We are back this week with another Ask the Expert Blog, where Smalley engineering experts answer difficult questions about retaining ring, snap ring, and wave spring design. This week, our engineering experts answer some questions about wave spring design modifications.
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Yes! Since our manufacturing process involves coiling flat wire on edge, we can control the amount of wire that is fed into each part. This gives us flexibility with most dimensions of the spring, and in this case, the ability to create a spring with a large gap. We can even create wave springs that are just a small fraction of the overall circumference. For example, if you only need 10° of the full circle, similar to a linear spring with a slight curve, we can create a custom design. If you let us know what you need, we will work with you to meet your requirements.
This is a common question that has several answers, depending on how the spring is being used. If you are looking to reduce the spring rate, cutting off turns would actually increase the spring rate and not decrease it like intended. This is because the number of turns inversely affects the spring rate in the Crest-to-Crest spring rate formula.
This concept is displayed by the force-deflection curve in the graph on the top right. Let’s say you have two load requirements for your application, 20 and 28 lb. The first load is output at a working height of 0.08 in., as indicated by the curve’s leftmost blue ‘x’. The 28 lb. load requirement is output at a working height of 0.06 in.
Now let’s take a part number out of our catalog for a Crest-to-Crest Wave Spring, C100-M1. The spring has a free height of .250 in. and a working height of .087 in. At this designated work height, the Crest-to-Crest Wave Spring outputs a load of 18 lb. Beyond this work height, the spring may take a set, making the spring forces unpredictable.
Read more about wave spring work height and compression.
Smalley’s wave springs are manufactured using a process called edgewinding. This begins by cold rolling round wire to flat dimensions. Cold rolling causes the metal grains to elongate and lock together, improving the strength and stability of the material.
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Once flattened, the wire is then coiled on edge to form a ‘crest-to-crest’ wave structure. The grain follows the direction of the coil, forming a circular-grain metallurgy that provides superior spring properties compared to stamped parts with unidirectional grain.
Edgewinding is a flexible and cost-effective process that enables customized designs without the need for tooling dies and with minimal material waste. In fact, it is the reason behind our No-Tooling-Cost™ policy. This method allows for seamless design changes at any stage, ensuring a quick and economical solution—whether for a prototype or full-scale production.
Selecting the right material is critical for optimal spring performance. There are several factors to consider during spring material selection, such as operating environment, cycle life, and budget.
Standard Smalley wave springs are available in carbon steel and 17-7 stainless steel. Smalley stocks over 40 additional material options, including exotic alloys such as Inconel X-750® and Elgiloy®, to withstand practically any environment.
Table 2. Comparison of materials to environments.
From small to large diameters, light to heavy-duty loads, carbon steel to exotic materials, wave springs have been the trusted, space-saving solution for tens of thousands of applications. From everyday consumer products such as the smartwatch on your wrist to life-saving medical devices such as robotic surgical instruments to extreme environments like oil wells deep under the Earth's surface, to as high as Mars, there is virtually no limit for wave springs.
One common application that utilizes the benefits of a wave spring is a flow valve. As fluid pressure increases a Crest-to-Crest Wave Spring precisely controls the linear displacement of the piston. While many spring systems can be designed into valves, engineers often choose wave springs because of their space-saving capability and linear compression behavior through 80% of the compression range. These unique features allow for more precise and repeatable control of both flow and pressure.