Springs are mechanical components of immense importance used in effecting motion, improving shock-absorbing capabilities, etc., in many products. In other words, rapid prototyping services such as 3D printing, and CNC machining can make diverse types of springs employed in effecting and making products such as watches, cellphones, etc.
Given the widespread use of springs in product design, understanding their types, applications, and performance characteristics is essential. This article provides a detailed overview of the different types of springs, their benefits, limitations, and practical applications.
Principle of Spring
Let’s start with something about spring. A spring stores energy when force is applied and releases it once the force is removed. Typically, regardless of the type, a spring returns to its original shape upon load removal.
The functionality of springs is governed by Hooke’s Law, which defines the relationship between the force applied and the spring’s elasticity. Simply put, Hooke’s Law states that the force required to compress or extend a spring is directly proportional to the displacement.
Mathematically Hooke’s Law is expressed as F= -kX,
F = force applied to the spring
X = displacement of the spring (the negative value indicates that the restoring force is opposite of the direction.
k = is the spring constant. It depends on the types of springs and shows stiffness.
Different Types of Mechanical Springs and Their Applications
Springs are made from different materials, shapes, functions, etc., which necessitates various applications. They have three main categories, with each category having different subcategories.
Category One: Helical Springs
HHelical springs are the most common in product manufacturing. Coiling wire into a helix shape creates these springs, offering various cross-sections. Below are the types of springs in this category.
1. Compression Springs
Compression springs feature an open-coil helical design with a constant coil diameter and variable shape, resisting axial compression.
The simplest example of its application is in the ballpoint pen, where it is responsible for the “popping” effect. It is also applicable in valves and suspension.
2. Extension Springs
Extension springs use a closed coil helical design, unlike compression types. They create tension, store energy, and use it to return to their original shape.
A simple example of its applications is in garage doors. Others are in pull levers, jaw pliers, and weighing machines.
3. Torsion Springs
Two ends of a torsion spring attach to different components. This keeps the two components apart at a certain angle. These springs use radial direction when force is acting radially due to rotation. What’s more, CNC machining capabilities can produce custom two-bodied torsion springs in high volumes.
4. Spiral Springs
Spiral springs are made by coiling rectangular metal strips into flat spirals. On activation, it stores a reasonable amount of energy and can release it at a constant rate. The constant release makes it suitable for mechanical watches, toys, and seat recliners.
Category Two: Leaf Springs
Leaf springs are made from rectangular metal plates, also known as leaves. The rectangular metal plates are normally bolted and clamped, and they have major use in heavy vehicles. Below are the different types of leaf springs and their applications.
1. Elliptical Leaf Spring
Connecting two semi-elliptical springs in opposite directions creates an elliptical leaf spring, forming an elliptical shape. In older cars, these springs attached the axle and frame, eliminating the need for shackles, as both semi-elliptical springs elongated equally during compression. However, they are no longer used in modern vehicles.
2. Semi Elliptical Leaf Spring
These are the most popular leaf springs in automobiles. They are made from steel leaves with different lengths but the same width and thickness. The uppermost/longest leaf at the two ends is the master leaf. The arrangement of the steel leaves resembles a semi-elliptical shape.
Semi-elliptical leaf springs have an end rigidly fixed to the vehicle frame and the other to the shackle. This helps in varying the lengths and absorbing shock when traveling in rough terrains. They require less maintenance, are easy to repair, and have a long life.
3. Quarter Elliptical Leaf Spring
Also known as the cantilever-type leaf spring, the quarter elliptical leaf spring is also old. They have one end fixed on the side member of the frame with the aid of a U-Clamp or I-Bolt. The other is freely connected to the front axle. When the front axle beam is subjected to a shock load, the leaves straighten to absorb the shock.
4. Three-quarter Elliptical Leaf Spring
A simple example of its application is a door hinge. Here, when you open the door, the spring will store its rotational energy; when you release the door, it uses the stored energy to bring the door back to its original position. The rotation force depends on the rotation of the spring.
This type combines a quarter elliptical spring and a semi-elliptical spring. One end of the semi-elliptical part attaches to the vehicle frame, while the other connects to the quarter elliptical spring, which is then secured to the frame with an I-bolt.
5. Transverse Leaf Spring
A transverse leaf spring is created by mounting a semi-elliptical spring across the vehicle’s width. The longest leaf is positioned at the bottom, with the mid-portion fixed to the frame using a U-bolt. While this design uses two shackles, it can cause rolling, making it unsuitable for automobile fasteners.
Category Three: Disk Springs
Disk springs are singular or multiple springs stacked together in series or parallel arrangements, allowing them to absorb high loads in tight spaces. Types of disk springs include:
1. Belleville Disk Spring
Also known as the coned-shaped disk spring, the Belleville disk spring has a cupped construction. They do not lie flat. Instead, they take a canonical shape that compresses and allows them to handle heavy loads.
2. Curved Disk Spring
Also known as crescent washers, they apply light pressure to their mating par to resist loosening as a result of vibration. They are suitable for distributing loads of threaded bolts, screws, and nuts evenly in machines that produce constant vibration.
3. Slotted Disk Spring
Slots on the outer and inner diameter of a disc create a slotted disk spring. This design reduces the load and increases deflection, making slotted disk springs widely used in automatic transmissions, clutches, and overload couplings.
4. Wave Disk Springs
Wave disk springs have multiple waves per turn and are suitable for providing prices and predictable loading. Here, they can act as a cushion by absorbing stress due to axial compression.
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Materials Used to Make Springs
Contrary to the common belief that springs are made only of iron, they come from various materials. These materials influence the properties, types, and applications of springs. Below are some common materials used:
Beryllium Copper Alloy
Springs made from this alloy offer high strength, low creep, and excellent conductivity. They are ideal for forming complex shapes, making them suitable for use in musical instruments, measurement devices, and bullets.
Ceramic
Ceramic material is suitable for making springs used at very high temperatures. It is resistant to abrasion, and water, and it is very hard. It also has a low coefficient of friction and low density.
One-Directional Glass Fiber Composite Materials
One-directional glass fiber composite material is a reinforced glass fiber that has powerful strength. Consequently, manufacturers are now considering it as a potential material for making all springs.
Rubber/Urethane
These materials are suitable for producing springs with a cylindrical/non-coil design. They are safe and reliable, and due to their non-conducting properties, they have applications in products where there is always an issue with magnetism, corrosion, and vibration.
Steel Alloys
Steel alloy is the most commonly used material for springs due to its excellent strength and durability. While it can be enhanced with other materials, its core properties remain highly reliable.
The Benefits of Using Springs in Your Projects
Springs are integral to many applications, providing flexibility, energy storage, and precise control. By incorporating them into your designs, you can enhance functionality and address mechanical challenges with greater efficiency. Let’s delve into how springs can add value to your projects.
Better Shock-absorbing Capability
Springs have a wide application in many products as they can reduce the effect of shock by absorbing them. When the product experiences a shock, the spring compresses and relaxes to absorb it. Consequently, they are important parts of vehicles.
Energy Storage
The spiral spring can serve as an alternative to a battery. When force is applied, it generates energy and continuously releases it, making it a crucial component of mechanical watches.
Joining Mechanism
Using spring can join two parts of a product or part together. For example, they are applied in a garage, door, and weighing machines to join two parts to function.
Product Stability
By its use in shock-absorbing capability, springs ensure that products that use them are stable. Product stability can also be a form of part friction and vibration reduction.
Disadvantages of Springs in Engineering
Springs, despite their usefulness, have limitations that can affect engineering outcomes.
Size and Weight Constraints
Springs may require increased size and weight to handle high loads, posing challenges in space-constrained or weight-sensitive applications, complicating the design, and potentially impacting system efficiency.
Complex Design Requirements
Designing springs to meet specific force and deformation criteria can be complex, requiring careful consideration of material properties, space constraints, and desired performance, often leading to intricate and challenging design processes.
They Lose Their Effects over Time
Springs lose their effect over time due to the simultaneous compression and relaxation. This depends on the material used in making it. Eventually, it will fail to obey Hooke’s law i.e., it will not return to the original shape on deformation.
Conclusion
Springs are essential for products that undergo motion. Modern versions vary in features and characteristics based on materials, design, and manufacturing processes. When selecting one for your product, it’s crucial to carefully evaluate these factors.
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FAQ
There are three main types: helical, disk, and leaf springs. Each category includes various subtypes. For example, helical types include torsion, extension, spiral, and compression.
Helical springs include four types, each with its application: torsion, extension, spiral, and compression.
The most common type is the torsion spring, which has two ends attached to different components to maintain a specific angle. For example, in a door hinge, when the door is opened, the spring stores rotational energy. When released, the stored energy returns the door to its original position