Looking for a Highly Fatigue Resistance Spring Material
Looking for a Highly Fatigue Resistance Spring Material
(OP)
We're currently using a stainless 17-7 Condition C material.
The material needs to go through a 4 slide die for cold forming and cutting. Thus, we need it in a 2" width by 0.015" thick roll.
It is subjected to a stainless of about 0.005, 1/2% strain and must be resistant to fatigue for at least a 1 million cycles.
We've tried 304 and 316 alloys as well as nickel titanium alloys, i.e. Nitinol. The 304 and 316 were far less resistant to fatigue and came out slightly warped because of the heat treating proces. The Nitinol proved to be too difficult to manufacture and thus too expensive.
I'd appreciate any suggestions or leads.
Elmer Lee
The material needs to go through a 4 slide die for cold forming and cutting. Thus, we need it in a 2" width by 0.015" thick roll.
It is subjected to a stainless of about 0.005, 1/2% strain and must be resistant to fatigue for at least a 1 million cycles.
We've tried 304 and 316 alloys as well as nickel titanium alloys, i.e. Nitinol. The 304 and 316 were far less resistant to fatigue and came out slightly warped because of the heat treating proces. The Nitinol proved to be too difficult to manufacture and thus too expensive.
I'd appreciate any suggestions or leads.
Elmer Lee





RE: Looking for a Highly Fatigue Resistance Spring Material
RE: Looking for a Highly Fatigue Resistance Spring Material
The question was not meant to elicit assistance in designing the spring itself. I simply was trying to get suggestions for materials.
The spring's max strain is about 0.005, which for most metals is pretty close to is fatigue limit, I think. I was hoping someone out there has work on applications requiring super elastic metals.
I hope that helps.
RE: Looking for a Highly Fatigue Resistance Spring Material
However, at this strain the stress in the spring is approximately 103.7 kgf/mm2 or 147.5 ksi. According to AMS 5529B 17-7PH strips at CH900 condition has a minimum tensile stress of 240ksi. Therefore, the stress on the your leaf spring is far beyond the 0.4 to 0.5 of tensile stress or yield stress. This leads to the conclusion that it is beyond the metal fatigue limit even before we take into account surface defects etc.
There are not many materials stronger than 17-7PH but you can try to find Marage 300 or 350, Custom 475 from Carpenter or Elgiloy. However these materials are difficult to attain and they are expensive.
There is other things that you may do with the current 17-7PH but they fall into the design area and manufacture process.But, as you mentioned you do not need assistance in designing the spring itself.
RE: Looking for a Highly Fatigue Resistance Spring Material
We're using 17-7 condition C that goes thorough a 900F age hardening process. Would that be any better that 17-7PH. Appreciate your help and input.
Elmer
RE: Looking for a Highly Fatigue Resistance Spring Material
You didn't mention how is the spring deflects is it defelects the 0.005 strain only to one direction all the time or both directions?
RE: Looking for a Highly Fatigue Resistance Spring Material
The 0.005 strain number is the theoretical amount calculated using a FEM model and some fudging. It is achieved with the half amplitude oscillation, in other words, just by lifting the tip up by x, the max strain should be 0.005.
So, I believe the answer to your question is that it is subjected to 0.005 strain in both directions.
RE: Looking for a Highly Fatigue Resistance Spring Material
RE: Looking for a Highly Fatigue Resistance Spring Material
Type 301 stainless steel is often used for small spring applications that require exceptional fatigue resistance. Type 301 develops its strength from strain hardening (cold working) instead of heat treatment, so warpage would not be a factor. Somers Thin Strip, a division of Olin Brass, offers Type 301 stainless steel strip in several different tempers, with the highest strength being 280 ksi ultimate tensile strength. I strongly recommend you contact them to discuss your application. Use the following link for more information:
http://www.olinbrass.com/somindex.html
RE: Looking for a Highly Fatigue Resistance Spring Material
Google: Sandvik Materials Technology.
(Also you will find that surface conditon has tons of effect on fatigue performance)
nick
RE: Looking for a Highly Fatigue Resistance Spring Material
good luck
RE: Looking for a Highly Fatigue Resistance Spring Material
Another note from the first job I had in the steel industry.
Toilet Paper comes in rolls. Steel comes in coils.
RE: Looking for a Highly Fatigue Resistance Spring Material
My mistake NickE. I'll know what to use when talking to a toilet paper manufacturer now. You've saved me from the ultimate embarrassment.
RE: Looking for a Highly Fatigue Resistance Spring Material
//ma
RE: Looking for a Highly Fatigue Resistance Spring Material
It seems we all grinding water. The solution is probably not by changing the material. I think you need to consider design change. If you can give more info on the spring shape and what it is supposed to do it may help. As you mentioned in your posts the deflection is what you are looking for. If so, you may be able to recieve the same delection with less strain using the same strip thickness or even thicker strip but with a different shape of spring.
RE: Looking for a Highly Fatigue Resistance Spring Material
Have you looked at low modulus alloys? BeCu, BeNi or alpha/beta Ti? These would involve a lot less force for the same defection.
If you want to stay with the same stiffness tehn look at 21=6=9 (XM-11). It is available as re-melted coil product from Allegheny-Ludlum. It is used for aircraft hyrol lines for places where Ti isn't suitable due to temperature or damage tolerance requirements.
In tubing it is cold drawn to about 125ksi yield and 150ksi UTS, though it can be worked to higher values and still have good ductility.
I'll try to get an S-N curve for you.
= = = = = = = = = = = = = = = = = = = =
Corrosion never sleeps, but it can be managed.
http://www.trenttube.com/Trent/tech_form.htm
RE: Looking for a Highly Fatigue Resistance Spring Material
RE: Looking for a Highly Fatigue Resistance Spring Material
Also you may want to look around at this website:
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RE: Looking for a Highly Fatigue Resistance Spring Material
How do you decide what material to use in designing a specific spring? Consider the leaf spring used for the suspension systems on older cars. These springs are essentially rectangular elastic beams loaded in bending. Suppose that such a beam of length L thickness t and width b can be modeled as simply supported at both ends, and loaded centrally with a force F. If the elastic modulus of the material is E, then the deflection D at the center of the beam is
D = (FL^3)/(4Ebt^3)
The maximum surface stress S is given by
S = (3FL)/(2bt^2)
If the spring is plastically deformed while under load, then it won’t be able to “spring back”. So we set the condition that the maximum stress must always be less than the yield stress Sy.
Sy > (3FL)/(2bt^2)
Substituting for F from the initial equation we find,
(Sy/E) > (6Dt)/(L^2)
For a spring in service to undergo a deflection D, the ratio of Sy/E must be high enough to prevent plastic deformation. So the best leaf springs are made from materials that have high values of Sy/E. For this reason spring materials tend to be heavily strengthened by work hardening, precipitation hardening, or solid solution strengthening. Note that small values of thickness t permit larger deflections D for the same value of Sy/E. This is why leaf springs are usually constructed of several beams stacked on top of one another.
I am uncertain of the specific geometry and loading conditions that you are using, but a similar analysis for your specific case should provide you with the combination of physical properties that will allow us to determine the appropriate materials for use in your design. If you do this analysis, get back to us and we may be able to provide you with specific materials that can satisfy your criteria.
Maui
RE: Looking for a Highly Fatigue Resistance Spring Material
RE: Looking for a Highly Fatigue Resistance Spring Material
Since so many have ask for specifics of the design, I thought it would be best to spend some time explaining it.
The sping is a leaf spring that can be modeled as a cantilever beam rigidly supported on both ends. The beam however is not straight, but instead made up of 3 curves of different radiis. One end of the beam is held stationary and the other is displaced about 0.75" in total, i.e. .375" upward, and the same amount downward. As the spring is deformed, the 3 curves essentially change radiis. There is a formula:
strain=thick/(1/R1-1/R2)
where R1 is the orginal curvature of the beam and R2 is the resulting curvature after deformation.
I've written a computer algorithm that uses the above equation, and knowing some geometric constraints, i.e. total spring length, max and min radius, and determines all of the spring geometries that when deflected the desired amount will not give a strain of more than 0.005 which I thought was the upper bound of any metal's fatigue strain. So the resulting spring would only have a max strain of 0.0025 because it would be deflected 1/2 the desired amount upwards and the equal amount downards.
If anyone wants to know more about this code, my MSN messenging name is axleshox@hotmail.com. I'm almost always online. I'd be happy to discuss this further.
In the end, the algorithm spit out about 30 different sets of spring shapes. They were all quite similar and I pick the one that seemed easiest to manufacture, i.e. did not bend over on itself too much.
What I am finding is that the spring seems to be holding up to simple upward and downward deflection. However, we realized later that the spring was also being subjected to a torsional load. As a result, the torsional plus the vertical deflection is starting to produce fatigue failure in the springs.
Nicke, the suggestion about parallel spring is an excellent one. We tried that once and found that if we were to lay up say 3 springs on top of each other, the bottom one would deflect as desired but the top two would start to bend in un-predictable ways. I attribute the problem to not having the springs tied to one another. I think essentially the top two springs are buckling.
We're probably going to redesign a few tools that will allow us to bond the springs together with low durometer rubber or urethane. That way, the different layers can still move in shear with respect to one another, but no buckling can result.
I started this thread in hopes to find a stronger, more flexible material. That would have been the easiest fix.
Redesigning the shape of the spring seems like it would be unfruitful. The algorith was fairly complete. The only way to further reduce stress and strain whle still maintaining the same deflection is to use a longer spring. Unfortunately, the spring is enclosed in a housing and we've already used up every piece of space we could find.
Sorry for such a long post. I hope someone is willing to read it all. Appreciate all the comments thus far. It's geat to know there is a community out there willing to lend a hand. Thanks all.
Elmer
RE: Looking for a Highly Fatigue Resistance Spring Material
Regards,
Cory
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