Springs are all around us in everything we do every day if they don't appear so obvious to see. From the shock absorbers in your car to the spring latches on doors and also deep into your mattress, springs play a role everywhere you look. Wave springs and coil springs are some of the most common types of springs that you can buy from the market today. However, in order for you to make an informed choice between these two items, here is a detailed look at some of their key differences.
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When it comes to selecting a spring for your application, the first question that comes to mind is, "What makes wave springs different from coil springs?" The difference of a wave spring over its counterpart lies in its name itself as they are made with thick wire in waves. This design provides them the ability to transmit large forces in narrow confines with great ease, thereby making them highly applicable for all sorts of extreme space-limiting applications. The frictional values are reduced as well in wave springs compared to their coil brethren providing gentle yet reliable operation without the expenses involved.
On the other hand, coil springs are constructed with a more flexible wire coiled. In this design, the function of the coil spring is rather more flexible so it is applicable in areas that require shock absorbance. In addition, coil springs have a higher load-bearing capacity and are thus essential in situations with heavy loads.
The choice between wave springs and coil springs extends beyond their inherent characteristics; it also hinges on the application at hand. Here are some critical factors to consider:
Shock Absorption and Vibration Dampening: Coil springs excel in scenarios necessitating shock absorption and vibration dampening. They further exhibit resistance to temperature fluctuations, rendering them ideal for use in extreme environmental conditions.
Space Efficiency: Wave springs shine when it comes to providing substantial support within limited spatial confines. Their ability to compress to smaller dimensions makes them a go-to choice for applications where space is a premium.
Versatility: Both wave springs and coil springs find their utility across a broad spectrum of applications. Selecting the right one primarily depends on the unique demands of your project.
There are several clear advantages in using wave springs, as opposed to the coil springs. First and foremost, they have an excellent load capacity, and do so in a more compact size. Also because they are lower in profile, this is advantageous for certain applications. In this regard it needs to be mentioned that wave springs are less prone to buckling or binding under heavy loading and their spring rate is more predictable than the case in most coil springs.
Coil springs are the failsafe choice in most applications, although wave springs definitely have their own advantages. They remain inexpensive and can be custom designed such that they fit the specific needs for a particular application. The constant force is perfect for accurate designs.
Wave springs find applications in various sectors of the economy including automotive, electronic and medical equipment industries among others. Other areas where coil springs are applied include pumps, valves and compressors.
Coil springs are commonly used in most applications since it consists of wire coiled around an interior core. It has more space in which to store energy, and that is why even for heavy-duty work such as automotive suspensions. Quality coil springs are considered very robust and long-lasting, which can support heavy wear in all the operating conditions. Besides, they also prove to be cost-effective in saving huge sums of money as compared to other modes of usage for different applications.
In the quest for the ideal spring, the divide between wave springs and coil springs becomes apparent. Here, we dissect the nuances, aiding you in making an informed choice for your specific application.
When faced with the decision, between wave springs and coil springs there are factors to consider. Wave springs are known for their compactness and ability to handle loads. They can be more costly. On the other hand, coil springs are budget friendly and easier to find for those who have less experience working with springs.
Wave springs offer advantages over coil springs particularly because they can operate effectively within spaces without compromising their load capacity. This makes them an excellent choice for applications where spatial constraints come into play such as in the aerospace industries.
Another significant advantage of wave springs is their ability to distribute loads evenly making them well suited for handling shocks and vibrations. This trait is especially valuable in settings.
However it's important to note that wave springs may be pricier due to their use of premium materials like steel. Additionally their manufacturing process can be more intricate which might result in lead times for orders.
The choice between wave springs and coil springs is not a one size fits all decision; it depends on the requirements of your application. In general wave springs excel in space efficiency. Force density makes them a great option for high pressure situations.
On the contrary coil springs might be an option, for applications that require consideration of weight as they are usually made with materials. Ultimately it's important to make a decision that matches the requirements of your project ensuring top notch performance and dependability.
Crest-to-Crest wave springs can offer similar loads and deflection to traditional coil springs, but at around half the height. They can reduce axial space by up to 50%, leading to an overall decrease in assembly size, weight and cost. For design engineers looking to utilise these benefits and discover if a crest-to-crest wave spring can replace a coil spring in their application, according to Simon Ward, technical manager, European partner of Smalley.
Wave springs and coil springs are both types of compression spring, primarily used to provide an axial force in either a static or dynamic application. However, there are differences. Coil springs are typically made of round wire, whereas wave springs are made from flat wire. This provides an opportunity to significantly reduce working heights within any assembly. Space-saving is key in medical applications, such as handheld instruments like dental tools and insulin pens, which must be lightweight and compact.
A wave spring, true to its name, utilises a sinusoidal waveform to generate the required axial force. A Crest-to-Crest wave spring has multiple turns to build up the free height of the spring to achieve the required deflection characteristics.
Another difference is the way that wave and coil springs store and release energy. A coil spring has a pitch angle and is torsional so it can twist as it compresses, meaning not all force is necessarily aligned with the axis. On the other hand, wave springs rely on bending: as load is applied, the waves begin to flatten, providing an upward force, allowing for complete axial load transmission.
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For design engineers currently using coil springs, switching to a Crest-to-Crest wave spring needs careful consideration. There is an extensive range of standard sizes that may suit, but in 70-80% of cases a bespoke design will be developed to maximise the benefits.
Before designing any wave spring, it helps to understand the space constraints and the spring performance characteristics. The final design is then achieved by modifying the number of waves and turns, adjusting material cross-section and wave heights. Choice of material also affects the design and will normally be dictated by the operating temperature and environment where the spring must function.
If a crest-to-crest spring does not suit the application, other options include single-turn and nested springs.
To identify the correct wave spring for your application, the best thing to do is work with a specialist.
Yes, we can increase spring rate with various modifications such as the number of waves, material thickness, and number of turns. Crest-to-Crest springs can function similarly to helical springs in a variety of applications. Smalleys engineers can help you identify the correct wave spring for your specific design requirements.
Smalley products are manufactured by coiling, not stamping. Our edgewinding process allows us the flexibility to add a gap or an overlap during manufacturing. A benefit of having a gap or an overlap is that Smalley parts will operate and/or cling when contacting a bore, while stamped products would bind while contacting a bore. Binding causes the spring to become rigid, and the spring properties, as a result, become unpredictable. This allows Smalley parts to work in tighter radial cavities. Furthermore, the edgewinding process results in our springs having a circular-grain metallurgy. The benefit of this is it gives our products strength and stability far superior to that of conventional wave washers, providing a more accurate, repeatable load.
Smalley is capable of matching the spring rate of these springs in most cases. Our engineering support is available for specific design questions.
Wave springs can provide similar forces and loads as a traditional coil spring. They achieve this at down to about half the height of a coil spring. Due to the 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.
Wave springs can save you money when taking the whole assembly into consideration. 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 savings that far outweighs the cost variance between the wave spring and coil spring.
Custom or standard, Smalley takes great pride in its unparalleled dedication to delivering quality wave spring solutions for a variety of industries. Both wave springs and traditional coil springs fall under the category of compression springs. While the primary function of a compression spring is to provide axial load, wave springs have a few key differences and advantages when compared to coil springs.
The key advantage of using a wave spring is in the axial space savings. Whether it is a static or dynamic application, wave springs may be the ideal solution where space is a constraint. Mega Coil
The apparent difference between a wave spring and a coil spring is the height. A wave spring can provide the same force and deflection as a coil spring but in considerably less axial space. Wave springs have up to a 50% reduced height, mainly because of the following two design features:
Coil springs are typically made of round wire, while wave springs use flat wire. Flat wire takes up less vertical space than round wire, which contributes to the reduction in work height.
Just as the name implies, a wave spring has multiple waves per turn. The wave design contributes to the load output of the spring. In the image below, we have a flat wire coil spring, a traditional coil spring, and a wave spring, respectively.
Because a flat wire coil spring has a thinner cross-section in comparison to the coil spring, a taller free height is required to achieve a similar load output. On the other hand, a wave spring also has a thin cross-section, yet has the lowest free height. This is due to the unique Crest-to-Crest design, which allows for similar spring rates to a coil spring, but with axial space-saving capabilities.
Now that you understand the most notable difference between a coil spring and a wave spring, let's go over some commonly asked questions.
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.
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.
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.
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