In the field of spring design and manufacturing, simulation analysis has become an indispensable part of product development. JiangsuSunzo Elastic Technology Co., Ltd. (hereinafter referred to as "Sunzo Spring") leverages its mature multi-physics simulation capabilities to continuously optimize the performance and reliability of spring products in structural, fatigue, and thermodynamic aspects.

1. Simulation capability

Zhongzhong Elastic focuses on the multi-field simulation analysis of spring parts, and has formed the following four core capabilities:

Ø Structural Statics/Dynamics Analysis

The deformation and stress distribution of the spring under static or dynamic load are evaluated to provide the basis for structural design.

Ø Fatigue and Strength Simulation

Predict the service life and failure risk of the spring under cyclic load to assist the product life assessment.

Ø Thermodynamic Simulation

Analyze the influence of high and low temperature environment on spring performance and improve its adaptability under extreme working conditions.

Ø topological optimization

The spring structure is optimized by algorithm to achieve the balance between lightweight and high strength.

2. Overview of the Simulation Process

The three-phase simulation process covers the whole process from parametric modeling to finite element verification:

Ø 1. Parametric modeling and selection

Enter key disc spring dimensions (e.g., thickness, outer diameter, inner diameter, free height) according to national standards (e.g., GB/T 1972-2023), calculate critical ratios for series selection, and perform modeling by incorporating material properties (e.g., elastic modulus, Poisson's ratio, yield strength).

Ø 2. Finite element simulation and verification

Create a geometric model using tools like SolidWorks, perform end-to-end self-contact analysis, set axial loads and limit displacement constraints, and simulate compression and rebound processes. Compare simulation data with theoretical calculations to verify the feasibility of the solution.

III. Typical cases

Ø Case 1: Structural statics analysis

Taking the standard disc spring series 31.5*16.3*2*2.75 as an example, the material is 51CrV4 and the axial load is 6173N. The simulation results show that the maximum stress point is point I, 2465MPa, and the maximum deformation is 0.5439mm, which is highly consistent with the theoretical value and verifies the feasibility of the design.

Static analysis results & stress distribution and deformation cloud map

Ø Case 2: Fatigue and strength simulation

For the disc spring series A71*36*4*5.6, a model was created in WORKBENCH to perform displacement loading simulation. Fatigue Tool analysis revealed the most hazardous area at the top contact point, with a minimum safety factor of 0.5528 and a minimum service life of approximately 2.71×10⁶ cycles.

Life and safety factor analysis & life assessment and safety factor distribution

It is worth noting that the selection of average stress treatment method in disc spring life analysis still needs more experimental data to establish a more accurate evaluation model.

epilogue

Simulation analysis serves not only as a 'verification tool' for product design but also as a 'driving engine' for optimizing spring performance and advancing technological iterations.Sunzo Elastic will continue to deepen its expertise in simulation technology, delivering more reliable and efficient spring solutions to clients.