Springs

A spring is an elastic member whose primary function

is to deflect or distort when loaded & thus absorbs
energy. It recovers its original shape when the load is
removed.
Springs may be used to:
1. cushion the effect of a shock or impact loading.
2. To maintain contact between two elements such as
a cam & its follower.
3. To measure forces as in spring balance, or to apply
forces as in brakes, clutches, cylinder valves, etc.
4. To store energy as in watches, toys etc.,

Dr. Ramesh Sharma

Dept .of. Mech Engg, RVCE Bangalore
 Types of Springs
Springs are mainly classified as;
1. Helical compression springs
2. Helical extension springs
3. Torsion springs
4. Laminated or leaf springs
5. Disc or Belleville springs.

Dr. Ramesh Sharma

Dept .of. Mech Engg, RVCE Bangalore
Compression Springs
Dr. Ramesh Sharma
Dept .of. Mech Engg, RVCE Bangalore
Extension springs
Dr. Ramesh Sharma
Dept .of. Mech Engg, RVCE Bangalore
 Torsion
springs

Dr. Ramesh Sharma

Dept .of. Mech Engg, RVCE Bangalore
Semielliptical Leaf Springs
Dr. Ramesh Sharma
Dept .of. Mech Engg, RVCE Bangalore
Disc or Belleville Springs
Dr. Ramesh Sharma
Dept .of. Mech Engg, RVCE Bangalore
Stresses in Helical Spring of circular wire
Consider a helical compression spring made of
circular wire subjected to a load ‘F’ as shown in fig.

d
T
F
D
Dr. Ramesh Sharma
Dept .of. Mech Engg, RVCE Bangalore
Let D = Mean diameter of the coil
d = Diameter of the spring wire
i = Number of active coils
G=Modulus of rigidity of spring material
c=spring index=(D/d)
t=Maximum shear stress induced in the wire
y=deflection of the spring
The action of the force tends to
(i) rotate the wire, thereby causing torsional stresses
‘t1’ in the wire.
(ii) Cause direct shear stress ‘t2’ due to direct shear force.
Dr. Ramesh Sharma
Dept .of. Mech Engg, RVCE Bangalore
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
 Axis of spring

combined stress taking curvature

Pure shear stress Direct shear stress
effect into account

For the equations, refer Page 169.

shear stress t ......11.1d Page 169
Wahl’s factor K…….11.2a Page 169
Spring index C ………11.2c Page 139
Dr. Ramesh Sharma
Dept .of. Mech Engg, RVCE Bangalore
Deflectionof helical spring
Tl
By torsion equation, angle of twist  
GJ
FD
where the twisting moment T 
2
Length of the wire l  Di
d 4
Polar moment of inertia J  . Substituting the above values,
32
FD Di 32 16 FD 2i
   4 
2 G d Gd 4
D D 16 FD 2i 8FD3i
Axial deflection y     4
 4
11.5a Page 139
2 2 Gd Gd
Spring scale OR Spring rate OR Stiffness
F d 4G
F0   3
11.7a Page 139
Dr. Ramesh Sharma
y 8iD Dept .of. Mech Engg, RVCE Bangalore
 Problem 1
Design a helical compression spring to support an
axial load of 3000 N, the deflection under the load
being limited to 60 mm. The spring index is 6. The
spring is to be made of chrome-vanadium steel. Take
factor of safety = 2.0
Given Data: F=3000N, y=60 mm, C=(D/d)=6, FOS=2.0
t(te/FOS) where te is elastic limit in torsion for
chrome-vanadium steel.
Dr. Ramesh Sharma
Dept .of. Mech Engg, RVCE Bangalore
 From Table 11.5, page 191, for chrome vanadium steel,
(Column. No 9 & 10)
Elastic limit in torsion te =690 MPa
Rigidity modulus G=78450 MPa
Applying Factor of safety of 2, the allowable shear stress
t=(690/2)=345 MPa (N/mm2).
1. Diameter of the wire:
8 FDK 8 FCK D
Shear stresst   (as C  )
d 3
πd 2
d
where K  Wahl' s stress factor
4C - 1 0.615
K   1.2525
4C - 4 C
8  3000  6  K
345   Dr.dRamesh
 12Sharma
.89mm  13mm
πd 2
Dept .of. Mech Engg, RVCE Bangalore
2. Mean diameter of the coil :
D  Cd  6 13  78 mm
Inside dia of coil Di  ( D  d )  (78  13)  65mm
Outside dia of coil D o  ( D  d )  (78  13)  91mm
3.Number of active turns(coils) :
8FD3i 8  3000  783  i
Deflection y   60   i  11.8  12 turns
Gd 4
78450 13 4

4.Free length of the spring : For squared & ground ends, free length
lo  (i  2)d  y  a 11.20a Page 142
where a  clearance between working coils under maximum load
Take a  25% of maximum deflection  25% of 60  15 mm
lo  (12  2)13  60  15  257mm

Dr. Ramesh Sharma Dept .of. Mech Engg,

RVCE Bangalore
 Table 11.4 Page 189
Different types of spring coil ends

Plain end Ground Square end Square & Ground

Dr. Ramesh Sharma Dept .of. Mech Engg,

RVCE Bangalore
 lo  2d 257  2 13
5. Pitch : p    19.25mm T 11.2(d ) P152
i 12
6.Stiffness or Spring rate :
F 3000
Fo    50 N/mm
y 60
Specifications :
(i) Material : Chrome - Vanadium steel
(ii) Wire diameter d  13 mm
(iii) Mean coil diameter D  78mm
(iv) Free length lo  257mm
(v) Total number of turns i '  14
(vi) style of ends : - Squared & ground
(vii) Pitch p  19.25 mm
(viii) Spring rate Fo  50Dr.N/mm
Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
 Problem 2
Design a helical compression spring for a safety valve.
The valve must blow off at a pressure of 1.2 Mpa &
should lift by 3 mm for 5% increase in pressure. The
valve diameter is 60 mm. The maximum allowable
shear stress is 400 MN/m2 & the modulus of rigidity
is 82.7 GPa. Take spring index as 8.
Data: p1= 1.2 MPa, p2=1.05p1=1.26 MPa,
valve dia Dv=60 mm , C=(D/d)=8, G=82.7x103Mpa
t  400 MPa Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
 Dv 2
  60 2
Initial load on the spring F1   p1  1.2
4 4
F1  3392.92 N
Dv 2   60 2
Maximum load on the spring F2   p2  1.26
4 4
F2  3562.57 N
F2 F2  F1
From fig 11.2a, page 156,  '
where y' is the compression
y2 y
of the spring as force changes from F1 to F2 . Here y'  3 mm
F2 y ' 3562.57  3
 y2    63mm
F2  F1 (3562.57  3392.92)
Now, for design, maximum load & corresponding deflection
have to be considered. Hence F Dept
Dr. Ramesh Sharma  3562.57
.of. Mech Engg, N, y  63 mm.
RVCE Bangalore
1.Diameter of the wire :
8FDK
Shear stresst  where K  Wahl' s stress factor
d 3

4C - 1 0.615 4  8 - 1 0.615
K     1.184
4C - 4 C 48 - 4 8
8  3562.57  8d 1.184
 400   d  14.66  15mm
d 3

2.Mean Diameter of the coil :

Mean coil dia D  8  d  8 15  120 mm
Inside dia of coil Di  ( D  d )  (120  15)  105mm
Outside dia of coil D o  ( D  d )  (120  15)  135mm
3.Number of active coils :
8FD3i 8  3562.57 1203  i
y   63  Dr. Ramesh Sharma Dept3 .of. Mech4Engg,  i  5.35  6 turns
Gd 4
82.7RVCE10Bangalore15
4.Free length of the spring :
lo  (i  2)d  y  a  (6  2)15  63  0.25(63)
lo  198.75mm
( clearance  25% of maximum deflection )
5.Pitch of the coil :
lo  2d 198.75  2 15
p   28.125mm
i 6
6.Stiffness or spring rate :
F 3562.57
Fo    56.55 N/mm
y 63 Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
Energy stored by a Spring: When a spring is gradually
loaded from zero to maximum force ‘F’ within the elastic
limit, the work done by the force in stretching the spring
is stored as ‘Strain energy or Resilience’ denoted by ‘U’.
1
U  Fy, where y is the deflection of the spring.
2
Load F  stress  area    A

Deflection y  Strain  length   l where
E
E  elastic modulus, l  length of the spring
 l  
2
1
 Strain energy U     A    V
2  E  2E
whereV  A  Dr.l Ramesh
 Volume
Sharma Dept .of.of
RVCE Bangalore
Mech the
Engg, spring
 Load F

0
Deflection y
Work done on the spring=shaded area=(1/2) x F x y
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
Proof Resilience :
The maximum energy stored in the body without
permanent deformation (i.e. upto elastic limit) is
known as ' Proof Resilience '.
Hence if the elastic limit stress is  e , then
e V2
Proof resilience  .
2E
Total strain energy
Modulus of resilience 
volume of the elastic body
e V
1 e
2 2
  
2E V 2E
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
Note:
1. When ‘n’ springs are used to absorb the energy
of a body of mass ‘m’ moving at a velocity ‘v’,
the kinetic energy of the moving body is
converted into strain energy (or resilience) of
the spring.
1 2 1 
Hence we can equate mv   Fy   n, where
2 2 
n  number of springs used (in parallel)
F  force on each spring
y  deflection of springs
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
2. When ‘n’ springs are used to absorb the
energy of a freely falling body of weight
‘W’ the potential energy of the falling
body is converted into strain energy (or
resilience) of the spring.
1
Hence we can equate W(h  y)   F  y  n
2
where
F  Force on each spring,
h  height of fall,
y  deflection of springs,
n  number of springs
Dr. Ramesh Sharma Dept (set
.of. Mech in
Engg, parallel)
RVCE Bangalore
 Problem 3
A railway wagon weighing 40 KN and moving
with a speed of 10 Kmph has to be stopped by
four buffer springs in which the maximum
compression allowed is 200 mm. Find the
number of turns in each spring of mean diameter
150 mm. The diameter of the spring wire is 25
mm. Take G = 82.7 GPa.
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
Velocity of wagon v :
1000 5
v  10 kmph  10   10   2.778 m/sec
3600 18
1 W 2 40 103  2.7782
Kinetic energy    v   15733Nm
2 g 2  9.81
K .E  15733 103 Nmm
1 
Equating K.E & Resilience of the springs ' U'    F  y n
2 
where n  number of springs (in parallel)
1 
15733 10    F  200   4
3

2 
Load on each spring F  39333 N
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
1.Number of active turns :
8FD3i 8  39333 1503  i
y   200 
Gd 4
82.7 103  254
 i  6.08  6 turns
2.Free length of the spring :
(Assume sqaured & ground ends)
lo  (i  2)d  y  a  (6  2)25  200  0.25(200)  450mm
3.Pitch of the coils :
lo  2d 450  2  25
p   66.67mm
i 6
F 39333
4.Stiffness : Fo    196.66 N/mm
yDr. Ramesh200
Sharma Dept .of. Mech Engg,
RVCE Bangalore
 Problem 4
Design a spring for an elevator shaft at the
bottom of which 8 identical springs are set in
parallel to absorb the shock of the elevator in
case of failure. The weight of elevator is 60 KN &
the counter weight is 20 KN. The elevator has a
free fall of 1.5 m from rest. The spring is made
of 25 mm diameter rod.
Determine the maximum stress in each spring,
if the spring index is 6 & each spring has 15
active turns. Take G=84 GPa.

Dr. Ramesh Sharma Dept .of. Mech Engg,

RVCE Bangalore
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
Deflection of spring :
8FD3i 8  F 1503 15
y   0.01234 F
Gd 4
84 10  25
3 4

Substituting for y in (i), we get

F(0.01234F)  15 106  10 4 (0.01234F)
F2  1215.56 106  10 4 F  F 2  10 4 F  1215.56 106  0
Solving, load on each spring F  40217.4 N
Deflection y  0.01234F  0.01234  40217.4
y  496.4mm
Shear stress induced in the spring
8FDK 8  40217.4 150 1.2525
t   1231.4 N/mm 2

d 3   253
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
Practice problems
#1 A car weighing 40kN and moving at 8kM/hr is
brought to rest by 2 helical springs. The
compression due to impact is 500mm and
clearance between the coils must be twice the
wire diameter. Assume spring index = 8 and
allowable shear stress for the spring material as
450 N/mm2. Take G = 80GPa. Design the spring.
#2 A load of 2kN is dropped axially on a helical spring
from a height of 250mm. The spring has 20 turns
and it is made of 25mm diameter wire. The spring
index is 8. Find the maximum shear stress
induced in the spring and the amount of
compression produced. Take G = 82.7GN/m2

Dr. Ramesh Sharma Dept .of. Mech Engg,

RVCE Bangalore
Problem 5
A bullet of 2N is fired from a gun. The
bullet travels a distance of 12 meters. The
compression of the spring when the gun
is loaded is 150mm and the diameter of
the barrel is 25mm. Design the spring
completely. Assume spring index as 6
and the material of the spring is Chrome
Vanadium alloy steel. Take FOS = 2.0

Dr. Ramesh Sharma Dept .of. Mech Engg,

RVCE Bangalore
Dr. Ramesh Sharma Dept .of. Mech Engg, RVCE Bangalore
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
Step 7:
Specifications of the spring
i. Material : Chrome-Vanadium Alloy steel
ii. Wire dia (d) : 4mm
iii. Mean coil dia(D) : 24mm
iv. Spring index (C) :6
v. Free Length (lo) : 540mm
vi. Pitch (p) : 6.18mm
vii. No. of active coils : 86
viii. Spring rate : 2.133 N/mm
ix. Type of ends : Square and Ground ends

Dr. Ramesh Sharma Dept .of. Mech Engg,

RVCE Bangalore
 Helical springs of Non circular Cross sections
Rectangular or square cross section springs are
used to obtain greatest load capacity in limited
space.
F b
b=width
h h=depth m=(b/h)
Spring index
C=D/b if b<h
C=D/h if h<b
Fig 11.2 (b)
Page 156 D
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
• For rectangular cross section refer equations 11.13(a),
11.13b & 11.13c page 170 & 171.
• For square cross section springs, refer equations,
11.15a, & 11.15b page 173.
Problem 9
A diesel engine weighs 800 KN is mounted on 16
springs in order to prevent vibration of the
building. The section of the spring is rectangular
with side ratio=1.8 & the longer side is parallel
to its axis. Each spring has 4 active coils & spring
index is 6. Determine (i) the cross section (ii)
Deflection of spring (iii) Maximum coil dia. Take
G=80 GPa & t=300 Mpa.
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
 800 103
Load on each spring F  (as there are 16 springs)  50000N
16
1.Diameter of the wire :
KFD(1.5h  0.9b)
Shear stresst '  2 2
where K  Wahl' s stress factor
bh
4C - 1 0.615 D b
K  where C  as  1 (given h  1.8b);
4C - 4 C b h
4  6 - 1 0.615
K    1.2525
4 6 - 4 6
1.2525  50000  6b(1.5 1.8b  0.9b)
 300  2 2
 b  37.5mm
b (1.8b)
 Mean coil dia D  6  b  6  37.5  225 mm
Height of cross section h  1.8b  67.5 mm.
2.Deflecti on under load :
2.83iFD3 (b 2  h 2 ) 2.83  4  50000  2253 (37.52  67.52 )
y  
3 3
bhG 37.53  67.53  80 103
 y  29.63mm Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
3.Inside & outside (maximum) dia of coil
Di  ( D  b)  (225  37.5)  187.5mm
Do  ( D  b)  (225  37.5)  262.5mm (Max dia of coil)
Note :
Shear stress induced if shorter side is parallel to axis;
put h  37.5mm & b  67.5 mm (i.e.inter change the values)
in the equation of shear stress.
1.2525  50000  225(1.5  37.5  0.9  67.5)
t ' 
67.52  37.52
t '  257.3Mpa

Dr. Ramesh Sharma Dept .of. Mech Engg,

RVCE Bangalore
 Problem 10
A railway car weighing 18 KN and moving at a
speed of 72m/min is brought to rest by a buffer
consisting of 2 helical springs of square cross
section. In bringing the car to rest, the spring
undergoes a deflection of 0.25m. The allowable
shear stress for the steel wire is 0.3 GPa. Spring
index=6. Rigidity modulus G=84 GPa. Design the
spring.
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
Load on each spring:
Given W  18KN  18 103 N, Velocity of rail car V  72m / min
72
V   1.2m / sec . Deflection y  0.25 m  250 mm
60
1  W  2 1  18 103 
K.E of rail car      V     1.2 2  1321.1Nm
2 g 2  9.81 
 K.E of rail car  1321.1103 Nmm
1 
Resilience or Energy stored by springs U   Fy   n
2 
1 
where n  number of springs. Here n  2, U    F  250   2  250 F Nmm
2 
Equating the K.E of rail car to energy stored by the springs,
1321.1103  250 F  Load on each spring F  5284.4N

Dr. Ramesh Sharma Dept .of. Mech Engg,

RVCE Bangalore
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
 Leaf springs
• Leaf springs are made out of flat plates.
• These can support lateral loads and act as a structural
member in addition to absorbing shocks.
• For flat springs (single leaf) (fig 11.10 page 180)
equations refer Pages 179 & 180, equation numbers
11.27(a) to 11.27(d).
• For multi leaf springs refer Page 181, equation numbers
11.28(a) & 11.28(b).
• For laminated springs refer equations 11.29(a) to
11.29(d), Page 181.

Dr. Ramesh Sharma Dept .of. Mech Engg,

RVCE Bangalore
 h F
Front view

b Top view

Fig 11.10(a) Page 180 (Cantilever spring)

b = width of plate, h= thickness of plate, l= length of

plate or distance of load F from fixed end.
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
Dr. Ramesh Sharma Dept .of. Mech Engg, RVCE Bangalore
 F b'
F
h h

l Front View
l

Top View b'

b=ib'

A plate of width ‘b’ can be sliced into a number of slices i of

width b stacked one below the other. Such a stack of leaves
is called ‘Multi leaf springs’.
For multi leaf springs, replace the term b by ib in the
equations.
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
 Problem 11
Design a cantilever spring of length 0.6 m to
absorb 800 Nm of energy with a deflection of
0.1m. The permissible stress in the leaves is 600
MPa. E=206.8 GPa. Take total number of leaves
as 10.
Data: Energy absorbed U=800 Nm
l=0.6m=600 mm, y=0.1m=100 mm,  =600 MPa
E=206.8 GPa=206.8x103 MPa, no of leaves i=10.
width of plate b=ib’=10b’ where b’=width of each
leaf.
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
 F

h Front view

2l

b Top view

Fig 11.10(d) P 180 (Simply supported beam spring)

Dr. Ramesh Sharma Dept .of. Mech Engg,

RVCE Bangalore
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
 Problem 12
Determine the width & thickness of a flat spring carrying
a central load of 3500 N. The deflection is limited to 30
mm. The spring is supported at both ends at a distance
of 650 mm. The allowable stress is 345 N/mm2 &
modulus of elasticity 207 GPa. The spring is of
constant thickness & varying width.

h
2l

Dr. Ramesh Sharma Dept .of. Mech Engg,

RVCE Bangalore
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
Practice Problems
#1 Determine the width and thickness of 6 leaves cantilever spring 300mm
long to carry a load of 1.55kN with a deflection of 30mm. The maximum
stress in the spring should not exceed 0.330 GPa. Take E = 204GPa and
assume constant width and depth.
#2 Fig below shows a cantilever spring having four graduated leaves of
each 5mm and 50 mm wide. Determine the force required to cause a
deflection of 25mm at the end. Also calculate the bending stress in beam.
Take E = 220 GPa and assume constant width and varying depth
F

L = 1.2mts

Dr. Ramesh Sharma Dept .of. Mech Engg,

RVCE Bangalore
 Laminated cantilever springs
A laminated spring is obtained by slicing the
triangular plate as shown & placing the slices one
below the other.
Such an arrangement makes the spring compact
so that the space occupied by the spring is
considerably reduced.
A triangular plate is chosen as the stress will be
uniform throughout. (Beam of uniform strength).

Dr. Ramesh Sharma Dept .of. Mech Engg,

RVCE Bangalore
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
 Prove that for the same deflection, stress induced in full
length leaves of a laminated spring is 50% more than the
stress induced in the graduated leaves. (i.e., f = 1.5g)
Let
if = the number of full length leaves
ig = the number of graduated leaves
b’= width of each leaf
h= thickness of each leaf
l=length of the cantilever
F= applied force at the free end of cantilever
Ff = the load shared by full length leaves
Fg = the load shared by graduated leaves
f = stress induced in the full length leaves
g = stress induced in the graduated leaves
y= deflection of the spring.

Dr. Ramesh Sharma Dept .of. Mech Engg,

RVCE Bangalore
 F

F
l
l
h
h
Full length
leaf
Graduated
leaves

b=ib' b'

Fig - A Fig - B

Dr. Ramesh Sharma Dept .of. Mech Engg,

RVCE Bangalore
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
Forces on Full length & Graduated Leaves

Dr. Ramesh Sharma Dept .of. Mech Engg,

RVCE Bangalore
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
 Semi elliptic laminated Springs
It is most commonly used in automobiles & may
be analyzed as a double cantilever with a load
(F/2) at the ends, where F is the load applied at
the central load.
The width of the central band must be deducted
from span 2l to obtain the effective length of
cantilever.
The equations for stresses induced in full length
leaves, graduated leaves, deflection are given in
Page 182 (11.31a,11.31b, & 11.31c)
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
 Nipping of Spring leaves (Equalization of stresses)
• The stress in the full length leaves is 50% greater than
that in the graduated leaves.
• For best advantage, all the leaves should be equally
stressed.
• This can be achieved by giving a greater radius of
curvature for full length leaves than the graduated leaves
before assembly. The gap or clearance between the
leaves is called ‘Nip’
• By this, all the leaves are pre stressed due to bolt load
when assembled with the help of a clip bolt.
• When an external load is applied, the pre stress in the
full length leaves is first relieved & then stressed in the
opposite direction, while the graduated leaves are
stressed in the same direction of the load.
• Thus the stresses in both the leaves can be equalized by
adjusting the initial gap ‘c’.
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
F/2 F/2

Fb Full length leaf

C=Nip
Fb Fb
/2 /2
F
Graduated leaf

Dr. Ramesh Sharma Dept .of. Mech Engg,

RVCE Bangalore
Derive expressions for bolt load ‘Fb’, nip ‘c’ & the
equalized stress ‘’ in a semi elliptic leaf spring.
Upon the application of load F, the total deflection
of graduated leaves will exceed the deflection of full
length leaves by an amount equal to nip or clearance
‘c’. i.e. c = yg- yf.
Let
Fb be the bolt load applied for assembling the leaves
F be the maximum load
b=width of each leaf, h=thickness of each leaf
l= Effective length, E=elastic modulus of spring.
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
 6 Fg l 3 4Ff l 3
We know that nip c  y g  y f c 3
 3
 (i )
Eig b' h Ei f b' h
As the nipping equalizes the stresses in the leaves,  g   f
6Ff l 6 Fg l Fg ig  ig 
     Fg    F f
i f b' h 2
i g b' h 2
Ff i f i 
 f 
F F  ig   ig  i f 
But the total load  Fg  F f   Ff  Ff  Ff  
2 2  i f   i 
 f 
if F if F
 Ff   where i  (ig  i f )  Total number of leaves.
2(ig  i f ) 2i
ig F
Similarly Fg  . Substituting Fg & F f in equation (i) for ' c'
2i
6 Fg l 3 4Ff l 3
3Fl 3 2 Fl 3 Fl 3
c      Eq11.42a P145
3
Eig b' h Ei f b' h 3 3
Eib' h Eib' h 3
Eib' h 3
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
A truck spring has 12 number of leaves, two of which
are full length leaves. The springs are 1m apart and
the central band is 70 mm wide. The central load is
to be 6KN with a permissible stress of 200 Mpa.
Determine the thickness, width & deflection of the
steel spring leaves if the ratio of total depth to width
of the spring is 3. E=206 GPa.
Given Data: F=6KN=6000 N
Number of full length leaves if=2
Total number of leaves i=12,
Ratio of total depth to width =(ih/b’)=(12xh)/b’=3
Or b’=4h
Hence number of graduated leaves ig=12-2=10
Effective length l=(1000 -70)/2=465 mm,
Max stress   200 MPa, E=206 x 103 N/mm2
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
Since the leaves are not pre stressed,maximum stress
occurs in the full length leaves;Hence  f  200Mpa
9 Fl 9  6000  465
 200  
b' h (2ig  3i f ) 4h  h 2 (2 10  3  2)
2

 h  10.65  11mm
 Thickness of the leaves h  11 mm,
width b'  4h  4 11  44 mm.
Deflectionof the spring
6 Fl 3 6  6000  4653
y 
b' h E (2ig  3i f ) 44 113  206 103 (2 10  3  2)
3

y  11.54mm

Dr. Ramesh Sharma Dept .of. Mech Engg,

RVCE Bangalore
 A locomotive spring has an over all length of 1100 mm and
sustain a load of 75 KN at its centre. The spring has 3 full
length leaves and 15 graduated leaves with a central band
100 mm wide. All the leaves are to be stressed to 0.4 GPa
when fully loaded. The ratio of total spring depth to width
is 2. Determine (i) Width & thickness of leaves (ii) nip or
clearance to be provided (iii) Load exerted on the band by
the clip bolt after assembly. Take E=206.8 GPa
Given Data: F=75KN=75000 N
Number of full length leaves if=3
Number of graduated leaves ig=15
Total number of leaves i=(15+3)=18
Ratio of total depth to width =(ih/b’)=(18xh)/b’=2
Or b’=9h
Effective length l=(1100-100)/2=500 mm,
Equalized stress 0.4 GPa=400 MPa,
E=206.8x103 N/mm2
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
 3Fl 3  75000  500
Equalizedstress   400 
ib' h 2
18  9h  h 2
 Thickness of the leaves h  12mm
Hence width of leaves b'  9h  9 12  108 mm.
Initial gap or nip ' c'
Fl 3
75000  500 3
c   13.5mm
ib' h E 18 108 12  206.8 10
3 3 3

Load on the band Fb

ig i f F 15  3  75000
Fb    4807.7 N
i (2ig  3i f ) 18(2 15  3  3)
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
 A multi leaf spring with camber is fitted to the chassis of an
automobile over a span of 1.2 m to absorb shocks due to a
maximum load of 20 KN. The spring material can sustain a
maximum stress of 0.4 GPa. The spring has 2 full length
leaves out of 8 leaves. The leaves are assembled with bolts
with a central band of width 150 mm. Design the spring
for a maximum deflection of 50 mm. Take E=206.92 GPa.
Given Data: F=20KN=20000 N
Number of full length leaves if=2
Total number of leaves i=8
Number of graduated leaves ig=8-2=6
Deflection y=50 mm
Effective length l=(1200-150)/2=525 mm,
Equalized stress 0.4 Gpa=400 Mpa,
E=206.92x103 N/mm 2
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
 3F l 3  20000  525
Equalizedstr ess   400 
ib' h 2 8  b'h 2
 b' h 2  9843.75mm 3  (i )
6F l 3
Deflectiony 
b' h 3 E(2i g  3i f )
6  20000  5253
i.e. 50 
b'h 3  206.92 103 ( 2  6  3  2 )
 b' h 3  93242.56 mm 4  (ii )
9843.75
(ii )  (i ) gives h  9.5 mm, Hence width b'  2
 109mm
9.5
Initial gap or nip ' c'
Fl 3 20000  5253
c   18.7 mm
ib' h E 8 109  9.5  206.92 10
3 3 3

Load on the band Fb

ig i f F 6  2  20000
Fb    1666.67 N
i (2ig  3i f ) 8(2  6  3  2)
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
Practice Problems
#1) An automotive leaf spring is to be designed to consist of
10 graduated leaves and 2 full length leaves. The spring is
to support a central load of 5kN over a span of 1100 mm
with central bandwidth of 100mm. The ratio of total depth of
spring to its width is 2.5. Determine the width & thickness of
leaves limiting the maximum equalized stress induced in the
leaves to 350 MPa. Also determine the initial gap to be
provided between the full length & graduate leaves with pre-
stress before the assembly.

#2) A 1mt long cantilever spring is composed of 8 graduated

leaves and one extra full length leaf. The leaves are 45mm
wide. A load of 2000N at the end of spring causes a
deflection of 75mm. Determine the thickness of the leaves
and the maximum bending stress in the full length leaf
assuming (a) Extra full length leaf has been pre-stressed
(b) Extra full length leaf has no pre-stress.
Dr. Ramesh Sharma Dept .of. Mech Engg,
RVCE Bangalore
#3 A semi-elliptic multi-leaf spring is used for the suspension of the rear
axle of a truck. It consists of two extra full length leaves and ten graduated
leaves including the master leaf. The center-to-center distance between the
spring eyes is 1.5m. The leaves are made of steel having yield stress = 1200
MPa and E= 210 GPa. Take FOS = 2.0. The spring is to be designed for a
maximum force of 30kN. The leaves are pre-stressed so as to equalize
stresses in all leaves. Determine:
i. the cross-section of leaves and;
ii. Deflection at the end of the spring.
#4 A semi-elliptical leaf spring for automobile suspension consists of
3 extra full length leaves and fifteen graduated leaves. The effective
distance between the supports is 1m. The maximum load on the spring is
75kN. The modulus of elasticity of the material is 210 GPa. The breadth of
each leaves is 9 times its thickness. The leaves are pre-stressed such that
the maximum stress induced in the leaves is 450 MPa. Determine the
following:
i. the width and thickness of leaves
ii. Initial gap (nip) between the leaves
iii. Load on clip bolts to close the initial gap

Dr. Ramesh Sharma Dept .of. Mech Engg,

RVCE Bangalore