Belleville washers answer by many names:  Belleville spring washer, cupped spring washer, coned-disc spring, conical spring washer, and disc spring. These unique conical-shaped metal discs support heavy loads with minimal deflection. They are a superb choice for applications that require high load bearing capacity, yet need resistance to vibrations and thermal expansion. In this comprehensive guide, we will delve into the design, application, advantages, disadvantages of the Belleville washer. We will also provide information on how to choose the right washer for your needs.

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Belleville washers' distinct spring-like, conical shape allow them to compress and exert and equal amount of force in response to heavy loads. Unlike conventional helical springs with multiple coils, Bellevilles deflect into a flattened state when the load is applied. This secures the load better and provides resilience against vibrations and other adverse conditions. These washers are the preferred choice when working with heavy loads in confined spaces or when specific spring load requirements need to be met. Bellevilles are not a good choice for very light loads though, because they won&#;t deflect correctly.

Applications of Belleville Washers

These versatile washers were originally conceived from the works of Julien Belleville in . Some of their first uses included landmines, artillery, and bolt action rifles.

Today, Belleville washers serve in a wide range of industries:  aerospace, automotive, manufacturing, valve manufacturing, energy, and medical industries. Their use has expanded from military applications to civilian uses. Some notable applications include:

1. Automotive Industry: They support pistons and cylinders in automobiles, reducing vibrations and noise while ensuring the integrity of the mechanical components.
2. Construction: Stacks of these washers are used under buildings as vibration dampers, especially in areas prone to seismic activity.
3. Aerospace Industry: They are employed to indicate swelling or shrinkage of wooden propellers in aircraft, enhancing safety and performance.
4. Manufacturing: In manufacturing processes, these washers help maintain stability and prevent thermal expansion, ensuring machinery functions optimally.

How Belleville Washers Work

The unique conical shape of Belleville washers allows them to function as springs, compressing and providing resistance when bolts and nuts are tightened. Their convex shape ensures optimal axial loading, making them highly efficient in distributing loads evenly and absorbing shocks. When properly chosen and installed, Belleville washers can enhance the reliability of machinery and prevent bolt failures.

Belleville washers achieve different loads and deflections depending upon the ways they are stacked and used together.

1. If you stack Bellevilles facing the same direction, you increase the load capacity. Two washers double the load, three washers triple it, and so forth.
2. If you stack Bellevilles so they face in opposite directions, you increase deflection. Two washer double the deflection, three washers triple it, and so forth.
3. If you combine the above stacking methods you increase the load capacity and the deflection. An example would be stacking two sets of parallel washers facing opposite directions.

Belleville washers can also be used with flat washers.

Design and Manufacture of Belleville Washers

Belleville washers are manufactured in compliance with DIN and DIN. DIN governs calculations for predictable deflection based on loads. DIN especially applies to heavy-duty Belleville washers used in static functions like bolted joint tightening.

Presetting is a critical step in the manufacturing process, where the washer is momentarily flattened to reduce its original unloaded height. Preset Belleville washers are typically used to maintain load or tension in bolted assemblies.

Advantages and Disadvantages of Belleville Washers

Belleville washers offer several advantages, including the ability to conserve space, provide a long service life, work in conjunction with coiled springs, and distribute loads evenly. They also excel in absorbing shocks, preventing bolt failures, and maintaining the positioning accuracy of ball bearings. However, it is crucial to choose the right washer for your application. Using them inappropriately can lead to disadvantages such as excessive compression for lighter loads.

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How to Choose the Correct Belleville Washer

Selecting the right Belleville washer for your application involves considering factors like load, environment, and bolt size. To choose the correct washer, follow these steps:

1. Determine the Load: Calculate the load the washer will bear to determine the required spring rate and deflection.
2. Select the Material: Choose a material that can withstand the environmental conditions of your application, such as high temperatures or corrosive agents.
3. Choose the Right Size: Ensure the washer fits snugly around the bolt, providing adequate support.

Conclusion

Belleville washers are essential components in numerous industries, offering reliable load bearing and shock-absorption capabilities. Their unique design, conical shape, and ability to distribute loads evenly make them a valuable choice for a wide range of applications. To harness the full potential of Belleville washers, it's crucial to select the right type, size, and material for your specific needs and to consider the appropriate stacking method. With their versatility and effectiveness, Belleville washers play a significant role in enhancing the reliability and performance of machinery and equipment across various sectors.

High Loads in Small Spaces

When your compression spring application requires a high load in small spaces, Lee Spring's Belleville Disc Washers can be the solution. Their conical configuration enables them to support high loads with relatively small deflections and solid heights compared to helical springs. Belleville Washers are often used to solve vibration, thermal expansion, relaxation and bolt creep problems.

Lee Spring Standard Series Belleville Disc Washers are manufactured from 300 Series Stainless Steel. Additionally, Lee Spring Standard Series Belleville Disc Washers are passivated in accordance with specification ASTM A967 (supercedes QQ-P35) to remove contaminants and further improve resistance to corrosion. 300 Series Stainless Steel is slightly magnetic and is recommended for applications with temperatures up to 500°F (260 °C).

The Lee Spring DIN Belleville Disc Washer Series offers metric disc spring washers to meet global demand for sizes specified by DIN .  Lee Spring also expand on size options past DIN &#;s standard size tables, made to DIN manufacturing and quality specifications to provide component flexibility for product designers. DIN Belleville Disc Washers are made with 51CrV4 spring steel (AISI ) and finished with a phosphate and oil surface for general protection from corrosion. 

DIN Belleville Disc Washer Series designs are classified into three groups based on the material thickness:

Group 1 &#; This range applies to disc spring washers with material thickness less than 1.25mm.  Lee Spring DIN Belleville Disc Washer Series include 88 sizes in Group 1, over a selection of outside diameters from 6mm (0.236&#;) to 40mm (1.575&#;) with inside diameters from 3.2mm (0.126&#;) to 20.4mm (0.803&#;).

Group 2 &#; This range applies to disc spring washers with material thickness from 1.25mm through 6mm.  Lee Spring DIN Belleville Disc Washer Series include 161 sizes in Group 2, over a selection of outside diameters from 20mm (0.787&#;) to 200mm (7.874&#;) with inside diameters from 10.2mm (0.402&#;) to 102mm (4.016&#;).

Group 3 &#; This range applies to disc spring washers with material thickness over 6mm through 14mm.  Lee Spring DIN Belleville Disc Washer Series include 41 sizes in Group 3, over a selection of outside diameters from 100mm (3.937&#;) to 250mm (9.843&#;) with inside diameters from 51mm (2.008&#;) to 127mm (5.000&#;).

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