English Views: 68 Author: Site Editor Publish Time: 2026-01-20 Origin: Site
Fault Diagnosis Engineering: Typical Fault Characteristics and Root Cause Tracing of Disc Spring and Wave Spring
In industrial equipment operations, failures of disc springs and wave springs not only impair individual component functionality but may also trigger cascading equipment issues. Jiangsu Sunzo Elastic, leveraging failure analysis engineering principles, provides a systematic diagnostic approach—from fault identification to root cause tracing—to help enterprises transition from reactive maintenance to proactive prevention.
Wear feature recognition:
Uniform wear: The spring contact surface exhibits uniform wear marks, with the thickness reduction exceeding 5% of the designed thickness.
Bias wear characteristics: Severe unilateral wear, often accompanied by installation misalignment or poor centering
Micro-wear: Fine pits and brown oxide powder appear on the contact surface, commonly observed in vibrating environments.
Fracture pattern analysis:
Fatigue fracture: The fracture surface exhibits shell-like or beach-like patterns, with crack initiation predominantly occurring at stress concentration areas.
Overload fracture: The fracture surface is fibrous or radiating, with no obvious fatigue expansion zone.
Stress corrosion cracking: Fracture extends along the grain boundary, with corrosion products on the fracture surface
plastic deformation ：
The permanent height loss exceeds 3% of the free height.
The working curve shifts due to the change in the cone angle of the disc spring
Collapse of Spring Wave Peak and Destruction of Wave Symmetry
elastic extenuation ：
The force value decreases by more than 10% under the same compression level.
Drift of stiffness characteristics, nonlinear characteristic change
Stress Calculation Deviation: Actual Operating Condition Exceeds Design Load Spectrum
Inappropriate material selection: Material properties do not match the working conditions
Structural Design Defect: Excessive Local Stress Concentration Factor
Heat treatment defects: uneven hardness, decarburization, excessive residual stress
Surface treatment issues: Insufficient protective layer thickness, poor adhesion
Dimensional control failure: Critical dimensions exceed tolerance range
Vibration environment: long-term operation near the resonance frequency
Temperature effect: The operating temperature exceeds the allowable range of the material.
Medium corrosion: Corrosive media in the environment
Improper installation: Overloading, excessive stroke, inadequate lubrication
Maintenance gap: Inspections and maintenance not performed at the specified intervals
Condition change: Spring parameters not adjusted after equipment upgrade
Optical detection: magnifying glass, endoscope, digital microscope
Dimension measurement: digital caliper, micrometer, height gauge
Hardness Test: Portable Hardness Tester
Surface analysis: roughness meter, coating thickness meter
Microscopic Analysis: Scanning Electron Microscopy (SEM), Energy Dispersive Spectroscopy (EDS)
Material analysis: Metallographic analysis, chemical composition analysis
Mechanical Testing: Fatigue Test, Relaxation Test
We provide comprehensive technical support for fault diagnosis:
On-site diagnostic service: Engineer will conduct an on-site inspection within 48 hours
Remote diagnostic support: Remote analysis of high-definition images and data
Emergency measures: Provision of temporary solutions to ensure continuous production
Failure Analysis Laboratory: Provides comprehensive material and tissue analysis
Root Cause Report: Issuing a Professional Failure Analysis Report
Improvement plan formulation: propose systematic improvement measures based on the analysis results
Health Monitoring Program: Designing a Customized Spring Health Monitoring System
Regular inspection service: Establish a periodic on-site inspection mechanism
Life Prediction Model: Establishing Life Prediction Model Based on Big Data
Establish a prevention system based on diagnostic results:
Design parameters are modified according to actual working conditions
Optimize the structure to reduce stress concentration
Select appropriate materials and surface treatments
Establish key process control points
Implementation of Statistical Process Control (SPC)
improve traceability system
Establish standard installation work instructions
Establish a regular maintenance inspection system
Conduct operator training and certification
Accurate fault diagnosis is the first step to solving problems, and root cause tracing is key to preventing recurrence. We provide reliable technical support for your equipment with professional diagnostic techniques.
