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Effective Computational Model for Determining the Geometry of the Transition Zone of End Coils of Machined Springs, Enabling Efficient Use of the Spring Material
This paper presents an analysis of the effect of the geometry of the end-coil transition zone
on the material stress state of a machined compression spring with a rectangular wire cross-section.
The literature relationships for determining the stresses in rectangular wire compression springs
neglect the effects associated with the geometry of this zone. A series of non-linear numerical analyses
were carried out for models of machined compression springs with a wide range of variation in
geometrical parameters. The results of these analyses were used to develop a computational model to
estimate the minimum value of the rounding radius ρmin, which ensures that the stresses in this zone
are reduced to the level of the maximum coil stresses. The model is simple to apply, and allows the
radius ρmin to be estimated for springs with a spring index between 2.5 and 10, a helix angle between
1◦ and 15◦, and a proportion of the sides of the wire section between 0.4 and 5.
