Computational Study of Coil Helical Spring

Advances in Intelligent Systems and Computing 467

P. Deiva Sundari Subhransu Sekhar Dash Swagatam Das Bijaya Ketan Panigrahi Editors

Proceedings of 2nd International Conference on Intelligent Computing and Applications ICICA 2015

Advances in Intelligent Systems and Computing Volume 467

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P. Deiva Sundari Subhransu Sekhar Dash Swagatam Das Bijaya Ketan Panigrahi •

•

Editors

Proceedings of 2nd International Conference on Intelligent Computing and Applications ICICA 2015

123

Editors P. Deiva Sundari Department of Electrical and Electronics Engineering KCG College of Technology Karapakkam, Chennai, Tamil Nadu India

Swagatam Das Electronics and Communication Sciences Unit Indian Statistical Institute Kolkata, West Bengal India

Subhransu Sekhar Dash Department of Electrical and Electronics Engineering SRM University Chennai, Tamil Nadu India

Bijaya Ketan Panigrahi Department of Electrical and Electronics Engineering Indian Institute of Technology Delhi New Delhi India

ISSN 2194-5357 ISSN 2194-5365 (electronic) Advances in Intelligent Systems and Computing ISBN 978-981-10-1644-8 ISBN 978-981-10-1645-5 (eBook) DOI 10.1007/978-981-10-1645-5 Library of Congress Control Number: 2016944398 © Springer Science+Business Media Singapore 2017 This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. The publisher, the authors and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authors or the editors give a warranty, express or implied, with respect to the material contained herein or for any errors or omissions that may have been made. Printed on acid-free paper This Springer imprint is published by Springer Nature The registered company is Springer Science+Business Media Singapore Pte Ltd.

Contents

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1 11

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45

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Contents

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Computational Study of Coil Helical Spring: Automobile Clutch V.C. Sathish Gandhi, R. Kumaravelan, S. Ramesh and M. Venkatesan

Abstract An open coil and closed coil helical springs works usually under critical conditions due to the continuous variations of load acting on the top surface. The analysis of an open coil and closed coil helical springs of an automobile clutches are carried out in ‘ANSYS’ software and the experimental study has been conducted for different load conditions. The various parameters like total deformation, stress intensity, strain energy and equivalent von-misses stress are considered for study. An experiment has been carried out for total deformation of an open and closed coil helical springs at various loads like 500, 1000 and 1500 N. The experimental results shows a good agreement for the simulation results. The results shows that the performance of an open coil helical spring is good compared with closed coil helical spring.










Keywords Helical spring Total deformation Stress intensity Von-misses stress

1 Introduction A spring may be defined as an elastic member whose primary function is to deflect or distort under the action of applied load; it recovers its original shape when load is released. Coil springs are manufactured to very tight tolerances to allow the coils V.C. Sathish Gandhi (&)
M. Venkatesan Department of Mechanical Engineering, University College of Engineering Nagercoil (A Constituent College of Anna University, Chennai), Konam, Nagercoil 629 004, Tamilnadu, India e-mail: [email protected] R. Kumaravelan Department of Mechanical Engineering, Velalar College of Engineering and Technology, Erode 638 012, Tamilnadu, India S. Ramesh Department of Mechanical Engineering, KCG College of Technology, Karapakkam, Chennai 600 097, Tamilnadu, India © Springer Science+Business Media Singapore 2017 P. Deiva Sundari et al. (eds.), Proceedings of 2nd International Conference on Intelligent Computing and Applications, Advances in Intelligent Systems and Computing 467, DOI 10.1007/978-981-10-1645-5_44

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spring to precisely fit in a hole or around a shaft. Most structures are designed will undergo acceptable deformation under specified loading conditions, but their main requirement is to remain rigid. A spring, however, will store energy elastically due to its relatively large displacement. The various application of springs are used to absorber shocks, applying forces in brakes and clutches, to control the motion between cams and followers and store energy in watches, toys etc.,. To ensure the application of springs the study of performance of coil springs are very important.

2 Literature Review The literature of the coil springs are composed based on the information from the simulation techniques and its applications. Gaikwad and Kachare [1] presented the static analysis of helical compression spring used in two-wheeler horn. In this work the safe load of spring is calculated analytically and compared with Simulation results. The simulation is performed in the NASTRAN solver. Patil et al. [2] studied the comparison of cylindrical and conical helical springs for their buckling load and deflection. Based on the existing theories and analytical buckling equation they performed the analysis and verified with an experimental results. These results shows that under the given operating conditions it is to decided the suitability of conical springs against buckling failure of cylindrical springs. Chavan et al. [3] studied the fatigue life of suspension spring by Finite element analysis. The stiffness of the spring is evaluated by the experimental studied and it is compared with the simulation results. Salwinski and Michalczyk [4] discussed an accurate calculation of helical springs with a rectangular cross-section wire. The helical spring is machined from the tubular blanks is considered for the study. It is pointed out that the FEA analysis of spring with open ended is not shown the accurate stress values. Dakhore and Bissa [5] discussed the failure analysis of locomotive suspension coil spring through FEA. The stress distribution, material characteristic, manufacturing and common failures are discussed. The analytical and simulation results are presented for a failed coil springs. Harale and Elango [6] presented a design of helical coil suspension system by combination of conventional Steel and composite material. It is pointed out that the conventional steel helical coil spring is very bulky and costly for the required stiffness. So that, the E-Glass fiber/Epoxy reinforced with conventional steel material. The simulation has been carried out for different design in COMSOL software. Rathore and Joshi [7] reported a review of fatigue stress analysis of helical compression spring. It is identified that for better estimation of numerical solution, fatigue stress, shear stress and life cycle the finite element simulation is the best one. Mulla et al. [8] presented finite element analysis of helical coil compression spring for three wheeler auto-rickshaw front suspension

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system. For this analysis the elastic characteristics and fatigue strength are considered. The simulation results of stress distribution of the springs are reported. Tati et al. [9] discussed the design and analysis for coiled spring for application subjected to cyclic loading. This design and analysis procedure provided the methods of analysis of springs in the FEA. Pyttel et al. [10] has been investigated the probable failure position in helical compression springs used in fuel injection system of diesel engines. The simulation is performed in the ABAQUS 6.10 software. The results shown that an oscillatory behaviour of stresses along the length at inner side of the spring. Budan and Manjunatha [11] is investigated on the feasibility of composite coil spring for automotive applications. The three different composition of springs are fabricated such as glass fiber, carbon fiber and combination of glass fiber with carbon fiber. The experiments are carried out for the weight comparison with each other. From the literature studied it is identified that the helical spring applications and its performances is studied. It is identified that the performance of the type of helical coil springs is not clearly disused. Therefore the present work represent the performance of the open and closed coil helical springs for the same input and identified the suitability of application.

3 Materials and Methods The helical springs are used in the clutches due to reduce the shock to the pressure plate. In this work the open coil and closed coil helical spring’s performance has been studied. The various parameters like total deformation, stress intensity, strain energy and equivalent von misses stress are considered for this study. An experimental study has been made to determine the total deformation of closed and opened coil springs at various loads. The spring models are created as per the dimensions of the spring which is used in the clutches in modeling software ‘Pro-E’. The various loads of 500, 1000 and 1500 N are considered for this study. The attempt has been made to analysis the open coil and closed coil helical spring using simulation software “ANSYS V-12” under static conditions. The Table 1 shows the design parameters of an open coil and closed coil helical spring taken from an automobile clutches. Table 1 shows the various dimensions of an open coil and closed coil helical springs. These values must be considered while designing and modeling of open coil and closed coil helical springs. Figure 1 shows the open coil helical spring and Fig. 2 shows the proto type of the closed coil helical spring used in the automobile clutches.

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Table 1 Design parameters of helical springs S. No.

Parameters

Units

Open coil

Closed coil

1 2 3 4 5 6 7 8 9

Wire diameter Mean coil diameter Spring index Number of coils Solid length Pitch Free length Poisson’s ratio Modulus of rigidity

mm mm – – mm mm mm – N/mm2

3.5 30 8.57 7 24.5 8 47 0.3 4.967 × 105

2.5 30 12 12 32.5 3 38.5 0.3 4.967 × 105

Fig. 1 Open coil spring

Fig. 2 Closed coil spring

3.1

Finite Element Analysis of Coil Springs

The following are the boundary conditions considered for the finite element analysis of both open and closed coil helical springs. (a) Bottom fixed and load on top surface 500 N (b) Bottom fixed and load on top surface 1000 N (c) Bottom fixed and load on top surface 1500 N

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3.1.1

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Meshing Model—Open and Closed Coil

Mesh generation is one of the most critical aspects of engineering simulation. Too many cells may result in long solver runs, and too few may lead to inaccurate results. ANSYS meshing technology provides a means to balance these requirements and obtain the right mesh for each simulation in the most automated way possible. The meshing of the open coil and closed coil helical spring is done in ANSYS using mesh tool of size 2.9 mm. The suitable combination type spring-damper 14 element is selected for both open coil and closed coil helical springs. Mesh scale factor is 1000 mm. Figure 3 shows the meshed model of the open coil helical spring. The mesh scale of this spring is 2.9 mm. Mesh scale factor is 1000 mm. The number of nodes are 6026. The number of elements are 19,212. Figure 4 shows the meshed model of the closed coil helical spring. The mesh scale of this spring is 2.4 mm. Mesh scale factor is 1000 mm. The number of nodes is 20,717. The number of elements is 55,899.

3.1.2

Analysis of Open Coil Spring—1500 N Load

Figure 5 bottom of the open coil helical spring is fixed and the load has been applied on the top surface of the helical spring. The analysis is carried out for different loads such as 500, 1000 and 1500 N. Here the simulation plots are presented for the maximum applied load of 1500 N. The 1500 N force has been

Fig. 3 Meshing model of open coil helical spring

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Fig. 4 Meshing model of closed coil helical spring

Fig. 5 Boundary condition—open coil

V.C. Sathish Gandhi et al.

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Fig. 6 Equivalent (von-Misses) stress—open coil

applied on the top side and various results of the stress, strain energy, total deformation has been taken and analyzed. In this case boundary conditions, equivalent stress, stress intensity, strain energy and the total deformation has been taken and analyzed. Figure 5 shows the boundary condition of open coil helical spring in the static condition. The bottom side of the spring is fixed in all directions. The 1500 N load is applied on top surface of a spring. Figure 6 shows the equivalent von-misses stress of the spring. The maximum stress distribution is on the side and the value is 3.6246 × 103 N/mm2. Figure 7 shows the strain energy distribution of spring. The maximum strain energy distribution is on the body of the spring is 44.309 × 106 J. Figure 8 shows the total deformation of the open coil helical spring under 1500 N force applied. The maximum deformation is occurred on the top contact side of the spring of 15.225 mm. Figure 9 shows the stress intensity of the open coil helical spring. The maximum stress intensity acting on the spring is 4.1648 × 103 N/mm2.

3.1.3

Analysis of Closed Coil Spring—1500 N Load

Figure 10 bottom of the closed coil helical spring is fixed and the load has been applied on the top surface of the helical spring. The analysis is carried out for different loads such as 500, 1000 and 1500 N. Here the simulation plots are presented for the maximum applied load of 1500 N. The 1500 N force has been applied on the top side and various results of the stress, strain energy, total deformation has been taken and analyzed. In this case

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Fig. 7 Strain energy—open coil

Fig. 8 Total deformation—open coil

boundary conditions, equivalent stress, stress intensity, strain energy and the total deformation has been taken and analyzed. Figure 10 shows the boundary condition of closed coil helical spring in the static condition. The bottom side of the spring is fixed in all directions. The 1500 N load is applied on top surface of spring. Figure 11 shows the equivalent von-misses stress of the spring. The maximum stress distribution is on the side and the value is 644 N/mm2. Figure 12 shows the

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Fig. 9 Stress intensity—open coil

Fig. 10 Boundary condition—closed coil

strain energy distribution of spring. The maximum strain energy distribution is on the body of the spring is 0.75174 × 106 J. Figure 13 shows the total deformation of the closed coil helical spring under 1500 N force applied. The maximum deformation is occurred on the top contact side of the spring of 11.228 mm. Figure 14 shows the stress intensity of the closed coil helical spring. The maximum stress intensity acting on the spring is 742.66 N/mm2.

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Fig. 11 Equivalent (von-Misses) stress—closed coil

Fig. 12 Strain energy—closed coil

3.2

Experimental Study of Helical Springs

Experimental study shows the total deformation of open coil and closed coil helical springs are calculated experimentally using a manually operated spring testing machine. The total deformation is calculated under varying loads like 500, 1000

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Fig. 13 Total deformation—closed coil

Fig. 14 Stress intensity—closed coil

and 1500 N. Figure 15 shows the testing of open coil helical spring is under compressive stress by apply the loads of 500, 1000 and 1500 N for testing the spring. The total deformation values for loads of 500, 1000 and 1500 N are 5, 10

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Fig. 15 Testing of open coil helical spring

and 15 mm respectively. Figure 16 shows the testing of closed coil helical spring is under compressive stress by apply the load of 1000 N for testing the spring. The total deformation values for loads of 500, 1000 and 1500 N are 5, 9 and 11 mm respectively. Fig. 16 Testing of closed coil helical spring

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4 Result and Discussion The static analysis of open and closed coil helical springs are studied for three various loads of 500, 1000 and 1500 N. The study has been made for the various parameters like strain energy, total deformation, equivalent von-misses stress and stress intensity are analyzed. The results of open and closed coil helical springs were obtained as discuss below.

4.1

Results of 500 N Load

Table 2 Shows the results of static analysis of an open and closed coil helical springs. The load of 500 N is applied for analysis the helical spring. The various parameters have been evaluated in the open and closed coil helical springs.

4.2

Results of 1000 N Load

Table 3 Shows the results of static analysis of an open and closed coil helical springs. The load of 1000 N is applied for analysis the helical spring. The various parameters have been evaluated in the open and closed coil helical springs.

4.3

Results of 1500 N Load

Table 4 Shows the results of static analysis of an open and closed coil helical springs. The load of 1500 N is applied for analysis the helical spring. The various parameters have been evaluated in the open and closed coil helical springs.

Table 2 Results of 500 N load for open and closed coil helical spring S. No.

Parameters

Value (open coil)

Value (closed coil)

1 2 3 4

Total deformation Strain energy Stress intensity Equivalent von-misses stress

5.0794 4.9232 1388.3 1208.2

5.6139 mm 0.18794 MJ 371.33 MPa 322 MPa

mm MJ MPa MPa

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Table 3 Results of 1000 N load for open and closed coil helical spring S. No.

Parameters

Value (open coil)

Value (closed coil)

1 2 3 4

Total deformation Strain energy Stress intensity Equivalent von-misses stress

10.15 mm 19.693 MJ 2776.5 MPa 2416.4 MPa

9.3192 mm 0.51788 MJ 616.41 MPa 534.52 MPa

Table 4 Results of 1500 N load for open and closed coil helical spring S. No.

Parameter

Value (open coil)

Value (closed coil)

1 2 3 4

Total deformation Strain energy Stress intensity Equivalent von-misses stress

15.225 44.309 4164.8 3624.6

11.228 mm 0.75174 MJ 742.66 MPa 644 MPa

4.4

mm MJ MPa MPa

Comparison of Results

The comparison of results of static analysis for open and closed coil helical springs is discussed. The parameters such us total deformation, stress intensity and von-misses stress are compared for the materials like Spring steel (Grade 1) for various loads of 500, 1000 and 1500 N. Figure 17 shows the value of total deformation for the various loads of 500, 1000 and 1500 N like the material are spring steel (Grade 1). It is observed that the closed coil helical spring has low value of total deformation as compared with the various loads. Figure 17 shows the relation between load and deflection of open and closed coil helical springs. The linear deformation is occurring on open coil helical spring. But closed coil helical spring gives linear output till the load of 500 N. Figure 18 shows the value of stress intensity for the various loads of 500, 1000 and 1500 N. It is observed that the closed coil helical springs has low value of stress intensity as compared with the loads. Figure 18 shows the comparison of stress intensity in graphical representation. In this graph the intensity variation is plotted linearly for open coil. For closed coil the variation of stress intensity is very minimum. The load is above 500 N the stress intensity is low for closed coil helical spring. Figure 19 shows the comparison of von-misses stress in graphical representation. In this graph the von-misses stress variation is plotted linearly for open coil. For closed coil the variation of stress is very minimum. The load is above 500N the von-misses stress is low for closed coil helical spring. The von-misses stress is maximum in the top edge of the both open coil and closed coil helical springs. Figure 20 shows the relationship between strain energy and load for closed and open coil helical spring. It is observed that in an open coil the strain energy rate is high as compared with closed coil.

Computational Study of Coil Helical Spring … Fig. 17 Load versus total deformation of coil springs Total Deformation (mm)

16

537

Open coil Closed coil

14 12 10 8 6 4 400

600

800

1000

1200

1400

1600

1200

1400

1600

1200

1400

1600

Load (N)

Fig. 18 Load versus stress intensity of coil springs

4500 Open coil Closed coil

Stress Intensity (MPa)

4000 3500 3000 2500 2000 1500 1000 500

400

600

800

1000

Fig. 19 Load versus equivalent Von-Misses stress of coil springs

Equivalent von-misses stress (MPa)

Load (N)

4000 Open coil Closed coil

3500 3000 2500 2000 1500 1000 500 400

600

800

1000

Load (N)

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Fig. 20 Load versus strain energy of coil springs

50

Strain energy (MJ)

40

Open coil Closed coil

30

20

10

0 400

600

800

1000

1200

1400

1600

Load (N)

4.5

Experimental Study

The spring testing machine is used for determine the total deformation in open coil and closed coil helical springs. The spring which is used in the clutches is taken for this study. The total deformation in the spring has been estimated for three different loads of 500, 1000, 1500 N are considered for this study. Tables 5 and 6 shows the experimental value of total deformation for an open and closed coil helical springs respectively. Figure 21 shows the relationship between load and total deformation for an open coil helical spring. An experimental and simulation results has been compared and it is very close to each other. It is observed that when the load increases the total deformation of an open coil helical spring is increased. It shows that the load and deformation are directly proportional to each other. Figure 22 shows the relationship between load and total deformation for closed coil helical spring. An experimental and simulation results has been compared and it is very close to each other. It is observed that when the load increases the total deformation of closed coil helical spring is increased. The deformation of the closed coil helical spring is less with respective to load as compared with open coil helical spring.

Table 5 Total deformation —Open coil spring (Experiment)

S. No.

Parameters

Unit

Open coil Helical spring—load (N) 500 1000 1500

1

Total deformation

mm

5

10

15

Computational Study of Coil Helical Spring …

Fig. 21 Load versus total deformation (open coil— experiment and simulation)

S. No.

Parameters

Unit

Closed coil Helical spring—load (N) 500 1000 1500

1

Total deformation

mm

5

9

11

16

Total Deformation (mm)

Table 6 Total deformation —closed coil spring (experiment)

539

14 12 10 8 FEA value Eperimental value

6 4 400

600

800

1000

1200

1400

1600

Open coil helical spring - Load (N)

Fig. 22 Load versus total deformation (closed coil— experiment and simulation)

12

Total Deformation (mm)

11 10 9 8 7 FEA value Eperimental value

6 5 400

600

800

1000

1200

1400

1600

Closed coil helical spring - Load (N)

5 Conclusion The open coil and closed coil helical spring are used in a automobile clutches has been Studied. The open and closed coil helical springs models are developed as per the dimensions of the springs which are used in clutches in modeling software ‘Pro-E’ and the analysis through simulation software “ANSYS V-12”. The study has been made for three different loads like 500, 1000 and 1500 N. For analyzing

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the open and closed coil springs the bottom side of the spring is fixed and the load is applied on the top side. The parameters like total deformation, equivalent von-misses stress, strain energy and stress intensity are analyzed. These results are compared and it is observed that, the open coil helical spring has high stress, strain energy and deformation. The total deformation of the open and closed coil springs are estimated in a spring testing machine and compared with simulation results. It shows a good agreement for the simulation results. From this study it is concluded that performance of an open coil helical spring is good compared with closed coil helical spring.

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