Compression Spring design depends on the consideration of many factors such as :
Kinds of material to be used for compression springs.
Manufacturing process of the compression springs.
Dimensional & load requirements for the compression spring.
Type of environment the compression spring will be operating in.
One of the most critical matters too often neglected is that of providing sufficient space for functional compression springs in newly designed machines and equipment. When this situation occurs it can necessitate the use of costly, highly stressed, close tolerance springs, which increases the risk of early failure.
Compression Spring Life
Compression springs are designed to last either the life of the product or some shorter time which is acceptable to the customer. In all applications it is assumed that a certain percentage of compression springs will fail prematurely so an attempt should be made to minimize the effect this failure will have on the performance of the product. Compression spring life can be extended by:
Careful design and selection of compression spring material.
Quality control of both material and manufacturing of the compression spring.
Compression Spring breakage is not the only failure that must be considered. Other problems such as loss of load and distortion may also be failures. Predicting compression spring life is not an exact science and must be carefully considered in all designs.
Corrosion of Compression Springs
Compression spring corrosion is one of the most neglected factors that can affect performance. All too often corrosion of microscopic proportion is the origin of compression spring failure, but its presence goes undetected and the cause of failure is erroneously attributed to something else. Compression springs made of uncoated steel must be given some kind of corrosion protection. The degree of protection of your compression spring depends on the nature of the application.
Compression Spring Tolerances
Because cost is a major consideration, compression springs must be produced in the most economical manner. Specified tolerances should be generous enough to permit the fabrication of acceptable compression springs by ordinary production methods. Also, it is advisable to apply tolerances only to functional requirements and dimensions. In doing so, this gives the compression spring maker the opportunity to make adjustments to compensate for the allowable variations present in the size and mechanical properties of all spring materials. Standard drawing forms that have tolerance boxes for machined dimensions are almost always impractical for compression springs. The product designer should delete them and apply realistic tolerances to the mandatory compression spring requirements.
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Compression springs are designed to last either the life of the product or some shorter time which is acceptable to the customer. In all applications it is assumed that a certain percentage of compression springs will fail prematurely so an attempt should be made to minimize the effect this failure will have on the performance of the product. Compression spring life can be extended by: