How to make Helical spring design
Channel: Engineering Encyclopedia
Date: 14/10/2021

Designing a helical spring involves determining the spring's dimensions, material, and characteristics to meet specific requirements. Here are the general steps for designing a helical spring:

Determine the Application Requirements:

Understand the application's requirements, including the required spring force, working environment (temperature, corrosion resistance, etc.), and space constraints.
Select the Material:

Choose a suitable material for the spring based on its mechanical properties and environmental factors. Common materials include carbon steel, stainless steel, and various alloys.
Calculate the Spring Parameters:

Calculate the following parameters:
Wire diameter (d): The diameter of the wire used to make the spring.
Mean coil diameter (D): The average diameter of the coil.
Outer diameter (OD): The outermost diameter of the spring.
Inner diameter (ID): The innermost diameter of the spring.
Number of active coils (N): The number of coils that contribute to the spring's flexibility.
Spring rate (k): The rate at which the spring changes in length per unit force applied (F = k * ΔL).
Determine Spring Rate and Load:

Calculate the required spring rate (k) based on the application's force requirements. Use Hooke's Law (F = k * ΔL) to calculate the spring load (F) for a given displacement (ΔL).
Design the Spring Geometry:

Using the calculated parameters, design the spring's geometry. Sketch the spring profile and dimensions, including the coil pitch and number of coils.
Consider Stress and Deflection Limits:

Ensure that the spring design stays within acceptable stress and deflection limits. Check for stresses caused by the spring's compression or extension and ensure they are within the material's allowable limits.
Optimize the Design:

Iterate the design if necessary to optimize it for performance and cost. Adjust parameters like wire diameter, coil diameter, or number of coils to meet the requirements.
Perform Stress Analysis:

Use software or manual calculations to perform stress analysis on the spring to verify that it can withstand the expected loads without failure.
Produce Manufacturing Drawings:

Create detailed manufacturing drawings that include dimensions, tolerances, material specifications, and any special requirements for fabrication.
Prototyping and Testing:

Before mass production, consider creating a prototype and conducting testing to verify that the spring performs as expected in the actual application.
Production and Quality Control:

Manufacture the springs according to the specifications outlined in the manufacturing drawings. Implement quality control measures to ensure consistency and reliability.
Documentation:

Maintain proper documentation of the spring design, calculations, manufacturing processes, and testing results for future reference and quality control.
It's essential to follow engineering standards and best practices when designing helical springs to ensure they meet the desired performance and safety requirements for their intended application. Additionally, consulting with experienced engineers or utilizing specialized spring design software can be beneficial in complex designs.


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