Views: 68 Author: Site Editor Publish Time: 2025-12-02 Origin: Site
Technical Analysis: Why the measured force value of disc spring is close to the theoretical calculation value?
In the engineering application of disc springs, the closeness between theoretical calculations and actual measurements serves as a key metric for evaluating design reliability. Through in-depth technical analysis and practical engineering experience, Jiangsu Sunzo Spring explains the multi-layered factors behind this phenomenon, demonstrating the inherent logic from theoretical frameworks to practical measurements.
From a purely theoretical standpoint, finite element analysis (FEM) can fully account for geometric details and material constitutive relationships, and is generally regarded as the theoretical solution closest to reality. We use the FEM calculation results as the benchmark force value, denoted as F.
The comparison with FEM results shows that the calculated value of the classical formula (e.g. AL formula) is usually about 5% higher than the FEM solution, i.e. the formula value is about 1.05F. This indicates that the formula itself has a certain conservative design margin.
In actual manufacturing and testing, two key factors tend to increase the measured force values, causing them to 'coincidentally' approach or even exceed the formula value:
The actual disc spring is not an ideal acute angle, and there are necessary process rounded corners on the inner and outer edges. This rounded corner will make the effective internal cone angle of the disc spring larger, which will lead to the relative decrease of its force arm. According to the principle of lever, to achieve the same deformation, a larger force is needed, which will increase the measured force value.
In the load test, there is inevitable friction between the upper and lower surface of the disc spring and the pressure plate of the testing machine. The friction will resist the deformation of the disc spring, which will increase the load reading measured at the same displacement.
It is the combination of these factors that makes the measured value often fall within the range of 1.05F to 1.1F. The overestimation tendency of the classical theoretical formula (1.05F) and the effect of increased measured values due to manufacturing fillets and testing friction (tending to 1.1F) intertwine, ultimately resulting in a comparison between theoretical calculations and measured values that appears relatively close.
At Jiangsu Sunzo Spring, we have a profound understanding and quantitative grasp of the patterns of these influencing factors. This understanding has been integrated into our disc spring design and manufacturing standards.
Fine design: We will consider the theoretical model, manufacturing process (e.g. the specification of the rounded corner) and the use condition (e.g. the friction coefficient) in the design, so that the performance prediction is closer to the reality.
High-Standard Verification: We rigorously adhere to the GB/T 1972 (National Standard for Disc Spring) for testing, while continuously calibrating our designs and processes using internal high-precision test data. This ensures the delivered products exhibit exceptional consistency and predictability in performance.
We are dedicated to translating complex technical principles into stable and reliable product performance, delivering disc spring solutions with precise performance for your equipment.
SUNZO has it’s own researching and development team and test center, has participate in rule-making of the latest national industry standards and the international ISO standards for disc springs.
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