English Views: 68 Author: Site Editor Publish Time: 2026-04-09 Origin: Site
Product Highlights: 001 117 and 001 128 Series (D=40mm) – Core Elastic Component Solutions for Industrial Equipment
The 40mm outer diameter disc springs, widely adopted as standard components in industrial applications, play a pivotal role in power transmission systems, vibration control mechanisms, and structural pre-tensioning systems for general-purpose machinery. Designed and manufactured in compliance with DIN2093 international standards, this series offers comprehensive thickness options ranging from 0.8mm to 5.0mm. Through flexible lamination configurations, they can withstand dynamic loads spanning 500N to 15,000N, making them ideal for elastic cushioning and energy absorption applications across diverse operational scenarios.
Technical parameters of typical products (using model 001 120 as an example)
Outer diameter (D): 40.00 mm (tolerance range ±0.15 mm)
Inner diameter (d): 14.30 mm (concentricity ≤0.05 mm)
Thickness (t): 2.00 mm (thickness deviation ±0.03 mm)
Free height (H₀): 3.05 mm (parallelism error ≤0.02 mm)
25% compression load: 1800 N (test conditions: room temperature 25°C, loading rate 5 mm/min)
50% compression load: 3363N (compliant with DIN2093-B standard load curve)
This product series has been widely applied in industrial scenarios such as vibration damping systems for mining machinery vibrating screens, tensioning mechanisms in port conveying equipment, and impact buffer devices for construction crushers. Manufactured from high-quality 60Si2MnA spring steel through a heat treatment process involving 860°C quenching followed by 420°C tempering, combined with phosphating surface treatment to form a protective film of 5-8μm thickness, the components maintain stable elastic performance across operating temperatures ranging from-40°C to 150°C. Each batch of products complies with ISO9001 quality management system certification, and bulk procurement offers comprehensive quality documentation including hardness tests (HRC42-47), load characteristic curves, and dimensional inspection reports.
Core Value Analysis for Batch Application
Full-range matrix: Covers thickness intervals from 0.8 to 5.0 mm, offering 12 standard models with support for various assembly configurations including single-disc, tandem, and stacked arrangements, meeting installation space and load requirements of different equipment.
Economic compatibility: Large-scale production processes are adopted, with standard models maintained in stock. Batch procurement enables tiered pricing optimization, thereby reducing procurement costs for equipment manufacturers.
Quality control system: From raw material spectral analysis to finished product load testing, 16 quality control points are implemented to ensure performance deviation within ≤3% for products of the same batch, thereby guaranteeing operational consistency of equipment.
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In the field of modern industrial equipment manufacturing, disc springs, as elastic components with high energy density, have expanded their applications from traditional machinery to high-end sectors such as new energy, rail transportation, and aerospace. According to the 2025 annual report by China Machinery Industry Federation, the annual market demand for disc springs in the general machinery sector reaches 320 million units, with the 40mm specification accounting for 28%, primarily used in vibration equipment, pressure machinery, and heavy-duty transmission systems. With the acceleration of Industry 4.0, equipment manufacturers are increasingly demanding higher reliability, consistency, and longevity from disc springs, driving the industry's transition from standardized components to customized solutions.
As the internationally recognized standard for disc springs, DIN2093 specifies product geometric dimensions, material properties, load characteristics, and testing methods. Compared to domestic standards such as GB/T 1972, DIN2093 imposes stricter requirements in thickness tolerance control (±0.03mm), fatigue life (≥10⁶ cycles), and temperature stability. This product series has obtained TUV Rheinland certification, with load-deformation curves showing a deviation of ≤2% from theoretical calculations and an elastic decay rate below 5% at 150°C—performance significantly surpassing industry averages.
In mining vibrating screen systems, the 001 128 series disc spring assembly (3.5mm thickness) utilizes 12 overlapping plates to form a vibration damping module. This design effectively controls screen box vibration amplitude within 0.5-1.2mm range, achieving 15dB noise reduction compared to traditional helical spring solutions while extending screen mesh service life by over 30%. A case study from an iron ore processing plant demonstrates that implementing this solution extended equipment maintenance intervals from 3 months to 8 months, resulting in annual maintenance cost savings of approximately 120,000 yuan.
The tensioning system for port belt conveyors employs 001 117 series disc springs (2.5mm thickness) integrated with sensors to form a closed-loop control system, enabling real-time compensation for belt tension. In a coal terminal project, this solution maintained belt tension fluctuations within ±5% tolerance, effectively addressing the response lag characteristic of traditional pendulum-type tensioning devices while achieving an 8% improvement in equipment operational efficiency.
The jaw plate cushioning system of the construction crusher employs 001 120 series disc springs, which can withstand instantaneous impact loads of 3000N through a six-piece composite assembly. Laboratory tests demonstrate that this configuration reduces jaw plate impact acceleration by 40% and decreases frame fatigue damage by 50%, significantly enhancing operational safety of the equipment.
This product series utilizes 60Si2MnA spring steel with the following chemical composition: C 0.56-0.64%, Si 1.50-2.00%, Mn 0.60-0.90%, P≤0.035%, and S≤0.035%. Impurities are removed through vacuum melting, achieving a steel purity of 99.97%. The forming process employs CNC cold rolling technology to ensure disc spring curvature radius deviation ≤0.02mm. Heat treatment is performed in a continuous mesh belt furnace, enabling precise temperature control within ±5°C to maintain consistent material mechanical properties. Surface treatments include conventional phosphating, as well as optional special coatings such as Dacromet and galvanizing, meeting corrosion-resistant requirements for marine and chemical environments.
Disc spring selection requires comprehensive consideration of four key factors: working load, deformation magnitude, installation space, and environmental conditions. The following calculation formula is recommended:
P = (E × t⁴ × f) / (4 × (1-μ²) × D² × K)
Where: E denotes the elastic modulus (206 GPa), μ represents the Poisson's ratio (0.28), K is the shape coefficient, and f indicates the compression ratio.
During installation, the following precautions should be observed: ① Ensure the disc spring axis aligns with the force direction; ② When used in tandem, apply grease to the contact surfaces of adjacent disc springs; ③ Maintain preload within 20-75% of the free height range; ④ Regularly inspect the disc spring surface condition, and replace immediately if cracks or permanent deformation are detected.
The product quality control implements a three-level inspection system:
1. Raw material inspection: Each batch of steel undergoes tensile testing (tensile strength ≥1275 MPa, yield strength ≥1100 MPa) and impact testing (-40°C impact energy ≥30 J).
2. Process inspection: Perform 100% dimensional inspection after molding, and conduct load testing in accordance with the GB/T 10867 standard.
3. Factory inspection: 3% of products are randomly selected from each batch for fatigue life testing, with 10⁶ cycles under rated load without fracture.
A heavy machinery group has implemented the 001 128 series disc springs in its next-generation hydraulic press products, replacing traditional helical springs. This innovation reduces equipment height by 20% while enhancing response speed by 35%. Through bulk procurement (annual consumption of 50,000 units), the company achieved an 18% reduction in unit costs. Another case involves a wind power equipment manufacturer that applied these disc springs to yaw systems. By optimizing stacking methods, maintenance cycles were extended from 6 months to 18 months, resulting in annual operational cost savings of approximately 450,000 yuan.
How do different temperature environments affect the performance of disc springs?
A: Within the temperature range of-40°C to 120°C, the product load variation rate should be ≤±3%; high-temperature alloy materials are recommended for temperatures exceeding 150°C.
How to determine the optimal lamination method for disc springs?
A: Same-direction lamination enhances load-bearing capacity, while opposite-direction lamination increases deformation capacity. The specific configuration should be determined through calculations based on equipment space and load characteristics.
