| STEP 1 Relevant
manufacturing details are entered into the items process sheet that will accompany the
springs until their completion. |
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| STEP 2 The
required material size is selected from our extensive spring steel stock and cut by
guillotine to the required lengths |
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| STEP 3 The spring
end treatment is then applied. This could involve tapering and/or spearing the ends of the
spring. An eye is then wound on the ‘main’ leaf, along with the
‘curl’, if required, to the ‘second’ leaf. |
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STEP 4 All our
leaf springs are formed hot on our own designed and built forming machines in either
complete spring packs or as individual leaves depending on the size of the spring. Once
formed the leaf spring is 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 During
final assembly the springs camber is checked and any deviations from specs. rectified.
Where specified our leaf springs are shot peened prior to final assembly.
The shot peening process involves the firing of small steel shot at the leaves
from a pre-determined angle to induce favourable residual stress in the outside fibres of
the material, which ultimately produces a spring more resistant to cracking. |
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| STEP 6 After the
shot peening process, if specified, the leaf 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, before being packaged for delivery
to the customer. |
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