Die Spring

Product Training

Mechanical Springs
Die Springs
Disc Springs
Spring produced by cold forming with or
without subsequent heat treatment.

Spring Manufacturing Plant

IEM is committed to the spring
manufacturing business.
43 years in die spring manufacturing.
You are purchasing die springs direct
from the manufacturer.

Features & Benefits

Adequate inventory for same day
shipments from the manufacturing plant
Inch sizes manufactured to Industry
Standards
Reliable, proven long life performance
High tensile chrome silicon material
Optimal rectangular wire design

Die Spring Terminology

Hole Diameter
Rod Diameter
Free Length
Preload
Operating travel
Deflection
Solid Height
Permanent Set
Load
Stress

Hole Diameter
This identifies the
outside diameter (O.D.) of
the die spring.
Each die spring is made
to fit in the hole, so the
O.D. of the spring is
actually less than the
hole diameter.

Rod Diameter
This is the nominal size of the
inside diameter of the die
spring.
Each die spring is designed to
fit a rod, so the I.D. of the
spring is actually greater than
the rod diameter.

Free Length

The length of the

spring before it is
subjected to any
operating force or
load.

Preload
The distance the free length
of the spring is reduced by
the pressure of the tool.
Preload is necessary to
compress the first coils of
the spring where stresses
are most caused by turning
down the end coils.

Operating travel
The distance which is
subtracted from the
spring length after the
operating force has
been applied.

Solid Height
The height of the spring
when it is compressed by
enough load to bring all of
the coils into contact with
each other.
Note: When changing over
a customer to the L-Series
springs, be sure to inform
customer to follow the
recommended deflections
as shown in our catalog

Die Spring Terminology

Deflection
The amount of change in
spring length after an
operating force has been
applied.

Permanent Set
This happens when the elastic limits are
exceeded and the spring does not return
to its original free length when the load is
released.

Load
This is the force that is built up by
compressing the spring.
Load is expressed in pounds per inch
deflection.
In our catalogs we show force in
pounds per 1/10th inch.

Stress
In a spring, this describes the
internal force that resists
deflection under load.
This force is equal to and in
opposite direction of, the external
load. Stress is expressed in
pounds per square inch or
newtons per square mm of a
sectional area.

Spring Material
The basic function of any mechanical
spring is to store energy elastically.
Therefore the selection of spring
material that displays the property of
elasticity (the ability to return to the
original shape and dimensions when
applied forces are removed) must be
considered for use when
manufacturing a spring.

Spring Wire Material

Our Die spring material:
Manufactured from spring quality
chromium silicon alloy steel in
accordance with ASTM A1000
specifications.
Provides a high tensile strength and
superior heat resistance.

Spring Material
Comparison

Basic Spring Wire Material

Shapes
SQUARE
WIRE
ROUND
WIRE
RECTANGULAR
WIRE

Wire shape

Modified trapezoidal cross

section of rectangular wire
changes to a D shape cross
section during coiling to
achieve a low stress level that
means a longer spring life.

Die Spring Manufacturing

Process
Coiling
Heat Treating
Remove Set Operation
Shot Peening
Grinding
Paint

Coiling
Coiling is the spring forming
process. The variables such as
diameters, pitch, number of coils,
type of ends, and free length are
determined and established by the
machine setup.

Stress Relief
Springs are passed through stress
relief oven immediately after
coiling in order to prevent micro
stress cracks that would otherwise
form from the coiling process.

Heat Treating

Close control of this process assures that

the spring reaches the proper Rockwell
hardness, the exact tensile strength, and
steel temper to produce a spring with a
given spring load.

Remove Set Operation

The springs are originally coiled longer than
the final length dimension required. Since die
springs are designed to produce heavy loads
and are heavily stressed, they will shorten
when initially placed under load.
The remove set operation brings the spring to
the pre-determined free length.

Remove Set
The manufacturing process of
closing a compression spring to
solid to eliminate load loss in
operation.
Pressed to solid with a predetermined and controlled load.

Shot Peening

Shot peening is a surface treatment that

helps combat surface fatigue and
increase spring life by smoothing the
wire surface imperfections.

Grinding
Grinding both ends
of the spring square
provides a reliable
bearing surface.

Closed End and Ground

Ends of each spring are

closed and ground square to
assure that the spring will
stand on either end and
provide a maximum bearing
surface

Grinding

Paint

Color Codes Inch Die

Springs
DUTY RANGE
Light Duty

COLOR
Green

Medium Duty

Blue

Heavy Duty

Red

Extra Heavy Duty

Yellow

Testing

Each spring batch is tested to verify

consistency in dimensions and
spring rates throughout the
manufacturing process

Die Spring Application

Application DOS and Donts:
DO design spring selection early
DO preload each spring
DO provide proper guidance
DO deepen spring pockets after
sharpening tools
DO provide safeguards
DO perform preventative maintenance

Die Spring Application

Application Dos & Donts:
Dont replace just one spring
Dont mix springs of different duties
Dont alter a spring
Dont expect maximum life at maximum
deflection

Spring Application
Die Spring Usage

Spring Design

General Principles:

The heavier the wire, the stronger the

spring.
The smaller the coil, The stronger the
spring.
The more active coils, the less load for
the same deflection.

Guidance

Normal rule for

requiring guidance
is when the spring
length is 4 times
the O.D.

Operating Deflections

Spring Rate
Example: Spring
One
Inch

Catalog
shows rate as
20 lbs per
1/10 inch:
When the
spring is
compressed
1 it produces
= 200 lbs
The Spring
Rate for this
spring is 200
lbs per inch

Turn Down Coils / Active Coils

Squared and Ground Ends
Turned
Down
Coils
Active Coils

Turned
Down
Coils

Causes for Failures

Over stressed (load loss)

Excess temperature
Fatigue
Insufficient or no pre-load
Operating frequency is high
Hydrogen embrittlement
Non-central loading
Shock
Tool marks
Inclusions

Troubleshooting Failures
Rough Rule of Thumb:
Breakage at end of spring: Overstressed
Application
Breakage in middle of spring: Possible
material or mechanical marks on wire

OEM Applications

Farm Equipment Mfgrs.

Dental Equipment Mfgrs.
Conveyor Mfgrs.
Ground Systems Mfgrs.
Metalworking Equip. Mfgrs.
Power Equipment Mfgrs.
Truck and Bus Mfgrs.
Furniture Mfgrs.
And thousands more!