How are springs designed? Mollificio Modenese has you covered

Have you ever wondered how springs are designed? Behind such a seemingly simple product, there is an equally complex engineering process that requires a deep understanding of mechanical principles and the use of advanced simulation tools.

In today's article, Mollificio Modenese walks us through the main stages involved in calculating and designing compression, tension, and torsion springs. From material selection to virtual simulation and custom production, we will discover how spring design combines technical expertise and advanced technologies to ensure reliable and high-performance solutions.

Stages of the calculation and design process

Here are the main stages of Mollificio Modenese's process:

  - client request analysis: technicians gather all the necessary information to define the spring characteristics, such as load type, stroke, elasticity, operating temperature, working frequency, and material;
  - calculation and simulation: specialized software perform precise calculations and virtual simulations to optimize the spring's dimensions and characteristics, ensuring compliance with European regulations;
  - prototyping: a spring prototype is developed to verify its functional characteristics and dimensional tolerances;
  - production: once the prototype is approved, the spring proceeds to mass production, using state-of-the-art machinery and closely monitoring every stage of the process.

Material selection

A crucial aspect of spring calculation and design is material selection. Mollificio Modenese carefully evaluates parameters such as operating temperature and exposure to corrosive agents. For applications at moderate temperatures, EN 10270-1 steel is suitable, while for harsher conditions, such as temperatures up to +250 °C, stainless steels like INOX AISI 302 are used. In extreme temperatures or highly corrosive environments, superalloys such as Inconel or Nimonic are adopted, along with more durable surface treatments.

Additionally, the fatigue life of the spring depends on the expected number of cycles and the operational frequency. For long-term dynamic applications, materials compliant with EN 10270-2 standards offer high resistance to intensive work cycles.

Number of cycles and frequency: crucial factors for fatigue life

The number of cycles and operational frequency directly affect the fatigue life of compression, tension, and torsion springs. Being subject to repeated loads, springs require fatigue-resistant materials, such as those compliant with EN 10270-2. Mollificio Modenese carefully evaluates these parameters to ensure that the springs can withstand repeated stress without permanent deformation.

In cases of high-frequency cycles, a resonance analysis is necessary to avoid vibrations that could compromise the spring's lifespan or cause structural failure.

Differences between compression, tension, and torsion springs according to Mollificio Modenese

At Mollificio Modenese, design parameters vary depending on the type of spring—compression, tension, or torsion—to ensure maximum efficiency and durability.

For compression springs, the available space and spring stroke are carefully evaluated. It is essential that the spring can compress without exceeding the minimum length to avoid yielding and maintain its elasticity.

In the case of tension springs, the key factors are the relaxed length and the tensile force applied to the loops. Mollificio Modenese designs these springs taking into account the maximum allowable extension, ensuring that the spring does not exceed the yield point, even under high dynamic loads.

For torsion springs, the key parameters include the torsion angle and the torque. Mollificio Modenese ensures the rotation angle stays within the elastic limits, preventing permanent deformation. Additionally, radial space is assessed to guarantee that the spring can rotate freely without interference with its inside diameter.

Mollificio Modenese’s technicians carefully manages these differences in design parameters to ensure that each spring meets the technical specifications and the diverse application sectors.

To learn more, we invite you to visit the company's online stand and get in touch with its team of experts.