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Wave Springs

Wave Springs

Wave springs are made from coiled flat wire with waves added to give it a bouncy effect. In some applications, wave springs are preferred over coil springs because they provide a lower working height for the same force.

Typically, wave springs occupy a very small area relative to the amount of work they can perform. Wave springs can reduce component size and weight by up to 50%. In fact, depending on design parameters, they can occupy 30-50% of the compressed height space of comparable round wire springs, thereby providing greater deflection for the same load specification. This not only saves space, but also provides smaller components that use less material, reducing production costs.

APPLICATIONS

Wave springs are used in a wide variety of applications where structural considerations limit mounting height, uniform force distribution is required and/or uniform rotational pressure over 360° is required. Wave springs are suitable for static and slightly dynamic load applications, however, fatigue is a key consideration when designing wave springs for dynamic load applications. For higher life cycles, stronger wave springs are required. Special solutions had to be found for extremely dynamic applications, since the considerable stresses on the side wave curves lead to material wear at the contact points. Typical applications include connectors, clutches, valves, pumps, seals, medical equipment, and more.

WAVE SPRING MATERIALS

When you need a wave spring, you need to consider the environment in which it will operate. Choosing the wrong material can kill your wave spring prematurely, and the environment can significantly shorten the life cycle of the spring. Please feel free to contact our team to discuss which material is right for your project.

CUSTOM WAVE SPRINGS

Custom wave springs can be manufactured in a variety of materials, finishes, and size options to meet your exact design specifications. You can work with engineers to assist with design and technical details to use custom wave springs in your application. Custom springs available in small and long-term batches. Request a custom wave spring quote today..

Helpful Wave Spring Tips

Avoid operating beyond the listed nominal loads and working heights, stresses may cause permanent deformation or failure of the spring. Entity height information is for reference only. Regardless of the actual load or size of the wave spring design, operating in the solid state will result in extreme overloading. Make sure to install a REDUX™ wave spring with the correct hole and rod size. The hole and rod diameters listed are correctly matched to the spring to ensure a loose fit. Spring outside and inside diameters are approximate only.

WAVE SPRING PRIMARY DESIGN CONSIDERATIONS
There are 4 critical factors when considering a wave spring:
1. Application limitations: hole/shaft, inner diameter/outer diameter, etc.
2.Load
3. Working height of applied load
4. Required materials

If the wave spring is designed for a static application, make sure the percent stress at the working height is less than 100%. If subjected to higher pressure, the spring will deform.
If the wave spring is designed for dynamic applications, ensure that the percent stress at working height is less than 80%. Wave springs will deform if subjected to higher stresses.

When designing with wave springs, keep the following in mind:
If the working height per turn of the wave spring is less than (2 * wire thickness), the wave spring will operate in a “non-linear” range and the actual load may be higher than calculated.

Number of laps must be between 2 and 20

The number of waves per revolution (N) must be in increments of ½

Min. Radical wall = (3 * Wire Thickness)
Max. Radical wall = (10 * Wire Thickness)

It is not recommended to compress wave springs to solid height.

Outside diameter (OD) expansion and outside diameter (OD) tolerance must be considered when designing springs to mount in a bore and/or on a shaft.

For an in-person consultation with an engineer, contact us today at info@coosprings.com.

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