3 Common Adjustments to Prevent Extension Spring Failure

Spring failure can cause costly and damaging problems for your extension spring application. In most cases of extension spring failure, the cause is stress or force that exceeds what the spring is designed to handle. For example, extension springs that are designed for strength usually have reduced elasticity, and will fail if stretched too far.  The spring breakage can occur at the ends or within the body. Other reasons for failure besides a flawed spring design are unforeseen environmental issues and improper installation.

Characteristically, extension springs are more vulnerable at the ends than within the body. When the loops or hooks are formed, the wire is bent upward and the diameter of the ends is slightly decreased. This bend and reduced diameter create a considerable concentration of stress. A well-engineered spring will take this concentration into account as it leads to premature failure.

If extension spring failure occurs due to overstressing, the spring design probably needs to be adjusted. These three common changes can decrease the likelihood of breakage:

1. Increase the Outer Diameter
2. Decrease Wire Diameter
3. Add More Coils

Obtaining accurate information about what will be required of the spring while you are in the design phase will greatly reduce the chances of extension spring failure. Such information may include the required extended length to the necessary load or the full measurements of an existing spring. The more exact the details are the less likely spring overstressing and breakage will occur.

See how to measure an extension spring.

Need assistance with an extension spring design adjustment or other spring failure problem? Our spring design experts are here to help.