Design & Manufacturing Considerations

· Load and stroke matching: Define rated working load, maximum ultimate load and working stroke range, with a 10%–15% safety margin to avoid plastic deformation from over-compression. For dynamic operating conditions, verify fatigue life separately and set a reasonable stress safety factor.

· Space constraint verification: Confirm axial and radial installation limits. For compression springs, verify solid height and fit clearance with guide rods/sleeves to prevent jamming and eccentric wear during operation.

· Material selection:

o Carbon spring steel, 65Mn, 60Si2Mn for general heavy-duty applications;

o 304, 316, SUS631 stainless steel for corrosion-resistant / medium-temperature environments;

o Alloy spring steels such as 50CrVA and chromium-silicon alloy for high-fatigue, high-temperature conditions;

o Beryllium copper, phosphor bronze and other copper alloys for conductive applications.

· Installation structure compatibility: Prioritize standardized end configurations (closed & ground ends, hooks, positioning bosses). For complex mounting features, evaluate forming feasibility concurrently.

· Wire pretreatment: Ensure flat wire rolling direction aligns with the coiling bend direction. Perform stress relief annealing before high-deformation forming to reduce springback and cracking risk.

· Forming process: Mandatory stress relief heat treatment after coiling/stamping to eliminate residual forming stress. Add shot peening for dynamic load springs to introduce compressive surface stress and extend fatigue life.

· Precision control: End-face grinding must ensure perpendicularity between end faces and the spring axis to avoid eccentric loading; key dimensions (free height, stiffness, load) require 100% inspection or batch sampling.

· **Surface treatment: Select galvanizing, nickel plating, black oxide, Dacromet or passivation based on operating conditions. For high-fatigue applications, avoid hydrogen embrittlement risk from excessively thick coatings.

· Never compress beyond the limit stroke, as this will cause permanent deformation and spring failure.

· For dynamic operation, ensure parallel supporting surfaces at both ends to avoid abnormal wear and fracture caused by lateral forces.

· For special environments (corrosion, high temperature, strong magnetism), confirm material and surface treatment compatibility in advance; do not directly apply standard environment solutions.

· Avoid long-term storage under compressive load to prevent force decay from stress relaxation.