Die Spring Product Training

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1 Die Spring Product Training

2 Mechanical Springs Die Springs Disc Springs Spring produced by cold forming with or without subsequent heat treatment.

3 Spring Manufacturing Plant IEM is committed to the spring manufacturing business. 43 years in die spring manufacturing. You are purchasing die springs direct from the manufacturer.

4 Features & Benefits Adequate inventory for same day shipments from the manufacturing plant Inch sizes manufactured to Industry Standards Reliable, proven long life performance High tensile chrome silicon material Optimal rectangular wire design

5 Die Spring Terminology Hole Diameter Rod Diameter Free Length Preload Operating travel Deflection Solid Height Permanent Set Load Stress

6 Hole Diameter This identifies the outside diameter (O.D.) of the die spring. Each die spring is made to fit in the hole, so the O.D. of the spring is actually less than the hole diameter.

7 Rod Diameter This is the nominal size of the inside diameter of the die spring. Each die spring is designed to fit a rod, so the I.D. of the spring is actually greater than the rod diameter.

8 The length of the spring before it is subjected to any operating force or load. Free Length

9 Preload The distance the free length of the spring is reduced by the pressure of the tool. Preload is necessary to compress the first coils of the spring where stresses are most caused by turning down the end coils.

10 Operating travel The distance which is subtracted from the spring length after the operating force has been applied.

11 Solid Height The height of the spring when it is compressed by enough load to bring all of the coils into contact with each other. Note: When changing over a customer to the L-Series springs, be sure to inform customer to follow the recommended deflections as shown in our catalog

12 Die Spring Terminology

13 Deflection The amount of change in spring length after an operating force has been applied.

14 Permanent Set This happens when the elastic limits are exceeded and the spring does not return to its original free length when the load is released.

15 Load This is the force that is built up by compressing the spring. Load is expressed in pounds per inch deflection. In our catalogs we show force in pounds per 1/10th inch.

16 Stress In a spring, this describes the internal force that resists deflection under load. This force is equal to and in opposite direction of, the external load. Stress is expressed in pounds per square inch or newtons per square mm of a sectional area.

17 Spring Material The basic function of any mechanical spring is to store energy elastically. Therefore the selection of spring material that displays the property of elasticity (the ability to return to the original shape and dimensions when applied forces are removed) must be considered for use when manufacturing a spring.

18 Spring Wire Material Our Die spring material: Manufactured from spring quality chromium silicon alloy steel in accordance with ASTM A1000 specifications. Provides a high tensile strength and superior heat resistance.

19 Spring Material Comparison

20 Basic Spring Wire Material Shapes SQUARE WIRE ROUND WIRE RECTANGULAR WIRE

21 Wire shape Modified trapezoidal cross section of rectangular wire changes to a D shape cross section during coiling to achieve a low stress level that means a longer spring life.

22 Die Spring Manufacturing Process Coiling Heat Treating Remove Set Operation Shot Peening Grinding Paint

23 Coiling Coiling is the spring forming process. The variables such as diameters, pitch, number of coils, type of ends, and free length are determined and established by the machine setup.

24 Stress Relief Springs are passed through stress relief oven immediately after coiling in order to prevent micro stress cracks that would otherwise form from the coiling process.

25 Heat Treating Close control of this process assures that the spring reaches the proper Rockwell hardness, the exact tensile strength, and steel temper to produce a spring with a given spring load.

26 Remove Set Operation The springs are originally coiled longer than the final length dimension required. Since die springs are designed to produce heavy loads and are heavily stressed, they will shorten when initially placed under load. The remove set operation brings the spring to the pre-determined free length.

27 Remove Set The manufacturing process of closing a compression spring to solid to eliminate load loss in operation. Pressed to solid with a predetermined and controlled load.

28 Shot Peening Shot peening is a surface treatment that helps combat surface fatigue and increase spring life by smoothing the wire surface imperfections.

29 Grinding both ends of the spring square provides a reliable bearing surface. Grinding

30 Closed End and Ground Ends of each spring are closed and ground square to assure that the spring will stand on either end and provide a maximum bearing surface

31 Grinding

32 Paint

33 Color Codes Inch Die Springs DUTY RANGE COLOR Light Duty Medium Duty Heavy Duty Extra Heavy Duty Green Blue Red Yellow

34 Testing Each spring batch is tested to verify consistency in dimensions and spring rates throughout the manufacturing process

35 Die Spring Application Application DO S and Don ts: DO design spring selection early DO preload each spring DO provide proper guidance DO deepen spring pockets after sharpening tools DO provide safeguards DO perform preventative maintenance

36 Die Spring Application Application Do s & Don ts: Don t replace just one spring Don t mix springs of different duties Don t alter a spring Don t expect maximum life at maximum deflection

37 Spring Application Die Spring Usage

38 Spring Design General Principles: The heavier the wire, the stronger the spring. The smaller the coil, The stronger the spring. The more active coils, the less load for the same deflection.

39 Guidance Normal rule for requiring guidance is when the spring length is 4 times the O.D.

40 Operating Deflections

41 Spring Rate Example: Spring One Inch Catalog shows rate as 20 lbs per 1/10 inch: When the spring is compressed 1 it produces = 200 lbs The Spring Rate for this spring is 200 lbs per inch

42 Turn Down Coils / Active Coils Squared and Ground Ends Turned Down Coils Active Coils Turned Down Coils

43 Causes for Failures Over stressed (load loss) Excess temperature Fatigue Insufficient or no pre-load Operating frequency is high Hydrogen embrittlement Non-central loading Shock Tool marks Inclusions

44 Troubleshooting Failures Rough Rule of Thumb: Breakage at end of spring: Overstressed Application Breakage in middle of spring: Possible material or mechanical marks on wire

45 OEM Applications Farm Equipment Mfgrs. Dental Equipment Mfgrs. Conveyor Mfgrs. Ground Systems Mfgrs. Metalworking Equip. Mfgrs. Power Equipment Mfgrs. Truck and Bus Mfgrs. Furniture Mfgrs. And thousands more!

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