Selecting the Right Wave Spring End-Type - Eureka Magazine

Rotor Clip engineers the right part, for the right application, whether its standard or custom. Providing Application Driven Solutions&#;&#;, we have the extensive experience designing products into applications across nearly every industry. When specifying wave springs, end-type configuration is just one of the many features that can be modified to suit your individual application requirements:

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Multi-Turn Wave Springs End Types

Plain Ends

Plain ends are the standard and generally most commonly spec&#;d end-type for multi-turn wave springs, in which the end stops at the next peak.

Shim Ends

Shim-ends have two extra flat turns/layers of material to support even loading on the top and bottom surface. Although, wave springs typically sit flat, in certain cases a shim-ended part would be beneficial if there&#;s an uneven surface that the spring is sitting upon. The shim end bridges unevenness in the application, such as when waves can potentially fall into a trough, a hole or slot.

Shim ends can occasionally have alternative design functions that allow them to positively impact application performance. On occasions, multiple shims have even been added to help affix the spring to the mating component by winding the ends into a groove.

Single-Turn Wave Springs End Types

Gap

These types of ends have a physical gap, the distance of the gap can be controlled as there may be components that need to clear it. Rotor Clip have even patented a type of single-turn wave spring with flat ends. These flat-ends protect bearings by eliminating sharp, damaging corners from the spring ends, instead flattening them so they rest smoothly against the mating assembly. It&#;s another reason why designers are increasingly discovering flat wire wave springs as an attractive option for spring-loaded applications.

Overlap

An overlap single-turn wave spring has ends that come together with one end &#;overlapping&#; the other. The result of this end-type offers no digging while mating with the surface and eliminates the likelihood of parts being tangled in a bulk packaging arrangement.

Specialty End-types

Floating Ends

Typically, with multi-turn wave springs the end comes down and rests on a peak of the turn below it. When the wave spring is compressed, that end is sitting on the mating surface, which could be an area that can allow scratching. This is especially the case if the wire thickness is very thick and promotes scratching in that concentrated area. For floating ends the end is cut back so it is not resting on the peak. Like the name implies, the end is floating and when compressed the end curls down into the part itself. This type of end configuration greatly mitigates any ability to scratch the mating surface.

Contact us to discuss your requirements of wavesprings. Our experienced sales team can help you identify the options that best suit your needs.

Need assistance on your selecting the right wave spring and end-type contact an engineer today.

Although wave-spring applications abound, there are basic rules to define spring requirements and determine whether a design can use a stock or standard spring or needs a special wave spring.

The first and most important consideration is the load the application will apply to the wave spring. Required load is defined as the amount of axial force the spring must produce when installed at its work height.

Read the related article: What are Wave Springs for Motion Designs?

Some applications require multiple working heights, so that there are critical loads at two or more operating heights. Often minimum and maximum loads are satisfactory solutions, particularly where tolerance stack-ups are inherent in the application.

In any case, remember to consider whether the spring will be subject to high temperature, dynamic loading (fatigue), corrosive media or other unusual operating conditions. Solutions to various environmental conditions typically call for special materials that withstand operating stresses.

Wave springs install into working cavities. These usually consist of a bore (in which the spring operates) or a shaft that the spring clears. The spring stays positioned by piloting in the bore or on the shaft. The distance between the loading surfaces defines the axial working cavity or the spring&#;s work height. This is where the spring&#;s material cross-section is important to the overall design.

Four critical factors dictate the most suitable wave spring for a given application: Physical design constraints (including bore geometry, shaft, ID, OD and so on), the application load, the working height at which the design applies load, and the spring material that will best withstand the application environment.  (More after the jump.)

If a spring is designed for a static application, make sure that the percent stress at working height is less than 100%. Springs will take a &#;set&#; or length loss in operation due to the high stress condition of the spring if subjected to a higher stress. If a spring is designed for a dynamic application, make sure that the percent stress at working height is less than 80%. Springs will take a set if put under higher stress. If the work height per turn is less than twice the wire thickness, the spring operates in a non-linear range and actual loads may exceed calculated loads.

&#; Number of turns must be between 2 and 20

&#; Number of waves per turn (N) must be in half-turn increments

&#; Minimum radial wall = (3 times the wire thickness)

&#; Maximum radial wall = (10 times the wire thickness)

One caveat: It&#;s best to avoid situations that compress a wave spring to solid. In addition, account for the expansion of the OD as well as the OD tolerance when designing a spring to fit in a bore or over a shaft.

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