Precautions During Spring Manufacturing
Release date:
2023-10-09
Spring manufacturing is a highly complex and meticulous process; only with the right expertise can we produce high‑quality springs. In particular, it’s crucial to be fully aware of the key considerations during spring fabrication, as these significantly impact subsequent production and product quality. So, what specific precautions should be taken in spring manufacturing? Let our editor share some insights—by learning more, you’ll discover a whole new world of springs.
1. For springs without support rings and for spring wires with small diameters, the spring ends shall not be welded; however, the wire ends must not exhibit noticeable looseness and should be deburred. For multi‑strand springs requiring welded ends, the length of the welded portion shall be less than three times the wire diameter (with a maximum of 10 mm). The heated length shall be less than one coil turn, and the weld shall be ground smooth after welding. When using gas welding, the welded area shall undergo localized low‑temperature annealing.
2. Support rings may be manufactured by either cold winding or hot winding, depending on product requirements. When using the hot-winding process, the spring must not be heated to the point of sparking or discoloration; for silicon-manganese steel, the temperature shall not exceed 850°C. The support ring shall make effective contact with the active coils, and the clearance between them shall not exceed 10% of the nominal inter‑coil clearance.
3. The characteristics of a multi‑strand spring can be tailored by adjusting the pitch, and the coil spacing can be fine‑tuned during winding. The pitch-to‑wire diameter ratio may range from 3 to 14 times, though a value of 8 to 13 is generally preferred. Moreover, the spring force is closely related to the free height, end coils, outer diameter, and wire material properties; these parameters can be modified by adjusting one or several of them.
4. For critical springs, the compression time is 24 hours; for standard springs, it is 6 hours or continuous compression 3–5 times, with each cycle held for 3–5 seconds. During compression, the clearance between the spring and the mandrel should ideally be 10% of the mandrel diameter; a clearance that is too small will make operation difficult, while a clearance that is too large may cause the spring to bend or deform. If one of the springs breaks during compression, all the remaining springs must be reprocessed.
5. For multi‑strand springs with a large H0/D2 ratio, special attention should be paid to deformation during heat treatment; consider using a mandrel and carefully arrange the spring during processing, while selecting appropriate heat‑treatment equipment. When repair is feasible, multiple tempering cycles and hot‑pressing can be employed to achieve the desired results.
6. For spring surface treatment, phosphating is generally sufficient; other treatments may also be employed. When zinc or cadmium plating is required, a hydrogen‑removal treatment must be performed after electroplating. Following hydrogen removal, a re‑inspection shall be conducted on 3% of the samples (with no fewer than three pieces), and no fractures shall be detected during this re‑inspection. Springs must be thoroughly cleaned to remove surface contaminants, salt residues, and oxide scale; sandblasting or gasoline cleaning may be used for this purpose, but acid pickling is prohibited.
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WeChat ID: Lyx0608Ljl
Address: No. 68, Beiwai Street, Changning City, Hunan Province, China
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