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Digital Ebook | A Design World Resource

Inside

Design World Motion Control Handbook: Wave Springs 2

VIDEO: Wave Springs Overview 3

An Introduction to Wave Springs 5

Custom-Made Rings & Springs 8

Wave Spring Performance 11

Related Videos 13

AND MORE!

Sponsored by
http://www.smalley.com/http://www.designworldonline.com/category/tech-tips/


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Page 2

Motion Control HANDBOOK

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A

t its most basic level, a spring is a device used tostore mechanical energy. Although often out of sight,springs play an important role in many motion controlapplications. Tey are used in gear assemblies, actuators,rotary unions, and different kinds of clutches, among other

applications. Tere are many different varieties and shapes and sizes ofsprings making it virtually impossible to cover them all in great length. However, there are some basics to spring technologies. For starters,there are generally three types of springs: tension, compression, and torsion.

ension springs operate in tension with a load attached,so as the load is applied the spring will be stretched out.

Compression springs, as the name implies, operate undercompression, so as the load is applied this type of spring willbecome shorter.

orsion springs operate with torsional or twisting loads, whichmeans a torque is applied to the spring.

Compression springs are some of the most common types ofsprings in use. Te compression style wave spring is made of coiledflat wire with waves added along the coils to give it a spring effect.Tey can be used in place of conventional round wire compressionsprings in applications with minimal space that yet require similardeflection. Generally, they occupy one-third to one-half of the space ofcomparable round wire springs offering more deflection with the sameload specifications.

Wave springs are one alternative to coil springs. Wave springs aretypically manufactured from a single filament of flat wire formed incontinuous precise coils with uniform diameters and waves. Tey aremanufactured with either plain ends (wavy) or squared-flat ends (shimends). Generally, 17-7 PH is used as the standard material for wave springs.

Wave SpringsCourtesy of Design World

One advantage of wave springs is that they save space in manyapplications. By reducing spring operating height, these springs alsodecrease the spring cavity. A smaller assembly size and less material usedin the manufacturing process lowers cost. Wave springs operate as load bearing devices. Tey take up playand compensate for dimensional variations within assemblies. A range offorces can be produced whereby loads build either gradually or abruptlyto reach a predetermined working height. Tis establishes a precise springrate in which load is proportional to deflection. Some manufacturers offer single, nested, and multi-turn wavestyle springs. A single-turn wave spring with overlapping ends saves

axial space so that more space is given for travel. Te spring clings to thebore, which saves more radial space. Te overlapping ends prevent radial

jamming because a circumferential movement is allowed. Te springends could move against each other so that the specification load at

work height is always given.
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Wave Springs(continued)

Nested wave springs suit applications requiring higher forcesto meet safety regulations, such as those in government or militaryapplications. A nested wave spring provides a higher load than a single-turn wave spring (or alternatively, a stamped wavy washer) and uses thesame radial space as a single-turn design. Multiple-turn wave springs do not cling to the bore, because radial

jamming affects the specified load at work height. If the design of themulti-turn wave spring results in peripheral movement of the turnsagainst each other, this could render the spring unstable. Compared to a single-turn design, bigger travel/deflection ispossible because the deflection in total is split. Every turn has to tolerateless deflection compared to a single-turn design. Use of a multi-turn

wave spring could also save 50% in axial space compared to a traditionalcoil spring. Tere is also no concern about torsional movements duringthe compression to work height as there is with a coil spring; a wavespring always provides its load in an axial direction. Very similar loads without big tolerances are provided at different

work heights; in that way, the application could be easily adjusted tomeet given requirements. Lastly, although wave spring applications can be diverse, there is abasic set of rules for defining spring requirements. Tose requirementsare used to select a stock/standard spring or design a special spring tomeet the specifications.

Selection tipsWhen selecting a wave spring, the load requirement is probably themain factor to consider. Te load requirement is defined as the amount

of axial force the spring must produce when installed at its work height. Some applications require multiple working heights, where loadsat two or more operating heights are critical. Often minimum andmaximum loads are satisfactory solutions, particularly where tolerancestack-ups are inherent in the application.

Featured Video:Motion Control Handbook Wave Springs Overview
http://www.designworld-digital.com/designworld/motion_control_handbook_2013#pg2http://www.designworld-digital.com/designworld/motion_control_handbook_2013#pg2http://www.designworld-digital.com/designworld/motion_control_handbook_2013#pg2http://www.designworld-digital.com/designworld/motion_control_handbook_2013#pg2http://www.designworld-digital.com/designworld/motion_control_handbook_2013#pg2http://www.designworld-digital.com/designworld/motion_control_handbook_2013#pg2https://www.youtube.com/watch?v=rLTujEM62_shttps://www.youtube.com/watch?v=rLTujEM62_shttp://www.smalley.com/request-catalog?utm_source=DW&utm_medium=Ebook&utm_content=Catalog&utm_campaign=DW%20Ebookhttps://www.youtube.com/watch?v=rLTujEM62_shttp://www.smalley.com/http://www.designworldonline.com/http://www.designworldonline.com/http://www.designworld-digital.com/designworld/motion_control_handbook_2013#pg2http://www.designworldonline.com/category/tech-tips/http://www.designworld-digital.com/designworld/motion_control_handbook_2013#pg2


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Wave Springs(continued)

High temperature, dynamic loading (fatigue), a corrosive media orother unusual operating conditions are also important considerations inspring applications. Solutions to various environmental conditions typicallycall for the selection of the optimal raw material and operating stress. Te working cavity usually consists of a bore the spring operates in

and/or a shaft the spring clears. Te spring stays positioned by pilotingin the bore or on the shaft. Te distance between the loading surfacesdefines the axial working cavity or work height of the spring. Materialcross-section also plays an important role in wave spring design. Tere are four critical factors when considering a wave spring

Constraints of the application:Bore/shaft, ID/OD etc.

Load Working height at which the load is applied Material desired

If a spring is designed for a static application, make sure that thepercent stress at working height is less than 100%. Springs will take aset or length loss in operation due to the high stress condition of thespring, if subjected to a higher stress. If a spring is designed for a dynamic application, make sure that

the percent stress at working height is less than 80%. Springs will takea set if subjected to a higher stress. If the work height per turn is less than 2X the wire thickness,the spring will operate in a non-linear range and actual loads may behigher than calculated.

Min. radial wall = (3X Wire Tickness) Max. radial Wall = (10X Wire Tickness)

It is not recommended to compress a wave spring to solid. Radialexpansion and diameter tolerance must be taken into account while

designing a spring to fit in a bore and/or over a shaft. DW

Formulas:

Operating Stress:S = (3PDm)/4bt2N2

Where:

S = operating stressP = load in pounds

Dm= mean diameter in inchesb = radial width of material ininchest = thickness of material in inchesN = number of waves per turn

Fatigue Stress Ratio:x = s-s1/s-s2Where:

s = Material tensile strengths

1= Calculated operating

stress at lower workingheight (must be less than s)s

2= Calculated operating

stress at upper workingheight

Deflection:f = ((PKZDm3)/(Ebt3n4)) x (ID/OD)

Where:

f = deflection in inchesP = load in pounds

K = multiple wave factorDm= mean diameter ininchesZ = number of turnsE = modulus of elasticity

b = radial width ofmaterial in inches

t = thickness ofmaterial in inchesN = number ofwaves per turn

Spring Rate:R = (P/f) = (Ebt3n4)/(KZDm3) x (ID/OD)

Where:

R = Spring rate in pounds/inch

P = load in poundsf = deflection in inchesE = modulus of elasticityb = radial width of materialin inches

t = thickness of material ininches

N = number of waves per turnK = multiple wave factorDm= mean diameter ininchesZ = number of turns
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An Introduction to Wave SpringsCourtesy of Smalley Steel Ring Company

Smalley Wave Springsoffer the unique advantage of space savingswhen used to replace coil springs. By reducing spring operating height,wave springs also produce a decrease in the spring cavity. With a smallerassembly size and less material used in the manufacturing process, a costsavings is realized. Wave springs operate as load bearing devices. Tey take up playand compensate for dimensional variations within assemblies. A virtuallyunlimited range of forces can be produced whereby loads build either

gradually or abruptly to reach a predetermined working height. Tisestablishes a precise spring rate in which load is proportional to deflection. Functional requirements are necessary for both dynamic and staticspring applications. Special performance characteristics are individuallybuilt into each spring to satisfy a variety of precise operating conditions.ypically, a wave spring will occupy an extremely small area for theamount of work it performs. Te use of this product is demanded, butnot limited to tight axial and radial space constraints.

Product PerformanceWith their smooth, circular coiled sinusoidal wave form, and rolled round

edges of pre-tempered raw material, Smalleys edgewound Wave Springsoffer many advantages over die stamped products. Loads and spring rates are more accurate, more predictable, and maybe toleranced better than 50 percent tighter than stampings. Te force ofa Smalley Wave Spring will increase at a uniform rate throughout most ofits available deflection. By any criteria, Smalley Wave Springs offer their users higherdependability and better performance. Since they are produced fromtempered or full hard raw material, there is no risk of distorting thespring during a hardening heat treatment. By contrast, subsequent

manufacturing procedures for stamped wavy washers can lead to problemssuch as fatigue cracking and inaccurate or inconsistent loading betweensprings. All told, the metallurgy, the mechanical properties and theuniform dimensional stability of the Smalley edgewound Wave Springprovide a component for precision quality applications. DW

Wave Spring Types

Gap Type Wave Spring Overlap Type Wave Spring

Gap & Overlap TypeConventional Gap and Overlap ype Wave Springs are used in a

wide variety of applications. For short deflections and low-mediumforces, they function with precision and dependability.

Tese two types of Smalley Wave Springs permit radialexpansion or growth in diameter within a cavity, without thebinding or hang-up normally associated with die stamped wave

washers. Just as their terms imply, the gap type is split to retain agap between the ends, while the overlap type has overlapping ends.Tus, the ends are free to move circumferentially as the springoutside diameter grows during compression. For example, the O.D. of a Gap ype Wave Spring wouldfit .020 loose per side in a bore. Its I.D. clears a shaft by .010 perside. As the spring is deflected, the O.D. and I.D. grow largeruntil the O.D. contacts the bore. Continued deflection causes the

gap ends to move closer together while the O.D. presses againstthe bore. An Overlap ype Wave Spring permits this type ofcycling action in a similar manner.

Page 5
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An Introduction to Wave Springs(continued)

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Crest-to-CrestCrest-to-Crest Wave Springs are prestackedin series, decreasing the spring rateproportionally to the number of turns. Usesare typically applications requiring low-medium spring rates and large deflections

with low-medium forces. Among majoradvantages, this design eliminates the needto keep the wave crests aligned. Te need touse a key locating device, or to insert a shim

between individual springs is not necessary.Because the spring is integrally formed, thewave peaks hold their configuration. As a replacement for helicalcompression springs, Crest-to-Crestsprings can develop similar forces, yetoccupy one-half () or less the axial space.Tis allows for strict space constraints.Crest-to-Crest Wave Springs will maintainthe same force and load specifications of aconventional round wire spring, but with

the advantages of resultant lowered andcompacted operating heights, free heights,and solid heights.

Crest-to-Crest withOptional Shim EndsCrest-to-Crest Wave Springsare also available with squared-shim ends. Shim ends providea 360 contact surface whencompared to the wave pointcontact of plain ends. Te shim-ends, under load, more evenlydistribute the springs force

upon adjacent components. Tisfeature is similar to the conceptof double-disc grinding springsfor a flat surface. Applicationsunder heavy loads using softermaterials, like plastic valves,may deform at contact pointsnecessitating the use of loaddistribution features. Shim endshave also been used to affixsprings to mating components,

as a flat locating surface thatmay be attached by variousmethods in the assembly.
http://www.smalley.com/request-samples?utm_source=DW&utm_medium=Ebook&utm_content=Samples&utm_campaign=DW%20Ebookhttp://www.smalley.com/crest-to-cresthttp://www.smalley.com/crest-to-crest-shimhttp://www.smalley.com/http://www.designworldonline.com/http://www.designworldonline.com/category/tech-tips/


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An Introduction to Wave Springs(continued)

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NestedNested Wave Springs are pre-stacked in parallel from one continuous filamentof flat wire. Te need to stack individual springs for higher loads is no longernecessary. Nested springs result in a spring rate that increases proportionally to thenumber of turns. Tey can exert tremendous forces, yet maintain the precision ofa circular-grain wave spring. In many applications, Nested Wave Springs replaceBelleville Springs, particularly in cases where a high but accurate force is needed.

WAVOWavo Springs are produced from round-section wire to provide higher loads whilemaintaining the accurate loading found in wave springs. As an alternative to BellevilleSprings, the Wavo provides similar loads but with an accurate, predictable spring rate.

Linear Springs

Linear springs are a continuous wave formed (marcelled) wire length producefrom spring tempered materials. Tey act as a load bearing device havingapproximately the same load/deflection characteristics as a wave spring. Forces act axially or radially depending on the installed position. Axialpressure is obtained by laying the spring flat in a straight line. Circular wrappingthe spring produces a radial force or outward pressure. Linear springs are availablecut to length or as a continuous coil, for the user to cut as needed.
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While Smalley has a large selectionof stock retaining ringsand wave springs to choose from, the uniqueness of applicationsoften demands a ring or spring to conform to application-specificrequirements. Our No-ooling-Cost process provides an economicalalternative, to produce a custom ring or spring to meet your exactspecifications. Tink of it as modifying a standard; change thediameter, material size, alloy or nearly any product characteristic to fit

within your assembly. Its really a simple solution to get exact ly whatworks best. At Smal ley, specials are standard, as many of our accounts

take advantage of getting exactly what works best. Retaining rings andwave springs are often the last design consideration in an assembly andcommonly have to fit in restrictive spaces and need to provide criticaloperating characteristics. Having the ability to easily specify non-standard sizes, offers a preferred option designers will often follow.

Smalley engineers establish themanufacturing processes needed. Tis includesprimary coiling operations, secondaryoperations for special product features suchas slots, tabs, holes, bends, hooks, joints,etc., plating and finishing, marking and othercharacteristics for most any feature required. o develop a packaging solution, Smalleyengineering has created standards with which

solutions are offered for consideration.Whether the part is coin-wrapped, bulkpackaged, wire tied, on a tube or individuallybagged, a Smalley engineer is involved with allaspects of handling and shipment. DW

Custom-Made Rings & SpringsCourtesy of Smalley Steel Ring Company

A. Pressure Relief ValveAn exact load appl ied to the top sealingplate was accomplished using a flat

wire wave spr ing. Air pressure enter ingthe top slots forces the plate awayfrom the sealing surface providing thepressure relief mechanism.

A.

B.

C.

B. Face SealWave Spring applies pressure, to precisely load thecarbon face against a mating surface, to properly

seal fluids. Te spring operates over a fixedworking range and provides an exact force, unlikethe stamped wavy washer it replaced which couldnot maintain the necessary spring rate.

C. Clutch DrivePressure on the round belt is producedby compressing the Wavo Spring

through the sheave halves. Te topthreaded cap rotates to adjust the Wavocompression. Te Wavo can produce ahigh force in a tight radial cavity.
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Custom-Made Rings & Springs(continued)

D. Bayonet ConnectorOverlap ype Wave Springinstalled in an electronicconnector assembly. As male andfemale components are rotatedtogether into final assembly, the

wave spring is compressed to its

working height. In this positionit exerts a constant force thatlocks both components together.D.E. Multi-ToothCutter

A custom designed wavespring with locating tabs iscontained in the housing.Te spring applies a preciseforce to the two cutterhalves, allowing them tooscillate but not rattle.

E.

F. Slip ClutchClutch drives when the V"- detentsare in the V-slots. A Smalley WaveSpring maintains pressure to hold thisposition. As torque is increased, theV-detents will ride up and out theV-slots, depressing the wave spring

and developing the slip mechanism.When torque is decreased, the wavespring forces the V-detents firmlyinto the V-slots to drive again.

F.

G.G. Bearing Pre-LoadOne of the most common wavespring applications world-wide isa bearing preload arrangement asillustrated. Having the proper load

will often extend bearing life bylowering operating temperatures,

reducing vibration, minimizingwear and providing for quieterand smoother performance.

H. Flow ValveAs fluid pressure increases theCrest-to-Crest Wave Springprecisely controls the lineardisplacement of the piston, whichpositions the orifice for proper fluidflow. Because of the space savingsof the Crest-to-Crest design, thevalve can be made smaller.H.

I.I. Low Voltage Connector

A Bayonet Connector couplesas the male end rotates andfollows the groove contourin the female end. A 2-urnNested Spirawave Wave Springprovides the pre-load between

the two ha lves. A 2-urnNested Spring was necessary todevelop a higher load in verytight radial and axial space.
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J.

J. Sprinkler ValveWith height restrictions accountedfor, the Smalley Crest-to-Crest WaveSpring maintains constant pressureon the pop-up head, holding itfirmly closed. In operation, waterpressure releases the head byovercoming the springs force.

K. Oil ValveTe force provided by the Crest-to-Crest

Wave Spring in this oil valve applicationprecisely regulates the amount of oil thatis released. Te Crest-to-Crest springprovides accurate resistance in a smallspace, allowing the overall size of thevalve to be greatly reduced.K.

L. Ball ValveA Smalley Crest-to-Crest WaveSpring is used to reduce the overallspring height in this application.Te wave spring allows the seatto oscillate on the ball, keeping atight seal in the operating position.

Te reduction in spring height andresulting smaller spring cavity alsoreduce the weight of the valve.L.

Custom-Made Rings & Springs(continued)

M. Quick DisconnectTe sliding member of thedisconnect is held in its forward/locked position against the retainingring, by the Crest-to-Crest Spring.

As the user slides the member in theopposite direction compressing the

spring, the detent balls align with agroove and release.M.

N.N. Vibration Isolator

Wavo Springs providehigh force and a relativelylarge axial displacement, inlimited space. Te springsare arranged in series for

additional travel.

O.

O. Floating GearFunctioning in acontained bracket, aCrest-to-Crest WaveSpring loads a gear withlight force allowing axial

movement. Te gearshown self-aligns withits mating gear duringoperation.
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Wave Spring PerformaceCourtesy of Smalley Steel Ring Company

Operating StressCompressing a wave spring creates bending stresses similar to a simplebeam in bending. Tese compressive and tensile stresses limit the amounta spring can be compressed before it yields or takes a set. Althoughspring set is sometimes not acceptable, load and deflection requirements

will often drive the design to accept some set or relaxation over time.

Maximum Design StressStatic Applications: Smalley utilizes the Minimum ensile Strength found

within our tables of standard springs to approximate yield strength due

to the minimal elongation of the hardened flat wire used in Smalleyproducts. When designing springs for static applications we recommendthe calculated operating stress be no greater than 100% of the minimumtensile strength. However, depending on certain applications, operatingstress can exceed the minimum tensile strength with allowances for yieldstrength. ypical factors to consider are permanent set, relaxation, loss ofload and/or loss of free height. Dynamic Applications: When designing wave springs for dynamicapplications, Smalley recommends that the calculation of operating stressnot exceed 80% of the minimum tensile strength.

Residual Stress and Pre-SettingIncreasing the load capacity and/or fatigue life can be achieved bycompressing a spring beyond its yield point or presetting. Preset springsare manufactured to a higher than needed free height and load and thencompressed solid. Both the free height and load are reduced and the materialsurfaces now exhibit residual stresses, which enhance spring performance.

FatigueFatigue cycling is an important consideration in wave spring design anddetermining precisely how much the spring will deflect can greatly impact

the price of the spring. An analysis should include whether the springdeflects full stroke or only a few thousandths each cycle or possibly acombination of both as parts wear or temperature changes.

Formula:

Fatigue Stress Ratio Estimated Cycle Life .00 < X < .40 Under 30,000 cycles .40 < X < .49 30,000 - 50,000 cycles .50 < X < .55 50,000 - 75,000 cycles .56 < X < .60 75,000 - 100,000 cycles

.61 < X < .67 100,000 - 200,000 cycles .68 < X


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Wave Spring Performace(continued)

More information about Single urn Gap or Overlap,Multiple urn (Crest-to-Crest) Spirawave,and Nested Spirawaveparts can be found on their pages.

HysteresisWave springs exert a greater force upon loading and lower force uponunloading. Tis effect is known as hysteresis. Te shaded area shows agraphic representation between the curves. In a single turn spring, friction due to circumferential and radialmovements are the prime causes. Crest-to-Crest and Nested Springs alsocontribute to the frictional loss as adjacent layers rub against each other.Sufficient lubrication will minimize this effect.

Diameter Expansion

Nested and Crest-to-Crest Spirawaves only: Multiple turn Spirawavesexpand in diameter when compressed. Te formula shown below is usedto predict the maximum fully compressed diameter.

Formula:

ODM = .02222 R N = b

Nomenclature

ODM= Outside diameter at solid (in)R= Wave radius (in) = (4Y2 + X2)/8YN= Number of waves= Angle = ArcSin[X/(2R)] (degrees)

b= Radial wall (in)X= 1/2 wave frequency = (DM)/(2N)Y= 1/2 mean free height = (H-t)/2Where H = Free height per turn (in)

P 13
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Wave Spring Performace(continued)

Linear SpringsLinear Springs are a continuous wave formed (marcelled) wire lengthproduced from spring temper materials. Tey act as a load bearingdevice having approximately the same load/deflection characteristics asa wave spring. Forces act axially or radially depending on the installed position.

Axial pressure is obtained by lying the expander flat in a straight line.Circular wrapping the expander (around a piston for example) produces aradial force or outward pressure. DW

Single WaveDeflection = f =

Single WaveOperating Stress = S =

Multiple WaveDeflection = f =

Multiple Wave

Operating Stress = S =

PL 3

4Ebt3

3PL2bt 2

PL 3

16Ebt3N4

3PL4bt 2N 2

Related Video:

Smalley Steel Ring Corporate Video

Wave Springs by Smalley Steel Ring Company

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E-Mail:

[email protected]

Web: www.smalley.com

Phone: 1-847-719-5900

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Phone:

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