Vibration modelling of helical springs with non-uniform ends

Helical springs constitute an integral part of many mechanical systems. Usually, a helical spring is modelled as a massless, frequency independent stiffness element. For a typical suspension spring, these assumptions are only valid in the quasi-static case or at low frequencies. At higher frequencies, the influence of the internal resonances of the spring grows and thus a detailed model is required. In some cases, such as when the spring is uniform, analytical models can be developed. However, in typical springs, only the central turns are uniform; the ends are often not (for example, having a varying helix angle or cross-section). Thus, obtaining analytical models in this case can be very difficult if at all possible. In this paper, the modelling of such non-uniform springs are considered. The uniform (central) part of helical springs is modelled using the wave and finite element (WFE) method since a helical spring can be regarded as a curved waveguide. The WFE model is obtained by post-processing the finite element (FE) model of a single straight or curved beam element using periodic structure theory. This yields the wave characteristics which can be used to find the dynamic stiffness matrix of the central turns of the spring. As for the non-uniform ends, they are modelled using the standard finite element (FE) method. The dynamic stiffness matrices of the ends and the central turns can be assembled as in standard FE yielding a FE/WFE model whose size is much smaller than a full FE model of the spring. This can be used to predict the stiffness of the spring and the force transmissibility. Numerical examples are presented.