Wave Spring Technology Explained
High-Efficiency Elastic Component Solutions in Precision Machinery
Fundamental Principles
Wave springs are mechanical components that achieve elastic deformation through periodic wave structures in metal strips, based on bending deformation theory in material mechanics:
- Deformation Mechanism: Axial loads cause elastic bending deformation of wave peaks and valleys, with deformation Δh proportional to load F
- Energy Storage: Energy density of 0.5-5J/cm³, 20-40% higher than traditional coil springs
- Contact Characteristics: Multiple wave peaks contact simultaneously for even load distribution (contact points N=2πR/p, R: mean radius, p: wave pitch)
- Mechanical Model: F = (Ebt³Δh)/(Kp³n), where E is elastic modulus, b is strip width, t is thickness, K is shape factor, n is effective wave count
Key Characteristics
Structural Features
- Space Efficiency: Axial height only 30-50% of coil springs
- Weight Advantage: 20-35% lighter at same load capacity
- Easy Installation: Can be installed without pre-compression
Mechanical Properties
- Stiffness Range: 0.1-500N/mm
- Deformation Capacity: Maximum compression 50-70% of free height
- Fatigue Life: 10⁵-10⁷ cycles (material dependent)
Functional Features
- Preload Capability: Provides 0.5-50N initial preload
- Damping Characteristics: Additional damping from inter-wave friction
- Guidance Function: Large diameter ratio provides natural guidance
Classification System
By Wave Structure
- Sinusoidal Wave: Standard sine curve, linear stiffness
- Trapezoidal Wave: 15-30% higher load capacity
- Staggered Wave: 90° phase shift between adjacent waves, reduced friction
By Layer Count
- Single Layer: 0.1-1mm thickness, simple applications
- Multi-Layer: 2-5 stacked layers, multiplied load capacity
- Composite: Combination of different material layers
By End Type
- Open Ends: Easy installation, ends not closed
- Closed Ends: Welded ends, even force distribution
- Flanged: With mounting positioning structure
Design Parameters
| Parameter | Symbol | Range | Design Impact |
|---|---|---|---|
| Wave Height | h | 0.2-10mm | Determines maximum deformation |
| Wave Pitch | p | 2-50mm | Affects stiffness and wave count |
| Thickness | t | 0.1-3mm | Determines load capacity |
| Strip Width | b | 2-100mm | Affects lateral stability |
| Wave Count | n | 3-30 | Determines total deformation capacity |
Stiffness Calculation: k = (Ebt³)/(1.5p³n), where E is elastic modulus (GPa)
Maximum Stress Verification: σmax = (3Fph)/(bt²) ≤ [σ]
Material Properties
| Material | Standard | E(GPa) | [σ](MPa) | Features |
|---|---|---|---|---|
| 304 Stainless Steel | ASTM A666 | 193 | 600 | Corrosion resistant |
| 17-7PH | AMS 5528 | 200 | 1200 | High strength |
| Inconel 718 | AMS 5596 | 210 | 1400 | High temperature resistant |
| Beryllium Copper | ASTM B194 | 130 | 900 | Electrical conductivity |
Material Selection Principle: Consider working temperature, corrosive environment, electrical requirements, cost, etc.
Manufacturing Process
- Material Preparation: Strip straightening (straightness ≤0.02mm/m)
- Wave Forming:
- Stamping: 200-500pcs/min, precision ±0.02mm
- Roll Forming: For continuous production, 10-30m/min
- Heat Treatment:
- Annealing: 400-500°C for stress relief
- Quenching+Tempering: For high carbon steel strength
- Surface Treatment:
- Electroplating: Zinc/Nickel/Chromium, 5-25μm thickness
- Passivation: Improves stainless steel corrosion resistance
- Testing:
- Dimensional Inspection: Projector/CMM measurement
- Performance Testing: Load-deformation curve testing
Application Scenarios
Precision Machinery
- Bearing Preload: 0.01-0.1mm axial clearance
- Valve Sealing: 10-100N contact pressure
Automotive Industry
- Transmission: Axial positioning, vibration resistance
- Clutch: Pressure equalization, wear compensation
Electronic Equipment
- Connectors: 0.5-5N contact retention force
- Heat Sinks: Uniform pressure distribution