Is-HElical Compression Springs
Is-HElical Compression Springs
Is-HElical Compression Springs
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IS 7906 (Part 5) :2004
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Indian Standard
( Second Revision)
ICS 21.160
@ BIS 2004
FOREWORD
This Indian Standard (Part 5) (Second Revision) was adopted by the Bureau of Indian Standards, after the draft
finalized by the Automotive Springs and Suspension Sectional Committee had been approved by the Transport
Engineering Division Council.
This standard was originally published in 1979 and revised in 1989. The second revision of the standard was
undertaken as a result of further experience gained in the manufacture and use of the components and other
developments in the field.
.
This standard is one of the series of standards on helical coiled compression springs. The other parts in this
series are as follows:
(Pm-t 1): 1997 Design and calculations for springs made from circular section wire and bar
(Part 2): 1997 Specification for cold coiled springs made from circular section wire and bar
(Pall 3): 1997 Data sheet for springs made from circular section wire and bar
(Part 4): 1987 Selection of standard cold coiled springs made from circular section wire and bar
(Part 6): 1978 Design and calculations for springs made from rectangular section bar steel
(Part 7): 1989 Quality requirements for cylindrical coil compression springs, used mainly as vehicle
suspension springs
(Part 8): 1989 Method of inspection of hot coiled compression springs made from circular section bars
In the preparation of this standard, assistance has been derived form DIN 2096 Part 1-1991 Helical compression
springs made of round wire and rod; Quality requirements for hot formed compression springs, issued by the
Deutsches Institut fur Normung (DIN).
The composition of the Committee responsible for the formulation of this standard is given at Annex A.
For the purpose of deciding whether a particular requirement of this standard is complied with, the final value,
observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with
IS 2: 1960 Rules for rounding off numerical values (revised). The number of significant places retained in
the rounded off value should be the same as that of the specified value in this standard.
IS 7906 (Part 5) :2004
Indian Standard
( Second Revision)
1 SCOPE IS No. Title
1.1 This standard (Part 5) covers hot coiled 3703:1980 Code of practice for magnetic par-
cylindrical compression springs made from round bar ticle flaw detection (first revision)
steel which are hardened and tempered after coiling. 7001:1989 Shot peening of steel parts
Specification (first revision)
1.2 This standard is applicable to springs having the
7906 Helical compression springs:
following parameters: (Part 1): 1997 Design and calculations for springs
a) Bar diameter, d from 8 to 60 mm, made from circular section wire and
b) Outside diameter, De <460 mm, bar (fh-st revision)
c) Unloaded length, & <800 mm, (Part 3): 1975 Data sheet for springs made from
d) Number of active coils, n c 3, and circular section wire and bar
e) Coil ratio, w from 3 to 12. (Part 7): 1989 Quality requirements for cylindri-
cal coil compression springs used
1.3 In case the lot size exceeds 5 000, then the
mainly as vehicle suspension
dimensional tolerances as given in IS 7906 (Part 7) springs
shall be applicable. 13190:1991 Recommended practice for eddy
2 REFERENCES current examination by rotating
probe method of round steel bars
The following standards contain provisions which
through reference in this text, constitute provision of 3 TERMINOLOGY
this standard. At the time of publication, the editions The following symbols and units shall apply (see also
indicated were valid. All standards are subject to Fig. 1):
revision and parties to agreements based on this Symbol Term Unit
standard are encouraged to investigate the possibility
of applying the most recent editions of the standards AD Permissible deviation of the mm
indicated below: mean coil diameter, D, of
the unloaded spring
IS No. Title
Ad Permissible deviation of the mm
1500:1983 Methodfor Brinell hardness test for
nominal diameter, d
metallic materials (second revision)
2500 Sampling inspection procedures A De Permissible deviation of the mm
external coil diameter, De, of
(Part 1): 2000 Attribute sampling plans indexed
the unloaded spring
by acceptable quality level (AQL)
for lot-by-lot inspection (third ADi Permissible deviation of the mm
revision) internal coil diameter, Di, of
(Part 2): 1965 Inspection by variables for percent the unloaded spring
defective AF Permissible deviation of the N
3195:1992 Steel for manufacture of volute and spring force, F, at a specified
helical springs (for railway rolling spring length, L
stock) (third revision)
A Lo Permissible deviation of the mm
3431:1982 .Steel for the manufacture of volute, Length, LO,of the unloaded spring
helical and laminated springs for
automotive suspension (second Ant Permissible deviation of the
revision) total number, nt,of turns
1
IS 7906 (Part 5) :2004
AR Permissible deviation of the N/mm S,= Ln Lc Safety gap, sum of the minimum mm
spring rate, R clear distance between adjoining
active turns at the spring length, L,
De+ Di
D=- Mean coil diameter mm Sp Spring deflection, correlated to mm
2
test force, Fp
De External coil diameter mm
D
~.~ Coiling ratio
Di Internal coil diameter mm
Permissible deviation of mm
el
generatix from the vertical,
measured on the unloaded spring
(see Fig. 1)
2
IS 7906 (Part 5) :2004
4.4 Total Number of Coils, nt 5.2 Roads with Machined Surface, that is ~th
Turned, Peeled or Ground Surface (see Table 2)
The total number of coils (@ varies depending on the
end construction of the spring. For different Table 2 Permissible Deviations of the Nominal
construction the number of coils is given below:
Diameter
Types of Ends Total Number of
N Nominal Diameter Permissible Deviations
According to Coils, nt No. d Ad
(1) (2) (3)
Fig. 1 and Fig. 2 n+ 1.50
Fig. 3 i) 8<d<10 ? 0.05
??+ 1.00
Fig. 4 n+ 1.50 ii) 10<d<20 ? 0.08
Fig. 5 n+ 1.67 iii) 20<d<30 * c).KI
iv) 30<d<40 * 0.12
4.5 Detailed design calculations for springs are
covered by IS 7906 (Part 1). v) 40<d *IJ15
5.1 Roads with Rolled Surface (see Table 1) 6.1.1 Springs for non-critical application can be
manufactured from as rolled bars.
Table 1 Nominal Diameter and Permissible
Deviations 6.1.2 Springs for critical applications, or where
specific fatigue life is to be met, or where load-rate
S1 Nominal D]ameter Permissible Deviations characteristics are important are generally made from
No. d Ad centreless ground bars. In case the springs are to be
(1) (2) (3) manufactured from centreless ground bars, the-same
O 8<d< 11.5 *(3.15 must be. mentioned in the order and enquiry or
ii) 12<d <21.5 appropriately in data sheet as given in IS 7906
iii) 22 <d <29.5 (Part 3).
iv) 30<d <39 6.1.2.1 If specified in the drawing/data sheet/
v) 40<d<50 purchase order, all ground bars should be subjected
vi)
to crack detection, by any one of the following
52<d<60
methods:
@ .(f) @ -.
FIG.2 ENDS FIG.3 ENDS OPEN FIG.4 PIGTAIL FIG.5 ONE END
CLOSEDAND AND UNGROUND ENDS FORGED AND
GROUND GROUND AND ONE
END OPEN
3
IS 7906 (Part 5) :2004
b) ;ddy current method as given in IS 13190. For increasing the fatigue life, the springs shall be shot
peened. After shot peening, the Almen arc height shall
6.1.3 Before coiling, both ends of the bars should be conform to those given in IS 7001 with a minimum arc
properly tapered (if specified in the spring drawing) to height of 0.4 mm.
give the finished spring a firm bearing. The taper
length should be approximately equal to 0.75 of the 6.6 Surface Protection
mean circumference of the spring. The taper portion The springs may be covered with suitable protective
should be smoothly tapered with the tips rounded off coating, immediately after shot peening to protect
and tip thickness at the edge should be approximately against corrosion. The protective coating to be
1/4 of the bar diameter. applied/anti-corrosive treatment to be given to the
6.2 Coiling and Heat Treatment springs, is subject to agreement between the purchaser
and the manufacturer, and should be specified in the
The bars for coiling should be uniformly heated in an purchase orderldrawingldata sheet.
indirectly heated furnace and soaked sufficiently. The
heated bars should be immediately coiled and pitched, 6.7 Crack Detection
taking care to ensure.that the red hot material remains 6.7.1 This is not applicable for springs made from
in contact with air for minimum possible time so as to rolled bars.
avoid oxidation. The springs shall be uniformly heat
treated for developing the required physical properties 6.7.2 If specified in the purchase order/data
of materials and shall have the following final sheet/drawing, springs made from ground bars should
hardness: be subjected to magnetic crack detection, the
percentage of springs to be checked and the
Material Hardness acceptance criteria should be mutually agreed to
between the purchaser and the supplier. This crack
Carbon steels 360 to 420 HB
detection must be immediately carried out after shot
Silica-manganese steels 380 to 460 HB
peening.
Chrome-alloy steels 400 to 460 HB
NOTES 7 TOLERANCES
1 The hardness should be measured only on inactive coils.
2 The hardness of the spring shall be measured on the outside For reasons of economy in production, tolerances
surface after removal of the decarburized layer. could be prescribed only for those parameters which
are necessitated by the particular application. If closer
6.2.1 For springs made from unground bars, the limit tolerances than those specified here are required, these
for decarburization may be fixed by agreement
shall be agreed to between the manufacturer and the
between the purchaser and the supplier. purchaser.
6.2.2 Hardness checking shall be done in accordance
7.1 Tolerances on Bar Diameter, Ad
with IS 1500.
7.1.1 Tolerance on bar diameter d, before coiling,
6.2.3 For springs made from centreless ground bars, both for rolled bars and ground bars shall be according
the total depth of decarburization shall not exceed in to IS 3195 or IS 3431 as applicable.
1 percent of the bar diameter.
7.1.2 After coilinglheat treatment the tolerance on
6.3 Scragging finished bar diameter for springs made from
Each and every spring should be scragged 3 times in centreless ground bars, shall be f 0.5 percent of the
quick succession. The scragging height should be as bar diameter or k 0.25 mm, whichever is higher.
indicated in the spring drawing/data sheet. In case
there is no such indication the springs should be 7.2 Tolerance, AD on Coil Diameter D, De$ Di for
scragged home. The scragging load in such cases Unloaded Springs
should not exceed 1.5 times the theoretical axial load
Tolerance shall be as given in Table 1. Only one
corresponding to the block length.
diameter shall be indicated for tolerance in the order
6.4 End Grinding or enquiry [see also IS 7906 (Part 3)] as follows:
Springs having ends as shown in Fig. 1 and Fig. 2. a) De, when the spring is working in a guide, and
Springs should be ground to ensure square seating of b) D,, when the spring is working over a guide
the spring. The ends should not have any sharp edges (arbor).
or burrs. Unless otherwise specified, the tip shall not
The numerical values of the permissible deviations in
protrude beyond the outside diameter by more than 20
Table 3 below apply solely to the end turn.
percent of the bar diameter.
4
IS 7906 (Part .5): 2004
Because the active turns of the spring exhibit wider 7.5 Tolerance, A LOon Unloaded Length, Lo of the
tolerances than those specified in Table 1 for the end Spring
turns, it is recommended, in the case of springs which In the case of springs with stipulated axial loads and
operate inside a sleeve or over a mandrel, to specify in their associated spring height, the length L of the
addition either the minimum diameter of the sleeve unloaded spring must in principle be regarded only as
and the maximum diameter of the mandrel, a guideline value. However, in cases where the length
respective y, on drawings and in enquiryldata sheeti ~ is tolerance, the following formulae apply to the
purchase order. permissible deviation:
7.3 Permissible Deviation of Ant, Total Number of a) In-case of sprin s made from as rolled bars:
Turns
Table 3 Tolerances
AR=+ O.065 :+1
Springs
(Clause 7.2)
S1 D, or Di AD. or ADi
No. A A
f 3 f \
Springs Made of Rods with a Rolled Springs Made of Rods with a Machined
Surface;for a Coiling Ratio, w Surface for a Coiling Ratio, w
A
f \ ~
Over up to Up to 8 Over 8
(1) (2) (3) (4) (5) (6) (7)
i) 50 t0.8 * 1.2 k 0.6 ?0.8
ii) 50 65 *1 * 1.5 ?0.7 *1
iii) 65 80 * 1.2 k 1.8 k ().8 * 1.2
iv) 80 100 f 1.5 k 2.3 *1 ~ 1.5
v) 100 125 i 1.7 * 2.6 f 1.1 * 1.7
vi) 125 160 *2 *3 * L3 &2
vii) 160 2oi3 ? 2.2 ? 3.3 * 1.5 * 2.2
VIII 200 250 h 2.6 * 3.9 i 1.8 k 2.6
ix) 250 300 +3.1 k 4.6 +2.1 +3.1
x) 300 460 ~4 * 5.5 k 2.5 -14
5
IS 7906 (Part 5) :2004
F=
fOO2[(L0+s(:+l)Rl
Di D
7.9 Minimum Space Between Individual Working Sampling shall be done in accordance with IS 2500
Coils Under Maximum Permissible Test Load (Part 1) and IS 2500 (Part 2).
tut-n ~ shall be greater than or equal to 2 percent of This testing is carried out on the spring in the normal
() direction of loading with the spring standing
the external coil diameter, De. vertically. In each case, before carrying out the static
Within S., the spring characteristics can be strongly test, the spring shall be compressed three times in
progressive. quick succession to the block length or to a length
6
IS 7906 (Part 5) :2004
S2 t
L2 These markings shall be stamped on springs madewith
L
wire diameters of 15 mm and above and shall be so
F. applied that they are not detrimental to the life and the
functioning of the springs.
t 0.7 F
IL 11.2 BIS CertYlcation Marking
u F,
u
~ 0.3 F.-
.
The product may also be marked with the Standard
: Mark.
E 0 0.3$. 0.7s. S.
s,
% 11.2.1 The use of Standard Mark is governed by the
% L.
L.
provisions of the Bureau of Indian Standards Act,
Lo
1986 and the Rules and Regulations made thereunder.
The details of conditions under which the licence for
SPRING DEFLECTION S
use of Standard Mark maybe granted to manufacturers
or producers may be obtained from the Bureau of
FIG.6 SPRINGCHARAmERISTICCURVE Indian Standards.
7
1S 7906 (Part 5) :2004
ANNEX A
(Ffvewrmd )
COMMITTEE COMPOSITION
Member Secrelary
SHRJP. K. SHARMA
Director (TED), BIS
8
Bureau of Indian Standards
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