| STEP 1 Relevant
details are entered into our in-house developed spring designing computer program that
gives required production specifications and produces a process sheet that will accompany
the springs until their completion. |
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| STEP 2 The
required diameter spring steel bar is cut to the correct length. For automotive springs
the steel used is a B.H.P. developed miro-alloyed spring steel grade X4K92M61S, other
applications are dependant on the size of the material used and the springs designed use. |
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| STEP 3 The spring
end treatment is then applied if applicable. This usually involves tapering one or both
ends of the spring. This is done as a hot process either under eccentric rollers or on
heavier material under a mechanical hammer. |
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STEP 4 All hot
wound coil springs are coiled on our own designed and built coil winders. Once wound the
spring is checked for correct set and then quenched in oil to produce a hardened spring.
The spring once quenched is too hard and brittle for use and must be toughened. This is
achieved by re-heating the spring to a pre-determined temperature that produces a finished
hardness that will resist sagging, while being ductile enough to avoid breakage. This
process is known as ‘tempering’.
Achieving the correct hardness, measured in Rockwell C, is the most important step in
the spring making process. At Industrial Springs we pay very close attention to all our
manufacturing processes that will influence the springs final hardness as this will
determine the longevity of the spring and how well it resists sagging or breakage. |
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| STEP 5 If
specified, the coil spring is shot peened. This process involves the firing of small steel
shot at the spring from all angles to induce favourable residual stress in the outside
fibres of the material, which ultimately produces a spring more resistant to cracking and
therefore a longer life.. |
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| STEP 6 After the
shot peening process the coil spring is ‘scragged’, this process involves
compressing the spring to a pre-determined height to induce a permanent set, raise the
elastic limit of the spring and induce favourable stresses in the spring. |
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| STEP 7 The last
manufacturing process is applying the surface finish, in the case of ‘Aurora’
springs this is a teal-blue long life powder coat finish, all other springs are to the
customers specification, before being packaged for delivery to the customer. |
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