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 their 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 spring's radius and height functions, allowing for precise winding. If the available equipment is limited, only a core-based approach may be used. The precision of the mandrel directly affects the final spring's accuracy.
When designing the coil spring mandrel, the parameters are typically based on the starting point of the winding process. This same principle applies to the support ring mandrel design. Additionally, the height of the spiral groove at the tip of the mandrel relative to the large end must be determined precisely.
Experimental results show that the height before and after rolling, as well as after heat treatment, remains relatively stable. Therefore, when calculating the mandrel's spiral groove height, the main factor to consider is the number of turns. The theoretical height of the support ring is fixed, but due to material rebound, the support ring must be slightly oversized before deformation. As a result, the spiral groove of the support ring mandrel is usually designed as a tight coil, where the pitch equals the wire diameter.
Manufacturing the mandrel itself is complex because the spiral track follows a three-dimensional function curve. Only a 3D machining center can accurately produce this structure. Despite the increased difficulty in design and production, equi-rigid conical springs offer significant advantages, including maximum deformation capability, constant stiffness, and full resistance to deformation. These properties make them ideal for various mechanical applications.
This paper provides a detailed theoretical foundation for the design and manufacturing of equal-rigidity conical helical compression springs, offering valuable insights for engineers and researchers in the field.
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