Analyze the performance of helical spring by various spring materials

1. DESIGN AND ANALYSIS OF HELICAL
COMPRESSION SPRING FOR
SHOCK ABSORBER
Presented
By
P.NAVEEN
S.SANGARGANESH
R.SRINIVASAN
K. SUKUMAR
Under the Supervision
Of
Prof. A. PERAMANAN M.E.,(Ph.D)
Department of Mechanical Engineering
Jai Shriram Engineering College, Tirupur.

2. ABSTRACT
The helical compression spring is used in a shock absorber to
absorb the shock and vibrations during tracking. The spring is made up
of elastic material to regain its original shape. The spring goes down
below its normal height when the weight of the vehicle pushes the
spring down. The compressed spring rebound to its normal dimension
or original length when the load is removed. For this project the
materials of Phosphor Bronze and Spring Brass were taken for
consideration. The Phosphor Bronze and Spring Brass are a non-ferrous
copper base alloy material which having a high fatigue resistance,
temperature resistance and corrosion resistance. The analysis was done
by considering bike loads based on the number of persons seated on
bike. As a result, this project highlights static and dynamic behaviours
of a helical compression spring. Finally compare this analysis result to
ferrous material (Carbon Steel) to find which one is better for make a
helical compression spring ferrous material or non-ferrous material.

3. CHAPTER-1
INTRODUCTION
• Helical compression springs are used widely all over the
world. It has different type of applications in different areas.
According to that the design considerations are to be made.
The chapter further discusses about basic phenomenon like
stability of spring, surge in spring, spring relaxation, fatigue
loading, strain energy. and basic design procedure of the
helical compression springs.

4. SPRINGS
• A spring is defined as an elastic machine element, which
deflects under the action of the load and returns to its original
shape when the load is removed.
• Springs are used to absorb shocks and vibrations.
• Springs are used to measure force.
• Springs are used to store energy.

5. SPRING MATERIALS
• The ideal spring material would have a high ultimate
strength, high yield point, and low modulus of elasticity in
order to provide maximum energy storage.
 Carbon Steel
 Alloy Steel
a) Chrome Vanadium
b) Chrome Silicon
 Stainless Steel

6. SPRING MATERIALS (Cont.)
 Copper Base Alloys
a) Phosphor Bronze
b) Silicon Bronze
c) Beryllium Copper
d) Spring Brass
 Nickel Base Alloys
a) Inconel
b) Monel

7. CHAPTER-2
LITERATURE REVIEW
The helical compression spring used in suspension system or shock
absorbers and linkages which are used to connect vehicle and allow relative
motion between them, spring is an important element in suspension system.
The suspension system reduces the amplitude of disturbances by absorbing and
handling shock impulses and dissipating kinetic energy generated due to
improper road condition. The project work is based on CATIA and ANSYS.
The statistical structural analysis would be done by finite element analysis
method in ANSYS for different spring materials and wire diameter of spring.
The ANSYS is done by considering bike mass, loads, and number of persons
seated on bike.

8. CHAPTER-3
PROBLEM IDENTIFICATION
• In the helical compression spring, the material of carbon steel is mostly
used because it having a high tensile and yield strength, despite their high
modulus of elasticity. The material of carbon steel having a high modulus
of rigidity so the deflection is low for carbon steel. If the deflection is less
the energy storing capacity is low.
• So we choose the phosphor bronze and spring brass which have a high
tensile and yield strength than carbon steel. The deformation is higher
because of low modulus of rigidity. These materials phosphor bronze and
spring brass are non-ferrous so temperature resistance and corrosion
resistance are more than carbon steel.

9. METHODOLOGY
Conclusion
Result and discussion
Analysis(ANSYS)
Modelling(CATIA)
Design calculation
Selection of material
Feasibility study
Problem identification

10. CHEMICAL COMPOSITION
Phosphor bronze
Tin 4.2to 5.8%
Phosphorous 0.03to0.35%
Iron(Max) 0.10%
Lead 0.05%
Zinc 0.30%
Copper+ tin
Phosphorous
95%
Carbon Steel
Carbon 0.03 to 1.25%
Iron 80 to 90%
Manganese 0.20to 16%
Phosphorous 0.040%
Silicon 0.50%
Sulfur 0.005%

11. CHEMICAL COMPOSITION
(Cont.)
Spring Brass
Copper 68.5-71.5%
Iron 0.05(Max)%
Lead 0.07(Max)%
Zinc
Remainder(Approxim
ately 30%)

12. MECHANICAL PROPERTIES
Phosphor Bronze
Modulus of
elasticity
103400 Mpa
Modulus of
rigidity
41370 Mpa
Tensile strength 550 Mpa
Yield strength 450 Mpa
Hardness
Rockwell
85
Carbon Steel
Modulus of
elasticity
193000 Mpa
Modulus of
rigidity
80000 Mpa
Tensile strength 540 Mpa
Tensile
strength, yield
415 Mpa
Hardness
Rockwell
46

13. Spring Brass
Modulus of elasticity 103400 Mpa
Modulus of rigidity 34500 Mpa
Tensile strength 690
Yield strength 480
Hardness Rockwell 90

14. SPECIFICATIONS OF HELICAL
SPRING
• Spring material : Carbon Steel
• Wire diameter, d = 8 mm
• Spring index, C = 6
• Mean coil diameter, D = 48 mm
• Number of coils, N = 15
• Loads Applied = I. 830
II. 1565 N
III. 2300 N
• Free length = 243.12 mm
• Pitch = 15.195 mm

15. SPECIFICATIONS OF HELICAL
SPRING(Cont…)
Load
(N)
Material Deflection
(mm)
Stiffness
(N/mm)
Shear stress
(Mpa)
Energy storage
(N-mm)
Carbon steel 33.62 24.68 13952.3
830 Phosphor bronze 65.00 12.76 247.86 26975.0
Spring brass 63.94 12.98 26535.0
Carbon steel 63.38 24.68 49594.85
1565 Phosphor bronze 122.45 12.76 467.02 95817.12
Spring brass 119.93 12.98 93845.2
Carbon steel 93.150 24.68 107122.5
2300 Phosphor bronze 180.23 12.76 686.35 207264.5
Spring brass 177.53 12.98 204159.5

16. DESIGN OF HELICAL SPRING

17. DRAFTING OF HELICAL SPRING

18. ANALYSIS OF HELICAL SPRING

20. Total deformation
• Carbon Steel
• 1565 N

21. Shear stress
• Carbon steel
• 1565 N

22. Total deformation
• Phosphor bronze
• 1565 N

23. Shear stress
• Phosphor bronze
• 1565 N

24. Total deformation
• Spring Brass
• 1565N

25. Shear stress
• Spring brass
• 1565N

26. Load(N) Material
Deformation(mm) Shear stress(Mpa)
Theoretical ANSYS Theoretical ANSYS
Carbon Steel 33.620 31.754 240.76
830 Phosphor Bronze 65.000 66.266 247.86 239.26
Spring Brass 63.940 60.680 240.05
Carbon Steel 63.380 59.874 453.96
1565 Phosphor Bronze 122.45 124.95 467.02 451.13
Spring Brass 119.87 114.42 457.62
Carbon Steel 93.150 87.993 667.16
2300 Phosphor Bronze 180.23 183.63 686.35 663.00
Spring Brass 176.94 168.15 665.19

27. 0
100
200
300
400
500
600
700
800
Carbon Steel Phosphor Bronze Spring Brass Carbon Steel Phosphor Bronze Spring Brass Carbon Steel Phosphor Bronze Spring Brass
830 830 830 1565 1565 1565 2300 2300 2300
Chart Title
Deformation(mm) Theoretical Deformation(mm) ANSYS Shear stress(Mpa) Theoretical Shear stress(Mpa) ANSYS

28. Total deformation
• Carbon Steel
• 1565N

29. Shear stress
• Carbon steel
• 1565 N

30. Total deformation
• Phosphor Bronze
• 1565 N

31. Shear stress
• Phosphor Bronze
• 1565 N

32. Total deformation
• Spring brass
• 1565N

33. Shear stress
• Spring brass
• 1565N

34. Load(N) Material
Frequency
(Hz)
Deformation(mm) Shear stress(Mpa)
Theoretical ANSYS Theoretical ANSYS
Carbon
Steel
2.718 33.620 32.123 243.51
830
Phosphor
Bronze
1.950 65.000 67.147 247.86 242.52
Spring
Brass
1.970 63.940 61.415 242.99
Carbon
Steel
1.980 63.380 60.232 456.66
1565
Phosphor
Bronze
1.420 122.45 125.08 467.02 454.32
Spring
Brass
1.438 119.87 115.13 455.52
Carbon
Steel
1.630 93.150 88.346 669.83
2300
Phosphor
Bronze
1.170 180.23 184.47 686.35 666.16
Spring
Brass
1.184 176.94 168.86 668.06

35. 0
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300
320
340
360
380
400
420
440
460
480
500
520
540
560
580
600
620
640
660
680
700
720
740
Carbon Steel Phosphor Bronze Spring Brass Carbon Steel Phosphor Bronze Spring Brass Carbon Steel Phosphor Bronze Spring Brass
830 830 830 1565 1565 1565 2300 2300 2300
Chart Title
Frequency (Hz) Deformation(mm) Theoretical Deformation(mm) ANSYS Shear stress(Mpa) Theoretical Shear stress(Mpa) ANSYS

36. CONCLUSION
In this project we have designed a helical compression spring.
Structural and harmonic analysis of the helical springs of various materials are
analyzed by ANSYS software. By comparing these results, the total
deformation of phosphor bronze material is more than the other materials
(carbon steel and spring brass) hence shock absorbing capacity of phosphor
bronze is more than carbon steel and spring brass. The stiffness of phosphor
bronze is less than the carbon steel and spring brass hence it can deflect a high
load. So finally conclude that as per analysis the Phosphor bronze is best.

37. REFERENCE
[1] Akshat Jain, Sheelam Misra, Arun Jindal, Prateek Lakhian, 2017,
“Structural Analysis of Compression Helical Spring Used in Suspension
System”, American Institute of Physics, Vol.3.
[2] Atul.M, Pungal, Prof. Bhosale.K.C, 2018, “Comparative analysis of two
wheeler suspension helical compression spring for steel and composite
material at different loading conditions”, International Research Journal of
Engineering and Technology, Vol.5.
[3] Chavhan.G.R, Burande.S.W, Dhole.L.P, 2014, “Analysis of shock absorber
using different material of spring” International Journal of Advanced
Engineering Technology, Vol .8.
[4] Khurmi R.S and Gupta J.K, 2005, “Theory of machines” Fourteen edition,
S.Chand Publication, pp. 907-940.
[5] Michael F.Ashby, 2011, “Material selection in mechanical design” Fourth
edition, Elsevier ltd, pp. 31-55.
[6] Pawar.H.B, Desale.D.D, 2018, “optimization of three wheeler front
suspension coil spring” ELSEVIER , Vol.7.

38. REFERENCE(Cont.)
[7] Prince Jerome Christopher.J, Pavendhan.R, 2012, “Design and Analysis of
Two Wheeler Shock Absorber Coil Spring” International Journal of
Modern Engineering Research, Vol.12.
[8] Robert L. Norton, 2010, “Machine design an integrated approach” Fourth
edition, Pearson publication, pp. 785-806.
[9] Singh Pankaj, Amilkanthwar Rushikesh, Walli Sanket, Jasoliya Viraj, Patel
Kaushal, 2017, “Design and analysis of helical compression spring used in
suspension system by finite element analysis method” International
Research Journal of Engineering and Technology, Vol.6.
[10] Vijayeshwar B.V, Preetham B.M, Bhaskar U, 2017, “Design and Static
Analysis of Helical Suspension Spring with Different Materials”,
International Advanced Research Journal in Science, Engineering and
Technology, Vol.4.

39. THANK YOU