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.
Goto HEGONG SPRING to know more.
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.
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.
Can a wave spring replace a coil spring?
Wave springs can provide similar forces as a traditional coil spring at down to about half the height of a coil spring. Due to space and weight savings, a wave spring cannot be directly substituted for a coil spring in your existing application without reducing the size of the spring cavity. Wave springs must be designed into your application in order to realize all of the benefits.
Does a wave spring provide the same function as a coil spring?
For more belleville washersinformation, please contact us. We will provide professional answers.
Yes, a wave spring provides the same function as a coil spring. Both wave springs and coil springs apply force axially when compressed. A wave spring starts out at free height, which is the height without any load applied. The wave spring is then compressed until its work height, where a specified load is output. This is the same as a coil spring follows.
The difference between a wave spring and a coil spring lies in the way they store and release energy. Wave springs rely on bending, similar to a simple beam, whereas coil springs are torsional. As a load is applied, the waves on the wave spring begin to flatten to provide an upward force, allowing for complete axial load transmission. Coil springs, on the other hand, twist as they compress, so not all the force is necessarily aligned with the axis.
Can a wave spring be made with the same or higher spring rate, compared to a helical coil spring?
In most cases, the spring rate can be matched or increased with various modifications such as the number of waves, material thickness, or number of turns. Please note that we tolerance load at a working height, unlike a coil spring that tolerances the spring rate.
Are wave springs cheaper than coil springs?
Wave springs can save you money when considering the whole assembly. Crest-to-Crest wave springs allow for smaller assemblies with a reduced spring height, which results in a smaller spring cavity. This translates into considerable cost-savings for the surrounding assembly, resulting in a net saving that far outweighs the cost variance between the wave spring and coil spring.
Bottom line? Wave springs may potentially have a higher piece price, but overall cost savings may be seen when designing a wave spring into your application.
So you're telling me a wave spring can make my assemblies smaller and potentially save me money, why wouldn't I use this for everything?
Wave springs are the ideal compression spring to fit tight axial and radial spaces; however, they are not the ideal solution for applications with large travel and/or accompanied by a high load requirement. Let's take a pogo stick for example. A spring in a pogo stick must have a large travel and the load output to rebound the weight of a human, making it better suited for a traditional coil spring.
Other applications where an alternative spring should be used is in cases where extension or torsion is required. Wave springs are designed for compression only.
I’m using a coil compression spring in my assembly and am ready to switch to a wave spring design to help with space savings. What do I need to know to find the wave spring best suited for my application?
Since a wave spring is typically not a direct replacement for a coil spring, a good place to start is to provide us with the parameters in which the wave spring will be working. Please fill out our Spring Application Checklist and a Smalley Engineer will contact you shortly to discuss your application.
Key Points