Helical Coil Spring

Helical Coil Spring :

A helical coil spring is a coiled wire wound mechanical device into a helix shape. It is designed to absorb and store energy, resisting compressive or tensile forces. These springs are commonly used in various applications, including automotive suspensions, machinery, and electronic devices. They’re called safety items because they help absorb shock, reduce vibrations, and prevent damage to other components, ensuring smooth operation and extending the lifespan of equipment. Helical coil springs protect the system and its users from potential harm by managing stress and strain.

Helical Coil Spring specification :

A helical coil spring is typically constructed using high-carbon, stainless, or alloy steel, chosen for its high tensile strength and durability. The spring’s wire is coiled into a helical shape, which can be either compression (shortened under load) or tension (elongated under load), depending on the application.

Helical Coil Spring construction :

● Wire Diameter : Varies according to the required strength and load capacity.
● Outer Diameter : Determined by the space and load requirements.
● Number of Coils : Affects the spring’s flexibility and load distribution.
● Pitch : The distance between adjacent coils.
● Raw Materials :
# High-Carbon Steel : Offers good strength and fatigue resistance.
# Stainless Steel : Provides excellent corrosion resistance and is used in environments where corrosion is a concern.
# Alloy Steel : Used for high-load applications due to its enhanced strength and durability.

Helical Coil Spring formula :

Several factors need to be considered to determine the dimensions of a helical coil spring to ensure it meets the specific application’s requirements. The key factors includes :
● The required load.
● The space is available for installation.
● The properties of the raw material used.
The load the spring must support directly influences its dimensions, including the wire diameter, coil diameter, and the number of active coils. The available installation space will dictate the maximum allowable dimensions, ensuring the spring fits the given constraints. Additionally, the grade of the raw material is crucial as it determines the spring’s compression capacity and durability. Higher-grade materials can withstand greater loads and provide longer service life, making them suitable for applications with high-duty cycles. By balancing these considerations, you can select the appropriate dimensions and material grade for the helical coil spring to meet the specific demands of your application.

Helical Coil Spring working principle :

A helical coil spring operates based on the principles of elasticity and Hooke’s Law. Here’s a simplified explanation of how it works :
● Structure : A helical coil spring is made of a coiled wire wound in a spiral shape. When the spring is compressed or stretched, the wire experiences a change in length due to the applied force.
● Elasticity : The wire in the spring is designed to return to its original shape after the force is removed. This property is known as elasticity.
● Hooke’s Law : This law states that the force exerted by a spring is proportional to the amount it is stretched or compressed.
● Function :
# Compression : When a helical spring is compressed, the coils get closer together, and the spring exerts a force that opposes the compression. The amount of force increases with the amount of compression.
# Tension : When stretched, the coils move further apart. The spring pulls back with a force proportional to the amount of stretch.
# Energy Storage : As the spring is deformed (compressed or stretched), it stores potential energy. This energy is released when the deformation force is removed, and the spring returns to its original shape.

Helical Coil Spring types :

Here’s a brief overview of the different types of helical coil springs :

● Compression type :
# Function : Designed to resist compressive forces (shortening). They are used to absorb shock and support loads.
# Structure : Coiled tightly to resist axial compressive forces. The coils are close together, allowing the spring to compress and store energy.
# Applications : Automotive suspensions, mattress springs, and machinery components.

● Extension Type :
# Function : Intended to resist stretching forces (lengthening). They pull apart to absorb and store energy.
# Structure : Coiled with spaces between the coils. The ends of the spring typically have hooks or loops for attachment.
# Applications : Garage door springs, trampolines, and various industrial applications.

● Torsion type:
# Function : Designed to resist twisting or rotational forces. They twist along their axis to store and release energy.
# Structure : Coiled in a helical shape but designed to twist around a central axis rather than compress or stretch.
# Applications : Clutch springs, some door hinges, and vehicle suspension systems.

Each type of spring is optimized for its specific application, balancing factors like strength, flexibility, and durability.

Helical Coil Spring design :

● Open Coil Helical Spring :
# Design : This spring has a simple helical shape with the coils spaced out and not touching each other. The wire coils are open and do not form a closed loop.
# Application : Commonly used in applications where the spring needs to compress or extend freely, such as in suspension systems or as return springs in various mechanisms.

● Closed Coil Helical Spring :
# Design : The coils of this spring are tightly wound so that each coil is in contact with the adjacent coils. The coil formation is closed, forming a compact and continuous helix.
# Application : Often used where a more compact design is needed or where the spring must provide a specific load-bearing capacity in a confined space.

● Conical Shape Helical Spring :
# Design : This spring tapers from a larger diameter at one end to a smaller diameter at the other, forming a conical or cone-like shape. The pitch and diameter of the coils may vary along the length of the spring.
# Application : Useful in applications with space constraints or varying load requirements, such as automotive suspensions or specialized machinery.
Pigtail Shape Spring.
# Design : This spring features coils resembling a pigtail or spiral shape, with the end coils often forming a curl or hook. It can have a variety of shapes but generally includes some sort of winding that resembles a pig’s tail.
# Application : Commonly used as a spring in applications requiring a hook or attachment point, such as in certain clutches or linkages.

Each type of helical spring serves different functions based on its design and application requirements.

Helical Coil Spring uses / application :

● Railway Bogie Suspension :
# Application : In railway bogies, helical coil springs are used to support the rail car’s weight and absorb shocks from the track. They help to maintain stability and provide a smoother ride by damping vibrations and reducing impact forces.
# Benefits : Enhances passenger comfort and reduces wear on railway components by smoothing out the effects of track irregularities and rail vibrations.

● Automobile Suspension :
# Application : Helical coil springs are a key component of the suspension system in automobiles. They support the vehicle’s weight, absorb road shocks, and maintain proper wheel alignment and contact with the road surface.
# Benefits : Improves ride comfort and handling by smoothing out bumps and vibrations, thus contributing to overall vehicle stability and safety.

● Various Machinery :
# Application : Helical coil springs are used in a wide range of machinery for different purposes, including:
# Return Springs : In mechanisms like mechanical switches or levers to return the mechanism to its default position.
# Compression Springs : In machinery that requires resistance to compressive forces, such as presses or clutches.
# Tension Springs : These are used in applications requiring pulling forces, such as conveyor systems or balance mechanisms.
# Benefits : Provides reliable performance under varying loads, absorbs shocks, and ensures smooth operation in machinery.

Why are we a top Helical Coil Spring manufacturer ?

● Uncompromising quality : We prioritize superior quality at every stage of production. Our commitment to using high-grade raw materials, conducting rigorous stage inspections, and adhering to precise dimensions ensures that our helical coil springs meet the highest standards. Our heat treatment processes are meticulously applied to enhance performance and longevity. As an ISO 9001:2015 certified company, we uphold the highest quality management practices.
● Competitive pricing : We offer a comprehensive range of helical coil springs at competitive prices, ensuring value for your investment without compromising quality. Our efficient manufacturing processes and supply chain management enable us to provide cost-effective solutions.
● Guaranteed performance : Our helical coil springs are designed and tested for reliable and consistent performance. We stand behind our products with guarantees, ensuring they meet the performance specifications required for your applications.
● Extensive experience : With years of industry experience, we have honed our expertise in designing and manufacturing helical coil springs. Our long-standing presence in the market reflects our deep understanding of industry needs and technological advancements.
● Global user feedback : Our products are trusted by users worldwide. Positive feedback from a diverse range of customers underscores our commitment to quality and customer satisfaction, reinforcing our reputation as a leading manufacturer in the global market.

Helical Coil Spring manufacturers :

We are Helical Coil Spring manufacturers upto the following capacity :

Wire Dia. – upto 70 mm.
Outer Dia. – upto 500 mm.
Free Height – upto 1000 mm.
Total Coils – As per user’s requirement.
Load Capacity – upto 40 Tons. (per pc.)

● Raw-material grades used : Spring Steels as per Indian standard – BS:970 EN-42, BS:970 EN-45, BS:970 EN-47, 50Cr.V4, 50Cr.4V2, 51Cr.V4, 50Cr.MoV4, 50Si7, 55Si7, 60Si7, SUP-9, SUP-9A, SAE-5160, IS:4454 Part-1 Grade-2, IS:4454 Part-1 Grade-2D, Stainless Steel etc. and others similar foreign grades JIS, ASTM etc.

● Painting and Coating used : Synthe2tic Enamel Paint, Powder Coating, Phosphate, Zinc Coating etc.