Stress Primary Reason for Extension Springs Failure

The most common cause for extension spring failure is the flawed design that leads to an overstressed spring. Exerting too much stress, or force, than allowed by design can trigger the spring to break or take set.  For example, an extension spring that is intended to be strong will have very little elasticity. If stretched out too far, it becomes highly stressed and susceptible to breakage. The damage can happen at the spring body or at the spring ends.

In dealing with extension springs, the ends are more fragile than the body. As the loops or hooks are formed, the wire is bent upward and the diameter of the ends is slightly reduced. The bend and smaller diameter creates a considerable concentration of stress. A properly engineered spring will take this concentration into account as it leads to premature failure.

If a spring is failing due to overstressing, it is likely the spring design needs to be changed. Here’s are common adjustments:

• Increase the outer diameter
• Decrease wire diameter
• Add more coils by making the body length longer

To avoid extension spring failure, it is important to provide accurate information about what is required. That ranges from the required extended length to the required load to the actual measurements of an existing spring. The more precise the details provided the less likely spring overstressing will occur. For more information about how to measure an extension spring or what information is needed, visit our custom extension springs page.

Other reasons for failure, apart from a flawed spring design, are unforeseen environmental implications and improper installation.

To be assured your extension springs are designed correctly for your application, please contact the spring design specialists at WB Jones.