Different Types of Belleville Washers and Advantages

06 May.,2024

 

Different Types of Belleville Washers and Advantages

Different Types of Belleville Washers and Advantages

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HEGONG SPRING

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Jul 18, 2023

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Belleville washers, also known as disc springs, are versatile components that provide controlled spring force and load distribution in mechanical assemblies. In this article, we will explore the different types of Belleville washers and their unique advantages. Understanding the characteristics of each type will help you select the most suitable Belleville washer for your specific application. Let’s dive in!

1. Flat Belleville Washers

Flat Belleville washers, as the name suggests, have a flat or disc-like shape with a uniform thickness throughout. They offer a simple and cost-effective solution for applications where moderate spring force and load distribution are required. Flat Belleville washers are commonly used in electrical connectors, fasteners, and small-scale assemblies.

Advantages of Flat Belleville Washers:

  • Ease of installation due to their flat shape
  • Cost-effective compared to other types of Belleville washers
  • Provide uniform spring force distribution
  • Suitable for applications with limited space constraints

2. Conical Belleville Washers

Conical Belleville washers feature a cone-shaped design with a thickness that tapers towards the outer edge. This type of washer provides a high spring rate, making it ideal for applications that require substantial spring force and load capacity. Conical Belleville washers find use in heavy-duty applications, such as large-scale machinery, automotive suspensions, and industrial equipment.

Advantages of Conical Belleville Washers:

  • Offer high spring force and load-carrying capacity
  • Excellent resilience and durability
  • Effective in absorbing shocks and vibrations
  • Ideal for applications with dynamic loads and heavy machinery

3. Wave Belleville Washers

Wave Belleville washers, also known as wave springs, have a unique wavy or corrugated shape that allows for multiple waves or turns within a single washer. This design provides increased deflection and spring force while maintaining a compact size. Wave Belleville washers are commonly used in applications that require high spring rates in limited axial space, such as valves, bearings, and automotive systems.

Advantages of Wave Belleville Washers:

  • Offer high deflection and spring force in limited space
  • Reduced axial size compared to other Belleville washer types
  • Can be stacked to achieve different load characteristics
  • Excellent for applications with space constraints and precise load requirements

4. Curved Belleville Washers

Curved Belleville washers feature a curved shape with a constant radius, providing a smooth and continuous spring action. These washers are often used in applications that require a moderate amount of spring force and flexibility. Curved wave washers find use in clamping systems, precision tools, and assemblies where consistent load distribution is crucial.

Advantages of Curved Belleville Washers:

  • Provide a smooth and continuous spring action
  • Ideal for applications that require moderate spring force
  • Offer consistent load distribution and clamping force
  • Suitable for precision tools and assemblies with strict load requirements

Conclusion

Belleville washers come in different types, each offering unique advantages depending on the application’s requirements. Whether you need a simple and cost-effective solution (flat Belleville washers), high spring force and load capacity (conical Belleville washers), compact size with increased deflection (wave Belleville washers), or consistent load distribution (curved Belleville washers), there is a Belleville washer type to suit your needs.

Consider the specific demands of your application, including the required spring force, load capacity, space constraints, and environmental factors, when selecting the appropriate Belleville washer. Consulting with experts and trusted suppliers will ensure you choose the right washer that optimizes performance, reliability, and longevity in your mechanical assemblies.

Contact us to discuss your requirements of belleville stack. Our experienced sales team can help you identify the options that best suit your needs.

Belleville101: What are Belleville Washers and Disc Springs?

BelleFlex® TechTips

What is a Belleville Washer or Disc Spring?

The Basics
Flat Washers
Spring Rate and Stacking
Understanding Load, Stress, and Fatigue Life
Belleville Spring Specifications
Presetting

The Basics

A Belleville washer or disc spring is a conical-shaped spring with an open center. It is shaped much like a washer and is typically smaller than a coiled spring. Because Belleville washers can bear a much larger load relative to its deflection rate than a coiled spring, they are ideal for cushioning heavy loads with short motion.

Like all springs, a Belleville disc spring will deflect in response to a load. Belleville washers and disc springs exhibit low deflections relative to high loads. The relationship between the load and deflection is non-linear, particularly as load increases. This quality makes Belleville washers and disc springs well-suited to areas with constant thrust that must stand up to heavy wear.

Belleville washers and disc springs provide the following advantages:

  • Conserve space
  • Offer a long service life
  • Can be used in conjunction with coiled springs
  • Offer great versatility when stacked in series or in parallel
  • Increase the reliability of machinery
  • Prevent bolt failures
  • Maintain the positioning accuracy of ball bearings
  • Minimize thermal expansion
  • Are self-damping
  • Distribute loads evenly
  • Absorb shocks

Our engineers can help you determine the washers or springs needed to meet the requirements of your specific application.
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Flat Washers

In some instances that must bear a heavy load, the addition of a flat washer increases the effectiveness of a Belleville washer or disc spring by helping to spread the load. In other applications, a flat washer can prevent a Belleville washer or disc spring from biting into softer metals. This is particularly important in preserving the integrity of bus bars, which are typically made from aluminum to withstand conditions of high current loading.

BelleFlex® engineers can help you to determine whether flat washers are needed for your specific application.
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Spring Rate and Stacking

The spring rate of a Belleville washer or disc spring is the amount of force associated with a given deflection measured in lb/in or N/mm. Every spring has its own spring rate, depending on its geometry and material. The formula to determine the load at a specific deflection uses Poisson’s ratio, Young’s modulus, as well as the outside diameter (De), inside diameter (Di), material thickness (t), and deflection-to-flat (ho).

The load/deflection ratio of a specific outer and inner diameter can be changed by using more than one Belleville washer or disc spring, stacked either in series or in parallel. Stacking Belleville washers and disc springs allows for precise customization of the load and/or deflection.

  • Stacking in parallel (same direction) will increase load.
  • Stacking in series (opposite directions) will increase deflection.
  • Belleville disc springs can also be stacked as a combination of the two alignments.

The exact configuration of Belleville washers or disc springs depends on the requirements and limitations of the application. Our engineers can provide assistance in determining the configuration that best meets your needs.
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Understanding Load, Stress, and Fatigue Life

It is also important to know the limits of a given Belleville washer or disc spring before it is put into service in an industrial environment. Calculating load and stress is a way to determine the point of failure for a spring, including Belleville washers and disc springs. Simply put, it’s a way to determine how much force (load) and how much stretch (stress) the spring can bear before it fails.

Fatigue life refers to the number of cycles a spring can withstand before it fails in a particular application. The fatigue life is based on the dimensions of the spring or spring stack, the preload, the final load, the deflection, and the frequency. The goal of determining the fatigue life is to ensure that your Belleville washer or disc spring solution will be able to withstand the stress to which it will be exposed. In situations in which a single Belleville cannot withstand the level of stress, a well-designed stack of Bellevilles can alter the load and stress performance and increase the fatigue life.

Well-designed springs contribute to increased efficiency and prolonged service life for your equipment. Our engineers are always available to provide assistance with all facets of Belleville washer and disc spring design, including load and stress calculations.
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Belleville spring specifications

The term “tolerance” refers to the amount of deviation from specification that may occur in a disc spring without compromising its performance. For Belleville disc springs, allowable tolerances for diameter, thickness, height, and load are provided in the DIN 2093 specification. Deutsches Institut für Normung (DIN) is an international standards organization, based in Germany that governs specifications of many industrial and technical materials.

BelleFlex® utilizes the following DIN specifications to guide our design and manufacturing process:

  • Our engineers employ the calculations of DIN 2092 to create Belleville disc springs with predictable deflection for a given load and a determinable minimum life cycle.
  • BelleFlex® adheres to DIN 2093 for the type, dimensions, material, permissible stress, permissible set, guide clearance, and testing of Bellevilles. Although DIN 2093 applies only to specific limited applications and sizes, all disc springs produced by BelleFlex® are manufactured in accordance with the quality and testing requirements contained in this specification.
  • BelleFlex® utilizes DIN 6796 in the manufacturing of heavy-duty Belleville washers.

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Presetting

Presetting takes place during the manufacturing process of a Belleville washer or disc spring when it is momentarily flattened. The process reduces the original unloaded height of the spring, as a result of the residual tensile stresses.

Preset Belleville washers and disc springs are typically used to maintain load or tension in bolted assemblies. This process is not always necessary and must be specified at the time the order is placed.
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