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.
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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.
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.
Contact us to discuss your requirements of belleville washers. Our experienced sales team can help you identify the options that best suit your needs.
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.
Wave springs offer many advantages over traditional coil springs, such as a space reduction of up to 50 per cent, while still offering the same force and deflection. TFC stocks over 10,000 carbon and stainless-steel wave springs from 6 mm to 500 mm that are suitable for many applications requiring accurate and high-performance solutions.
However, if you still can’t find a part to fit your needs, then Smalley’s No-Tooling-CostTM process enables the prototyping and manufacture of bespoke products. TFC’s technical team can work with you to design the most effective solution for the application, whether it is using a standard material or one of our more exotic high-performance alloys.
Is carbon steel suitable?
Carbon steel is traditionally used to manufacture Smalley Wave Springs because its materialistic structure has a good tensile and yield strength, making it suitable for many industrial applications. However, the maximum recommended temperature for the material is around 121°C, so an alternative material should be considered if you are operating at high temperatures. Extremely low temperatures may also require a change of material to either stainless steel or a nickel alloy.
Carbon steel is vulnerable to corrosion if used in extreme conditions and not sealed correctly. Designers should consider an alternative, perhaps one of our stainless steels or a high-performance alloy, such as Inconel or Elgiloy. These materials are specifically designed and tested to withstand more exposed or corrosive environments.
One of our experienced engineers can work with you to review the options available, ensuring your spring meets the requirements of the application, both mechanically and environmentally.