Types of Springs: Understanding Their Uses, Materials ...

There are several types of springs used in different capacities. Generally, there are three main categories, and each category has its subcategories. Below are the properties of the different spring types and their applications.

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Category One: Helical Springs

Helical springs have a general helix shape (hence the name) but different cross-sections. They are the most common types of springs in rapid prototyping and are widely applicable in product manufacturing. Below are the different types of helical springs.

Compression Springs

Compression springs are open coiled springs with a constant diameter and space between each coil. The springs are compressible only one way as they resist axial compression. These spring types are widely applicable in product manufacturing, such as valves and suspension.

Extension Springs

Extension springs are closed compression springs. They function by elongating during tension and storing energy. When on tension removal, the mechanical spring returns to its original shape dissipating the energy. Extension springs are an important part of garage doors, pull levers, jaw pliers, and weighing machines.

Torsion Springs

A torsion spring is attached to two components horizontally or vertically using their two ends. They function by storing and releasing rotational energy. The tighter the winding, the more energy the spring stores and releases on load removal. They are applicable in garage doors, watches, etc.

Spiral Springs

Spiral springs are rectangular metal strips made into a flat spiral that can store and release a reasonable amount of energy at a constant rate. Due to the constant release of energy, they are applicable in making mechanical watches, seat recliners, toys, etc.

Category Two: Leaf Springs

These spring types are from rectangular metal plates or leave bolted, clamped, and applicable in shock absorption in heavy vehicles. Below are the different leaf springs types.

Elliptical Leaf Spring

Elliptical leaf spring comprises two stacked, bolted, and clamped leaves with semi-elliptical shapes connected in opposite directions. Although they have opposite directions, there is no need for spring shackles due to the leaf’s subjection to the same amount of elongation on compression. These springs were important in old cars where car manufacturers attached them to the axle and frame. However, they are not much important nowadays.

Semi Elliptical Leaf Spring

Semi elliptical leaf spring comes from steel leaves having the same width and thickness but different lengths. The longest/uppermost leave is the master leaf. They are the most popular leaf spring in automobiles as they require less maintenance and have a long life.

Semi elliptical leaf springs have an end fixed rigidly to the automobile frame and the other to the shackles. Therefore, the length varies when driving in rough terrains, aiding in shock absorption.

Quarter Elliptical Leaf Spring

Like the elliptical leaf spring, the quarter elliptical leaf spring is olden. Also known as the cantilever type of leaf spring, it has one end fixed on the frame side member using a U-clamp or I-bolt and the other freely connected to the axle. Therefore, when the front axle beams experience shocks, the leaves can easily straighten and absorb the shock.

Three-Quarter Elliptical Leaf Spring

This leaf spring is a combination of the quarter elliptical spring and semi-elliptical spring. On the one hand, the semi-elliptical ends are attached to the vehicle frame and the quarter elliptical spring. On the other hand, the free end of the quarter elliptical spring is then attached to the vehicle frame using an I-bolt.

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Transverse Leaf Spring

These are semi-elliptical leaf springs mounted transversely along a vehicle width. In this arrangement, the longest leaf is at the bottom while the mid-portion is fixed to the frame using a U-bolt. Transverse leaf springs lead to rolling. Therefore, they have limited use in the automobile industry.

Category Three: Disk Springs

Disk springs are springs with conical shapes and flexible effects. Consequently, they are applicable in limited space. Below are the types of disk springs.

Belleville Disk Spring

Belleville disk spring or coned-shaped disk spring has a cupped construction. Therefore, they don’t lie flat. They can compress and handle heavy loads. Therefore, they are applicable to products used in high-stress conditions.

Curved Disk Spring

Curved disk springs or crescent washers function by applying light pressure to the mating pair. Therefore, they can resist loosening due to vibration. They are applicable in products that use threaded bolts, fasteners, screws, and nuts in machines which high and constant vibration.

Slotted Disk Spring

Slotted disk springs have slots on the outer and inner diameter. Therefore, they reduce spring load and increase deflection. They are widely applicable in automatic transmissions, clutches, and overload couplings.

Wave Disk Springs

Wave disk springs look like architectural projects with their multiple waves per turn. Consequently, they are applicable in predictable loading as they can act as a cushion by absorbing stress when compressed axially.

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The Trail Gear leaf springs use seven thin leaves that allow each leaf to have a lower spring rate and be softer when compared to springs with less leaves that are thicker. This might not be intuitive since the spring pack looks so thick, but the spring rate is only 235 pounds per inch.

The military wrap on the fixed end of the spring is a great safety feature. Even if the main leaf (topmost, longest leaf in the pack) breaks, this military wrap will allow us to limp off the trail without the axle falling out of the back of the truck.

These bolted spring clamps prevent the leaves from fanning out, yet they do not hinder suspension motion like a traditional spring clamp can do. Trail Gear knows all of the tricks required to get the best ride quality and most articulation out of a set of leaf springs.

The Trail Gear springs include polyurethane bushings that are fluted to accept grease. We greased the bushings with standard wheel bearing grease to limit wear and squeaks on the trail. Also note not to overtighten your shackle bolts or they cannot move freely within the bushings.

We had already fabricated new spring mounts that are low profile and slide over rocks and other obstacles. Trail Gear offers similar mounts to put their leaf springs under just about any 4x4 with body-on-frame construction.

We used an engine hoist to lift up the back of the truck and unload the springs, then set the axle down on jack stands. This made the process of swapping leaf springs simple. If you do not have a cherry picker, a tall set of jack stands can be used under the frame with a second set of shorter stands under the axle.

The new Trail Gear leaf springs provide excellent articulation on the trail in a simple, cost effective package. Before tossing your leaf springs for links and coils, remember that not all leaf springs are created equal.

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Leaf springs have been used since the days of horse drawn carriages, and are still found on the back of new pickup trucks today for one simple reason: they work! Leaf springs locate the axle fore and aft and side to side, hold up the chassis, and provide excellent load-carrying capabilities. That doesn’t mean that they are all the same, though. Even if the design is old, there is the potential for a surprising amount of technology in a high-quality leaf spring.

When it came time to replace the leaf springs on the rear of this Toyota pickup, we ordered a set of Trail Gear 3-inch lift springs from Summit Racing. Trail Gear springs are packed with features that allow them to provide increased articulation and a smooth ride while withstanding the rigors of off-road use. These springs are 56 5/8-inches long, requiring new front frame mounts. Why go through the trouble? A longer spring does not have to arch as much for a given amount of up-and-down movement as a shorter spring. We had previously built custom low-profile mounts on our frame, but Summit Racing carries Trail Gear spring hangers for those starting from scratch.

In addition to being longer than the factory leaf springs, the Trail Gear springs pack the latest technology into one of the oldest suspension designs. The springs are made from shot-peened steel and feature diamond-cut and tapered individual leaves with PTFE sliders between them that maximize articulation and can withstand millions of cycles without fatigue.  All leaf springs are not created equal, but these Trail Gear springs have improved our suspension articulation and ride quality without the need to convert to an expensive and complicated link suspension.

If we had an old dog, Trail Gear could likely teach it some new tricks.

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