Can a wave spring replace a coil spring?
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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?
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
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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.