Analysis of Engineering Limitation of the Number of Disc Spring Laminations and Laminations

When employing disc spring assemblies to handle heavy loads or significant deformation, a critical design challenge is determining whether there exists a reasonable upper limit for the number of parallel (stacked) and series (connected) configurations. Jiangsu Sunzo Spring will analyze the constraints on disc spring combinations by integrating mechanical principles with industry engineering expertise, helping you avoid performance degradation or failure risks caused by improper assembly.

1、Number of laminations (parallel connections) limit: generally 3 pieces, maximum 4 pieces

The number of layers is limited by the uniformity of stress and the cumulative error of manufacturing.

General recommendation: In conventional design, the number of overlapping sheets in the same group generally does not exceed 3. Under this quantity, through precise manufacturing and appropriate lubrication, a relatively uniform load distribution among the sheets can be ensured.

Extreme condition: In the case of extremely limited space and acceptable compromise on the uniformity of load, the number of discs can be increased to 4. However, it should be noted that the more discs there are, the higher the requirements for the parallelism and thickness consistency of the disc springs, otherwise it is easy to overload the edge discs.

2、Limitation on the number of pairs (series): Constrained by uneven stress and stability

The objective of the countermeasures is to increase the total deformation. The number of countermeasures is more strictly limited, mainly constrained by two factors:

1. The stress inhomogeneity is aggravated:

Friction effect: When multiple mating sets are used with guide post/guide sleeve positioning, the relative motion between the disc spring at the moving end (near the loading point) and the guide component becomes more intense, resulting in greater friction resistance. This leads to a higher load proportion borne by the disc spring at the moving end compared to the stationary end. The uneven load distribution worsens with increasing mating sets, reducing overall efficiency and potentially causing localized early fatigue.

2. Stability requirements (aspect ratio limit):

To prevent lateral buckling of slender opposing disc spring columns under compression, engineering practice often employs empirical guidelines to control their total height. Authoritative sources (e.g., Lin Shiyu's "Disc Spring") propose that the total free height H of an opposing disc spring assembly should not exceed three times its outer diameter D, i.e., H ≤ 3D. This serves as a critical empirical criterion for ensuring the compressive stability of composite structures.

3、Engineering Guidance: Tradeoff between Performance, Space and Reliability

The analysis provides a clear combination principle for the design of disc spring:

Pursue high load capacity (composite): Prioritize enhancing the loadbearing capacity of individual panels (e.g., through optimized design or selection of higherstrength materials) rather than simply increasing the number of composite layers. If multiple layers are required, strictly control the quality of individual panels and interlayer lubrication.

For long stroke applications (overlapping), it is essential to evaluate both load nonuniformity risks and stability conditions (H≤3D). To meet these requirements, hybrid configurations (overlapping and overlapping) or alternative elastic element solutions may be considered.

Professional consultation value: Complex combination design requires comprehensive consideration of friction, tolerance, stability and end conditions. It is recommended to seek professional support during the design phase.

4、Professional services of Sunzo Spring: Reliable provider of integrated solutions

At Jiangsu Sunzo Spring, we go beyond individual products to deliver mechanically validated, reliable integrated solutions for our clients.

Simulation and verification: For complex combination requirements, we can use the analysis tools to evaluate the load distribution and stability, and put forward optimization suggestions.

Robust quality control foundation: We recognize that the performance of integrated circuits is fundamentally determined by the consistency of individual chips. Through stringent dimensional and performance controls, we provide highquality "partlevel" assurance for integrated applications.

Full solution package: We provide a complete assembly kit including disc springs, guide components (if required), and installation guidance, with detailed performance specifications and user manuals.

We are committed to helping clients avoid common pitfalls during the early design phase. By understanding and adhering to the inherent limitations of composite design, we collaboratively develop disc spring solutions that not only meet technical specifications but also deliver exceptional reliability and durability.