Gap wave spring, also known as wave springs, are a type of compression spring that are designed with several waves instead of a single helical coil. This unique design allows them to have a smaller operating height compared to traditional springs, making them ideal for applications with limited space. Gap wave springs are typically made from materials such as stainless steel, carbon steel, and alloys.
HEGONG SPRING Product Page
Gap wave springs are used in a wide range of applications across various industries. They are commonly used in the automotive industry for shock absorbers, steering systems, and transmissions. In the aerospace industry, they are used in landing gear systems, control systems, and actuators. Gap wave springs are also used in medical devices, consumer electronics, and industrial equipment.
One of the main advantages of gap wave springs is their ability to maintain a constant load over a wide deflection range. This makes them ideal for applications where a consistent force is required, such as in valves and pumps. Gap wave springs are also able to handle high loads in a small space, making them useful in applications where space is limited.
Gap wave springs offer several advantages over traditional springs. One of the main advantages is their ability to reduce the overall size of a design. Because of their unique design, gap wave springs can operate with a smaller height compared to traditional springs, allowing for more compact designs. This is particularly useful in applications where space is limited, such as in mobile devices, medical implants, and automotive parts.
Another advantage of gap wave springs is their ability to maintain a constant load over a wide deflection range. This means that they can provide a consistent force, even when compressed or extended beyond their original length. This makes them ideal for applications where a consistent force is required, such as in valves, pumps, and clutches.
There are several types of gap wave springs, each designed for specific applications. The most common types of gap wave springs include:
1. Nested Wave Springs
Nested wave springs are designed with multiple waves that are nested inside each other. This design allows them to provide a higher load capacity compared to traditional springs of the same size.
1. Multi-Wave Springs
Multi-wave springs are designed with several waves that are evenly spaced and have different heights. This design allows them to provide a higher load capacity compared to traditional springs of the same size.
Gap wave springs work by compressing or extending the waves in the spring. When a load is applied to the spring, the waves compress, providing a force that is proportional to the amount of compression. The force provided by the spring is directly proportional to the amount of deflection, making it easy to control the force provided by the spring.
When selecting a gap wave spring, there are several factors to consider. These include:
1. Load Capacity
The load capacity of the spring is an important factor to consider when selecting a gap wave spring. The load capacity is the maximum force that the spring can provide before it reaches its solid height.
2. Operating Height
The operating height of the spring is the height at which the spring can provide the required force. It is important to select a spring with an operating height that is suitable for the application.
3. Material
The material of the spring is important as it affects the strength and corrosion resistance of the spring. Common materials used for gap wave springs include stainless steel, carbon steel, and alloys.
4. Environment
The environment in which the spring will be used is also an important factor to consider. This includes factors such as temperature, humidity, and exposure to corrosive substances.
Gap wave springs are easy to install and maintain. When installing a gap wave spring, it is important to ensure that the spring is compressed to the correct height for the application. This can be done by using a spring compressor or by hand.
To maintain a gap wave spring, it is important to regularly inspect the spring for signs of wear or damage. If the spring is damaged or worn, it should be replaced immediately to prevent failure.
Gap wave springs are used in a wide range of applications across various industries. Some of the most common applications of gap wave springs include:
1. Automotive Industry
In the automotive industry, gap wave springs are used in shock absorbers, steering systems, and transmissions. They are also used in clutches and brakes.
2. Aerospace Industry
In the aerospace industry, gap wave springs are used in landing gear systems, control systems, and actuators. They are also used in satellite deployment mechanisms.
3. Medical Industry
In the medical industry, gap wave springs are used in medical implants such as pacemakers and insulin pumps. They are also used in surgical instruments.
4. Consumer Electronics
In consumer electronics, gap wave springs are used in mobile devices, cameras, and audio equipment. They are also used in computer keyboards and mice.
5. Industrial Equipment
In industrial equipment, gap wave springs are used in pumps, valves, and actuators. They are also used in clutches and brakes.
For more belleville washersinformation, please contact us. We will provide professional answers.
In recent years, there have been several advancements in gap wave spring technology. These advancements have led to the development of new materials, designs, and manufacturing processes.
One of the most significant advancements in gap wave spring technology is the use of additive manufacturing. Additive manufacturing allows for the production of complex geometries that were previously impossible to produce using traditional manufacturing methods.
Another advancement in gap wave spring technology is the development of new materials. These materials offer improved corrosion resistance, strength, and durability compared to traditional materials.
Gap wave springs are an important component in many applications across various industries. They offer several advantages over traditional springs, including a smaller operating height, the ability to maintain a constant load over a wide deflection range, and the ability to handle high loads in a small space.
With advancements in technology and manufacturing processes, gap wave springs are becoming increasingly popular in various industries. As we continue to push the limits of what is possible, gap wave springs will play an increasingly important role in modern engineering.
Crest-to-Crest wave springs can offer similar loads and deflection to traditional coil springs, but at around half the height. They can reduce axial space by up to 50%, leading to an overall decrease in assembly size, weight and cost. For design engineers looking to utilise these benefits and discover if a crest-to-crest wave spring can replace a coil spring in their application, according to Simon Ward, technical manager, European partner of Smalley.
Wave springs and coil springs are both types of compression spring, primarily used to provide an axial force in either a static or dynamic application. However, there are differences. Coil springs are typically made of round wire, whereas wave springs are made from flat wire. This provides an opportunity to significantly reduce working heights within any assembly. Space-saving is key in medical applications, such as handheld instruments like dental tools and insulin pens, which must be lightweight and compact.
A wave spring, true to its name, utilises a sinusoidal waveform to generate the required axial force. A Crest-to-Crest wave spring has multiple turns to build up the free height of the spring to achieve the required deflection characteristics.
Another difference is the way that wave and coil springs store and release energy. A coil spring has a pitch angle and is torsional so it can twist as it compresses, meaning not all force is necessarily aligned with the axis. On the other hand, wave springs rely on bending: as load is applied, the waves begin to flatten, providing an upward force, allowing for complete axial load transmission.
SWAPPING
For design engineers currently using coil springs, switching to a Crest-to-Crest wave spring needs careful consideration. There is an extensive range of standard sizes that may suit, but in 70-80% of cases a bespoke design will be developed to maximise the benefits.
Before designing any wave spring, it helps to understand the space constraints and the spring performance characteristics. The final design is then achieved by modifying the number of waves and turns, adjusting material cross-section and wave heights. Choice of material also affects the design and will normally be dictated by the operating temperature and environment where the spring must function.
If a crest-to-crest spring does not suit the application, other options include single-turn and nested springs.
To identify the correct wave spring for your application, the best thing to do is work with a specialist.
Yes, we can increase spring rate with various modifications such as the number of waves, material thickness, and number of turns. Crest-to-Crest springs can function similarly to helical springs in a variety of applications. Smalleys engineers can help you identify the correct wave spring for your specific design requirements.
Smalley products are manufactured by coiling, not stamping. Our edgewinding process allows us the flexibility to add a gap or an overlap during manufacturing. A benefit of having a gap or an overlap is that Smalley parts will operate and/or cling when contacting a bore, while stamped products would bind while contacting a bore. Binding causes the spring to become rigid, and the spring properties, as a result, become unpredictable. This allows Smalley parts to work in tighter radial cavities. Furthermore, the edgewinding process results in our springs having a circular-grain metallurgy. The benefit of this is it gives our products strength and stability far superior to that of conventional wave washers, providing a more accurate, repeatable load.
Smalley is capable of matching the spring rate of these springs in most cases. Our engineering support is available for specific design questions.
Wave springs can provide similar forces and loads as a traditional coil spring. They achieve this at down to about half the height of a coil spring. Due to the space and weight savings, a wave spring cannot be directly substituted for a coil spring in your existing application without reducing the size of the spring cavity. Wave springs must be designed into your application in order to realize all of the benefits.
Wave springs can save you money when taking the whole assembly into consideration. Crest-to-Crest Wave Springs allow for smaller assemblies with a reduced spring height, which results in a smaller spring cavity. This translates into considerable cost-savings for the surrounding assembly, resulting in a net savings that far outweighs the cost variance between the wave spring and coil spring.
Custom or standard, Smalley takes great pride in its unparalleled dedication to delivering quality wave spring solutions for a variety of industries. Both wave springs and traditional coil springs fall under the category of compression springs. While the primary function of a compression spring is to provide axial load, wave springs have a few key differences and advantages when compared to coil springs.
The key advantage of using a wave spring is in the axial space savings. Whether it is a static or dynamic application, wave springs may be the ideal solution where space is a constraint. Mega Coil
The apparent difference between a wave spring and a coil spring is the height. A wave spring can provide the same force and deflection as a coil spring but in considerably less axial space. Wave springs have up to a 50% reduced height, mainly because of the following two design features:
Coil springs are typically made of round wire, while wave springs use flat wire. Flat wire takes up less vertical space than round wire, which contributes to the reduction in work height.
Just as the name implies, a wave spring has multiple waves per turn. The wave design contributes to the load output of the spring. In the image below, we have a flat wire coil spring, a traditional coil spring, and a wave spring, respectively.
Because a flat wire coil spring has a thinner cross-section in comparison to the coil spring, a taller free height is required to achieve a similar load output. On the other hand, a wave spring also has a thin cross-section, yet has the lowest free height. This is due to the unique Crest-to-Crest design, which allows for similar spring rates to a coil spring, but with axial space-saving capabilities.
Now that you understand the most notable difference between a coil spring and a wave spring, let’s go over some commonly asked questions.
The difference between a wave spring and a coil spring lies in the way they store and release energy. Wave springs rely on bending, similar to a simple beam, whereas coil springs are torsional. As a load is applied, the waves on the wave spring begin to flatten to provide an upward force, allowing for complete axial load transmission. Coil springs, on the other hand, twist as they compress, so not all the force is necessarily aligned with the axis.
Bottom line? Wave springs may potentially have a higher piece price, but overall cost savings may be seen when designing a wave spring into your application.
Other applications where an alternative spring should be used is in cases where extension or torsion is required. Wave springs are designed for compression only.
Interested in learning more about wave springs? Check out our new E-Book below.
Browse the most current issue of Design World and back issues in an easy to use high quality format. Clip, share and download with the leading design engineering magazine today.
We're generally constantly bringing you the most responsible shopping company, with the widest range of designs and styles, and the best materials. These efforts include the availability of custom designs and rapid dispatch of audi coil spring,oem shock absorber,automotive shock absorber,high tension spring,lowering spring,automotive suspension springs,types of springs,custom coil springs,car suspension springs,car coil spring