Conical Spring

What is a Conical Spring ?

Conical Spring definition – It is a type of Compression Spring shaped like a cone, meaning it’s coils have a gradually changing diameter. It’s designed to compress under load, like a regular Spring but with unique advantages due to its tapered shape. Conical Spring is typically made from spring steel wire, chosen based on the Spring’s application, environment and load requirements.

Conical Spring manufacturers :

● We are Conical Spring manufacturers up to the following capacity :

Wire Dia. – upto 50 mm.
Outer Dia. – upto 400 mm.
Free Height – upto 800 mm.
Total Coils – As per user’s requirement.
Load capacity – upto 30 Tons. (per pc.)

● Raw-material grades used in Conical Spring manufacturing :

BS:970 / EN-42 / BS:970 / EN-45 / BS:970 EN-47 / 50Cr.V4 / 50Cr.4V2 / 51Cr.V4 / 50Cr.MoV4 / 50Si7 / 55Si7 / 60Si7 / SUP-9 / SUP-9A / SAE-5160 / IS:4454 Part-1 Grade-2 / IS:4454 Part-1 Grade-2D / Stainless Steel / others similar foreign grades JIS, ASTM etc.

● Painting and Coating used in Conical Spring manufacturing :

Synthetic Enamel Paint / Powder Coating / Phosphate / Zinc Coating etc.

● Conical Spring manufacturing process / flow chart :

Raw material Dimension Checking > Raw material Chemical Testing > Centre Less Grinding > Both End Forging > Bar Heating in Furnace at approx. 950º C > Coiling on Coiling Pitching Machine > Oil Quenching for Hardening > Tempering in Furnace at approx. 450º C > Scrag Testing > Height Checking > End Grinding > Dimension Checking > Load Testing > Shot Peening > Surface Oiling / Painting / Coating > Packing > Delivery.

● Why we are most trusted Conical Spring manufactures ?

Our 40 years of experience
Rigorous quality control system
Competitive pricing
Worldwide customer satisfaction
Guaranteed performance

Conical Spring application / uses :

● Conical Spring used in Battery contacts (Battery holders) :

The conical shape helps maintain consistent electrical contact under varying compression levels.
Allows nesting of coils for compact storage.

● Conical Spring used in Mechanical seals (Pumps and rotating equipment) :

Used to provide consistent axial load while accommodating shaft movement.
Offers variable stiffness that can handle different pressure ranges.

● Conical Spring used in Automotive suspension systems :

Provides progressive spring rate, improving comfort and control.
Helps with space-saving around wheel assemblies.

● Conical Spring used in Aerospace components :

Lightweight and compact solutions where variable force is required.
Used in landing gear and actuating systems.

● Conical Spring used in Vibration dampening devices :

The changing diameter allows energy dissipation and flexibility in dynamic environments.
Electrical Switches and Relays.
Used to ensure a responsive return movement in compact mechanisms.

● Conical Spring used in Toys and consumer products :

For example, retractable pens and pop-up mechanisms where space is constrained.

● Conical Spring used in Consumer products :

Retractable pens – Provides smooth operation in small form factors.
Toys and pop-up mechanisms – Useful where a spring needs to fully collapse or fit into a tight space.

Conical Spring design :

Conical Spring design involves calculating the dimensions and material properties to meet specific performance requirements like load capacity, deflection, and available space.

● Key Design Parameters for a Conical Spring :

Large end diameter (D₁) – Diameter of the wider end
Small end diameter (D₂) – Diameter of the narrower end
Wire diameter (d) – Thickness of the spring wire
Free length (L) – Length of the spring when not compressed
Number of active coils (N) – Coils that actually compress under load
Spring rate (k) – Force required per unit of deflection (non-linear in conical springs)
Solid height – Length of the spring when fully compressed (can be shorter than cylindrical springs due to nesting)

● Conical Spring design consideration :

Load requirements – Determine the maximum and minimum load the spring needs to support.
Space constraints – Design to fit within the axial and radial space available.
Material selection – Based on environment temperature, corrosion, fatigue, etc.
Spring rate – Progressive (non-linear) rate increases as coils close during compression.
End style – Can be plain, squared, or ground depending on stability needs.

Conical Spring types :

Conical Springs come in several types based on their geometry, function, and end configurations.

● Regular Conical Compression Spring types :

Shape – Linear taper from large to small diameter.
Use – General-purpose, space-saving compression.
Behavior – Progressive spring rate (resistance increases as compressed).

● Nested (Fully Telescoping) Conical Spring types :

Shape – Designed so each coil fits perfectly into the next when fully compressed.
Use – Applications requiring minimum solid height (very compact when compressed).
Example – Battery holders, precision devices.

● Barrel-Shaped (Convex) Conical Spring types :

Shape – Middle diameter is wider than both ends (barrel-shaped).
Use – Enhanced lateral stability and load distribution.
Example – Automotive suspensions or applications with side forces.

● Hourglass-Shaped (Concave) Conical Spring types :

Shape – Narrowest in the middle, wider at both ends.
Use – Centered force distribution; used where buckling needs to be minimized.

● Variable Pitch Conical Spring types :

Shape – Coil spacing changes along the length.
Use – Custom load-deflection characteristics, often used in energy-absorbing designs.

● Conical Torsion Spring (Less common) types :

Function – Rotates (twists) rather than compresses.
Use – Specialized rotational applications needing compact profiles.