Coil Spring
Coil Spring is manufactured from round and rectangular flat bar or wire. Coil spring is treated as a safety component. It is forming by coiling in coiling machine in round ring shape maintaining the inside diameter continuously as per requirement up to required length. Coil Spring is manufactured in the form of gap between two coils is called Compression Spring and also other type in solid for without gap and forming pulling hook at both end called Tension Spring. It is main used to absorbing load, jerk, shock, vibration etc.
Coil Spring manufacturers :
We are Coil Spring manufacturers upto most heavy duty for Railway Bogie & Wagon, Automotive suspension, Heavy industrial machinery and other engineering appliances. Coil Spring manufacturing procedure, Raw-material Grades used, our manufacturing capacity and other useful details are stated below :
● Our manufacturing capacity : Basically we are manufacturers of most heavy duty Coil Spring with highest used Bar Dia., O.D. and Length. Find here the actual range of the same :-
Wire Dia. – upto 70 mm.
Outer Dia. – upto 500 mm.
Free Height – upto 1000 mm.
Total Coils – As per user’s requirement.
Load Capacity – upto 40 Tons. (per pc.)
● Raw-material grades used in Coil 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 Coil Spring manufacturing :
After completion of Coil Spring manufacturing and it’s quality checking, Painting or Coaating is mandatory operation to keep it rust free for long time. Following things are used :- Synthetic Enamel Paint / Powder Coating / Phosphate / Zinc Coating etc.
● Coil Spring manufacturing process / Flow chart :
Raw material procurement > Raw material dimension checking > Raw material Chemical testing > Centre Less grinding > Both ends 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 > Ends grinding > Dimension checking > Load testing > Shot peening > Surface oiling / painting / coating > Packing > Delivery.
Coil Spring specification :
The specifications of a Coil Spring can vary depending on its application, design, and the type of load it’s meant to handle. Here are the key specifications to consider :
● Raw-Material : High-carbon steel, stainless steel, phosphor bronze, or composite materials. The material affects the Coil Spring’s strength, corrosion resistance, and durability.
● Wire diameter : The thickness of the wire used to make the Coil Spring. Thicker wires result in stronger springs, capable of handling heavier loads.
● Outer diameter (OD) : The total diameter of the Coil Spring, including the wire thickness. Affects the spring’s ability to fit within certain spaces.
● Inner diameter (ID) : The diameter inside the coil. Determines the clearance around the Coil Spring for movement or mounting.
● Free length : The length of the Coil Spring when it’s not under any load (unstressed). Helps in calculating the spring’s compression or extension range.
● Spring rate (Stiffness) : The amount of force required to compress or extend the Coil Spring by a certain distance (measured in N/mm or lb/in).
● Number of active coils : The coils that are free to deform under load. More coils generally mean a more flexible Coil Spring.
● End type : Closed and ground, open, or ground and ground. Determines how the Coil Spring is mounted or attached.
● Load capacity : The maximum load the Coil Spring can handle without permanent deformation. Safety and performance in applications like automotive suspensions or industrial machinery.
● Fatigue life : The number of load cycles the Coil Spring can withstand before failure. Repeated stress applications, like in vehicles or machinery.
Coil Spring design :
There are various Coil Spring design are found as per their applicable and load bearing capacity. Here are some description how actually Coil Springs are designed :
● Closed ends : Both ends of this design of Coil Spring is ground flat and parallel to each other. This type of design allows the Spring to stand upright and distribute the load evenly.
● Open ends : Both ends of this design of Coil Spring is not modified; they remain in their natural helical shape.
● Pigtail ends : Both ends of this design of Coil Spring is coiled down to a smaller diameter, resembling a pigtail. This design allows the Spring to fit into a socket or seat.
Coil Spring types :
● Compression type Coil Spring : This type of Spring is designed to compress when a load is applied and return to its original shape when the load is removed.
● Extension type Coil Spring : This type of Spring is tightly coiled coils that produce tension when a load or force is applied to their ends, forcing them to lengthen. They are also referred to as Extension or Expansion Spring.
● Torsion type Coil Spring : This type of Spring is to operate with a twisting or rotational force. They store and release angular energy or apply torque.
Coil Spring uses :
Coil Spring is used for various engineering items from Railway Bogie to Pen as per their application and demands. Here are some description against their application :
● Automobile sector : It is a crucial component in Automobile Suspension systems. It is providing a smoother ride by mitigating the impact of road irregularities. Coil Spring help maintain vehicle stability, support the weight of the vehicle and ensure proper alignment of wheels for improved handling and safety.
● Railway Bogie & Wagon : In Railway Bogies, it’s serve as primary suspension elements. They are used to support the weight of the Train and passengers while absorbing shocks and vibrations from the tracks. This ensures a smoother and safer ride, reducing wear and tear on both the Train and the tracks and enhancing passenger comfort.
● Machinery : These are widely used in various types of machinery for different purposes like : Crusher, Vibrator, Screening Machine, Valve, Actuator, Vibration Isolator, Elevator.