UNIT – IV

DESIGN OF ENERGY STORING

ELEMENTS

Prepared by R. Sendil kumar

 INTRODUCTION
SPRINGS:
Spring is an elastic body whose function is
to distort when loaded and to recover its
original shape when the load is removed.
APPLICATION:
1. To absorb energy – suspension systems,
shock absorber, etc.
2. To store energy – watches, toys, etc.
3. To apply force – Brakes, clutches, safety
valves etc.
Continue…
4. To ensure position or contact in Ic engines valves
& cam-follower.
5. To accommodate misalignment – Joining of
railway compartment.
SPRING MATERIAL:
1. Oil – tempered carbon steel
2. Music wire
3. Phasphor Bronze
4. Beryllium Copper
5. Monel metal
6. Brass
Continue…
TYPES OF SPRING:
1. Helical springs
(a) Closed coil spring
(b) open coil spring
2. Conical and volute spring
3. Torsion spring
4. Laminated (or)Leaf spring
5. Disc (or) Bellevile spring
6. Special purpose spring
HELICAL SPRINGS

Open coiled Closed coil

helical spring helical spring
1. The gap between sucessive Small
turns is large
2. Helix angle is less than 10º
more than 10º
3. It can take up tensile It can take up tensile
& compressive load load only
4. Friction effect is less Friction effect is
more
2. Conical and volute springs:
3.Torsional spring:

4. Laminated (or) Leaf spring:

5. Disc (or) bellevile springs
6. Special purpose spring
Classification
 Types of Springs

Helical:

Compression

Extension
Torsion
SPRING PRODUCTS

Tension Spring

Compression Spring
 More Springs

Washer Springs:

Power springs:
Beams:
Applications
PRODUCT APPLICATION
Adjuster Spring
TERMS USED IN COMPRESSION
SPRING
SOLID LENGTH
When the compression spring is compressed until the coils
come in contact with each other the spring is said to be solid.
The solid length of a spring is the product of total number of
coils and the diameter of the wire.
LS=n’×d
n’- total number of coils
d- diameter of the wire
FREE LENGTH
It is the length of the spring in the free or unloaded
condition. It is equal to the solid length plus the maximum
deflection or compression of the spring and the clearance
between the adjacent coils.
LF=n’×d+δmax+0.15 δmax
SPRING INDEX
It is defined as the ratio of the mean diameter of
the coil to the diameter of the coil to the diameter
of the wire.
C=D/d
D- mean diameter of coil
d- diameter of wire
SPRING RATE
It is defined as the load required per unit
deflection of the spring.
q=W/δ
W- applied load
δ - deflection of the spring
PITCH
The pitch of the coil is defined as the
axial distance between adjacent coil in
uncompressed state.
Pitch length=free length/(n’-1)

Mostly square and ground ends

condition is used for compressive
spring.
n’ = n+2
ENDS FOR COMPRESSION HELICAL
SPRING:
 End Conditions
Plain Plain Ground

Na=
Active Coils

Square Square Ground

DESIGN OF HELICAL SPRINGS
There are two aspects of design of springs
1. Stress induced
2. Deflection of the spring
Stresses induced
1. (a) Direct shear stress
(b) Torsional shear stress
 The wall factor after the account for the curvature effect

Using the above equation, wire diameter is to be found.

Deflection of the spring (δ (or) y:
δ = 8WD3n/Gd4
Problems:

1. A helical spring is made from a wire

of 6 mm diameter and has outside
diameter of 75 mm. If the permissible
shear stress is 350 Mpa and modulus
of rigidity 84 kN/mm2, find the axial
load which the spring can carry and
the deflection per active turn.
Continue…

2. Design a spring for a balance to measure 0

to 1000 N over a scale of length 80mm. The
spring is to be enclosed in a casing of 25
mm diameter. The approximate number of
turns is 30. The modulus of rigidity is 85
kN/mm2. Also calcualte the maximum
shear stress induced.
Continue…
3. A helical compression spring made of oil
tempered carbon steel is subjected to a load
which varies from 400 N to 1000 N. The
spring index is 6 and design factor of safety is
1.25. If the yield shear stress 770 Mpa and the
endurance shear stress is 350 Mpa.
(i) Size of the spring wire
(ii) Diameter of spring
(iii) Number of turns of spring
(iv) Free length of spring. The compression
spring maximum load 30 mm. Take G = 80
kN/mm2.
 Given: Given : D = 50 mm ; d = 5 mm ; *n = 20 ; W = 500 N

Find: Maximum Shear Stress ( ) 

Solution:
Spring index D 50
C    10
d 5
1 1
Shear stress factor KS  1   1  1.05
2C 2 10

Maximum Shear stress

PSG 7.100
Continue…

5. Design a close – coiled helical spring of

silicon – manganese steel for the valve of an
IC engine capable of exerting a net force of 65
N when the valve is open and 54 N when the
valve is closed. The internal and external
diameters are governed by space limitations,
as it has to fit over bushing of 19 mm outside
diameter and go inside a space of 38 mm
diameter. The valve lift is 6 mm. (N/D 2010)
6. A helical compression spring made of circular
wire is subjected to an axial force, when varies
from 2.5 kN to 3.5 kN over this range of forces,
the deflection of the spring should be
approximately 5mm. The spring index can be
taken as 5. The spring has square and ground
ends. The spring is made of patterned and cold
drawn steel wire and ultimate strength of 1050
N/mm2 and modulus of rigidity 81370 N/mm2.
The permissible shear stress for the spring wire
should be taken 50% of the ultimate strength.
Find, (i)wire diameter (ii) mean coil diameter (iii)
number of active coils (iv) total number of coils
(v) solid length of the spring (vi) free length (vii)
required spring rate (viii) actual spring rate.
7. Design a close coiled helical springs for a
service load ranging from 2250 N to 2750
N. The axial deflection of the spring for the
load range of 6mm. Assume a spring index
of 5. The permissible shear stress intensity
is 420 Mpa and modulus of rigidity G = 84
kN/mm2. Neglect the effect of
concentration. Draw a fully dimensioned
sketch of the spring. Show spring details
the finish end coils.
8. Design a helical spring for a spring loaded
safety valve (Ramsbottom safety valve) for
the following conditions: Diameter of valve
seat = 65 mm, operating pressure = 0.7
N/mm2, maximum pressure when the valve
blows off freely = 0.75 N/mm2, maximum
lift of the valve when the pressure rises
from 0.7 to 0.75 N/mm2 = 3.5 mm,
maximum allowable stress = 550 Mpa,
modulus of rigidity = 84 kN/mm2, spring
Index = 6. Draw a neat sketch of the free
spring showing the main dimensions.
 Leaf spring
It is used in automobile suspension systems.
These are called graduated (or) laminated
springs, because number of flat plates are
stacked together. By geometry they are semi-
elliptical in shapes.
Continue…
Problems:
A locomotive semielliptical laminated spring has an
overall length of 1m and sustains a load of 70 kN
at its centre. The spring has 3 full length leaves
and 15 graduated leaves with a central band of
100 mm width. All the leaves are to be stressed to
400 Mpa, when fully loaded. The ratio of the total
spring depth to that of width is 2. Take young
modulus is 210 kN/mm2. Determine (i) the
thickness and width of the leaves (ii) the initial
gap that should be provided between the full
length and graduated leaves before the band load
is applied and (iii) the load exerted on the bank
after the spring is assembled.
Continue…
Design a leaf spring for the following
specifications: Total load 140 kN,
Number of springs supporting the load
= 4, maximum number of leaves 10,
span of the spring = 1000 mm,
permissible deflection = 80 mm, Take
young’s modulus (E) = 200kN/mm2
and allowable stress in the spring
material as 600 Mpa.
A semi elliptical laminated spring is made of 50
mm wide and 3 mm thick plate. The length
between supports is 65 cm and the width of
band is 6 cm. The spring has 2 full length
leaves and 5 graduated leaves. If the spring
carries a central load of 2 kN. Find (i)
maximum stress in full length leaves and
graduated leaves, for a initial condition of no
stress in the leaves. (ii) maximum stress if the
initial stress is provided to cause equal stress
when loaded.
Practice:

 A closed – coiled helical compression spring has

plain ends and is to fit over a 25 mm diameter
rod. When a compressive force of 100 N is
applied to the spring it compresses by 50 mm. If
the spring has a preferred wire diameter of 4 mm,
and the spring material has a maximum allowable
shear stress of 180 MN/m2 and a modulus of
rigidity of 81 GN/m2, determine
(i) The mean coil diameter of the spring
(ii) The number of coil in the spring
(iii)The solid length of the spring
(M/J 2014)
Continue…

Design a closed coiled helical spring subjected a

tensile load of magnitude varying from 2500
N to 3000 N and axial deflection of spring for
the range of load is 65 mm. Design the spring,
taking the spring index as 6 and safe shear
stress for material equal to 465 Mpa.
(N/D 2014)
DESIGN OF FLYWHEELS
 Flywheel
 A rotating mechanical device that is used to
store rotational energy.

 A flywheel is used in machines , serves as a

reservoir which stores energy during the period
where the supply of energy is more than the
requirement.

 Conversely, a flywheel releases stored energy by

applying torque to a mechanical load, thereby
decreasing the flywheel's rotational speed.
 Flywheel
 In other words it can be defined as “it stores energy
during power stroke and delivers during idle strokes”.

 A little considerations will show that when the flywheel

absorbs energy, its speed increases and when it releases,
the speed decreases. Hence a flywheel does not maintain a
constant speed, it simply reduces the fluctuation of speed.

 The flywheel’s position is between the engine and clutch

patch to the starter.
 How is it used?

 A rotating mechanical device that is used to

store rotational energy.
 It acts like a reservoir and stores the energy in
mechanical form
 It Supply energy when required.
 Releases it when it is more then required.
 Energy is stored by the formula
E = ½ Iω2
 Where “I” is the moment of inertia and it can vary for
different shapes of wheels. For solid disk the
“I=Mr2/2”.
 “ω” is the rotational velocity and it is in (rad/sec).
 Functions and Operation

 Fly wheel smoothen out variations in the speed of a

shaft caused by torque fluctuations if source of
driving torque is fluctuating.
 It is also used to provide continuous energy in system.

 It is also used to supply intermittent pulses of energy

at transfer rates that exceed the abilities of its energy
source.
 How to Design Flywheel?

Design Approach:-
There are two stages for it
 The degree at which energy is required to smoothen
and its moment of inertia.
 The geometry of flywheel.
Design Parameters:-
 It depend upon acceptable changes in the speed.
Speed fluctuation:-
 The change in the shaft speed during a cycle is called
the speed fluctuation and it is given by
Fl =ωmax−ωmin
Flywheel in automotives
 A Flywheel is used to maintain constant angular
velocity of the crankshaft in a reciprocating
engine.

 In this case, the flywheel—which is mounted on

the crankshaft—stores energy when torque is
exerted on it by a firing piston and it releases
energy to its mechanical loads when no piston is
exerting torque on it.
Problems
The intercepted areas between the output torque curve
and the mean resistance line of a turning moment
diagram for a multi cylinder engine, taken in order
from one end are as follows:
-35,+410, -285, +325, -335, +260, -365, +285, -260
mm2.
The diagram has been drawn to a scale of 1mm = 70 N-
m and 1mm = 4.5º. The engine speed is 900 rpm and
the fluctuation in speed is not to exceed 2% of the
mean speed.
Find the mass and cross-section of the flywheel rim
having 650 mm mean diameter. The density of the
material of the flywheel may be taken as 7200 kg/m3.
The rim is rectangular with the width 2 times the
thickness. Neglect effect of arms etc.
The areas of the turning moment diagram for
one revolution of a multi cylinder engine with
reference to the mean turning moment, below
and above the line, are -32, 408, -267, 333, -
310, 226, -374, 260, -244 mm2. The scale for
abscissa and ordinate are: 1 mm = 2.4º and
1mm = 650 N-m respectively. The mean speed
is 300 rpm with a percentage speed fluctuation
of ±1.5%. If the hoop stress in the material of
the rim is not to exceed 5.6 Mpa, determine
the suitable diameter and cross section for the
flywheel, assuming that the width is equal to 4
times the thickness. The density of material
may be taken as 7200 Kg/m3. Neglect the
effect of the boss and arms. (N/D 2014)
A multi-cylinder engine is to run at a constant load
at a speed of 600 rpm. On drawing the crank
effort diagram to a scale of 1mm = 250 N-m and 1
mm = 3º, the areas in sq. mm above and below the
mean torque line are as follows:
160, -172, 168, -191, 197, -162 sq. mm. The speed
is to be kept within ± 1% of the mean speed of the
engine. Calculate the necessary moment of inertia
of the flywheel. Determine suitable dimensions
for cast iron flywheel with a rim whose breadth is
twice its radial thickness. The density of cast iron
is 7250 kg/m3, and its working stress in tension is
6 Mpa. Assume that the rim contributes 92% of
the flywheel effect. (N/D 2011, M/J 2014)
Practice:
An engine runs at a constant load at a speed of 480
rpm. The crank effort diagram is drawn to a scale
1mm = 200 N-m torque and 1 mm = 3.6º crank
angle. The areas of the diagram above and below
the mean torque line in sq.mm are in the following
order: +110, -132, +153, -166, +197, -162. Design
the flywheel if the total fluctuation of speed is not to
exceed 10 rpm and the centrifugal stresses in the
rim is not to exceed 5 Mpa. Assume that the rim
breadth is approximately 2.5 times the rim thickness
and 90% of thee moment of inertia is due to rim.
The density of the material of the flywheel is 7250
kg/m3. (M/J 2012)
END