What is a Tension Spring? Its Usage and Manufacturing Process
Tension springs (extension springs) are essential spring types that store and exert force in mechanical systems. In this article, we will thoroughly examine what a tension spring is, its wide range of applications, and the critical steps in its manufacturing process, highlighting its importance in the industry.
What is a Tension Spring?
Tension springs, also known as extension springs, are a type of mechanical spring that resists the pulling force applied to them and tends to return to their original length when that force is removed. Essentially, they connect two components via hooks or loops (called ends) at their two ends, and as these components attempt to separate, the spring increases the force, applying tension to the system. This spring type stores energy by stretching and is usually produced with tightly wound coils, which gives them an initial tension force. The tension spring plays a critical role in many fields, from automotive to white goods, offering long-lasting and reliable performance thanks to their design. Correct material selection is the key to tension spring performance.
The Wide Range of Industrial Applications for Tension Springs
Tension spring varieties are among the most preferred spring types in the engineering and manufacturing sectors. Their strength and force-storing capabilities mean they have a wide range of applications. For example, spring mechanisms are found in washing machine drum balancing systems, automobile brake and clutch systems, garage door spring mechanisms, and even medical devices. These springs are also frequently used in household items, latches, and trampolines, ensuring that covers and panels close or move securely. Each application requires a custom-designed tension spring with different materials, wire thicknesses, and end types. This spring is a vital component that directly affects the reliability and functionality of the system.
Key Stages in Tension Spring Manufacturing
The manufacturing process of a tension spring consists of a series of stages that require high precision. The process typically begins with the selection of the appropriate material, such as high-carbon steel, stainless steel, or special alloy wires. The wire is tightly wound to the specified diameter and pitch setting using specialized CNC spring coiling machines. At this stage, the spring's initial tension (starting force) is also set. Then, application-specific hooks (such as English loops, German loops, or extended loops) are bent and formed at the two ends of the spring. To permanently set the spring's shape and improve its mechanical properties, post-coiling heat treatment (stress relieving) is applied. Finally, coating processes (zinc, nickel, or painting) may be done to increase corrosion resistance and improve appearance. The quality of every tension spring is guaranteed by meticulous control and testing at each of these stages.
