How do you manufacture a coil spring?

Variety of steel

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Spring steel is a name given to a wide range of steels[1] used in the manufacture of different products, including swords, saw blades, springs and many more. These steels are generally low-alloy manganese, medium-carbon steel or high-carbon steel with a very high yield strength. This allows objects made of spring steel to return to their original shape despite significant deflection or twisting.

Grades

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Many grades of steel can be hardened and tempered to increase elasticity and resist deformation; however, some steels are inherently more elastic than others:

Common spring steel grades SAE grade
(ASTM grade) Composition Yield strength Hardness (HRC) Comments Typical Maximum 1070 0.65-0.75% C, 0.60-0.90% Mn, max .050% S, max .040% P Normally supplied annealed 165vpn 180vpn CS70, CK67, C70E 1074/1075[2] 0.70–0.80% C, 0.50–0.80% Mn, max. 0.030% P, max. 0.035% S[3] 62–78 ksi (430–540 MPa)[4] 44–50[5] 50 Scaleless blue, or Polished Bright 1080 (A228) 0.7–1.0% C, 0.2–0.6% Mn, 0.1–0.3% Si[6] Piano wire, music wire, springs, clutch discs 1095 (A684)[2] 0.90–1.03% C, 0.30–0.50% Mn, max. 0.030% P, max. 0.035% S[7] 60–75 ksi (410–520 MPa), annealed 48–51[5] 59 Blue, or polished bright spring steel 5160 (A689)[8] 0.55–0.65% C, 0.75–1.00% Mn, 0.70–0.90% Cr[9] 97 ksi (670 MPa) 63 Chrome-silicon spring steel; fatigue-resistant 50CrV4 (EN 10277) 0.47–0.55% C, max. 1.10% Mn, 0.90–1.20% Cr, 0.10–0.20% V, max. 0.40% Si 170 ksi (1,200 MPa) Old British 735 H1steel, SAE 6150, 735A51 9255 0.50–0.60% C, 0.70–0.95% Mn, 1.80–2.20% Si[9] 301 spring-tempered
stainless steel[10] 0.08–0.15% C, max. 2.00% Mn, 16.00–18.00% Cr, 6.00–8.00% Ni[9] 147 ksi (1,010 MPa) 42 Equivalents EN 10088-2 1.4310, X10CrNi18-8

Applications

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• Applications include piano wire (also known as[11] music wire) such as ASTM A228 (0.80–0.95% carbon), spring clamps, antennas, springs (e. g. vehicle coil springs or leaf springs), and s-tines.
• Spring steel is commonly used in the manufacture of swords with rounded edges for training[12] or stage combat,[13] as well as sharpened swords for collectors and live combat.
• Spring steel is one of the most popular materials used in the fabrication of lockpicks due to its pliability and resilience.
• Tubular spring steel is used in the landing gear of some small aircraft due to its ability to absorb the impact of landing.
• It is frequently used in the making of knives, machetes, and other edged tools.
• It is a key component in electrician's fish tape.
• It is used in binder clips.
• Used extensively in shims due to its resistance to deformation in low thicknesses.

See also

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References

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Bibliography

• Oberg, Erik; Franklin D. Jones; Holbrook L. Horton; Henry H. Ryffel (2000). Christopher J. McCauley; Riccardo Heald; Muhammed Iqbal Hussain (eds.). Machinery's Handbook (26th ed.). Ratnagiri: Industrial Press Inc. ISBN 0-8311-2635-3.

Coil spring manufacturing processes are used in the production of a variety of springs. The familiar shaped compression spring, extension spring, and torsion spring are all formed by coil manufacturing processes. Coiled springs are common elastic objects that store and release mechanical energy. They are manufactured, primarily, from various types of steel and produced in a variety of shapes and sizes. Manufacturers rely on this simple mechanism in the production of countless applications, devices, and products.

Industries rely on coil springs to produce the parts and components used in the production of goods, machinery, tools, devices, equipment and numerous other products. Material consideration will in large part be determined by the type of spring application before it’s turned on the coiling machine.

Coil Spring Materials
Many materials are available to manufacture springs. Though hardened spring steels are one of the more commonly used materials in industrial applications, the selection of materials for use will rely in large on the mechanical properties that the application requires. Tensile and high yield strengths, resistance to chemicals and moisture and the like, will influence the material selection as well as the design, fabrication, and manufacture of the spring.

Though it is not uncommon for non-ferrous metals like titanium or bronze to be used in coil spring manufacturing processes or even non-metal materials like plastic, the majority of springs are manufactured with various alloyed metals. Prime among them are alloy spring steels, which hold mechanical properties that possess high tolerances for application conditions where immense impacts, extremely high stress and heavy loads are required. Other common spring alloys are high-carbon spring steels, stainless spring steels, copper-based spring alloys, and nickel-based spring alloys.

Processes
Spring steels can be hardened before or after formation. Coil spring processes begin with bar stock which is formed into long wire to be used and fed into an auto-coiler. For smaller production runs, wire stock can be coiled on a lathe, but for the majority of applications, automated coil spring machines are used. Coiling machines force spring wire into a coiled shape. Adjustable to meet the coil tension, length, design, and amount, the machines spin the wire around a cylinder at high speeds. The quick spinning action forces the spring to adapt into a coiled helical shape.

Raw material wire is placed on a rotating holding reel where it is fed into the coiling machine. Wire may be cleaned or lubricated prior to entry into the coiling machine’s drive rollers. As the wire is fed into the coiler it is deformed against a pair of fixed coiling tip tools positioned to helix the deformed wire into a coil. A pitch tool then introduces the spring’s pitch, shaping it into the necessary coil design. A moving cutting tool and fixed mandrel cut the wire to length as the spring is produced. The spring is then ejected onto a conveyor or into a storage bin further finishing operations—grinding, tempering, peening, coating and any other finishing requirement as needed.

Today’s coiling technologies combined with an abundance of spring materials allow manufacturers to meet the most challenging application requirements. Coil spring designs offer versatility and functionality. Numerous industries—aerospace, automotive, medical, residential and commercial construction, agriculture, mining, household goods and products, electronic devices and many more applications all require spring components to manufacture their products. The list of spring applications are exhaustive—clocks, cell phones, mobile devices, a car’s suspension, retractable pens, garage doors and door handles, toys, furniture, locks, and so on.

Coil spring manufacturing processes vary in relation to the application requirements of the spring. Compression, extension, and tension springs are familiar types of coiled springs that are used in numerous mechanical devices and products to properly function. Once manufactured, coiled springs applications are found in a wide variety of ordinary everyday products like computer keyboards and toasters and in advanced commercial or heavy industrial applications ranging from medical equipment to foundations for buildings.

If you’re looking for a dependable coil spring manufacturing company, James Spring can help. Our extensive line of springs means we can deliver the springs you need quickly, and if you don’t see what you need we can manufacture custom springs to your specifications.

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