Flat Wire Compression Springs: A Comprehensive Guide
If you’re in the market for compression springs, you may have come across flat wire compression springs. These springs are widely used in industries such as aerospace, automotive, and medical. In this article, we’ll take an in-depth look at flat wire compression springs, their construction, uses, and advantages.
What are Flat Wire Compression Springs?
Flat wire compression springs, as the name suggests, are compression springs made from flat wire. Typically, these springs are made from round wire that is coiled into a cylindrical shape. However, flat wire compression springs are made by coiling flat wire into a helical shape. The result is a spring that has a wider base and a lower height than a traditional compression spring.
Construction of Flat Wire Compression Springs
Flat wire compression springs can be manufactured using a variety of materials, such as stainless steel, music wire, and phosphor bronze. The choice of material depends on the application for which the spring will be used. For example, stainless steel is often used in applications that require corrosion resistance, while music wire is commonly used in high-stress applications.
The manufacturing process for flat wire compression springs involves coiling the flat wire into a helical shape using a CNC coiling machine. The spring is then stress relieved to ensure it maintains its shape and properties. Finally, the spring is finished to the required dimensions and specifications.
Advantages of Flat Wire Compression Springs
Flat wire compression springs offer several advantages over traditional compression springs, including:
Reduced Height
Flat wire compression springs have a lower height than traditional compression springs. This means they can be used in applications where space is limited.
Increased Stability
Flat wire compression springs have a wider base than traditional compression springs. This increased stability makes them ideal for use in applications where the spring will be subject to lateral forces.
Improved Fatigue Life
Flat wire compression springs have a longer fatigue life than traditional compression springs. This is because the flat wire design distributes stress more evenly across the spring, reducing the risk of stress concentrations.
Increased Load Capacity
Flat wire compression springs have a higher load capacity than traditional compression springs of the same size. This is because the flat wire design allows for more material to be used in the spring without increasing its size.
Applications of Flat Wire Compression Springs
Flat wire compression springs are used in a variety of applications, including:
Aerospace
Flat wire compression springs are used in aerospace applications to actuate valves, dampen vibration, and control motion.
Automotive
Flat wire compression springs are used in automotive applications to actuate valves, control suspension, and absorb shock.
Medical
Flat wire compression springs are used in medical applications to provide controlled force in medical devices such as catheters and surgical instruments.
Industrial
Flat wire compression springs are used in industrial applications to provide controlled force in machinery and equipment.
Conclusion
Flat wire compression springs offer several advantages over traditional round wire compression springs. They have a lower height, increased stability, improved fatigue life, and increased load capacity. They are used in a variety of applications, including aerospace, automotive, medical, and industrial. If you’re in the market for compression springs, flat wire compression springs may be the right choice for your application.
Application of Stainless Steel Compression Springs
1. What are stainless steel compression springs?
Coil springs, called compression springs, store mechanical energy when compressed. These open coil springs provide resistance to compressive loads. When these springs are subjected to a compressive load, they compress, shorten and absorb a large amount of potential force. After the load is reduced or removed by the stored energy, the springs are forced to return to their original length and shape. Compression springs become more compact when weighted. In contrast to extension springs, the coils of compression springs do not touch when relaxed; instead, they compress tightly when stressed.
2. What are the applications of stainless steel compression springs?
Automotive: It would be very difficult to build most cars without at least some stainless steel compression springs. Compression springs are used in various parts of the car, such as seats, hoses, and even the suspension. The seat uses bulk compression springs to fit the body and provide more comfort. Naturally, a variety of sizes and shapes are available to meet the wide variety of uses for automotive compression springs.
Door locks: Springs have traditionally been critical to the proper function of door locks. Due to the mechanism of the lock and key system, most metal locks contain some sort of steel spring which relies on the key release to hold the bolt in place and maintain pressure on the door lock. The spring creates this tension. Locksmiths have used compression locks for this purpose since the 1700's.
Pen: A stainless steel compression spring including 316 stainless steel compression springs can be observed by examining the ballpoint pen. This spring allows the pen to write while exposing the nib, which is then protected within the casing to prevent the ink from drying out. This makes it possible to use the pen without a bulky and easily lost cap.
Aviation: Most air travel would not be possible without multiple types of springs. Springs on an aircraft may not be visible, but air turbines, guidance systems, engine controls, wheels, brakes, gauges, fuel cells and diesel engines are just a few of the components on an aircraft that require springs.
Arms: Whenever you think about tension, think about compression springs. Consider the strain required to fire a bow. A crossbow is a simpler weapon if a compressed spring is used instead of the body stainless steel stamping part. Technological advancements continue in modern semi-automatic pistols, which use a compressed spring to absorb energy from recoil and redirect it to advance the slide or bolt and reload the weapon for subsequent shots.
Medical devices: Stainless steel compression springs are used in many medical device applications, from tiny springs in inhalers, pill dispensers, and syringes to many diagnostic tools. Additionally, there are springs for a variety of medical equipment including catheters, valves, peristaltic pumps, wheelchairs, endoscopic equipment, staplers, and surgical, orthopedic, and other tools.
Types of Compression Springs - Barrel Compression Springs
Types of Compression Springs
Conical, hourglass and barrel-shaped are all types of compression springs are used in applications requiring a low solid height, increased lateral stability or resistance to surging. Conical springs can be designed so that each coil nests wholly or partly into an adjacent coil. Solid height can be as low as one wire diameter. Rate for conical springs usually increases with deflection because the number of active coils decreases progressively as the spring approaches solid. By varying the pitch, conical springs can be designed to have a uniform rate. Rate for conical springs is calculated by considering the spring as many springs in a series.
Compression Spring Types
There are many different types of springs, including compression springs. Conical, hourglass and barrel-shaped springs are often specified where the large end is meant to work in a bore and the small end is meant to work over a rod. These types of springs offer the advantage of a reduced solid height compared to straight compression springs.
Some uses for hourglass and barrel-shaped springs are as follows:
Small Solid Height: Hourglass and barrel-shaped springs can be designed so that each active coil fits within the next coil, so the solid height can be equal to one or two thickness of wire. This is useful where the solid height is limited.
Variable Rate: These springs offer a constant, or uniform pitch, and have an increasing force rate instead of a constant force rate (regular compression springs). The larger coils gradually begin to bottom as a force is applied. A variable pitch can be designed to give a uniform rate if necessary.
Stability: Hourglass and barrel-shaped springs offer more lateral stability and less tendency to buckle than regular compression springs.
Vibration: Resonance and vibration is reduced because conical springs have a uniform pitch and an increasing natural period of vibration (instead of a constant) as each coil bottoms.
Designing a variable diameter spring so that the adjacent coils rub against one another during deflection increases resistance to resonance phenomena but also may shorten the spring’s life due to wear. Click here to view all materials available for compression springs.
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