279

TECHNICAL UNIVERSITY OF CLUJ-NAPOCA

24 - 25 September 2009

OPTIMAL DESIGN OF HELICAL COMPRESSION SPRINGS FROM

TAMPING RAMMERS
Lucian TUDOSE, Radu Mircea MORARIU-GLIGOR, Simion HARAG
Abstract: Two of the major components of the tamping rammers are the helical compression springs,
which provide the necessary force to compact the soil. The two (or three) springs must respect some
constraints: dimension, resistance, vibrations, etc. This paper presents a method for optimal design of
these springs using genetics algorithms.
Keywords: tamping rammer, compression spring, genetic algorithms.

1. INTRODUCTION
The tamping rammers (Figure 1) are
equipments used for compaction in confined
areas, where the utilization of similar
equipments is not possible. They also ensure a
high degree of compaction.

Fig. 1. Tamping rammer

The tamping rammers supply a high force of

impact and are highly recommended for the
compaction of the cohesive or semi-cohesive
soils.
The characteristics of a tamping rammer are:
work frequency: 500-800 blows per minute;

The possibilities of using tamping rammers

include: compacting the soil around the
foundations, preparing the soil for pouring
concrete, compacting the soil used to fill the
grooves for pipes and cables and also
compacting the asphalt used in reparation of
streets and sidewalks [7].

Fig. 2. Tamping rammer components

mass between 50 and 120 kg; compaction

depth: 60-80 cm; number of passing required
for compaction of an area: 3-5; inclination on
vertical axis: 10 -17.
Tamping rammers provide three types of
compaction: impact, vibration and kneading.

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2. PROBLEM FORMULATION
Considering the conditions of activity of the
machines and also their technological
destination, the optimal parameters for
reliability, maintainability and ergonomics must
be ensured beginning with the projection stage.
To most of machines the dynamics and
reliability parameters are determined by the
presence of the antivibrating elements in their
structure.
Among the applications of the helical
springs to the vibrating machines are: damping
the impact energy and vibrations, accumulation
of energy that must be released gradually,
changes the characteristic frequency of the
parts.
The springs are subjected to centric axial
forces, of compression or stretching. The
helical springs are formed by wire, with round
or rectangular section, coils being made

F1
Fn
Fb

Hb

H1
Hn

H0

Dm
D

fb

fn

f1

through wrapping up on a screw propeller,

against a cylindrical or conical surface.

The tamping rammer is composed of:

foot (1), pleated tube (2, 3), reduction gear (4),
rubber anti-vibrating elements (5), driving
engine (6), frame (7), and handle (8) (Figure 2).
The transmission of motion from the driving
engine (6) is achieved through a reduction gear
(4), which drives a slider-crank mechanism
bounded by a piston. The piston acts through
elastic springs above the foot (1) and generates
an oscillatory movement.
The pleated tube (2, 3) is filled with oil to
ensure the effect of damping; the lack of oil
leads to a dysfunction of the equipment.
The handler (8) is isolated against vibration
by rubber elements (5).
The mass of the machine along with the
force developed by the helical compression
springs produce an impact force with which the
foot acts over the soil. Large tamping rammers
are equipped with a supplementary helical
spring, shorter than the others, which acts when
the compression force of the springs exceeds a
certain value.
The optimal design of springs is not a
novelty. The mono-objective problem was
firstly described and solved with traditional
optimization methods by Arora [1] and
Belegundu [3].

Fig. 3. Spring geometric elements and their

characteristic

The helical compression springs have a big

spread in the antivibrating isolation systems.
The specifics parameters of a helical spring
that must be considered in design are (Figure
3): maximum load, minimum load, length of
the spring, the materials properties, etc.
Based on this, the wire diameter, spring
mean diameter, spring free length, total number
of coils, spring solid length, etc will be
determined.
An important parameter of the springs used
in vibratory machines and especially in tamping
rammers is the spring rate.
For a helical compression spring (Figure 3)
the longitudinal spring rate is given by the
equation:
E d4
cos
ky =

(1)
3
16 D n 1 + cos 2
where:
E
=
1
(2)
2G
and for < 80 we use the equation:
G d4
ky =
(3)
8 D3 n
If the free length of the spring exceeds four
times the springs diameter, the stability of the
spring during functioning becomes critical, and
the compressive buckling of the spring can
appear. The stability of the spring, defined by
slenderness ratio, is also influenced by the way
the spring is fixed to its ends. To improve
rigidity we need to recalculate the spring, or to
guide it to bolts or through a tube. This solution

is accompanied by the increase of the rubbing

and wear.
To improve the central charges care it is
necessary to process the ends of the springs
also, reducing also the danger of supplementary
loading of the coils.
In choosing the length of the active coils, the
following limitations must be considered:
Dm
2
0,2 t Dm
(4)
4
3
Another aspect that must be considered in
designing the helical compression springs is
their longitudinal vibrations. The free
pulsations of a helical cylindrical spring are
determined by the equation:
k
j = j
; j = 1, 2, 3, ...
(5)
m
where k is the spring rate, and m is its mass.
d1

3. OPTIMAL DESIGN WITH GENETIC

ALGORITHMS

For an optimal design of the helical springs

we considered the following input dates:
maximum load Fmax, minimum load Fmin, stroke
(working range) h, wire steel density ,
Youngs modulus E, rigidity modulus G, end
support parameter, work frequency, wire
material properties (according to ASTM A229 /
SAE J315).
The objective function chosen for this
optimization is the mass of the two springs.
The load that acts over both springs was
divided in 3:1 ratio between them, meaning that
the exterior spring gets three times more than
the interior one. This rapport resulted based on
analyzing more constructive variants of
tamping rammers.
Figure 5 illustrates two springs from the

H0

R m1
R m2 d 2

281
Optimizations of the helical compression
springs have been made by several authors [8],
[9] but optimal design of two springs ensemble
from vibrating machines has never been
achieved so far.

Fig. 4. Helical springs with round section

mounted in parallel

In the situation in which the available space

is reduced, more helical springs are used, more
often two (Figure 4). The system is equivalent
to a number of springs with different stiffness,
mounted in parallel, which deforms with the
same deflection f under an exterior force F.
The component of the tamping rammer
contains two identical sets of two or three
helical springs. The springs from the inside are
assembled on the piston rod and also on a rod
rigidity tied on the rammers foot. Both set of
springs are introduced in the cylinder through
which the piston slides.

Fig. 5. Component springs from tamping rammer

RT 66, produced by Belle Group

tamping rammer RT 66 produced by Belle

Group.
The maximum load to which the springs are
submitted has resulted from studying the
movement of the machine and the forces that
act over the springs during functioning, through
permanent stage of vibrations.

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The minimum load was chosen so that it
ensures pre compression of the springs because
of the weight of the machine. This condition
applies to the inside spring, the minimum load
is established by the equation:
Fn1 Fn 2
=
(6)
F11 F12
The working range of the spring was
determined based on the geometrical
characteristics of the rammers elements as well
as based on studying its behavior during
functioning [10].
The genes defined for the optimization
problem are: the wires diameters: d1, d2, the
springs indices: i1, i2, coefficient of the distance
between coils, at maximum load, from the
inside spring: k1.
The constraints imposed in this problem are:
1. The admissible strength (two constraints):
g1, 2 =

SF min y
SF1, 2 y

(7)

2. Must be checked the endurance strength

(two constraints);
SF min f
1
(8)
g 3, 4 =
SF1, 2 f
3. The load at spring solid length must be
larger than the maximum load (with at least
5% - two constraints);
1,05
F
1
(9)
g5, 6 = 1, 2 max
F1, 2b
4. The minimum clearance at maximum load
should be at least 0,5 mm (two constraints);
0,5
g 7 ,8 =
1
(10)
d1, 2 k1, 2
5. Must be checked the compressive buckling
to axial compression (two constraints);
f
(11)
g9,10 = 1, 2 max 1
f1, 2 f
6. The pitch of coils should be within an
imposed range (four constraints);
g11,12 =
g13,14

0,25 D1, 2 m 0,2

1;
t1, 2

3 t1, 2
=
1
2 D1, 2 m

(12)

7. The work frequency should be less than

resonance frequency (two constraints);
g15,16 =

CFF f
1
f1, 2 Hz

(13)

8. The distance between coils, at the maximum

load must be between two values: 0,1 - 0,5
mm (two constraints);
k2
1;
0,5
0,1
1
g18 =
k2
g17 =

(14)

9. The maximum stress of two springs should

be approximate equal (20%) (one
constraint).
g19 =

5 1t _ max 2t _ max

max(1t _ max , 2t _ max )

(15)

The parameters of the optimization process

with genetics algorithms are: binary
codification; the selection was through roulette
wheel selection; crossover rate: 0.75; mutation
rate: 0.1; the number of individuals in a
population: 200; number of generations: 250.
The material of which the springs are made
is alloy steel chrome and siliceous, tempered in
oil, the symbol of the material is TH 289
(produced by ISPAT INTERNATIONAL
N.V.). The wires made from this material are in
concordance with the European norms EN
10270-2.
This material has high mechanical properties
and is resistant to high temperature and
oxidation. The addition of siliceous removes
the come back fragility provoked by the
chrome, and it stops the separation of the
graphite, characteristic defect at steel siliceous.
The chemical composition of this material is
represented in table 1:
C
0.50

0.60

Mn
0.60

0.80

P
max.
0.020

S
max.
0.020

Si
1.20

1.60

Cr
0.50

0.80

Table 1
Cu
max.
0.10

Table 2 presents the results obtained after

optimization with genetics algorithms:

283
Table 2
Parameter

Symbol

Outside
spring

INPUTS
Maximum load [N]
F1,2max
3080
Minimum load [N]
F1,2min
1950
Stroke (working range)
H1,2
55
[mm]
Wire steel density
7.87

10-6
[kg/mm3]
Youngs modulus [MPa]
E
2.06105
Rigidity modulus [MPa]
G
78000
End support parameter

0.5
Work frequency [Hz]
f
6
GENES
Wire diameter [mm]
d1,2
9
Spring index
i1,2
8.87
Coefficient of the
k1
0.14
distance between coils
Mass of the springs [kg]
M1,2
0.951
SPRINGS PARAMETERS
Spring stiffness (spring
c1,2
20.545
rate) [N/mm]
Minimum deflection
f1,2min
94.912
[mm]
Maximum deflection
149.912
f1,2max
[mm]
Spring mean diameter
D1,2m
79.830
[mm]
Spring outside diameter
D1,2e
88.830
[mm]
Spring inside diameter
D1,2i
70.830
[mm]
Number of active coils
n1,2c
6
of the spring
Number of end coils of
n1,2r
1.5
the spring
Total number of spring
n1,2t
7.5
coils
Spring solid length
H1,2b
67.5
[mm]
Pitch of unloaded spring
t1,2
35.245
[mm]
Spring free length [mm]
H1,20
224.972
Spring mounted length
130.06
H1,2min
[mm]
Spring length at
H1,2max
75.06
maximum load [mm]
Helix angle of the
1,20
8
unloaded spring []
Wire length [mm]
l1,2s
1899.4
Deflection at solid limit
f1,2b
157.47
[mm]
Load at solid limit [N]
F1,2b
3235.3
Slenderness ratio
1,2
2.818
Coefficients of the
c1,2f
0.805
critical slenderness ratio
Critical slenderness ratio
2c
Proper frequency [Hz]
f1,2Hz
82.381

Inside
spring

1090
690
55
7.87
10-6
2.06105
78000
0.5
6
5.3
9.2
0.309
7.273
94.912
149.912
48.760
54.060
43.460
9
2.5
11.5
60.95
23.525
224.972
130.06

To solve the problem we used the

Cambrian v.1.2 software belonging to the
Optimal Design Center of the Technical
University of Cluj-Napoca.
4. CONCLUSIONS

Designing an ensemble of two or three

helical compression springs is based on using
some proportionality relationships between the
elements of the two springs. For the springs that
compound the tamping rammers the problem of
dimensioning them is more complex, in
calculus there are several factors that must be
regarded: the springs have the same length, the
springs work pre tensioned, a spring works
inside the other, the exterior spring is guided
into a cylinder and the interior spring is guided
on the piston rod, no yield of the two springs is
allowed, the working frequency of the springs
must be smaller than its own frequency.
Dimensioning through classical method
requires a lot of time and it doesnt present the
certitude of finding an optimal solution. For
these reasons the optimal design with genetic
algorithms was chosen.
The results obtained were spectacular; the
values after the optimal dimensioning process
were very close to those obtained by measures.
This method can be applied to any ensemble
of two helical compression springs that works
in the conditions specified above, especially for
the springs from the vibratory machines.
5. ACKNOWLEDGEMENTS

This work has been supported by the

Romanian governmental grant PN II ID PCE
2007 Project Code ID_1077.

75.06
8.731
1782.26
157.47
1145.24
4.614
6.980
5.284
130.036

6. REFERENCES

[1] Arora, J. Introduction to Optimum Design,

McGraw-Hill, New-York, 1989.
[2] Azarm, S., Tuan, T. Helical Compression
Spring, Supplementary Course Notes.
Geometric Programming, Department of
Mechanical Engineering, University of
Maryland at College Park, 1995.

284
[3] Belegundu, A. D. A Study of
Mathematical Programming Methods for
Structural Optimization, Dept. of civil and
environmental engineering, University of
Iowa, 1982.
[4] Broman, G., Jnsson, A. The nonlinear
behaviour of a rammer soil compaction
tamping machine, Proceeding of 14th ASCE
Engineering Mechanics Conference, Austin,
Texas, 21-24 May 2000.
[5] Haupt, R. L., Haupt, S. E., - Practical
genetic algorithms, 2nd ed., John Wiley &
Sons, Inc., 2004.
[6] Michalewicz Z. Genetic Algorithms +
Data Structures = Evolution Programs,
Springer Verlag, Berlin, 1992.
[7] Raymond, G.P. Prepared Notes for
Geotechnical
Engineering,
Queens

University, Faculty of Applied Science,

Kingston, Canada, 2005.
[8] Shih, C.J., Tseng, T.C. Reliability-based
optimization of robust feasibility in
mechanical design using PVP technique and
fuzzy formulation, Journal of the Chinese
Institute of Engineers, Vol. 28, No. 1, pp.
77-88, 2005.
[9] Tudose L., Pop D. Optimal Design with
Genetic Algorithms, Editura Mediamira,
Cluj-Napoca, 2002 (in romanian).
[10] Ursu-Fischer, N., Morariu-Gligor, R.M.
Contribution to the Tamping Rammer
Dynamical and Numerical Study, Acta
Technica Napocensis, Series Machine
Construction, Materials, No. 49, 2006, ISSN
1224-9106, pag. 9-16.

PROIECTAREA OPTIMAL A ARCURILOR ELICOIDALE DE COMPRESIUNE DIN COMPONENA

MAIURILOR COMPACTOARE
Arcurile elicoidale sunt repere foarte importante din componena maiurilor compactoare, acestea asigurnd fora
necesar compactrii solului. Montate n baterii de cte dou sau trei, arcurile elicoidale trebuie s respecte o serie de
constrngeri: dimensionale, de rezisten, vibraii, etc. n acest context, proiectarea acestor arcuri implic luarea n
considerare a unui numr semnificativ de factori, lucrarea de fa prezentnd o metod de proiectare optimal utiliznd
algoritmi genetici.

Lucian TUDOSE, PhD, Professor, Technical University of Cluj-Napoca, Department of Machine

Elements and Tribology, e-mail: [email protected], Tel. 00 40 0264-401665.
Radu Mircea MORARIU-GLIGOR, Lector, Technical University of Cluj-Napoca, Department of
Mechanics and Computer Programming, Faculty of Machine Building, [email protected]
Ariesului 102/107, Cluj-Napoca, 0264-414380.
Simion HARAG, PhD, Reader, Technical University of Cluj-Napoca, Department of Machine
Elements and Tribology, e-mail: [email protected], Tel. 00 40 264 401665.