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While finding the best possible design solution can be challenging, knowing what options are available can make it easier for you.
One option Smalley provides is a wave spring.
A wave spring, a type of compression spring, is a solution that optimizes space concerns while providing form, fit, and function.
Let's start by defining what a spring is. Most people have used or at least have heard of springs. They're virtually everywhere, from the bed you wake up on, to the gas pump you use to fuel your car, to as far as the rovers on Mars. If you unscrew your pen, you'll find a spring in there to push the plunger and the ink tip up and down as you click.
There are three main types of springs ' compression, extension, and torsion. The type we'll focus on today is a compression spring.
Invented by Smalley more than 100 years ago, a wave spring is a type of compression spring made of flat wire with a unique 'multiple waves per turn' design. This innovative design is why a wave spring can offer the same spring force as a traditional round wire coil spring but at 50% of its operating height.
Similar to a traditional coil spring, a wave spring starts at free height. Free height is the natural height of the spring with no load applied, denoted as H in the image below. Work height, denoted as WH, is a height the spring is compressed to at a specified load. As the wave spring is compressed, a load is output until a working height is reached. At the spring's work height, the specified load is achieved.
This concept is displayed by the force-deflection curve below. Let's say you have two load requirements for your application, 20 and 28 lb. The first load is output at a work height of 0.08 in., as indicated by the leftmost blue 'x' on the curve. The 28 lb. load requirement is output at a work 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 work 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.
Now that you have a basic understanding of what a wave spring is and how it works, we'll go over our manufacturing process. Edgewinding, our No-Tooling-Cost' manufacturing process, is the only process we trust to deliver precise yet flexible solutions to meet your wave spring needs.
The process begins by cold working round wire to flat dimensions. Cold rolling causes the metal grains to elongate and lock together, improving the strength and stability of the material.
After cold rolling, the flat wire is then coiled on edge to form the Crest-to-Crest wave structure.
Since the grain follows the direction of the coil, it provides better spring properties than if the shape were to be stamped and the grain only went in one 'direction. The circular-grain metallurgy is formed during this process, which gives our parts better spring properties.
Edgewinding is a flexible and economical process, allowing us to customize designs with no tooling dies and nearly no material waste. What this means for you is that we can easily incorporate design changes during any stage of the process. It is both quick and economical for you, whether it's a prototype or a production run.
There are 5 main types of wave springs ' Crest-to-Crest, Overlap- & Gap-Type Single-Turn, Nested Spirawave®, Wavo®, and Linear. While all wave springs are based on a 'wave' type design, they all have distinct features that determine spring performance under load.
The use-case is described in the table below.
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.
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. 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.
As fluid pressure increases a Crest-to-Crest Wave Spring precisely controls the linear displacement of the piston.
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Do you have trouble finding a spring that fits in your application? Coil springs require large travel, making your application design less than optimal.
Wave washers, coil springs, disc springs, the list goes on ' these are all traditional springs that work well in many engineering applications.
What if there was a more compact, light-weight design?
Whether you have space constraints, need more design flexibility, or are looking to meet a specific load requirement, adding a Smalley wave spring to your design toolkit can open up a world of new design possibilities. Knowing when to use a wave spring and understanding the value it brings can take your designs to the next level.
So when should you use a wave spring? Below are the top 6 advantages of using a wave spring.
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.
Quick and economical customization with Smalley's No-Tooling-Cost' edgewinding manufacturing process.
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.
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.
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.
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. If our carbon and 17-7 stainless steels do not meet your application's unique requirements, 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.
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.'
In applications with tight space constraints, Smalley wave springs are the ideal solution. Choose from over 4,000 carbon steel and stainless steel wave springs in stock, or explore a custom design with No-Tooling- Costs'. Get started with a Smalley engineer today and request a free sample to add to your design tool kit.
Interested in learning more about wave springs?
Check out our new E-Book below.
Summary Infographic
Are you interested in learning more about small wave springs? Contact us today to secure an expert consultation!