Nomograms for the design of light weight hollow helical springs

The helical spring is a widely used element in suspension systems. Traditionally, the springs have been wound from solid round wire. Significant weight savings can be achieved by fabricating helical springs from hollow tubing. For suspension systems, weight savings result in significant transportation fuel savings. This paper uses previously published equations to calculate the maximum shear stress and deflection of the hollow helical spring. Since the equations are complex, solving them on a computer or spreadsheet would require a trial-and-error method. As a design aid to avoid this problem, this paper gives nomograms for the design of lightweight hollow helical springs. The nomograms are graphical solutions to the maximum stress and deflection equations. Example suspension spring designs show that significant weight savings (of the order of 50% or more) can be achieved using hollow springs. Hollow springs could also be used in extreme temperature situations. Heating or cooling fluids can be circulated through the hollow spring.