Fatigue Analysis of Helical Spring
Subjected to Multi-axial Load
Tarek Al Musalli, Tesfaye Kebede Ali, and Balasubramanian Esakki
Abstract Helical spring is being widely used in diverse industrial applications such
as automobiles, airplanes, mechanical watches, lock mechanisms, airsoft gun and
even in writing pens. It is a long-term investment product, which subjected to timevarying loads. Prediction of fatigue life characteristics of helical springs is a major
concern. The main challenge is to find the appropriate mechanical criteria that can
predict the number of life cycles. Helical springs are subjected to multi-axial load and
it causes shear effect on the coil wire. In order to predict the fatigue life characteristics
of under this loading condition, non-proportional multi-axis approach is preferred due
to handling of varying loads. The present study focuses on performing finite element
analysis (FEA) to investigate the fatigue behavior of helical spring with stress-life
and strain-life approaches. FEA results are compared with the stress and strain life
theoretical calculations to predict the fatigue life and numerical simulations are also
carried out to determine the maximum shear stress. It is observed that strain-life
approach is able to predict the fatigue life accurately than stress-life methodology.
Keywords Helical spring · Fatigue analysis · Stress life · Strain life
1 Introduction
A helical spring is a flexible object that distorts its function when subjected to a
load and restores its original shape when the load is released [1]. This element
is included in many machine industrial applications. For example, the automotive
industry uses helical spring in the suspension, brakes, and transmission components
to absorb shock or vibration. Helical springs are always exposed to alternating loads
and require millions of operating cycles to be maintained without failure, so it must
be designed for infinite fatigue life. There are few previous studies have dealt with
T. A. Musalli · T. K. Ali · B. Esakki (B)
Department of Mechanical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D
Institute of Science and Technology, Avadi, Chennai, Tamil Nadu 600062, India
e-mail: balasubramaniane@veltech.edu.in
© The Editor(s) (if applicable) and The Author(s), under exclusive license
to Springer Nature Singapore Pte Ltd. 2021
N. Gascoin and E. Balasubramanian (eds.), Innovative Design, Analysis
and Development Practices in Aerospace and Automotive Engineering, Lecture Notes
in Mechanical Engineering, https://doi.org/10.1007/978-981-15-6619-6_41
377
Subjected to Multi-axial Load
Tarek Al Musalli, Tesfaye Kebede Ali, and Balasubramanian Esakki
Abstract Helical spring is being widely used in diverse industrial applications such
as automobiles, airplanes, mechanical watches, lock mechanisms, airsoft gun and
even in writing pens. It is a long-term investment product, which subjected to timevarying loads. Prediction of fatigue life characteristics of helical springs is a major
concern. The main challenge is to find the appropriate mechanical criteria that can
predict the number of life cycles. Helical springs are subjected to multi-axial load and
it causes shear effect on the coil wire. In order to predict the fatigue life characteristics
of under this loading condition, non-proportional multi-axis approach is preferred due
to handling of varying loads. The present study focuses on performing finite element
analysis (FEA) to investigate the fatigue behavior of helical spring with stress-life
and strain-life approaches. FEA results are compared with the stress and strain life
theoretical calculations to predict the fatigue life and numerical simulations are also
carried out to determine the maximum shear stress. It is observed that strain-life
approach is able to predict the fatigue life accurately than stress-life methodology.
Keywords Helical spring · Fatigue analysis · Stress life · Strain life
1 Introduction
A helical spring is a flexible object that distorts its function when subjected to a
load and restores its original shape when the load is released [1]. This element
is included in many machine industrial applications. For example, the automotive
industry uses helical spring in the suspension, brakes, and transmission components
to absorb shock or vibration. Helical springs are always exposed to alternating loads
and require millions of operating cycles to be maintained without failure, so it must
be designed for infinite fatigue life. There are few previous studies have dealt with
T. A. Musalli · T. K. Ali · B. Esakki (B)
Department of Mechanical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D
Institute of Science and Technology, Avadi, Chennai, Tamil Nadu 600062, India
e-mail: balasubramaniane@veltech.edu.in
© The Editor(s) (if applicable) and The Author(s), under exclusive license
to Springer Nature Singapore Pte Ltd. 2021
N. Gascoin and E. Balasubramanian (eds.), Innovative Design, Analysis
and Development Practices in Aerospace and Automotive Engineering, Lecture Notes
in Mechanical Engineering, https://doi.org/10.1007/978-981-15-6619-6_41
377