Obviously, the choice of available types of surface treatments is almost endless, therefore we think it sufficient to discuss only those treatments that currently are most commonly applied to disc springs. However, with consideration to &#;plating&#; treatments, it is absolutely essential to bear in mind the following:-
For more information, please visit HEGONG SPRING.
During the process of electroplating, hydrogen gas may be absorbed through the surfaces of the disc spring, which in turn may lead to the spring becoming brittle. Whilst it is possible that a subsequent heat treatment, referred to as de-embrittle may relieve this condition, our experience has shown this to be unreliable.
A zinc phosphate coating usually with subsequent oil or wax treatment. This treatment is widely offered as &#;standard&#; on most stock-range carbon steel disc springs. The protection offered is sufficient to prevent corrosion throughout storage and normal transit conditions. It is adequate also for those applications where the disc springs are not directly exposed to the elements. However, where the application involves a more hostile environment, i.e. disc springs open to weather or marine conditions, chemical or acid laden atmosphere, etc; then a superior treatment or material must be considered.
This is a method of depositing substantial thicknesses of zinc on the surfaces of disc springs without the risk of &#;hydrogen embrittlement&#; associated with normal electro-plating. The zinc is impacted onto the surfaces by way of tumbling the disc springs in a rotating barrel, together with glass beads, metal powder, and promoting chemicals. In addition to removing the risk of embrittlement, the &#;peening&#; aspect of this process is beneficial in terms of some stress relieving of the components. There are two forms of subsequent passivation treatment:-
As is the case with mechanical plating processes, the risk of hydrogen embrittlement is avoided with this method of chemically depositing a nickel coating. However, compared with other treatments discussed here, this process is relatively costly, but the high degree of corrosion resistance and smooth &#;satin-like&#; finish often justify the extra expense.
The sherardizing process again uses zinc, this time in the form of zinc dust mixed with an inert filler which, together with the parts to be coated, is placed in a sealed container. The container is placed in a special furnace and rotated at a temperature which is sufficient to &#;fuse&#; the coating but without risk of affecting the spring properties of the components. Coating thicknesses from 10 micro metres to 50 micro metres are possible, which makes for a wide range of protective coatings.
This process involves dipping the components in an organic resin and zinc mixture, the surplus is removed by spinning, and the bonding of the coating is completed at oven temperatures which have no effect on the metallurgical or heat treatment properties of the components. Salt-spray corrosion resistance tests on this coating can result in a performance equivalent to that obtained with electroless nickel plating.
a. Thickness (t): The measurement of the disc spring&#;s thickness, usually uniform throughout its circumference. b. Outer Diameter (Do): The outermost edge-to-edge distance of the disc spring. c. Inner Diameter (Di): The innermost edge-to-edge distance of the disc spring. d. Mean Diameter (Dm): The average diameter, calculated as (Do + Di) / 2. e. Deflection (δ): The change in height or deformation of the disc spring when subjected to an external load. f. Spring Rate (k): The ratio of the change in load to the corresponding deflection. It determines the stiffness of the disc spring.
Before diving into the calculations, let&#;s familiarize ourselves with the essential terminology associated with disc springs:
Disc springs, also known as Belleville washers, are a versatile type of spring commonly used in various mechanical applications. These conically shaped springs can provide high load capacities and deflection while occupying minimal space. Understanding how to calculate disc springs is crucial to ensure their optimal performance within a specific design. In this blog, we will explore the fundamental principles behind disc spring calculations, enabling you to determine the necessary dimensions and characteristics for your application.
Disc Spring Calculator Step 1: Determine the Required Load and Deflection: Identify the maximum load (F) that the disc spring needs to support and the desired deflection (δ) under that load. These values will form the basis for further calculations.
If you want to learn more, please visit our website disc spring company.
Step 2: Determine the Material Properties: Disc springs are typically made from various materials such as steel, stainless steel, or alloys. Obtain the relevant material properties, including the Young&#;s modulus (E) and the Poisson&#;s ratio (ν). These values describe the material&#;s elasticity and its ability to resist deformation.
Step 3: Calculate the Spring Rate (k): The spring rate represents the relationship between the load and deflection and is determined using Hooke&#;s Law. The formula for calculating the spring rate is:
k = F / δ
Disc Spring Calculator Step 4: Determine the Disc Spring&#;s Geometry: To calculate the geometry of the disc spring, consider the following factors:
a. Outer Diameter (Do): The outer diameter is typically determined based on the available space in the application. It should be large enough to provide adequate stability and prevent buckling under load.
b. Inner Diameter (Di): The inner diameter is generally determined using the mean diameter (Dm) and the required deflection (δ). The formula for calculating Di is:
Di = Dm &#; (2 × δ)
c. Thickness (t): The thickness of the disc spring influences its load capacity and deflection characteristics. It is often chosen based on empirical data or engineering guidelines for a specific application.
Step 5: Verify Stress and Fatigue Limits: After using the disc spring calculator to find the dimensions, it is essential to ensure that the disc spring operates within the material&#;s stress and fatigue limits. Check the maximum allowable stress and compare it with the calculated stress using established formulas.
Calculating disc springs requires a thorough understanding of their terminology, material properties, and the principles behind their design. By following the steps outlined in this guide, you can determine the appropriate dimensions and characteristics necessary to achieve optimal performance in your specific application. With a disc spring/Belleville washer calculator, remember to consider factors such as load, deflection, material properties, and stress limits to ensure a safe and efficient design.
Identifying high-quality disc springs requires careful consideration of several factors, including material composition, manufacturing process, design, and testing. By selecting high-quality disc springs from American Belleville, you can ensure the safety, reliability, and longevity of your mechanical applications. Choose American Belleville, where we adhere to strict quality control standards and provide excellent customer service and support. Ask for disc spring quote here!
Contact us to discuss your requirements of belleville springs limited. Our experienced sales team can help you identify the options that best suit your needs.