Springs are present in a variety of devices around you. Springs play a vital role in these devices, from your kid’s toys to the hinges of your doors and your medical equipment to dishwashers. Despite being very versatile, the manufacturing process of all these springs is quite the same. All the springs have to go through the same grind, which gets them into a final shape.
We are not saying there isn’t any difference between all types of springs. Springs used in medical equipment and aeronautical engineering projects demand special care because they have to undergo a relatively higher temperature and survive longer. Although the specific type of metal used may differ based on the device of your personalized spring, the production process generally follows the same standardized approach.
Forming Custom Springs:
Coiling is the first thing we do here at Arrow Manufacturing. Regardless of the spring type, every spring starts its journey as a simple piece of wire. The core material of the wire, its size, and other dimensions depend upon the purpose of its future use.
We have a large variety of coilers ranging from a diameter of .003″ to .112″! The wire is supplied to the coiling machines, which quickly transform the wire into desired shape and size.
Heat Treatment and Quenching:
The second heating round involves exposing springs to less intense temperatures and controlled cooling. This round removes stress caused by other steps and helps the spring restore flexibility.
Once our desired spring is formed, then we start heating it. Springs are exposed to intense heat, enabling them to preserve the memory of their newly created shape. These springs are exposed to a temperature reaching 1688˚F. Rapid cooling follows the heat treatment in which oil vats are used as a cooling source. The cooling process gives strength and brittleness to these springs.
Then there is a second round of heating, which involves medium-level heating and cooling the products. This step removes any stress from the coiling and quenching process and restores the spring’s flexibility.
Grinding:
A force is applied at the ends of compression and extension springs to make their ends ground flat. These springs are pushed up and down in the process known as grinding.
Shot Peening:
Shot peening is another step in the manufacturing process of custom springs. Hundreds and thousands of tiny balls are thrown over these springs to flatten the spring’s external surface and eliminate any cracks caused by the coiling, heating, or grinding process. This step enhances the springs’ lifetime and minimizes the possibility of cracks when the subject is exposed to stress.
Setting:
The setting is the second last step of manufacturing a custom spring. The spring has to undergo a series of compression and extension until its final form. In addition to helping the spring achieve its ultimate length, this step sets up the spacing between the coils, referred to as pitch.
Electrostatic Powder-Coating:
In the ultimate step of this process, a delicate layer of powder is coated over spring. This powder serves as protection against the rusting of the spring. Some of our customers like coating specific colors over springs to add some beauty to these springs. We provide custom paint or coating service to our customers. For example, customers demand OEM automotive components in yellow, black, or red.
Design and quality control are the other crucial steps of the spring manufacturing process. A high-quality spring will be of no use if it doesn’t meet the required specification.
Our products are passed through many quality checks before we finally ship them out. Our optical and mechanical control systems ensure that springs are delivered with desired specifications and highest quality.
