I am designing a spring for a hand-held application. All spring action will be driven by hand, so speeds, impacts will be low.
Since it's a hand operated tool, I need a spring to be as compact as possible.
Let me preface this by saying that I am at a dangerous place: I know enough to be dangerous, but haven't designed enough springs to have either good intuition, nor great knowledge of the driving calculations. I am using Advanced Spring Design.
What are the risks in designing the spring to be at, say, 95% compression for the largest load/displacement? I am not all that concerned with linearity; think of this a tactile limit stop for the user. They will feel the spring, but doubtfully will register the non-linear rate over the travel of about 3/16".
According to ASD, the fatigue prediction is comfortably >10E7, our goal is less than 1/2 million cycles.
material is 17-7 h900
thanks for your thoughts