Customizing Disc Springs: Size, Preload, & Configuration Strategies for High Performance

Introduction

In modern engineering, performance often depends on precision — the right component, the right dimension, and the right configuration. Disc springs, also known as Belleville washers, are no exception. While their fundamental purpose remains to resist axial loads within a compact space, their performance can vary dramatically depending on size, preload, and configuration.

At RALEIGH SPRING – YOUR RELIABLE DISC SPRING MANUFACTURER, customization is at the core of our design philosophy. We understand that no two applications are identical — a spring used in a wind turbine faces vastly different operational challenges compared to one in a precision medical device. That’s why Raleigh provides fully customizable DIN2093 Metric Disc Washer Series, manufactured to DIN quality standards and tailored for flexibility, durability, and precision.

In this article, we’ll explore how engineers can customize disc springs to optimize performance, control load-deflection behavior, and ensure long-lasting reliability in demanding mechanical systems.

1. Understanding the Fundamentals of Disc Spring Design

Disc springs are annular coned elements that provide resistance to an axial load. When compressed, the conical shape flattens, generating a force that can be adjusted by changing geometric and material parameters. This unique mechanical property allows for enormous design flexibility.

They can be arranged in different configurations:

• Single Disc Spring – Simple, compact, high-load resistance.

• Parallel Stack – Increases total spring load.

• Series Stack – Increases deflection while keeping the same load.

• Combination Stacks – Balances both load and deflection for complex applications.

To learn more about Raleigh’s standard and customized designs, visit https://www.raleigh-springs.com/Disc-Spring.

2. The Power of Customization

Every engineering application has its own mechanical fingerprint — defined by parameters such as space constraints, load limits, vibration frequency, and environmental conditions. Customization allows engineers to fine-tune spring performance to those exact needs.

Raleigh Spring provides full customization for:

• Outer and inner diameters

• Thickness and cone height

• Material selection

• Surface finish and coating

• Stack configuration and preload adjustment

This precision manufacturing approach ensures compatibility with existing assemblies while maximizing load efficiency and lifecycle performance.

3. Sizing Strategies for Maximum Efficiency

The geometry of a disc spring — particularly its diameter, thickness, and cone height — directly affects its stiffness, deflection, and force output.

a. Outer and Inner Diameter

The outer diameter (Do) defines the spring’s total footprint, while the inner diameter (Di) controls how the load is transferred through the bearing surfaces. Larger diameters distribute stress over a wider area but require more space; smaller diameters allow compact designs with higher spring rates.

b. Thickness (t)

Thickness is the single most influential factor in determining spring stiffness. The spring force increases roughly in proportion to the cube of the thickness — meaning small adjustments can make significant changes in load behavior.

c. Cone Height (h0)

The cone height dictates how much deflection the spring can achieve before flattening. Higher cone heights allow greater deflection and energy storage, but at the cost of higher stress levels.

Raleigh engineers often employ finite element analysis (FEA) and DIN2093 standard formulas to optimize these parameters for specific load-deflection profiles.

4. Preload: The Key to Consistent Performance

Preload refers to the initial compression applied to a disc spring before operation begins. It ensures immediate response to dynamic loads and minimizes vibration or backlash in assemblies.

Advantages of Proper Preload:

• Enhances system rigidity

• Reduces vibration amplitude

• Prevents component loosening under cyclic loading

• Extends fatigue life

However, excessive preload can cause premature stress fatigue, while too little can result in performance lag.

Raleigh Spring’s engineers calculate preload based on:

• Desired operational deflection range

• Maximum and minimum load cycles

• Material yield strength

• Operating temperature and environment

Our precision manufacturing process allows us to achieve preload tolerances within micrometers, guaranteeing consistent performance across production batches.

5. Configuration Strategies: Series, Parallel, and Beyond

Disc springs can be configured in multiple ways to achieve specific load or deflection characteristics. These stack configurations are the key to achieving tailored mechanical responses.

a. Parallel Configuration

All springs are oriented in the same direction.

• Effect: Load capacity increases proportionally with the number of discs, while deflection remains the same.

• Use Case: Clutches, braking systems, heavy mechanical assemblies.

b. Series Configuration

Alternate the orientation of springs in the stack.

• Effect: Increases total deflection while maintaining the same load.

• Use Case: Precision instruments, actuators, and safety valves where flexibility matters.

c. Combination (Parallel + Series)

A hybrid configuration balances both high load and large deflection.

• Effect: Tunable spring behavior for complex systems with variable loads.

• Use Case: Aerospace, wind energy, and industrial robotics.

Each configuration type can be mathematically modeled using Raleigh’s advanced simulation tools to predict force-deflection curves and fatigue life with high accuracy.

6. Material Selection for Custom Performance

Material choice directly impacts not only the spring’s strength but also its resistance to temperature, corrosion, and fatigue. Raleigh offers several material options, each suited for distinct environmental and mechanical demands:

www.raleigh-springs.com
Raleigh Spring Technology Co., Ltd.

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