Structural Design and Analysis of Hybrid Helical Compression Springs

A common problem in spring design is how to reduce the maximum stress experienced by helical compression spring and still sustain the given load-length prerequisite projected within the overall dimensions of length and diameter. But in practical situation available spring space in both along length and diameter will be fully utilized without any margin. In such cases, if maximum stress experienced by the spring results to be high then it will not be possible to review the specified requirements. The present work aims at offering a promising solution for such situation by proposing hybrid design of helical compression spring so as to achieve stress reduction to the desired attenuation. Detailed mathematical modeling is carried out which simplifies the design. Monograms will be furnished as an outcome of design using which amount of stress reduction anticipated for a given spring index of the single spring can be quickly quantified. Influence of spring index on maximum stress will be studied as part of this work. MATLAB Software is developed which embeds the formulation derived which can be used as a hand calculator which will be extremely useful for a spring designer to quickly estimate the design parameters. This software will also be helpful to carry out sensitivity analysis of the proposed design with in no time so as to achieve optimized configuration of the proposed hybrid spring.