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Design of Flat Strip Springs
Flat strip parts can be very complicated in their form. Inside many productssuch as mobile phones, computers and medical equipment there are a widevariety of shapes all formed from a simple coil or sheet of flat material. Manyflat strip parts are designed to perform more than one mechanical functionthereby reducing the number of components.
The number of different variations of strip parts is virtually infinite. The onlyobstacle to strip design is the imagination of the designer, and the practicallimitations of manufacture.
The simplest strip spring is probably a leaf spring operating as a cantilever,with simple-to-calculate loads and deflections. Many strip parts are, ineffect, made up of a number of sections operating as cantilevers.
Strip springs are not limited to just simple cantilevers. There are spring
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Navigator Design ContestDesign a new packaging for the Navigator Students ream.
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washers such as disc springs which are able to provide a high spring ratesover a small movement, and constant force springs, used in seat beltretention, devices that are able to provide an almost constant force over alarge deflection.
Due to the wide variety of strip parts it is difficult to discuss them in anygreat detail, also the complexities of many of the equations fall outside thebounds of this Guide. When designing a strip component it is good practiceto ask the advice of a spring designer.
The simplest part to produce is the most economical to produce in smallquantities. But even complex parts, when produced on production tooling,can also be produced at low cost.
Good Design PracticeMaterial hardness is very important when designing a flat strip component.The hardness of the material affects the minimum bend radius. Below is atable of ‘minimum bend radius’ for a number of materials.
t = thickness.Note: The direction of rolling is along the strip.
The bend radius refers to the inside bend radius.Going below the above figures would prove to be difficult, and may lead tocracking of the material on the outside bend radius of the material.
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As can be seen, the orientation of the bend on the strip affects the minimumbend radius. If a component requires bends perpendicular to each other withradii close the minimum bend radius, it is good design practice to orientatethe component by 45º relative to the rolling direction.
Avoid punched holes or slots too close to the edge of the component oranother hole.This can cause the hole to deform the edge or the other hole.
Avoid punched holes or slots on a bend or too close to a bend. This maycause the hole to stretch and affect the smoothness of the bend.
When forming a bend in a spring material it is important to remember ‘SpringBack’.Depending on the hardness of the material, all spring materials will exhibitsome form of ‘Spring Back’. For instance, when forming a bend of 90º, thematerial will return to an angle greater than 90º. The spring back will alsoaffect the radius of the bend. This must be taken into account whendesigning the tooling and consequently when designing the part.
It is best to consult the spring designer/manufacturer when applyingtolerances to a spring component. Standard drawing tolerances can increasethe cost of the component.
Article written by David Banks-Fear and published on MDF by kindpermission of Southern Springs & Pressings Limited.
David Banks-Fear is a Mechanical Design Forum Group member. He is atechnical author and consultant design engineer with nearly 40 years ofexperience. He and his design team are available to assist with anytechnical design issues with springs, pressings and precision engineeredparts. Email: [email protected]
1 Comment
Khadija Ouajjani - 4th Apr '14, 20:31 Reply
Once again David, I'm amazed by the rich high quality
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how do I calculate the sizeof an piston being used ina commercial Vehicle liketruck or bus. WhatPurnendu 24th Feb '15, 18:02