波形弹簧的选型设计是确保其在特定应用中高效、可靠运行的关键。选型时需要考虑多个因素，以确保波形弹簧能够满足工作环境和性能要求。以下是波形弹簧选型设计时应注意的主要细节：
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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.
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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.
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