Although wave-spring applications abound, there are basic rules to define spring requirements and determine whether a design can use a stock or standard spring or needs a special wave spring.
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The first and most important consideration is the load the application will apply to the wave spring. Required load is defined as the amount of axial force the spring must produce when installed at its work height.
Read the related article: What are Wave Springs for Motion Designs?
Some applications require multiple working heights, so that there are critical loads at two or more operating heights. Often minimum and maximum loads are satisfactory solutions, particularly where tolerance stack-ups are inherent in the application.
In any case, remember to consider whether the spring will be subject to high temperature, dynamic loading (fatigue), corrosive media or other unusual operating conditions. Solutions to various environmental conditions typically call for special materials that withstand operating stresses.
Wave springs install into working cavities. These usually consist of a bore (in which the spring operates) or a shaft that the spring clears. The spring stays positioned by piloting in the bore or on the shaft. The distance between the loading surfaces defines the axial working cavity or the spring&#;s work height. This is where the spring&#;s material cross-section is important to the overall design.
Four critical factors dictate the most suitable wave spring for a given application: Physical design constraints (including bore geometry, shaft, ID, OD and so on), the application load, the working height at which the design applies load, and the spring material that will best withstand the application environment. (More after the jump.)
If a spring is designed for a static application, make sure that the percent stress at working height is less than 100%. Springs will take a &#;set&#; or length loss in operation due to the high stress condition of the spring if subjected to a higher stress. If a spring is designed for a dynamic application, make sure that the percent stress at working height is less than 80%. Springs will take a set if put under higher stress. If the work height per turn is less than twice the wire thickness, the spring operates in a non-linear range and actual loads may exceed calculated loads.
&#; Number of turns must be between 2 and 20
&#; Number of waves per turn (N) must be in half-turn increments
&#; Minimum radial wall = (3 times the wire thickness)
&#; Maximum radial wall = (10 times the wire thickness)
One caveat: It&#;s best to avoid situations that compress a wave spring to solid. In addition, account for the expansion of the OD as well as the OD tolerance when designing a spring to fit in a bore or over a shaft.
Wave washers, also referred to as wave springs, are wavy metal washers designed to provide a compensating spring force or absorb shock when under load. Many design variations have evolved to best serve these basic functions.
Wave washers are one of several types of spring washers. They are defined by their wave-like appearance and their ability to bear a load as they are deflected in a linear range.
Types of Wave Springs
Product &#;Medium and Small mulit-turn Wave Springs
Material&#; SUS631/17-7PH
Product &#;Mulit-turn Wave Springs
Structure form&#;Mulit-turn&#;Peak to Peak&#;wave springs
Material&#; SUS631/17-7PH
Product &#;Mulit-turn Wave Springs
Structure form&#;Mulit-turn&#;Peak to Peak&#;wave springs with shim ends
Material&#; SUS631/17-7PH
Product &#;Tiny Mulit-turn Wave Springs
Material&#; SUS631/17-7PH
Product &#;Various Mulit-turn Wave Springs
Material&#; SUS631/17-7PH, SUS304, SUS316 available
6 Advantages of a Wave Spring
1. REDUCE AXIAL SPACE
Spring operating height can be reduced by up to 50%.
In applications with tight space constraints, Crest-to-Crest wave springs optimize space concerns. The &#;multiple waves per turn&#; design can offer the same spring force as a traditional coil spring, but at a reduced operating height. A reduction in operating height also decreases the spring cavity, yielding an overall smaller assembly size. Significant cost savings may be seen with a smaller, more light-weight assembly, as it takes less time and material to produce.
2.DESIGN FLEXIBILITY
We can customize wave springs to fit your exact application requirements. The number of turns, end type, material type, and thickness are just a few parameters we can customize.
Our ability to accommodate virtually any design comes from our unique edgewinding process, where we take flat wire and then coil it on edge. With the freedom to coil to nearly any diameter (0.157 &#; 120 in.; 4 - mm), we can efficiently optimize your design, all without the need for additional tooling.
Additional reading:Are brother and JUKI the same?
Want more information on wave washer use? Feel free to contact us.
3. ACCURATE AND PREDICTABLE LOADS WHERE YOU NEED IT
Accurate and predictable loads are achieved by putting a tolerance on load(s) at specific working height(s).
Whether it&#;s a static or a dynamic application, you&#;re able to pinpoint the load that a wave spring outputs. This is because we tolerance critical load(s) at specified working height(s), so you can expect reliable, consistent performance in your application.
4. VERSATILITY
Wave spring technology is the trusted solution across many different industries and applications.
From small to large diameters, light to heavy-duty parts, carbon steel to exotic materials, wave springs has been the trusted solution for tens of thousands of applications. From everyday consumer products like the smartwatch on your wrist, or the coffee maker in your kitchen, to an oil well deep under the Earth&#;s surface, to as high as, well, Mars, there is virtually no limit for wave springs. Below are some examples of common applications that utilize the benefits of a wave spring.
Flow Valves: As fluid pressure increases, a Crest-to-Crest Wave Spring precisely controls the linear displacement of the piston.
Pressure Relief Valves: Air pressure under the assembly causes the spring load to increase, which forces the plate away from the sealing surface and provides a pressure relief mechanism. As pressure decreases, the spring returns to its original work height, allowing the unit to seal again.
Face Seals: The wave spring applies pressure to precisely load against a mating surface, properly sealing fluids.
Vibration Isolators: Under constant loading, the isolator dampens vibration from equipment operation. Wave springs are used to provide precise and predictable loading.
5. EXOTIC ALLOYS
Exotic alloys are an option for your applications in extreme environments.
There are a variety of key factors when it comes to choosing the right material for your application, including environment, budget, and cycle life. Using a material that is not optimized for the environment that it&#;s in can lead to performance issues and decreased application life. We offer a variety of custom materials.
From cryogenic to high temperatures, magnetically-sensitive to electrically conductive, deep-sea to outer space, our engineering team will tailor a wave spring fit for optimal performance.
6. FREE SAMPLES & ECONOMICAL PROTOTYPES
We know it&#;s important to ensure fit and function with prototype testing, so we offer free samples of our standards.
We also offer custom, economical prototypes that can be delivered to you in a short lead time with no minimum order quantity. This is a unique benefit of our edgewinding process, as traditional stamped parts have high up-front tooling costs, minimum order quantities, and traditionally longer lead times.
Other applications of wave washers
Wave washers, also referred to as wave spring washers, are some of the best load-bearing washers available. They are tiny metal discs with holes in the middle, similar to small doughnuts in appearance. These components are not flat, but have a wavelike look as their name suggests. They are designed to absorb stress when beneath a load, and their three-point contact area and curved design makes them ideal for the task. There are a number of different ways they are used.
Shock Absorbers
Wave washers can be built as shock absorbers to function like compression springs. If you are dealing with space limitations, they can be particularly effective.
Compensators
Wave washers can also assist in compensating for discrepancies in the operational capabilities of different mechanical devices. They can aid in preventing unwanted movement or vibrations if there are misalignments. If you are using bolts or screws, they can help stop any loss of friction that may cause the pieces to become unattached and fall out.
Improve Functionality of Ball Bearings
These parts can also be used to prolong the life of ball bearings and improve their performance. They help by lowering bearing noise and getting rid of any vibrations that might otherwise impact how the bearings function.
Selection Criteria
In order to pick the correct component, you need to know the required outside and inside ring diameters. The outside diameters define the circumferences of wave spring washers, and the inside diameters are set by the size of the bolt or cylinder they must encompass. Two other important criteria are the thickness and overall height of the pieces. They come in several different materials; steel is a good choice and particularly durable. A well-equipped construction supply store should have a wide range of them available in many different sizes.
Wave washers are versatile components that can be used for a variety of applications including shock absorbers, compensators and improving the functionality of ball bearings.
The company is the world’s best belleville disc washers supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.
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