The performance, lifespan, and applicable scenarios of springs depend on material selection and production processes. High quality springs need to take into account the elastic limit, toughness, and fatigue resistance of the material. At the same time, standardized production processes are used to ensure accurate parameters and stable performance. Although the materials and processes of different types of springs may differ, the core processes have commonalities.
Core material classification and adaptation scenarios: Spring steel, divided into carbon steel spring steel (such as 65Mn) and alloy spring steel (such as 50CrVA, 60Si2Mn). Carbon steel spring steel has low cost and good elasticity, and is suitable for conventional scenarios (such as civilian hardware and simple machinery); Adding elements such as chromium, vanadium, and silicon to alloy spring steel enhances its fatigue resistance, high temperature resistance, and corrosion resistance, making it suitable for high loads and harsh working conditions (such as automobiles, aerospace, and heavy machinery); Stainless steel spring steel (such as 304, 316), with strong corrosion and rust resistance, suitable for humid and corrosive environments (such as medical equipment, outdoor equipment, food machinery); Copper alloy springs (such as brass and bronze) have good electrical and thermal conductivity, moderate elasticity, and are suitable for electronic devices and precision instruments.
The core production process is divided into five steps: raw material pretreatment, rust removal and annealing treatment of spring wire, improving material toughness, and avoiding fracture during processing; Forming processing, the spring wire is processed into the desired shape (spiral, sheet, waveform, etc.) through a spring winding machine. Conventional springs are processed using an automatic spring winding machine, while special-shaped springs are processed using customized forming equipment; Heat treatment, including quenching and tempering, is a key step in improving the elasticity and strength of springs. Quenching enhances hardness, tempering eliminates internal stress, and ensures that the spring can fully reset after deformation; Surface treatment, according to the working conditions, includes galvanizing, chrome plating, electrophoresis, spraying and other treatments to enhance rust prevention and corrosion resistance; Inspect the factory, check the size, stiffness, load-bearing capacity, fatigue life and other parameters of the spring, reject unqualified products, and ensure compliance with standards.
Differentiated process: Customized mold design and simulation testing steps need to be added for special-shaped springs; The shock absorber spring needs to optimize the heat treatment process to enhance its damping characteristics; Precision springs need to add precision testing steps to ensure that parameter errors are controlled within the allowable range.