经过Elmar Kampmann, Mechanical Engineer and David Marvuglio, Design Engineer, Rotor Clip
Flat-wire wave springs offer a great balance of size and spring force. Here’s what you need to know to design with these alternatives to traditional springs.
Even if you routinely use spring elements in your designs, chances are you haven’t tried wave springs yet. You’re not alone. Most engineers have plenty of experience with traditional coil and disc springs, while single- and multi-turn wave springs remain something of a mystery. Yet wave springs, particularly those made from flat wire, should be better known given their compelling engineering advantages.
单匝波弹簧：应用包括轴承预载，连接器和流体电源密封，以及噪音和振动衰减。它们通常取代冲压波垫圈。
这些优点的主要原因是优异的力量高度。精心设计的波浪弹簧可以产生与卷轴弹簧产生相同甚至更大的力，其工作高度高达两倍的两倍。
良好的波浪弹簧还在一系列偏转方面产生更一致的力。它们的偏转曲线具有比线圈或圆盘弹簧更宽，更平坦的线性力区域。波簧仅在预期的轴向方向上传递那些弹簧力。它们不会遭受传统螺旋弹簧可以发生的扭转装载和扭曲。
此外，波弹簧具有组装优势。许多波形弹簧具有在钻孔或轴上自定位的能力。一个多匝波弹簧可以经常更换整个圆盘弹簧，消除组装步骤。
作为传统弹簧元件的替代品，波弹簧可以提高弹簧加载部件的性能。但要最大限度地提高波浪弹簧的工程潜力，您应该在独特的品质周围设计。
轴向空间储蓄。The most immediately noticeable quality of wave springs is just how much axial space they can save. In static applications, a wave spring will typically need just 50% of the work height of a coil spring to deliver an equivalent force. In dynamic applications, the work height advantage is typically about 30%, less than static applications, but still substantial. The reason for the difference comes down to the fundamentals of multi-turn wave spring design. To minimize the bending stresses in dynamic applications, the wave spring will typically require more turns than in a static application. And more turns result in additional work height.
Coil springs require as much as twice the working height of a wave spring.
一致的弹簧力。弹簧元件通常表现出直线和非线性力行为，这取决于它们的偏转。这种线性行为可以在弹簧的载荷偏转曲线上以图形方式显示。通常，曲线的更广泛和更平坦的线性区域，更容易击中特定的弹簧力要求。波浪弹簧在这个部门有一个明显的优势。它们通常具有30至70％之间的线性力。线圈和圆盘弹簧都具有太大较窄的线性力区域。可预测的弹簧力可能是许多应用中的大益处。例如，机械密封件成功地使用波弹簧来预加载密封表面。具有可预测的弹簧力允许密封设计师从过高的预载，从预加载的超低，泄漏过多的磨损之间的平衡。
机械密封件成功地使用波弹簧来预加载密封表面。
尺寸公差改进。波动春天可预测力的侧面优点涉及保持弹簧元件的空腔和轴的尺寸公差。这些公差通常是需要适应弹簧的力量高度要求的需求。通过指定在一系列偏转范围内的力相对一致的波形弹簧，通常可以松开弹簧腔和轴上的尺寸公差。这种能力代表了一个主要的，但经常被忽视，成本因素支持波浪泉。
与三种类型的弹簧相比，负载偏转曲线。
没有扭转载荷。Whenever you compress a coil spring to its work height, loads are not just in the axis of compression, but also torsional. These torsional loads can cause the pre-loaded component to rotate in use, potentially resulting in excess wear. Torsional loads can also decrease the spring’s working load. Many applications, including seals, can suffer from this rotational wear problem. Wave springs don’t have this issue. Their wave forms can only compress axially, in some cases changing their diameter slightly.
Increased travel.与传统圆盘弹簧相比，多转波弹簧提供更多的旅行。一个多匝波弹簧可以代替使用多个圆盘弹簧来实现必要的行程的组件。大多数应用需要相对短的行程距离，通常小于1毫米。但要使您了解有可能的想法，我们设计了多匝波弹簧，提供高达50毫米的旅行。用一个波形弹簧替换堆叠的圆盘弹簧组件，可能导致成本和质量效益。不仅可以少于堆叠的圆盘弹簧的单个春季成本较少，而且还减少了错误数量的圆盘弹簧将进入成品组件的可能性。
拨打所需僵硬。Wave spring stiffness is determined by thickness and type of spring material, as well as by the number of waves per turn of spring. You can easily dial in a required stiffness by optimizing the number of waves per turn using well-known design formulas. Increasing the number of waves per turn does have an influence on free height and compressed diameter of the wave spring. More turns also increases the hysteresis since each wave has some friction associated with it. All these effects are easily offset. You can account for free-height and diameter effects during design. And hysteresis can be eliminated by presetting the wave spring—that is, compressing to its work height over several cycles.
快速定制。与需要工具的冲压产品不同，可以通过改变卷绕设备的参数来定制波弹簧。此功能允许您指定自定义波浪弹簧，而无需担心与自定义工具相关的成本或延迟。这种能力是称重引起波浪弹簧的另一种成本因素。
有波兰簧的进气泵。
波形弹簧不是平等的
我们为波形弹簧布局的所有优点假设弹簧由高质量的材料制成，在受控环境中制造，并适当为手头的应用设计。一些制造商滚动自己的扁平电线并在自己的机器中形成。垂直整合允许它们适应原料中的批量批量变化，包括各种钢和其他合金。它还确保了所有轧制和卷绕过程的紧密统计控制。
Wave spring used in fuel filter.
When it comes to wave springs, the importance of this manufacturing expertise can’t be understated. Even small variations in wire thickness, wave geometry or metallurgy can all have drastic effects on a wave spring’s performance in the field. Force characteristics in particular can suffer if the spring hasn’t been made properly. High-quality springs let you take advantage of all the design benefits waves springs can offer.
加载波弹簧。
螺旋缠绕波弹簧的公式
命名法：
T =材料的厚度，[mm] od =外径，[mm] sw =材料的径向宽度，[mm] Id =内径，[mm] f =载荷，[n] dM.=平均直径，[mm] w.h.=工作高度，[mm] b =偏转，[mm] h =自由高度，[mm]σ=操作应力，[n / mm]2] n =匝数
E = Modulus of Elasticity, [N/mm2] z =每转的波数
K = Wave Factor
单匝波弹簧具有间隙或重叠和多转波弹簧：
单匝波弹簧的操作应力不应超过扁平线材的最小拉伸强度。保持偏转30％和70％。对于多转，请保持20％至80％之间的偏转。
Deflection B = (F · K · Dm3.的）/ (E · SW · T3.·z4）x id / od
Operating Stress s = (3 · π · F · DM.的）/ (4 · SW · t2·Z.2的）
嵌套多转波弹簧：
单匝波弹簧的操作应力不应超过扁平线材的最小拉伸强度。保持偏转30％和70％。
Deflection B = (F · K · Dm3.的）/ (E · SW · T3.·Z.4.·n）x id / od
Operating Stress s = (3 · π · F · DM.的）/ (4 · SW · t2·Z.2·n）
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The article mentioned the space of wave spring is 50% less than compression spring. How about the stroke? Will it still same as compression spring? What I mean is, will the spring constant same as compression spring?