Springs are an essential component of many devices, from mechanical watches to cars to aerospace equipment. They are designed to store and release energy, making them an important part of many machines. At Daichi Springs, we specialize in creating high-quality springs for a variety of applications. In this blog post, we'll take a closer look at how springs are made.
How Are Springs Made?
Step 1: Material Selection
The first step in making a spring is selecting the right material. Springs can be made from a wide range of materials, including high carbon, steel, stainless steel, titanium, and even plastic. The choice of material depends on factors such as the application, the required strength and durability, and the environment in which the spring will be used.
Generally, high carbon spring materials are known to be relatively inexpensive and versatile, but do not offer much resistance to high-temperature and corrosive environments. While steel alloys like chrome silicon are accepting of high temperatures, they are still susceptible to corrosion. Alternately, stainless steel is acknowledged for being highly resistant to corrosion and having the potential to withstand high temperatures.
Step 2: Wire Forming
Once the material has been selected, the next step is to form the wire into the shape of the spring. This is done using a variety of techniques, including coiling, bending, and twisting. The wire is typically fed into a machine that automatically forms it into the desired shape.
Coiling can be done through either cold wound or hot wound coiling processes. Cold winding starts with a wire at room temperature, which is wound around a shaft. The material here has already been fully heat-treated and stress-relieved to reach peak strength. Meanwhile, hot winding is used for thicker wire or bar stock sizes over 0.500'' (12mm). The metal is heated beforehand to increase its flexibility. It is then coiled around a shaft while it is still extremely hot. After it has been coiled, it is immediately taken off of the shaft or mandrel and oil-dipped to cool and harden rapidly.
Step 3: Heat Treatment
After the wire has been formed, whether it was coiled hot or cold, stress is induced on the material. So, it needs to be heat-treated for the spring to relieve its stress and retain its memory. This allows it to bounce back under stress and improve its overall strength and durability. The heat treating process involves heating the wire to a high temperature for a specific amount of time. Then, it is allowed to cool rapidly. The specific temperature, duration of time, and cooling rate depend on the size, material, and desired properties of the spring.
Another round of the exact process may be done, depending on the manufacturing process involved. Modern spring manufacturing processes commonly use a conveyor belt oven, wherein the spring moves along the conveyor belt within the oven at a designated speed that allows it to receive enough heat treatment.
Step 4: Finishing
Once the spring has been heat-treated, it may undergo additional finishing processes like grinding or polishing to improve its surface finish and dimensional accuracy. This is particularly important for springs that will be used in precision applications, such as aerospace equipment or medical devices.
Other finishing options include plating and coating, which are done to improve the spring's overall chemical and physical properties. These processes provide corrosion resistance and strength, as well as impart new or reinforce existing properties to the spring. For instance, a copper plating provides higher electrical conductivity, while a nickel plating imparts a chrome finish. Being another option, coating prevents wear and rust on surfaces, and can be done in many colors.
Step 5: Quality Control
Finally, the spring undergoes rigorous quality control testing to ensure that it meets the required specifications. This involves testing the spring's strength, durability, and dimensional accuracy using specialized equipment and techniques.
Daichi Metal Springs Manufacturing
At Daichi Springs, we take great pride in the quality of our springs. We use only the highest-quality materials and employ rigorous quality control processes to ensure that each spring we produce meets our exacting standards. Whether you need a single spring for a custom application or a large batch of springs for a production run, you can count on Daichi Springs for high-quality, reliable springs that will perform flawlessly for years to come.
In conclusion, springs are an essential component of many machines, and making them requires careful attention to material selection, wire forming, heat treatment, finishing, and quality control. At Daichi Springs, we have the expertise and experience to produce high-quality springs for a wide range of applications. If you need springs for your project, be sure to contact us to see how we can help or request a quote today.