Design and Fabrication of Manual Spring Rolling Machine

Kurian Seby.et.al. Int. Journal of Engineering Research and Application www.ijera.com
ISSN : 2248-9622, Vol. 6, Issue 10, ( Part -1) October 2016, pp.48-51
www.ijera.com 48 | P a g e
Design and Fabrication of Manual Spring Rolling Machine
Kurian Seby*,Nikhil Chacko*,Nithin P Rajan*,Sony Thekkiniyath*,
Kapil Dev E J*, Christy V Vazhappilly**
*(UG Scholar, Department of Mechanical Engineering, Jyothi Engineering College, Thrissur, India)
** (Assistant Professor, Department of Mechanical Engineering, Jyothi Engineering College, Thrissur, India)
ABSTRACT
This paper is to discuss to design and fabrication of a manual spring rolling machine by a simple mechanism
arrangement for the production of closed and open coil helical springs. This machine is operated by manual
method. This machine produces closed coil helical spring of different diameter and different length. 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. A work holding mechanism is used to hold the mandrel;
it is attached to the main shaft of machine. Mandrel is fitting in the work holding mechanism, the mandrel’s
outer diameter is known as internal diameter of the spring.
Keywords: Spring rolling, Helical spring, Mandrel, Spring wire
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 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 is 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. 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.
II. PROBLEM STATEMENT
Rolling process for production of open and
closed coil helical spring was difficult for different
materials due to the variation in modulus of rigidity.
And for the purpose of production of springs with
different diameters usage of chuck made difficulty
due to its unavailability and increased cost and also
its maintenance. Which also abruptly increases the
weight of the mechanism more than expected. So we
had to replace the chuck by another holding
mechanism which solved the difficulties that caused
by chuck.
III. OBJECTIVE AND SCOPE
The goal of this project is to design and
fabrication of a manual spring rolling machine by a
RESEARCH ARTICLE OPEN ACCESS

simple mechanism arrangement for the production of
closed and open coil helical springs. The specific
characteristics being variable spring diameters,
variable spring coil diameters of various materials
by manual rolling process. The scope of this project
is the application of this “MANUAL SPRING
ROLLING MACHINE” in small scale industries for
the production of open and closed helical springs of
varying spring coil diameters and varying spring
diameter, without much expense in a small scale
level.
The importance of this study was that to
know about the different springs that are used in
many automobile parts and other mechanisms, and
the crucial role that they play in different
mechanisms. The spring machine is made by a very
simple arrangement. This machine is 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.
IV. WORKING PRINCIPLE
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 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 diameters) 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.
Figure 1 Flow Chart
Table 1 Components of spring rolling machine

Figure 2 Spring rolling machine with dimension
V. DESIGN OF THE SPRING ROLLING
MACHINE
The design part of our manual spring
rolling machine was done in Solid Works software
version 2011.
Figure 3 Spring rolling machine – Model
Figure 4 Components of Spring rolling machine
VI. CALCULATION
a. 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
Tensile strength, (σu) = 1620 N/mm2
Load = σu x area = 1620 x (π/ 4)x d2
= 1620 x ( π/ 4)
x22
= 5089.38 N
Torque (T) = 5089.38 x 250
= 12.72 x 105
N-mm
b. Bending Moment
M = W x L
= 5089.38x 150
M = 7.63 x 105
Nmm
Teq = √𝑇2
+ 𝑀2
=√(12.723 × 105
)2
+
(7.63 × 105
)2
= 14.841 x 105
Nmm
c. Calculation Of Spring
Diameter of wire = d = 2mm
Mean diameter of spring D = 35mm
Radius of spring = R = 17.5mm
Load on the spring = P = 100N
Pitch of spring = P = 2mm
We consider No.of coil = n =10
Spring index C= D
d
Deflection y= 8PC3n
Gd
Stiffness q= Gd
8C3n
Table 2 List of materials used for making spring and
their G, Deflection, Stiffness

Figure 5 Displacement Analysis
Figure 6 Stress Analysis
Figure 7 Strain Analysis
Springs are usually made from alloys of
steel. The most common spring steels are music
wire, oil tempered wire, chrome silicon, chrome
vanadium, and 302 and 177 stainless. Other
materials can also be formed into springs, depending
on the characteristics needed. Some of the more
common of these exotic metals include beryllium
copper, phosphor bronze, Inconel, Monel, and
titanium.
Figure 8 Fabricated manual spring rolling machine
VII. CONCLUSION
After completing the work, it is concluded
that work is simple in construction and compact in
size for use. Even in the absence of power supply it
can be operated manually, and also manufacturing of
machine is easy and cost of the machine is less .This
machine can fabricate spring up to 3mm wire
diameter of spring with less production time with
ease by mass or batch production. This work can be
implemented in small scale industries.
ACKNOWLEDGEMENTS
The authors would like to thank
Department of mechanical Engineering, Jyothi
Engineering College, Cheruthuruthy, Kerala, for
their technical support and valuable suggestions.
REFERENCES
[1]. Mr. Chetan P. Sable , prof. P.D.Kamble ,
Mr. Dhiraj D. Dube review on” Paper Plate
Making Machines” International Journal of
Research in Aeronautical and Mechanical
Engineering /vol.2 issue.2,february 2014.
pgs:105-111.
[2]. Supriya Burgul review on “Design and
Fatigue Life of a Mechanical Spring”
International Journal of Research in
Aeronautical and Mechanical Engineering /
vol.2 issue 7, july 2014 pgs:76-83
[3]. Mr. Niranjan Singh review article on
“General Review of Mechanical Spring
used in Automobile Suspension System”
International Journal of Advanced
Engineering Research and Studies/
December 2013 ,vol.1
[4]. Mr. Desheng Li review on “Vibration of a
Tapered Roller Bearing with Localized
defect on Multiple Rollers” International
Congress on Sound and Vibration/ July
2015
[5]. O.Vahid – Araghi and F. Golnaraghi
”Frictional Induced Vibration in Lead
Screw Drives” chapter 2 february 2011

Design and Fabrication of Manual Spring Rolling Machine

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