Question 1:
If we don't pull the spring hard/far enough, when we release it it wouldn't provide much force. But if we stretch it too far, or keep it under tension for too long without firing, it would deform and then not work anymore, am I right?
You are right. The effect you are describing is called creep. most materials suffer from it. However, in this particular problem, I don't expect it to be relevant, or easy to model.
Question 2:
There are two ways to make an estimation.
- a rough estimation with energies
- an estimation with differential equations of motion
both of them have problems.
Q 2.1: Energies
IF $\Delta s$ is the extension of the spring, then the energy of the pulled string will be equal to:
$$\frac{1}{2}k \Delta s^2 $$
Assuming that at the highest point $m_1, m_2$ don't have a velocity (this is not the real case), then
$$(m_1+m_2) \cdot g \cdot h =\frac{1}{2}k \Delta s^2 $$
therefore: $$h =\frac{k \Delta s^2}{2 (m_1+m_2) \cdot g } $$
NOTE: this is a rough estimation.
Q 2.2 Differential equations of motion
Assuming the following coordinate system
where:
- $F_s$ is the spring force, and its equal to $F_s = k(y_2-y_1)$
the following system of Differential equations can be written (there are a few asterisks -see below):
$$\begin{cases}m_1 \ddot{y}_1 =F_s -m_1\cdot g \\
m_2 \ddot{y}_2 =-F_s - m_2\cdot g +N_2
\end{cases}$$
where $N_2$ is the reaction from the ground. This is one of the asterisks, in that the $N_2$ and $y_2$, both of them need to be positive non zero, however only one of them can be (if $y_2$ is greater than 0 then the box is not in contact so there is no reaction from the ground). more precisely:
$$N_2 =\begin{cases}0 & y_2>0 \\m_2\cdot g+ k(y_2-y_1) & y_2=0 \\\end{cases}$$
Analytically, I can't think of a neat way to solve this, however you can solve this numerically.
Additionally for the numerical scheme, to simplify things you can assume that if in a timestep $i$, $y_{2,i}<0$. then in the next timestep $y_{2,i+1} = -y_{2,i} $ (this indicates that there is a bounce).
Question 3:
There are too many ways, your question there needs to focus.