Abstract
Design of helical springs used in valvetrains of high revolving internal combustion automotive engines is analyzed and optimized. The object of study is elastic nonlinear helical spring with variable non-circular wire cross-section. Variable radius and pitch angle of the helix are also taken into account. The design problem is to optimize the spring resonance characteristics under the geometrical constraints and the constraint on the maximal stresses. The static loading of the spring is modeled to calculate the nonlinear stiffness matrix. A variational method is employed to solve the static problem for the helical spring under stepwise external loading. A nonlinear condensation procedure is suggested for dynamic solution instead of full simulation to make the numerical procedure more time-effective. Dynamics of the spring is compared to experimental data for several industrial springs showing good matching. It is demonstrated that as the result of the suggested optimization procedure the dynamic characteristics of industrial valve springs can be improved up to 10% while controlling the maximum stresses.
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