Deep Analysis of Failure Cases Caused by Design Defects of Disc Spring

The rationality of disc spring design is a critical inherent factor determining its service performance and service life. Design flaws may lead to uneven force distribution and localized stress concentration under actual operating conditions, resulting in premature failure and significantly compromising equipment reliability and safety.

1、Engineering Key Points and Influence Mechanisms in Core Parameter Design

Key design parameters of disc springs include cone angle, thickness, ratio of outer diameter to inner diameter, effective working turns, and free height. These parameters are closely interconnected, collectively determining the overall mechanical properties and load-bearing characteristics of the spring. For instance, an excessively large cone angle may lead to uneven load distribution, compromising structural stability, while an insufficient cone angle could significantly reduce structural stiffness, failing to meet load-bearing requirements. Additionally, the thickness-to-outer-diameter ratio must be precisely calculated and optimally matched to prevent plastic deformation caused by inadequate load capacity or reduced elastic recovery capability, which may adversely affect the spring's reusability.

2、Design Principles and Structural Optimization Strategies for Stress Concentration Avoidance

During operation, stress concentration in disc springs primarily occurs at inner and outer edge regions, transitional fillet areas, and potential notches or grooves. If these edges lack proper chamfering or fillet treatment, or if notches exhibit excessively sharp profiles, such locations become stress concentration points under cyclic or impact loads, significantly reducing fatigue life. Additionally, excessively small fillet radii directly lead to substantially increased stress concentration coefficients. Under long-term alternating load conditions, this design makes the components highly susceptible to crack initiation and eventual fatigue fracture failure.

3、Analysis of Typical Failure Cases Caused by Improper Laminated Design

The disc spring assembly used in heavy machinery equipment exhibited severe load distribution imbalance among individual springs due to flaws in the initial composite design scheme. Certain springs were subjected to prolonged overload stresses exceeding their design limits, resulting in premature fatigue fracture failure. By implementing advanced finite element simulation analysis techniques, we systematically optimized the spring assembly's composite configuration, contact conditions, and load transfer pathways. This approach effectively improved load distribution uniformity, successfully resolved early failure issues caused by design deficiencies, and significantly enhanced the component's overall durability and reliability.

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