Unique Features of Conical Springs

 

Conical springs have several unique characteristics that may be useful in certain applications. Often referred to as tapered springs, the coils of a conical spring gradually increase in size along its length. They have a wide variety of applications in many different industries. Here are three features of conical springs:

Stability

Even minimal side deflection of a cylindrical spring can cause it to buckle, but tapered body of a conical spring is much more stable, requiring less lateral support.Conical springs are the preferred choice where loading is not perfectly axial, or where the entire length of the spring cannot be supported by a rod or housing.

Variable Spring Rate

A conical spring with a constant wire thickness or pitch will have a variable spring rate, with the spring force increasing as the spring is compressed.This can be useful where higher stiffness is required for increasing loads.By producing the spring with a wire thickness that varies along its length, the spring rate can be made constant.This allows conical springs to perform like their cylindrical counterparts.

Minimal Solid Height

When a cylindrical spring is compressed, its coils stack on top of each other.Depending upon the wire thickness and number of coils, the resulting height can be significant.Because of its tapered geometry, the coils of a conical spring can be designed to nest completely within one another so that the compressed spring height is equivalent to a single wire thickness. This allows conical springs to be used in areas where axial space is limited.

Conical springs have unique qualities that make them a practical choice for many applications.A spring manufacturer will help you determine the best spring type for your needs and can assist you in designing a spring to meet your specifications.

Getting the Right Springs for Your Equipment

Springs are a crucial element in proper equipment performance, providing the necessary cushioning and damping for trouble-free operation.The wrong spring can produce poor equipment performance and may cause damage to other components.Working with a qualified spring manufacturer can ensure that your springs perform properly, reducing premature failure and prolonging the life of your equipment.Here are three areas where a manufacturer’s expertise can be especially valuable:

Material and Treatment

Premature spring failure can result from a variety of factors, including:

·         Corrosion

·         Fatigue

·         Relaxation

Selecting the appropriate material and treatment for your spring’s operating environment can substantially prolong its life. The right manufacturer will have extensive expertise in spring materials and can provide performance simulation and in-depth material analysis to determine the best choices for your spring.

Spring Geometry

Proper spring design involves much more than simple force and deflection analysis.Manufacturing and assembly tolerances will affect the spring’s function, and improper dimensions or tolerances may lead to performance issues or premature failure.An expert spring manufacturer will assist you in determining the correct dimensions and tolerances and will assure that those tolerances are met during manufacturing through the use of specialized measurement technology.

Prototype and Test

Prototyping your spring design to confirm that it meets your specifications prior to manufacture is a crucial step in the design process.The best manufacturers will not only provide you with high quality prototypes, but will also perform well-designed stress, life cycle and fatigue testing of both prototypes and manufactured samples to ensure that springs will perform as expected.

A Valuable Partnership

Installing the right springs in your equipment will prevent premature failure and protect other components, reducing costly down time and avoiding unnecessary part replacement. Spring design depends upon many factors, and the expertise of a qualified spring manufacturer can be a valuable asset.When choosing a manufacturer, be sure to consider the depth of expertise and services offered to ensure a quality spring design and optimum performance.

Choosing Flat Wire Springs

Flat wire springs are compression springs made from flat wire and have a rectangular cross section. They come in all sizes and shapes, and are typically used in the production of push button switches, shock absorbers and ballpoint pens. Their cross section is much larger than that of your common round wire spring. This provides you with several important benefits, such as offering a higher energy absorption than a round wire spring since they are able to store more energy in a small space. The larger surface area of the flat wire spring enables it to absorb higher impact loads than round wire springs because it distributes forces over a bigger surface. 

To make a flat wire spring, first you start with round wire drawn to the correct size for flattening. Then the round wire is rolled to a flat cross section using a series of rolling operations. 

Knowing what your springs are made of is a huge advantage to you when it comes time to order replacements.

Flat wire springs can be made from a selection of materials such as brass, steel and metals like titanium, tantalum, nickel, copper and niobium. Brass is the most popular choice in making flat wire springs because it is relatively inexpensive. However, using brass sacrifices the longevity of your springs in high stress applications, as it lacks durability. Using stainless and high-carbon steel is also a fairly inexpensive way to make flat wire springs, so it is also a popular choice by customers. Exotic metals like titanium are the preferred choice by customers looking to design springs to be used in custom applications. 

There are many applications that call for using a flat wire spring. Some of these applications include, but are not limited to, communication equipment, construction equipment, medical instruments, electronic components and plastics. 

Choosing the wrong spring can result in the loss of time and money from having to remove your broken spring and then replace it with the correct one. So you may want to consider going with a flat wire spring instead of the traditional round wire spring.