3 Spring
3 Spring
3 Spring
Aims
The aim of this document is to provide as much information as possible on spring design It is the result of work to which a large number of professions and functions have contributed: designers, material specialists, calculation engineers, buyers, suppliers The aim is to allow the designer to quickly identify best practices for spring design This guide aims at a large degree of openness. The aim is not to forbid but to specify.
Contents
Spring design cycle Choosing the material Material correspondences Wire diameters Influence of temperature Choosing anticorrosion protection Stress level Stainless steels: stress corrosion Very stressed springs When must a spring be shot peened? Relaxation Fatigue, endurance Tolerances Spring packaging Information to be marked on the drawing Purchasing reflexes
Compression springs - Definition Advice End geometry Setting Tangling Specification Control method Extension springs - Definition Advice Ends Loop radii Loop fatigue behaviour Initial tension Tangling of extension springs Specification Control method Torsion springs: Definition Advice Legs geometry Radial legs bending radius Polarisation of torsion springs Specification Control method
All springs
Compression
0.50 to 10.00 mm
< 200 C
All springs
< 10.00 mm
< 250 C
NS : ++++ HS : +++++
5
d
10
JIS G 3522 SWPB 1991 (>) JIS G 3561 SWOSC-V 1994 (<) JIS G 4314 SUS 302 1988 (<)
10
2200 2000
R m (MP a)
E N 1 0 2 7 0 -3 X 1 0 C rN i1 8 -8 N S J IS G 4 3 1 4 S U S 3 0 2 W P A J IS G 4 3 1 4 S U S 3 0 2 W P B
A S TM A 3 1 3 /A 3 1 3 M 3 0 2
Wire diameters
There are no standards for wire diameters. Up to a diameter of 1 mm, we shall choose a wire diameter every 0.05 mm
0.10 0.60 0.15 0.65 0.20 0.70 0.25 0.75 0.30 0.80 0.35 0.85 0.40 0.90 0.45 0.95 0.50 1.00 0.55
Influence of temperature
Temperature variations result in variation of rigidity modules (E, G) that will lead to variations in proportional loads.
Rigidity variation
TC
Disadvantages
For compression springs, grinding the ends removes the coating difficult to properly cover draw and torsional springs with touching coils for small gprings, the coils are bonded after coating.
Do not use electrolytic zinc plating: there is a risk of hydrogen embrittlement requiring degassing that is hard to control at industrial level and whose effects are not guaranteed. Likewise, do not use phosphating, as there is, to a lesser extent than zinc plating, a risk of hydrogen embrittlement during acid pickling, particularly on small diameters Zinc and copper are incompatible: galvanic couple
Temperature withstand:
150C continuously 200C for 1 hour
Material Patented carbon steel SM, SH and DH EN10270-1 Oil hardened steel VDCrSi EN10270-2 Austenitic stainless steel X10CrNi18-8 EN10270-3
Stress level: very stressed The rules defined in this document are springs used to design a spring guaranteeing a
safety margin with respect to stress In some cases, the stress level in the wire may have to be increased, in particular for stainless steels This is possible provided there is compliance with rules not included in the software and not mentioned in this document. For this spring type, work in co-operation with the simulation engineer, the spring manufacturer and/or the IST.
Shot peening
Shot peening is a process consisting of, after coiling, impacting the spring with solid spherical particles at high speed The aim of shot peening is to enhance spring fatigue behaviour The effect of shot peening is to create surface compression stresses and erase surface defects Shot peening is only applicable to compression springs and to extension spring loops
Relaxation
Relaxation and creep are two consequences of the same phenomenon. Under certain conditions, steels may have a viscous behaviour. Viscosity is characterised by a flow that will tend to relax stresses. This phenomenon is particularly pronounced when temperature and/or stress is high. Consequences:
450 400 350 300 effort (N) 250 200 150 100 50 0 23 25 27 29 31 33 35 37 39 longueur (mm)
L2 L1
For springs working between two positions L1 and L2, a cycle is defined by the path L1, L2, L1 Fatigue behaviour can be enhanced (in some cases) by shot peening Prestressing also enhances fatigue behaviour of compression springs
Tolerances
P2 P1
Springs (compression, extension, torsion) will be defined by two operating points, or one operating point and the rate
P2
R
L2
L1
2 operating points
In order to determine tolerances on forces, we can take as a starting point DIN 2095, 2097 et 2194 standards To determine tolerances on rate, we can take as a starting point BS 1726-1, 1726-2 et 1726-3 standards
Spring packaging
Spring packaging is linked to tangling risks This risk concerns all springs Packaging in coils (Staer tubes) is very restrictive with respect to logistics and is very expensive For compression springs, prefer addition of dead coils at the ends of the spring or in the middle of the body.
Purchasing reflexes
Marking sales references on a drawing is equivalent to permanently choosing one supplier, and has a serious impact on spring cost Avoid springs requiring a specific manufacturing means. Special machines are costly and bind us to one supplier. Prestressing of compression springs is expensive: more than 30% of spring cost. Is it always essential? For compression springs, grinding of ends accounts for 30% of spring cost. Is it always essential? Packaging: packaging in Staer tubes is extremely costly: prefer addition of dead coils. Paintwork: requirements relating to paintwork generate high additional costs.
Functional parameters:
L1, L2 : working lengths (mm) F1, F2: forces (N) Ln: minimum operating length (mm)
Execution
Representation
Open, Unground Close, Unground Open, ground Close, ground Close in pigtail form Close and directed towards the centre
P2 +/R
Lmax Lc
L2
L1 Lc
Lmax
L2
L1 Lc
Lmax
L2
L1
P1-P2
P1-Rate
P2-Rate
For springs defined with a force and the rate, we can apply the same control method, and calculate the rate between lengths L1 and L2
hooks
inserts
German loop
English loop
Give preference to German loops: the bend radii are greater than for English loops
Loop definition:
Loop type Orientation Drawing indicating the functional dimensions (opening, additional lengths)
English loop
1,3
1,3
P2 +/K
L0 max
L1
L2
Lmax
L1
L2
Lmax
L1
L2
Lmax
P1-P2
P1-Rate
P2-Rate
Functional parameters:
Ra, Rb: legs distance (mm)
2 radial legs
2 tangent legs
In the case of radial legs, the bending radius radius generates additional stresses
d3 r > d/2 3 < d 6.5 r>d d > 6.5 r > 1.5 d
1.7 1.6 1.5 1.4 q 1.3 1.2 1.1 1 0 0.5 1 1.5 r/d 2 2.5 3
Bending radii recommended by EN 10270 standard, without damage for the wire are :
When the spring is designed, if polarisation is not considered, the real operating angle of the spring is less than the design angle When the spring exhibits a large polarisation, a working drawing is used to obtain the real position of the spring real The angles design can then be marked on the drawing, and the spring designed with the angles real
real
A2 +/K
A1
A2
Amax
A1
A2
Amax
A1
A2
Amax
C1-C2
C1-Rate
C2-Rate
A1 +/-
A1
A2
Amax
C1-drawing
In some cases, when housing is restricted, it might be interesting to specify the rate by defining wire diameter, coil diameter and number of turns (or height)
Drawing example
rules New
For more details on stress ratios Summary carbon steels and austenitic stainless steels
Spring type
Prosc-ressorts
IST : EN DIN
IST : BS ASTM Steel : k Max < 0.70 Rm Stain.: k Max < 0.59 Rm
Steel
Max < 0.56 Rm Max < 0.56 Rm + Stainless steel : k perm < 0.56 Rm Goodman(k ) + k Max < 0.56 Rm Max < 0.45 Rm + Inox : k perm < 0.45 Rm Goodman(k ) + Max < 0.45 Rm k Goodman(k ) + Max < 0.56 Rm Max < 0.45 Rm Goodman(k ) + Max < 0.45 Rm
Compression Dynamic Steel : k Max < 0.70 Rm Stain.: k Max < 0.59 Rm Steel + Goodman(k ) Steel : k Max < 0.49 Rm Stain.: k Max < 0.40 Rm Steel + Goodman(k ) Steel : k Max < 0.49 Rm Stain.: k Max < 0.40 Rm Steel + Goodman(k )
For more details on stress ratios Comparison of criteria - EN/DIN Static - BS/ASTM + IST Compression springs
Carbon steels (49-70%Rm) Austenitic stainless steels (40-59%Rm)
For more details on stress ratios Comparison of criteria - EN/DIN static - BS/ASTM + IST extension springs
For more details on stress ratios Comparison of criteria - EN/DIN Dynamic BS/ASTM + IST Compression springs in Fatigue
max max
59 % Rm
EN/DIN IST
Rm Stainless steels
min
For more details on stress ratios Comparison of criteria - EN/DIN Dynamic - BS/ASTM + IST extension springs in fatigue
max max
40 % Rm
EN/DIN IST
Rm Stainless steels
min
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