How to Select Wave Springs

Wave Springs serve as an innovative alternative to standard round wire compression springs, particularly in scenarios where space is at a premium and a precise load deflection is necessary. At Lee Spring, our stock wave spring series and custom wave springs can be tailored to your precise needs, ensuring that you find exactly what you're looking for. Our REDUX™ Wave Series features readily available wave springs for immediate shipping, alongside our capability to produce custom wave springs.

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One of the key advantages of wave springs is their remarkably compact design relative to the work they can accomplish. They can significantly reduce assembly size and weight, often achieving decreases of up to 50%. Depending on the specifications, a wave spring can occupy only 30-50% of the compressed height typically needed for comparable round wire springs, while still delivering the same load characteristics. This results in not just space efficiency, but also the potential for smaller components that utilize fewer materials, leading to decreased production costs.

Understanding Wave Spring Design

At its core, a wave spring is a compression spring crafted from coiled flat wire that incorporates waves along its coils to enhance its spring functionality. Wave springs can be designed with either a flat end, known as a shim end, or a wavy end.

Typical Applications for Wave Springs

Wave springs are versatile and can be utilized in numerous applications where space constraints, uniform force distribution, and consistent rotational pressure are critical factors. They are suitable for both static and slightly dynamic loading environments, yet it is vital to consider fatigue when applying wave springs for dynamic loads. Applications that may employ wave springs include connectors, clutches, valves, pumps, seals, and medical devices.

Materials Used in Wave Springs

Lee Spring's REDUX™ Wave Springs are crafted from a single strand of 17-7 Stainless Steel flat wire, precisely coiled to maintain uniform diameters and wave heights. For customized solutions, an array of materials and finishes are available. Attention to material selection is crucial in high-temperature or corrosive environments. Consult a Lee Spring engineer for tailored advice.

Availability of Stock Wave Springs

We offer stock wave springs in both imperial and metric dimensions - seek out our stock wave springs for specifics.

• Imperial sizes range from .250" (6.35 mm) to 1.75" (44.45 mm), accommodating loads from 2 lbs (8.9 N) to 90 lbs (400.3 N).
• Metric options vary from 6 mm (.236 in) to 45 mm (1.772 in), aligning with loads from 6 N (1.35 lbs) to 400 N (89.9 lbs).

Specifications of the REDUX™ Wave Springs

Material: Stainless Steel Type 17-7 PH
Wire: Single strand of pre-tempered flat wire
Temperature: Max 650° F (340° C)
Finish: Passivated
Coils: Continuous coil
Design: Consistent diameter and wave height

Custom Wave Springs for Specific Needs

Custom wave springs can be developed with a variety of materials, finishes, and sizes to suit your specific design requirements. Collaborate with a Lee Spring engineer to navigate the design and technical details of employing a custom wave spring in your project. We produce custom springs in both small and large quantities. Contact us for a quote on custom wave springs today.

Essential Tips for Using Wave Springs

Ensure that you do not exceed the indicated Nominal Load and Working Height to avoid permanent deformation or failure of the spring. The provided Solid Height information is merely for reference. Squeezing the spring to solid may result in significant overstress regardless of the wave spring’s size or load characteristics.

Moreover, ensure the proper installation of the REDUX™ Wave Spring with correctly sized holes and rods. The recommended Hole Diameter and Rod Diameter should align with the spring to guarantee an effective fit. Note that the spring’s Outside Diameter and Inside Diameter are rough estimates only.

For additional information on wavesprings, do not hesitate to reach out to us for expert guidance!

Continue your research on wave spring functionality and compression operational capabilities.

Wave Springs: A Brief Introduction

Finding the ideal design solution can often be a daunting task. However, understanding your available options can simplify the process immensely. One such solution is provided by Smalley with their wave springs.

Defining Wave Springs

Most people are familiar with springs, as they are integral components in countless objects, from our daily items, such as pens, to advanced technologies like space exploration rovers. Springs are categorized into three main types: compression, extension, and torsion. Our focus today will be on compression springs.

The wave spring, innovated by Smalley over a century ago, utilizes a unique design featuring flat wire with multiple waves per turn. This distinctiveness allows wave springs to achieve an equivalent spring force compared to conventional round wire springs, all at half the operational height.

Operational Mechanics of Wave Springs

Likewise, akin to a traditional coil spring, a wave spring operates from a free height, which is its height under no load. When compressed, the wave spring delivers a load until it reaches its designated working height, at which point the specified load is exerted.

For instance, let’s consider a Crest-to-Crest Wave Spring, designated as part number C100-M1. This particular spring possesses a free height measurement of .250 in. and reaches a work height of .087 in., delivering a load of 18 lb at this working height. Exceeding this height can potentially lead to unpredictable spring forces due to the spring possibly taking a set.

Interested in discovering more about wavesprings? Don't hesitate to get in touch with us today for an expert consultation!

Manufacturing Process of Wave Springs

Having established a basic understanding of wave springs and their functions, let's now delve into how they are manufactured. Our No-Tooling-Cost Edgewinding production method is our go-to approach to ensure an accurate yet adaptable solution to meet your wave spring demands.

This process initiates with the cold working of round wire into flat dimensions. Cold rolling improves the strength and stability of the material due to the elongation of its metal grains.

The subsequent step involves creating the Crest-to-Crest wave structure by coiling the flat wire on edge. This unique way of production enables better spring properties as the grain follows the coil direction, ensuring enhanced performance compared to traditional stamping methods.

This flexibly and cost-effectively designed Edgewinding can accommodate various design adjustments throughout production, offering a speedy and economical approach whether you're looking for prototypes or larger orders.

Types of Wave Springs Available

Five primary types of wave springs exist: Crest-to-Crest, Overlap- & Gap-Type Single-Turn, Nested Spirawave™, Wavo™, and Linear. Although they share a wave design principle, each type has unique characteristics that influence their performance under different load conditions.

Material Selection for Wave Springs

Choosing the right material is fundamental for achieving optimal performance. In selecting materials, several factors must be assessed, including operating conditions, longevity, and budget.

Smalley Wave Springs are generally available in carbon steel and 17-7 stainless steel, with over 40 other material options, such as exotic alloys like Inconel X-750™ and Elgiloy™, to withstand diverse environments.

Applications of Wave Springs

Wave springs serve numerous applications across various fields, excelling in diameters and load capabilities. They have proven to be reliable solutions in both consumer goods—as seen in smartwatches—and critical medical devices such as robotic instruments, operating smoothly in challenging environments from deep oil wells to space exploration missions.

Flow valves are prominent examples that leverage the unique characteristics of wave springs. Unlike many spring systems that may be used in valves, wave springs are often favored for their compact size and predictable linear compression, facilitating accurate flow and pressure control.

Begin Your Journey with Wave Springs

• Are you ready to experience the benefits of wave springs? Request your FREE SAMPLES from an extensive collection of over 4,000 wave springs available in carbon and stainless steel.
• If you're uncertain about which component best fits your application, reach out via Live Chat during business hours or schedule a Consultation with an engineer to identify the perfect wave spring for your needs.

Learn More About Wave Springs

For further information regarding our disc spring supplier options, please do not hesitate to contact us. We are here to provide you with professional responses to all your inquiries.