Production of flat springs

Flat springs are used in many branches of industry. Whether in aerospace, mechanical and vehicle engineering or electrical engineering, technical springs are among the most important construction elements. Due to the wide range of possible applications, the manufacture of flat springs requires in-depth expertise and first-class quality.

The development and manufacture of technical springs are inextricably linked to the development of their materials. From the early use of natural products such as wood and fibres to the later use of metals such as bronze and iron, today it is mainly metallic strips, sheets, rods and wires or plastics that are used to manufacture springs.

Nowadays, technical springs are moulded metal parts made of steel, spring steel, stainless steel and non-ferrous metals. Sheet metal, spring steel strip and spring steel are available for the production of flat springs. The manufacturing technique then varies depending on the material.

Casting and forging were processing techniques with roots in antiquity. With the development of metal technology, these techniques became increasingly sophisticated. Until modern times, the forging of rods and wires as well as the Flat forging of strips was a fundamental manufacturing process. This was later followed by production using drawing techniques and rolling mills.

Today, flat springs made from sheet metal or spring steel strip are punched or laser-cut. Punching technology is used to produce precision parts with smooth cut surfaces. This manufacturing process with low material waste allows for Production of large quantities of workpieces in a short time.

The manufacturing process known as punching is suitable for the production of identical parts (workpieces) from strips, sheets or rods. Punching is often a process consisting of several steps.

The punched parts are produced in one or more work sequences:

• Cutting (punching/cutting)
• Forming (bending, drawing, grinding and embossing)
• Laser cutting

All of these additional processes expand the variety of shapes of the stamped parts for the production of customised flat springs. Shape and dimensional accuracy of the tool are decisive for production accuracy.

Flat springs are available in various designs: straight, curved, coiled and disc-shaped springs. Depending on the future requirements for the springs, they are either manufactured using a pure bending or punching process or further processed by laser cutting and subsequent forming by bending, embossing or deep drawing. There are almost no limits to the design.

Through a subsequent surface treatment flat springs can be given a number of additional desired properties. Often the springs should be harder and/or more resistant to rust or heat. However, the desired effects also include electrical conductivity or extreme mechanical resilience.

In today's industrial world, consistent high-tech quality and uncompromising precision are essential. In order to fulfil the complex requirements, it is necessary for the Production of customised flat springs sound expertise and experience. The highest customer demands have therefore become the standard for Schaaf. In combination with our modern and efficient machinery, we supply you with exactly the flat spring products that meet your requirements.