Spring Materials and Characteristics
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.
Coil spring
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}
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r {\displaystyle r}
[11]
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]
Compression Springs, Extension Springs, Torsion Springs and Conical Springs in Stock
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