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    A round wire helical spring is loaded by the axial force. The maximum shear stress in the wire cross section will be at
    Question

    A round wire helical spring is loaded by the axial force. The maximum shear stress in the wire cross section will be at

    A.

    Outer fibre

    B.

    Inner fibre

    C.

    Center of the cross section

    D.

    Both outer and inner fibres

    Correct option is B

    In a round wire helical spring subjected to an axial load, the maximum shear stress occurs at the inner surface of the wire's cross-section.

    Stress Concentration: The curvature of the helical coil creates higher stress on the inner side of the wire.
    Superposition: While torsional stress is highest on the outer fiber, the combined effect of torsional and direct shear stresses (modified by curvature) shifts the peak stress to the inner fiber.

    The total shear stress is the sum of torsional and direct shear stresses. However, their distributions differ: Torsional stress peaks at the outer surface. Direct shear stress is uniform but adds constructively at the inner surface due to the spring’s curvature.Wahl Correction Factor (K)For helical springs, the curvature of the wire amplifies the stress at the inner surface.The Wahl factor accounts for this:K=4C14C4+0.615Cwhere C=2Rd (spring index).The maximum shear stress then becomes:τmax=K8FDπd3where D=2R is the mean coil diameter.\begin{aligned}&\text{The total shear stress is the sum of torsional and direct shear stresses. However, their distributions differ:} \\&\bullet\ \textbf{Torsional stress} \text{ peaks at the \textit{outer surface}.} \\&\bullet\ \textbf{Direct shear stress} \text{ is uniform but \textit{adds constructively at the inner surface} due to the spring's curvature.} \\[1em]&\textbf{Wahl Correction Factor } (K) \\[0.5em]&\text{For helical springs, the \textit{curvature of the wire} amplifies the stress at the \textit{inner surface}.} \\&\text{The Wahl factor accounts for this:} \\&K = \frac{4C - 1}{4C - 4} + \frac{0.615}{C} \\[1em]&\text{where } C = \frac{2R}{d} \text{ (spring index)}. \\[1em]&\text{The maximum shear stress then becomes:} \\&\tau_{\text{max}} = K \cdot \frac{8FD}{\pi d^3} \\[1em]&\text{where } D = 2R \text{ is the mean coil diameter.}\end{aligned}​​

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