Spring design and its fabrication play an important role in manufacturing and industry around the globe. Springs come in all shapes and sizes to meet industry needs and are made from a wide range of metal alloys. Materials used for spring design and wire forming consist of high strength alloys. In general, wire formed into springs is cold rolled or drawn, and a made of medium to high carbon steel with high yield strength that allows for excellent elastic properties. Coil springs and flat springs are the two basic types of springs in use, with compression and extension springs the most common types of springs.
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The manufacturing of springs begins with the designing process, with attention given to the particular material relevant to the application. The design should be based on expected loads, the rate of usage, and physical dimensions. For example, extension springs decrease in diameter when resistance is applied and therefore working tolerances need to be calculated in the design.
Mechanical Properties
The mechanical principles of springs are very basic. They are an elastic component. Potential mechanical energy is stored in the elastic materials of the spring while in a relaxed position. That energy is released and expended without any external power source through absorption or resistance only when it is needed and without forceful deformation. Compression springs absorb, such as the suspension systems found in automobiles. Extension springs resist and return moving objects back to their starting positions, such as those found on garage doors. As basic as springs are, their component function in machinery and equipment are essential to manufacturing as a whole and as an intricate part in a variety of finished products.
General Characteristics
Springs are often manufactured with tempered steel or stainless steel consisting of varying degrees of chromium alloys, depending on the environmental conditions for the application. Other metals used include copper, bronze, and titanium. Plastics are also used in the manufacture of springs. From paperclips to medical devices, toasters to earthquake-proof foundations, trampolines to complex transportation systems, springs are used in a wide variety of applications and consumer goods. They are found around the home, in manufacturing plants, and in nearly all sectors of transportation.
The Extension Spring
As mentioned, extension springs are resistant to stretching forces. They are the familiar cylindrical shaped coils with hooks or loops at each end for connecting components. How tightly the wire coils are wound determines how much energy is stored and released when the coils are spread between components. All the coils are active and potential energy is stored within while retracted. When a pulling force is applied, the tension within the spring is deformed and will attempt to return to its initial zero-deflection state. Examples of extension springs are found in garage doors, door closers, vise grips, trampolines, automotive interiors, and carburetors.
A list of common extension spring and wire form materials would include:
High Carbon Spring Wire
Stainless Steel Wire
Carbon and Alloy Wire
Hard Drawn Wire
High-Temperature Alloy Wire
Alloy Steel Wire
Non-Ferrous Alloy Wire
Depending on the application, these types of wires will necessarily have different uses, purposes, and special properties in the manufacture of springs. Method of manufacturing include processes such as cold-drawn for uniform tensile strengths, cold rolled annealed or oil tempered, corrosion resistance for nearly all environmental extremes and conditions, the need to withstand high temperature with lower stress, non-magnetic alloys, or the need to conduct electricity.
As technologies have advanced and improved in metalworking and heat-treating, improvements in spring manufacturing have occurred as well. Today’s springs have more elasticity, are more durable, and can carry greater loads. However, successful spring manufacture begins with the designing process and the consideration of materials and functional demands of the intended application of the spring. For the success of the industry, the successful spring design is absolutely indispensable.
Mechanical device which stores energy
(l-r) Tension, compression and torsion coil springs A selection of conical coil springs
The most common type of spring is the coil spring, which is made out of a long piece of metal that is wound around itself. Coil springs were in use in Roman times, evidence of this can be found in bronze Fibulae — the clasps worn by Roman soldiers among others. These are quite commonly found in Roman archeological digs.
Coil springs can be either compression springs,[1] tension springs[2] or torsion springs,[3] depending on how they are wound.
A coil spring is a mechanical device which is typically used to store energy and subsequently release it, to absorb shock, or to maintain a force between contacting surfaces. They are made of an elastic material formed into the shape of a helix which returns to its natural length when unloaded.
They are commonly used in mattresses, automotive suspensions,[4] and residential plumbing. Coil springs come in a variety of sizes and shapes and can be used for a variety of applications. Small coil springs are often used in electronic devices, while larger ones are used in automobile suspensions. Coil springs can be made from various materials, including steel, brass, and bronze.[5]
Spring rate
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Spring rate is the measurement of how much a coil spring can hold until it compresses 1 inch (2.54 cm).[6] The manufacture normally specifies the spring rate. If a spring has a rate of 100 then the spring would compress 1 inch (2.54 cm) with 100 pounds (45 kg) of load.[7]
Types
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A double volute spring mounted in pruning shears. Illustration of various arc springs and arc spring systems (systems consisting of inner and outer arc springs).
Types of coil spring are:
Tension/extension coil springs,[8] designed to resist stretching. They usually have a hook or eye form at each end for attachment.
Compression coil springs,[9] designed to resist being compressed. A typical use for compression coil springs is in car suspension systems.
Volute springs[10] are used as heavy load compression springs. A strip of plate is rolled into the shape of both a helix and a spiral. When compressed, the strip is stiffer edge-on than a wire coil, but the spiral arrangement allows the turns to overlap rather than bottoming out on each other.
Arc springs (bow springs) are a special form of coil spring which was originally developed for use in the dual-mass flywheel of internal combustion engine drive trains. The force is applied through the ends of the spring. A torque
M = F ⋅ r {\displaystyle M=F\cdot r}
F {\displaystyle F}
r {\displaystyle r}
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Torsion springs, designed to resist twisting actions. Often associated to clothe pegs or up-and-over garage doors.[12]
Heavy-duty springs
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Heavy-duty springs are designed to withstand high levels of force and tension.[13] They are typically used in industrial and commercial applications where heavy loads need to be supported or generated. Heavy-duty springs can be made from various materials, including steel, stainless steel, and titanium.[14] They are typically much stiffer and thicker than standard springs (3 mm — 65 mm thick)[15] and can have a wide range of sizes and shapes. Because of their strength and durability, heavy-duty springs are typically used in automotive and mining applications. They are also commonly used in construction, motorsport, rail and other industries where heavy equipment is used.
Design
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Spring design must take into account the desired stiffness of the spring, as well as the amount of space that is available for the spring. In addition, springs must be designed to withstand the forces that will be applied to them, such as the car's weight or the gas pressure. Spring design is an important part of many engineering applications, and it is crucial to ensure that products work correctly and safely.[16]
Applications
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Coil springs have many applications; notable ones include:
Coil springs are commonly used in vehicle suspension. These springs are compression springs and can differ greatly in strength and in size depending on application. A coil spring suspension can be stiff to soft depending on the vehicle it is used on. Coil spring can be either mounted with a shock absorber or mounted separately. Coil springs in trucks allow them to ride smoothly when unloaded, and once loaded the spring compresses and becomes stiff. This allows the vehicle to bounce less when loaded. Coil spring suspension is also used in high performance cars so that the car can absorb bumps and have low body roll. In off-road vehicles, they are used because of their range of travel they allow at the wheel.
Coil springs in valvetrain
Coil springs used in the engine are compression springs and play an important role in closing the valves that feed air and let exhaust gases out of the combustion chamber. The spring is attached to a rocker that is connected to the valve.
Tension and extension coil springs of a given material, wire diameter and coil diameter exert the same force when fully loaded; increased number of coils merely (linearly) increases free length and compressed/extended length.
Manufacture
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Metal coil springs are made by winding a wire around a shaped former – a cylinder is used to form cylindrical coil springs.[18]
Spring manufacture is the process of making springs by coiling, winding, or forming steel wire or other materials. Spring manufacturing includes various processes, including cold coiling and hot coiling. [19]
To meet the demands of today's consumers, spring manufacturers must be able to produce springs in a wide range of sizes and shapes. As a result, spring manufacture has become increasingly complex and specialized.[20] They must have a thorough understanding of spring design to produce quality products. In addition, they must be able to operate various machines to produce springs with the desired characteristics. Spring manufacture is a critical part of the economy, and spring makers play an important role in ensuring that products meet the highest quality standards.[21]
Coil springs for vehicles are typically made of hardened steel. A machine called an auto-coiler takes spring wire that has been heated, so it can easily be shaped. It is then fed onto a lathe that has a metal rod with the desired coil spring size. The machine takes the wire and guides it onto the spinning rod, as well as pushing it across the rod to form multiple coils. The spring is then ejected from the machine and an operator will put it in oil to cool off. The spring is then tempered to lose the brittleness from being cooled. The coil size and strength can be controlled by the lathe rod size and material used. Different alloys are used to get certain characteristics out of the spring, such as stiffness, dampening, and strength. [22]
After sorting the products in the order of your choosing, you can start looking through the list to decide which spring will work best. You can find the spring based on the maximum load or the maximum deflection. When you find the spring that meets your load and travel requirements, you can then check whether the spring rate meets your working loads. Furthermore, you can check pricing at different quantities by clicking on the Quick View icon.
If you still need help deciding select your springs and “Add to Compare” by clicking on the icon of two circles joined together on each product. This is to be able to compare them side by side in a more efficient manner. To enter the Compare Products page, find the link at the top of the page. Then, just quickly add them to your cart to complete your order. If you need further assistance finding your springs, you may contact our team of experts to help you out.
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This chapter delves into the fundamentals of compression springs and outlines crucial considerations for selecting the right type.
Coil springs, known as compression springs, serve as energy storage mechanisms when compressed. These helical, open-coiled springs resist compressive forces and, when compressed, shorten to absorb substantial potential energy.
Upon reduction or removal of the load, compression springs regain their initial shape and length due to the energy storage. When loaded, the springs become more compact, differing from extension springs where non-stressed coils remain uncontacted.
For designers and engineers, understanding spring mechanics, particularly Hooke's Law, is critical, as it dictates that deformation force is proportional to deformation amount. This principle applies to the need for increased force when compressing a spring.
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The spring constant, indicated in Newtons per meter or pounds per inch, dictates the deformation force needed. A higher constant implies a stiffer spring. It is influenced by wire diameter, coil diameter, free length, and number of active coils.
Comprehending the spring constant is vital for manufacturers to achieve optimal spring performance. If the constant is overly high or the wire excessively slender, the spring risks failure. Precision in large-scale spring manufacturing ensures stability and prevents damage due to carefully calibrated spring coiling machines.
When selecting compression springs, consider various factors:
Compression springs feature diverse end types that are standard or custom-designed, such as open, closed, ground, and ungrouded ends. These configurations can impact the spring rate, despite constant factors like wire size, coil count, and outer diameter (OD).
Closed-end compression springs stand upright on flat surfaces due to closed terminal coils, favored for their simplicity and cost efficiency, as they demand less processing. For springs with high slenderness ratios, additional rod or shaft support may be necessary.
Ground end compression springs, a variant of closed-end springs, have precisely ground ends to align with spring dimensions. This precision comes with increased production time and costs. The ground ends ensure proper slenderness ratios, allowing effective operation without extra rod or shaft support.
Double closed end compression springs boast two closed terminals, similar to closed and squared ends. Produced akin to extension and torsion springs, all coils are in contact. These ends enhance stability, offering higher slenderness ratios, necessitating reinforced ends to prevent buckling, often at lower costs than their closed or ground counterparts.
Open end compression springs are less common due to stability concerns without rod or shaft support. With open and spaced coils, these springs suit applications prioritizing minimized solid height.
Paired with closed ends, open ends enhance load distribution and mitigate buckling risks. Ground ends, however, increase manufacturing costs due to additional processing.
Not all producers carry closed and ground ends as standard inventory, an essential distinction. Custom end varieties may include expanded coils for ring grooves, offset legs for alignment, or reduced coils for screw attachment.
Popular spring materials include carbon steel and exotic alloys. Music wire, high carbon steel, is commonly used, while stainless steel 302, though less strong, offers superior corrosion resistance.
Nickel alloys are selected for extreme temperature tolerance, corrosive resistance, and non-magnetic properties, available under various brand names. Copper alloys, such as phosphor bronze and beryllium copper, are prized for excellent electrical conductivity and corrosion resistance.
Outer Diameter (OD): For springs inserted into holes, consider the outer diameter. If surrounded by internal components, measure their dimensions. OD expands under compression, essential to consider if used in tubes or bores. The OD measures across the outer coil edges.
Manufacturing processes can restrict spring OD, impacting required assembly space. Manufacturers offer work-in-hole diameters based on anticipated OD expansion and tolerances, crucial when ordering custom springs or choosing from catalogs.
Inner Diameter (ID): For springs fitting over shafts or mandrels, account for the inner diameter. A minimum clearance of ten-thousandths of an inch prevents friction. The ID calculates by deducting twice the wire diameter from the OD.
Free Length: Ensure the spring's free length exceeds available space for a preloaded state, maintaining position. Free Length, the spring length without compression or force, measures from end to end or tip to tip.
Solid Height: Wire diameter and total coil count dictate solid height, crucial to ensure loaded heights do not exceed or undercut the solid height.
Environmental factors, temperature, and moisture exposure influence spring performance. Costlier materials withstand higher temperatures, increasing spring expenses.
Spring Pitch: Pitch refers to space between adjacent coils, from center to center. Calculate by measuring coil gaps and adding wire thickness.
Active Coils: These are the coils in compression springs that compress and deflect under load, contributing to the spring's movement.
Total Coils: This includes both active coils and non-deflecting, closed coils devoid of pitch.
Noting total and active coil counts is important. Closed or ground-end springs have inactive ends, whereas open-end springs boast fully engaged active coils.
Considering a spring's load or travel is imperative. The spring rate or spring constant indicates necessary compression force per unit length, typically in pounds per inch (lbs/in). Designers use this to anticipate spring travel under loads. Advanced compression adds stress, potentially leading to spring set, affecting original length recovery post-load, though they may still operate based on application.
Appropriate wire diameter and material selection is vital to align with load, travel, and environment requirements. The Rockwell scale gauges wire hardness, providing insights into its flexibility and rigidity. This assessment measures indents from a specific load, elucidating durability and stress performance.
This chapter explores the full range of manufacturing techniques and processes used in the production of compression springs, as well as the selection and characteristics of materials that ensure optimal spring performance. Understanding these details is critical when sourcing or specifying compression springs for engineering, mechanical, or industrial applications.
The production of compression springs relies on advanced manufacturing methods and precise engineering processes designed to meet specific technical requirements such as load capacity, spring rate, and environmental durability. The most common manufacturing processes include:
Coiling is a foundational step in fabricating compression springs, where high-strength spring wire is straightened to improve uniformity and accuracy. Wire is fed into CNC coilers equipped with programmable controls, allowing precise adjustments for the compression spring's free length, coil diameter, pitch, and number of active coils. These factors directly impact the spring's compression force and functionality. Modern coiling machines often use high-resolution cameras and laser micrometers for real-time quality assurance, ensuring that the spring meets stringent dimensional tolerances and customer specifications. After the coiling operation, the spring is cut from the wire and prepared for subsequent heat treatment and surface finishing.
During the coiling process, spring wire experiences significant internal stresses and strain, which, if not addressed, can lead to brittleness, deformation, or failure during use. To combat this, springs are subjected to a stress-relief heat treatment—typically in a controlled-atmosphere oven—where temperatures and holding times are carefully regulated. This process allows the metal’s microstructure to relax, forming stronger metallic bonds and stabilizing the spring’s geometry. Proper stress relieving enhances the spring's fatigue resistance and long-term durability, making the springs suitable for dynamic and cyclic loading conditions.
After heat treatment, compression springs may go through a variety of finishing operations to optimize their surface properties, corrosion resistance, and mechanical performance. These secondary processes can be tailored to the specific demands of each application. Key finishing steps include:
Compression springs can be manufactured from a wide range of spring materials, each chosen for its unique balance of fatigue strength, tensile strength, elasticity, and corrosion resistance. Proper material selection is essential for ensuring springs meet the mechanical demands and environmental factors of their intended application, minimizing the risk of spring failure and maximizing lifespan.
Among metallic materials, various grades of steel remain the industry standard for compression spring production. Common spring steels include stainless steel, carbon steel, high-carbon music wire, and hard-drawn steel. Each type of spring wire offers different performance characteristics:
Additional spring materials include chrome vanadium and chrome silicon steel alloys, which provide enhanced fatigue resistance, shock load tolerance, and high-temperature strength—making them the preferred choice for heavy-duty applications such as automotive suspension, aerospace, and industrial equipment. Non-ferrous metals like titanium, phosphor bronze, and beryllium copper are selected for specialty springs that require properties such as electrical conductivity, lightweight strength, or high corrosion resistance. Ceramics and high-performance plastics may also be used for springs in specific advanced engineering or high-temperature environments.
When designing a custom compression spring, engineers must consider both material choice and spring geometry—including wire diameter, coil diameter, and number of coils. Larger wire diameters yield greater load-bearing capacity, while reducing coil diameter increases overall spring stiffness. Improper selection of spring material or dimensions can lead to premature fatigue, breakage, or even failure of surrounding components, posing operational and safety concerns.
Whether selecting standard springs or requesting custom compression spring manufacturing, collaborating with experienced spring manufacturers ensures application-specific guidance on spring design, material choice, stress analysis, and finishing options to optimize compression spring performance and reliability in your project.
Compression springs are fundamental mechanical components that store and release energy by resisting compressive forces. These coil springs are widely used in manufacturing, engineering, automotive, aerospace, electronics, medical devices, and consumer products. Understanding the different types of compression springs is crucial for engineers, product designers, and procurement specialists looking to select the ideal spring configuration for specific applications. The main types of compression springs include:
Convex springs, often referred to as barrel-shaped springs, have a unique design where the coils are wider in the middle and taper towards the ends. This specialized coil geometry allows the coils to nestle into each other when compressed, reducing the solid height and increasing the spring’s travel capability. Specifically, in a convex spring, the outer diameters at the top and bottom are smaller compared to the diameter at the center. These springs are commonly used to produce linear force where space is limited and precise spring force is required.
Barrel springs are versatile and can be manufactured in various diameters, wire gauges, and materials, offering numerous design possibilities. They are often favored over standard compression springs due to their ability to save space, reduce buckling, minimize lateral movement, and adapt to different shapes to fit specific needs. These springs can be designed to either telescope or remain non-telescoping. In applications requiring enhanced stability, resistance to mechanical vibration, and precision under dynamic loads, manufacturers prefer convex springs. They are commonly utilized in industries such as toys, furniture, mechanical seals, valves, and the automotive sector for components like suspension systems and actuators.
Conical springs, shaped like a cone, have a diameter that tapers from one end to the other, with coils gradually decreasing in size along the length of the spring. This design allows for a progressive change in the coil diameter, enabling the coils to nest within each other. Such springs enhance stability while reducing the solid height. Some conical springs are designed to achieve a telescoping effect when compressed, where the tapered shape allows the coils to collapse into a smaller diameter, increasing the available travel or deflection. This makes them an ideal choice for applications requiring significant compression travel, minimal space, or high spring loads.
Conical springs offer enhanced stability compared to conventional compression springs. Their tapered design, with a larger outer diameter at the bottom, ensures improved stability, resistance to lateral deflection, and reduces the likelihood of buckling. This design helps maintain balance and consistent performance even under substantial axial compression. Conical compression springs are often used in electrical contacts, battery compartments, shock absorbers, and dynamic load applications where solid height and space constraints are a concern.
The image below illustrates a Belleville spring, which is characterized by its coned disk design. Invented by Julian Belleville and patented in France in , this spring design is known for its high load-bearing capacity in a compact space. The spring's load-deflection characteristics vary depending on the (h/t) ratio, which determines its stiffness and compressive force capability. Belleville springs are widely used in applications such as plate clutches, brakes, pressure relief valves, vibration dampening, and various types of fastened connections that require precise preload or tension adjustment.
Here are some advantages of using Belleville springs:
Belleville disc springs are popular for critical applications in industrial machinery, bolted joint assemblies, power transmission, and heavy-duty equipment where consistent force and compensating for thermal expansion or relaxation is necessary.
Concave springs, also referred to as hourglass springs, feature a design where the coil diameter is reduced in the center compared to the ends. This symmetrical hourglass shape improves spring alignment, helping to maintain the spring's position and minimizing lateral movement or buckling under load. The broader end coils contribute to an uneven pressure distribution, enhancing overall stability and performance. Concave springs are available in various materials such as stainless steel, alloy steel, and corrosion-resistant metals, enabling them to be tailored for specialized applications—including precision instruments, vibration dampening, and shock absorption systems.
Compared to straight coil compression springs, concave springs offer space-saving benefits and are designed to operate in compact environments where side loading must be minimized. Their unique geometry makes them ideal as return springs, component separators, and in various control mechanisms within mechanical and electrical devices.
Straight coil compression springs, also called constant diameter or cylindrical springs, feature a uniform outer and inner diameter along their entire length. These are the most common type of compression spring and are characterized by a cylindrical coil geometry made from round, square, or rectangular wire profiles.
Each coil in a straight coil compression spring maintains a consistent diameter, ensuring uniform load distribution and predictable spring rate (spring constant). The ends of these springs can be ground (for stability on flat surfaces) or closed, offering a reliable 270° bearing surface. Their cylindrical form distinguishes them from tapered compression springs, which have a conical shape and variable coil diameters.
Straight coil compression springs are versatile, readily available in standard sizes and custom configurations, and widely utilized in automotive suspensions, industrial equipment, valve assemblies, pumps, and everyday consumer products like pens and electronics.
A volute spring features coils with a cone shape rather than a round, oval, or square cross-section. Much like a conical compression spring, it functions in a similar manner. Instead of being compressed into a smaller space, the cone shapes nestle over each other. As a result, a volute spring typically achieves a lower solid height compared to a non-conical compression spring of the same length. Volute springs are notable for their ability to absorb shock and withstand heavy loads in rugged environments.
Volute springs are often used in railway switches, heavy machinery, industrial presses, and agricultural equipment, where robust compression resistance and durability are required.
Variable pitch springs feature coils with varying spacing along their length, with some sections having wider gaps and others being more tightly wound. The term "pitch" refers to the distance between adjacent coils. In variable pitch springs, these intervals differ along the spring’s length, allowing for a range of performance characteristics and progressive compression rates.
Springs with a variable pitch are strategically engineered for applications that require variable force output during compression, such as automotive valve springs, safety devices, and dynamic systems where a progressive rate is essential to avoid surging or material fatigue. By altering the spring pitch, designers can optimize behavior under fluctuating loads and tailor the pressure curve to meet specific performance requirements.
Magazines utilize compression springs with oval or rectangular coils to propel cartridges or bullets into a handgun's chamber. These specialty compression springs must be produced with high precision, rigorous tolerances, and stringent quality standards. Various design options are available, including differences in length, coil count, wire diameter, and required spring force. Given that magazine springs often operate near their solid height and endure repetitive cycling, the spring rate, fatigue resistance, and material choice are critical factors in the design process.
Magazine springs are often made from high-carbon music wire or stainless steel to ensure longevity and reliable performance. Optimization of spring design is vital for feeding reliability, consistent force delivery, and easy maintenance in firearms and ammunition systems.
A torsion spring is a mechanical tool that stores and releases rotational energy. The torsion spring is attached to a mechanical part at each end. The winding of the spring is tightened and stores potential energy when it is turned around its axis at one end. As the other end is kept fixed, it is deflected about the body's centerline axis. The spring stores more potential energy as the winding becomes tighter and resists more rotating force. The spring will unwind as it performs an elastic rebound after being released, releasing the tensioned energy.
Torsion springs generate an equal and opposite rotational force (torque) at their ends, which can apply torque to the connected mechanical components. These precision springs are designed to hold mechanical parts statically in place or allow movement when a specific torque threshold is met. As the spring is twisted to tighten the winding, it faces more bending stress compared to rotational stress.
In contrast to compression and tension springs, which deal with linear and rotational forces, torsion springs are unique in that they operate solely under rotational forces. They rely on the material's elasticity to return to their original winding position after being twisted.
Torsion springs can exert force in either a clockwise or counterclockwise direction, depending on the direction of the twist. To achieve maximum force output, the spring should be twisted in the direction of its winding.
These specialized springs are utilized across various industries, including automotive (for trunk lids and hoods), aerospace, agriculture, door hinges, and electronic devices. Numerous variations exist to suit different applications, such as double torsion springs, leg configurations, and custom spring dimensions for advanced mechanical designs.
Tapered compression springs feature a cone-shaped design, with a larger outer diameter at the base and a smaller diameter at the top. This tapered form enhances stability, reducing the risk of buckling compared to standard compression springs. These springs are known for their low solid height, which improves stability and resistance to surging. The solid height of tapered compression springs can be as minimal as the diameter of a single wire. They are designed to resist compression forces and store energy when compressed.
Due to their excellent space efficiency and enhanced ability to withstand lateral forces, tapered compression springs are often chosen for applications in automotive engines (such as valve springs), power transmission, actuators, safety switches, and compact mechanical assemblies. Their progressive rate characteristics and customized end configurations make them a smart choice in dynamic systems requiring both stability and high-performance energy absorption.
Choosing the right type of compression spring is essential for optimizing performance, durability, and safety in your mechanical system. Consulting with experienced spring manufacturers can help you select the appropriate spring material, finish, and design for your unique requirements, ensuring reliability in demanding operational environments.
This chapter will explore the various applications and advantages of compression springs.
Compression springs are utilized in a variety of applications, including:
Pens: A compression spring can be observed by examining a ballpoint pen. This spring enables the pen to write while exposing the tip and then shields the tip inside the housing to prevent the ink from drying out. This makes it possible to use pens without cumbersome and easily lost caps.
Firearms: Whenever considering tension, consider compression springs. Take into account the strain needed to fire a bow and arrow. The crossbow is a much simpler weapon if the human component is replaced with a compression spring. Technological advancements continue with the modern semi-automatic handgun, which uses a compression spring to absorb the energy produced by recoil and then redirect it to advance the slide or bolt and reload the weapon for the subsequent shot.
The benefits of compression springs are as follows:
Putting a component back in the right position: Door latches on both automobiles and building doors are an additional advantage that demonstrates how frequently utilized and essential compression springs are. Imagine raising a handle to open a door to get the greatest understanding of how a spring operates. The lock mechanism's compression spring would restore it to the locked position if the motion was used without pulling the door open. The spring can be compressed by tugging or turning the device; if it retains its position, the spring will stay compressed; otherwise, it will latch once more.
The drawbacks of compression springs are as follows:
Typical issues related to compression springs include:
When one end of a helical spring is placed on a rigid support and the other end is abruptly loaded, the coils do not deflect evenly. This is because it takes time for the tension to propagate along the spring wire. Initially, the coils at the end closest to the applied load absorb most of the deflection before passing some of it to the adjacent coils. A compression wave travels through the spring towards the supported end and then reflects back to the deflected end. This behavior is similar to a disturbance traveling through a closed water body before returning to its origin. This compression wave can continue traveling along the spring. If the applied load varies and the intervals between load applications match the time it takes for the wave to travel from one end of the spring to the other, resonance occurs. This causes the coils to experience high strain and significant deflections, potentially leading to the spring's failure. This phenomenon is known as surge.
The following methods can be employed to prevent spring surge:
Experimental data suggest that when the free length of a spring (LF) exceeds four times its mean or pitch diameter (D), the spring acts like a column and may buckle under relatively low loads. The following formula can be used to calculate the critical axial load (Wcr) that leads to buckling.
To prevent buckling, consider the following measures:
Compression springs can store mechanical energy when they are compressed. These open-coiled, helical springs provide resistance to compressive loading. When these springs are subjected to a compression load, they compress, grow shorter, and absorb a large amount of potential force. The springs are forced back to their original lengths and forms after the load is reduced or eliminated by the stored energy.
Thus, the selection of compression springs has to be made in consideration of the intended application, characteristics, benefits, and disadvantages of compression springs.