At present, according to DIN and (GB/T -) standard, disc spring manufacturing process for the thickness is divided into three categories:
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The first kind of: thickness t < 1.25 mm, punching, cold forming, To wear away Angle
The second type: 1.25 mm &#; thickness &#;6 mm, punching, cold forming, inside outside diameter processing to Grinding flat or excellent punching, cold forming, remove the edge of angle
Third class: 6 mm &#; thickness &#;16 mm, casting embryos, surface all processing to Grinding flat and punching, cold forming, inside outside diameter processing to acute Angle or fine punching, torsion spring cold forming, constant force spring acute Angle.
According to DIN and (GB/T -) standard, the manufacturing methods of disc spring as following:
Methods 1: excellent punching, inside outside diameter precision processed into required size (High-grade)
Method 2, excellent punching, then use rolling grinding and remove part of impact groove and acute Angle (Medium-grade)
But on the market at present, still have one of Worst class disc spring, its not only violated the DIN and (GB/T -) of the provisions of the standard, also do not conform to the disc spring quality requirements. Manufacturing method is simple punching, rolling grinding remove sharp Angle.
Note, this kind of product is suitable only for use in steady state . or must go through strict test, the technology can be used for the dynamic situation after approval.
The difference of the manufacturing process
When Punching,disc spring impact surface will produce Small ditch lines .
When loading,The outer edge of the disc spring will produce a series of tangential tensile stress.as figure 1 showing:
The disc spring according to the first methods of process, precision machining of the inner and outer diameter is no small vertical ditch lines, only horizontal sewing pattern, and the direction of tensile strength (the tangent direction), the rupture disc spring almost never happens.
Precision machining differences:
the surface go through precision processing , longitudinal grooves completely removed, the direction of sewing patterns is consistent with the main tension direction, did not occur in the risk of rupture
Excellent punching differences:
punching, small vertical grooves cross over the direction of tangent tension, resulting in the notch effect (Figure 1)
Scroll before grinding
Roll grinding, clearing parts of the vertical groove lines, the surface is smooth
Rolling after grinding
Ordinary punching the difference:
longitudinal rill cross over the direction of the tangential force, resulting in a large notch effects, in dynamic occasions, not recommended to use because the working life is short
Belleville springs are unique axially tapered and loaded springs that can serve as sealing aids and be used individually, in series, or in parallel.
1. When deformed under load, a Belleville spring stores potential energy.
2. If slack occurs, the disc spring releases some of this stored energy.
3. The stress distribution in a disc spring decreases uniformly from the inside to the outside, allowing for low stroke and high compensation force.
4. Belleville springs have excellent shock absorption and can support large loads with minimal deformation, making them ideal for applications with limited axial space.
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5. They can be combined in various configurations.
- Superposition combination
- Inversion combination
- Compound combination.
Using various combinations of the same disc spring allows for a wide range of spring characteristics. These can include inversions and superpositions, as well as combinations of different thicknesses and quantities of springs.
6. Disc springs exhibit variable stiffness characteristics. By adjusting the ratio of the height of the truncated cone to the thickness of the disc, different spring characteristic curves can be achieved, including linear, increasing, decreasing, or combinations thereof. Additionally, variable stiffness can be obtained by combining discs of different thicknesses or stacking varying numbers of discs.
7. If some discs in a Belleville spring become damaged, only the affected disc needs to be replaced, making maintenance and repair convenient.
8. The disc spring is annular in shape, allowing for concentric force transmission.
Belleville springs are versatile and can be combined in various ways, making them popular across multiple industries, including metallurgy, engineering, electric power, machine tools, and construction.
They serve as strong buffers and shock absorbers in heavy machinery. Additionally, they are used as pressing devices in applications such as clutches, safety valves, and pressure-reducing valves.
The use of Belleville springs offers several advantages over traditional spring types:
Higher Load Density: They can achieve a higher load capacity within a smaller footprint.
Consistent Performance: The unique design allows for a stable performance under varying loads and conditions.
Adjustable Stiffness: By stacking multiple Belleville springs, engineers can customize the spring rate to meet specific requirements.
Long Service Life: With proper material selection and maintenance, Belleville springs can operate effectively over extended periods.
In conclusion, Belleville disc springs are a vital component in various industries due to their ability to provide reliable force and energy storage in a compact design. Their unique working mechanism, combined with their versatile applications, makes them an ideal choice for engineers and manufacturers alike. For businesses looking to incorporate Belleville springs into their projects, it&#;s essential to partner with a reputable supplier that understands your specific needs. If you would like to learn more about how Belleville springs can benefit your applications, contact us today.
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