Springs are mechanical components used in various products, such as watches, cars and cell phones. There are many types of feathers, each with unique characteristics, making selection difficult.
Therefore, you need to learn more about them. This article explains the common types of springs, their applications, materials, and the causes of mechanical spring failure to help you choose the right one.
Hooke's Law: Understanding the Spring Principle
A spring is a mechanical component that stores energy when compressed by a load and releases it again when the load is removed. This is the normal functioning of all springs, regardless of their type, as expressed in Hooke's law.
Hooke's law relates the force exerted by a load on a spring and its elasticity. According to the law, the force exerted by a load necessary to compress or expand a spring is directly proportional to the displacement, expressed by the following mathematical expression: F= -kX
Where;
F = force exerted by the load on the spring
X = spring displacement (this is a negative value indicating that the force to reset the spring acts in the opposite direction)
k = spring constant, which indicates the stiffness of the spring and depends on the type of spring
Types of feathers and their uses
There are different types of springs with different capacities. Generally, there are three main categories and each category has its subcategories. Below you will find the characteristics of the different types of springs and their applications.
Category One: Helical Springs
Coil springs have a general helical shape (hence the name) but different cross-sections. They are the most common types of springs in rapid prototyping and are widely used in product manufacturing. Below are the different types of coil springs.
Compression Springs
Compression springs are open spiral springs with a constant diameter and distance between the individual turns. Springs can only be compressed in one direction because they resist axial compression. These types of springs are often used in the manufacture of products such as valves and suspensions.
Tension springs
Tension springs are closed compression springs. They work by stretching when tension is applied and storing energy. When the tension is released, the mechanical spring returns to its original shape and releases the energy. Tension springs are an important part of garage doors, tension levers, jaw pliers and scales.
Torsion Springs
A torsion spring is attached to two components with its two ends horizontally or vertically. They work by storing and releasing rotational energy. The tighter the winding, the more energy the spring stores and releases when the load is released. They are used in garage doors, clocks, etc.
coil springs
Coil springs are rectangular metal strips formed into a flat spiral that can store and release a reasonable amount of energy at a constant rate. Due to the constant release of energy, they are used in the manufacture of mechanical watches, armchairs, toys, etc.
Category Two: Leaf Springs
These types of springs consist of rectangular metal plates or sheets that are screwed or fixed and are used for shock absorption in heavy vehicles. The different types of leaf springs are listed below.
Elliptical Leaf Spring
An elliptical leaf spring consists of two stacked, bolted and secured leaves of semi-elliptical shape, connected in opposite directions. Although they face in opposite directions, spring clips are not necessary because the blade experiences the same stretch when compressed. These springs were important in early cars, where automakers attached them to the axle and chassis. However, nowadays they are no longer so important.
Semi-elliptical leaf spring
Semi-elliptical leaf springs consist of steel sheets with the same width and thickness but different lengths. The longest/topmost sheet is the main sheet. They are the most popular leaf springs in automobiles because they require less maintenance and have a long lifespan.
With semi-elliptical leaf springs, one end is rigidly attached to the vehicle frame and the other to the shackles. Therefore, the length varies when driving on uneven terrain, which helps absorb shocks.
Elliptical Quarter Leaf Spring
Just like the elliptical leaf spring, the quarter-elliptical leaf spring is also older. It is also known as a cantilever spring. One end is fixed to the side of the frame with a U-clamp or I-bolt, the other is loosely connected to the shaft. Therefore, when the front axle beams are subjected to shock, the blades can easily straighten and absorb the shock.
Three-quarter elliptical leaf spring
This leaf spring is a combination of quarter elliptical spring and half elliptical spring. The ends of the half ellipse are attached to the vehicle frame and the quarter ellipse spring. On the other hand, the free end of the quarter of the elliptical spring is then attached to the vehicle frame using I-bolts.
Transverse leaf spring
These are semi-elliptical leaf springs mounted across the entire width of the vehicle. In this arrangement, the longer blade is at the bottom, while the middle section is attached to the frame with a U-bolt. Transverse springs cause rolling. Therefore, they are only used to a limited extent in the automotive industry.
Category Three: Disc Springs
Disc springs are springs with a conical shape and flexible effect. Therefore, they can be used in limited spaces. Below are the types of disc springs.
Belleville disc spring
Belleville disc springs or conical disc springs have a cup-shaped construction. Therefore, they do not lie down. They can compress and support heavy loads. Therefore, they are suitable for products used under high stress conditions.
Curved disc spring
Curved disc springs or half-moon discs work by applying slight pressure to their counterpart. Therefore, they can resist loosening due to vibration. They are applicable to products that use threaded bolts, fasteners, screws and nuts in machines subject to strong and constant vibrations.
Slotted disc spring
Slotted disc springs have grooves on the outer and inner diameter. This reduces spring load and increases deflection. They are often used in automatic transmissions, clutches and overload clutches.
Corrugated Plate Springs
Wave springs look like architectural designs with their multiple waves around them. Therefore, they are suitable for predictable loads as they can act as shock absorbers and absorb stresses during axial compression.
Functions of feathers
Springs are an important part of many industrial products. Some spring functions and corresponding application areas are listed below.
Shock absorbing properties
Springs can compress and expand due to the applied load/force. Therefore, they have good shock absorption capacity. This use of springs is very important in the automotive industry because when a vehicle is struck, the spring compresses to absorb the shock. It then releases the energy continuously.
Store and release energy
Springs can store and release mechanical energy constantly. Therefore, they can serve as an alternative to batteries in some devices. An important example is mechanical clocks and gun bolts.
Control the movement of the mechanism
Springs can control the movement of some components. That is why they are often used in garages, doors, scales, valve springs for internal combustion engines and control springs in clutches.
Vibration Damping
Springs also help to dampen or dampen vibrations. Therefore, they are important for producing stable products in vibrant environments. Mechanical springs are used to dampen vibrations in automobiles and railway carriages, among other things.
Types of Materials Used to Make Springs
The springs are made from different materials and manufactured using innovative processes. Below are some examples of materials used and their meaning.
The springs are made from different materials and manufactured using innovative processes. Below are some examples of materials used and their meaning.
1. Low alloy steel
Low alloy steels contain nickel or molybdenum and are therefore superior to carbon steels. Springs made from these materials have the following properties:
- Their high heat resistance makes them suitable for use in machines that use or generate high heat.
- High compressive strength, resulting in longer service life under axial loads.
- The addition of chromium, molybdenum and nickel increases the creep and corrosion resistance of the spring.
2. Cold drawn wire
Cold drawn wire is created through hardening, which improves the basic crystalline structure of the material. Therefore, cold drawn wire springs have higher tensile strength, tension tolerance and temperature tolerance.
3. Oil hardened spring wire
Oil-hardened yarns have high resistance to fatigue, heat and permanent fatigue. Therefore, oil-hardened spring wires are often used in the automotive industry. They are also used in the manufacture of suspension products.
4. Bainite hardened strip
Hardened bainite strips are made from heat-treated steel. Therefore, springs made of bainite-hardened steel have high strength and fatigue resistance.
5. Stainless steel for springs
Stainless steel contains chromium, nickel, magnesium and even carbon. Stainless steel springs have high yield strength, corrosion resistance and heat resistance. Therefore they can be used in washers, lockpicks and antennas.
6. Copper and titanium
Copper or titanium alloys are corrosion resistant, heat resistant, robust and durable. Therefore, copper and titanium springs are mainly used as torsion springs in common door hinges, retractable hinges and some medical devices.
Common manufacturing process for spring types
Springs are manufactured through a process that consists of winding, heat treatment, grinding, coating and finishing. The process is simple, although there are some variations depending on the type of spring.
1. Winding
The operator inserts the spring wire into a CNC machine or mechanical spring machine and straightens it. He then coils, shapes or bends the stretched wire into the desired shape. These processes can also occur individually or in combination.
– Winding involves winding the stretched wire onto the desired coil using a spring winder or CNC spring winding machine. Winding is applicable in the production of compression, tension and torsion springs.
-Forming uses a spring winder or CNC spring former that uses multiple curves, rings and spokes to create different spring shapes. Molding is applicable in the production of tension springs, torsion springs and wire molds.
-In bending, the straight wire is bent into different shapes using a CNC bending machine. Therefore, it is suitable for making wire molds.
2. Heat treatment
The heat treatment causes the formed spring to undergo tension relief. Therefore, it can easily return to its original shape when subjected to stress. Depending on the type and amount of material, the spring is heated to a specific temperature for a specific time.
Depending on the type of material and the manufacturing process, the heat treatment is repeated and then cooling occurs.
3. Ties
Grinding involves grinding the end of the spring using a grinder. This makes it stand upright when oriented vertically.
4. Coating and finishing
Coating and finishing are important to improve the aesthetic and functional properties of the spring. For example, galvanic copper plating makes the spring conductive and powder coating improves its aesthetic value. Finish options include shot peening (cold-formed springs), finishing, powder coating and anodizing.
Error causes and solutions for spring types
A broken spring can cause machine damage, increased maintenance costs and, as a result, loss of confidence in a product based on mechanical springs. Therefore, you should try to avoid spring breaks. The best way to do this is to understand the causes. Below are the causes and solutions for broken springs.
1. Spring Stress
Spring tension occurs when you subject the spring to a force that its design cannot handle. This will cause the spring to break. You can solve this problem by reducing the force to what the design can handle, or by creating a spring designed for that tension. You can make this spring by using the right material or by optimizing the heat treatment.
2. Wrong choice of material
The type of material used to make the spring can determine the properties of the spring. For example, stainless steel and copper springs are very resistant to corrosion. Therefore, if you want such a property, it would be wrong to use another material. You can avoid this by learning about the different materials feathers are made from.
3. Poor or incorrect workmanship
Surface treatments such as powder coating, anodizing, etc. help improve the aesthetic or functional properties of the spring. For example, you can use anodizing to improve the corrosion resistance of the spring. Therefore, if the surface of a spring is poorly treated or not treated when necessary, it can make the spring susceptible to corrosion and lead to failure under severe or corrosive conditions.
4. Undefined working temperature
The spring must be suitable for the operating temperature. You can improve the heat resistance of the spring by choosing a material with this property, subjecting it to heat treatment or using a finishing option.
5. Substandard Manufacturing Processes
When making springs, attention should be paid to quality. This determines its function and aesthetics. Typical examples of the machining method used are CNC machining. Manufacturers must closely examine the process and ensure tools are precisely designed to reduce spring breakage.
Concluding
Springs are an important part of any product that is moved. When compressed and expanded, they can store and release energy. To choose the right spring, you need to know what types of springs are used today.
Each feather has its own characteristics and properties depending on the materials used, design and manufacturing process. Therefore, when deciding to make a spring for your product, you must consider the above factors. Or you can get professional advice from spring experts.
Custom prototyping service at WayKen
Common questions
What are the three types of springs that exist?
The main types of springs are coil springs, disc springs and leaf springs. Each type of spring has several subcategories with unique features, functions and applications. Subcategories of coil springs include torsion springs, tension springs, spiral springs, and compression springs.
What types of disc springs are there?
There are four types of disc springs, each with unique features and applications. The four are: Belleville springs, bow, slot and wave plate.
Which type of spring is most common?
Torsion springs are the most common type of spring. They are used in door hinges and work by storing rotational energy when the door is opened. When the door is released, the spring releases energy to return the door to its original position.
