SPRING MANUFACTURING PROCESS

SPRING DESIGN
Spring dimensions can be calculated with a high degree of accuracy, using theoretical models. We use in-house
developed software for all traditional spring types, and we use specially configured FEM (finite element method)
software for complicated geometries. High speed shock loading and transient phenomena are which are important in
same applications. ELCEN has prepared a manual which offers basic information about most common spring types and
the theories used.
COIL SPRING MANUFACTURING
Every spring is manufactured from high quality steel. There are many steel mills around the world, but only a few are
specialized to produce the high quality steel needed for modern suspension spring with high stress levels.
ACCORDING TO DESIGN & ROW MATERIAL STANDARD
1) Pre-heat treated (oil quenched as per ASTM-A229) / Maximum Temp. 300°F
2) Annealed (unquenched as per ASTM-A 228) wire is used. / Maximum Temp. 250°F
3) Carbon structural steel as per ASTM A 36

COLD COILING
The cold wire formed into spring shape through the computer controlled automatic machines. The wire is pushed
forward over a support block toward a grooved head that deflects the wire, forcing it to band. The head and support
block are moved relative to each other in as many as five directions to control the diameter and pitch of the spring that
is being formed. For extension or torsion springs, the ends are bending into the desired loops, hooks, or straight
sections after the coiling operation is completed.
HOT WINDING
Thicker wire or bar stocks are heated the make it flexible to formed and coiled into the spring. Steel bar up to 3” (75
mm) diameter, and custom springs have reportedly been made from bars as much as 6” (150 mm) thick. The steel is
coiled around a mandrel while red hot. Then it is immediately removing from the coiling machine and plunged into oil
to cool it quickly and harden it. At this stage, the steel too brittle as a spring, and it subsequently tempered.

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 SPRING MANUFACTURING PROCESS

HEAT TREATMENT
Whether the steel coiled are hot or cold, the process has created stress within the material, to relive this stress and
allow the steel to maintain its characteristic resilience the spring are tempered by heat treating it. The spring is heated
in an over held at the appropriate temperature for a predetermined time and then allowed to cool slowly. For example
a spring made of music wire is heated to 500°F (260°C) for one hour.

GRINDING
If the design calls for flat ends on the spring, the ends are ground at this stage of the manufacturing process. The spring
is mounted in a jig to ensure the correct orientation during grinding and it is held against a rotating abrasive wheel
until the desired degree of flatness is obtained. When highly automated equipment is used the spring is held in a sleeve
while both ends are ground simultaneously first by coarse wheels and then by finer wheels. An appropriate fluid
(water or an oil-based substance) are used to cool the spring lubricate the grinding wheel and carry away particles
during the grinding.

SHOT PEENING (SHOT BLASTING)

This process strengthens the steel to resist metal fatigue and cracking during its lifetime of repeated flexing’s. The
entire surface of the spring is exposed to a barrage of tiny steel balls that hammer it smooth and compress the steel
that lies just below the surface.

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 SPRING
MANUFACTURING
MANUFACTURING
PROCESS
PROCESS

COATING
Powder Coating is a type of coating that is applied as a free-flowing, dry powder. The main difference between a
conventional liquid paint and a powder coating is that the powder coating does not require a solvent to keep the binder
and filler parts in a liquid suspension form. The coating is typically applied electrostatically and is then cured under
heat to allow it to flow and form a "skin". The powder is the thermoplastic or a thermoset polymer. It is usually used to
create a hard finish that is tougher than conventional paint.

i) Powder Coating process standard as per ASTM D 7802-12

ii) Standard guide testing coating powder as per ASTM D 3451-06
iii) Salt spray testing ( 1000 hour) as per ASTM B 117

COMPRESSION SPRINGS
ELCEN Spring warehouses are largest inventory of high-grade, straight, cylindrically-shaped compression springs in
the world. All the springs found in this section of the catalog are fabricated from round wire. Rectangular wire is
sometimes employed to reduce the solid (totally compressed) height or increase the space efficiency of the design.
ELCEN Spring’s die springs are made from rectangular wire for this reason.

SELECTION A COMPRESSION SPRING:

i) Next, find the length or rate (strength) you require. These, too, are normally in increasing order.
ii) Spring rate is the load (pounds) it takes to deflect (compress) the spring one theoretical inch, i.e., if the
rate = 40 lbs./in., it would take 10 pounds to deflect it 1/4 inch, or 80 pounds for 2 inches, etc..
iii) If the length or rate is not known but the installed working length (W.L.) is, then select a spring — say
30% longer — than the W.L...
iv) You must know the load at the W.L... Just subtract the W.L. from the spring’s selected free length and
multiply by its rate to obtain the load to compare with your required value.
v) If the load required is not obtained, select a new candidate with either an increase or decrease in rate
(strength) or free length.
vi) Be certain that the tabulated solid length (completely compressed) for your candidate spring indicates
enough room for deflection and, also, that the deflection is not significantly greater than the tabulated
“Maximum Suggested” for stress reasons.

Note: If the spring needed for your application cannot be found in our catalog inventory, we can fabricate it for you.
Often, there is no cost increase for this service as we have low quantity requirements.

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 SPRING MANUFACTURING PROCESS

DESIGN INFORMATION:
The basic compression rate and wire stress for a compression spring can be estimated with the following:

Note: One should not employ the curvature (k) correction stress in an expression solving for deflection. Use the
uncorrected stress only or errors will occur. The uncorrected stress can be used for static applications.

Large wire and bar stock sizes also require an empirically derived reduction in the standard rate calculation of up to
9%.For these reasons, refinements in large spring design should be left to the experienced spring designer

SELECTING A COMPRESSION SPRING:

Where:
D = Mean diameter, (O.D. - d) inches
d = Wire diameter, inches
G = Modulus (spring steel = 11.5x106, stainless = 10x106), p.s.i.
K = Stress correction factor
N = Number of total coils
n = Number of active coils
P = Applied load, pounds
p = Pitch, distance between centerlines of wires of adjoining coils
R = Spring rate, pounds per inch (lbs. /in.)
S = Wire stress, psi
= Deflection, inches
= 3.14

The suggested maximum allowable spring-wire stress values can be derived from the “Minimum Tensile Strength”
(MTS) tables found in the “Material Properties” section of this catalog. The MTS values vary with the spring-wire
diameter. Further, 30 to 45 percent of the MTS value, depending on the material type, is used as a corrected stress
target to produce a long fatigue life. The table, “Properties of Common Spring Materials”, found also in the “Material
Properties” section of this catalog, indicates the appropriate percentage value of the MTS to use for a given spring
material.
SPRING TYPE OF ENDS
CHARACTERISTICS OPEN & CLOSED &
OPEN CLOSED
GROUND GROUND
SOILD LENGTH D (N+1) dxN d (N+1) dxN
ACTIVE COIL (n) N N-1 N-2 N-2
TOTAL COIL (N) N N n+2 n+2
FREE LENGTH (L) (p x n) +d pxN (p x n) + 3d (p x n) + 2d

WAHL CURVATURE STRESS CORRECTION

SPRING INDEX

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