Composite coil spring

Types of Composite Coil Spring

Composite coil springs are a type of helical spring made from composite materials. The composite materials used to manufacture these springs are corrosion-resistant and lightweight. The unique features of composite coil springs make them suitable for various applications. However, the type of composite coil spring that will be ideal for a certain application will depend on the requirements of the application. Here are the different types of composite coil springs.

• Glass Fiber Composite Spring

  This type of composite coil spring is used in various applications, especially where there is a need for lightweight components without compromising the strength of the spring. One of the key features of glass fiber composite springs is corrosion resistance.

• Carbon Fiber Composite Spring

  Carbon fiber composite springs are known for their high tensile strength and stiffness. Because of these unique features, they have a low spring constant and are suitable for applications that require minimal resistance to deflection. Also, carbon fiber composite springs have a high fatigue life, which means they can be used in applications with repetitive loads or continuous loading. Due to the high tensile strength of carbon fiber composite springs, they are suitable for applications that require high load-bearing capacity.

• Polymer Composite Spring

  Polymer composite springs are designed and manufactured to meet specific requirements. The properties of polymer composite springs can be customized depending on the type of polymer and the reinforcement material used. One of the main advantages of polymer composite springs is that they are lightweight. The weight of polymer composite springs can be reduced up to 70% compared to metal springs.

• Aramid Fiber Composite Spring

  Like glass fiber composite springs, aramid fiber composite springs are known for their impact resistance properties. In addition to having good impact resistance, aramid fiber composite springs also have good abrasion resistance. Because of the unique features of aramid fiber composite springs, they are suitable for applications that require springs with high resistance to wear and tear.

Specifications and Maintenance of Composite Coil Spring

• Material

  The materials used in the composite coil spring must be maintained. This is because each material has its own merits but cannot be used for long when maintained improperly. The composite coil spring can be made of three different materials: steel, plastic, or a combination of both. When the steel is used, the spring is going to be durable and offer excellent performance. It is going to be used in heavy-duty applications. On the other hand, a spring made of plastic is going to be lightweight and corrosion-resistant. The only disadvantage is that it is not going to handle high loads or temperatures. When the two materials are combined, the steel provides the spring with strength and durability. At the same time, the plastic offers corrosion resistance and low friction. This combination is going to result in a composite coil spring that is suitable for various applications.

• Spring Rate

  The spring rate of composite coil springs must be maintained. This is because it affects the performance of the spring. Each application or load requires a different spring rate. The rate of the coil spring can be changed when it is compressed or stretched. When the spring is overstretched or compressed during use, it is not going to offer the required performance. The typical spring rate of composite coil springs is between 10 to 100 N/mm.

• Load Capacity

  The load capacity of the composite coil spring should be maintained because it is important for the performance of the application. The load capacity is the maximum load the spring can carry without permanent deformation. When the load capacity is exceeded, the spring is going to be deformed permanently, and this is going to affect its performance. The load capacity of composite coil springs varies depending on the material and design. The load capacity of coil springs is between 500 to 5000 N.

• Free Length

  The free length of the composite coil spring should be maintained. This is because it affects the installation and functionality of the application. The free length is the length of the spring when it is not under tension or load. The free length of composite coil springs ranges from 50 to 500 mm. When the length of the spring is not maintained, it is not going to fit properly into the application.

• Wire Diameter

  The composite coil spring's wire diameter is critical. This is because it affects the spring's rate and load capacity. The standard wire diameter of the composite coil spring ranges from 1 to 10 mm. When the diameter is not maintained, it is going to affect the performance of the spring.

To ensure that composite springs maintain their required specifications, users should adhere to the following:

• Composite springs should not be overloaded; they should only carry the load they are designed to carry.
• Inspect the springs regularly to know if there are any signs of wear, damage, or deformation.
• Users should clean the springs regularly to prevent the build-up of dirt and debris.
• Composite springs must be lubricated periodically to reduce friction and wear.
• Users should not modify the spring length or wire diameter.

How to choose composite coil springs

Choosing the right coil springs for a project requires several considerations. Here are some of them:

• Load requirements:

  It is vital to consider the loads that will be applied to the springs. The spring choice should be able to support the loads without going through permanent deformations. Think about the spring's free length, load at the mean coil spring, and spring rate.

• Installation space:

  Buyers should consider the available space for installation and choose a spring that will have a perfect fit. The spring will be able to operate effectively without interference from surrounding parts or components.

• Application type:

  Composite coil springs are made for different applications. Buyers should consider the application the spring is intended for. Is it for automotive use, industrial machinery, or other applications? Different applications have specific requirements, such as corrosion resistance, high-temperature performance, and fatigue resistance.

• Spring configuration:

  Buyers should select the composite coil spring designs suitable for their applications. The most common types are the round and rectangular spring coils. A rounded coil spring provides uniform strength and smooth operation, making it ideal for many applications. On the other hand, the rectangular coil spring offers a better fit for specific applications but operates with more friction.

• Material considerations:

  Composite coil springs are made of spring steel and other materials. Each material has unique features. Steel offers high strength and durability, making it suitable for heavy-duty applications. Buyers should consider the spring material based on the load requirements, environmental conditions, and application type.

• End treatments:

  Buyers should consider the end treatments based on the assembly methods and requirements. The composite coil spring can have different end treatments, such as squared, ground, and closed ends. The spring's ends can be machined or left as is, depending on the specific requirements.

• Quality standards:

  Buyers should get composite coil springs from reputable manufacturers that meet various quality standards. The springs' quality should be consistent, with high-performance features and durability.

How to DIY and Replace Composites Coil Springs

Before attempting to replace a composite coil spring, it's important to understand how critical it is to vehicle safety and handling. Improper installation can lead to serious accidents. That said, here are the general steps for replacing a composite coil spring:

Tools and Materials Needed:

• New composite coil springs
• Spring compressors
• Socket set
• Wrench set
• Jack and jack stands
• Wheel chocks
• Torque wrench
• Eye protection
• Gloves

Steps:

• 1. Ensure the vehicle is on a level surface. Use wheel chocks to prevent it from rolling.
• 2. Loosen the lug nuts while the vehicle is still on the ground.
• 3. Jack up the vehicle and place jack stands under it. Remove the wheels.
• 4. Follow the manufacturer's service manual for the exact instructions on disassembling the suspension and removing the old springs.
• 5. Use spring compressors on the old springs to safely release the tension. Once the tension is released, remove the spring compressors.
• 6. Install the new composite coil springs using the manufacturer's instructions.
• 7. Ensure that the springs are properly seated in the spring perches.
• 8. Reassemble the suspension components and wheels.
• 9. Lower the vehicle and use a torque wrench to tighten the lug nuts to the manufacturer's specifications.

Q and A

Q: Are composite coil springs noisy?

A: Generally, composite coil springs are not noisy. They operate quietly. If there is any noise, it could be due to improper installation, lack of lubrication, or being worn out?

Q: What is the difference between a composite spring and a steel spring?

A: The key difference between a composite spring and a steel spring is the material. A composite spring is made of composite materials like fiberglass, while a coil spring is made of steel."

Q: How long do composite springs last?

A: Composite springs have a better spring rate and are lightweight. They are not affected by corrosion like steel. The lifespan of composite springs depends on the application, but they have a long and durable lifespan.