EN
· Load and function definition: Clearly define rated working force, maximum stroke, movement direction and expected service life; reserve a 15%–20% safety margin for force performance to avoid overload failure.
· Minimum bend radius design: Set the inner bend radius no less than 1–2 times the wire diameter (adjusted according to material ductility) to reduce stress concentration and avoid cracking during forming.
· Material selection:
o Carbon steel wire / 65Mn for general load-bearing and static working conditions;
o Stainless steel wire (304, 316, 17-7PH) for corrosion resistance and medium dynamic load scenarios;
o Beryllium copper, phosphor bronze for conductive and high-fatigue contact applications;
o High-carbon alloy steel wire for heavy load and high strength requirements.
· Mounting compatibility: Design positioning structures, mounting holes or snap features according to assembly requirements; avoid sharp edges at contact positions to prevent scratching mating parts.
· Wire pretreatment: Carry out stress relief annealing on hard-state wire materials before forming to improve ductility, and reduce springback and cracking risks.
· Forming compensation: Preset springback compensation values in tooling and programming based on material properties and bending angles to ensure dimensional accuracy after forming.
· Post-forming heat treatment: Perform stress relief annealing after forming to eliminate residual stress caused by bending, and improve dimensional stability and fatigue life.
· Precision inspection: Implement full inspection or sampling inspection for key dimensions such as bending angle, mounting position and fit size; conduct 100% force testing for functional load-bearing parts.
· Surface treatment: Select zinc plating, nickel plating, passivation, black oxide or Dacromet coating according to service environment; control coating thickness for high-fatigue parts to avoid hydrogen embrittlement risk.
· Do not apply lateral or eccentric loads beyond the design direction, which may cause permanent deformation or fracture at bending points.
· Never exceed the maximum working stroke or rated load; over-deformation will lead to irreversible elastic force attenuation.
· For dynamic cyclic applications, verify fatigue life in advance and avoid long-term operation near the ultimate stress level.
· In corrosive, high-temperature or conductive scenarios, confirm material and surface treatment compatibility before use; do not directly apply ordinary carbon steel parts in harsh environments.
· Ensure correct assembly orientation; improper installation will change the stress bearing point and cause premature failure.