Overstressing: How to Avoid Extension Springs Failure
An extension spring is most fragile and vulnerable at its ends. As the loops or hooks are formed, the wire is sharply bent upward. The sharp bend creates a significant concentration of stress. A correctly designed spring will take this concentration into account so as to prevent premature failure.
When an extension spring fails due to spring overstressing, it is likely the spring design needs to be adjusted. Some simple design changes can prevent overstressing and extension spring failure:
- Increase the outer diameter
- Decrease wire diameter
- Add more coils by making the body length longer
When specifying extension springs, provide the spring manufacturer with the most detailed information as possible about the application. This should include details such as the necessary extended length and the required load or, in the case of spring replacement, the actual measurements of the existing extension spring.
Other reasons for extension spring failure, apart from a flawed spring design, are unforeseen environmental implications and improper installation. In order to best ensure success, make sure your extension springs are designed correctly for your application.
Contact the spring design specialists at WB Jones for assistance with your extension spring design!