What is Spring Load?

Spring load is a fundamental parameter that defines how a spring reacts under various forces. It is directly related to the material properties, geometry, and manufacturing processes of the spring. Accurate knowledge and control over spring load are essential for predicting how a spring will behave in real-world applications. This necessitates rigorous spring load testing, a process that evaluates the mechanical properties of springs under controlled conditions to verify that they meet design specifications and performance criteria.

In this comprehensive article, we will delve into the technical aspects of spring load, the importance of load testing in ensuring reliability and performance, and the methodologies involved in the testing process. We will also introduce advanced tools like Acxess Spring's Online Spring Force Tester, which facilitate precise calculations and simulations, providing valuable insights without the need for physical prototypes.

Understanding Spring Load Testing

What is Spring Load Testing?

Load testing is a systematic procedure where controlled forces are applied to a spring to assess its mechanical response. The primary goal is to determine the relationship between the applied load and the resulting deformation, typically represented in a load-deflection graphic. This graphic provides insights into the spring's stiffness, elastic limit, and potential plastic deformation regions.

The testing process involves:

• Applying Incremental Loads: Forces are gradually increased to observe the spring's behavior at different stress levels.

• Measuring Deflection: The displacement resulting from each load increment is precisely measured in travel distance.

• Recording Data: Load and deflection data are shown in real time for analysis, using computerized online spring force tester systems for accuracy.

Types of Springs and Their Testing

Different spring types exhibit unique mechanical behaviors and therefore require tailored testing methodologies.

Compression Springs: These springs resist compressive forces and shorten under load. Testing involves compressing the spring and measuring the load at specified travel deflections. Key considerations include ensuring the spring does not reach solid height (fully compressed state) prematurely, which could lead to coil clash and failure.

Extension Springs: Designed to resist load forces which make the extension springs extend under load. Testing focuses on measuring the load required to achieve specific extensions, accounting for initial tension inherent in the spring's design.

Torsion Springs: These springs operate by twisting about their axis, resisting applied torque. Testing measures the angular deflection resulting from applied torque, ensuring the spring can withstand the required rotational stresses without yielding.

Key Parameters Measured

Understanding and measuring the following parameters are critical during load testing:

• Spring Rate (k): The rate is defined as the change in load per unit deflection (k = Load ÷ Travel). It is a measure of the spring's stiffness in a unit of measure like pounds per inch (lbs/in) of compression or extension. In metric it is Newtons per millimeter (N/mm) and is essential for predicting how the spring will behave under varying loads.

• Load at Deflection: This specifies the exact load the spring exerts or supports at a particular deflection travel point, crucial for applications requiring precise force control.

• Free Length: The unloaded length of the spring, which serves as a baseline for measuring deflection and ensuring the spring fits within the assembly.

• Solid Height: The length of the spring when all coils are compressed and touch each other.

Introducing Acxess Spring's Online Spring Force Tester

What is the Online Spring Force Tester?

As technology advances and design standards become more stringent, the demand for precise and efficient spring testing methods has grown significantly. Traditional spring testing involves physical devices and equipment that can be time-consuming to set up, costly to maintain, and require specialized training to operate. These limitations have paved the way for innovative digital solutions that offer greater flexibility, accuracy, and convenience.

One such cutting-edge solution is the Online Spring Force Tester (OSFT) developed by Acxess Spring. The OSFT is a web-based application that revolutionizes the spring testing process by allowing users to conduct comprehensive load analyses of their springs without the need for physical testing equipment. This tool simulates real-world operational load and travel deflection conditions, providing an accessible and highly functional platform for engineers, designers, and quality control professionals.

The OSFT offers a suite of testing capabilities, including:

• Spring Load Testing

• Spring Travel Testing

• Spring Rate Testing

By integrating these features into a user-friendly web application, the OSFT streamlines the spring testing process, making it more efficient and accessible. Users simply input specific operational parameters and receive immediate feedback on the performance of their springs, enabling them to make informed decisions and adjustments early in the design phase.

Key Features of the Online Spring Force Tester

The Online Spring Force Testeris equipped with advanced functionalities designed to provide detailed insights into spring performance:

Spring Load Testing

Spring load  testing is crucial for determining the maximum load a spring can withstand without failing. The OSFT enables users to specify a range of loads up to the maximum load and observe the spring's behavior under these conditions. This helps identify the load capacity of the spring and ensures it meets the application's requirements.

Spring Travel Testing

This feature assesses the maximum deflection of both compression and extension springs without causing permanent deformation. For compression springs, it evaluates how much they can compress without reaching its solid height or experiencing permanent deformation. For extension springs, it determines the maximum safe extension length. By simulating gradual or sudden load changes, the OSFT helps users ensure that springs operate safely within their desired range of motion.

Spring Rate Testing

Understanding a spring rate, or spring constant, is essential for applications where precise force control is required. The OSFT allows users to perform spring rate testing by applying incremental loads virtually and recording the resulting deflections. This data is plotted on a load versus deflection animation, enabling accurate analysis of the spring's stiffness characteristics.

Visual Simulations

One of the standout features of the OSFT is its ability to provide real-time visual simulations of spring behavior. Users can input operational parameters and watch animations that depict how the spring responds to various loads and deflections. This visual feedback is invaluable for identifying potential failure points and gaining a comprehensive understanding of the spring's performance in real-world scenarios.

How to Use the Online Spring Force Tester

Using the Online Spring Force Tester is a straightforward process designed to integrate seamlessly with Acxess Spring's Instant Spring Quote. Here is a step-by-step guide:

1. Access ISQ and Choose the Spring Type: Visithttps://instantspringquote.com/. Select the type of spring you wish to test—compression, torsion, or extension.

2. Input Your Dimensions: Enter your specific spring requirements, such as dimensions and material type. 

3. Check Your Spring: Once you've selected a spring, its detailed specifications are automatically transferred to the Force Tester TAB. Pproceed to set up the testing parameters.

4. Set Up Load Requirements: In the OSFT interface, input the specific load and deflection requirements for your test. This includes:

   • Load Requirements: Specify the load that the spring will experience

   • Or you can specify the loaded height of the spring.

   • Load Height Requirements: Specify the loaded height or enter the load of your spring to visually assess how the spring behaves throughout its travel.

5. Run the Simulations: Initiate the simulation by hitting the tab key to observe real-time graphical feedback on the spring's performance. The OSFT will display animations and graphs illustrating load versus deflection and loaded heght and other critical performance metrics.

6. Other websites: You can, also, use the OSFT on other Acxess Spring websites like: Spring Creator 5.0, The Spring Store, Compression Spring and Stock Spring Catalog. And we have a short video tutorial for how to test your spring on those sites:

By following these steps, users can efficiently utilize the Online Spring Force Tester to evaluate and optimize their spring designs. The tool's integration with Instant Spring Quote and its user-friendly interface make it accessible to both seasoned engineers and those new to spring design.

Practical Example Using the Online Spring Force Tester

To illustrate the practical applications of the Online Spring Force Tester for Spring Load Testing, let's explore a detailed example for each type of spring: compression, extension, and torsion. This example demonstrates how to input data, interpret results, and make informed decisions to optimize spring designs while working with inch pounds of force, and newton millimeters.

Testing a Compression Spring Design

Design Scenario:

An engineer is tasked with designing a compression spring for a valve mechanism that requires a specific load at a certain deflection, while ensuring that the spring operates within safe stress limits.

Specifications:

• Required Load at Deflection: 8.75 lbf. at 0.75 inches of compression

• Maximum Allowable Deflection: 0.9 inch 

• Material Constraints: Must use Stainless Steel 302 (ASTM A313) for corrosion resistance

• Space Limitations: Outer diameter must not exceed 1.25 inches

• Initial Design Parameters:

  • Wire Diameter: 0.1 inches

  • Outer Diameter: 1.2 inches

  • Free Length: 2 inches

  • Number of Active Coils: 8

Steps:

1. Input Parameters:

   • Material: Select "Stainless Steel 302".

   • Wire Diameter (WD): Enter 0.1 inches.

   • Outer Diameter (OD): Enter 1.2 inches.

   • Free Length: Enter 2 inches.

   • Number of Active Coils: 8.

   • For which, Number of Total Coils: Enter 10.

By entering this dimension, Instant Spring Quote recommends part number AC100-1200-10000-SST-2000-C-N-IN as the best match for our design:

2. Calculate Mean Diameter (MD):
   MD = OD − WD = 1.2 in − 0.1 in = 1.1 in

MD = 1.1 in 

3. Run Initial Simulation:

   • The tool calculates the spring rate (k) using:
     k = Gd^4 ÷ (8D^3 * n)
     Where G (modulus of rigidity) for Stainless Steel 302 ≈ 9,949,475.938 psi.

   • The calculated spring rate is approximately:
     k= 9,949,475.938 x (0.1)^4 ÷ 8 x (1.1)^3 x 8

   • k= 9,949,475.938 x 0.0001 ÷ 8 x 1.331 x 8

   • k = 994.9475938 ÷ 85.184 ≈ 11.6799

   • k ≈ 11.6799  lbf/in 

4. Assess Initial Results:

   • Load at 0.75 inches Deflection (x):
     F = k • x = 11.6799 lbf/in × 0.75 in = 8.7599 lbf.
     This means the selected spring can handle the desired load of 8.75

5. Finalize Design:

   • The adjusted design meets the required load and operates within safe stress limits.

6. Interpret Graphical Outputs:

   • Analyze the load vs distance traveled to confirm linear behavior up to the required load.

Utilizing the Tool for Optimization

Online Spring Force Tester facilitates rapid iterations:

• Parameter Adjustments: Easily modify inputs to see immediate effects on performance metrics.

Safety Factor Evaluation: Automatically calculates safety factors based on material properties and applied loads.

Exporting and Reporting

Data Export: Share calculation results via a URL and in various formats (3D CAD and 3D Blueprint) for documentation or presentation purposes.

Educational Benefits

• Learning Aid: For students and novice engineers, the tool provides a practical way to understand the relationship between design parameters and spring performance.
• Visualization: Graphical outputs help visualize concepts such as linearity, stiffness, and stress distribution.

The Importance of Spring Load Testing

Ensuring Performance and Safety

Springs are designed to operate under specific load conditions, and their performance is intrinsically linked to how they respond to these loads. A spring that does not meet its load specifications can lead to inadequate force transmission, excessive deflection, or even mechanical failure. Load testing ensures that the spring's load-deflection characteristics align with the intended design. By applying known forces and measuring the resulting deflection (or vice versa), engineers can verify the spring's stiffness (spring rate) and maximum load capacity. This process identifies any deviations due to material inconsistencies, manufacturing defects, or design errors, allowing for corrections before the spring is deployed in critical applications.

Compliance with Specifications

Engineering designs often require strict adherence to specifications to ensure interoperability and safety. Springs must meet these specifications to function correctly within assemblies and systems. Load testing validates that each spring produced matches the mechanical properties defined in the design phase. This is especially crucial in regulated industries such as aerospace, medical devices, and automotive manufacturing, where non-compliance can lead to regulatory penalties, product recalls, or liability issues.

Quality Assurance and Customer Trust

In a competitive market, product reliability is a key differentiator. Manufacturers who implement rigorous quality assurance processes, including thorough load testing of springs, demonstrate a commitment to excellence by knowing beforehand what the spring is capable of doing. Then manufacturing this spring to exact standards. This builds trust with customers, who can be confident that the products they purchase will perform as expected. Moreover, consistent quality reduces warranty claims and enhances brand reputation, contributing to long-term business success.

Take the Next Step

To streamline your spring design and testing process, take advantage of Acxess Spring's powerful tools:

• Instant Spring Quote: Quickly input your spring dimensions and receive immediate custom spring instant quotes. This tool lets you instantly receive quotes. There are over 70 trillion spring configurations available.

• Online Spring Force Tester: Integrate your selected spring into the OSFT to perform comprehensive load testing simulations. Gain valuable insights into your spring's performance, optimize designs, and ensure compliance with all necessary standards.

Don't leave your spring performance to chance. Visit Instant Spring Quote and start designing and testing your springs with confidence. By leveraging these advanced tools, you can enhance reliability, ensure compliance with specifications, and reinforce customer trust in your products. Embrace the future of spring load testing and secure a competitive edge in your industry today.