Linear wave spring

Linear wave spring expanders are Carbon steel or Stainless Steel

Description:

A linear wave spring is a continuous wave forming in the shape of a long strip spring. A load-bearing device has roughly the same load and deflection characteristics.

Compared with stamping springs, linear springs use pre-tempered raw materials and rounded edges, and the load and elastic coefficient are more accurate and predictable, 50% better than stamping parts, and the elastic coefficient is stable within the allowable deformation range.

Linear spring has high reliability, excellent performance, no deformation, smooth surface, no pits, scratches, breaks, and other small defects. Stamped springs may have defects such as fatigue fracture and inaccurate loading in the subsequent manufacturing process. In terms of metallurgy, mechanical properties, and dimensional stability, linear springs can provide higher precision quality.

Linear wave spring is used to replace traditional round wire spring with their unique space-saving potential. The use of a wave washer also indirectly reduces the spring assembly space due to the reduced working height of the spring. Smaller installation sizes and less material application result in a significant cost reduction.

It is particularly suitable for applications requiring weight reduction and applications limited by a small installation space. Typical application areas include aerospace, precision machinery, hydraulic seals, and high-end motors.

Although wave washers are not very familiar to some people, you need to know that their scope of application is very wide. A wave spring is an elastic element with several peaks and valleys on a thin metal ring. Therefore, under normal circumstances, it is mainly used in occasions where the load and deformation are not large, the spring stiffness is required to be small and the axial preload must be applied. Therefore, they are especially suitable for some applications requiring weight reduction and some applications restricted by small installation space.

Comparing stainless steel wave springs and carbon steel springs:

1. Different material composition.
The main disadvantage of carbon steel wave spring is that it is easy to rust, especially in high temperature and high humidity environment. Once rusted, the metal structure of the material corrodes, causing the material to deform and break. Therefore, if the ambient temperature and humidity of the product are high, a stainless steel wave washer should be selected.
2. The production process is different.
The production process of carbon steel material is to obtain the high hardness of the spring produced by the low hardness base material through quenching and tempering. This process results in poor toughness and low service life of carbon steel materials, and the phenomenon of overall spring fracture in practical applications. The stainless steel material is obtained by several calendering by a low hardness base metal mill.
3. Material price difference.
Since the stainless steel material has a chromium content of 16-18% and a nickel content of 6%-8%, the price is 2-3 times more expensive than carbon steel. The same specification of spring, stainless steel spring will be about 2 times more expensive than carbon steel spring.
The spring force of stainless steel spring is lower than that of carbon steel spring, the hardness is lower than that of carbon steel wire, but the service life is long; carbon steel spring wire is easier to rust than stainless steel spring wire, and has higher requirements for the use environment.

Surface treatment of wave springs:

There are several common methods for surface treatment of springs, such as bluing, phosphating, electroplating, and electrophoresis.

Oxidation: Heat the spring to an appropriate temperature in air or chemicals to form a blue (or black) oxide film on the surface to improve the corrosion resistance and appearance of the wave spring.

Blackening: The same as the oxidation principle, the spring is heated in the air or directly immersed in a concentrated oxidizing solution to produce a very thin oxide film on the surface of the wave washer. Material protection technology.

The surface of the wave spring should be smooth, no rust, no burrs, no cracks, and a uniform oxide layer.

Lisheng Spring is a professional linear wave spring wholesaler, you are welcome to come to consult.

Advantages of linear wave washer

Linear wave springs are mechanical devices that are used to provide a preload on a fastener or to maintain the position of a component. They offer several advantages over traditional coil springs, including:

1. Space savings: Linear springs have a smaller profile and take up less space than traditional coil springs, making them ideal for applications where space is limited.
2. Increased force: Linear wave washers can provide a greater force than traditional coil springs of the same size, making them ideal for applications where a high preload is required.
3. Consistent force: Linear springs provide a consistent force throughout their deflection range, unlike traditional coil springs which lose force as they are compressed.
4. Low solid height: Linear wave springs have a low solid height which is the height of the spring when it is not compressed. This means they can be used in applications where space is limited.
5. Low coefficient of friction: Linear springs have a low coefficient of friction, which means they can be installed and removed easily.
6. Durability: Linear springs are made of high-quality materials and are designed to withstand high loads and temperatures, making them more durable than traditional coil springs.
7. Customizable: Linear springs can be customized to specific requirements, such as size, shape, and material.
8. Lightweight: Linear springs are lightweight, making them easier to handle and install.

Overall, Linear wave spring can be a great option for applications where space is limited, high force and consistent force are needed, as well as consistent performance over time and ease of installation.

Materials Available

OIL TEMPERED (SAE1070-1090), HARD DRAWN SAE 1060 – 1075, stainless steel 304,316,631, 17-7PH(SUS), beryllium copper, phosphor copper, 65Mn, A-286, Inconel Alloy X-750, X-718, Elgiloy, MONEL K-500, MONEL 400 etc.

Processing Steps

Design → Drawing→ Flat the wire → CNC Machining → Heat treatment → Surface → Finishing → Quality Inspection → Packing

Specification:

Wave spring measurements:

Introduction

Wave springs are remarkable mechanical components that have revolutionized the field of engineering with their unique design and versatile applications. These innovative springs offer numerous advantages over traditional coil springs, making them a preferred choice in various industries. In this comprehensive article, we will explore the fascinating world of wave springs, diving into their design, functionality, applications, and the wide range of benefits they provide to engineers and manufacturers.

I. The Anatomy of Wave Springs

1.1 What Are Wave Washers?

Wave springs, also known as wave washers or coiled wave washers, are mechanical springs characterized by their distinctive wave-like shape. Unlike traditional coil springs, which are helical in nature, wave springs feature multiple waves or corrugations along their circumference. These waves provide unique mechanical properties, allowing them to store and release energy efficiently.

1.2 Types of Wave Springs

Wave springs come in several variations, including:

• a. Single Turn Wave Springs: These have a single wave and are suitable for applications with limited radial space.
• b. Multi-Turn Wave washer: Featuring multiple waves, these springs offer higher deflection and load capacity.
• c. Nested Wave Springs: These springs consist of two or more wave springs nested within each other, offering enhanced load-bearing capabilities.

II. Functionality and Benefits

2.1 Key Functions of Wave Springs

Wave springs are designed to perform various functions in mechanical assemblies, including:

• a. Axial Load Bearing: They can absorb axial loads and maintain a consistent load over their working range.
• b. Space Optimization: Their compact design allows for space-saving in tight assemblies.
• c. Precise Load Deflection: Wave springs provide precise control overload and deflection.
• d. Damping and Vibration Control: They help dampen vibrations and reduce noise in machinery.
• e. Load Stacking: Wave springs can be stacked to increase load capacity without significantly increasing size.

2.2 Advantages Over Traditional Springs

Wave springs offer numerous advantages compared to traditional coil springs:

• a. Reduced Axial Space Requirement: They occupy less axial space, making them ideal for applications with space constraints.
• b. Increased Load Capacity: Wave springs can provide higher loads for a given space.
• c. Precise Load/Deflection Characteristics: Engineers can design wave springs with specific load/deflection profiles.
• d. Improved Fatigue Life: Their design minimizes stress concentrations, leading to a longer fatigue life.
• e. Cost-Effective Solutions: They reduce material and manufacturing costs compared to traditional springs.

III. Applications Across Industries

3.1 Automotive Industry

Wave springs are widely used in the automotive sector, serving in applications such as:

• a. Transmission Systems: Wave springs help in maintaining proper clearance and preload in transmissions.
• b. Clutch Assemblies: They ensure consistent clutch pedal feel and engagement.
• c. Suspension Systems: Wave springs contribute to ride comfort and handling stability.

3.2 Aerospace Industry

In aerospace applications, wave springs are employed in:

• a. Landing Gear Systems: They assist in shock absorption and load distribution.
• b. Actuators and Control Systems: Wave springs provide precise force control in critical components.
• c. Spacecraft Mechanisms: They are used in deployable structures and mechanisms.

3.3 Medical Devices

Wave springs play a crucial role in medical equipment, including:

• a. Surgical Instruments: They contribute to the precision and reliability of surgical devices.
• b. Implantable Devices: Wave springs are used in various implantable medical devices.
• c. Diagnostic Equipment: They help control pressure and motion in diagnostic instruments.

IV. Design Considerations

4.1 Material Selection

Choosing the right material is essential for wave spring performance. Materials like stainless steel, carbon steel, and alloys are commonly used, depending on factors such as corrosion resistance and temperature requirements.

4.2 Size and Configuration

Designers must consider the size, number of waves, and stacking options to meet specific load and deflection requirements.

4.3 Operating Environment

The operating conditions, including temperature, humidity, and exposure to chemicals, impact material selection and design choices.

V. Installation and Maintenance

5.1 Proper Installation

Correct installation is crucial to ensure wave springs function as intended. Engineers and technicians should follow manufacturer guidelines and recommendations.

5.2 Maintenance Practices

Maintaining wave springs, like any mechanical component, is essential to ensure their longevity and optimal performance. Here are some key maintenance tips for wave springs:

• Regular Inspection: Periodically inspect the wave spring for signs of wear, damage, or deformation. Look for any visible cracks, distortion, or corrosion. Early detection of issues can prevent more significant problems down the line.
• Cleanliness: Keep the wave spring and the surrounding area clean. Dirt, debris, or contaminants can accumulate in the spring and affect its performance. Use a soft brush or compressed air to remove any particles.
• Lubrication: Some wave springs may require lubrication, especially if they are exposed to moisture or harsh conditions. Refer to the manufacturer’s guidelines for the appropriate lubrication interval and type of lubricant to use.
• Temperature and Environment: Be mindful of the operating environment of the wave spring. Extreme temperatures, humidity, or exposure to corrosive substances can degrade the spring’s performance. Consider using protective coatings or enclosures if necessary.
• Load and Stress: Ensure that the wave spring is not subjected to excessive loads or stresses beyond its design limits. Overloading can lead to permanent deformation or failure. Review the specifications and guidelines provided by the manufacturer for load limits.

VI. Future Trends and Innovations

6.1 Additive Manufacturing

The emergence of additive manufacturing technologies allows for the production of highly customized and complex wave spring designs, expanding their potential applications.

6.2 Smart Springs

Integrating sensors and data-monitoring capabilities into wave springs is an evolving trend, enabling real-time performance analysis and predictive maintenance.

6.3 Sustainable Materials

The use of eco-friendly and sustainable materials in wave spring production aligns with the growing focus on environmental responsibility.

Wave springs represent a remarkable innovation in the world of mechanical engineering and manufacturing. Their unique design, versatility, and superior performance make them indispensable components in a wide range of applications across industries. As technology continues to advance, the application possibilities for wave washers will only expand, making them an exciting and continually evolving field of study for engineers and manufacturers alike. Understanding the design, functionality, and benefits of wave springs is essential for harnessing their full potential in modern mechanical assemblies.