Design And Fabrication Of Manual Spring Rolling Machine

IJSART - Volume 1
Issue 4 –APRIL 2015
ISSN [ONLINE]: 2395-1052
Design And Fabrication Of Manual Spring Rolling
Machine
P.Venkadeshwaran1, R.Sakthivel 2, M.Manojkumar 3, M.Rajkumar 4
Department of Mechanical Engineering
1, 2,3,4
Nadar Saraswathi College of Engineering and Technology, Theni, Tamilnadu, India
Abstract- In this working industry a wide rang of power and
hand operated machine are used. This project the spring
machine is very simple arrangement. This machine can be
operated by manual method. This machine produces closed
coil helical spring of different diameter and different length.
In our project is the spring rolling machine. Rolling is the
process of bending metal wire to a curved form. The article in
the shape of round is made by spring roller shaft. Rolling
operation can be done on hand or power operated rolling
machine. It can make a spring from a shaft. A shaft is a
rotating machine element which is used to transmit power
from one place to another. A bearing is machine element
which supports another moving machine element. Guider is
used to guide the raw material (spring wire). This guider
moves on the shaft automatically. This self movement is
achieved by the lead of spring. Handle is used to operate the
rolling machine manually, without electric power frame is
carries an all parts of the machine, it is made up of mild steel.
Chuck is used to hold the mandrel, it may be attached with the
main shaft of machine. Mandrel is fitting in the chuck, the
mandrel’s outer diameter is known as internal diameter of the
spring.
shapes a gradual curve is to be put in the metal rather than
sharp bends. The gap between the springs can be regulated by
proper arrangement. Spring are elastic bodies (generally
metal) that can be twisted, pulled or stretched by some force.
They can return to their original shape when the force is
released. In other words it is also termed as a resilient
member. A spring is defined as an elastic machine element,
which deflects under the action of the load & returns to its
original shape when the load is removed [1]. Mechanical
springs are used in machine designs to exert force, provide
flexibility, and to store or absorb energy. Springs are
manufactured for many different applications such as
compression, extension, torsion, power, and constant force.
Depending on the application, a spring may be in a static,
cyclic or dynamic operating mode. A spring is usually
considered to be static if a change in deflection or load occurs
only a few times, such as less than 10,000 cycles during the
expected life of the spring. A static spring may remain loaded
for very long periods of time. The failure modes of interest for
static springs include spring relaxation, set and creep. [2]
Keywords- Shaft, bearing, guider, handwheel, frame, chuck, mandrel
James M. Meagher et al. [3] the author presents
theoretical model for predicting stress from bending agreed
with the stiffness and finite element model within the
precision of convergence for the finite element analysis. The
equation is calculated by principal stresses and von misses
stress and it is useful for fatigue studies. A three dimensional
finite element model is used for two coil of different wire
model, one is MP35N tube with a 25% silver core and other a
solid MP35N wire material helical conductor and the result is
compared with the proposed strength of material model for
flexural loading. M. T. Todinov et al. [4] author gives for
helical compression spring with a large coil radius to wire
radius ratio, the most highly stressed region is at the outer
surface of the helix rather than inside. The fatigue crack origin
is located on the outer surface of the helix where the
maximum amplitude of the principal tensile stress was
calculated during cyclic loading, according to the author
fatigue design should be based on the range of the maximum
principal tensile stress.
I. INTRODUCTION
A Spring is a device that changes its shape in
response to an external force, Returning to its original shape
when the force is removed. The energy expended in deforming
the spring is stored in it and can be recovered when the spring
returns to its original shape .The amount of deformation is
directly proportional to force exerted. Spring rolling industry
is a large and growing industry. There are many special
purpose machines used in this industry to-day. The proper
selection of the machines depends upon the type of the work
under –taken by the particular industry. There are many
examples of spring rolling work include iron, copper, tin,
aluminum, stainless and brass.This project the “SPRING
ROLLING MACHINE” finds huge application in all spring
rolling industry. Rolling is the process of bending metal wire
to a curved form. The article in the shape of round is made by
spring roller shaft. Rolling operation can be done on hand or
power operated rolling machine. In forming round spring
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II. RELATED WORKS
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Kotaro watanabe et al. [5]a new type rectangular wire
helical spring was contrived by the authors is used as
suspension springs for rally cars, the stress was checked by
FEM analysis theory on the twisting part. The spring
characteristic of the suspension helper spring in a body is
clarified. Manufacturing equipment for this spring is proposed.
B. Ravi kumar et al. [6] author was analysed the failure of a
helical compression spring employed in coke oven batteries
surface corrosion product was analyzed by X-ray diffraction
(XRD) and scanning electron microscope - energy dispersive
spectroscopy (SEM–EDS). Here used various testing
procedure as chemical, surface corrosion product, fracture
surface analysis. The conclusion of this work that the most
probable cause of failure of the helical compression springs
was corrosion fatigue accentuated by loss of surface residual
compressive stress.
Dammak Fakhreddine et al. [7] In this paper the
author presents an efficient two nodes finite element with six
degrees of freedom per node, capable to model the total
behaviour of a helical spring. the working on this spring is
subjected to different cases of static and dynamic loads and
different type of method (finite element method, dynamic
stiffness matrix method) is governing equations by the motion
of helical spring. This element permits to get the distribution
of different stresses along the spring and through the wire
surface without meshing the structure or its surface. L. Del
Llano-Vizcaya et al. [8] In this paper author used a critical
plane approach, Fatemi–Socie and Wang–Brown, and the
Coffin–Manson method based on shear deformation. The
stress analysis was carried out in the finite element code
ANSYS, and the multiaxial fatigue study was performed using
the fatigue software Code and compared with experimental
results in order to assess the different criteria. A failure
analysis was conducted in order to determine the fatigue crack
initiation point and a comparison of that location with the
most damaged zone predicted by the numerical analysis is
made. The M (Manson) method to estimate strain-life
properties from the monotonic uniaxial tension test, gives
better predictions of the spring fatigue lives than the MM
(Muralidharan) method.
III. COMPONENTS
ISSN [ONLINE]: 2395-1052
having a step. It is supported by the bearing.A shaft is a
rotating machine element which is used to transmit power.
3.2 Bearing:
A bearing is machine element which supports another
moving machine element. The moving machine element is
known as journal. Bearing permits a relative motion between
the contact surfaces of the members, while carrying the load.
A certain amount of power is wasted in overcoming frictional
resistance. In order to reduce frictional resistance and wear
and to carry away the heat generated, lubricant may be
provided. The lubricant used is usually a mineral oil refined
from petroleum. The bearing block is used to hold the
bearings. It is made up of cast iron. All the bearings are fitted
on the machine frame. A bearing is machine element which
supports another moving machine element.
3.3 Guider:
Guider is used to guide the raw materials (spring
wire).This guider moves on the shaft automatically. This self
movement is achieved by the lead of the spring.
3.4 Hand wheel:
Handle is used to operate the rolling machine
manually, without electric power.
3.5 Frame:
Frame is carries an all part’s of the machine, It is
made up of mild steel.
3.6 Chuck:
Chuck is used to hold the mandrel, it may be attached
with the main shaft of the machine.
3.7 Mandrel:
Mandrel is fitted in the chuck, the mandrel’s outer
diameter is known as internal diameter of the spring.
3.1 Shafts:
A shaft is a rotating machine element which is used
to transmit power from one place to another. The various
members such as pulleys, bearing, etc are mounted on the
shaft to transfer the power from one shaft to another. These
members along with forces exerted upon them causes the shaft
to bending. It is made up of mild steel. It is a straight rod,
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IV. EXPERIMENTAL MODELING
ISSN [ONLINE]: 2395-1052
which is fixed in the frame stand. The guide will rotate freely
according to the speed of the spring rolling shaft.
The main shafts one end is coupled to the chuck and
other end is coupled to the hand wheel. A spindle shaft or
mandrel (various diameter) is attached to the chuck and it
rotates.
The spring rolling shaft is rotated when the hand
wheel is rotates. The spring is rolled with the spring rolling
shaft. The change in the length of spring due to the rotation of
the spring is decided by the operator. After making the
required length of the spring the hand wheel is rotation is
stopped. After producing the finished product of spring, the
procedure is repeated for mass production.
VI. DESIGN CALCULATION
6.1 TORQUE ON THE SHAFT
Torque (T) = Load x Distance between guide & mandrel
Where,
Spring diameter = 2mm (0.002m)
From P.S.G data book pg.no 7.105 for properties of spring
steels
Fig 1: Dimensions of model spring rolling machine
Tensile strength, (σu) = 1620 N/mm2
Load = σu x area
= 1620 x π / 4x d2
= 1620 x π / 4x 22
= 5089.38 N
Torque (T) = 5089.38 x 100
= 5.08 x 105 N- mm
6.2 BENDING MOMENT
Fig 2. Schematic diagram of manual spring rolling machine
V. WORKING PRINCIPLE
M=WxL
= 5.08 x 105 x 150
M = 7.62 x 107 Nmm
When the hand wheel is rotated, the shaft will run.
The main shaft is coupled to the bearing with the help of mild
steel plate arrangement. The main shaft is rotated with help of
hand wheel rotation. Before the hand wheel rotation, The
spring wire locked to the lock nut in the spring mandrel. The
spring wire is supplied by applying the load through a guide
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ISSN [ONLINE]: 2395-1052
From data book at pg.no 7.1 in Deflection is
Y = 8PC3n / Gd
Where
C = spring index = D/d
= 17/2
= 8.5
6.5 FIND THE STIFFNESS
Q = Gd/ 8C3n
From data book at pg.no 7.100 for helical spring
T2 + M2
Teq =
=
5.08 x 105 + 7.62 x 107
= 8.75 x 103 Nmm
Max available load of the shaft
From P.S.G data book pg.no. 1.9 for C45 steel
8.4 x 104 x2
Q = ---------------------8 x 8.53 x 15
Q = 2.27 N/mm
Or
Stiffness = Load / Deflection
= 100 / 43.86
q = 2.28 N/mm
Yield stress (σy) = 360 N/mm2
σy = Load / Area
Load (W) = 360 x π / 4x d2
(W) = 360 x π / 4x 172
= 0.8 x 105 N
6.6 ANGLE OF TWIST WHOLE LENGTH OF SPRING
Q = 64 WR2n / Gd4
64 x 100 x8.52 x15
= -----------------------8.4 x 104 x 24
Q = 5.16 radius
6.3 CALCULATION OF SPRING
Dia of wire = d = 2mm
Mean dia of spring = D = 17mm
Radius of spring = R = 8.5mm
Load on the spring = P = 100N
Pitch of spring
= P = 2mm
Modulus of regidity = G = 8.4 x 104 N/mm
6.4 FIND THE DEFLECTION
We consider No.of coil = n =15
VII. CONCLUSIONS
1. After completing the project, conclude that our project is
simple in construction and compact in size for use. Even
through power supply is failure it can be separated
manually, and also manufacturing of machine is easy and
cost of the machine is less.
2. This machine upto 6mm wire diameter of spring can be
produced in lesser time and easily by mass or batch
production. This project can be implemented in small scale
industries.
REFERENCES
8 x 100 8.53 x 15
Y = ------------------------8.4 x 104 x 2
Deflection
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[1] Bhandari V B.Design of machine elements. New
York: Tata McGraw-Hill; 1994.
= 43.86mm
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IJSART - Volume 1
Issue 4 –APRIL 2015
ISSN [ONLINE]: 2395-1052
[2] Shigley J. Mechanical engineering design. New
York: McGraw-Hill; 1981
[3] James M. Meagher and Peter Altman.Stresses from
flexure in composite helical implantable leads S13504533(96)
00022-7.
[4] M.T. Todinov. Maximum principal tensile stress and
fatigue
crack origin for compression springs.
International Journal of Mechanical Sciences 41
(1999) 357-370
[5] Kotaro Watanabe,Masashi Tamura, Ken Yamaya,
Takahiko Kunoh. Development of a new-type
suspension spring for rally cars. Journal of materials
processing technology 111 (2001) 132-134.
[6] B. Ravi Kumar, Swapan K. Das, D.K.
Bhattacharya.Fatigue failure of helical compression
spring in coke oven batteries.
Engineering
Failure Analysis 10 (2003) 291–296.
[7] Dammak Fakhreddine, Taktak Mohamed, Abid Said,
Dhieb Abderrazek,Haddar Mohamed. Finite element
method for the stress analysis of isotropic cylindrica
helical spring. Journal of mechanics A/solids 24
(2005) 1068-1078.
[8] L.
Del
Llano-Vizcaya,
C.Rubio-Gonzalez,
G.Mesmacque ,T. Cervantes-Hernandez. Multiaxial
fatigue and failure analysis of helical compression
springs.Engineering failure analysis 13 (2006) 13031313.
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