DESIGN OF ENERGY

STORING ELEMENTS
Assignment 2 - ME9261
SPRINGS - INTRODUCTION
A spring is defined as an elastic body, whose function is to distort
when loaded and to recover its original shape when the load is removed.

Important applications of springs:
To cushion, absorb or control energy due to either shock or vibration as in
car springs, railway buffers, air-craft landing gears, shock absorbers and
vibration dampers.
To apply forces, as in brakes, clutches and spring loaded valves.
To control motion by maintaining contact between two elements as in cams
and followers.
To measure forces, as in spring balances and engine indicators.
To store energy, as in watches, toys, etc.

TYPES OF SPRINGS
Helical springs - The helical springs are made
up of a wire coiled in the form of a helix and is
primarily intended for compressive or tensile
loads.
Conical and volute springs - The conical and
volute springs, as shown in are used in special
applications where a telescoping spring or a
spring with a spring rate that increases with
the load is desired.
Torsion springs - These springs may be of helical
or spiral type . The helical type may be used only
in applications where the load tends to wind up the
spring and are used in various electrical
mechanisms. The spiral type is also used where the
load tends to increase the number of coils and when
made of flat strip are used in watches and clocks.
Compressive and tensile helical spring
TYPES OF SPRINGS CONT
Laminated or leaf springs - The laminated or leaf
spring (also known as flat spring or carriage spring)
consists of a number of flat plates (known as leaves)
of varying lengths held together by means of clamps
and bolts. These are mostly used in automobiles.
Disc or bellevile springs - These springs consist of a
number of conical discs held together against
slipping by a central bolt or tube. These springs are
used in applications where high spring rates and
compact spring units are required.
Special purpose springs - These springs are air or liquid springs, rubber springs, ring
springs etc. The fluids (air or liquid) can behave as a compression spring.
HELICAL SPRINGS
The material of the spring should have high fatigue strength, high ductility,
high resilience and it should be creep resistant. It largely depends upon the
service for which they are used i.e. severe service, average service or light
service.
The springs are mostly made from oil-tempered carbon steel wires
containing 0.60 to 0.70% carbon and 0.60 to 1.0% manganese.
The helical springs are either cold formed or hot formed depending upon the
size of the wire.

Terms used in Compression Springs:
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.
Solid length of the spring LS = n.d
where n' = Total number of coils, and d = Diameter of the wire.
HELICAL SPRINGS
Free length: The free length of a compression spring is the length of the spring
in the free or unloaded condition.
Free length of the spring, LF = Solid length + Maximum compression +
*Clearance between adjacent coils (or clash allowance)
LF = n'.d +max +0.15 max
Spring index: The spring index is defined as the ratio of the mean diameter
of the coil to the diameter of the wire. Mathematically,

Spring index, C = D / d
where D = Mean diameter of the coil, and d = Diameter of the wire.
Spring rate: The spring rate (or stiffness or spring constant) is defined as the
load required per unit deflection of the spring. Mathematically,
Spring rate, k =W / where W = Load, = Deflection of the spring.

Pitch: The pitch of the coil is defined as the axial distance between adjacent
coils in uncompressed state. Mathematically,
Pitch of the coil, p = Free length (n 1)
The pitch of the coil may also be obtained by using the following relation,
STRESSES IN HELICAL SPRINGS OF
CIRCULAR WIRE
Consider a helical compression spring made of circular wire and subjected to an axial
load W.
Let D = Mean diameter of the spring coil,
d = Diameter of the spring wire,
n = Number of active coils,
G = Modulus of rigidity for the spring material,
W = Axial load on the spring,
= Maximum shear stress induced in the wire,
C = Spring index = D/d,
p = Pitch of the coils,
= Deflection of the spring, as a result of an
axial load W.
Consider a part of the compression spring. The load W tends to rotate the wire due to the
twisting moment ( T ) set up in the wire. Thus torsional shear stress( ) is induced in the
wire.
In addition to the torsional shear stress (1) induced in the wire, the following stresses
also act on the wire :
1. Direct shear stress due to the load W, and
2. Stress due to curvature of wire.
Direct shear stress due to the load W,
Maximum shear stress induced in the
wire,
= Torsional shear stress + Direct
shear stress
Maximum shear stress
induced in the wire,




K = Wahl stress factor
Deflection of Helical Springs of Circular Wire:

TENSION SPRING IN A PRINTING PRESS
Tension springs are widely used in printing machines
FLYWHEEL AT A PRINTING PRESS
FLYWHEEL - INTRODUCTION
A flywheel used in machines serves as a reservoir which stores energy
during the period when the supply of energy is more than the requirement
and releases it during the period when the requirement of energy is more
than supply.
The difference between the maximum and minimum speeds during a cycle
is called the maximum fluctuation of speed. The ratio of the maximum
fluctuation of speed to the mean speed is called coefficient of fluctuation
of speed.

Energy stored in a flywheel:
when a flywheel absorbs energy its speed increases and when it gives up
energy its speed decreases.

Stresses in a Flywheel Rim:

1. Tensile stress due to centrifugal force,
2. Tensile bending stress caused by the restraint
of the arms, and
3. The shrinkage stresses due to unequal rate
of cooling of casting.
DESIGN OF FLYWHEEL ARMS
DESIGN OF SHAFT, HUB AND KEY
QUESTIONS
Design a compression helical spring to carry a load of 500 N with a deflection of 25 mm.
The spring index may be taken as 8. Assume the values for the spring material:
solution:
Permissible shear stress = 350 MPa
Modulus of rigidity = 84 kN/mm2
Which springs are widely used in printing machines
(a) Helical tension spring (b) Spiral spring (c) Torsion spring (d) Bellevile spring

Ans : Helical tension spring
QUESTIONS
The maximum fluctuation of speed of a flywheel is the
(a) difference of minimum fluctuation of speed and the mean speed
(b) difference of the maximum and minimum speeds
(c) sum of the maximum and minimum speeds
(d) variations of speed above and below the mean resisting torque line
Ans: (b) difference of the maximum and minimum speeds

The coefficient of fluctuation of speed is the ........... of maximum fluctuation of speed
and the mean speed.
(a) product (b) ratio (c) sum (d) difference
Ans: (b) ratio

Due to the centrifugal force acting on the rim, the flywheel arms will be subjected to
(a) tensile stress (b) compressive stress (c) shear stress (d) none of these
Ans: (a) tensile stress
THANK YOU