| Customization: | Available |
|---|---|
| Function: | Pressed |
| Material: | Steel |
|
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| Wave Spring Parameter Data | ||
|---|---|---|
| Category | Specification | |
| Description | Wave springs are flat wire springs with wave peaks, used as load-bearing devices to compensate for dimensional variations. MultiWave springs offer greater deflection than round wire springs while using less axial space. | |
| Tag | Multi-Wave Compression Springs / Wave Spring | |
| Length | 57.15 mm | |
| Non-Standards | Customized | |
| Outer Diameter (OD) | 60 mm | |
| Inner Diameter (ID) | 50 mm | |
| Shape | Round | |
| Sample | Offered | |
| Turn Direction | Left rotation / Right rotation | |
| Material | Stainless Steel (304H, 316, 316L, 631, 65Mn), etc. | |
| Applications | Aerospace, automobile, petroleum, medical equipment, wind energy, construction machinery, consumer electronics, mechanical seals, electric connectors, bearing preload. | |
| Packing | Plastic bag, carton box, pallet | |
| Workcraft Process | Blanking Testing → Coiling → Inspection → Heating Treatment → Cleaning → Surface Finishing Final Treatment Testing → Packing → Shipping |
|
| Final Treatment & Materials | Final Treatment Options Heat Treatment (ovens) for mechanical durability. Chemical Treatments: Tribofinishing, passivation, painting, cataphoresis. Subcontracting available for specialized processes. |
|
| Materials Processed | Material Type | Examples |
| Spring Steel | SM, SH, DH | |
| Chrome Silicon | Bosswinn©, Bosswinn©, Bosswinn© | |
| Stainless Steel | 1.4310, 1.4401, 1.4568, 1.4462, 1.4301 (soft), 1.4441 (implantable) | |
| High-Performance Alloys | Inconel (600, 625, 718, 750), Monel, Nimonic, Uranus, Titanium | |
| Non-Ferrous Metals | Phosphor bronze, beryllium, copper, brass (square/rectangular sections) | |
| Notes | Space-saving: Wave springs reduce axial space requirements in assemblies. Customization: Millions of combinations possible based on mechanical/dimensional needs. Consultation: Contact technical services for material-specific feasibility (e.g., rolling constraints). |
1. Material Selection & Procurement**
- **Material Standards**: Ensure compliance with industry specs (e.g., ASTM, DIN, JIS).
- **Supplier Quality**: Audit suppliers for consistency in material properties (tensile strength, corrosion resistance).
- **Inventory Control**: Maintain optimal stock levels to avoid delays (Just-in-Time or JIC strategies).
---
2. Process Planning & Workflow Optimization**
*A. Blanking & Forming**
- **Precision Cutting**: Use CNC laser/blanking machines for accurate flat wire cutting.
- **Wave Formation**: Ensure consistent wave height and pitch using automated coiling machines.
B. Heat Treatment & Stress Relief**
- **Controlled Tempering**: Oven treatments to enhance durability and fatigue resistance.
- **Process Validation**: Hardness testing (Rockwell/Vickers) to confirm material properties.
C. Surface Treatment**
- **Passivation** (for stainless steel) to prevent corrosion.
- **Tribofinishing** for smoother edges and reduced friction.
D. Final Inspection & Testing**
- **Dimensional Checks**: OD, ID, wave height, free length.
- **Load Testing**: Verify spring rate (force vs. deflection).
- **Fatigue Testing**: Simulate long-term use under cyclic loads.
3. Quality Control & Compliance**
- **ISO 9001/AS9100**: Implement standardized QC protocols.
- **Statistical Process Control (SPC)**: Monitor production variations in real time.
- **Defect Tracking**: Use Pareto analysis to address frequent issues (e.g., wave misalignment, cracks).
4. Production Scheduling & Lead Time Management**
- **Batch vs. Continuous Production**: Decide based on order volume.
- **Lead Time Reduction**: Optimize setup times for custom orders.
- **ERP/MRP Integration**: Track orders, materials, and machine utilization digitally.
5. Equipment & Maintenance**
- **Machine Calibration**: Regular checks on coiling and heat treatment equipment.
- **Predictive Maintenance**: Use IoT sensors to detect wear before failure.
6. Workforce Training & Skill Development**
- **Operator Training**: CNC programming, metallurgy basics, quality inspection.
- **Cross-Functional Teams**: Encourage collaboration between R&D, production, and QC.
*7. Cost Control & Waste Reduction**
- **Lean Manufacturing**: Minimize scrap via optimized blanking patterns.
- **Recycling**: Reuse metal offcuts where possible.
- **Energy Efficiency**: Use induction heating instead of gas furnaces where applicable.
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## **8. Supply Chain & Logistics**
- **Packaging Standards**: Anti-rust coatings, moisture-resistant packing for export.
- **Shipping Coordination**: Partner with reliable logistics providers for on-time delivery.
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### **Key Performance Indicators (KPIs) for Production Management**
| **KPI** | **Target** |
|------------------------|------------------------------------|
| Defect Rate | < 0.5% |
| On-Time Delivery | > 98% |
| Machine Downtime | < 5% |
| Production Lead Time | Optimized per order complexity |
| Material Utilization | > 90% efficiency |
Conclusion**
Effective **wavy spring production management** requires:
**Strict process control** (forming, heat treatment, inspection).
**Advanced quality assurance** (SPC, fatigue testing).
**Efficient scheduling & cost optimization**.
**Skilled workforce & continuous improvement**.
| Checkpoint | Method/Equipment | Acceptance Criteria | Frequency |
|---|---|---|---|
| Material Certification | Review mill test reports | Must match ordered specifications | 100% of batches |
| Chemical Composition | Optical emission spectrometer | Within alloy specification ranges | Per heat/lot |
| Tensile Strength | Universal testing machine | Meets ASTM/ISO material standards | First article + 5% |
| Surface Defects | Visual inspection + magnifier | No cracks, pits, or inclusions | 100% visual check |
| Wire Dimensions | Micrometer/calipers | ±0.02mm tolerance | Every coil start |
| Parameter | Measurement Method | Tolerance | Check Frequency |
|---|---|---|---|
| Wave Height | Optical comparator | ±0.05mm | Every 50 pieces |
| Wave Pitch | Profile projector | ±0.1mm | Every 50 pieces |
| OD/ID Concentricity | CMM (Coordinate Measuring Machine) | ≤0.1mm TIR | First/last piece |
| Surface Finish | Surface roughness tester | Ra ≤ 1.6μm | Hourly |
| Burr Presence | Tactile inspection + microscope | No detectable burrs | Continuous |
| Checkpoint | Test Method | Standard | Frequency |
|---|---|---|---|
| Hardness | Rockwell hardness tester | HRC 38-42 (varies by mat'l) | Per batch |
| Microstructure | Metallurgical microscope | Uniform grain structure | First/last batch |
| Temper Color | Visual inspection | Consistent coloration | 100% visual |
| Dimensional Change | Pre/post-treatment CMM scan | ≤0.5% dimensional shift | First article |
| Test | Equipment | Acceptance Criteria | Sampling Rate |
|---|---|---|---|
| Load-Deflection | Spring compression tester | ±5% of specified rate | 100% |
| Fatigue Life | Cyclic testing machine | 1M cycles without failure | 1 per 5,000 pcs |
| Free Height | Height gauge | ±0.1mm | 100% |
| Surface Integrity | Dye penetrant inspection | No cracks detected | 1 per batch |
| Torque Resistance | Torque tester (for spec apps) | ±10% of spec value | As required |
Real-time Monitoring: Automated SPC software tracking critical dimensions
Control Limits: ±3σ for all critical parameters
Process Capability: Minimum Cpk of 1.33 for all CTQ characteristics
Trend Analysis: Weekly review of control charts for early deviation detection
Material Traceability: Laser marking with heat/batch numbers
Inspection Records: Digital storage for 10+ years
Certification: Full documentation package including:
Material certs
Heat treatment records
Dimensional reports
Performance test data
Defect Classification:
Critical: Affects safety/function (0% acceptance)
Major: Affects performance (≤0.1% acceptance)
Minor: Cosmetic only (≤1% acceptance)
Corrective Actions:
Immediate process stop for critical defects
8D problem solving for recurring issues
Process FMEA updates every 6 months
Automated Optical Inspection (AOI): For 100% wave profile verification
X-ray Inspection: For internal defect detection (critical applications)
Residual Stress Analysis: X-ray diffraction for high-performance springs
Operator Training: Certified to ISO 9001 work standards
QC Technician: ASQ Certified Quality Inspector
Metallurgist: On staff for material analysi
| Step | Action | Purpose |
|---|---|---|
| 1.1 | Clean springs with degreaser | Remove oil/residue that could cause corrosion |
| 1.2 | Apply corrosion inhibitor (VCI paper/fluid) | Prevent oxidation during transit |
| 1.3 | Separate by size/specification | Prevent mixing and interlocking |
| Method | Materials | Best For |
|---|---|---|
| 2.1 | Anti-tangle plastic sleeves | Small springs (ID < 20mm) |
| 2.2 | Foam end caps + shrink wrap | Large/heavy-duty springs |
| 2.3 | Corrugated cardboard dividers | Medium springs (20-100mm OD) |
A. Stacking Configuration:
Alternating layer direction (90° rotation per layer)
Maximum stack height: 150mm to prevent deformation
Interlayer material: PE foam sheets (3mm thickness)
B. Container Options:
| Container Type | Capacity | Protection Level |
|---|---|---|
| Plastic tubes with end caps | 5-50 pcs | High (for precision springs) |
| Corrugated partitions boxes | 50-200 pcs | Medium (general purpose) |
| Wooden crates with foam lining | 200+ pcs | Heavy-duty (overseas) |
Magnetic springs: Pack in mu-metal containers
Medical-grade springs: Double vacuum sealing
High-precision springs: Individual CNC-machined holders
Hazard Symbols: (if applicable)
Fragile
Magnetic (if relevant)
Non-sterile (medical applications)
Technical Information:
Spring ID number
OD/ID dimensions
Load rating
Material grade
Handling Instructions:
"Do not stack" (for precision springs)
"Keep dry" (non-stainless materials)
"This side up" arrows
| Risk Factor | Mitigation Method |
|---|---|
| Vibration | Air bubble cushioning (minimum 30mm) |
| Compression | Steel-reinforced box corners |
| Humidity | Silica gel packets (10g per m³) |
| Temperature swings | Insulated packaging (for special alloys) |
Drop test: 1.2m height onto concrete (sample packages)
Vibration test: 3hrs @ 5-500Hz (simulate truck transport)
Climate test: 24hrs at 85% RH (for humid routes)
Just-in-Time Delivery: Special racks for automated unloading
RFID Tags: For high-value/lot-tracked springs
Returnable Packaging: Stainless steel containers (for regular shipments)
Pro Tip: For springs with extremely tight tolerances (>±0.025mm), pack in individual hard plastic cases with foam inserts that match the spring's free height to prevent any compression during transit.
Proper packing preserves spring performance and reduces rejection rates - investing in quality packaging typically saves 3-5% in replacement costs for most manufacturers.
Because of their versatility, compression springs can be used in many applications, including:
Compression springs are undoubtedly used in our everyday lives, everyday products, machines, etc.
Major original equipment manufacturers (OEMs) that produce products for various industries use compression springs in many of their products.
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