The height before and after the elastic yellow roll and the height before and after the heat treatment did not change much.
The production of equi-rigid conical springs is challenging due to the complexity of the winding path. Several parameters, such as the outer diameter, pitch, helix angle, and cone angle, are variable and must be carefully controlled during manufacturing. Conventional equipment often struggles to produce these springs accurately. However, with a core automatic coil spring machine, it's possible to program the radius change function and height variation function, allowing the machine to wind the spring precisely. If advanced equipment isn't available, only a core-based winding method can be used. The precision of the mandrel directly affects the quality of the final spring.
When designing the mandrel for a coil spring, the parameters are typically based on the starting point of the winding. This approach applies equally to the support ring mandrel design. A critical factor in this process is determining the height of the spiral groove at the tip of the mandrel relative to the starting point at the larger end.
Through experimental studies, it was observed that the height before and after rolling, as well as before and after heat treatment, remains relatively stable. Therefore, when calculating the height of the mandrel’s spiral groove, the main consideration is the number of turns. The theoretical height of the support ring should be precise, but due to material rebound, the support ring must be slightly over-sized before processing. As a result, the spiral groove on the support ring mandrel is designed as a tight coil, with a pitch equal to the wire diameter.
Because the spiral path of the spring mandrel follows a three-dimensional cubic function curve, only a 3D machining center can accurately produce the groove. The design and manufacturing of equi-rigid conical springs are more complex than traditional springs, yet they offer unique advantages, such as achieving maximum deformation, maintaining constant stiffness, and providing full resistance throughout the compression cycle. These properties make them highly suitable for various mechanical applications. This paper presents a theoretical foundation for the design and production of equal-rigidity conical helical compression springs, offering valuable insights for engineers and manufacturers.
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