Compression Spring
What is a Compression Spring ?
“Compression Spring” is a type of mechanical spring that stores potential energy when compressed and exerts a force to return to its original shape when the compressive load is removed. It typically has a coiled shape and is designed to resist forces that try to shorten or compress it along its axis.
● Compression Spring design :
Compression Springs can be designed with various end types and shapes, each affecting their performance and application. Here’s a brief overview of the different designs :
1. Open ends : The ends of this deign of Compression Springs are not closed or ground flat. Open ends Compression Spring can be used where end alignment and consistent load distribution are less critical. Open ends are often simpler and less expensive to manufacture but might not be as stable in certain applications.
2. Closed ends : The ends of this design of Compression Springs are closed by forming the wire into a rounded or flattened shape. Closed ends Compression Spring can help improve load distribution and reduce the risk of the coil ends becoming misaligned. This design is often used in applications where the Spring needs to be more stable and aligned.
3. Pigtail ends : The ends of this design of Compression Springs are coiled in a pigtail shape, usually with a small curl or hook. Pigtail ends Compression Springs are often used in applications where the Spring needs to be attached or connected to another component. This design helps in easier attachment and alignment.
4. Conical ends : The ends of this design of Compression Springs are tapered, creating a conical shape. Conical ends Compression Springs are designed to guide the Spring into a more controlled alignment when compressed. They can help reduce friction and improve the performance of the Spring, especially in applications where space is constrained or precise alignment is necessary.
● Compression Spring specification :
A Compression Spring is designed to resist compression and return to its original length when the applied force is removed. The specifications of a compression spring vary depending on its application, material, and design. Here are the key specifications to consider :
1. Material : Common materials like Stainless steel, music wire, phosphor bronze, titanium, etc.
2. Wire Diameter (d) : The thickness of the wire used to make the spring. Typical range – 0.1 mm to 10 mm.
3. Outer Diameter (D) : The overall diameter of the spring including the wire. Depends on the application requirements.
4. Inner Diameter (ID) : The diameter of the hole through the center of the spring.
5. Spring Length (L) : The total length of the spring when uncompressed. Can be fixed or adjustable depending on the design.
6. Free Length (L0) : The length of the spring when no load is applied.
7. Compressed Length (Lc) : The minimum length the spring can be compressed to without damage.
8. Load capacity : Maximum force the spring can handle without permanent deformation.
9. Number of Active Coils (n) : The coils that actually flex and carry the load. Non-active coils (at the ends) are used for manufacturing stability.
10. End type : Closed and Ground: Ends are flat and ground for stability. Open Ends: For specific applications like reducing friction.
11. Surface finish : Options include plain, polished, coated, or plated for corrosion resistance.
12. Tolerance : Dimensional tolerances for precise fitting.
13. Operating temperature range : Important for materials affected by temperature changes.
● Compression Spring types :
1. Helical Coil Compression Spring : This type of Compression Springs are coiled in a helical shape and are designed to resist compressive forces. When a load is applied, the coils compress and store energy. It is used in various applications, such as in automotive suspensions, electronic devices, and machinery, where the Spring needs to absorb shock or provide a restoring force.
2. Tension Spring : This type of Compression Springs are also known as Extension Springs, these are designed to resist stretching forces. They are wound in a helical shape but work by elongating rather than compressing. They are commonly used in applications like door closures, trampolines, and other mechanisms where pulling forces are involved.
3. Torsion Spring : This type of Compression Springs are designed to resist rotational forces or twisting. They are typically wound in a spiral shape and work by turning around their axis. It is often used in applications where rotational force is required, such as in clothespins, garage doors, and various types of machinery.
● Compression Spring application :
Compression Springs are versatile components used in a wide range of applications due to their ability to store and release mechanical energy. Here are some common applications :
1. Automotive Suspension : Compression Springs are used in automotive suspension system to absorb shocks and vibrations from the road, providing a smoother ride and improving vehicle handling. They help to maintain consistent contact between the tires and the road, reducing wear and tear on other suspension components.
2. Railway Bogie & Wagon : Compression Springs are used in Railway bogies and wagons, used to support the load and absorb the impact from uneven tracks, ensuring a smoother ride and reducing wear on the Rail infrastructure. They help to maintain stability and comfort for passengers and cargo while also improving the durability of Rail vehicles.
3. Machinery : Compression Springs are used in Crushers, Vibrators, Screening machines, Valves, Actuators, Isolators, Elevators.
Compression Spring manufacturers :
● We are Compression Spring manufacturers up to the following capacity :
1. Wire Dia. – upto 70 mm.
2. Outer Dia. – upto 500 mm.
3. Free Height – upto 1000 mm.
4. Total Coils – As per user’s requirement.
5. Load Capacity – upto 40 Tons. (per pc.)
● Raw-material grades used in Compression Spring manufacturing :
1. BS:970
2. EN-42
3.BS:970
4. EN-45
5. BS:970 EN-47
6. 50Cr.V4
7. 50Cr.4V2
8. 51Cr.V4
9. 50Cr.MoV4
10. 50Si7
11. 55Si7
12. 60Si7
13. SUP-9
14. SUP-9A
15. SAE-5160
16. IS:4454 Part-1 Grade-2
17. IS:4454 Part-1 Grade-2D
18. Stainless Steel
19. Others similar foreign grades JIS, ASTM etc.
● Painting and Coating used in Compression Spring manufacturing :
1. Synthetic Enamel Paint
2. Powder Coating
3. Phosphate
4. Zinc Coating
etc.
● Compression Spring manufacturing process :
1. Raw material Dimension Checking
2. Raw material Chemical Testing
3. Centre Less Grinding
4. Both End Forging
5. Bar Heating in Furnace at approx. 950º C
6. Coiling on Coiling Pitching Machine
7. Oil Quenching for Hardening
8. Tempering in Furnace at approx. 450º C
9. Scragging Test
10. Height Checking
11. End Grinding
12. Dimension Checking
13. Load Testing
14. Shot Peening
15. Surface Oiling / Painting / Coating
16. Packing
17. Delivery
● Why are we the top Compression Spring Manufacturers & Exporters ?
1. Our 40 years experience : With four decades of expertise in the industry, we have honed our skills and knowledge to deliver superior Compression Springs. Our extensive experience ensures that we understand the nuances of quality and performance like no other.
2. Advanced quality control system : We utilize state-of-the-art control systems to monitor and maintain the highest standards of production. Our technology ensures precision and consistency in every Spring we manufacture. We are also ISO 9001:2015 certified.
3. Competitive pricing : We offer the most competitive prices in the market without compromising on quality. Our efficient manufacturing processes and cost-effective solutions enable us to provide the best value for your investment.
4. Global customer satisfaction : Our commitment to quality and service has earned us the trust of buyers worldwide. We take pride in our strong reputation for reliability and excellence in the global market.
5. Guaranteed performance : We stand behind our products with a guarantee of performance. Our rigorous testing and quality assurance processes ensure that every Spring meets the highest standards of durability and functionality.