Views: 66 Author: Site Editor Publish Time: 2025-11-27 Origin: Site
Theoretical Formula Verification of Disc Spring:Comparison of FEM Simulation of Shell Element and Axisymmetric Element
Technical Exploration: How to Verify and Optimize the Disc Spring Theory Formula with Finite Element Method?
In modern disc spring design, finite element analysis (FEA) has become a critical tool for validating theoretical formulas, predicting product performance, and optimizing design solutions. Accurate modeling is the foundation for obtaining reliable results. Leveraging advanced disc spring technology and simulation capabilities, Jiangsu Sunzo Spring compares two typical FEA element types to demonstrate how to effectively validate disc spring simulations.
To verify the theoretical calculation formula of disc spring, two kinds of element types are usually used to establish the finite element model.
Shell model: The disc spring is simplified into a curved shell, which is more efficient in calculation.
The axisymmetric unit model: Using the geometric symmetry of the disc spring, a two-dimensional section model is established, and then the model is rotated 360 degrees around the central axis to form a three-dimensional analysis.
The comparison between the simulation results of the two models and the classical theoretical calculation formula shows that there is a systematic deviation.
The shell model: The calculated force value is usually about 8% lower than the theoretical formula value.
The model of axisymmetric unit is more consistent with the theoretical formula, the deviation is about 5%.
Why is the axisymmetric unit more accurate?
The fundamental reason lies in the load application point simulation being closer to real-world conditions. While shell elements by default apply loads to their neutral surface, actual disc springs experience loads on their upper and lower surfaces – a configuration that better aligns with the modeling approach of axisymmetric elements. Therefore, when conducting high-precision stress analysis or force verification, it is recommended to use axisymmetric elements for modeling to obtain reliable results that more closely match measured data.
At Jiangsu Sunzo Spring, we have fully integrated advanced finite element analysis into our disc spring design and R&D processes. We not only strictly comply with the National Standard for Disc Springs, but also utilize CAE simulation techniques:
Precise prediction performance: Before the product trial production, the load-displacement curve and stress distribution can be predicted accurately.
The optimization design scheme is to evaluate the effect of different structural parameters (e.g. h₀/t) on the performance and realize the design optimization.
Enhance development efficiency: Reduce reliance on traditional trial-and-error methods, shorten R&D cycles, and ensure disc spring solutions delivered to customers combine theoretical reliability with practical feasibility.
We leverage modern design tools, including FEM, to transform deep technical insights into high-quality, reliable products, delivering end-to-end technical support for your projects—from virtual validation to physical delivery.
SUNZO has it’s own researching and development team and test center, has participate in rule-making of the latest national industry standards and the international ISO standards for disc springs.
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