one of the most important

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By Prof S S Chauhan, IEC College of Engineering & Technology, Greater Noida

Design of Helical Springs

A helical spring is a spiral wound wire with a constant coil diameter and uniform pitch. The most

criteria to consider in designing springs. Most helical springs are mass produced by specialists

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organizations. It is not recommended that springs are made specifically for applications if

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off-the-shelf springs can be obtained to the job.

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The design of a new spring involves the following considerations:

Space into which the spring must fit and operate.
Values of working forces and deflections
Accuracy and reliability needed.

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Tolerances and permissible variations in specifications.

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Environmental conditions such as temperature, presence of a corrosive atmosphere.

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Cost and qualities needed.

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The designers use these factors to select a material and specify suitable values for the wire size, the

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number of turns, the coil diameter and the free length, type of ends and the spring rate needed to

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satisfy working force deflection requirements. The primary design constraints are that the wire size
should be commercially available and that the stress at the solid length be no longer greater than

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when the load exceeds a critical value. Similarly compression coil springs will buckle when the free

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length of the spring is larger and the end conditions are not proper to evenly distribute the load all

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Stability of the spring (Buckling)

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Buckling of column is a familiar phenomenon. Buckling of column is a familiar phenomenon. We

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the tensional yield strength. Further functioning of the spring should be stable.

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have noted earlier that a slender member or column subjected to compressive loading will buckle

along the circumference of the coil. The coil compression springs will have a tendency to buckle
when the deflection (for a given free length) becomes too large. Buckling can be prevented by
limiting the deflection of the spring or the free length of the spring.
The behavior can be characterized by using two dimensionless parameters, critical length and
critical deflection. Critical deflection can be defined as the ratio of deflection (y) to the free length
(Lf) of the spring. The critical length is the ratio of free length (Lf) to mean coil diameter (D) The
critical deflection is a function of critical length and has to be below a certain limit. As could be
noticed from the figure absolute stability can be ensured if the critical length can be limited below a
limit.

Similarly compression coil springs will buckle when the deflection (for a given free length) becomes
too large. The condition for absolute stability can be given as:

For steels this can be simplified as:

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