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Endless Possibilities: Understanding the Expanding World of Machined Springs
 

Endless Possibilities: Understanding the Expanding World of Machined Springs

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This webinar addresses the high points of the original Choosing Between Machined and Wire Wound Springs webinar, and then goes into more detail regarding the unique differences that can significantly ...

This webinar addresses the high points of the original Choosing Between Machined and Wire Wound Springs webinar, and then goes into more detail regarding the unique differences that can significantly affect design considerations. In particular, issues regarding coil and slot geometries plus length limitations will be discussed. The topic of Multiple Starts and why these are becoming more important in many modern spring applications will be viewed from both the performance and cost vantage points. Torsion springs will be revisited with examples of moment computations. The discussion will conclude with examples of springs in dynamic, resonant usage.
Attended this webinar to learn:
• Differences in spring coil geometries revealed
• Design considerations: differences of machined springs vs wire wound springs
• Insights into torsional spring attachments
• Single Degree of Freedom spring-mass functioning system

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    Endless Possibilities: Understanding the Expanding World of Machined Springs Endless Possibilities: Understanding the Expanding World of Machined Springs Presentation Transcript

    • Endless Possibilities: Understanding the Expanding World of Machined Springs
    • Before We Start  This webinar will be available afterwards at designworldonline.com & email  Q&A at the end of the presentation  Hashtag for this webinar: #DWwebinar
    • Moderator Presenter Miles Budimir Gary Boehm Design World Helical
    • Understanding the Expanding World of Machined Springs © 2013 Helical Products Co, Inc. 4
    • A Webinar based upon the Helical White Paper Wire Springs versus Machined Springs, A Comparison Authored by Gary L Boehm PE Helical Products Co Inc, Santa Maria, CA © 2013 Helical Products Co, Inc. 5
    • • Founded in 1958 • Invented Beam Style Couplings Shown here © 2013 Helical Products Co, Inc. 6
    • Springs Wire-Wound Springs © 2013 Helical Products 7
    • Springs Wire-Wound Springs Machined Springs © 2013 Helical Products Co, Inc. 8
    • • Wire Springs existed before the Industrial Revolution • First Machined Springs in 1960’s • Now- New designs created daily • Both are manufactured with CNC controlled machines © 2013 Helical Products Co, Inc. 9
    • Wire Wound Machined Springs Springs yes yes 1% maybe yes 0.1% no maybe 10% Precision © 2013 Helical Products Co, Inc. 10
    • Wire Wound Springs are typically made from medium and high strength steels, nickel alloys, titanium and stainless steels that gain their strength predominately from heat treating and cold reduction. CRES (Corrosion Resistant Steels), moderate to high strength a 17-4PH per AMS 5643 b 15-5PH per AMS 5659 c CC455 per AMS5617 d X750 Inconel per AMS 5667 and 5670 Very high strength steel a C300 per AMS6514 Other materials of interest a 7075-T6 Aluminum (high strength) b 7068-T6511 Aluminum (very high strength) c 38644 Beta C Titanium (very high strength and corrosion resistant) d Delrin 100 (machinable plastic) e Ultem 2300 (machinable plastic) © 2013 Helical Products Co, Inc. 11
    • A long, torsion Machined Spring using a dime for size comparison. Wire Springs can be larger. A small, compression Machined Spring. Wire Springs can be smaller. © 2013 Helical Products Co, Inc. 12
    • Some of the many Machined Spring Attachments available for Compression and Extension Springs © 2013 Helical Products Co, Inc. 13
    • Feature Coils Section Round Square Rectangular, radial Rectangular, radial with high ratio Rectangular, longitudinal Rectangular, longitudinal with high ratio Wire Wound Springs yes yes yes Machined Springs no yes yes no yes yes yes yes yes Zero width Slots Number of coils yes Zero width w/prestress 0.100 inch Over 0.250 inch 1 coil minimum 20 coils 50 coils yes yes yes yes yes yes © 2013 Helical Products Co, Inc. yes, with special process no yes maybe yes yes maybe 14
    • Percentage of Compression based upon Free Length Wire Wound Springs Machined Springs 10% 20% 30% 40% 50% 60% 70% 80% 90% yes yes yes yes yes yes maybe yes yes yes yes maybe maybe no © 2013 Helical Products Co, Inc. maybe no no no 15
    • • In a closed-ground wire compression spring, the active coil (that in which strain energy can be stored) extends to the very end of the spring. © 2013 Helical Products Co, Inc. 16
    • • In a Machined, Compression Spring, the active spring coil stops short of the spring end relegating at each end one slot width and one structural width unavailable for storing energy. © 2013 Helical Products Co, Inc. 17
    • Production time is the major influence in cost. Cost wise, Wire Wound Springs benefit greatly from short production times. Machined Springs cannot approach the low cost of wire product. It would be very surprising to find a very simple and inexpensive Machined Spring, produced in high quantities costing less than $1 USD each. • • • • • • • However, these value enhancements related to Machined Springs usage helps to validate their usage: Integrated attachments Enhanced performance or functionality Via Multiple Starts, more uniform elastic reactions, and better control of internal moments Higher precision Reduced assembly and acquisition efforts No sound creation from coil contacts No debris created by coil contacts Without one or more of these benefits being present, there is usually little justification of employing Machined Springs in place of Wire Springs. © 2013 Helical Products Co, Inc. 18
    • Wire Springs Machined Springs Wire Springs are often shot peened for enhanced fatigue resistance. This process is possible because the gap between the coils is typically wide enough to permit passage of shot that can condition the inside of the opposite coil, as well as the outside of the coils. Machined Springs typically have coil slots that are too small for the passage of shot. Hence, shot peening is not common. To insure fatigue resistance, features such as stress relief holes and slots can be added to the slot ends. Selecting high strength, fatigue resistant, materials is also a significant benefit. © 2013 Helical Products Co, Inc. 19
    • Wire Springs Machined Springs It is not uncommon to plate Wire Springs with materials such as zinc and nickel for corrosion protection. Plating Machined Springs is uncommon because of the existence of sharp edge corners that typically receive insufficient coverage. The use of CRES and titanium materials provides excellent corrosion protection for most Machined Spring applications. Machined Springs made form aluminum are typically anodized or coated to prevent corrosion. © 2013 Helical Products Co, Inc. 20
    • Flexure configurations for Compression and Extension Springs that resist rotation given axial deformation. These techniques are difficult, but not exclusively unavailable for wire springs. © 2013 Helical Products Co, Inc. 21
    • Triple Available only in Machined Springs Single Double Available in both Wire and Machined Springs Available only in Machined Springs © 2013 Helical Products Co, Inc. 22
    • Single Start © 2013 Helical Products Co, Inc. Multiple Start 23
    • © 2013 Helical Products Co, Inc. 24
    • Some of the many Machined Spring Attachments available for Torsion Springs © 2013 Helical Products Co, Inc. 25
    • Attachment Type Wire Spring Machined Spring Tang (Radial) External and Internal yes* yes* Dual Tang (Radial) External and Internal no yes** Tang (Axial) External and Internal yes* yes* Dual Tang (Axial) External and Internal no yes** Dual Pin Holes (Axial) no yes** Geometric ID Shapes (square, hex, etc) no yes** *Force at distance requiring force resolution **Pure moment drive © 2013 Helical Products Co, Inc. 26
    • Multiple Start Machined Springs have a history of providing effective Single Degree of Freedom elastic elements for such systems. Double Start Springs set the baseline for such usage, but Triple Start Springs are the gold standard because of their uniform stiffness in all lateral directions. © 2013 Helical Products Co, Inc. 27
    • www.heli-cal.com © 2013 Helical Products Co, Inc. 28
    • Thank you for sharing your time with us… And now… Does anyone have a question? © 2013 Helical Products Co, Inc. 29
    • Questions? Design World Miles Budimir mbudimir@wtwhmedia.com Phone: 440.234.4531 Twitter: @DW_Motion Helical Gary Boehm machinedsprings@heli-cal.com Phone: 805.928.3851 Twitter: @HelicalProducts
    • Thank You  This webinar will be available at designworldonline.com & email  Tweet with hashtag #DWwebinar  Connect with  Discuss this on EngineeringExchange.com